A.O. Smith 100 Series Service Handbook Download Page 1

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COMMERCIAL BOILERS/WATER HEATERS

Service Handbook

PRINTED IN THE U.S.A. 0513

320822-003

SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT

FOR MODELS: XB/XWH

1000, 1300, 1700

2000, 2600, 3400

SERIES 100/101

INSTALLATION CONSIDERATIONS - PRE SERVICE CHECKS

- BOILER/WATER HEATER CONSTRUCTION -

OPERATION & SERVICE - TROUBLESHOOTING

25589 Highway 1

McBee, SC 29101

Summary of Contents for 100 Series

Page 1: ...822 003 SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT FOR MODELS XB XWH 1000 1300 1700 2000 2600 3400 SERIES 100 101 INSTALLATION CONSIDERATIONS PRE SERVICE CHECKS BOILER WATER HEATE...

Page 2: ...2 Servicing should only be performed by a Qualified Service Agent...

Page 3: ...ter Assembly 21 Control Panel Assembly 22 Control Board Assembly 25 Display System Touch Screen Display 29 Connector Terminals 29 START UP AND OPERATIONS 31 Prior To Start Up 31 General 31 Filling And...

Page 4: ...any of the procedures described in this manual If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual SERVICE REMINDER When per...

Page 5: ...valve due to excessive pressure build up This condition is not covered under the limited warranty The Temperature Pressure Relief Valve is not intended for the constant relief of thermal expansion A...

Page 6: ...n instructions contained in the Instruction Manual that came with the boiler water heater have been observed and followed Factory installed pumps on XB boilers XWH water heaters are sized for up to a...

Page 7: ...em instead of a single larger burner or boiler water heater Using boilers water heaters in parallel is more efficient costs less reduces emissions improves load control and is more flexible than the t...

Page 8: ...take fault conditions and Control System lock outs 6 Ensure there is a water trap formed in the condensate drain tube line connected to the exhaust elbow on the boiler water heater and that the conden...

Page 9: ...FILTER BOX TOUCH SCREEN DISPLAY VENT EXHAUST HIGH VOLTAGE CONNECTION BOX MAIN POWER SUPPLY SWITCH SENSOR COMMUNICATION BOX PRESSURE RELIEF VALVE WATER OUTLET ALL BRONZE CIRCULATION PUMP FACTORY INSTA...

Page 10: ...ER BOX TOUCH SCREEN DISPLAY VENT EXHAUST HIGH VOLTAGE CONNECTION BOX MAIN POWER SUPPLY SWITCH SENSOR COMMUNICATION BOX PRESSURE RELIEF VALVE WATER OUTLET ALL BRONZE CIRCULATION PUMP FACTORY INSTALLED...

Page 11: ...3 pin socket on the combustion blower assembly to power the electronic speed control The control board sends a PWM Pulse Width Modulation signal an instruction to start stop and control the blower mot...

Page 12: ...lume is 1 1 GPM 4 2 LPM per tube Under these conditions the maximum temperature difference between the outgoing and returning water is 80 F 26 7 C With a Maximum Allowable Working Pressure of 160 PSI...

Page 13: ...are taken into account in order not to worsen the phenomenon of corrosion Combustion air must not contain chlorine ammonia or alkali agents Installation of the product near a swimming pool a washing...

Page 14: ...cavity between the nozzle and the venturi housing This negative pressure pulls gas from the outlet of the 24 VAC gas valve into the blower where it is mixed with combustion air and then supplied to t...

Page 15: ...d to an ignition transformer From the ignition transformer the spark ignitier is energized A Low High Gas Pressure Switch is installed on the gas manifold The Low Pressure Gas Switch is a normally ope...

Page 16: ...16 Servicing should only be performed by a Qualified Service Agent Figure 8 BURNER ASSEMBLY 1300 2600 Figure 9 BURNER ASSEMBLY 1700 3400...

Page 17: ...at the test jacks or on the bar graph on the display is the measured voltage in the range from 0V to 30V The display could show stronger numerical data The incoming flame signals are filtered to elimi...

