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VF VWH0500N, Installation & Operation Manual

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VF VWH0500N Installation & Operation Manual Download Page 1

Installation & Operation Manual

Models:  500 - 2000

Up To 4:1 Turndown

This manual supplies information for the 
installation, operation, and servicing of the 
appliance.  It is strongly recommended that this 
manual and the VF Series Service Manual be 
reviewed completely before proceeding with an 
installation.  Perform steps in the order given.  
Failure to comply could result in severe personal 
injury, death, or substantial property damage.

 WARNING:

Save this manual for future reference.

100161775 / 2000019057 / VFS-I-O Rev C

Summary of Contents for VWH0500N

Page 1: ...liance It is strongly recommended that this manual and the VF Series Service Manual be reviewed completely before proceeding with an installation Perform steps in the order given Failure to comply cou...

Page 2: ...6 3 GAS CONNECTIONS Gas Supply 27 Gas Pressure Test 27 Checking Manifold Gas Pressure 27 Gas Connection 27 Gas Piping 28 Checking Gas Supply Pressure 29 High and Low Gas Pressure Switches 30 4 WATER C...

Page 3: ...flow requirements Checking equipment Upon receiving equipment check for signs of shipping damage Pay particular attention to parts accompanying the appliances which may show signs of being hit or oth...

Page 4: ...ntake system or any location from which fumes could reach the appliance or vent air intake system Codes The equipment shall be installed in accordance with those installation regulations in force in t...

Page 5: ...adjustments The appliance output ratings up to 4000 feet shall be reduced by 4 for each 1000 feet above sea level For operation above 4000 feet consult the factory VF Series AHRI Rating Model Number N...

Page 6: ...he appliance This module contains the programming that operates the blower gas valve and pumps in addition to other programmable features 15 Air intake The air intake pipe allows fresh air to flow dir...

Page 7: ...air circulation around the controls inside the unit 31 Manual shutoff valve Manual valve used to isolate the unit from the gas supply Models 500 1000 Front View Models 500 1000 Right Side inside unit...

Page 8: ...Side inside unit Models 1500 2000 Right Side inside unit Models 1500 2000 Rear View Models 1500 2000 Front View The VF Series How it works IMG00615 19 25 9 30 IMG00617 23 1 3 5 4 22 26 20 21 IMG00616...

Page 9: ...rotected so that it is not subject to physical damage by a moving vehicle 4 DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present 5 The appliance mu...

Page 10: ...ts as shown above Multiple appliances may be installed in a modular water heater installation Multiple appliances may be installed side by side with no clearance between adjacent appliances because th...

Page 11: ...Outside Air from 2 Openings Directly from Outdoors Outside Air from 1 Opening Directly from Outdoors in2 Inside Air from 2 Ducts Delivered from Outdoors Inside Air from 2 Ducts Delivered from Interior...

Page 12: ...y free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated c...

Page 13: ...ting materials can result in loss of life from flue gas spillage into working or living space Venting Category Definitions Reference National Fuel Gas Code ANSI Z223 1 CAT IV Positive pressure condens...

Page 14: ...e pressure gas fired appliance A Category IV flue MUST have all vent joints and seams sealed gastight and have provisions for a drain to properly collect and dispose of condensate that may occur in th...

Page 15: ...mbustion air from equipment room see page 17 CAT IV B CAT II requires an adapter kit See page 14 Vertical Direct Vent installation with rooftop combustion air inlet see page 16 CAT II IV E Horizontal...

Page 16: ...VENT TERMINATION SIZES MODEL CAT II VENT SIZE CAT IV VENT SIZE MODEL CAT II VENT SIZE CAT IV VENT SIZE VWH0500 7 4 VWH1500 8 6 VWH0750 9 5 VWH2000 10 8 VWH1000 10 6 B CAT II requires an adapter kit Se...

Page 17: ...special combustion air inlet cap for installation on an exterior sidewall The sidewall air inlet cap supplied in the kit is sized to provide combustion air for a single appliance only TABLE 2E AIR INL...

Page 18: ...9910119001 VWH2000 8 8 9910119006 VWH1000 6 6 9910119002 Vent Cap Air Inlet Cap F CAT IV Horizontal vent air installation with vertical or sidewall combustion air page 15 The Horizontal Vent Air vent...

Page 19: ...ategory IV venting system operates with a positive pressure in the vent This positive pressure is generated by the internal combustion air blower which operates the combustion process and also exhaust...

Page 20: ...tside of the building must not exceed a maximum of 50 equivalent feet 15 2m in length Subtract 5 feet 1 5m of equivalent length for each 90 elbow installed in the vent Subtract 2 1 2 feet 0 7m of equi...

