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A.O. Smith 500 - User Manual

A.O. Smith 500
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1
A DIVISION OF A. O. SMITH CORPORATION
MC BEE, SC., RENTON, WA.,
STRATFORD-ONTARIO, VELDHOVEN-THE NETHERLANDS
www.hotwater.com
GAS-FIRED COMMERCIAL
COPPER BOILERS FOR HYDRONIC
HEATING AND HOT WATER SUPPLY
USER'S INFORMATION MANUAL
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
not turn off or disconnect the electrical supply to the pump.
Instead, shut off the gas supply at a location external to the
appliance.
PLEASE KEEP THESE INSTRUCTIONS ADJACENT TO BOILER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.
PART NO. 212132-001PRINTED IN U.S.A. 0306
INDEX PAGE
LIGHTING INSTRUCTIONS ....................................... 2-3
MAINTENANCE .......................................................... 3-4
OPERATING SEQUENCE, EMC5000 ......................... 8-14
CONNECTION DIAGRAM ............................................ 13
EMC5000 INSTRUCTIONS ...................................... 14-18
WARRANTY ................................................................. 19
WARNING
Do not use this boiler if any part has been under water.
Immediately call a qualified service technician to inspect the
boiler and to replace any part of the control system and any
gas control which has been under water.
CAUTION
TEXT PRINTED OR OUTLINED IN RED CONTAINS
INFORMATION RELATIVE TO YOUR SAFETY.
PLEASE READ
THOROUGHLY BEFORE INSTALLING AND USING THIS
APPLIANCE.
WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or loss of life.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electrical switch;
do not use any phone in your
building.
Immediately call your gas supplier
from a neighbors phone. Follow the
gas suppliers instructions.
If you cannot reach your gas
supplier, call the fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
Question and Answer IconNeed help?

Do you have a question about the A.O. Smith 500 and is the answer not in the manual?

Summary

A.O. Smith Water Heaters Users Information Manual

Important Safety Warning: Fire and Explosion Risk

Warning about fire or explosion due to incorrect manual following.

Gas Leak Emergency Procedure

Steps to take if gas is detected, including not using electrical devices.

Professional Installation and Service Requirement

Emphasizes that installation and service must be done by qualified professionals.

Overheating and Gas Supply Failure Safety

Instructions for overheating or gas supply failure, advising against disconnecting electrical supply.

Water Damage Safety Warning

Do not use the boiler if any part has been submerged in water.

Manual Index

Lists the main sections and their corresponding page numbers.

Gas Boiler Lighting Instructions

Pre-Operation Safety Precautions

Critical safety warnings and instructions before operating the appliance.

Gas Control Knob Operation Diagrams

Visual guide to operating gas control knobs for different brands.

Boiler Operating Steps

Step-by-step guide on how to start and operate the boiler.

How to Turn Off Gas Supply

Procedure for safely shutting off the gas supply to the appliance.

Boiler Lighting Process Details

Gas Shut-Off Valve Waiting Period

Critical waiting period for the gas shut-off valve before lighting.

Flammable Environment Hazards

Warning about using gas boilers in areas with flammable liquids or vapors.

Water Temperature Regulation and Scald Risk

Guidance on setting water temperature to prevent scalding, with a risk table.

Boiler Location Considerations

Factors to consider when installing the boiler in various locations.

Blocked Vent Safety System

Explanation of the blocked vent shut-off system and required actions.

Burner System Operation and Maintenance

Burner Flame Observation and Characteristics

Guide to observing burner flame characteristics for optimal performance.

Flammable Material Storage Warning

Strict warning against storing flammable materials near the appliance.

Chemical Vapor Corrosion Effects

Information on how chemical vapors can cause boiler corrosion.

Circulation Pump Maintenance

Instructions for maintaining the circulation pump.

Electronic Ignition Control Board Overview

Description of the EMC5000 electronic control system components.

Central Control Board (CCB) Details

CCB Component Layout Diagram

Diagram showing the component layout of the Central Control Board.

