State Industries ASME SW 37-670 User's Manual
Contents
1. BENE lode d HP SWITCH ass X 2 xi 3 8 i 31 8 m m m t m 0 4 1 aM L n EP L E SE rt fot 71 rusES tat bea dud LP SWITCH og 1 1 ct c i i B e z us Uu CONTACTS 2 bd V i A cue S Led H i S B BLK I S a a et st 1 Swe 1 1 2 Bk HEATING ELEMENT S EE X3 COIL S 1 IFAMANUAL RESET HLMT IS USED THE SECOND AUTO RESET HLMT SWITCH IS NOT USED STD WIRING OPTIONAL OR FIELD WIRING AS REQ D o n o CONTACTOR COIL 30 INDICATION LIGHT DIAGRAM 2 THREE PHASE WYE WITH THERMOSTAT 13 JUMPER PRIMARY XFMR SEC r USED ON OFF 208 240V 3PH FUSS 120V SEC T1 gk lll BLK BLK EguP O C Lis id R T SAFETY NR BLK 5 RA QURE 4 AUTO RESET RESET jog NO WARRICK 8 OPTL AUTO RESET HI LIMIT HI LIMIT FLOW 6 MODEL 2681 0 OPTL OPTL LWCO 2 oc P ir cd um HI LIMIT E SEENDE f mi 07 O O em Se 2 BLK BLK BLK pis BLK G2. TIME CLOCK M 74 OPTL c GND 4 eL 2 x 4 SWITCH 1 Le Q4 gt l al 3l g NC 2 amp an a r4 r3 r4 r4 rd F4 577 _ Lat qp 42d UL _ LP SWITCH Ir x 3l gl 3l 81 D NO z a mj boss d d od CURT Cl ci C2 cat cs 5 5 ue 22 22 cp CONTACT S VM z f R BENE 47721 I _ AA os __ M SS rR PEE lt l HEATING ELEMENT S CONTACTOR COIL S NOTE S 1 IFAMANUAL RESET HLMT IS USED THE SECOND AUTO RESET HLMT SWITCH IS NOT USED STD WIRING OPTIONAL OR FIELD WIRING AS REQ D DIAGRAM 1 THREE PHASE DELTA WITH THERMOSTAT REMOVE JUMPER POWER ON OFF AUTO RESET MAN RESET EEG IF USED g HI LIMIT HI LIMIT 300 600V 3PH PRIMARY XFMR FUSE FUSES 120 SEC SEE NOTE ji SEE NOTE 1 BK BLK 50 GND SAFETY DOOR ee eee ae Pe FE 1 r CUN UA Wu ca 1 m M uunc EG i LWCO n 7 MANUAL _ RESET 5 NE ee 1 M cur See cena pot ieee ee 2 d TIME CLOCK ee ee
3. 15 Important 15 M 15 High Temperature Limit 15 10125 15 Lg iL o NL 15 Temperature Regulation S o S 0L 15 Temperature CODI Ol Sia sass patasusctobi i to picta EU REIIHUPEIIU GuEU bot I HARD MEEXAE SET RREN IER 16 Bere m MT 16 MAINTENANCE 17 Schedule E 17 2 17 17 Sediment Removal 17 Lime Scale Removal si veriicccassasecncnesensianapuscnmandwiewnunussasiacdataowinaamiscabaaseammincnt 17 18 18 HOt 18 Boiler Makes Strange 5 5 18 Leakage 18 ILC ndash uites eM OLD EER Le ets 19 NIROL Thank You for purchasing this boiler Properly installed and maintained it should give you years of trouble free service Abbreviations Found In This Instruction Manual ANSI American National Standards Institute ASME American Soc
4. 505 Cle PROP 25101121 70 NN 7 OFF VER jam 4 we je 4 et 1 Aet 4 asec HEATING ELEMENTS 1 le DELAY 1 2 le bELAY2 s NOTE S THERMISTOR Ee DANS e 1 SUBSTITUTE AMANUAL RESET HLMT SWITCH FOR ONE 1 OF 5 2 THE AUTO HLMT SWITCHES 6 4 2 STD WIRING WI 7 OPTIONAL OR FIELD WIRING AS REQ D CONTACTOR COIL Ji INDICATION LIGHT DIAGRAM 4 THREE PHASE WYE WITH STEP CONTROL 14 THE ABOVE DIP SWITCH SETTINGS ARE AN EXAMPLE FOR THE FOLLOWING 2200 OHM PROPORTIONAL PROGRESSIVE VERNER OFF SECONDS 10 SECOND 3 STAGE OPERATION 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 TECHNICIAN ANY QUESTIONS WHICH THEY MAY HAVE IN REGARD TO THE OPERATION AND MAINTENANCE OF THE BOILER BEFORE FILLING THE SYSTEM FOR OPERATION the hot water system should be internally cleaned and flushed to remove any contaminants which may have accumulated during installation See section of this manual titled SYSTEM CLEANING GENERAL Never operate the heating elements without being certain the boiler is filled with water and a pressure relief valve is installed in the relief valve opening provided LWCO An electronic type low water cutoff is provided on all boilers as standard equipment The water probe is installed near the top of the tank to monit
5. Boiler maintenance includes periodic tank flushing and cleaning removal of lime scale from the heating elements Circulating pumps should be oiled MAINTENANCE SCHEDULE Monthly Sediment 5 Needed UNeLIME Removal As Needed Delimer and element gaskets Circulating Pump s Per pump makers instructions Pressure Relief Anue Valve Test y PRESSURE RELIEF VALVE TEST A DANGER Tank Lime Scale Removal Elements Oiling Manually Operate e Burn hazard e Hot water discharge e Keep clear of Pressure Relief Valve discharge outlet The pressure relief valve must be manually operated at least once a year Caution should be taken to ensure that 1 no one is in front of or around the outlet of the pressure relief valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot To test the relief valve lift the lever at the end of the valve several times see Figure 2 The valve should seat properly and operate freely RELIEF VALVE DISCHARGE PIPE FIGURE 2 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 relief valve need to be replaced call the toll fr