Page 18: ...0 VAC to the Ignition Transformer during the pre ignition and startup cycle only The Ignition Transformer takes the input voltage and outputs the ignition voltage as high as 14 kV to the Spark Igniter...

Page 19: ...2000 feet 610 meters for Propane and 10 100 feet 3079 m for Natural gas For higher elevations call the toll free support phone number shown on the back cover of this manual for technical assistance Mo...

Page 20: ...ture Probe is a temperature sensor only and has two leads The Outlet Temperature Probe also contains the manual reset high temperature limit switch and has four leads The control system displays the I...

Page 21: ...ssembly includes a filter which slides inside the filter housing and filter brackets The filter is made of of wire mesh screen and is meant to block dust particles and other debris from entering throu...

Page 22: ...ntrol Panels Assemblies for the XB boilers XWH water heaters The main components include Control Boards Master Local Display Power Supply 24 VAC Terminal Block Step Down Transformer Pump Relay Fuse Bl...

Page 23: ...23 Servicing should only be performed by a Qualified Service Agent Figure 15 UPPER CONTROL PANEL ASSEMBLY 2000 2600 3400...

Page 24: ...24 Servicing should only be performed by a Qualified Service Agent Figure 16 LOWER CONTROL PANEL ASSEMBLY 2000 2600 3400...

Page 25: ...ype 10K at 77 F 25 C or 12K at 77 F 25 C Limit Sensor NTC Type 10K at 77 F 25 C and Fans VFD INPUTS Analog Inputs 1 NTC Sensor Imputs 10kohm or 12kohm NOTE 12kohm and 10kohm single sensors cannot be u...

Page 26: ...26 Servicing should only be performed by a Qualified Service Agent Figure 17 CONTROL BOARD ASSEMBLY...

Page 27: ...ol Board for Lead lag application C Modbus MB2 RS 485 Ground G Connects to Local Burner Control Board for Lead lag application ECOM 1 Not Used 2 Not Used 3 Not Used J4 1 Not Used 2 Not Used 3 Not Used...

Page 28: ...input from 10K Ohm NTC Outlet Temperature Sensor Connects to Pin 1 on Outlet Temperature Sensor 11 HEADER Supply for and signal input from 10K or 12K Ohm NTC Header Sensor 12 HEADER Ground reference...

Page 29: ...mption 12W max 4 Operating Temperature 4 to 158 F 20 to 70 C 5 Storage Shipping Temperature 22 to 176 F 30 to 80 C 6 Humidity 90 RH non condensing 7 Enclosure rating IP10 NEMA 1 8 Approvals FCC Part 1...

Page 30: ...30 Servicing should only be performed by a Qualified Service Agent Figure 19 DISPLAY CONNECTOR TERMINALS SCHEMATIC DIAGRAM Figure 20 DISPLAY CONNECTOR TERMINALS LEAD LAG DIAGRAM...

Page 31: ...pressure Close bypass valve and permit pressure to be established by the pressure reducing valve 2 Vent all high points in system to purge system of air Provisions should be made to permit manual vent...

Page 32: ...sing the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the hot water supply tan...

Page 33: ...ugh the heat exchanger the factory supplied pump is sized for an additional 50 feet 15 2 m of equivalent feet of piping between the boiler water heater and a storage tank All piping between the boiler...

Page 34: ...34 Servicing should only be performed by a Qualified Service Agent LIGHTING AND OPERATING INSTRUCTIONS...

Page 35: ...lower to supply the correct gas air ratio for optimum performance and efficiency The combustion blower speed is controlled automatically and determines the amount of negative pressure experienced by t...

Page 36: ...response of the CO2 measuring instrument Adjust the settings in small increments and allow the combustion readings to stabilize before readjusting When desired adjustments are complete reinstall the b...

Page 37: ...the next burner settings Depending on the boiler water heater size and capacity the flame voltage will be between 10 15 volts for low fire and 25 32 volts for high fire settings Check for gas valve se...