Page 21: ...ous levels of carbon monoxide in the flue products This will cause operational problems with the heater and possible spillage of flue products that can cause personal injury death or property damage T...

Page 22: ...rrect installation and or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the heater This can result in incomplete combustion and pote...

Page 23: ...vent pipe d Ensure that the air inlet pipes are properly supported The PVC CPVC or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer s recommended solvents and standard comme...

Page 24: ...apet wall must be a minimum of 2 feet 0 61m higher than the parapet wall The vent cap should have a minimum clearance of 4 feet 1 22m horizontally from and in no case above or below unless a 4 foot 1...

Page 25: ...positive pressure flue products from the chimney These flue products can easily escape into an occupied living space causing a health hazard If there is any doubt about the condition of a masonry chi...

Page 26: ...idewall Vent Termination Clearances Venting options D E F Figure 2 10_Vent to Forced Air Inlet Figure 2 11_Vent to Doors and Windows MECHANICAL DRAFT VENT TERMINATION 24 MIN 12 MIN Figure 2 12_Vent Ab...

Page 27: ...fold gas pressure Reference the VF Series Service Manual for information regarding manifold gas pressure Gas connection Safe operation of the appliance requires properly sized gas supply piping See ga...

Page 28: ...the existing gas line is of sufficient capacity Verify pipe size with your gas supplier 2 Use new properly threaded black iron pipe free from chips If tubing is used make sure the ends are square deb...

Page 29: ...gas utility gas supplier qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control 10 If gas supply pressure is within normal range proceed to re...

Page 30: ...PROVIDED IF REQUIRED BY LOCAL CODES SEE REGULATOR INSTALLATION NOTE ON PAGE 33 ROUTING MAY VARY LOW PRESSURE SWITCH HIGH PRESSURE SWITCH TYPICAL SHUTOFF VALVE FIELD PROVIDED IF REQUIRED BY LOCAL CODES...

Page 31: ...g may experience problems with the operating controls safety switches obstruction of the flue gas passages on the heat exchanger incomplete combustion and possiblefluegasspillage Sustainedoperation at...

Page 32: ...stems will be subject to considerable expansion and contraction Rigid pipe hangers could allow the pipe to slide in the hanger resulting in noise transmitted into the system Padding is recommended on...

Page 33: ...heater MUST NOT be operated other than for brief periods during initial system startup with an inlet water temperature of less than 140 F 60 C If normal system return temperatures are less than the r...

Page 34: ...Water connections 0 5 10 15 20 50 60 70 80 90 100 Press Drop in Feet Head Flow in Gallons Per Minute Pressure Drop Chart Models 500 1000 TABLE 4C 0 5 10 15 20 25 70 80 90 100 110 120 Press Drop in Fe...

Page 35: ...oved metal clad cable 3 The circulating pump must run continuously when the appliance is being fired 4 To avoid serious damage DO NOT energize the appliance until the system is full of water Ensure th...

Page 36: ...ting Field Wiring EMS or remote thermostat connection An EMS remote thermostat or other remote temperature control may be connected to the water heater see FIG 5 3 Follow the manufacturer s instructio...

Page 37: ...output of the Boiler Management System or use the voltage signal to enable the heater Connect the enable terminals to the enable output of the BMS when used 2 Make sure the ground terminal is connect...

Page 38: ...NG AUTOMATION CONTROL TANK SENSOR 1 2 3 TANK 4 THERMOSTAT 5 6 7 8 9 LOUVER 10 PROVING 11 12 13 14 15 16 17 18 19 20 21 TANK 22 SENSOR 23 24 25 26 27 28 0 10V INPUT IMG00625 Figure 5 4_Low Voltage Fiel...

Page 39: ...o full of liquid 8 Remove the four 4 screws securing the top cover to the condensate trap and remove the cover FIG 6 1 9 Locate the plastic ball inside the float tube Verify there is nothing under the...

Page 40: ...at once WARNING Figure 7 1_Condensate Trap Propane water heaters only Your propane supplier mixes an odorant with the propane to make its presence detectable In some instances the odorant can fade and...

Page 41: ...trol if used open Is water temperature above 200 F 93 3 C 3 Is thermostat set below tank temperature 4 Is gas turned on at meter or water heater 5 Is incoming gas pressure less than 4 inches water col...

Page 42: ...Figure 7 2_Operating Instructions 42 7 Start up Installation Operation Manual...

Page 43: ...will reduce the fan speed If the outlet water temperature exceeds 195 90 6 C the control will shut the unit down until it cools off The control module monitors the flue temperature by a sensor locate...

Page 44: ...has expired or a set amount of running hours or cycles has expired all adjustable by the installer The display will alternate the standard text on the display screen with Service Due every 5 seconds T...