6. Portion of Table 310 16 Portion of Table 310 16 Allowable Ampacities of Insulated Allowable Ampacities of Insulated Copper Conductors Aluminum and Copper Clad Aluminum Conductors Not more than three conductors in raceway or cable or direct burial based on ambient temperature of 30 C 86 F Not more than three conductors in raceway or cable or direct burial based on ambient temperature of Temperature Rating of Conductor See Table 310 13 in Code 75 C 167 F Types RH RHW RUH 14 2 THW THWN XHHW USE Temperature Rating of Conductor See Table 310 13 in Code 75 C 167 F Types RH RHW RUH 12 2 THW THWN XHHW USE These capacites relate only to conductors described in Table 310 13 in Code For ambient temperatures over 30 C see Correction Factors Note 13 in Code WIRING DIAGRAM Sia JUMPER PILOT LT AUTO RESET HI LIMIT HI LIMIT SEC IFUSED amp SWITCH HI LIMIT FUSES XFMR 4 SEE NOTE 1 SEE NOTE 1 120V SEC FUSE zc P BLK BLK e BLK BLK os EH EQUIP E a GND 2 WHT WHT WHT 9 m n D BLK SAFETY DOOR INTERLOCK Y r e MODEL S6B1A0 GND i a Me LWco MANUAL RESET 1 PUSHBUTTON RED
7. before bathing or Temperature available limiting valves are Read instruction manual for safe temperature setting PRESSURE RELIEF VALVE An ASME rated pressure relief valve is furnished with the boiler A fitting for the 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 relief valve opening provided The pressure rating of the 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 10 Relief Valve must comply with ASME code Properly sized Relief Valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death A discharge pipe from the relief valve should terminate at an adequate floor drain Do not thread plug or cap the end of the drain line CAUTION Pressure Relief Valve discharge pipe must terminate at adequate drain The Discharge Pipe e Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall not be exposed to freezing temperatures
8. RELIEF VALVE OUTLET OPENING ELECTRICAL CUTOFF BLOCK Cy Se 27 P TEMPERATURE ADJUSTMENT LOW WATER CUTOFF MODULATING ACTUAL CONFIGURATION MAY VARY Nm PILOTLIGHT CONTROL SWITCH STEP CONTROL gt SWITCH CIRCUIT f FUSES CONTROL CIRCUIT TRANSFORMER D gt lt lt gt SS Ed n POWER CIRCUIT NE FUSES Ss S n met SWS ES ser SAJ NS FUSE S SD DE RIS S mI mE Se RS ES bo Sl c m SIS S APPROVAL UL ASME MODEL AND RATIN MA 09642518 model 18 DIGIT MODEL NO item 10 XXXXXXXXXX serial J07R000385 gas type O lot 3 STATE WATER HEATERS P O BOX 58549 RENTON WA 98058 1549 AUTOMATIC WATER BOILER MODEL NO ASME NO PH CY AMP VOLTS EE a TOTAL WATTS STORAGE CAP J Gattons NO ELEMENTS WATTS EA MAX workinc PRESSURE TEST PRESSURE USE ON A C CURRENT ONLY FOR SUPPLY CONNECTIONS USE WIRE SUITABLE FOR AT LEAST 75C 17T8 LISTED LOCATING THE BOILER FACTS TO CONSIDER ABOUT THE LOCATION CAUTION All boilers eventually leak Donotinstall without adequate drainage Carefully choose a location for the boiler The placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance Whether replacing an old boiler or putting the boiler in a n
9. Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the 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 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 See the maintenance section of this manual forinstructions WATER LINE CONNECTIONS The boiler may be installed by itself or with a separate storage tank on both single and two temperature systems When used with a separate storage tank the circulation may be either by gravity or by means of a circulating pump When a circulating pump is used itis important to note that the flow rate should be slow so that there will be a minimum of turbulence inside the heater 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
10. be located in an area where the general public does not have access to set temperatures Figure 1 shows the approximate time to burn relationship for normal adult skin Time to Produce 2nd amp 3rd Degree Burns Adult Skin 180 F 82 C Nearly Instantaneous About 1 2 second About 1 1 2 seconds Less than 5 seconds About 30 seconds More than 5 minutes 160 F 82 C 150 F 82 C 140 F 82 C 130 F 82 C 120 F 82 C 80 F 82 C FIGURE 1 Additional instructional literature is provided with the boiler for adjusting this control 16 Always close and lock the cabinet door after making a temperature adjustment Turn on electricity DRAINING ADANGER hazard Hotwater discharge Keep clear of drain valve discharge outlet The boiler must be drained if it is to be shut down and exposed to freezing temperatures Maintenance and service procedures may also require draining the boiler 1 Turn off the electrical disconnect switch 2 Open a nearby outlet until the water is no longer hot and close the make up water valve and system valves as necessary 3 Open a nearby outlet to vent the parts of the system being drained 4 Open the boiler drain valve 5 the boiler is being drained for an extended shutdown it is suggested the drain valve be left open during this period Follow FILLING instructions to restore boiler to service
11. of water will grow when it is heated As the volume of water grows there will be a corresponding increase in 11 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 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 pressure relief valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Contact a local plumbing service agency to have a thermal expansion tank installed FLECTRICAL DATA GENERAL Check the boiler model and rating plate information against the characteristics of the branch circuit electrical supply Do not connect the boiler to an improper source of electricity Voltage applied to the boiler should not vary more than 5 to 10 of the model and rating plate marking for satisfactory operation Do not energize the branch circuit for any reason before the boiler is filled with water Doing so may cause the heating elements to burn out Such damage is not covered under the terms of the warranty The branch circuit is connected to the block through an opening provided on top of the boiler The boiler should b