Page 38: ...S7910A Local Keyboard Display Module Flame Sensor Temperature Sensor NTC Type 10K at 77 F 25 C or 12K at 77 F 25 C Limit Sensor NTC Type 10K at 77 F 25 C 24V Digital I O OVERVIEW Functions provided by...

Page 39: ...single ModBus address to service the requests of the ModBus master in a Lead Lag arrangement SPECIFICATIONS 1 Electrical Ratings Operating voltage 24VAC 20 to 30 VAC 60 Hz 5 30 amps Single Heat Excha...

Page 40: ...ed g Internal system fault occurred 4 PRE IGNITION TIME a Lockout Interlock opens b IAS Purge and Ignition enabled and the Interlock opens c Preignition Interlock opens d Pilot Valve terminal is energ...

Page 41: ...s for more than 240 seconds a lockout will occur Hydronic Central Heating XB Boilers Start up sequence central heating request system in standby 1 Heat request detected On Setpoint On Hysteresis 2 The...

Page 42: ...a system S7999D display and the other port supports communications from the LL Master with its slaves The Lead Lag master is a software service that is hosted by a Burner Control System It is not a pa...

Page 43: ...add stage action has been triggered it will remain in this condition until either a stage has been added or The criteria for its being in an add stage condition is no longer met only then will it tak...

Page 44: ...l diagnostics historical files and faults S7999D OI Display only Allows switching view between multiple burners Allows viewing Lead Lag Master Real time data trending analysis and transferring saved t...

Page 45: ...guides drill 1 4 in holes through the door panel 5 Place the display in the opening aligning the mounting holes in the device with the drilled holes in the panel 6 Secure the display to the panel wit...

Page 46: ...o upgrade the software in the System Display and should normally be bypassed Three LEDs exist for I O traffic one for the Ethernet network port and two for Modbus ports Modbus Com Port 2 is not active...

Page 47: ...47 Servicing should only be performed by a Qualified Service Agent Figure 31 S7999D DISPLAY PAGE FLOW...

Page 48: ...a tree structure in which the user navigates up and down to arrive at the desired Function The page descriptions are provided below so that you can understand the purpose of each and view the selecti...

Page 49: ...em R7910A functions The configuration page allows the user to view and set parameters that define how the connected R7910A functions in the hydronic heating system All parameters are factory configure...

Page 50: ...the same password in each control but there is no requirement to do so Make sure to record your password The user is notified that a new password is needed to change a parameter or until a password i...

Page 51: ...tton is pressed VERIFY Pressing the Verify button displays safety configuration parameters for an additional verification step to commit the changes Safety parameters are grouped into blocks that incl...

Page 52: ...corners respectively However leaving the session at this point leaves the control in an unrunnable state and confirms whether the installer still wants to do so The settings of all parameters in each...

Page 53: ...All digital I O status at time of fault Annunciator 1 8 states All annunciator I O status at time of fault Fault data Fault dependent data An alert log can be displayed for each control by pressing t...

Page 54: ...OI display When the OI display first obtains the lockout and alert history from the control during the display data synchronization no timestamps are assigned since the times that the lockouts occurre...

Page 55: ...mps on view annunciation information and switch between hydronic heating loops Central Heat and Domestic Hot Water as shown in Figure 47 If a password is required to change any of the settings on this...

Page 56: ...installation displays a blank I O level Not all analog I O can be displayed at the same time on the page so a horizontal scroll bar is used to move the view left and right to show all analog I O statu...

Page 57: ...The control configuration is grouped into the functional groups as shown in Table 11 HYDRONIC CONTROL System Identification and Access CH Central Heat Outdoor Reset DHW Domestic Hot Water DHW Storage...

Page 58: ...oom door Take combustion readings again to see if this corrects the problem If the combustion readings improve with the intake air pipe disconnected the intake air pipe is either restricted or has too...

Page 59: ...tallation to avoid this problem Turn off the power supply Disconnect the Venturi from the Combustion Blower See Figure 7 on Page 15 Unplug the 3 pin and 5 pin plugs to the Combustion Blower Assembly S...

