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GAS FIRED COMMERCIAL COPPER BOILERS

1. 2 SAFE INSTALLATION USE AND 3 GENERAL SAFETY e 4 INTRODUCTIONS peye voua dane ns eerie 5 Abbreviations USEN scanere ni aas 5 a AEREE 5 CONTROL COMPONENTS isit sis asos kk esawoaoes we sanson tb ses 6 BOILER START UP AND OPERATIONS 10 Filling the system PIECAULONS 2 ik pedi ma ab vues cathe aou 10 Pilot and MAIN DUMMET ka by ae 10 Checking and adjusting input 12 TROUBLESHOOTING via ia ann pete 16 MAINTENANCE PROCEDURES 24 Manual reset high limit switch continuity 24 Pressure relief valv test 24 Cleaning and flushing iMStUC ONS 24 Venting 25 n onn po np t 26 EIT WARRANTY secre poukisa te 27 SAFE INSTALLATION USE AND SERVICE The proper installation use and servicing of thi
2. RESET BUTTON HIGH LIMIT SWITCH COVER PROTECTOR SWITCH FIGURE 5 HIGH LIMIT SWITCH PRESSURE RELIEF VALVE An ASME rated pressure relief valve is furnished with the boiler A fitting for the pressure relief valve is provided in the top of the boiler Never operate the heating elements without being certain the boiler is filled with water and a properly sized pressure relief valve is installed in the pressure relief valve opening provided The pressure rating of the pressure relief valve should be equal to or less than the rated pressure capacity of any component in the system including the boiler Should the valve need to be replaced call the toll free phone number listed on the back of this manual for further technical assistance AWARNING e Pressure Relief Valve must comply with ASME code e Properly sized Pressure Relief Valve must be installed in opening provided e Can result in overheating and excessive tank pressure e Can cause serious injury or death A discharge pipe from the pressure relief valve should terminate at an adequate floor drain Do not thread plug or cap the end of the drain line CAUTION e Pressure Relief Valve discharge pipe must terminate at adequate drain The Discharge Pipe Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall not be exposed to free
3. SURE PILOT IS BURNING IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS BELOW ON THIS LABEL TO TURN OFF GAS TO APPLIANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER MAIN PILOT BURNER TO TURN OFF GAS TO APPLIANCE 1 TURN OFF ALL ELECTRICAL POWER TO APPLIANCE 2 TURN TOP KNOB OF GASCONTRO L VALVE CLOCKWISE CYTO OFF FIG A 3 TURN MAIN FIRING VALVE COUNTER CLOCKWISE O OFF FIG C AND TURN PILOT FIRING VALVE COUNTERCLOCKWISE TO OFF FIG E 4 SET THE THERMOSTAT TO LOWWEST SETTING TROUBLESHOOTING Before any extensive troubleshooting perform the following e Voltage 24 vac is supplied by transformer Ensure that e Boiler is wired according to wiring diagram Voltage 120 vac is supplied to the boiler Note Cross wiring the 24 volt circuit of the relay will short the transformer e System control tank temperature control thermostat etc is calling for boiler operation call for heat Other contacts switches are closed relay low water cutoff flow switch coil protector pressure switch etc e Gas supply pressure is within the maximum and minimum operating ranges listed on the boiler rating plate label All wire terminals connectors are firmly attached to valves modules switches limit controls etc For Propane LP models only check for possible lockout condition of the ignition module TABLE 3 CER TEMP 80 RECO
4. burnt or cracked and or ground wire YES Ensure ground strap is the closest metal to the igniter sensor rod electrode to prevent the spark from shorting out to other metal parts pilot screen pilot shield etc Carefully bend down wards top of ground Ignition cable must not touch metal surfaces or current strap to achieve carrying wires 1 8 spark gap Is there a 1 8 gap between ground strap and electrode YES Is ceramic insulator surrounding the electrode in good Replacepilot Dame condition not cracked or broken YES Replace ignition NO Is there excessive draft conditions that may cause pilot module burner ignition problems YES Correct draft problems in a manner that would ensure adequate combustion and ventilation air and proper pilot burner performance 18 CHECKING HONEYWELL S 8600H OR S 8600M INTERMITTENT IGNITION CONTROLS PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT situation by a W Does the pilot flame cover 3 8 to 1 2 installation or user s manual on how to of igniter sensor rod adjust pilot flame YES Replace ignition module Does spark stay on for more than 15 seconas after the pilot is proven lit 15 voltage 24 Vac across terminals MV amp MV PV Attach NO Are the wires securely attached to the main wires valve operator on the gas control and to firmly terminals MV amp MV PV on ignition module Replace
5. GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT injury or loss of life GAS VALVE CONTROL KNOB FIGURE A FIGURE B OFF POSITION ON POSITION HONEYWELL GAS VALVE WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal FLAMMABLE C USE ONLY YOUR HAND TO TURN THE GAS CONTROL KNOB NEVER USE TOOLS IF THE KNOB WILL NOT TURN BY HAND DON T TRY TO REPAIR IT CALLA QUALIFIED SERVICE TECHNICIAN FORCE OR ATTEMPTED REPAIR MAY RESULT IN AFIRE OR EXPLOSION DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATER AND INLET LINES ARE FULLY OPEN FIGURE C FIGURE C FIGURE D ea HANDLE OFF HANDLE ON POSITION POSITION MANUAL SHUTOFF VALVE HANDLE OFF POSITION PILOT HANDLE ON POSITION PILOT PILOT FIRING VALVE OPERATING INSTRUCTIONS 5 STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL SET THE THERMOSTAT TO LOWEST SETTING TURN OFF ALL ELECTRIC POWER TO THE APPLIANCE THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT DO
6. cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This boiler can cause low level exposure to some of the substances listed in the Act IMPORTANT DEFINITIONS Gas Supplier The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building APPROVALS ANBI CERTIFIED www ahridirectory org GP CERTIFIED Low Lead Content H GENERAL SAFETY AWARNING Read and understand this manual and all Warnings and Cautions within before installing and using this appliance Place these instructions adjacent to boiler and notify owner to keep for future reference A DANG ER Untempered hotwater can cause severe burns instantly resulting in severe injury or death Children elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe tempera
7. from 100 F 37 7 C to 220 F 104 4 C It is recommended that lower water temperatures be used to avoid the risk of scalding It is further recommended in all cases that the water temperature be set for the lowest temperature which satisfies the user s hot water needs This will also provide the most energy efficient operation of the boiler and minimize scale formation The boiler should be located in an area where the general public does not have access to set temperatures Setting the water temperature at 120 F 49 C will reduce the risk of scalds Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm and the physically mentally disabled Table 1 shows the approximate time to burn relationship for normal adult skin If anyone using hot water provided by the boiler being installed fits into one of these groups or if there is a local code or state law requiring a certain water temperature at the point of use then special precautions must be taken Contact a qualified service technician or qualified agency TABLE 1 TEMPERATURE AND TIME TO PRODUCE BURNS Time to Produce 2nd amp 3rd Degree Burns on Adult Skin 180 F 82 C Nearly instantaneous 170 F 77 C Nearly instantaneous 160 F 71 C About 1 2 second Water Temperature Use anti scald valve s in the hot water system to reduce the risks of scalds at points of use such as lavatories si
