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321078 - AO Smith Water Heaters

1. DON WALSAS SNI1V3H 3ATVA YIJANE INOZ 029 002 YITIOA 3ATVA LYOd 7103 e FANSSTA 8 aNJIDTT7 3ATVA Yo 58 INALSAS ONILVSH MNVL TWOLLAJA Lb JANDIJ 5 Jejioq GBUIDIAJSS 20 UMOUS 9IAJ9S uu s s au jueuodwo Aue Hues eunsse d jou 6 5 Gunjas pue ayi 7 pouejold SILON GJKHSINIJ WALSAS WALSAS YOL vAVIJIS A TOULNOI FAN VAZINIL SINJWFYINDAY STOINVNIGYO 58809 1V9071 S391440 YSHLO ANY ONIdid 03 1539918 SMOHS SIHL NOILNVO FJOVO 5 gt 3ATVA 431734 WALSAS 3ATVA IVWILLYINYINOH 049 00 MH 3ATVA LYOd TIN e FANSSTA 8 1 H WJFLSAS JATVA ONIXIW AVM ANVL Y344N9 TWOLLAJA
2. 8 V IZIS TOULNOD SINIWFYINDIFAY STONVNIGYO ANY 53009 1 20 1 HLIM J39Y9 JYNIVYIUNIL ONLLVTINDUID SIDIAFA GNV NOILVYNDIANOO ONI did 031539918 SMOHS ONIMYAYO SIHL 3ATVA DN 3ATVA 43134 WALSAS ONIdld 3ATVA 8 029 002 437104 MH 3ATVA LAOd 7103 Q FANSSTA 8 JHNLYYJdANAL 1 H 56 HOLIMS JILVM TANIVAJJNIL DON 3ATVA LAOd TIN e INALSAS MNVL 2134408 TVLNOZIYOH 3102 66 JANJIJ Besn 5 Jejioq GBUIDIAJSS 104 UMOUS 9IAJ9S uu s s au jueuodwos Aue jo Hues eunsse d jou 5 Gunjes 9 9 pue eunjeledwaj ayi 7 pouejold kk l SILON G3HSINId 1 8 7 bd ANVL NOISNVdX3 343N9 WWYSHL 4001 INOZ 5 3NOZ 4 L L L L ZON PON w WY W
3. 10 UMOUS 9lAJ9S uu s s jueuodwoo Aue eunsse d jou 5 Gunles 94 SALON 146504 SV 1 OL 15019 SV 19 414901 YOOT4 ANYL NOISNVdX3 I Gro B 331 Aldans SLVNYSLIV YSLVM WALSAS SFANLXIJ LOH HOLIMS d31VA 10 1400 SYNLVYAdWAL NYL SLNSAWSYINOAY IWNOILIGGV JYNIVYIDNIL E ONLLVINDAUIJ 5 ANY 58809 TVOO 1 HLIM MOSHO S391430 ANY ONIdid 115499 5 SMOHS NIMYYA SIHL ONINYVM JAYA AWA WALSAS 3ATVA 531193 MNVL JOVYOLS 1 1 2 1108 INO FYNIVYIJWIL 0Z9 00 MH 3ATVA LAOd 1103 Q JYNSSJYd 8 JTANIVAIJdWIL AaN9IDI E e H 48 NFISAS MNVL 16 TVWILLAJA 5 OML INO LE eoue sisse 10 p su ol eys s y sseJxe yue
4. City and State Zip Code Date Installed Model No Serial No Dealer s Phone No Dealer s Address FILL INWARRANTY AND KEEP FOR FUTURE REFERENCE 61 Smith 25589 Highway 1 McBee 5 29101 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com 62
5. eunsseud pue eunjeledwaj ayi 77 YOOT3 ANVI NOISNVdX3 Aldans gt 1 WALSAS ANYL ATALS NOILOANNOO 1 TV 59901 14 OL LOH HOLIMS 3331VA TOYLNOD MNVL SININJFAINDOJA IWNOILIGGV FOVS JYNIVYFIUNIL ONILVINOUIO SSHONVNIGHO ANY 58809 HLIM MOSHO S301430 YSHLO NOILVYNSISNOO SONI did 415499 5 SMOHS SIHL ANA YOSHO IN 3ATVA 4434 WALSAS 3ATVA JOVYOLS TWOLLYAFAAYITIOH INO FTANIVAYI WIL INO 029 00 MH 3ATVA TIVE LAOd TINA Q 8 9 1 ar 47 NJFISAS MNVL 5 TWLNOZIYOH TIOA INO 706 gouejsisse Joj eys 5 y 0 se se 245 rejog 06 uo paseq si Guidid 0 7 ebesn eys
6. A THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT DO NOT TRY TO LIGHT THE PILOT BY HAND 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 DO NOT TRY TO LIGHT ANY APPLIANCE DO NOT TOUCH ANY ELECTRIC SWITCH e DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR 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
7. 727 ANNI 5 BUJAS UMOUS 9IAJ9S 5 5 ay jueuodwoo Aue Hues 5 jou 991 2 pouejold SALON Y00714 WALSAS WALSAS AlddnS WALSAS 3ATVA ONIXIW AVM E 95 A EP TOULNOD SINAWFYINDIY HOS SHONVNIGHO ANY 53809 1V9071 HLIM YOFKI Fovo JYNIVYFIUNAIL SFIDIAFA YSHLO ANY ONIdid 31539975 SMOHS ONIMYAYA SIHL NOILNYO DN JAVA Yo W31SAS ONILVFH JAYA ONIXIN FATVA VE LYOd 77104 e 3unssaud 8 SYNLVYAdWAL YIJANE TvOILH3A d31lO8 029 002 4371084 MH 1 60 LIMITED WARRANTY A 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
8. CONVENTIONAL INSTALLATIONS electrical work must be installed in accordance with current editions National Electrical Code ANSI NFPA 70 and or the Canadian Electrical Code PART 1 CSA C22 1 Electrical Code and must conform to local regulations The boiler when installed must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the current editions National Electrical Code ANSI NFPA 70 and or the Canadian Electrical Code Part 1 CSA C22 1 Electrical Code Strict adherence to piping and wiring diagrams is required to prevent constant pump operation when system temperature control is satisfied Otherwise the warranty is void as stipulated in the limited warranty on the instructions manual 42 The electrical connections must be made so that the circulating pump will operate before the gas control valve opens At no time may the controlling system allow the burner to fire when there is no water flow through the boilers Refer to the diagram in Figure 24 on Pages 43 for proper wiring sequence with conventional single boiler installations The thermal balancer shown is factory included by A O Smith This device serves as a pump shutdown delay switch to balance the rising boiler water temperature to system temperature before the pump stops Overshooting of boiler temperature is prevented and stack loss after shutdown is ne
9. 3ATVA 38184 JOVYOLS TWINOZIYOH YITIOB OML JFYNIVAYIJWIL INO 029 00 FANSSTA 8 JANIVAIJdWIL E e OB H 50 NJFISAS 30 4015 TWILLAJA SAT INO eoue sisse 10 p su ol eys s y se 2 se aq 245 juewsoe d 1u eAinb 06 UO paseq si Buidid V r eys sepoo 10 UMOUS SGAJBA uu s s y u jueuodwoo jo Hues eunsse d jou jeys ainsseid pue eunjeledwej ayi 7 7 SILON Q3HSINI4d NOISNVdX3 Alddns 331VAA N NLJFYA WALSAS MNVL FTALS 010 404 YJFLVM C109 4 A ws ZILI 0 r 66 ds anle 3215 ONIdid 3215 ONIdid a HOLIMS TOYLNOD SYNLVYAdWAL SINFTNJFAINOTAY TVNOILIGAV JYNIVYIDNIL E
10. 41 WIRING onn lo a kon ooo do l kapakka goat asasin a 42 Wiring 42 PIPING DIAGRAMS 47 LIMITED WARRANTY L uu u kanon ab venn REE E 61 SAFE INSTALLATION USE AND SERVICE The proper installation use and servicing of this 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 4A WARNING situation which if not avoided could result in injury or death CAUTION indicates a potentially hazardous 4A 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
11. 5 se 5 se aq 245 juewsoe d 1u eAinb 06 uo si 0 V r eys sepoo 10 UMOUS SGAJBA NAOS uu s s au u jueuodwoo jo Hues eunsse d jou jeys eunsseud pue eunjeledwaej ayi 7 SALON Y00714 GSHSINIS NV L NOISNVdX3 07109 WALSAS ANVL FTALS 010 404 YALVM ALVNYSLTV STFANLXIJ OL ds aid 3215 ONIdid 3215 ONIdid en QTOJINVW HOLIMS TOYLNOD FYNIVYFGNIL SINFTNJFAYAINOTAY TVNOILIGAV YOS JYNIVYIDNAIL E dnd S NI1V 10939 ANY 58809 1TVO9O 1 HLIM MOSHO SIDIAFA YSHLO ANY ONIdid 11549 9 5 SMOHS SIHL ONINYVM 3ATVA DON 545 3ATVA 38184 YNVL 9 18 WOILYSNVYSTIO OML FANIVAYIJWIL INO 0Z9 00 MH FAWA LYOd TIN Q 8 JANIVAIJdWIL 0 9 E e o H 49 INALSAS 5 TWLNOZIYOH ISIT
12. YO 53 ANY 59803 1V901 HLIM JYNIVYIUNAL ONILVTNDUIJ SIDIAFA ANY NOLLVYNJI4NOD ONI did 0318399218 SMOHS SIHL ON 3ATVA WALSAS ONIdld DJINOYGAH At VANODIS AUVNWI d INO 029 002 MH 3ATVA jdang e 9 1 lt 53 INALSAS ONldld AJVANOJIIS OML 96 AYNSIS 5 20 Jejioq 104 UMOUS 9IAJ9S Wa SAS au jueuodwoo Bues eunsse d jou eys Bunjas pue eunjeledwaj ayi SILON I WALSAS A 4007 AlddNS WALSAS 3901 38010 sv 5331 5 0 YOLvAUVAIS 029 02S 0 66 8 V IZIS ROINN ONIdid Y37109 TOULNOI FAN VAZANIL SHAONVNIGHO ANY 53809 1929201 HLIM YOFKI Fovo JYNIVYFIUNIL ONLLVTNDUIJ SFIDIAFJA YJIHLO ANY NOLLVANJI4NOD ONI did 031539915 SMOHS ONIMYAYA SIHL FATVA
13. 108 HOLIMS TOYLNOD JANIVAJJNIL ONLLVINDAIL E e eo H 9 1 SLNAWSYINOAY TWNOILIGGV SHONVNIGHO ANY 53002 1 201 S391440 YSAHLO ANY NOILVYNSIANOO ONIdid 031539915 SMOHS SIHL JAYA IN 3ATVA 44134 3 0553 S ANQAS W31SAS AUJAOOFA 3ATVA LAOd TIN Q 8 JANIVAIJdWIL 39 18 1 1 2 1108 JIYHI FANIVYIJWIL 029 00 MH 52 INALSAS SNIdId DJINOJGAH 5 X37109 INO SE eys 10 D S Wa SAS ay u Aue jou jeys 5 pue 991 7 SILON YOOT3 NOISNVdX3 NaNLJA WALSAS No gave SV d3H13SO L 15019 SV 8331 SIDV ld 029 029 5 FJANIVAIJdNIL 4001 0 66 8 HONI IZIS 5 31108 MA MOUNIS MOT TOYLNOI SININFYINDIAY
14. OML JANIVAJJWIL ZE gouejsisse 10 p su ol eys sseJxe 5 se asojo se aq 245 juewsse d Buidid 06 uo paseq si O V 7 eys sepoo 10 UMOUS SGAJBA uu s s au u Ju uoduuoo Hues eunsse d jou 5 pue eunjeledwaj ayi 7 SALON NOISNVaX13 Aldans 0109 WALSAS HOLIMS JILVM JANIVAJJNIL DON 3ATVA LAOd 1103 Q NOLLVDOT STANIXIL OL LOH HONI V 3215 ONIdid 3215 ONIdid GTOJINVW 31109 TOYLNOD FTANIVAIJNIL ANVI SINFNTJAINOJAY 5 ANY 58800 1 201 HLIM S391440 ANY 931539915 SMOHS SIHL ONINYVM 3ATVA 44134 3 0553 545
15. PN 3ATVA 391195 WALSAS ONIdld 8 OML 029 002 S437108 MH 3ATVA e 0 9 1 54 INALSAS ONIdld 238 SIFTTO9 JIJAHKL ZE TANDIJI gouejsisse uBis p eys s y u Gunesy y 0 eonDJBJd se se eys juewsdejd 06 uo si yus O V F 5 Jejioq 20 UMOUS 9IAJ9S 5 ay jueuodwoo Hues eunsseud jou eunjeledwaj 991 2 ynoKe pouejold SILON YOOTJ3 Q3HSINId MNVL NOISNVdX3 lt dN IAYW N WALSAS WALSAS Q OQ N moons SY YSHLASOL 45019 SV 5931 SIDV ld 4001 gOvav IS 8 IZIS 3215 ONIdid X37109 MH h QIOSINVIN SNIdId G TOULNOI FANIVAZIWNIL SINJWFYINDIY
16. ANY SIAOI 1V9071 HLIM MOSHO SIDIAFIA ANY ONIdid ANS 091539915 SMOHS SIHL DON 545 3ATVA 38184 YNVL 9 18 SSYHL JYNLVYAdWAL INO 029 00 MH AV NAN FAWA LYOd 1103 Q FANSSTA d 8 JANIVAIJdWIL gt H 51 WALSAS 5015 TWLNOZIYOH SUHATIOd ITAHKL TANIVAIJWIL ve TANDII eoue sisse 10 p su ol eys s y 10 sseJxe se 2 se aq juewsoe d 1u eAinb 06 UO paseq si 0 V 1194 eys sepoo 10 UMOUS au jueuodwo Aue Hues eunsse d jou 5 sAjeA eJnssejd pue eunjeledwaej 94 Guidid SILON NOISNVaX13 LN3NWIG Aldans YALVM 2100 NOLLVDOT N NLJFYA WALSAS OL LOH OzZt G6E HONI HONI V FZIS FZIS ONIdld 5 1
17. 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 37 TABLE 19 CONTINUOUS RETRY MODELS C 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 not applicable me 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 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 o
18. 1 l DELETE UNIT 3 IF ONLY 2 UNITS ARE DESIRED WIRE ACCORDINGLY i I CONNECT BLACK CONNECT TO WHITE i TRANSFORMER WIRE TRANSFORMER WIRE la UNIT 3 1 SEE RESPECTIVE UNIT SAFETY FLOW DIAGRAM FOR FACTORY SWITCH INSTALLED WIRING FLOW CLOSES CIRCUIT Nate WIRING IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITHTHE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C WIRE OR EQUIVALENT EXCEPT FOR THE FLAME BY FACTORY SENSOR AND IGNITION CABLE 1 0 UNITS ONLY WHICH ARE 250 C AND WIRES CONNECTED BYINSTALLER TO THE COIL PROTECTOR WHICH ARE 200 C FIGURE 28 TEMP 80 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM FOR HOT WATER SUPPLY APPLICATION 46 PIPING DIAGRAMS WALSAS 5 TWOILYSA AF TOY 62 JANDII eoue sisse eys JO UI yue 5 0 se se aq eys 199 06 uo paseq si poyjaw V F ebesn 1194 evo 10 UMOUS IANS y u jueuodwoo Aue ainssaid jou eys