12. replacing e fuses always use the correct size for the circuit See page 12 through 14 The principal components of the heater are identified on page 8 The model and rating plate on page 9 interprets certain markings into useful information Both of these references should be used to identify the heater its components and optional equipment 2 The installation must conform with these instructions and the local code authority having jurisdiction and the requirements of the power company In the absence of code requirements follow NFPA 70 current edition The National Electrical Code may be ordered from National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 3 after reading this manual you have any questions or do not understand any portion of the instructions call the toll free number on the back cover for further assistance A sample rating plate and barcode tag are shown on page 9 of this manual In order to expedite your request please have the serial number and item ID from the barcode tag available for the technician 4 Carefully plan your intended placement of the boiler Examine the location to ensure the boiler complies with the Locating the New Boiler section in this manual Installation and service of this boiler requires ability equivalent to that of a licensed tradesman or qualified agency page 2 in the field involved Plumbing and electrical work are required 5 For installatio
13. result death or injury WARNING indicates a potentially hazardous A WARNING situation which if not avoided could result in death or injury CAUTION indicates a potentially hazardous A CAUTION situation which if not avoided could result in minor or moderate injury CAUTION used without the safety alert symbol CAUTION indicates a potentially hazardous situation which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances listed IMPORTANT DEFINITIONS e 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 and electrical supply are required in addition to electrical testing skills when performing service e ANSI
14. 2223 1 2006 Sec 3 3 83 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 NERAL SAFETY INFORMATION PRECAUTIONS 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 which has been under water If the unit is exposed to the following do not operate boiler until all corrective steps have been made by a qualified service agency 1 External fire 2 Damage 3 Firing without water GROUNDING INSTRUCTIONS This boiler must be grounded in accordance with the National Electrical Code and or local codes These must be followed in all cases Failure to ground this boiler properly may also cause erratic control system operation on ELECTRONIC CONTROL models This 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 HYDROGEN GAS F
15. 535 850 1 638 240 rf ow mw mw om mm ON 1 60 9 30 2 60 8 30 3 60 7 30 4 60 6 30 5 60 5 30 6 60 4 30 Amperage 3 Phase 208V 240V 480V 575V 1 843 020 8 60 2 30 648 2 047 800 10 60 1501 1299 720 2 252 580 8 60 2 90 1668 1443 792 2 457 360 4 90 6 60 864 723 2 662 140 6 90 4 60 2 866 920 9 90 1 30 3 071 700 10 90 3 276 480 8 90 2 120 3 481 260 6 90 4 120 3 636 040 4 90 6 120 3 890 820 2 90 8 120 4 095 600 10 120 c c 4 300 380 8 120 2 150 4 709 940 4 120 6 150 5 119 500 10 150 5 529 060 10 90 6 120 5 938 630 10 90 7 120 Q 6 143 400 8 90 9 120 Y 2 6 348 180 6 90 11 120 6 757 740 6 90 12 120 5 5 7 167 300 6 90 13 120 7 576 860 1 120 14 150 7 986 420 18 120 2 90 8 395 980 18 120 2 150 8 805 540 14 120 6 150 9 315 100 10 120 10 150 3240 2711 9 624 660 6 120 14 150 3384 2832 10 034 220 2 120 18 150 3528 2952 NOTE For boilers 3000KW to 6000KW consult factory Consult factory for optional number of steps and Kw per step FEATURES AND COMPONENT RELIEF VALVE LOW WATER CUTOFF GAUGE OPENINGS PRESSURE RELIEF VALVE s AUTOMATIC HIGH LIMIT AUTOMATIC HIGH LIMIT RESET HIGH LIMIT i _ OPTIONAL d CLEANOUT ELEMENT PLATE INLET FRONT
16. Instruction Manual o Mati MODELS SW 37 670 INSTALLATION OPERATION SERVICE MAINTENANCE LIMITED WARRANTY WATER HEATERS A DIVISION OF A O SMITH CORPORATION RENTON WASHINGTON www statewaterheaters com EE Se _ ante Spe 2 2 Se a Thank you for buying this energy efficient boiler from us We appreciate your confidence in our products PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE PRINTED 0110 316393 000 AFE INSTALLATION RVI Your safety and the safety of others is extremely important in the installation use and servicing of this boiler Many safety related messages and instructions have been provided in this manual and on your own boiler to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual Itis 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 hazardous A DYN C zd 8 situation which if not avoided will