8. minute delay Control remains in wait mode When the fault corrects control resumes normal operation after a one minute delay Remain in lockout until Call for Heat is cycled Remain in lockout until Call for Heat is cycled Control waits until flame is no longer sensed and then goes to soft lockout Flash code continues Control auto resets from soft lockout after one hour Control auto resets from soft lockout after one hour e Heartbeat Constant 1 2 second bright 1 2 second dim cycles A single flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence If system fails to light on next trial for ignition check gas supply pilot burner flame sense wiring contamination of flame sensor burner ground connection Check for pilot flame Replace gas control valve if pilot flame is present If no pilot flame cycle Call for Heat If error repeats replace control Check flame sense lead wire for damage or shorting Check that flame sensor is in proper position Check flame sensor ceramic for cracks damage or tracking Check transformer and AC line for proper input voltage to the control Check with full system load on the transformer Check gas supply line pilot burner spark and flame sense wiring flame sensor contaminated or out of position burner ground connection Check gas supply pilot burner flame sense wiring
9. not applicable 5 minute Retry Delay Pilot flame not detected during trial for ignition Recycle Flame failed during run Flame sensed out of sequence Flame sense leakage to ground Low secondary voltage supply below 15 5 Vac 5 minute Retry Delay On every third retry on the same Call for Heat On every 6th flame failure during run on the same Call for Heat Flame sensed out of sequence longer than 10 seconds FF 2 3 4 7 6 2 6 3 6 4 ON Soft lockout due to error detected Control auto resets from soft lockout during self check sequences after one hour AFlash Code Descriptions Flash Fast rapid blinking Initiate new trial for ignition after retry delay completed Initiate new trial for ignition Flash code will remain through the ignition trial until flame is proved If situation self corrects within 10 seconds control returns to normal sequence If flame out of sequence remains longer than 10 seconds control goes to Flash code 6 4 see below Control remains in wait mode When the fault corrects control resumes normal operation after a one minute delay Control remains in wait mode When the fault corrects control resumes normal operation after a one minute delay Initiate new trial for ignition after retry delay completed 5 minute retry delay then initiate new trial for ignition Control waits until flame is no longer sensed and then goes to soft lo
10. not light as the contact in this circuit is normally open when the resistor is cool 3 Remove the test light Apply 120 volts to the white and red leads which power the 1900 ohm resistor After a warming period the contacts of the thermal balancer should operate 5 Remove the test light 6 Apply the test light as described in steps 1 and 2 While the resistor is still warm the lamp indications should be the opposite as described previously 1900 OHM RESISTOR NO SWITCH CONTACTS WHITE BLACK YELLOW FIGURE 4 THERMAL BALANCER RED MANUAL RESET HIGH LIMIT This boiler is equipped with a manual reset high limit switch located under the small cover on the side of the jacket see Figure 5 This device provides positive shutdown of the boiler in the event of boiler or system malfunction Should the surface temperature of the copper tubing heat exchanger reach 250 F 120 C the high limit switch will activate the gas control valve will close the pilot and main burners will be extinguished If the high limit switch should shut off unit check the following conditions No water in boiler e Restricted water flow through the boiler Improper wiring boiler firing without circulating pump operating Pump failure After correcting failure condition remove the protector switch cover and push the reset button The high limit switch may be reset after the coil surface cools to 6 F 3 3 C below the trip setting
11. repeats replace control Reset by cycling Call for Heat If error repeats replace the control e X Y flash codes signify that the LED flashes X times at 2Hz remains off for two seconds flashes Y times at 2Hz remains off for three seconds and then repeats the sequence 22 TABLE 6 LOCKOUT MODELS B H D AND J ONLY GREEN LED STATUS CODES GREEN LED FLASH CODE INDICATES NEXT SYSTEM ACTION No Call for Heat not applicable RECOMMENDED SERVICE ACTION Flash Fast Startup Flame sense calibration not applicable Heartbeat Normal operation not applicable Recycle Flame failed during run Flame sensed out of sequence Flame sense leakage to ground Failed trial for ignition resulting in lockout More than 5 flame failures during run on the same Call for Heat resulting in lockout Flame sensed out of sequence longer than 10 seconds Soft lockout due to error detected during self check sequences AFlash Code Descriptions e Flash Fast rapid blinking Low secondary voltage supply below 15 5 Vac Initiate new trial for ignition Flash code will remain through the ignition trial until flame is proved If situation self corrects within 10 seconds control returns to normal sequence If flame out of sequence remains longer than 10 seconds control goes to Flash code 6 4 see below Control remains in wait mode When the fault corrects control resumes normal operation after a one
12. serious personal injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual CAUTION Improper installation and use may result in property damage Donotoperate boiler ifflood damaged Installinlocation with drainage e Fill boiler with water before operation e Bealert for thermal expansion Refer to instruction manual for installation and service INTRODUCTION This design complies with the current edition of the ANSI Z21 13 low pressure boiler standard Compliance under this standard implies that when the boiler underwent test the gas manifold and control assembly provided on the boiler met safe lighting and other performance criteria Detailed installation diagrams are found in this manual These diagrams will serve to provide the installer a reference for the materials and methods of piping necessary It is essential that all water gas piping and wiring be installed as shown on the diagrams You should thoroughly read and understand this manual before installation and or operation of this boiler The factory warranty will be void if the boiler s have been improperly installed or operated In addition to these instructions the boiler s shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made These shall be carefully followed in all cases Authoriti
13. should the input exceed the rate shown on the boiler s rating label e Overfiring could result in damage to the boiler s and sooting e Gas and carbon monoxide detectors are available Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 1 Follow steps 1 thru 6 of the OPERATING INSTRUCTIONS on Page 15 Attach a pressure gauge or a manometer to the manifold pressure tapping and refer to Table 2 for correct manifold pressure Follow steps 7 thru 11 of the OPERATING INSTRUCTIONS Use this formula to clock the meter Be sure that other gas consuming appliances are not ON during this interval 3600 T x H Btuh Btuh T H The approximate actual input rate Time in seconds to burn one cubic foot of gas Heating value of the fuel gas in Btu per cubic foot of gas EXAMPLE 0 seconds ft 050 Btu ft natural gas O Gas flow through meter 3600 x 1050 9 0 420 000 Btuh Small changes in the input rate may be made by adjusting the manifold pressure refer to Gas Manifold Pressure Regulators in the Instruction Manual Under no circumstances should you exceed the maximum input rate for the boiler Refer to Recovery Capacities Table in the Instruction Manual 12 5 Repeat steps 1 thru 6 of the OPERATING INSTRUCTIONS 6 Remove the pressure gauge or manometer from the manifold pressure tapping Replace the screw in plug in the manifold pr