19. 14 3 INDICATOR INDICATOR FIGURE 3 AUTO RESET HIGH LIMIT INTERMITTENT IGNITION CONTROL MODULE The Honeywell S 8600 control module contains the electronic 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 a loss of flame shuts off main gas and starts trial for pilot ignition Please refer to TROUBLESHOOTING SECTION for more information l FIGURE 4 S 8600 INTERMITTENT IGNITION CONTROL MODULE IID THERMAL BALANCER Figure 5 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
20. 7920 46 44 40 38 36 34 32 Rise Feet Number Example Known 5 model HW 670 boilers See illustration Connector rise 2 Note 1 is minimum Total vent height 30 Problem Determine diameter of connector manifold and common vent Procedure Enter the top of the HW 670 table total vent height at 30 and the side at 2 connector rise A 14 connector diameter is indicated for each connector rise To determine the manifold and common vent size enter table on this page total vent height at 30 and the side at 5 boilers A manifold diameter of 24 610 mm is indicated GAS SUPPLY CONNECTIONS GAS SUPPLY PIPE CONNECTIONS 1 In Canada When using manual main shutoff to support the weight of the piping with valves ensure that it is identified by the installer 2 Install sediment trap per 54 US and CAN B149 1 for Canada Make sure to install ground joint union for servicing Support the piping with hangers not by the boiler or its accessories The gas control valve and blower will not support the weight of the piping Failure to comply could result in severe personal injury death or substantial property damage Purge all air from the gas supply piping Before setting the boiler in operation check the boiler and its gas connection for leaks Disconnect the boiler from the gas supply piping system during any pressure testing at
21. 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 repeats replace control Reset by cycling Call for Heat If error repeats replace the control X Y flash codes signify that the LED flashes X times at 2Hz remains off for two seconds flashes times at 2Hz remains off for three seconds and then repeats the sequence 39 GENERAL MAINTENANCE 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 passa
22. 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 Burner 9 Correct wiring incorrect Boiler outlet High limit control temperature exceeds Circulating pump on Circulating pump and defective or set too high 210 100 C burner on max should be set at Replace Replace Set tank temperature control thermostat System maintains desired for desired water water temperature temperature 32 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
23. 670 FIGURE 21 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 should the input exceed the rate shown on the boiler s rating label Overfiring could result in damage to the boiler s and sooting e Gas and carbon monoxide detectors 6 Remove the pressure gauge or manometer from the manifold pressure tapping Replace the screw in plug in the manifold pressure tap Repeat steps 7 thru 11 of the OPERATING INSTRUCTIONS on Page 31 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 16 TABLE 16 CONSUMPTION RATE REFER TO OPERATING AT FULL INPUT OR FULL CAPACITY TYPE GAS TIME TO CONSUME 1 CU FT OF GAS SECONDS HW 420 HW 670 a HEATING VALUE Minor variances from input on rating plate can be corrected by adjustment of gas pressure regulators Refer to Gas manifold pressure regulators on Page 25 22 6 The inlet gas pressure must not exceed or be less than the values shown on rating plate are available Breathing carbon monoxide can c
24. 1 d alaw ANCER SEE RESPECTIVE UNIT DIAGRAM DISCONNECTED FACTORY INSTALLED WIRING 24 I L TO BLACK TRANSFORMER WIRE on eee 1 2e 1 I NC I 1 NO SAFETY FLOW SWITCH FLOW CLOSES CIRCUIT WIRING NOTE FACTORY IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED BY INSTALLER IT MUST BE REPLACED WITH TYPE 105 C WIRE OR ITS EQUIVALENT EXCEPT FOR THE FLAME DISCONNECT SENSOR AND IGNITION CABLE 1 1 0 UNITS ONLY WHICH ARE 250 C AND WIRES CONNECTED TO THE COIL PROTECTOR WHICH ARE 200 C FIGURE 27 CER TEMP 80 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM FOR HOT WATER SUPPLY APPLICATION 45 a 12 NEUTRAL 20 VR SR I I I I 1 I THERMIAL BALANCER CIRCULATING PUMP au _ 140 I 1 f TANK TEMPERATURE CONTROL i I 1900 OHM 3 1 I I i I CONNNECT TO BLACK CONNECT TO WHITE TRANSFORMER WIRE TRANSFORMER WIRE a i W M SEE RESPECTIVE UNIT l SAFETY FLOW DIAGRAMI FOR FACTORY l SWITCH INSTALLED WIRING I l 1 1 CONNECT BLACK CONNECT TO WHITE TRANSFORMER WIRE TRANSFORMER WIRE UNIT 2 4 SEE RESPECTIVE UNIT DIAGRAM FOR FACTORY i SAFETYFLOW I SWITCH INSTALLED WIRING
25. 7 os 00 gade EES 16 ken pk pyan Ze kok kk 16 SYSTEM CONNECHUONS ano tid ka meta ke kok ka sa k 16 Air Regue ments T u LLL se kayis konenn EEEE 16 Uncontined 5 of a n ok bon e ako an 16 Fresh Air Openings for Confined 127 VENTING uu au a k lod k bo een E ale piba ba spo papal saaa 21 Standard po e pa en po ae 21 Sidewall Venting 22 Venting un u a 22 GAS SUPPLY CONNECTIONS 24 Gas Manifold Pressure 25 BOILER START UP AND 26 Filling uuu 26 PRECAUTIONS eseye saka SENERE E EE CESA 26 Pilotand 26 Checking and Adjusting 28 TROUBLESHOOTING 32 GENERAL a i 40 Manual Reset High Limit Switch Continuity Test 40 Pressure Relief Valve Test Cleaning and Flushing Instructions u u 40 Venting Maintenance
26. FIGURE 16 EXAMPLE FOR COMBINED VENT SIZING TABLE SIDEWALL VENTING The optional sidewall power vent system is certified for maximum 100 equivalent venting The power vent kits p n for HW300 399 420 520 670 are 325614 000 325614 001 325614 002 and 325614 003 respectively If you are installing the optional power vent kit refer to your HW Power Vent Kit Installation Instructions for proper wiring and installation procedures Contact your local A O Smith representative for details VENTING SYSTEM Have venting system checked every six months for obstructions and or deterioration in vent piping Refer to Venting Maintenance on Page 41 1 Insofar as is practical close all doors windows and air inlets to the building Turn on all exhaust fans range hood bathroom exhaust etc so they will operate at their maximum speed Close fireplace dampers 2 After allowing the boiler to operate for five minutes test for spillage at the draft hood relief opening 3 Checking the draft Operate vent connected gas utilization equipment for several minutes and check to see that the combustion products are going up the chimney or gas vent properly by passing a lighted match or taper around the edge of the relief opening of the draft hood If the chimney or gas vent is drawing properly the match flame will be drawn into the draft hood If not the combustion products will tend to extinguish this flame If the combustion products are esc
27. FILLED WITH WATER AND ALL AIR HAS BEEN EXPELLED FROM APPLIANCE 3 TURN OFF ALL ELECTRIC POWER TO THE APPLIANCE SET SYSTEM TEMPERATURE CONTROLLER TO LOWEST SETTING PURGE ALL GAS LINES OF AIR 4 DO NOT ATTEMPT TO LIGHT THE PILOT BY HAND 5 REFER TO DIAGRAMS ABOVE TURN TOP KNOB OF GAS CONTROL CLOCKWISE TO OFF POSITION FIG A 6 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 APPLIANCE WARNING tf you do not follow these instructions exactly a fire or explosion may result causing property damage personal OFF POSITION LIGHTING INSTRUCTIONS FLAMMABLE WHAT TO DO IF YOU SMELL GAS eDO NOT TRY TO LIGHT ANY APPLIANCE eDO NOT TOUCH ANY ELECTRIC SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING eIMMEDIATELY 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 REPAIR MAY RESULT IN A FIRE OR EXPLOSION D DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER W
28. INLET PRESSURE TAP GROUND TERMINALS 2 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 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 21 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 Clean or replace orifice A clogged orifice will restrict gas flow and result in low thermocouple output g Incorrect orifice Replace The Orifice size is stamped on the wrench flats h Clogged primary air opening 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 GROUND PILOT ADJUSTMENT GAS UNDER CAP SCREW CONTROL HW 420 520 amp
29. Property Damage Hazard This boiler should not be installed on carpeting This boiler should not be located in an area where it may be subject to freezing This boiler must be located near a floor drain It should be located in an area where leakage from the boiler or connections will not result in damage to the adjacent area or to lower floors of the structure A WARNING Flammable items pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the boiler Open containers or flammable material should not be stored or used in the same room with the boiler A DANGER There is a risk of fire or explosion in areas where gasoline other flam mable liquids or engine driven equipment and vehicles are stored operated or repaired when a fuel burning appliance such as a boiler is operated Flammable vapors are heavy and travel along the floor They may be ignited by sparks causing fire or explosion p Some local codes permit operation of gas appliances if installed 18 inches or more above the floor This may reduce the risk if location in such an area cannot be avoided A hot water boiler installed above radiation level or as required by the authority having jurisdiction must be provided with a low water cutoff device at the time of boiler installation 15 REPLACING EXISTING COMMON VENTED BOILER When an existing boiler is removed from a common ven
30. Si ost 0996 067 22 06 8672 08 76712 0262 81 09 251 06 61721 hr 6 06 079 0 5077 OL EIA S NLE 000 JO SEY APEJO 22906 090 90 doiq 55 pue 559110 69 0 O AA Ul p JO SEY JO pue JO Ayioedey SVD SVD JIJILINW 3215 431539905 2 318 1 20 VENTING STANDARD VENTING A WARNING The instructions in this section on venting the boiler must be followed to avoid choked combustion recirculation of flue gases Such conditions cause sooting or risks of fire and asphyxiation Type B venting may be used with these boilers All local utility regulations on venting should be followed Vent sizing installation and termination shall be in accordance with the current edition of the National Fuel Gas Code ANSI 2223 1 or CAN CSA B149 1 Installation Codes or applicable provisions of the local building codes Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure The minimum distance from adjacent public walkways adjacent buildings openable windows and building openings shall not be less than those values specified in the National Fuel Gas Cod
