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GAS-FIRED COMMERCIAL
COPPER BOILERS FOR HYDRONIC
USER'S INFORMATION MANUAL
HEATING AND HOT WATER SUPPLY
GB/GW-300, 400, 500, 650, 750
SERIES 400, 401, 402, 403, 404, 405,
2-STAGE UNITS
WARNING
Should overheating occur or the gas supply fail to shut off, do
WARNING: If the information in this
not turn off or disconnect the electrical supply to the pump.
manual is not followed exactly, a fire or
Instead, shut off the gas supply at a location external to the
explosion may result causing proper
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FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY THE UNIT SHOULD NOT BE INSTALLED DIRECTLY ON A OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST CARPETED FLOOR. A FIRE HAZARD MAY RESULT. Instead, NEVER BE PLACED ON OR ADJACENT TO THE BOILER. OPEN the boiler must be installed on the A. O. Smith Combustible CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE Floor Kit Base or concrete blocks extending beyond the full width STORED OR USED IN THE SAME ROOM WITH THE BOILER. and depth of the boiler by at leas
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It is recommended that lower water temperatures be used to LIGHTING INSTRUCTIONS avoid the risk of scalding. It is further recommended, in all cases, that the water temperature be set for the lowest temperature These models have an automatic hot surface ignition system which satisfies the user's hot water needs. This will also provide mounted on the combustion chamber panel inside the front the most energy efficient operation of the water heater and jacket. This hot surface igniter ignites th
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the surrounding air pressure. Inspection of the boiler and vent ELECTRONIC HOT SURFACE system is necessary to insure that flue gas leakage to the IGNITION CONTROL BOARD surrounding area does not occur. The EMC5000 control system is a fully integrated, state of the art Inspect the external surfaces of the vent system every 3 months electronic control system. It consists of sensors, output devices, for corrosion and leakage. Inspect the vent terminations for a power switch, a 24vac transformer,
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Figure 1A. CCB (Drawing #211758) 5
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Figure 1B. FCB (Drawing #211759) 6
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Figure 1C. PDB (Drawing #211760) 7
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closed and everything else is in the proper state, a "call for stage 1 and on stage 2 of a 4-stage system and optional on heat" condition will be initiated. These leads should be others.): shorted together, when a thermostat is not being used. If it is Independent outputs that provide power to operate low and desired that the thermostat control the temperature of the high speed blower output. Dip switches on the FCB's enable/ boiler, the operating setpoint of the system should be set disable
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CCB/FCB Dip Switches: Dipswitch configurations are READ ONLY ON POWER UP. These switches are only to be set at the factory or by authorized trained personnel only! Once set at installation they generally remain that way for the duration of the life of the product. If a switch is changed, power must be cycled before the change will take effect. The status of all dipswitches can be observed on the system status screen on the UIM.CCB - Ten Position Dipswitch (Central Control Section): Water Hea
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• Stored values are recalled from memory. control probe (inlet or tank) falls below the operating setpoint • Configuration dipswitches are read. minus the differential setpoint for stage 1. It will stop heating the • Pending faults are recalled water when the temperature rises to the operating setpoint. If • Micros on all boards start running (indicated by a flashing the system has multiple stages then the differential setpoint for Yellow LED near each micro) each stage is also subtracted from
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The folllowing status information is displayed from this screen: Status Displayed *(True Condition) Input Output ECO Outlet temperature too high open - - - - LW/CO Water Level low open - - - - Blk Flue Flue blocked open - - - - Flow Water flowing closed - - - - Low Gas Gas pressure low open - - - - Tstat Thermostat requesting heat closed - - - - Hi Limit Outlet temp exceeds High Limit setpoint - - - - - - - - Pump Pump output activated - - - - On IRI Gas Pwr IRI output relay activated - - - - On
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except the fault states. If enabled the powered vent and the cold purging) the system switches to the Heat Igniter State. IRI gas valve are turned on. A command is sent to all active • Heat Igniter State: stages to cold purge the system. Cold purging clears out The sequence of operation is as follows: "The igniter relay is any combustion gas that may be in the combustion chamber. energized and the heat up period begins. After 18-20 seconds, When purging is complete the system moves to the Hea
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• User Settings Screen: change the High Limit Differential Setpoint: Each setpoint or user setting has either a limited selection of 1. Touch the MENU key. values, or a limited range of values. The Up/Down keys are 2. Scroll the ">" with the down key next to USER SETTING used to change values. After changing an item, the Select SCREEN. key is pressed to accept the change, or the Menu key is 3. Touch the SELECT key. pressed to reject the change and restore the item to its original 4. Scroll the
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14 CONNECTION DIAGRAM (Drawing #211769) FIGURE 4.
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15
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Number of cycles for each stage (Number of times stage item is selected, the ">" will then flash slowly to indicate that has been in heat mode). the item has been selected. The Up and Down keys are then Kbtu rating of the boiler (0 to 5750Kbtu in 10Kbtu increments) used to change its value. The software revision level of the CCB, and FCB micro- controllers. From the Current Error Screen this key is used to reset the system from an error: Current Error Screen: • Displays the last error that the
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TROUBLESHOOTING IGNITION SYSTEM Fault Messages and Lockout Status (* = stage number: 1 or 2) Fault Displayed Description Red LED Lockout “Display Fail” Communications with UIM interrupted Continuous Auto Reset • Check communication cable to UIM. Try moving to other Internal Communications connector on CCB. Also check the connectors where the cable is plugged in for best connecting wires. “Comm. Fail Stg.*” Communications with FCB interrupted Continuous Auto Reset • Same as above. Also try swa
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“Blocked Flue” Flue is Blocked Continuous SOFT • Caused by the blocked flue switch contacts being open when they should have been closed. Check for flue blockage, switch contacts, wiring. “High Limit” Outlet temp. exceeded high limit setpoint Continuous Auto Reset • Caused when the temperature of the outlet probe exceeds the high limit setpoint. This is an internal “software” limit switch and not an actual device. Check that the over temperature is not being caused by improper setup or operati
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Other troubleshooting hints: 6. Running the system with the gas turned off will allow the system to run through all operating steps up to flame sensing. 1. Input switches can be easily checked by observing their 7. Proper operation of the flame sensing circuit can be almost activation on the UIM System Status screen. Force the boiler completely verified through the use of a 14007 diode. The to remain in the Standby mode by opening the Thermostat anode end of the diode should be connected to th
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NOTES 20