14. the pilot gas adjustment located in the gas control valve The pilot flame should envelop 3 8 to 1 2 inch 10 12 mm of the tip of the thermocouple Remove pilot adjustment cover screw Figure 8 Turn inner adjustment screw or pilot adjusting valve clockwise to decrease or counterclockwise to increase pilot flame Be sure to replace cover screw on combination gas control valve after adjustment to prevent possible gas leakage f Clogged pilot burner orifice e Clean or replace orifice A clogged orifice will restrict gas flow and result in low thermocouple output g Incorrect orifice e Replace The Orifice size is stamped on the wrench flats h Clogged primary air opening e Restricted air passages will soften the pilot flame and result in poor thermocouple flame impingement GROUND STRAP PROPER PILOT FLAME ADJUSTMENT BURNER HEAD INSULATED ELECTRODE TYPICAL PILOT BURNER FLAME WIRING TERMINALS 3 OUTLET PRESSURE TAP PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW PILOT ADJUSTMENT GAS UNDER CAP SCREW CONTROL HW 420 520 amp 670 FIGURE 8 ADJUSTING PILOT FLAME CHECKING AND ADJUSTING INPUT AWARNING e Under no circumstances should the input exceed the rate shown on the boiler s rating label e Overfiring could result in fire or explosion e Gas and carbon monoxide detectors are available AWARNING Breathing Hazard Carbon Monoxide Gas e Under no circumstances
15. CONTROL COUNTER CLOCKWISE TO ON FIG OPEN FIRING AND PILOT MANUAL VALVES COUNTER CLOCKWISE 8 TURN ON ALL ELECTRIC POWER TO THE APPLIANCE 9 SET SYSTEM TEMPERATURE CONTROLLER TO DESIRED SETTING 10 WHEN CONTROLLER CALLS FOR HEAT THE CIRCULATING PUMP WILL OPERATE AND THE PILOT BURNER WILL BE SPARK IGNITED GAS CONTROL WILL OPEN AND MAIN BURNER WILL THEN IGNITE NOTE IF PILOT FAILS TO IGNITE TURN OFF APPLIANCE AND CONSULT YOUR INSTALLATION AND USER S MANUAL FOR ADJUSTMENTS AND TROUBLE SHOOTING IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER TO TURN OFF GAS TO APPLIANCE C TURN TOP KNOB OF GAS CONTROL VALVE CLOCKWISE TO OFF POSITION SEE FIG A CLOSE FIRING AND PILOT MANUAL VALVES CLOCKWISE SEE ABOVE LIGHTING AND OPERATING INSTRUCTIONS NATURAL AND PROPANE WITH LI D FOR HW420 8 UP FOR YOUR SAFETY READ BEFORE LIGHTING W A A A THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT DO NOT TRY TO LIGHT THE PILOT BY HAND B BEFORE LIGHTING SMELL ALL AROUND THE APPLIANCE AREA FOR GAS BE SURE TO SMELL NEXT TO THE FLOOR BECAUSE SOME GAS IS HEAVIER THAN AIR AND WILL SETTLE ON THE FLOOR WHAT TO DO IF YOU SMELL GAS e DO NOT TRY TO LIGHT ANY APPLIANCE e DO NOT TOUCH ANY ELECTRIC SWITCH e DO NOT USE ANY PHONE IN YOUR BUILDING e IMMEDIATELY CALL YOUR
16. E OFF POSITION LIGHTING INSTRUCTIONS If you do not follow these instructions exactly a fire or explosion may result causing property damage personal FLAMMABLE WHAT TO DO IF YOU SMELL GAS DO NOT TRY TO LIGHT ANY APPLIANCE DO NOT TOUCH ANY ELECTRIC SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT C USE ONLY YOUR HAND TO TURN THE GAS CONTROL KNOB NEVER USE TOOLS IF THE KNOB WILL NOT TURN BY HAND DO NOT TRY TO REPAIR IT CALL A QUALIFIED SERVICE TECHNICIAN FORCE OR ATTEMPTED A THIS APPLIANCE IS EQUIPPED WITH AN IGNITION REPAIR MAY RESULT IN A FIRE OR EXPLOSION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT DO NOT TRY TO LIGHT THE PILOT BY HAND D DO NOT USE THIS APPLIANCE IF ANY PART n HAS BEEN UNDER WATER IMMEDIATELY CALL B BEFORE OPERATING SMELL ALL AROUND THE APPLI A QUALIFIED SERVICE TECHNICIAN TO ANCE AREA FOR GAS BE SURE TO SMELL NEXT TO INSPECT THE APPLIANCE AND TO REPLACE THE FLOOR BECAUSE SOME GAS IS HEAVIER THAN ANY PART OF THE CONTROL SYSTEM AND ANY AIR AND WILL SETTLE ON THE FLOOR GAS CONTROL WHICH HAS BEEN UNDER WATER GAS VALVE FIGURE A FIGURE B FIGURE jeu CONTROL KNOB As Ore POSITION 55 An FIGURE D ee ON 6 POSITION 9 gt PILOT PILOT FIRING VALVE ON POSITION 7 TURN TOP KNOB OF GAS
17. LATION OPERATION REPAIR OR REPLACEMENT OF THE BOILER THE WARRANTOR Should NOT BE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OF THE UNIT INCONVENIENCE LOSS OR DAMAGE TO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE THE WARRANTOR SHOULD NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY WHETHER DIRECT OR INDIRECT AND WHETHER ARISING IN CONTRACT OR TORT a Some states and provinces do not allow the exclusion or limitation of the incidental or consequential damage so the above limitations or exclusions may not apply to you b This warranty gives you specific legal rights and you may also have other rights which vary from state to state or province to province Fill in the following for your own reference Keep it Registration is not a condition of warranty The model and serial number are found on the boiler s rating plate Owner Installation Address City and State Zip Code Date Installed Model No Serial No Dealer s Name Phone No Dealer s Address FILL IN WARRANTY AND KEEP FOR FUTURE REFERENCE 27 f Smith 25589 Highway 1 McBee SC 29101 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com 28
18. NOT TRY TO LIGHT THE PILOT BY HAND REFER TO DIAGRAMS ABOVE TURN TOP KNOB OF GAS CONTROL CLOCKWISE OFF POSITION FIG A TURN MANUAL SHUTOFF VALVE COUNTERCLOCK WISE TO OFF FIG C TURN PILOT MANUAL VALVE COUNTERCLOCKWISE TO OFF FIG E WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS THEN SMELL FOR GAS INCLUDING NEAR THE FLOOR IF YOU SMELL GAS STOP FOLLOW B IN THE SAFETY INFORMATION ABOVE ON THIS LABEL IF YOU DON T SMELL GAS GO TO THE NEXT STEP TURN TOP KNOB OF GAS CONTROL COUNTER CLOCKWISE TO ON FIG TURN PILOT FIRING VALVE CLOCKWISE ON FIG F TURN ON ALL ELECTRIC POWER TO THE APPLIANCE 11 SET THERMOSTAT TO DESIRED SETTING PILOT BURNER WILL BE IGNITED BY ELECTRONIC SPARK 12 LOCATE PEEP HOLE IN FRONT OF THE PILOT BURNER MAKE SURE PILOT IS BURNING ADVISORY THERE IS AFIFTEEN 15 SECOND TRIAL PERIOD FOR PILOT IGNITION WHICH IS TIME ENOUGH FOR IGNITION WHEN AIR HAS BEEN BLED FROM GAS LINES PRIOR TO IGNITIION ATTEMPT IF PILOT FAILS TO IGNITE AND YOU SUSPECT THAT IT IS DUE TO AIR IN THE LINES CLOSE PILOT MANUAL VALVE AND REPEAT LIGHTING PROCEDURE STEPS 1 THRU 12 13 WITH PILOT FLAME ESTABLISHED TURN MANUAL SHUT OFF VALVE CLOCKWISE TO ON FIG D TO ALLOW GAS TO REACH MAIN BURNER NOTE THE REDUNDANT MAIN COMBINATION VALVE WILL ALREADY BE OPEN AND MAIN BURNER WILL IGNITE ADVISORY IF MAIN BURNER FAILS TO IGNITE MAKE
19. User s Manual GAS FIRED COMMERCIAL COPPER BOILERS MODELS HW a 300 399 420 520 670 A S m h FOR HYDRONIC HEATING AND HOT WATER SUPPLY PT UP FLOW MODELS ae OPERATION MAINTENANCE eu rkay LIMITED WARRANTY Aart CERTIFIED www ahridirectory org Low Lead Content H li A O SMITH 18 WARNING If the information in these i instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death 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 e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department AWA RN l N G Installation and service must be Read and understand this manual performed by a qualified installer and all Warnings and Cautions service agency or the gas supplier installing and using Place these instructions adjacent av to boiler and notify owner to keep Thank you for buying this energy efficient boiler for future reference We appreciate your confidence in our products PRINTED IN THE U S A 0212 321082 000 TABLE OF CONTENTS TABLE OF CONTENT S