17. LAMMABLE A WARNING Flammable hydrogen gases may be present Keep all ignition sources away from faucet when turning on hot water Hydrogen gas can be produced in a hot water system served by this boiler that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To reduce the risk of injury under these conditions it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe as the water begins to flow THERE SHOULD BE NO SMOKING OR OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN When servicing this unit verify the power to the unit is turned off prior to opening the control cabinet door AWARNING Read and understand this instruction manual and the safety messages herein before installing operating or servicing this water heater Failure to follow these instructions and safety messages could result in death or serious injury This manual must remain with the water heater AWARNING Relief Valve must comply with ASME code Properly sized Relief Valve must be installed in opening provided e Can result in overheating and excessive tank pressure Can cause serious injury or death CAUTION Improper Installation use an
18. NDS 3 STAGE REMOVE PRIMARY XFM SEC usen 500 600 5 FUSES 120V SEC FUSE REI BLK NI BLK BLK EQUIP C2 D rec bH i E NE WHT WHT a E 12 a INTERLOCK ee AUTO RESET RESET E OPTL AUTO RESET pod en FLOW os sue er 26B1A0 am TIME CLOCK SWITCH Tt s LEM IN HEUIMIT SEENOTE SEE NOTE oul hw BLK BK wy BK RED p S L NC p Ne c 71 2 oa murem erc ee D i l Poy 34 x 3e m aj m a m m e m Sgt eg LN 1 l G LI LI Lo Las ES 4 FUSES L2 L uJ LJ ey uJ BLK d 4 E BLK BLK BLK BLK BLK BLK I t I y 4 4 52 2 c2 cs cx c4 cio ci SOLITECH 1 Tow e mem CONTACTS 950 10 STEP 6 L A X 20 410 E y 10FF 2200 1 N N 20rF BO onis 9 11 ism BLK 2689664 30FF 4 20 5 y gt i 1 T 40FF LI oNo tovpc Z
19. ONTEN 4 INTRODUC 4 Preparing Tor the Installation 4 DIMENSIONS AND CAPACITIES DATA 5 2 8 9 MODELAND c 9 LOCATING THE NEW 9 Facts to Consider About the Location 252i iio rea erasa troie 9 INSTALLATION E 10 Required Ability p 10 General 10 Pressure Relief 10 Water Line avus bike ere 10 Closed Water SY SIOINS ii 11 11 ELECTRICAL DATA A I EECV 12 General 12 Branch 12 Calculating Amperage Overcurrent 12 Circ ltS osos Point cn DM EMI Po EUN EE e ERN SE NU 12 12 WIRING DIAGRAMS 13 OPERA 8
20. RN RED oe 4 1 PT C LN cu NC C lNO e ep 1 5 GND PROBE 4 ar NE NE aL __ 1 1 qo d 2 0 gt o gt a gt ai gt oi d E d x EB al a 2 m B JEN em emo VM 1 l ER BE L4 cy h r4 h r5 09 19 E E G E TE C4 ysEs DOT LJ LJ LJ CJ LJ LJ b J E go d d BLK 1 1 EE as LNEL q 50400 e 4 2 62 ca c4 c4 cia SOLITECH 6 T T T T CONTACTS 550 10 STEP 5 5 o o t Y E gt a ge 4 2 ED BETES og 5660568 1 OFF 9 2200 20FF 135 0 30FF 4 20 2 40FF 10 2 HEATING ELEMENTS Ee d ARA 70FF B veR NOTE S aw asec SOLID STATE 1 SUBSTITUTE AMANUAL RESET HLMT SWITCH FOR ONE 1 OF THERMOSTAT Ee md x THE AUTO RESET HLMT SWITCHES THERMISTOR 3 BO wees F STD WIRING 4 le 3 OPTIONAL OR FIELD WIRING AS REQ D BE i CONTACTOR COIL 5 381 INDICATION LIGHT 8 lel 16 THE ABOVE DIP SWITCH SETTINGS ARE AN EXAMPLE FOR THE FOLLOWING 2200 OHM PROPORTIONAL DIAGRAM 3 PROGRESSIVE VERNER OFF THREE PHASE DELTA WITH STEP CONTROL SECO
21. SME numbers are found on the boiler s rating plate Model No ASME No Date Installed Dealer s Name Dealer s Address Phone No City and State Zip KEEP THIS WARRANTY AND MANUAL POSTED ADJACENT TO THE BOILER FOR FUTURE REFERENCE WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED BE SURE YOUR DEALER HAS FILLED IN THIS WARRANTY 19 WATER HEATERS A DIVISION OF A O SMITH CORPORATION RENTON WASHINGTON Technical Support 800 527 1953 Parts Department 800 433 2515 www statewaterheaters com
22. and tighten electrical connections as necessary 2 on the electrical disconnect switch and pilot switch es mounted on the boiler cabinet 3 Observe the operation of the boiler during the first heating cycle e Temperature control and contactor operation should be checked by allowing the boiler to come up to temperature and shutoff automatically TEMPERATURE REGULATION Always turn off the electricity at the electrical disconnect switch when making a temperature control adjustment It is suggested the temperature adjustment be turned to the lowest setting which satisfies the hot water requirements of the system TEMPERATURE CONTROLS The boilers covered in this instruction manual are equipped with adjustable thermostat or step control to regulate water temperature and other controls to provide safety features See the wiring diagrams on page 13 amp 14 and or literature included with this manual for additional information Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and or death The temperature at which injury occurs varies with the person s age and duration of exposure The slower response time of children the elderly or disabled persons increases the hazards to them Never allow small children to use a hot water tap or draw their own bath water Never leave a child or disabled person unattended in a bathtub or shower The boiler should