Page 60: ...nstable power DCDC output H 6 Internal fault Invalid processor clock H 7 Internal fault Safety relay drive error H 8 Internal fault Zero crossing not detected H 9 Internal fault Flame bias out of rang...

Page 61: ...fety GVT model ID does not match application s model ID Contact the qualified service technician L 55 Application configuration data block CRC errors Contact the qualified service technician L 56 57 R...

Page 62: ...81 Delta T limit 1 Check Inlet and Outlet sensors and pump circuits for proper operation 2 Recheck the Delta T Limit to confirm proper setting 3 If previous steps are correct and fault persists replac...

Page 63: ...he combustion chamber Correct any errors 2 Make sure that the flame detector is wired to the correct terminal 3 Make sure the F G wires are protected from stray noise pickup 4 Reset and sequence the m...

Page 64: ...Check VFDs ability to change speeds 3 Change the VFD 4 If the fault persists replace the module H or L 129 Fan speed failed during preignition H or L 130 Fan speed failed during ignition H or L 131 F...

Page 65: ...NDBY and PREPURGE measure the voltage between Terminal J6 5 and L2 N Supply voltage should be present If not the lockout switch is defective and needs replacing 5 If the fault persists replace the rel...

Page 66: ...Invalid Delta T limit enable setting L 186 Invalid Delta T limit response setting L 187 Invalid DHW high limit enable setting L 188 Invalid DHW high limit response setting L 189 Invalid Flame sensor t...

Page 67: ...gh limit enable setting Contact the qualified service technician L 235 Invalid Outlet connector type setting Contact the qualified service technician L 236 Invalid Inlet connector type setting Contact...

Page 68: ...Parameter PCB was configured 35 Range PCB was configured 36 Program Module PM incompatible with product was inserted into socket CODE DESCRIPTION 37 Program Module application parameter revision diffe...

Page 69: ...en step rate was invalid 112 MIX max modulation rate was invalid vs RPM 113 MIX max modulation rate was absolute max or absolute min rates CODE DESCRIPTION 114 MIX modulation range max minus min was t...

Page 70: ...gned CODE DESCRIPTION 191 Lead Lag base load common setting was invalid 192 Lead Lag DHW demand switch setting was 193 Lead Lag Mix demand switch setting was invalid 194 Lead Lag modulation sensor set...

Page 71: ...s invalid 272 Abnormal Recycle Pressure sensor fault 273 Abnormal Recycle Safety relay drive test failed CODE DESCRIPTION 274 Abnormal Recycle Demand off during Pilot Flame Establishing Period 275 Abn...

Page 72: ...ware SLO AD linearity 339 Abnormal Recycle Hardware SLO bias not set 340 Abnormal Recycle Hardware SLO bias shorted CODE DESCRIPTION 341 Abnormal Recycle Hardware SLO electronics 342 Abnormal Recycle...

Page 73: ...Internal error Safety key bit 4 was incorrect 483 Internal error Safety key bit 5 was incorrect 484 Internal error Safety key bit 6 was incorrect 485 Internal error Safety key bit 7 was incorrect 486...

Page 74: ...anger T rise enable was invalid 562 T rise degrees was out of range 563 T rise response was invalid 564 Outlet T rise limit was exceeded 565 Heat exchanger T rise limit was exceeded 566 Heat exchanger...

Page 75: ...B BOILERS 1000 3400 ONE BOILER PRIMARY SECONDARY HYDRONIC PIPING SYSTEM LEGEND TEMPERATURE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE CIRCULATING PUMP TANK TEMPERATURE CONTROL DRAIN FULL PORT BALL VA...

Page 76: ...76 Servicing should only be performed by a Qualified Service Agent Figure 56 HOT WATER SUPPLY WATER HEATER WITH VERTICAL TANK...

Page 77: ...77 Servicing should only be performed by a Qualified Service Agent NOTES...

Page 78: ...78 Servicing should only be performed by a Qualified Service Agent NOTES...

Page 79: ...79 Servicing should only be performed by a Qualified Service Agent NOTES...

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A.O. Smith 100 Series, Service Handbook

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Summary of Contents for 100 Series

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