20. VERY SYSTEM CHECKOUT PROCEDURE Use this checkout for Cer Temp 80 Recovery Systems For hot water supply application only SYSTEM OPERATION CHECKOUT SEQUENCE CAUSE REMEDY CORRECT INCORRECT Tank temperature control Pump and burner remain thermostat defective Set tank temperature burner shut off incorrect 20 F 10 C below tank With thermal balancer continuous operation water temperature pump off delay of Gas control valve stuck Correct or replace approximately 2 minutes or defective valve Burner on incorrect High limit control set too Replace If ow problem proven to ee be at this control by High limit control applying jumper to differential too wide terminals Circulating pump on incorrect iach itch h Remove control Set tank temperature oP PIGS ow Haas cover depress control thermostat Circulating pump and activated reset button 20 F 10 C above tank burner on water temperature Gas control valve or wiring defective Check wiring Repair or replace valve Power off or system Check power supply Circulating pump and wiring is incorrect and wiring burner off Tank temperature control thermostat defective System wiring is Li Burner on 9 Correct wiring incorrect Boiler outlet High limit control temperature exceeds Circulating pump on Circulating pump and defective or set too high 210 F 100 C burner on max should be
21. arious system accessories and even deteriorate circulation seals and impellers It is recommended that after installation the boiler and system when filled should include the proper percentage of cleaning solution related to approximate water volume of the system Fire and circulate for about one hour and then flush clean with fresh water Commercial grease removing solutions are available from your distributor VENTING MAINTENANCE It is recommended that the heating surfaces and vent piping of the boiler be checked every six months for dust deterioration and carbon deposits Remove all soot or other obstructions from chimney and flue which will retard free draft Replace any damaged or deteriorated parts of the venting system Qualified servicers should follow this procedure when the boiler s external heating surfaces and vent pipe need cleaning A WARNING Do not use a nylon brush or other static creating material to clean dust and carbon deposits from heating surfaces and vent Such deposits are flammable and may be ignited by static electricity Use a metal brush to minimize the danger of explosion 1 off the electrical power main manual gas shutoff and pilot valves if applicable Allow boiler parts and vent to cool before disassembly 2 Remove the boiler draft diverter and vent pipe running to the chimney e Check parts and chimney for obstructions and clean as necessary 3 Remove burner from bo
22. ckout Flash code continues Control auto resets from soft lockout after one hour e Heartbeat Constant 1 2 second bright 1 2 second dim cycles A single flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence If system fails to light on next trial for ignition check gas supply pilot burner spark and flame sense wiring flame sensor contaminated or out of position burner ground connection If system fails to light on next trial for ignition check gas supply pilot burner flame sense wiring contamination of flame sensor burner ground connection Check for pilot flame Replace gas control valve if pilot flame is present If no pilot flame cycle Call for Heat If error repeats replace control Check flame sense lead wire for damage or shorting Check that flame sensor is in proper position Check flame sensor ceramic for cracks damage or tracking Check transformer and AC line for proper input voltage to the control Check with full system load on the transformer Check gas supply line pilot burner spark and flame sense wiring flame sensor contaminated or out of position burner ground connection Check gas supply pilot burner flame sense wiring contamination of flame sensor burner ground connection Check for pilot flame Replace gas control valve if pilot flame present If no pilot flame cycle Call for Heat If error
23. cludes keeping pilot shield not shown free of lint cleaning the burner head the primary air opening and the orifice of the pilot burner Figure 7 a Open fused disconnect switch or shut off electrical power to the boiler b Disconnect wire from MV wire on valve c Close fused disconnect switch to restore electrical power to the boiler The pilot will now ignite provided the system is calling for heat d Adjust pilot flame To adjust the pilot flame remove the cap screw from the pilot adjusting screw Figure 8 and turn to deliver a sufficient flame at the pilot burner to cover 3 8 to 1 2 10 12 mm of the sensing probe tip See Figure 7 Check for good terminal connection at the sensing probe at the pilot burner assembly if pilot does not light IGNITOR SENSOR ROD PILOT BURNER GROUND WIRE TO ELECTRONIC IGNITION i CONTROL muma IGNITION CABLE PILOT GAS TUBING SPARK IGNITION PILOT BURNER FIGURE 7 SPARK IGNITION PILOT BURNER AND BURNER FLAME WIRING TERMINALS 3 PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW OUTLET PRESSURE TAP INLET PRESSURE TAP GROUND TERMINALS 2 OUTLET PILOT ADJUSTMENT GAS UNDER CAP SCREW CONTROL HW 300 amp 399 Check for electrical power to the valve If electrical power and gas are present at the valve and the pilot does not operate when system calls for heat replace valve e Low gas pressure Adjust pilot flame by means of
24. contamination of flame sensor burner ground connection Check for pilot flame Replace gas control valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Reset by cycling Call for Heat If error repeats replace the control e X Y flash codes signify that the LED flashes X times at 2Hz remains off for two seconds flashes Y times at 2Hz remains off for three seconds and then repeats the sequence 23 MAINTENANCE PROCEDURES These boilers are designed to give many years of efficient and satisfactory service when properly operated and maintained To assure continued good performance the following recommendations are made The area around the boiler should be kept clean and free from lint and debris Sweeping the floor around the boiler should be done carefully This will reduce the dust and dirt which may enter the burner and pilot air passages causing improper combustion and sooting The flow of combustion and ventilation air to the boiler must not be obstructed The boiler area must be kept clear and free from combustible materials gasoline and other flammable vapors and liquids Any safety devices including low water cutoffs used in conjunction with this boiler should receive periodic every six months inspection to assure proper operation A low water cutoff device of the float type should be flushed every six months All pressure relief valves should be inspec