Flame Control Board (FCB) Details

FCB Component Layout Diagram

Diagram showing the component layout of the Flame Control Board.

Power Distribution Board (PDB) Details

PDB Component Layout Diagram

Diagram showing the component layout of the Power Distribution Board.

Boiler Appliance Operating Sequence

EMC5000 Controller Operating Modes

Overview of the four operational modes of the EMC5000 controller.

CCB and FCB Input Signals

Describes the various input signals received by the CCB and FCB.

CCB and FCB Output Signals

Details the output signals generated by the CCB and FCB.

CCB;FCB Indicator Lamps and Fuses

Explains the function of indicator lamps and fuses on the control boards.

CCB;FCB DIP Switch Configuration

Central Control Section DIP Switches

Configuration settings for the CCB's ten-position dipswitch.

Flame Control Section DIP Switches

Configuration settings for the CCB's three-position dipswitch.

FCB DIP Switch Functions

Explanation of the eight-position dipswitch functions on the FCB.

Boiler Temperature Setpoint Control

Example Temperature Setpoint Configuration

Illustrates a 2-stage system with specific setpoints and differentials.

User Interface Module (UIM) Operation

Instructions on how to use the UIM for system control and monitoring.

UIM Touch Switch Functions

Describes the functions of the five touch switches on the UIM.

UIM Status LED Indicators

Explains the meaning of the system status LED indicators on the UIM.

UIM Display Screens Overview

System Status Display Information

Details the system status information displayed on the UIM.

UIM Screen Navigation and Types

Explains how to navigate and the types of screens available on the UIM.

Control Status Screen Details

Displays the software states of the CCB and FCB micros.

CCB Control State Descriptions

Provides detailed descriptions of the CCB's control states.

FCB Control State Descriptions

FCB Idle State

Description of the FCB's idle control state.

FCB Pre-Purge State

Description of the FCB's pre-purge control state.

FCB Heat Igniter State

Description of the FCB's heat igniter control state.

FCB Check for Flame State

Description of the FCB's flame check control state.

User Settings Screen Configuration

Operating Setpoint Adjustment

Procedure for adjusting the base temperature setpoint for the control algorithm.

High Limit Setpoint Adjustment

Procedure for adjusting the automatically resettable high limit setpoint.

High Limit Differential Setpoint Adjustment

Procedure for adjusting the high limit differential setpoint.

Operating Differential Setpoint Adjustment

Procedure for adjusting independent operating differential setpoints for each stage.

Boiler Connection Diagram

External Junction Box Connections

Details wiring connections for the external junction box.

Central Control Board Wiring

Illustrates wiring connections to the Central Control Board.

Power Distribution Board Wiring

Shows wiring connections for the Power Distribution Board.

Wiring Legend and Notes

Igniter Circuit Wiring

Specific wiring details for the igniter circuit.

User Interface Board Wiring

Wiring connections for the User Interface Board.

Flame Control Board Wiring

Wiring connections for the Flame Control Board.

Boiler Type and Function DIP Switches

Explains functions of DIP switches for boiler type and features.

UIM Touch Switch Operations

Menu Key Function

Describes how to access the menu screen using the Menu key.

Select Key Function

Explains the functions of the Select key for navigation and selection.

Up and Down Keys Function

Details how to use the Up and Down keys for navigation and value adjustment.

Help Key Function

Describes how to use the Help key for accessing information.

Troubleshooting Ignition System Faults

Fault Messages and Lockout Status

Lists fault messages, their descriptions, Red LED status, and lockout type.

Display Fail Error

Error when communications with UIM are interrupted.

Communication Fail Stage Error

Error indicating communication failure with FCB stages.

Low AC Voltage Error

Error indicating insufficient incoming AC line voltage.

Fault Messages and Lockout Status (Continued)

Blocked Flue Error

Error indicating a blocked flue condition.

High Limit Error

Error when outlet temperature exceeds the high limit setpoint.

ECO Fault Error

Error indicating the ECO contacts in the outlet probe are open.

