Gebruiksaanwijzing /service van het product TC-099 van de fabrikant A.O. Smith
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V ariable Fire Boiler Domestic Hot W ater/Hydronic Heating VF Boiler MODELS COVERED VW and VB 500, 750, and 1000 Models Series 100 and 101 Part No. TC-099 S e r v i c e H a n d b o o k Part No. TC-099 • Printed in the U.S.A. • 0407 ©2007 A. O. Smith Corporation COMMERCIAL V isit the “Information Central” link of www .
A. O. SMITH WATER PRODUCTS COMPANY VF BOILER SERVICE MANUAL Technical Training Department ©2007 CONTENTS Introduction... .............. ................. ................. .............. ...... Qualification s.............. .............. ...........
VF BOILER SERVICE MANUAL AOS WPC - Tech Training 2 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent INTRODUCTION This Service Manual is designed to aid in servicing and tro ubleshooting A. O. Smith VF boilers.
AOS WPC - Tech Training 3 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL T ools Required • Instruction Manual that came with the boiler . • Hand tools common to in stallation and service of commer cial water heaters and boilers.
VF BOILER SERVICE MANUAL AOS WPC - Tech Training 4 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent EMC 5000 MODULATI ON CONTROL SYSTEM This portion of the serv ice manual will cover the EMC 5000 Modulation Control system (EMC - Energy Managem ent Control).
AOS WPC - Tech Training 5 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL UIM - USER INTERFACE MODULE - OVERVIEW The UIM is an assembly that consists of several electr onic component s.
VF BOILER SERVICE MANUAL AOS WPC - Tech Training 6 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent UIM - USER INTERFACE MODULE - ST ATUS LIGHT S LCD dis.
AOS WPC - Tech Training 7 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL UIM - USER INTERFACE MODU LE - USER INPUT BUTTONS Select Button is used to: • Enter menu screens. • Activate adjustment mode for various settings.
VF BOILER SERVICE MANUAL AOS WPC - Tech Training 8 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent UIM - USER INTERFACE MODU LE - CHANGING SETTINGS 1 2 3 4 5 6 The sequence of UIM scre en displays below is an example of ho w to navigate the menus to change the Operating Set Point.
AOS WPC - Tech Training 9 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL UIM - USER INTERFACE MODULE - MENU SCREENS At the top center of the UIM panel is the display LCD. This LCD is used to provide information to the user through menu activated screens.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 10 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent UIM - USER INTERFACE MODULE - MENUS Log & System Info Screen: This screen displa ys the following: • Elapsed hours of operation (T otal time system has been powered up).
AOS WPC - Te ch Training 11 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL PRINCIPLES OF OPERATION VF boilers do not ha ve a gas orifice. The blower “pulls” gas from the gas valve into a V enturi attached to the suction (inlet) side of the blower (p age 12).
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 12 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent PRINCIPLE OF OPERATION (CONT) V enturi Operati on - Gas T r ain A V enturi is connected to the in let side of the combus tion blower on VF Boilers.
AOS WPC - Te ch Training 13 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL PRINCIPLE OF OPERATION (CONT) Blower Speed V erifi.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 14 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent PRINCIPLE OF OPERATION (CONT) Config Key - Blower Speed Programming The Config Key is an 18” long cable with a plug on one end and an EEPROM memory chip sealed at the other .
AOS WPC - Te ch Training 15 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL SEQUENCE OF OPERATION MCB board applies power to pu mp relay Pump I s Ener gized Flow Switch Closes Contacts NO Boiler enters Service Mode and locks out.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 16 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent SEQUENCE OF OPERATION (CONT) MCB Senses Minimum 2.
AOS WPC - Te ch Training 17 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL S T ART UP PROCEDURE Prior T o St art Up In additi.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 18 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent S T ART UP PROCEDURE (CONT) St art Up Procedure 1. Before starting the boiler , please review th e boilers Instruction Ma nual supplied with the boiler .
AOS WPC - Te ch Training 19 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL S T ART UP PROCEDURE (CONT) Adjusting Manifold Gas 13. Set the boiler to Max Mode (F iring Modes - page 17).
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 20 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent POOR COMBUSTION - IGNITION PROBLEMS If the high and.