Page 45: ...fter prepurge the blower slows down and the hot surface igniter HSI is energized HTR PREPURGE OUT 123 9F 129 5 Once the HSI is hot the trial for ignition begins with the opening of the gas valve HTR I...

Page 46: ...ng hours Total cycles Installer Most parameters are available only to the installer accessible only by entering the installer access code see the VF Series Service Manual Saving parameters reference t...

Page 47: ...hamber and vent system of residual flue products Service The unit has been placed in a temporary mode that will allow the unit to fire for the purpose of combustion analysis OUT F When the outlet sens...

Page 48: ...ual fan motor RPM FLAME SIG uA The control will display the flame signal in dc microamps Press the Forward arrow key on the display to access Screen 5 5 DHW CFH OFF The control has not received a call...

Page 49: ...TABLE 9A MAXIMUM WATER FLOW CAUTION The maximum flow rate through a VF water heater with a copper heat exchanger must be set to provide and not exceed the following flow Model Maximum Flow 500 1000 7...

Page 50: ...circulating pump an optional Cupro Nickel heat exchanger and a revised temperature rise specification based on the water chemistry of the water to be heated Water with a hardness of less than 5 grain...

Page 51: ...RESSURE RATING OF ANY COMPONENT IN THE SYSTEM 3 SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE 4 MAXIMUM PIPING LENGTH BETWEEN TANK AND WATER HEATER S...

Page 52: ...XCEED PRESSURE RATING OF ANY COMPONENT IN THE SYSTEM 3 SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE 4 MAXIMUM PIPING LENGTH BETWEEN TANK AND WATER H...

Page 53: ...TING OF ANY COMPONENT IN THE SYSTEM 3 SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE 4 A O SMITH PIPING METHOD IS BASED ON 50 EQUIVALENT FEET OF PIPIN...

Page 54: ...EXCEED PRESSURE RATING OF ANY COMPONENT IN THE SYSTEM 3 SERVICE VALVES ARE SHOWN FOR SERVICING WATER HEATER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE 4 A O SMITH PIPING METHOD IS BASED ON 50 EQUIVA...

Page 55: ...GPM Ft Hd 500 1000 75 15 1500 2000 90 15 When installing multiple water heaters and or multiple storage tanks the diameter of the inter connecting pipe and all fittings must be increased An increase...

Page 56: ...ncomplete combustion and possiblefluegasspillage Sustainedoperation at lower than specified water temperatures may cause hazardous conditions that may result in personal injury or non warrantable dama...

Page 57: ...r heater is normally supplied with a temperature and pressure relief valve sized in accordance with applicable codes Units may be supplied with an optional pressure only relief valve When a water heat...

Page 58: ...an the burner Perform start up checkout and performance verification per Section 7 Start up If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air...

Page 59: ...tible materials gasoline and other flammable vapors and liquids Inspect appliance interior 1 Remove the outer access panels and inspect the interior of the appliance 2 Vacuum any sediment from inside...

Page 60: ...ot been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable u...

Page 61: ...urner flames at each start up after long shutdown periods or at least every six months A burner viewport is located on the burner mounting flange Perform start up and checks 1 Start appliance and perf...

Page 62: ...prevent damage to the venturi and burner gaskets 9 Disconnect the power wires to the hot surface igniter 10 Remove the hot surface igniter The hot surface igniter is fragile Use care to prevent impac...

Page 63: ...Service Manual 11 Carefully reinstall the heat exchanger and V baffles if removed from the appliance 12 Reinstall the inner jacket panel burner manifolds wires and hoses Use new gasket material to ens...

Page 64: ...ary from l a u t c a o t r e f e R s m a r g a i d n o n w o h s e s o h t components for proper connector block locations whe t i n u t o o h s e l b u o r t o t s m a r g a i d g n i s u n 3 2 1 3 2...

Page 65: ...X6 6 X6 11 CN2 6 2 4 5 6 21 22 23 24 25 26 27 28 7 3 1 CN2 4 CONNECTION BOARD CN1 10 CN1 3 X8 12 X8 1 TANK SENSOR CONNECTION BOARD X8 2 X8 3 X8 4 OUTLET SENSOR INLET SENSOR FLUE SENSOR INTERGRATED CON...

Page 66: ...66 Installation Operation Manual Notes...

Page 67: ...or and returning the claimed defective part to such distributor c All cost necessary or incidental for any material and or permits required for installation of the replacement 4 LIMITATIONS ON IMPLIED...

Page 68: ...e Revision B ECO C14970 reflects wiring and ladder diagram updates Revision C Change 500001030 reflects the update of Table 4 D on page 34 as well as the addition of the factory startup logo on the ma...

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