31. U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 11 USE ANTI SCALD VALVE S in the hot water system to reduce the risks of scalds at points of use such as lavatories sinks and bathing facilities A change 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 40 for deliming instructions Record temperature rise at initial reference start up for future DRAIN VALVE NOT SUPPLIED A drain valve must be obtained and installed on each boiler and tank for draining purposes BOILER INSTALLATION CONSIDERATIONS HYDRONIC SYSTEM All modern hydronic type boilers ar
32. a test pressure in excess of 1 2 PSIG 3 5 kPa The boiler must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing at test pressures equal to or less than 1 2 PSIG 3 5 kPa Do not check for gas leaks with an open flame instead use the bubble test Failure to use the bubble test or check for gas leaks can cause severe personal injury death or substantial property damage 6 Use pipe sealing compound compatible with propane gases Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury death or substantial property damage 7 Make sure the maximum inlet gas pressure do not exceed the value specified Minimum value specified is for input adjustment only Make sure to use two wrenches when tightening gas piping at the boiler using one wrench to prevent the boiler gas line connection from turning Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components Do not use wrench on valve body as damage would occur GAS PRESSURE REQUIREMENTS The maximum allowable gas supply pressure for this boiler is 14 inches w c 3 5 kPa Install a positive lock up gas pressure regulator in the gas supply line if inlet gas pressure can exceed 14 inches w c 3 5 kPa at any time If a p
33. any procedures outlined in this manual DIMENSIONS AND CAPACITY DATA EXTRA OPENING N GAS INLET FOR THERMOMETER AND PRESSURE H RELIEF VALVE HW 520 AND HW 670 lt p MALE 8 5 LOCATION OF MANUAL LET MAIN SHUTOFF VALVE a LAN 1 OUTSIDE JACKET WHEN G CODE REQUIRE NOT SUPPLIED NPT FIGURE 1 DIMENSIONS TABLE 1 DIMENSIONS AND CAPACITY DATA MODELS DIMENSIONS IN INCHES HW 300 HW 399 HW 420 HW 670 STATO ABT STATIS 100 as ae 1429 f oon Fort Genter tre waeroa meo prat ener wes we 426 Ca ovaro Wan of Seng pre OR e r 2 e s T 12 Jacker Dimer approx 2538 Fam 699 5 Horeonal Length between Water merana Outer saten s1200 532049 wegh es Krogan ason NOTE All dimensions i
34. 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 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 5 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 5 TEMPERATURE AND TIME TO PRODUCE BURNS Water Temperature Time for Permanent Burns p 2nd amp 3rd Degree F 9 Most Severe Burns Time for 1st Degree Burn Less Severe Burns
35. ground wire 15 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 current 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 33 CHECKING HONEYWELL S 8600H OR 5 8600 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 8 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 ca
36. has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Installation Codes When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 1 Installation Codes CHEMICAL VAPOR CORROSION Boiler corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors Spray can propellants cleaning solvents refrigerator and air conditioning refrigerants swimming pool chemicals calcium and sodium chloride water softener salt waxes and process chemicals are typical compounds which are potentially corrosive These materials are corrosive at very low concentration levels with little or no odor to reveal their presence Products of this sort should not be stored near boiler Also air which is brought in contact with boiler should not contain any of these chemicals If necessary uncontaminated air should be obtained from remote or outside sources Failure to observ
37. inches 300 mm of the bottom of the enclosure The vertical ducts shall communicate directly with the outdoors See Figure 13 Each duct opening shall have a minimum free area of 1 square inch per 4 000 Btu hr 550 mm per kW of the aggregate input rating of all appliances installed in the enclosure When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be not less than 3 inches AIR FROM OTHER INDOOR SPACES FIGURE 14 AIR FROM OTHER INDOOR SPACES The confined space shall be provided with two permanent openings one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure See Figure 14 Each opening shall communicate directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an Unconfined Space Each opening shall have a minimum free area of 1 square inch per 1 000 Btu hr 1100 mm per kW of the aggregate input rating of all appliances installed in the enclosure Each opening shall not be less than 100 square inches 645 cm GAS CONNECTIONS CAUTION The gas type must match the gas type on the rating plate Gas supply pressure must match pressure indicated on the rating plate Isolate boiler from gas supply piping system Disconnect boiler and m
38. meter 35 31 feet Where is necessary to use more than the average number of pipe fittings i e elbows tees and valves in gas supply line use a pipe larger than specified to compensate for increased pressure drop vecc else 1972 905 0626 2076 70 ssrt 957 0691 5961 leve 9587 815 9208 M 85 929 5 797 5 8 168 766 807 260 k t 80977 2861 8292 89 99 88 997 525 755 765 079 769 897 898 SOOT 9521 5087 961 822 752 682 262 STE eve OZE 257 65 99 666 0 089521187 06 20 08 8 8 re LZ 0262 09 OS 6 21 07 16 06 19 02 9067 07 59009 9715 5591 Jo 169 60 PL JO SEN JO u edig Jo SV9 JIJILINW 3215 GALSADONS ITEVL 252 967 60 Love 26 252 core 62 2097 9629 899 817 977 798 256 09 907 697 boot 091 9624 cece MI SIE 667 275 175 009 659 207 977 678 vier 997 VEC 872 662 Zee 256 017 Shp 767 955 508 2571 Ser 067 202 022 Zee 792 062 OE 827 49 __002
39. 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 RESET BUTTON HIGH LIMIT SWITCH COVER PROTECTOR SWITCH FIGURE 6 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 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
40. 0 FIGURE 18 GAS CONTROL VALVES NATURAL GAS amp PROPANE 25 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 3 on Page 9 2 Reset System Controller to maximum setting causing 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 see Trouble Shooting in this manual 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 a
41. 2 For higher flow rate turn the range adjusting screw clockwise 3 For lower flow rate tum the range adjusting screw counterclockwise The switch is factory set at approximately the minimum flow rate refer to Table 9 It must not be set lower than the factory setting as this may result in the switch failing to return at a condition 4 Replace flow switch cover Where units are installed in multiples each boiler must be individually protected by a flow switch 5 1 I 6 TO 8 PIPE FLOW SWITCH PADDLE TEE OR WELDING a HALF COUPLING FLOW DIMENSION A MUST BE AT LEAST 5 PIPE DIAMETERS FROM NEAREST ELBOW VALVE OR OTHER PIPE RESTRICTIONS FLOW FIGURE 9 FLOW SWITCH 14 GENERAL REQUIREMENTS REQUIRED ABILITY Installation or service of this boiler requires ability equivalent to that of a qualified service technician in the field involved Plumbing air supply venting gas supply and electrical work are required LOCATION When installing the boiler consideration must be given to proper location The location selected should provide adequate air supply and be as centralized with the piping system as possible This location should also be such that the gas ignition system components are protected from water dripping spraying etc during boiler operation and service circulating pump replacement control replacement etc A CAUTION
42. 250 C AND INSTALLI WIRES CONNECTED TO THE COIL PROTECTOR WHICH ARE 200 C FIGURE 26 SCHEMATIC CER TEMP 80 1 UNIT INSTALLATION FOR HOT WATER SUPPLY APPLICATION 44 4 X 4 JUMCTION BOX WITH TERMINAL STRIP 120 50 60 Hz 11 HOT L2 NEUTRAL CONNECT TO WHITE TRANSFORMER FUSED CONNECT s SWITCH CIRCULATING UNIT 1 PUMP THERMAL SEE RESPECTIVE UNIT DIAGRAM W BALANCER FOR FACTORY INSTALLED WIRING GND 1 GND i r l I I CONNECT TO BLACK TRANSFORMER WIRE I I I 1 1 I 1 I TEMPERATURE I I CONTROL I I 1 1 1 LL s ee Z a SAFETY FLOW SWITCH ee 1 koi 4 X 4 JUMCTION BOX WITH TERMINAL STRIP CONNECT TO WHITE TRANSFORMER wf E ie 1 L UNIT 2 1 ka SEE RESPECTIVE UNIT DIAGRAM jew FOR FACTORY INSTALLED WIRING t 1 7993 4 t r 1 4 4 1 CONNECT BLACK TRANSFORMER WIRE I l paa ep I 1 1 ta eCOM i 81 I I NO I S SAEETVELOWISWITOII DELETE UNIT 3 IF ONLY 2 UNITS I ARE DESIRED WIRE ACCORDINGLY NOTE I I DISCONNECT THE THERMAL 1 po BALANCERS ON UNITS 2 AND 3 n 4 4 X 4 JUNCTION BOX 1 WITH TERMINAL STRIPS CONNECT TO WHITE TRANSFORMER WIRE n L 1 UNIT 3
43. ANY S3009 Fovo JYNIVYFIUNAIL ONILVTNDUIJ SFIDIAFJA YSHLO ANY NOLLVANJI4NOD ONI did qa1s3SSnS SMOHS 3ATVA AWA DON WALSAS AB VANODIS AUVAWIY 029 002 Y37108 3ATVA e aNJIDTI7 99 INALSAS SNIdId SINOYGAH AJVANOJIS 5 86 eoueg sisse Joj euinbe eys s y JO Gunesy y 0 eonDELd se se aq 5 Jejog yo 199 juejeAINbe 06 uo paseq si F 5 5 104 UMOYS 5 ay u nss id jou eunjeledwaej 991 7 jnoKe pouejold SILON Y00714 GSHSINIS gt N WALSAS WALSAS gt AlddNS WALSAS YOLVeVdAS N SV 45019 SV 5441 SIDV ld FIFOY d TANIVAIJINIL 4001
44. ATER 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 GAS VALVE man pa FIGURE A FIGURE B FIGURE C CONTROL KNOB HANDLE OFF YON POSITION RI PILOT WE 695 FIGURED 5 HANDLE ON 9 POSITION 53 POSITION PILOT FIRING VALVE 7 TURN TOP KNOB OF GAS 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 11 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 OFF POSITION SEE FIG A CLOSE FIRING AND PILOT MANUAL VALVES CLOCKWISE y SEE ABOVE LIGHTING AND OPERATING INSTRUCTIONS NATURAL AND PROPANE WITH 1 1 0 FOR HW420 amp UP FOR YOUR SAFETY READ BEFORE LIGHTING W A
45. CAP SCREW OUTLET PRESSURE TAP INLET PRESSURE TAP GROUND TERMINALS 2 INLET D OUTLET SS PILOT ADJUSTMENT UNDER CAP SCREW GAS CONTROL HW 300 amp 399 Adjustment if required is performed as follows 1 Set primary system temperature control dial thermostat at lowest setting so that boiler will not call for heat 2 Attach a pressure gauge to the tapping in the control string elbow 3 Reset primary system temperature control dial thermostat to highest setting Main burner will now ignite 4 With main burner firing adjust pressure if necessary by turning pressure regulator adjusting screw with a screwdriver Clockwise to increase pressure Counterclockwise to decrease pressure 5 Set primary system temperature control dial thermostat to lowest setting 6 Remove pressure gauge and replace sealing plug 7 Set primary system temperature control dial thermostat to desired setting Do not increase gas pressure above that specified on the rating plate as overfiring will result in damage to the boiler as well as increased risk of fire sooting and asphyxiation If gas pressure regulator cannot be adjusted to correct pressure with sufficient gas pressure at the valve replace with new gas control valve WIRING TERMINALS 3 OUTLET PRESSURE TAP PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW PILOT ADJUSTMENT UNDER CAP SCREW GAS CONTROL HW 420 520 amp 67