25. ctronic components of the system and also serves as a control wiring system for the controls mounted on the boiler The control module performs the following functions 1 Checks for safe start by sensing for a false flame condition on start up 2 Generates a potential of 15 000 volts for spark ignition of the pilot burner 3 Opens the pilot valve 4 Discontinues ignition spark when the pilot flame is established The S 8600 control used on propane gas models provides safety lockout if the pilot fails to ignite within the pilot flame establishing period The S 8600 control used on natural gas models continues trial for ignition until pilot flame is established 5 After proof of pilot flame opens then main valve On a power loss shuts the boiler down When power is restored it will begin a new ignition cycle 7 loss of flame shuts off main gas and starts trial for pilot ignition Please refer to Troubleshooting section for more information l FIGURE 3 S 8600 INTERMITTENT IGNITION CONTROL MODULE IID THERMAL BALANCER Figure 4 shows the internal wiring of the thermal balancer The device may be tested after disconnecting the four leads from their respective terminals on the unit 1 Apply a test light to the yellow and red leads The lamp should light as the contact in this circuit is normally closed when the resistor is cool 2 Apply a light to the black and yellow leads The lamp should
26. es having jurisdiction should be consulted before installations are made In the absence of local codes the installation must comply with the current editions as follows In the United States The National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electric Code NFPA 70 In Canada Installation Code CAN CSA B149 1 and Canadian Electrical Code CSA C22 1 ABBREVIATIONS USED Abbreviations found in this Instruction Manual include e ANSI American National Standards Institute e ASME American Society of Mechanical Engineers NEC National Electrical Code e NFPA National Fire Protection Association UL Underwriters Laboratory e CSA Canadian Standards Association QUALIFICATIONS QUALIFIED INSTALLER OR SERVICE AGENCY Installation and service of this boiler requires ability equivalent to that of a Qualified Agency as defined by ANSI below In the field involved Installation skills such as plumbing air supply venting gas supply and electrical supply are required in addition to electrical testing skills when performing service ANSI 221 13 CSA 4 9 Qualified Agency Any individual firm corporation or company that either in person or through a representative is engaged in and is responsible for a the installation testing or replacement of gas piping or b the connection installation testing repair or servicing of appliances and equipment that is experienced in such work that is famil
27. essure tap 7 Repeat steps 7 thru 11 of the OPERATING INSTRUCTIONS on Page 15 The boiler will resume normal operation When the boiler is operating at full capacity or full gas input it should consume 1 cu ft of gas in approximately the time indicated in Table 2 TABLE 2 CONSUMPTION RATE REFER TO OPERATING AT FULL INPUT OR FULL CAPACITY TYPE GAS TIME TO CONSUME 1 CU FT OF GAS SECONDS HW 420 fwaz HW 670 pe Pa fe HEATING VALUE BTUI FT 22 6 e Minor variances from input rating plate can be corrected by adjustment of gas pressure regulators The inlet gas pressure must not exceed or be less than the values shown on rating plate STAGE 1 TRIAL FOR IGNITION STAGE 2 MAIN BURNER OPERATION THERMOSTAT CONTROLLER CALLS FOR HEAT SPARK GENERATOR POWERED First valve pilot operator opens PILOT BURNER OPERATION Pilot burner lights Pilot burner does not light Module senses Module flame current After 15 sec ignition shut down 5 minute time delay before re try S 8600H After 15 sec ignition system locks out must be manually reset FLAME CURRENT SENSED e Spark generator off e Second valve operator main opens POWER INTERRUPTION System shuts off restarts when power is restored MAIN BURNER OPERATION Module monitors pilot flame current PILOT FLAME FAILURE Main valve closes Module starts trial for ignition THERMOSTAT CONTROLLER SATISFIED Valve
28. g and administrative charges for forwarding the replacement part from the nearest distributor and returning the claimed defec tive part to such distributor c All cost necessary or incidental for any material and or permits required for installation of the replacement LIMITATIONS ON IMPLIED WARRANTIES Implied warranties including any warranty of merchantability imposed on the sale of this boiler under state or provincial law are limited to one 1 year dura tion for the boiler or any of its parts Some states and provinces do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you CLAIM PROCEDURE Any claim under this warranty should be initiated with the dealer who sold the boiler or with any other dealer handling the warrantor s products If this is not practicable the owner should contact U S Customers Canadian Customers A O Smith Corporation A O Smith Enterprises Ltd 500 Tennessee Waltz Parkway 599 Hill Street West Ashland City TN 37015 Fergus ON N1M 2x1 Telephone 800 527 1953 Telephone 1 888 479 2837 a The warrantor will only honor replacement with identical or similar parts thereof which are manufactured or distributed by the warrantor b Dealer replacements are made subject to in warranty validation by warrantor DISCLAIMERS NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE ON BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANTABILITY OF THE BOILER OR THE INSTAL
29. iar with all precautions required and that has complied with all the requirements of the authority having jurisdiction If you are not qualified as defined by ANSI above and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform 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 CONTROL COMPONENTS CONTROL PANEL HIGH LIMIT CONTROL THERMAL BALANCER TRANSFORMER IGNITION MODULE GAS VALVE PILOT BURNER OBSERVATION HOLE MAIN MANUAL VALVE PILOT MANUAL SHUTOFF VALVE FIGURE 1 COMPONENT LOCATIONS AUTO RESET HIGH LIMIT The high limit is a safety device wired in series with the ignition system Set the high limit control to approximately 100 F above the maximum designed system temperature If the boiler outlet water temperature should exceed the high limit setting the main gas control valve will close but the circulating pump will continue to operate Maximum adjustable setting is 115 C 239 F cut out with a 30 C 86 F to 250 C 482 F adjustable differential see DIFFERENTIAL Figure 2 ADJUSTING Q 0 SCREW 1 CUT IN CUT OUT in f 3 INDICATOR INDICATOR FIGURE 2 AUTO RESET HIGH LIMIT INTERMITTENT IGNITION CONTROL MODULE The Honeywell S 8600 control module contains the ele
30. iler and other metal parts as required to clean and vacuum the heat exchanger and combustion coils e Refer to parts list supplied with this manual for disassembly aid 4 Reinstall the parts removed in steps 2 and Be sure the vent pipe has a minimum upward pitch of one quarter inch per foot of length 21 mm m and is sealed as necessary 5 Restore electrical power and gas supply to boiler e Place boiler in operation by following the lighting instructions in this manual e Check for gas leaks and proper boiler and vent operation 25 NOTES 26 LIMITED WARRANTY A O Smith Corporation the warrantor extends the following LIMITED WARRANTY to the owner of this boiler 1 If within TEN years after initial installation of the boiler a heat exchanger or gas burner should prove upon examination by the warrantor to be defective in material or workmanship the warrantor at his option will exchange or repair such part or portion This term is reduced to FIVE years if this boiler is used for water heating purposes other than hydronic space heating a This warranty is extended to the owner for all other parts or portion during the FIRST year following initial installation of this boiler b The warranty on the repair or replacement of the part or portion will be limited to the unexpired term of the original warranty CONDITIONS AND EXCEPTIONS This warranty should apply only when the boiler is installed in accordance with loca