AOS WPC - Te ch Training 21 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL POOR COMBUSTION - IGNI TION PROBLEMS (CONT) Burner Inspection 2. Remove the burner and inspec t the burner for any signs of damage or debris inside.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 22 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent POOR COMBUSTION - IGNI TION PROBLEMS (CONT) VFD Operating Parameters Approximate MCB/VFD operating parameters for natural gas m odels are shown in the first table below .
AOS WPC - Te ch Training 23 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL POOR COMBUSTION - IGNI TION PROBLEMS (CONT) Manifold Gas Pressure Check 5.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 24 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent CONTROL PANEL LAYOUT The illustration below shows the control p anel on VF boilers. Blower Prover Switches VF boilers are equipped with High and Low blower prover switches or BPS.
AOS WPC - Te ch Training 25 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL MCB - MODULATING CONT ROL BOARD - OVERVIEW MCB / C.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 26 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent MCB - MODULATING CONTROL BOARD - OVERVIEW (CONT) The MCB circuit board is the ma in controller . All instructi ons for burner modulation and temperature control originate from this circuit board.
AOS WPC - Te ch Training 27 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL MCB - SECTION A The upper left corner of the MCB cont ains the following sockets/component s: Red LED (illuminated when the F1 fuse is open or missing) F1 Fuse (7.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 28 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent MCB - SECTION B The upper middle section of the MCB.
AOS WPC - Te ch Training 29 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL MCB - SECTION C The upper right corner of the MCB .
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 30 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent MCB - SECTION D MCB Master Control Dip Switches System configurations are m ade on the MCB circuit boards wit h dip switches.
AOS WPC - Te ch Training 31 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL MCB - SECTION E The lower left corner of the MCB c.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 32 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent MCB - SECTION F This section of the MCB contains the communication or “Comm” ports: ICSP Port The ICSP port (In Circuit Serial Progra mming) is us ed for pro gramming t he MCB board .
AOS WPC - Te ch Training 33 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL MCB - SECTION G Along the bottom edge of the MCB there is a second dip sw itch (SW2). This page det ails and explains the SW2 dip switch.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 34 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent MCB SECTION H This section of the MCB contai ns a small “Daughter Board” th at cont ains the J23 and J24 sockets.
AOS WPC - Te ch Training 35 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL PDB - POWER DISTRIBUTI ON BOARD - OVERVIEW The PDB provides connection points for li ne-input (120 V AC) power , the pump, and the transformer .
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 36 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent PDB - SECTION A The left side of the PDB circuit board cont ains a terminal strip (TB1) used to connect the 120 V AC power supply to the boiler , the pump relay , and the pump motor .
AOS WPC - Te ch Training 37 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL PDB - SECTION B The mid section of the PDB contai .
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 38 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent PDB - SECTION C The upper right corner of the PDB c.
AOS WPC - Te ch Training 39 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL PDB - SECTION D The lower right corner of the PDB contains the J3 Socket and the JP1 jumper . The J3 Socket is described here the JP1 jum per is described on page 40.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 40 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent PDB - POWER SUPPLY T EST The lower right cor ner of the PDB also contains two jumpers and three pow er supply status LED lights.
AOS WPC - Te ch Training 41 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL ERROR MESSAGES - T ROUBLESHOOTING The EMC 5000 control system performs exhaustive self diagnostics and displays detected fault conditions on the UIM (page 6).
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 42 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent ERROR MESSAGES DISPLAYED MESSAGE CONDITION/INDICATE.
AOS WPC - Te ch Training 43 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 44 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Config Key CRC” Data read fro m the Config Key by the MCB was not properly confirmed at power up.
AOS WPC - Te ch Training 45 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Low AC V olt age” Power supply polarity is reversed.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 46 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/I.
AOS WPC - Te ch Training 47 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 48 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Sequence Err” Enable/disable circuit wires to VFD disconnected.
AOS WPC - Te ch Training 49 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 50 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/I.
AOS WPC - Te ch Training 51 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 52 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/I.
AOS WPC - Te ch Training 53 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 54 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/I.
AOS WPC - Te ch Training 55 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 56 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Blocked Flue” MCB senses the normally closed Blocked Flue (Exhaust) pressure switch cont acts are op en.