46. FIGURE FIGURE D 0 HANDLE OFF HANDLE ON POSITION POSITION MANUAL SHUTOFF VALVE HANDLE OFF POSITION PILOT HANDLE ON POSITION PILOT PILOT FIRING VALVE OPERATING INSTRUCTIONS 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 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 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 y TO ON FIG B TURN PILOT FIRING VALVE CLOCKWISE 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 IGNIT
47. ION 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 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 TURNOFF ALL ELECTRICAL POWER TO APPLIANCE 2 TURN TOP KNOB OF GASCONTRO L VALVE CLOCKWISE CYTO OFF FIG A 3 TURN MAIN FIRING VALVE COUNTERCLOCKWISE OFF FIG AND TURN PILOT FIRING VALVE COUNTERCLOCKWISE TO OFF FIG 4 THE THERMOSTAT LOWWEST SETTING TROUBLESHOOTING Before any extensive troubleshooting perform the following Voltage 24 vac is supplied by transformer Ensure that 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 System control tank temperature control thermostat etc is calling for
48. Instruction Manual GAS FIRED COMMERCIAL COPPER BOILERS MODELS HW lik 300 399 420 520 670 A S FOR HYDRONIC HEATING AND HOT WATER SUPPLY UP FLOW MODELS INSTALLATION OPERATION LI rkay MAINTENANCE LIMITED WARRANTY INDOOR ONLY CERTIFIED www ahridirectory org 68 fw Low Lead Content H WARNING If the information in these 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 neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department N G Installation 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 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 0213 321078 002 TABLE OF CONTENTS TABLE OF CONTENTS u
49. O Smith Enterprises Ltd 500 Tennessee Waltz Parkway 599 Hill Street West Ashland City TN 37015 Fergus ON 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 INSTALLATION 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
50. SA B149 1 MULTIPLE VENT TABLE Table 14 on Page 23 has been compiled to show the material sizes in a Type B doublewall combined vent system Refer to the current edition of NFPA 54 or CAN CSA B140 1 for further information A combined vent system is one in which two or more boilers at one level are attached to a common vent In order to use Table 14 the connector rise and total vent height must be known Connector rise is vertical distance from the draft hood outlet to the point where the manifold connection is made Total vent height is the least vertical distance from a draft hood outlet to the top of the vent Local codes or utility requirements often govern termination height ULC listed doublewall gas vents up through 24 610 mm diameter can be installed in heated and unheated areas and can pass through floors ceilings partitions walls and roofs provided the required one inch clearance is observed These vents should be installed in accordance with National Fuel Gas Code ANSI 2223 1 B149 1 EXAMPLE SHOWING USE OF THE HW 670 COMBINED VENT SIZING TABLE NOTE MANIFOLD MAY BE SLOPED UPWARD BUT ALL BOILERS MUST HAVE REQUIRED ONE FOOT MINIMUM CONNECT OR RISE VENT TOP OR CAP a HEIGHT MANIFOLD SEE NOTE CONNECTOR RISE NOTE MANIFOLD LENGTH FROM THE BASE OF THE VERTICAL VENT TO THE NEAREST APPLIANCE SHOULD NOT EXCEED 10 FEET OR 507 OF THE TOTAL VENT HEIGHT WHICHEVER IS GREATEST
51. STALLED AND MUST BE SUPPLIED BY THE INSTALLER BY FACTORY BY INSTALLER WIRING DIAGRAMS 43 120 VAC 50 60 Hz L4 HOT La NEUTRAL 4 X 4 JUNCTION BOX WITH TERMINAL STRIP CONNECT TO WHITE TRANSFORMER WIRE FUSED DISCONNECT _ ____ n CIRCULATING UNIT 1 POMETE __ W THERMAL SEE RESPECTIVE UNIT DIAGRAM BALANCER FOR FACTORY INSTALLED WIRING beda Ce FREE l CONNECT TO BLACK TRANSFOMER WIRE 1 I l I I TEMPERATURE 1 CONTROL 1 ese eres ee al SAFETY FLOW SWITCH A OO FIGURE 25 CER TEMP 80 1 UNIT INSTALLATION FOR HOT WATER SUPPLY APPLICATION SCHEMATIC A L1 HOT 120 VAC aL NEU i L2 I GND I L THERMAL BALANCER CIRCULATING CANADIAN PUMP MODELS 0 9 I I LANE if TEMPERATURE GND CONTROL LUGIN J BOX 1 5 MODELS I CONNECT TO BLACK CONNECT WHITE TRANSFORMER WIRE TRANSFORMER WIRE a gt lt ma se ne K SEE RESPECTIVE UNIT DIAGRAM FOR FACTORY Ena on INSTALLED WIRING TFLOW CLOSES CIRCUIT NOTE IF ANY OF THE ORIGINAL WIRE AS SUPPLIED MUST BE REPLACED WIRING USE ONLY TYPE 105 C WIRE OR EQUIVALENT EXCEPT A en THE FLAME SENSOR AND IGNITION CABLE MUST BE
52. W 399 13 49 HW 420 13 49 HW 520 17 63 HW 670 21 81 12 Pipe sizing and boiler loop pump selection data are shown in Table 8 for several different temperature rises across the boilers TABLE 8 PUMP AND PIPE SIZING DATA PIPING FROM TEES IN MAIN TO BOILER BRANCHES 1 1 2 PR 150 125 100 60 13 1 1 2 HV 150 125 60 13 1 1 2 HV 150 125 2 1 2 1 1 2 HV 1 1 2 HV 150 60 13 2 1 2 2 1 1 2 HV NOTE Pipe loop sizes and pump selections based on 50 equivalent feet of pipe and fittings All pump sizes listed are B amp G model numbers HOT WATER SUPPLY BOILER SYSTEM GENERAL WATER LINE CONNECTIONS Piping diagrams will serve to provide the installer with a reference for the materials and methods of piping necessary for installation It is essential that all water piping be installed and connected as shown on the diagrams Check the diagrams to be used thoroughly before starting installation to avoid possible errors and to minimize time and material cost It is essential that all water piping be installed and connected as shown on the diagrams Figure 29 to Figure 42 on Pages 47 to 60 These boilers can be used ONLY in a forced circulation hot water heating system Since most forced circulation systems will be of the closed type install the water supply line as shown on piping diagrams Fast filling of large pipe old radiator installations and pressure purging of series loop systems where high pr
53. Y W SNUNLIY INOZ FTANLVAJANIL TVNOILIGAV 404 STOINVNIGYO 58809 TVOO 1 HLIM S391440 ANY NOLLVANJI4NOD ONIdid 03 1539918 SMOHS SIHL NOILNVO ONLLVTNDAIL 3ATVA 44134 WALSAS ONILLVJFH 3ATVA YIJ4NE TWLINOZIYOH ONIdWNNA INOZ 029 006 MH FANSSTA 8 FTANIVAJANIL aa H GNd941 57 INALSAS MNVL 1134408 TWOILLAJA INOZ 5 20 BUJAS 104 UMOYS SGAJBA 1 uu s s au Ju uoduuoo Aue eunsse d jou eys Bunjas 5 pue eunjeledwaj ayi noKe pouejold 1 SILON Ll ug YOO T3 aw NOISNVdX3 pd 3 7 YOLVINNNDOV 001 INOZ ISANNad INOZ 7 SNANLJAY INOZ J HOE eee TOULNOI SYNLVYadWAL SINJWFYINDIY 58809 1201 S391440 ANY ONIdid 031539918 SMOHS 5
54. ain manual gas shutoff valve from gas supply during pressure testing of gas system Make sure the gas on which boiler is to operate is same as that specified on the rating plate Do not install boiler if equipped for a different type of gas Consult your gas supplier This boiler is not intended to operate at gas supply pressure other than shown on the rating plate A lock up or positive shut off type regulator must be installed in gas supply line For proper gas regulation the lock up style regulators must be installed no closer than a minimum of 3 feet from the boiler and a maximum of 8 feet away from the boiler Exposure to higher gas supply pressure may cause damage to gas control valves which can result in fire or explosion If overpressure has occurred such as through improper testing of gas lines or emergency malfunction of supply system the gas control valves must be checked for safe operation Make sure that the outside vents on supply regulators and the safety vent valves are protected against blockage These are parts of the gas supply system not boiler Vent blockage may occur during ice build up or snowstorms The boiler must be isolated from the gas supply piping system by closing its main manual gas shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig Disconnect the boiler and its main manual gas shut off valve from the gas supply pip
55. akage corrosion and other deficiencies which could cause an unsafe condition Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Close fireplace dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Test for spillage at the draft hood relief opening after five minutes of main burner operation Use the flame of a match or candle After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Any improper operation of the common venting system should be corrected so the installation conforms with the current edition of National Fuel Gas Code ANSI 22234 or CAN CSA B149 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code ANSI 2223 1 CAN C
56. aping from the relief opening of the draft hood do not operate the equipment until proper adjustment or repairs are made to provide adequate draft through the chimney or gas vent 4 Next turn on all other fuel burning appliances within the same room so they will operate at their full input Repeat step C above checking the draft on each appliance IMPROPER DRAFT PROPER DRAFT FIGURE 17 VENTING SYSTEM TABLE 14 COMBINED VENT SIZING TABLES MODEL HW 300 BOILER Required Connector or Smoke Pipe Diameter Total Vent Height Measured in Feet Above Draft Hood 15 20 30 40 50 60 80 Connector Diameter in Inches LL 10 10 10 10 10 10 4ormore 15 40 50 100 Manifold and Vent Diameter in Inches 2 60 14 12 12 12 qo 10 10 20 16 14 14 14 12 12 12 12 12 Connector Rise in Feet 100 10 if Units Combined Total Input Btuh x 1000 MODEL HW 399 BOILER Required Connector or Smoke Pipe Diameter 10 15 40 50 60 100 Total Input funts gery tooo 19 115 20 40 so 1 700 Combined 4 19 2 2 18 16 16 16 14 14 14 Connector Rise in Feet Number MODEL HW 420 BOILER Required Connector or Smoke Pipe Diameter Total Vent Height Measured in Feet Above Draft Ho