31. irmly plugged into module Is pilot ground wire firmly attached to the pilot assembly and GND terminal on module YES Replace pilot burner and Are high voltage cable and ground wire in good condition not brittle or ground wire burnt or cracked Make sure pilot flame spreader hood is the closest metal to the electrode to prevent the spark from shorting out to other metal parts pilot screen pilot shield etc Carefully bend down wards top of ground High voltage cable must not touch metal surfaces or current carrying strap to achieve wires 1 8 spark gap Is there a 7 64 spark gap between the tip edge of the hood and electrode and is the gap located in the pilot gas stream YES NO kai Replaceianitionmmodule Is the ceramic insulator surrounding the electrode in good condition not cracked or broken YES Replace pilot burner assembly 20 The following procedures are provided as a general guide Any module should be replaced if it does not perform properly on checkout or troubleshooting In addition replace any module if it is wet or looks like it has ever been wet LED STATUS AND TROUBLESHOOTING The control has two LEDs one for flame sensing and one for system status n ano ROD ZAWARNING 25 3 ES Weak Flame Signal System will operate reliably but flame signal is less than desired NOTE This indication may flash temporarily during or shortly af
32. l plumbing and building codes ordinances and regulations the printed instructions provided with it and good industry practices In addition a pressure relief valve certified by C S A and approved by the American Society of Mechanical Engineers must have been installed and fresh water used for filling and make up purposes a This warranty should apply only when the boiler is used 1 with outlet water temperatures not exceeding the maximum setting of its operative and or high limit control at water pressure not exceeding the working pressure shown on the boiler 3 when filled with boiler water free to circulate at all times and with the heat exchanger free of damaging scale deposits 4 ina non corrosive and non contaminated atmosphere 5 in the United States its territories or possessions and Canada 6 atawater velocity flow rate not exceeding or below the boiler s designed rates 7 indoor installation only b Any accident to the boiler any misuse abuse including freezing or alteration of it any operation of it in a modified form or any attempt to repair leaks in the heat exchanger will void this warranty SERVICE AND REPAIR EXPENSE Under this limited warranty the warrantor will provide only a replacement part The owner is responsible for all other costs Such costs may include but are not limited to a Labor charges for service removal repair or reinstallation of the component part b Shipping delivery handlin
33. ls to completely reset and continues to release water turn off power to the boiler at the main disconnect switch or breaker Close the cold water inlet to the boiler and follow the draining instructions in this manual to drain the boiler Should the pressure relief valve need to be replaced call the toll free phone number listed on the back of this manual for further technical assistance CLEANING AND FLUSHING INSTRUCTIONS INTERNAL CONTAMINANTS The hydronic system must be internally cleaned and flushed after a new or replacement boiler has been installed to remove contaminants that may have accumulated during installation This is doubly important when a replacement boiler is installed into an existing system where stop leak or other boiler additives have been used Failure to clean and flush the system can produce acid concentrations that become corrosive cause gases to form that block water circulation or lead to formation of deposits on the boiler surfaces any of which could result in damage to the system and circulating pump All hot water heating systems should be completely flushed with a grease removing solution to assure trouble tree operation Pipe joint compounds soldering paste grease on tubing and pipe all tend to contaminate a system Failure to flush contaminates from a system can cause solids to form on the inside of boiler heat exchangers create excessive amounts of air and other gases to block circulation foul v
34. main gas control valve Ensure the ground wire and ignition cable are separate from each other prevents shorting Replace pilot burner NO out and or ground wire Are they in good condition not brittle burnt or cracked Is the ceramic insulator surrounding the Replace pilot burner igniter sensor rod in good condition not broken or cracked Is the igniter sensor rod in good Clean rod or replace condition not worn corroded sooted pilot burner if necessary or damaged Replace ignition module 19 CHECKING HONEYWELL S8600H OR S 8600M INTERMITTENT IGNITION CONTROLS NO SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT Turn off gas supply Fix connection and or Is there a good connection between terminals tighten module to the boiler Is module securely attached to boiler for good ground connection Is voltage 24VAC across transformer positive terminal and GND with call for heat Check the circuit providing 24 VAC Replace ignition module ls voltage 24VAC across ignition module terminals 24 Volt and GND o call for heater NOTE For Propane LP models only Pilot Valve will be de energized if module goes into lockout condition Reset system by turning electrical Turn on gas supply and or power off or by turning system controller down below call for heat Wait power supply one minute then turn system on Turn off power supply NO HTT oui Is high voltage cable assembly f
35. nks and bathing facilities Achange in water temperature in the storage tank lower than the Tank Temperature Control setting will cause the sensor to close its contacts and consequently energize the boiler If the Tank Temperature Control is out of calibration replace it with a new one do not attempt to fix this control THERMOMETERS Thermometers should be obtained and field installed as shown in the installation diagrams Thermometers are installed in the system as a means of detecting a possible liming condition in the boiler An increase of 5 F 3 C over the normal temperature rise through the boiler is an indication that lime is present The term temperature designates the difference between the boiler inlet and outlet water temperature An increase of 5 F 3 C above the recorded temperature rise may signify a liming condition in the coils or heat exchanger Refer to Cleaning and Flushing Instructions on Page 24 for deliming instructions Record temperature rise at initial start up for future reference DRAIN VALVE NOT SUPPLIED A drain valve must be obtained and installed on each boiler and tank for draining purposes BOILER START UP AND OPERATIONS After placing the boiler into operation the ignition system safety shutoff device must be tested by the following test method 1 Reset High Limit Temperature Control to lowest setting See Figure 2 on Page 7 2 Reset System Controller to maximum setting ca