23. current protection should be computed on the basis of 125 percent of the total connected load amperage Where the standard ratings and settings do not correspond with this computation the next higher standard rating or setting should be selected BOILER CIRCUITS The boiler s electrical components are pictured and identified on page 8 The model and rating plate illustration on page 9 identifies the electrical characteristics Basically there are two electrical circuits The control circuit where the temperature control directly or indirectly operates the contactor coils The power circuit which is operated by the control circuit carries the electrical load of the heating elements Thefollowing describes the circuits and includes typical wiring diagrams All circuits are designed for 60 or 50 Hertz alternating current 12 Refer to ELECTRICAL CONFIGURATION TABLE below and wiring diagram provided with your boiler before completing connections to electrical supply NOTE Wiring diagrams in this manual are typical examples The specific wiring diagram as built for your boiler is typically attached to the inner side of the control panel CONTROL CIRCUIT All control circuits are operated on single phase 120V A transformer is used in the control circuit Control circuit wiring is 14 Awg THHN or THWN type rated 600 volts 105 Seperate instructional literature is provided with the boiler for step control
24. d service may result in property damage Do not operate water heater if flood damaged nspect anode rods regularly replace when significantly depleted Install in location with drainage Fill tank with water before operation Properly sized thermal expansion tanks are required on all closed water systems Refer to this manual for installation and service WARNING Flammable hydrogen gases may be present Keep all ignition sources away from faucet when turning on hot water WARNING Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF Failure to do this could result in death serious bodily injury or property damage Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing showering Temperature limiting valves are available Read instruction manual for safe temperature setting TABLE CONTENT SAFE INSTALLATION USE AND 2 GENERAL SAFETY INFORMATION ies inet 3 IM NE MU 3 Hydrogen 3 TABLE OF C
25. e connected to a separate grounded branch circuit with overcurrent protection and disconnect switch These are part of the electrical supply system not components of the boiler as such they are obtained locally The boiler should be grounded in accordance with national and local codes BRANCH CIRCUIT The branch circuit wire size should be established through reference to the National Electrical Code or other locally approved source in conjunction with boiler amperage rating Branch circuit wiring which connects to the boiler terminal block should be temperature rated at 75 C For convenience portions of the wire size tables from the Code are reproduced here It is suggested the electrician size the branch circuit at 125 percent of the boiler rating and further increase wire size as necessary to compensate for voltage drop in long runs Branch circuit voltage drop should not exceed 3 at the boiler CALCULATING AMPERAGE OVERCURRENT PROTECTION The boiler is factory wired for connection to three wire single phase or three and four wire three phase branch circuits In addition a ground conductor may be required A diagram of the wiring as built is furnished with the boiler for the electrician s use An amperage table is on pages 7 amp 12 of this manual The boiler model and rating plate provides full load amperage data Typical or Standard wiring diagrams are provided on pages 13 amp 14 of this manual The rating of the over
26. ee phone number listed on the back of this manual for further technical assistance Tank flushing and circulating pump lubrication should be performed in accordance with the above schedule Tank sediment removal and element lime scale removal must be performed when needed as determined by period inspections Following are the instructions for performing recommended maintenance SYSTEM CLEANING The hot water system should be internally cleaned and flushed to remove contaminants which may have accumulated during installation System cleaning provides chemical stability necessary for component life and system performance 17 Failure to clean the system may cause 1 Poor heating due to formation of gas Residential pipe dope thread cutting oil solder flux dirt and other foreign materials breakdown to form gas This is indicated by a continuing need for purging even through the system is closed 2 Pump seal leakage Acidic water low pH and contamination such as soil and sand result in premature or recurring pump seal failures 3 Automatic air valve leakage Contaminants cause sticky sealing surfaces and result in leakage 4 Relief valve operation Gas formation increases system pressure and relief valve spillage 5 Water leaks at joints and fittings Corrosion and eventual failure of connections occur when system pH is low 6 Noisy operation Heat transfer surfaces can be fouled with dirty oily water Thi