57. as close to the pipe as possible Install the flow switch in the branch top opening of the reducing tee and provide adequate paddle length in the flow stream For example in a 2 pipe installation use a 2 x 2 x 1 reducing tee For 2 or 3 pipe use paddle segments as supplied For other pipe sizes i e 1 1 4 1 1 2 and 2 1 2 trim the paddle to the proper pipe size see Figure 9 below If a standard tee is used install a face or hex bushing in the top opening The paddle must be adjusted or trimmed to the size of the pipe in which it will be installed Any part of the paddle must not touch the pipe or any restrictions in the pipe Screw the flow switch in position so the flat of the paddle is at right angles to the flow The arrow on the side case must point in the direction of the flow 6 19 32 167 5mm 5 17 32 140 5mm L 4 9 16 115 9 4 PIPE PIPE hnr l 4 3 17 32 89 7mm lP n lt 2 29 32 73 8mm gt 2 13 32 64 4 1 29 32 48 4mm 4 111 16 om 1 3 8 34 5mm gt TABLE 9 FLOW SWITCH Minimum Pipe Rate Contacts Closed Flow LPM HW 300 22 0 Contacts Open No Flow LPM 14 0 Model Number 3 7 5 0 The flow switch may be field adjusted to obtain higher minimum flow rates than those shown inTable 9 To adjust the flow rate setting 1 Remove the flow switch cover
58. ause brain damage or death Always read and understand instruction manual Follow steps 1 thru 6 of the OPERATING INSTRUCTIONS on Page 31 Attach a pressure gauge or a manometer to the manifold pressure tapping and refer to Table 16 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 Btuh Btuh Ts 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 O seconds ft 050 Btu ft natural gas 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 on Page 25 Under no circumstances should you exceed the maximum input rate for the boiler given in Table 3 on Page 7 5 Repeat steps 1 thru 6 of the OPERATING INSTRUCTIONS 28 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 5 8600 After 15 sec ignition system loc
59. boiler operation call for heat Other contacts switches are closed relay low water cutoff flow switch coil protector pressure switch etc 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 17 CER TEMP 80 RECOVERY 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 j 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 problem proven to ee be at this control by High limit control applying jumper to differential too wide terminals Circulating pump on incorrect Coil tat itch h Remove control Set tank temperature ow Haas cover depress control thermostat Circulating pump and activated reset button 20 F 10 C above tank burner on
60. e ANSI 2223 1 or CAN CSA B149 1 Installation Codes DRAFT HOOD The draft hood furnished with this boiler must be installed without alteration Provision must be made if the boiler is installed in confined space or a small boiler room to accommodate draft hood spillage and avoid risks described above The upper air opening called for in the AIR REQUIREMENTS section of this manual is for this purpose VENT CONNECTION Size and install proper size vent pipe Do not reduce pipe size to less than that of the draft hood outlet Horizontal runs of vent pipe shall be securely supported by adequately placed approximately every 4 feet or 1 meter noncombustible hangers and or slip joints suitable for the weight and design of the materials employed to prevent sagging and to maintain a minimum upward slope of 1 4 21 mm m per foot from the boiler to the vent terminals see Figure 15 Dampers or other obstructions must not be installed in the vent Be sure that the vent pipe does not extend beyond the inside wall of the chimney 21 CORRECT METHOD OF VENT PIPE INSTALLATION INCORRECT INSTALLATION WITH NO UPWARD ANGLE FOR ONE BOILER ka MINIMUM UPWARD PITCH 1 4 TO THE FOOT 21mm m FOR TWO BOILERS FIGURE 15 VENT PIPE INSTALLATION Where a continuous or intermittent back draft is found to exist the cause must be determined and corrected A special vent cap may be required If the back draft cannot be corrected by the norma
61. e exceptionally fast heating units The low water volumes in relation to firing rates require special attention to water flow rates for smooth efficient operation These considerations for the A O Smith copper heat exchanger boilers are covered below Conventional 20 10 drop in systems for a fully loaded boiler will maintain the following approximate flow rates TABLE 6 WATER FLOW RATES MODELS HW 300 24 91 HW 399 32 121 HW 420 34 127 HW 520 42 158 HW 670 54 203 Figure 29 to Figure 42 on Pages 47 to 60 show typical installations of the boiler with pipe sizing and circulating pump selected by the installer to provide adequate water flow whenever the boiler is firing In a system with several large zones of which any might be smaller than approximately 1 3 of the system should include a hydronic balancer as shown in the piping diagrams The balancer connects between the system supply and the return line before the circulating pump inlet Adjustment of the balancing cock should permit adequate boiler flow rate when only the smallest zone is in operation Attention should be given to balancing inputs and water flow rates where wide variations of system flow rates can occur The recommended minimum flow rates that will result in approximately 50 F 30 C temperature rise across the boiler are as follows TABLE 7 MINIMUM WATER FLOW RATES RESULTING IN TEMPERATURE RISE MODELS GPM LPM HW 300 10 36 H
62. e provided to replace the exhausted air When an exhaust fan is installed in the same space with a boiler sufficient openings to provide fresh air must be provided that accommodate the requirements for all appliances in the room and the exhaust fan Undersized openings will cause air to be drawn into the room through the boiler s vent system causing poor combustion Sooting serious damage to the boiler and the risk of fire or explosion may result It can also create a risk of asphyxiation LOUVERS AND GRILLES The free areas of the fresh air openings in the instructions that follow do not take in to account the presence of louvers grilles or screens in the openings The required size of openings for combustion ventilation and dilution air shall be based on the net free area of each opening Where the free area through a design of louver or grille or screen is known it shall be used in calculating the size of opening required to provide the free area specified Where the louver and grille design and free area are not known it shall be assumed that wood louvers will have 25 free area and metal louvers and grilles will have 75 free area Non motorized louvers and grilles shall be fixed in the open position FRESH AIR OPENINGS FOR CONFINED SPACES The following instructions shall be used to calculate the size number and placement of openings providing fresh air for combustion ventilation and dilution in confined spaces The illust
63. e this requirement will void warranty INSTALLATION CLEARANCES These boilers are approved for installation on combustible flooring in an alcove with minimum clearance to combustibles of TABLE 10 INSTALLATION CLEARANCES HW HW 399 670 VENT 6 152 4 6 152 4 6 152 4 6 152 4 6 152 4 2 inches 51 mm clearance is allowable from combustible construction for hot water pipes Sufficient area should be provided at the front and rear of the unit for proper servicing Clearances of 24 inches 609 4 mm in the rear and 48 inches 1 219 mm in the front are required by code In a utility room installation the door shall be wide enough to allow the boiler to enter or to permit the replacement of another appliance such as a boiler LEVELING Each unit should be checked after installation to be certain that it is level prior to starting the unit If the unit is not level obtain and insert shims under the legs of the unit to correct this condition SYSTEM CONNECTIONS The system installation must conform to these instructions and to the requirements of the local code authority having jurisdiction Good practice requires that all heavy piping be supported 16 AIR REQUIREMENTS AWARNING e Install appliance in accordance with the Instruction Manual and NFPA 54 or CAN CSA B149 1 Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual To avoid i
64. easonably quiet operation during ignition burning and extinction 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 combustion and ventilating air to the unit Maintain a clear area around the boiler at all times FIGURE 19 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 30 and 31 Allow boiler parts to cool before disassembly b Remove main burner manifold assembly from boiler 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 o
65. ed during self check sequences AFlash Code Descriptions 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 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 Heartbeat Constant 1 2 second bright 1 2 second dim cycles Asingle 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
66. eneral guide Any module should be replaced ifit 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 ano ZAWARNING 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 after 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 18 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 22 LOCATION OF LED S Flame LED Yellow Indicates flame presence and strength Refer to Table 18 Status LED Green Signal below minimum Indicates system operation status and error conditions Refer threshold for system to Table 19 and Table 20 on Pages 38 and 39 for status operation specific to each model may flash temporarily during or after lightoff on some applications
67. er 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 Soft lockout due to error detected Control auto resets from soft lockout Reset by cycling Call for Heat If during self check sequences after one hour error repeats replace the control AFlash Code Descriptions Flash Fast rapid blinking Heartbeat Constant 1 2 second bright 1 2 second dim cycles Asingle flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence X Y flash codes signify that the LED flashes X times at 2Hz remains off for two seconds flashes times at 2Hz remains off for three seconds and then repeats the sequence 38 TABLE 20 LOCKOUT MODELS DAND J ONLY GREEN LED STATUS CODES GREEN LED FLASH CODE INDICATES NEXT SYSTEM ACTION 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 detect