Low Water Error

Error indicating a low water level condition.

General Troubleshooting Hints

Checking Input Switches via UIM

How to check input switch functionality using the UIM Status screen.

System Operation Without Gas

Procedure for testing system operation without gas supply.

Flame Sensing Circuit Verification

Method for verifying flame sensing circuit operation using a diode.

CCB Individual Checkout

Procedure for checking out the CCB individually using dipswitch settings.

New Boiler Limited Warranty

Heat Exchanger Warranty Coverage

Details the warranty coverage for the heat exchanger, including duration.

Warranty Conditions and Exceptions

Lists the conditions and exceptions that apply to the warranty.

Service and Repair Expense Responsibility

Outlines the owner's responsibility for costs related to service and repair.

Warranty Claim Procedure

Steps to follow when making a warranty claim.

Summary

A.O. Smith Water Heaters Users Information Manual

Important Safety Warning: Fire and Explosion Risk

Warning about fire or explosion due to incorrect manual following.

Gas Leak Emergency Procedure

Steps to take if gas is detected, including not using electrical devices.

Professional Installation and Service Requirement

Emphasizes that installation and service must be done by qualified professionals.

Overheating and Gas Supply Failure Safety

Instructions for overheating or gas supply failure, advising against disconnecting electrical supply.

Water Damage Safety Warning

Do not use the boiler if any part has been submerged in water.

Manual Index

Lists the main sections and their corresponding page numbers.

Gas Boiler Lighting Instructions

Pre-Operation Safety Precautions

Critical safety warnings and instructions before operating the appliance.

Gas Control Knob Operation Diagrams

Visual guide to operating gas control knobs for different brands.

Boiler Operating Steps

Step-by-step guide on how to start and operate the boiler.

How to Turn Off Gas Supply

Procedure for safely shutting off the gas supply to the appliance.

Boiler Lighting Process Details

Gas Shut-Off Valve Waiting Period

Critical waiting period for the gas shut-off valve before lighting.

Flammable Environment Hazards

Warning about using gas boilers in areas with flammable liquids or vapors.

Water Temperature Regulation and Scald Risk

Guidance on setting water temperature to prevent scalding, with a risk table.

Boiler Location Considerations

Factors to consider when installing the boiler in various locations.

Blocked Vent Safety System

Explanation of the blocked vent shut-off system and required actions.

Burner System Operation and Maintenance

Burner Flame Observation and Characteristics

Guide to observing burner flame characteristics for optimal performance.

Flammable Material Storage Warning

Strict warning against storing flammable materials near the appliance.

Chemical Vapor Corrosion Effects

Information on how chemical vapors can cause boiler corrosion.

Circulation Pump Maintenance

Instructions for maintaining the circulation pump.

Electronic Ignition Control Board Overview

Description of the EMC5000 electronic control system components.

Central Control Board (CCB) Details

CCB Component Layout Diagram

Diagram showing the component layout of the Central Control Board.

Flame Control Board (FCB) Details

FCB Component Layout Diagram

Diagram showing the component layout of the Flame Control Board.

Power Distribution Board (PDB) Details

PDB Component Layout Diagram

Diagram showing the component layout of the Power Distribution Board.

Boiler Appliance Operating Sequence

EMC5000 Controller Operating Modes

Overview of the four operational modes of the EMC5000 controller.

CCB and FCB Input Signals

Describes the various input signals received by the CCB and FCB.

CCB and FCB Output Signals

Details the output signals generated by the CCB and FCB.

CCB;FCB Indicator Lamps and Fuses

Explains the function of indicator lamps and fuses on the control boards.

CCB;FCB DIP Switch Configuration

Central Control Section DIP Switches

Configuration settings for the CCB's ten-position dipswitch.

Flame Control Section DIP Switches

Configuration settings for the CCB's three-position dipswitch.

FCB DIP Switch Functions

Explanation of the eight-position dipswitch functions on the FCB.