AOS WPC - Te ch Training 57 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Flame Stg1” Flame or ig nition failure.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 58 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Flame Stg1” (cont) Flame or ig nition failure.
AOS WPC - Te ch Training 59 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Flame Stg1” (cont) Flame or ig nition failure.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 60 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent ERROR MESSAGES (CONT) DISPLAYED MESSAGE CONDITION/INDICATES CHEC K/REPAIR “Igniter St g1” MCB is not sensing minimum igniter current of 2.
AOS WPC - Te ch Training 61 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL BOILER CONTROLS Boiler controls that are improperly in stalled or set up can cause serious operat ional and service related problems such as short cycling.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 62 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent BOILER CONTROLS (CONT) Primary System Control A Primary System Control is a top level “system” temperatur e control.
AOS WPC - Te ch Training 63 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL BOILER CONTROLS (CONT) Controlling Probe The Operating Set Point on the VF boiler ’s EM C 5000 control system r eacts to temperature sensed by the Controlling Probe.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 64 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent BOILER CONTROLS (CONT) INTERNAL T EMPERATUR E CONTR.
AOS WPC - Te ch Training 65 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL BOILER CONTROLS (CONT) EXTERNAL CONTROLS Enable/Disable Control Circuit The Enable/Disable Control Circuit is always active.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 66 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent BOILER CONTROLS (CONT) EXTERNAL CON TROLS (CONT) T ypes of External Controls An External Control can be a Pr imary System Control or a Supe rvisory Control or both.
AOS WPC - Te ch Training 67 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL OPERATING T EMPERATURES T emperature rise through the boiler: 20 - 40°F . The temperature rise ( Δ T = Delta T) through the boiler should be ma intained between 20 - 40°F while firing at 100%.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 68 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent T ECHNICAL SPECIFICATIONS Input Power and Ci rcuit Protection: Input Specifications: † Power Supply Voltage 120 VAC †.
AOS WPC - Te ch Training 69 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL T ECHNICAL SPECIFICATIONS Input Specifications (cont): † Output Specifications: † High Blower Pr over Pressur e Switch †.
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 70 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent T ECHNICAL SPECIFICATIONS Ignition Timing: Default .
AOS WPC - Te ch Training 71 of 72 Ashland City, TN © 2007 Servicing sh ould only be performed by a Qualified Service Agen t VF BOILER SERVICE MANUAL GLOSSARY Δ T: Symbol used for “Delta T .” E ngineering term to conv ey “temperature rise” or “difference” through a boiler or heat exchanger .
VF BOILER SERVICE MANUAL AOS WPC - Te ch Training 72 of 72 Ashland City, TN © 2007 Servicing shou ld only be performed by a Qualified Service Agent GLOSSARY (CONT) UIM - User Interface Module: Plastic housing that hol ds the UIB, LCD, and TSB. Provides means to both send and receive information from the user .
V ariable Fire Boiler Domestic Hot W ater/Hydronic Heating VF Boiler MODELS COVERED VW and VB 500, 750, and 1000 Models Series 100 and 101 Part No. TC-099 S e r v i c e H a n d b o o k Part No. TC-099 • Printed in the U.S.A. • 0407 ©2007 A. O. Smith Corporation COMMERCIAL V isit the “Information Central” link of www .
Een belangrijk punt na aankoop van elk apparaat A.O. Smith TC-099 (of zelfs voordat je het koopt) is om de handleiding te lezen. Dit moeten wij doen vanwege een paar simpele redenen:
Als u nog geen A.O. Smith TC-099 heb gekocht dan nu is een goed moment om kennis te maken met de basisgegevens van het product. Eerst kijk dan naar de eerste pagina\'s van de handleiding, die je hierboven vindt. Je moet daar de belangrijkste technische gegevens A.O. Smith TC-099 vinden. Op dit manier kan je controleren of het apparaat aan jouw behoeften voldoet. Op de volgende pagina's van de handleiding A.O. Smith TC-099 leer je over alle kenmerken van het product en krijg je informatie over de werking. De informatie die je over A.O. Smith TC-099 krijgt, zal je zeker helpen om een besluit over de aankoop te nemen.
In een situatie waarin je al een beziter van A.O. Smith TC-099 bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de A.O. Smith TC-099 kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met A.O. Smith TC-099 . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.