68. essures are not available requires bypassing of the pressure reducing valve Generally pressure purging is not possible with a well pump system High point air venting is essential If the system is of the open type a pressure reducing valve will not be required as the water supply to the system will be controlled by a manually operated valve An overhead surge tank is required CLOSED WATER SYSTEMS Water supply systems may because of code requirements or such conditions as high line pressure among others have installed devices such as pressure reducing valves check valves and back flow preventers Devices such as these cause the water system to be a closed system THERMAL EXPANSION As water is heated it expands thermal expansion In a closed system the volume of water will grow when it is heated As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent Temperature Pressure Relief Valve operation water discharged from the valve due to excessive pressure build up This condition is not covered under the limited warranty The Temperature Pressure Relief Valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank must be installed on all closed systems to con
69. 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 local 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 insta
70. ge 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 Devices for Hot Water Supply Systems Z21 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 See Figure 29 to Figure 42 on Pages 47 to 60 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 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
71. ges 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 inspected 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 ree 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 re
72. gligible A WARNING An electrical ground is required to reduce risk of electric shock or possible electrocution Make the ground connection to the screw provided in the electrical supply junction box on the boiler If any of the original wire as supplied with the boiler must be replaced it must be replaced with type 105 c wire or its equivalent except for the flame sensor and ignition cable which are 250 and wires connected to the coil protector which are 200 c CONNECTION DIAGRAM 120 VAC 60 HZ L1 12 NEUTRAL ka GND 4 X 4 JUNCTION FUSED DISCONNECT SWITCH L TANK TEMP PROBE COM NO SAFETY FLOW SWITCH REQUIRED WITH TERMINAL STRIP BOX En IGNITION EE 2 MODULE THERMAL BROWN BALANCER WHITE MV PV YELLOW TRANSFORMER 120 24V WHITE TAN WHITE TAN COIL LIM PILOT SCHEMATIC DIAGRAM L1 HOT L2 NEUTRAL 4 5 120 60 HZ FUSED T DISCONNECT MERRE 4 SWITCH TANK TEMP PROBE SAFETY FLOW WATER PUMP SWITCH 120V _ TO 7 CHASSIS GROUND IGNITER WIRE TO PILOT NOTE IF REPLACING ANY FACTORY WIRING USE TYPE 105 C WIRE OR EQUIVALENT EXCEPT FOR THE IGNITION WIRE WHICH USES 250 C WIRE AND THE COIL LIMIT WHICH USES 200 C WIRE FIGURE 24 GAS CONTROL VALVE THESE COMPONENTS UWIRING ARE NOT FACTORY IN
73. haust fans kitchen ventilation systems clothes dryers and fireplaces shall also be considered in determining the adequacy of a space to provide combustion ventilation and dilution air UNUSUALLY TIGHT CONSTRUCTION In unconfined spaces in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of unusually tight construction for example weather stripping heavily insulated caulked vapor barrier etc additional air must be provided using the methods described in the Confined Space section that follows CONFINED SPACE A confined space is one whose volume is less than 50 cubic feet per 1 000 Btu hr 4 8 cubic meters per kW of the total input rating of all appliances installed in the space Openings must be installed to provide fresh air for combustion ventilation and dilution in confined spaces The required size for the openings is dependent on the method used to provide fresh air to the confined space and the total Btu hr input rating of all appliances installed in the space DIRECT VENT BOILERS Boilers installed in a direct vent configuration that derive all air for combustion from the outdoor atmosphere through sealed intake air piping are not factored in the total boiler input Btu hr calculations used to determine the size of openings providing fresh air into confined spaces EXHAUST FANS Where exhaust fans are installed additional air shall b
74. he valve body 19 Fittings and unions in gas line must be of metal to metal type Apply joint compounds pipe dope sparingly and only to the male threads of pipe joints Do not apply compound to the first two threads Use compounds resistant to the action of liquefied petroleum gases The boiler and its gas connection must be leak tested before placing the boiler in operation SIZING GAS SUPPLY LINE FOR SINGLE BOILER INSTALLATIONS AND FOR INSTALLATIONS OF MULTIPLES OF TWO OR THREE OF SAME SIZE BOILERS Use Table 11 or CAN CSA B149 1 current edition to size iron pipe or equivalent gas supply line Table 11 is based on a pressure drop of 0 3 inches of water and a specific gravity of 0 60 approximately that of natural gas Propane LP gas has an S G of about 1 53 If the service pressure is five inches water column or less use one pipe size larger in order to minimize pressure drop in the line TABLE 11 MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS PER HOUR BASED UPON A PRESSURE DROP OF 0 3 INCH WATER COLUMN AND 0 6 SPECIFIC GRAVITY GAS from Gas Nominal Iron Pipe Size Inches Meter 2 219 3 T 70 21 46 96 560 1 050 1 700 3 000 6 200 24 90 170 350 530 990 1 600 2 800 5 800 The heating value of Natural Gas is approximately 1 050 Btu Ft Propane LP Gas has a heating value of approximately 2 500 Btu Ft Distance 1
75. include ANSI American National Standards Institute ASME American Society of Mechanical Engineers e NEC National Electrical Code e 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 familiar 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
76. ing during any pressure testing of the gas supply system over 1 2 psig The gas supply line must be capped when not connected to the boiler It is important to guard against gas control valve fouling from contaminants in the gas ways Such fouling may cause improper operation fire or explosion If copper supply lines are used they must be approved for gas service When local codes require a main manual shut off valve outside the boiler jacket a suitable main manual shut off valve must be installed in a location complying with those codes Before attaching gas line be sure that all gas pipe is clean on inside To trap any dirt or foreign material in the gas supply line a sediment trap must be incorporated in piping The sediment trap must be readily accessible and not subject to freezing conditions Install in accordance with recommendations of serving gas supplier Refer to the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CAN CSA B149 1 Size of gas supply piping may be larger than heater connection on installations where a significant run of piping is required To prevent damage care must be taken not to apply too much torque when attaching gas supply pipe to boiler gas inlet When installing and tightening gas piping use a second wrench to hold the gas control valve to keep the valve from turning To prevent damage to the gas control valve do not use pipe wrench on t
77. ion 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 across terminals MV 8 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 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 35 CHECKING HONEYWELL 58600 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 15 voltage 24VAC across transformer positive terminal and GND with call for heat Check the circ
78. is boiler must be connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the boiler CORRECT GAS Make sure the gas on which the boiler will operate is the same as that specified on the boiler rating plate Do not install the boiler if equipped for a different type of gas consult your supplier PRECAUTIONS If the unit is exposed to the following do not operate until all corrective steps have been made by a qualified service technician 1 Exposure to fire 2 If damaged 3 Firing without water 4 If the boiler has been exposed to flooding it must be replaced PROPANE OR LIQUEFIED PETROLEUM LP GAS MODELS Boilers for propane LP gas are different from natural gas models A natural gas boiler will not function safely on propane LP gas and no attempt should be made to convert a boiler from natural gas to propane LP gas Propane LP gas must be used with great caution It is highly explosive and heavier than air It collects first in the low areas making its odor difficult to detect at nose level If propane LP gas is present or even suspected do not attempt to find the cause yourself Leave the building leaving doors open to ventilate then call your gas supplier or service agent Keep area clear until a service call has been made At times you may not be able to
79. is used per the recommended installation procedure Constant circulation of water through the building s system main is permissible as long as the water does not constantly flow through the boiler Only all bronze or stainless steel circulating pumps are to be used with the unit when it is installed in hot water supply systems BEARING OIL MOTOR OIL FIGURE 8 A TYPICAL CIRCULATING PUMP Although each circulating pump that requires oiling is oiled and operated by the manufacturer It must be oiled again before operated See Figure 8 above Refer to the pump manufacturer s instructions for lubrication requirements FLOW SWITCH The flow switch is a safety device which must be installed at the water outlet of the unit to prevent main burner operation in the event ofinadequate water flow through the unit An accessory package containing a flow switch is available for this application This switch may be mounted in a horizontal pipe line or a vertical pipe line with upward water flow Do not install the switch where the water flow is downward For proper performance mount the switch in a section of pipe where there is a straight run of at least 5 pipe diameters on each side of the flow switch i e do not locate adjacent to valves elbows orifices etc The flow switch shall be mounted in a standard 1 1 2 x 1 1 2 x 1 tee for a 1 1 2 pipe application For larger pipe sizes use a reducing tee in order to keep the switch
80. ks out must be manually reset FLAME CURRENT SENSED e Spark generator 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 Valves close pilot and main burners are off 29 LIGHTING AND OPERATING INSTRUCTIONS NATURAL AND FOR HW300 HW399 FOR YOUR SAFETY READ BEFORE LIGHTING A HOT WATER PRODUCE 3rd DEGREE BURNS IN 6 SECONDS AT 140 F 60 injury or loss of life 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 A THIS APPLIANCE 15 EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT DO NOT TRY TO LIGHT THE PILOT BY HAND B BEFORE OPERATING SMELL ALL AROUND THE ANCE AREA FOR GAS BE SURE TO SMELL NEXT TO THE FLOOR BECAUSE SOME GAS IS HEAVIER THAN AIR AND WILL SETTLE ON THE FLOOR SS HONEYWELL GAS VALVE W STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL 2 MAKE SURE BOILER AND SYSTEM ARE