27. er vessel with a reduced height be furnished A Lifting lugs and channel skid base on 96 gallon and larger units LIFTING LUGS UL MINIMUM CLEARANCE REQUIREMENTS 24 ALL SIDES 12 TOP NOTE ALLOW 30 CLEARANCE FOR HINGED CONTROL COMPARTMENT DOORS ELEMENTS CAN BE CHANGED WITH 24 CLEARANCE RELIEF VALVE FITTING AMPMETER ott VOLTMETER TEMPERATURE OPTL AND PRESSURE GAUGES G CONTROL COMPARTMENT INLET BOILER DRAIN Model Number Prefix Gal Cap Std KW Input SW 5 5 5 5 5 5 5 6 2 6 2 6 2 6 2 6 2 6 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 8 2 NOTE For boilers 3400KW to 6000KW consult factory All fittings under 4 will be threaded type All fittings 4 and larger will be flanged Where overall height is a problem a larger diameter vessel with a reduced height may be furnished 6 Model Number Md Mid SW 37 Std KW Input DIMEN ION DATA conto BOILER SPECIFICATIONS STANDARD Gal Hr BTU Output 153 585 204 720 100 F Rise Number of Elements Number of Steps Standard Number and KW of Steps 1 45 1 60 255 975 1 75 307 170 3 30 358 365 3 30 1 15 409 560 4 30 511 950 5 30 614 340 6 30 716 730 584 505 252 819 120 668 577 288 921 510 751 650 324 1 023 900 834 722 360 1 126 290 1 228 680 1 331 070 1 433 460 1
28. ew location the following critical points must be observed The boiler must be located 1 level surface Shim the channel type skid base as necessary if levelling is required 2 Near a floor drain The boiler should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the boiler or to lower floors of the structure 3 discharge opening of the temperature and pressure relief valve should always be piped to an open drain 4 Close to the point of major hot water usage and the power supply Hot water piping and branch circuit wiring should be as short as possible Insulate hot and cold water piping where heat loss and condensation may be a problem Boiler construction permits installation maintenance and service work to be performed through panels located in multiple sides of the boiler Suggested clearances from adjacent surfaces are 12 inches on top 30 inches in front for access to the unit The boiler may be installed in a confined space if adequate ventilation is provided The temperature of the space in which the boiler is installed must not go below 32 F or above 122 F INSTALLATION REQUIRED ABILITY Installation and service of this boiler requires ability equivalent to that of a qualified agency page 2 in the field involved Plumbing and electrical work is required GENERAL The installation must conform with these instructions and t
29. g element be removed periodically for examination If it is scaled all of the elements should be removed and cleaned If the tank bottom has an accumulation of sediment it should be cleaned Lime scale should be removed from the elements by dissolving the accumulation in UNeLIME delimer UNeLIME is a non muriatic delimer available through your dealer or distributor Do not use muratic or hydrochloric acid base deliming solutions to remove lime scale from the elements Do not pour delimer into tank All models 1 Turn off electrical disconnect switch 2 Drain the boiler following DRAINING instructions 3 Remove the cabinet panel which covers the heating elements e Remove insulation as necessary to reach the element area 4 Remove the bolts from each element and remove the elements from the opening Disconnect element wiring as necessary Use a twisting pulling action to remove elements scaled beyond the size of the tank opening Brush loose scale from elements Silicates sulfates and aluminates mustbe removed by scraping or other mechanical means Lime scale dissolvents will not remove these types of scale which are occasionally encountered 5 Lime scale removal Place limed ends of heating elements into UN LIME delimer and allow scale to dissolve Do not permit delimer or water to contact heating element electrical terminals Flush cleaned ends of elements with water when deliming or cleaning is completed Remove sedimen
30. he local code authority having jurisdiction and the requirements of the power company In the absence of code requirements follow NFPA 70 current edition In the absence of local codes the installation must comply with the latest editions of the National Electrical Code NFPA 70 or the Canadian Electrical Code CSA C22 1 The National Electrical Code may be ordered from National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 The Canadian Electrical Code is available from the Canadian Standards Association 8501 East Pleasant Valley Road Cleveland OH 44131 Do NOT test electrical system before boiler is filled with water follow the START UP procedure in the OPERATION section of this manual The principal components of the boiler are identified in the Features and Components illustration on page 8 Boilers are usually placed in a series with the heating system on the outlet side of the circulating pump The boiler piping should include inlet and outlet water valves to permit maintenance and service work to be performed without disturbing the rest of the system Detailed system installation drawings are normally provided by the equipment purchaser or system designer Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury A DANGER Feel water showering