36. own in the Piping Diagrams of the Instruction Manual Where cast iron radiation and motorized valves are used conventional system pressure and installation practices should be followed Provisions should be made to permit manual venting of radiators or convectors PRECAUTIONS If the unit is exposed to the following do not operate boiler until all corrective steps have been made by a qualified service technician Flooding to level of burner or controls or higher Exposure to fire If damaged Firing without water Sooting 4 CAUTION Should overheating occur or the gas supply fail to shut off turn off the gas supply at a location external to the boiler i e main manual gas shutoff valve PILOT AND MAIN BURNER To maintain safe operation of the boiler check the pilot and the main burner once every six months for proper flame characteristics 1 MAIN BURNER The main burner characteristics Figure 6 should display the following Provide complete combustion of gas Cause rapid ignition and carryover of flame across entire burner e Give reasonably quiet operation during ignition burning and extinction e Cause no excessive lifting of flame from burner ports If the proceeding burner characteristics are not evident check for accumulation of lint or other foreign material that restricts or blocks the air openings to the burner or boiler Also check for good flow of combu
37. rent to achieve 1 8 carrying wires spark gap Is there a 1 8 gap between ground strap and electrode YES NO e Replace Ignition Is the ceramic insulator surrounding the electrode cracked or broken Module YES Replace pilot burner assembly 17 CHECKING HONEYWELL S 8600H OR S 8600M INTERMITTENT IGNITION CONTROLS SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT Ensure all manual shutoff valves are fully open all filters are clean all gas connections are gas tight pilot tubing is not damaged obstructed or kinked and pilot orifice is unclogged Check for air in gas line purge bleed line if necessary Are the wires securely attached to the pilot operator on the gas control and to the PV amp MV PV terminals on the ignition module YES Attach wires firmly Install a pressure gauge in the pilot tubing line between the gas control and the pilot burner assembly Ensure that the pilot adjustment screw under cap is adjusted to a position that will permit gas to flow Replace gas control valve Is pilot gas flowing during ignition attempt Turn on power supply Turn off power supply YES NO Is ignition cable firmly plugged into pilot assembly and module Securely connect Is ground wire firmly attached to pilot assembly and GND terminal on cable and or ground module wire YES i NO Replace pilot burner Are ignition cable and ground wire in good condition not brittle
38. s boiler is extremely important to your safety and the safety of others Many safety related messages and instructions have been provided in this manual and on your boiler to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this boiler This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently A DANGER hazardous situation which if not avoided will result in injury or death WARNING indicates a potentially hazardous AWaRNING situation which if not avoided could result in injury or death CAUTION indicates a potentially hazardous CAUTION situation which if not avoided could result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous CAUTION situation which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to
39. s close pilot and main burners are off LIGHTING AND OPERATING INSTRUCTIONS NATURAL AND PROPANE FOR HW300 HW399 FOR YOUR SAFETY READ BEFORE LIGHTING WARNING Ak warnine WATER CAN PRODUCE 3rd DEGREE BURNS IN 6 SECONDS AT A injury or loss of life 140 F 60 C IN CASE OF POWER FAILURE DO NOT ATTEMPT TO OPERATE APPLIANCE IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE REFER TO THE USER S INFORMATION MANUAL PROVIDED WITH THIS APPLIANCE INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER HONEYWELL GAS VALVE 1 W STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL MAKE SURE BOILER AND SYSTEM ARE FILLED WITH WATER AND ALL AIR HAS BEEN EXPELLED FROM APPLIANCE TURN OFF ALL ELECTRIC POWER TO THE APPLIANCE SET SYSTEM TEMPERATURE CONTROLLER TO LOWEST SETTING PURGE ALL GAS LINES OF AIR DO NOT ATTEMPT TO LIGHT THE PILOT BY HAND REFER TO DIAGRAMS ABOVE TURN TOP KNOB OF GAS CONTROL CLOCKWISE OFF POSITION FIG A WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS THEN SMELL FOR GAS INCLUDING NEAR THE FLOOR IF YOU SMELL GAS STOP FOLLOW B IN THE SAFETY INFORMATION ABOVE ON THIS LABEL IF YOU DON T SMELL GAS GO TO THE NEXT STEP A SET THE SYSTEM CONTROLLER TO THE LOWEST SETTING B TURN OFF ELECTRICAL POWER TO APPLIANC
40. set at Replace Replace Set tank temperature control thermostat System maintains desired for desired water water temperature temperature 16 CHECKING HONEYWELL S 8600H OR S 8600M INTERMITTENT IGNITION CONTROLS NO SPARK AT PILOT BURNER Turn off gas supply Replace ignition module NO Is voltage 24 Vac across the 24 V terminals on module during Call for heat YES Is voltage 24 Vac across the PV amp MV PV terminals on call for heat YES NO NOTE S 8600M will automatically reset every 5 minutes S8600H pilot valve will be de energized if module goes into lockout condition Reset system by turning electrical power off or by turning system controller to off or down below call for heat Wait one minute then turn system on Turn on gas supply YES Turn on power supply Tit off powersupply Is ignition cable firmly plugged into pilot Securely connect cable assembly and module and or ground wire Is ground wire firmly attached to pilot assembly and GND terminal on module Replace pilot burner Are ignition cable and ground wire in good condition and or ground wire not brittle burnt or cracked Ensure ground strap is the closest metal to the igniter sensor rod electrode to prevent the spark from shorting out to other metal parts pilot screen pilot shield etc Carefully bend downward NO top of ground strap Ignition cable must not touch metal surfaces or cur
41. stion and ventilating air to the unit Maintain a clear area around the boiler at all times FIGURE 6 MAIN BURNER The boiler should be periodically inspected by a qualified servicer for continuous safe operation Qualified servicers should follow this procedure when the boiler s burners need cleaning a Turn off the electrical power and close the main manual gas shutoff valve Refer to Lighting amp Operating Instructions on Pages 14 and 15 Allow boiler parts to cool before disassembly b Remove main burner manifold assembly from boiler e Refer to parts list supplied with this manual for disassembly aid c Remove any loose foreign material such as dust or lint with a vacuum Check all ports orifices and air openings for blockage Dislodge any foreign material causing blockage Remove any soot or carbon deposits with a rag making sure to remove any lint left on burner by vacuuming again Reinstall the burner manifold assembly on boiler e Restore electrical power and gas supply to boiler Put the boiler back in operation by following the lighting instructions in this manual or on the lighting and operating label on the boiler Refer to Pages 14 and 15 e Check for gas leaks and proper boiler and vent operation 2 PILOT BURNER ELECTRONIC IGNITION To establish pilot flame without main burner operation it will be necessary to perform the following steps Servicing of the pilot burner every six months in