81. l methods or if a suitable draft cannot be obtained a blower type flue gas exhauster may be employed to ensure proper venting and correct combustion if permitted by local codes Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure CONNECTING BOILER TO A COMMON VENT Do not connect the boiler to common vent or chimney with solid fuel burning equipment This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems Where a separate vent connection is not available and the vent pipe from the boiler must be connected to a common vent with oil burning equipment the vent pipe should enter the common vent or chimney at a point ABOVE the flue pipe from the oil fired unit Where two or more appliances vent into acommon vent connector or manifold the area of the common vent or vent connector should at least equal the area of the largest vent connector plus 50 of the areas of the additional draft hood outlets When removing a boiler from a system with a common vent use the following steps Be sure the other appliances connected to the common vent are not in operation Seal any unused openings in the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction le
82. 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 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 5 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 6 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 Restricted water flow through the boiler Improper wiring boiler firing without circulating pump operating Pump failure After correcting failure condition
83. lier mixes an odorant with the propane to make its presence detectable But in some instances the odorant can fade and the gas may no longer have an odor Before operating the boiler make sure the propane supplier verify the correct odorant level in the gas Do not adjust or attempt to measure the outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane equiring no field adjustment Attempting to alter or measure the outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage GAS MANIFOLD PRESSURE REGULATORS The gas manifold pressure regulator is included in the combination gas control valve Figure 18 and is set to operate on the gas specified on the boiler model and rating plate Periodically check main burner Figure 19 on Page 26 and pilot flame Figure 20 on Page 27 for proper operation This should be checked every six months Do not subject the gas control valve to inlet gas pressures of more than 14 W C 1 2 5 1 If higher gas pressures encountered a service regulator is necessary TABLE 15 CORRECT MANIFOLD PRESSURE FOR FULL BOILER INPUT IN INCHES OF WATER COLUMN Number Input Natural Propane 10 0 10 0 10 0 Hw 670 Nat 660 000 35 Hw 670 Prop 670 000 WIRING TERMINALS 3 PRESSURE REGULATOR ADJUSTMENT UNDER
84. llation 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 handling 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
85. n inches millimeters except pipe size which is TABLE 2 FLOW HEAD AND TEMPERATURE RISE TEMPERATURE RISE AND PRESSURE DROP 40 DEG F RISE PD FT HEAD BTU INPUT OUTPUT NATURAL PROPANE PY S NATURAL 8 GAS NATURAL 8 GAS Kai gt N TABLE 3 RECOVERY CAPACITIES overs TYPE OF KO CE e ELECTRICAL REQUIREMENTS TABLE 4 ELECTRICAL REQUIREMENTS VOLTS 20 6 woo o CONTROL COMPONENTS CONTROL PANEL HIGH LIMIT CONTROL THERMAL BALANCER 54 TRANSFORMER IGNITION MODULE GAS VALVE PILOT BURNER OBSERVATION HOLE MAIN MANUAL VALVE PILOT MANUAL SHUTOFF VALVE FIGURE 2 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 3 ADJUSTING 0 0 SCREW zan CUT IN CUT OUT
86. n the lighting and operating label on the boiler Refer to Pages 30 and 31 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 includes keeping pilot shield not shown free of lint cleaning the burner head the primary air opening and the orifice of the pilot burner Figure 20 a Open fused disconnect switch or shut off electrical power to the boiler b Disconnect wire from MV wire on valve 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 21 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 20 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 l CONTROL ___ IGNITION CABLE PILOT GAS TUBING SPARK IGNITION PILOT BURNER FIGURE 20 SPARK IGNITION PILOT BURNER AND BURNER FLAME WIRING TERMINALS 3 PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW OUTLET PRESSURE TAP
87. nd 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 Vent all high points in system to purge system of air If pressure bleeding of system is desired install valves as shown in Figure 29 to Figure 42 on Pages 47 to 60 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 Figure 19 should display the following characteristics Provide complete combustion of gas Cause rapid ignition and carryover of flame across entire burner Give r
88. njury combustion and ventilation air must be taken from outdoors Do not place chemical vapor emitting products near the boiler For safe operation an adequate supply of fresh uncontaminated air for combustion and ventilation must be provided An insufficient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life Such a condition often will result in a yellow luminous burner flame causing sooting of the combustion chamber burners and flue tubes and creates a risk of asphyxiation Do not install the boiler in a confined space unless an adequate supply of air for combustion and ventilation is brought in to that space using the methods described in the Confined Space section that follows Never obstruct the flow of ventilation air If you have any doubts or questions at all call your gas supplier Failure to provide the proper amount of combustion air can result in a fire or explosion and cause property damage serious bodily injury or death UNCONFINED SPACE An unconfined space is one whose volume is not less than 50 cubic feet per 1 000 Btu hr 4 8 cubic meters per kW of the total input rating of all appliances installed in the space Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors are considered a part of the unconfined space Makeup air requirements for the operation of ex
89. od 15 20 30 40 50 60 100 Connector Diameter in Inches Total Input funts sere tooo 10115 1 20 9 100 Combined 120 18 16 16 14 14 14 14 14 12 4 20 2 18 16 16 16 14 14 14 Connector Rise in Feet Number 23 MODEL HW 520 BOILER Required Connector or Smoke Pipe Diameter Total Vent Height Measured in Feet Above Draft Hood 15 40 so 100 Connector Diameter in Inches funts ston tooo 0115 20 30 40 T so Combined Manifold and Common Vent Diameter in Inches 2 140 16 16 14 14 14 14 12 12 12 Connector Rise in Feet Number MODEL HW 670 BOILER Input 660 000 or 670 000 Btuh Draft Hood Outlet 12 Required Connector or Smoke Pipe Diameter 5 30 40 50 60 100 Connector Diameter in Inches Units genx 1000 115 so 100 Combined 2 120 18 16 16 14 14 14 14 14 780 22 2 20 18 18 16 16 16 14 2440 26 4 22 20 20 18 18 18 16 6 560 32 28 28 26 24 24 22 22 20 8 480 36 34 32 28 2 26 24 24 so 540 38 36 30 28 28 26 24 40 38 36 32 28 26 26 _12
90. of the following 1 1 square inch 3000 Btu hr 700 mm per kW of the total input rating of all appliances located in the enclosure and 2 Notless than the sum of the areas of all vent connectors in the space OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS FIGURE 12 OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS The confined space shall be provided with two permanent horizontal ducts one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm of the bottom of the enclosure The horizontal ducts shall communicate directly with the outdoors See Figure 12 Each duct opening shall have a minimum free area of 1 square inch per 2 000 Btu hr 1100 mm per kW of the aggregate input rating of all appliances installed in the enclosure When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension ofrectangular air ducts shall be not less than 3 inches OUTDOOR AIR THROUGH TWO VERTICAL DUCTS The illustrations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only Do not refer to these illustrations for the purpose of vent installation FIGURE 13 OUTDOOR AIR THROUGH TWO VERTICAL DUCTS 18 The confined space shall be provided with two permanent vertical ducts one commencing within 12 inches 300 mm of the top and one commencing within 12
91. 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 various 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 HOT WATER SUPPLY BOILERS PREVENTIVE MAINTENANCE For care of the HW water system please refer to the A O Smith Users Information Manual supplied with the boiler VENTING MAINTENANCE Itis 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 which will retard free draft Replace any damaged or deteriorated parts of the venting system Qualified ser
92. ositive lock up regulator is required follow these instructions 1 Positive lock up gas pressure regulators must be rated at or above the input Btu hr rating of the boiler they supply 2 Positive lock up gas pressure regulator s should be installed no closer than 3 feet 1 meter and no farther than 8 feet 2 4 meters from the boiler s inlet gas connection 3 After installing the positive lock up gas pressure regulator s an initial nominal supply pressure setting of 7 inches w c 1 7 kPa while the boiler is operating is recommended and will generally provide good boiler operation Some addition adjustment maybe required later to maintain a steady gas supply pressure 24 4 When installing multiple boilers in the same gas supply system it is recommended that individual positive lock up gas pressure regulators be installed at each unit PIPE SIZES FOR PROPANE GAS Make sure to contact the gas supplier for pipe sizes tanks and 100 lockup gas pressure regulator PURGING GAS LINE Gas line purging is required with new piping or systems in which air has entered Gas purging should be performed per NFPA 54 for US and CAN B149 1 for Canada CHECK GAS SUPPLY INLET PRESSURE CSA or UL listed flexible gas connections are acceptable but make sure that the line has adequate capacity to allow your boiler to fire at full rate Consult with local codes for proper installation or service procedures Do not adjust or attempt