Boiler Temperature Setpoint Control

Example Temperature Setpoint Configuration

Illustrates a 2-stage system with specific setpoints and differentials.

User Interface Module (UIM) Operation

Instructions on how to use the UIM for system control and monitoring.

UIM Touch Switch Functions

Describes the functions of the five touch switches on the UIM.

UIM Status LED Indicators

Explains the meaning of the system status LED indicators on the UIM.

UIM Display Screens Overview

System Status Display Information

Details the system status information displayed on the UIM.

UIM Screen Navigation and Types

Explains how to navigate and the types of screens available on the UIM.

Control Status Screen Details

Displays the software states of the CCB and FCB micros.

CCB Control State Descriptions

Provides detailed descriptions of the CCB's control states.

FCB Control State Descriptions

FCB Idle State

Description of the FCB's idle control state.

FCB Pre-Purge State

Description of the FCB's pre-purge control state.

FCB Heat Igniter State

Description of the FCB's heat igniter control state.

FCB Check for Flame State

Description of the FCB's flame check control state.

User Settings Screen Configuration

Operating Setpoint Adjustment

Procedure for adjusting the base temperature setpoint for the control algorithm.

High Limit Setpoint Adjustment

Procedure for adjusting the automatically resettable high limit setpoint.

High Limit Differential Setpoint Adjustment

Procedure for adjusting the high limit differential setpoint.

Operating Differential Setpoint Adjustment

Procedure for adjusting independent operating differential setpoints for each stage.

Boiler Connection Diagram

External Junction Box Connections

Details wiring connections for the external junction box.

Central Control Board Wiring

Illustrates wiring connections to the Central Control Board.

Power Distribution Board Wiring

Shows wiring connections for the Power Distribution Board.

Wiring Legend and Notes

Igniter Circuit Wiring

Specific wiring details for the igniter circuit.

User Interface Board Wiring

Wiring connections for the User Interface Board.

Flame Control Board Wiring

Wiring connections for the Flame Control Board.

Boiler Type and Function DIP Switches

Explains functions of DIP switches for boiler type and features.

UIM Touch Switch Operations

Menu Key Function

Describes how to access the menu screen using the Menu key.

Select Key Function

Explains the functions of the Select key for navigation and selection.

Up and Down Keys Function

Details how to use the Up and Down keys for navigation and value adjustment.

Help Key Function

Describes how to use the Help key for accessing information.

Troubleshooting Ignition System Faults

Fault Messages and Lockout Status

Lists fault messages, their descriptions, Red LED status, and lockout type.

Display Fail Error

Error when communications with UIM are interrupted.

Communication Fail Stage Error

Error indicating communication failure with FCB stages.

Low AC Voltage Error

Error indicating insufficient incoming AC line voltage.

Fault Messages and Lockout Status (Continued)

Blocked Flue Error

Error indicating a blocked flue condition.

High Limit Error

Error when outlet temperature exceeds the high limit setpoint.

ECO Fault Error

Error indicating the ECO contacts in the outlet probe are open.

Low Water Error

Error indicating a low water level condition.

General Troubleshooting Hints

Checking Input Switches via UIM

How to check input switch functionality using the UIM Status screen.

System Operation Without Gas

Procedure for testing system operation without gas supply.

Flame Sensing Circuit Verification

Method for verifying flame sensing circuit operation using a diode.

CCB Individual Checkout

Procedure for checking out the CCB individually using dipswitch settings.

New Boiler Limited Warranty

Heat Exchanger Warranty Coverage

Details the warranty coverage for the heat exchanger, including duration.

Warranty Conditions and Exceptions

Lists the conditions and exceptions that apply to the warranty.

Service and Repair Expense Responsibility

Outlines the owner's responsibility for costs related to service and repair.

Warranty Claim Procedure

Steps to follow when making a warranty claim.

A.O. Smith 500 Specifications

General IconGeneral
BrandA.O. Smith
CategoryWater Heater
Capacity50 Gallons
Energy SourceElectric
Voltage240V

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