42. ted and manually operated at least twice a year More frequent inspections may be necessary depending on water conditions Periodic checks at least twice a year should be made for water and or gas leaks The boiler mounted gas and electrical controls have been designed to give both dependable service and long life However malfunction can occur as with any piece of equipment It is therefore recommended that all components be checked periodically by a qualified service technician for proper operation Tee RESET HIGH LIMIT SWITCH CONTINUITY Do not depress the switch reset button prior to testing With the boiler being cold disconnect the leads from the switch With a multimeter place a probe on each side of the switch If the meter reads zero the switch is good If you receive an infinite or OL signal the reason could be 1 Switch contacts open Depress reset button on switch switch cannot be reset until water temperature in the boiler coils drop below 200 F Meter should read zero 2 Defective switch or bad leads e With leads attached depress the switch button If the meter does not read zero the switch is defective and must be replaced PRESSURE RELIEF VALVE TEST ADANGER e Burn hazard e Hot water discharge e Keep clear of Pressure Relief Valve discharge outlet 24 PRESSURE RELIEF DISCHARGE PIPE FIGURE 10 PRESSURE RELIEF VALVE TEST If after manually operating the valve it fai
43. ter lightoff on some applications Marginal Flame Signal less than 1 1 System may not operate reliably over time Service call recommended NOTE This indication TABLE 4 YELLOW LED FLAME CODES YELLOW LED RECOMMENDED FLASH CODE INDICATES SERVICE ACTION Heartbeat Normal Flame Signal not applicable Perform routine maintenance to assure optimum flame signal Check gas supply pilot burner flame sense wiring contamination of flame sensor burner ground Flame LED Status LED connection FIGURE 9 LOCATION OF LED S may flash temporarily during or shortly after lightoff on some e Flame LED Yellow applications Indicates flame presence and strength Refer to Table 4 e Status LED Green Signal below minimum Indicates system operation status and error conditions Refer threshold for system to Table 5 and Table 6 on Pages 22 and 23 for status specific operation to each model No Flame or Flame not applicable AFlash Code Descriptions Heartbeat Constant 1 2 second bright 1 2 second dim cycles The flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence 21 TABLE 5 CONTINUOUS RETRY MODELS C M E AND K ONLY GREEN LED STATUS CODES GREEN LED FLASH CODE INDICATES NEXT SYSTEM ACTION RECOMMENDED SERVICE ACTION Flash Fast Startup Flame sense calibration not applicable Heartbeat Normal operation
44. ture setting ADANGER Fire or Explosion Hazard e Donotstore or use gasoline or other flammable vapors and liquids in the vicinity ofthis or any other appliance Avoid all ignition sources if you smell LP gas Do not expose boiler control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use 4 Read instruction manual before installing using or servicing A DANGER e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Flammable Vapors AWARNING Explosion Hazard Overheated water can cause water tank explosion Properly sized temperature and pressure relief valve must be installed AWARNING For continued protection against risk of fire e Do not install boiler on carpeted floor e Do not operate boiler if flood damaged A WARNING Breathing Hazard Carbon Monoxide Gas e Special consideration must be taken with installations above 2 000 feet Please contact an A O Smith qualified service agent to obtain the proper setup and instructions before lighting Failure to implement the proper setup will result in improper and inefficient operation of the appliance resulting in production of increased levels of carbon monoxide gas in excess of the safe limits which could result in
45. using a call for heat and allowing unit to run until High Limit Temperature Control trips 3 Resetting the High Limit Temperature Control to a higher setting unit should run 4 Reset System Controller and High Limit Temperature Control to desired temperature If unit fails to run refer to Troubleshooting section in this manual on Page 16 Before operating the boiler the entire system must be filled with water purged of air and checked for leaks Do not use Stop Leak or other boiler compounds The gas piping should also be leak tested Any safety devices including low water cutoffs used in conjunction with this boiler should receive periodic every six months inspection to assure proper operation A low water cutoff device of the float type should be flushed every six months All pressure relief valves should be inspected and manually operated at least twice a year IMPORTANT It is recommended that a qualified service technician perform the initial firing of the boiler At this time the user should not hesitate to ask the individual any questions which he may have in regard to the operation and maintenance of the unit FILLING THE SYSTEM 1 Fast fill system through bypass until pressure approaches desired system pressure Close bypass valve and permit pressure to be established by the pressure reducing valve 2 Ventall high points in system to purge system of air If pressure bleeding of system is desired install valves as sh
46. vices for Hot Water Supply Systems 221 22 CSA 4 4 The T amp P valve must be of the automatic reset type and not embody a single use type of fusible plug cartridge or linkage The T amp P relief valve should have a maximum temperature rating of 100 C 210 F a pressure rating NOT exceeding the lowest rated working pressure of any system component and a discharge capacity exceeding the total input of the water boilers supplying water to the storage tank Locate the T amp P relief valve a in the top of the storage tank or b in the side of the tank on centerline within upper 6 inches from the top of the tank Refer to the Piping Diagrams section in Instruction Manual Tapping shall be threaded in accordance with the latest version of the Standard for Pipe Threads General Purpose inch ANSI ASME B 120 1 TANK TEMPERATURE CONTROL The water temperature in the storage tank is controlled by the Tank Temperature Control The sensing element is mounted inside the hot water storage tank Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury ADANGER Feel water before bathing or showering Temperature limiting devices such as mixing valves must be installed when required by codes and to ensure safe temperatures at fixtures The tank temperature control is adjustable
47. zing temperatures Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the pressure relief valve and the discharge pipe Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Shall not have any valve or other obstruction between the pressure relief valve and the drain Once the boiler is installed and filled with water and the system is pressurized manually test the operation of the pressure relief valve If any pressure relief valve is replaced the replacement valve must comply with the current editions of the ASME Boiler and Pressure Vessel Code Section IV or CSA B51 as applicable Select a pressure relief valve with a discharge NOT less than the boiler input and a pressure rating NOT exceeding the working pressure of any component in the system A O Smith supplies a 125 psi pressure relief valve for hot water supply systems and 50 psi pressure relief valve for space heating application An ASME rated temperature and pressure relief valve must be installed on each and every water storage tank in a hot water supply system The storage tank temperature and pressure T amp P relief valve must comply with the applicable construction provisions of the Standard for Relief valves and Automatic Gas Shutoff De

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