31. he electrical disconnect switch usually contains fuses The boiler has fuses located behind the cabinet door see page 5 for location If the water was excessively hot and is now cold the high temperature cutoff may have operated manual reset equipped models Toreset turn off electricity and remove the back panel and push the reset button Repeated operation of the high temperature cutoff should be investigated by your servicer capacity of the boiler may have been exceeded by a large demand for heat Large demands require a recovery period to restore water temperature Sediment or lime scale may be affecting boiler operation Refer to MAINTENANCE for details Water is too hot 1 Refer to TEMPERATURE REGULATION Boiler makes sounds 1 Sediment or lime scale accumulation on the elements may cause 18 sizzling and hissing noises when the boiler is operating he sounds are normal however the tank bottom and elements should be cleaned Refer to MAINTENANCE for details 2 Some of the electrical components of the boiler make sounds which are normal Contactors will click or snap as the boiler starts and stops Transformers and contactors often hum Water leakage is suspected 1 Check to see if the drain valve is tightly closed 2 If the outlet of the relief valve is leaking it may represent Excessive water pressure or air in the system Faulty relief valve 3 Examine the flange area of
32. he warrantor s products If this is not practicable the owner should contact U S Customers Canadian Customers State Water Heaters State Water Heaters 500 Tennessee Waltz Parkway 599 Hill St W Ashland City TN 37015 Fergus ON N1M 2X1 Telephone 800 365 0024 Attn Warranty Telephone 888 479 9283 a The warrantor will only honor replacement with identical or similar tank or parts thereof which are manufactured or distributed by the warrantor b Dealer replacements are made subject to in warranty validation by warrantor 7 DISCLAIMER NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE BOILER OR THE INSTALLATION OPERATION REPAIR OR REPLACEMENT OF THE TANK OR PARTS THE WARRANTOR SHALL 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 SHALL 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 IN TORT a Some states do not allow the exclusion or limitation of the incidental or consequential damage so the above limitation or exclusion 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 Fill in the following for your own reference Keep it Registration is not a condition of warranty The model and A
33. iety of Mechanical Engineers GAMA Gas Appliance Manufacturer s Association NEC National Electrical Code NFPA National Fire Protection Association UL Underwriters Laboratory PREPARING FOR THE INSTALLATION 1 Read the General Safety section of this manual first and then the entire manual carefully If you don t follow the safety rules the boiler may not operate safely It could cause DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE This manual contains instructions for the installation operation and maintenance of the electric boiler It also contains warnings throughout the manual that you must read and be aware of All warnings and all instructions are essential to the proper operation of the boiler and your safety READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE BOILER Detailed installation diagrams are in this manual These diagrams will serve to provide the installer with a reference for the materials and method of piping suggested IT IS NECESSARY THAT ALL WATER PIPING AND THE ELECTRICAL WIRING BE INSTALLED AND CONNECTED AS SHOWN IN THE DIAGRAMS Particular attention should be given to the installation of thermometers at the locations indicated in the diagrams as these are necessary for checking the operation of the heater Be sure to turn off power when working on or near the electrical system of the heater Never touch electrical components with wet hands or when standing in water When
34. ion 6 in the United States its territories or possessions and Canada 7 when operated free of the damaging effects of uncontrolled thermal expansion and or water hammer b Any accident to the boiler any misuse abuse including freezing or alteration of it any operation of it in a modified form will void this warranty 4 SERVICE AND REPAIR EXPENSE Under this limited warranty the warrantor will provide only repair or a replacement tank or part thereof 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 tank or any component part b Shipping delivery handling and administrative charges for forwarding the new tank or replacement part from the nearest distributor and returning the claimed defective tank or part to such distributor c All cost necessary or incidental for any materials and or permits required for installation of the replacement tank or part 5 LIMITATION ON IMPLIED WARRANTIES Implied warranties including any warranty of merchantability imposed on the sale of this boiler under state law are limited to one 1 year duration for the tank or any of its parts Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you 6 CLAIM PROCEDURE Any claim under this warranty should be initiated with the dealer who sold the boiler or with any other dealer handling t