93. p 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 15 ground wire firmly attached to pilot assembly and GND terminal cable and or ground module wire YES NO Replace pilot burner Are ignition cable and ground wire in good condition not brittle 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 1 8 between ground strap and electrode YES NO 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 34 CHECKING HONEYWELL S 8600H OR 5 8600 INTERMITTENT IGNITION CONTROLS PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT 2 situat
94. peration 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 lockout Flash code continues Control auto resets from soft lockout after one hour 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 burn
95. rations shown in this section of the manual are a reference for the openings that provide fresh air into confined spaces only Do not refer to these illustrations for the purpose of vent installation See Venting section on Page 21 for complete venting installation instructions 17 OUTDOOR AIR THROUGH TWO OPENINGS FIGURE 10 OUTDOOR AIR THROUGH TWO OPENINGS The confined space shall be provided with two permanent openings one commencing within 12 inches 300 mm of the top and one commencing within 12 inches 300 mm ofthe bottom of the enclosure The openings shall communicate directly with the outdoors See Figure 10 Each opening shall have a minimum free area of 1 square inch per 4 000 Btu hr 550 mm per kW of the aggregate input rating of all appliances installed in the enclosure Each opening shall not be less than 100 square inches 645 cm OUTDOOR AIR THROUGH ONE OPENING FIGURE 11 OUTDOOR AIR THROUGH ONE OPENING Alternatively a single permanent opening commencing within 12 inches 300 mm of the top of the enclosure shall be provided See Figure 11 The boiler shall have clearances of at least 1 inch 25 mm from the sides and back and 6 inches 150 mm from the front of the appliance The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area
96. rd 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 Authorities having jurisdiction should be consulted before installations are made In the absence of local codes the installation must comply withthe 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 Thank you for purchasing this boiler Properly installed and maintained it should give you years of trouble free service ABBREVIATIONS USED Abbreviations found in this Instruction Manual
97. 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 cause cancer birth defects or other reproductive harm and requires businesses to of potential exposure to such substances WARNING 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 CERTIFIED www ahridirectory org CERTIFIED Low Lead Content H GENERAL SAFETY GROUNDING INSTRUCTIONS This boiler must be grounded in accordance with the National Electrical Code Canadian Electrical Code and or local codes Boiler is polarity sensitive correct wiring is imperative for proper operation Th
98. set until water temperature in the boiler coils drop below 200 F Meter should read zero 2 Defective switch or bad leads 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 40 PRESSURE RELIEF DISCHARGE PIPE FIGURE 23 PRESSURE RELIEF VALVE TEST If after manually operating the valve it fails 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
99. 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 freezing 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 10 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 stora
100. smell an propane LP gas leak One cause is odor fade which is a loss of the chemical odorant that gives propane LP gas its distinctive smell Another cause can be your physical condition such as having a cold or diminishing sense of smell with age For these reasons the use of a propane gas detector is recommended If you experience an out of gas situation do not try to relight boilers yourself Call your local service agent Only trained propane professionals should conduct the required safety checks in accordance with industry standards HIGH ALTITUDE INSTALLATIONS A WARNING Breathing Hazard Carbon Monoxide Gas Special consideration must be taken with installations above 2000 feet 610 m 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 monixide gas in excess of the safe limits which could result in serious personal injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Rated inputs are suitable up to 2000 feet 610 m elevation Consult the factory for installation at altitudes over 2000 feet 610 m INTRODUCTION This design complies with the current edition of the ANSI Z21 13 low pressure boiler standa
101. ting system the common venting system is likely to be too large for proper venting of the appliances remaining connected to it At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation 1 2 Seal any unused openings in the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe After it
102. to measure gas control valve outlet pressure Attempting to alter or measure the outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Make sure the gas piping are sized for the proper flow and length of pipe to avoid excessive pressure drop The gas meter and the gas regulator must be properly sized for the total gas load Perform the below steps when checking inlet gas supply 1 Turn the main power switch to the OFF position 2 Shut off gas supply 3 Remove the 1 8 pipe plug on the main gas shutoff valve and install a suitable 1 8 fitting field supplied for the manometer tubing Place the tubing of the manometer over the tap once the 1 8 fitting is installed 4 Slowly turn on the gas supply 5 Ensure inlet pressure is within specified range 6 Ifthe gas pressure is out of range contact the gas utility gas supplier qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control CHECK FOR GAS LEAKS Before operating the boiler make sure to check the floor near and around the boiler for gas odorant or any unusual odor Remove the top access panel and check for odor in the interior of the boiler enclosure Do not start the boiler if there is any indication of a gas leak Use an approved leak detection solution and repair any leaks at once In the case of propane boilers the supp
103. trol the harmful effects of thermal expansion Contact a local plumbing service agency to have a thermal expansion tank installed An expansion tank or a similar device may be required in the inlet supply line between the boiler and the meter or valve to compensate for the thermal expansion of water under supply pressure see Piping Diagrams section on Page 47 An air separator as shown in the piping diagrams is recommended especially for modern commercial hydronic systems VENT VALVES It is recommended that automatic loose key or screwdriver type vent valves be installed at each convector or radiator MANIFOLD HEADERS Split systems with individual supply and return lines from the boiler room should normally have this piping connected to supply and return manifold headers near the boiler To achieve good water distribution with maximum pressure drop for several circuits manifolds of at least 2 1 2 64 mm diameter are suggested on HW 399 HW 420 HW 520 and HW 670 units HW 300 units should have 1 1 2 38 mm diameter manifolds The circuits should be spaced on the header at a minimum of 3 76 mm center to center Install a balancing cock in each return line Manifold headers are recommended for split systems with or without zone valves and also those installations with zone circulating pumps If the system is to be split at remote points good practice requires special attention be given to main pipe sizing to allow balancing of
104. uit 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 44 Is high voltage cable assembly firmly 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 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 between the tip edge of the hood and electrode and is the gap located in the pilot gas stream YES NO kai 3 Betistsstakilionatdyis 15 the ceramic insulator surrounding the electrode in good p condition not cracked broken YES Replace pilot burner assembly 36 The following procedures are provided as a g
105. uu anken beni ks padi won ad pa oak n seman tapan 2 SAFE INSTALLATION USE AND 3 GENERAL SAFETY s aa saten ban A nee boat ra pan founo yo 4 INTRODUCTION kk reye yan ranean 5 Abbreviations crab stsauncondepasp rien keep 5 QualiCALONS apeze 5 DIMENSIONS AND CAPACITY 6 CONTROL COMPONENTS a koupon nieve 8 BOILER INSTALLATION CONSIDERATIONS 12 SYST M kok asasen 12 Hot Water Supply Boiler System General Water Line Connections ka vues e 12 Closed Water SYSIOMS kisqa Sasa uk 13 Thermal 13 Vent ValVeS uu tuanya asa epa 13 Manifold Head lS uyu a 13 Cooling PIPING eee ina bk eed aa ke 13 FWA k ga 13 GENERAL REQUIREMENTS 15 Required 15 LOCAUOM 15 Replacing Existing Common Vented 15 Chemical Vapor Corrosion 2216 Installation
106. vicers 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 Check parts and chimney for obstructions and clean as necessary 3 Remove burner from boiler 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 3 Besure 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 Place boiler in operation by following the lighting instructions in this manual Check for gas leaks and proper boiler and vent operation 41 WIRING CONNECTIONS A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing
107. water flow The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle 13 COOLING PIPING When the boiler is used in conjunction with a refrigeration system it must be installed so that the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler see Figure 7 Water temperature in the heating system must be reduced to less than 100 F 38 C before cooling system is started or damage to the chiller unit may occur RETURN SUPPLY BOILER COOLING CIRCULATOR CHILLER FIGURE 7 SCHEMATIC SHOWING PROPER PIPING ISOLATION OF THE BOILER FROM THE CHILLER If the boiler is connected to chilled water piping or its heating coils are exposed to refrigerated air the boiler piping system must be equipped with flow valves or other automatic means to prevent gravity circulation through the boiler during the cooling cycle CIRCULATING PUMP Constant circulating pump operation of the boiler voids the warranty Constant water flow through the unit will wash away the copper s natural protective coating This is called velocity erosion This erosion is not as great a problem when intermittent circulating operation

321078 - AO Smith Water Heaters

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