35. n in California this boiler must be braced or anchored to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from California Office of the State Architect 1102 Q Street Suite 5100 Sacramento CA 95811 6 Massachusetts Code requires this boiler to be installed in accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 DIMENSION DATA UL MINIMUM CLEARANCE REQUIREMENTS OUTLET 24 ALL SIDES 12 TOP RELIEF VALVE NOTE ALLOW 30 CLEARANCE FOR HINGED CONTROL COMPARTMENT DOORS FITTING ELEMENTS CAN BE CHANGED WITH 24 CLEARANCE TEMPERATURE AND PRESSURE ELEMENTS INSTALLED a LIFTING LUGS GAUGES TYPICAL 2 FROM THIS SIDE ONLY CONTROL BOILER DRAIN t BOILERS WITH SINGLE CONTROL PANEL SS AN ADDITIONAL CONTROL PANEL MAY BE REQUIRED FURNISHED WITH PANEL MOUNTED RIGHT OR ON UNITS ABOVE 500 KW RATED 208 OR 240 VOLTS LEFT SIDE FACING INLET SIZES AND DATA NW37 THRU NW150 Model Number Inlet amp Gal Std KW Input Outlet Boiler Drain 1 1 1 1 1 1 1 1 1 1 1 1 2 AAJA AAAA 3 3 2 3 3 3 3 3 3 3 3 3 4 4 4 4 4 5 5 5 5 All fittings under 4 will be threaded type All fittings 4 and larger will be flanged 3 fittings extend 4 beyond jacket Where overall height is a problem a larger diamet
36. or the presence of water The control circuit is opened if the water level is below this point Power On Off The pilot switch on the cabinet front permits the boiler to be turned on and off without having to operate the electrical disconnect switch Additional switches may be provided for manually operating contactor coils Relief Valve An ASME rated pressure relief valve is furnished with the boiler A fitting for the relief valve is provided in the top of the boiler A drain line from the relief valve should terminate near a suitable drain Do not thread plug or cap the end of the drain line The pressure setting of the relief valve should not exceed the pressure capacity of any component in the system including the boiler HIGH TEMPERATURE LIMITS Automatic High Limit The boiler control circuit contains two high temperature cutoff switches This device shuts off the heating elements if excessive water temperatures are reached The high temperature cutoff has an adjustable range of 100 to 240 F and automatically resets on a drop of temperature Manual High Limit Optional A manual reset high limit may be in the control circuit in addition to the automatic high limit previously described The control has an adjustable range of 110 F to 290 F and activates and locks on a temperature increase When the temperature declines the manual reset high limit can be reset A manual reset high limit is an optional substitution for one of
37. s plus gas lead to noisy water circulation FLUSHING ADANGER Burn hazard Hot water discharge Keep clear of drain valve discharge outlet 1 Turn off the electrical disconnect switch 2 Open the boiler drain valve Allow water to flow to an open drain until it runs clean Do not come in contact with the water being drained as it may be very hot 3 Close the drain valve when finished flushing 4 Turn on the electrical disconnect switch SEDIMENT REMOVAL Water borne impurities consist of fine particles of soil and sand which settle out and form a layer of sediment on the bottom of the tank In time if not removed the level of sediment might reach the heating elements For convenience sediment removal and element lime scale removal should be performed at the same time as follows WATER AND LIME SCALE REMOVAL Water and lime scale accumulations on the heating elements is a normal condition common to all immersion type elements Factors which affect the amount of this formation are 1 Amount of make up water used As the volume of make up water heated increases more scale results 2 Water temperature As the temperature of the water is increased more scale is deposited on the elements 3 Characteristics of water supply Regardless of water treatment the elements should be examined regularly Water scale accumulations may cause noises to occur during operation It is recommended that a lower heatin
38. t and scale from the tank bottom through the tank cleanout e The make up water valve and boiler drain valve be opened to flush during the cleanout process Clean remaining gasket material from tank and element flanges Do not reuse original element gasket The element gasket is Part No 5109 Replace elements as follows Put anew gasket on each element Install into tank opening Uniformly tighten element bolts Torque to approximately 32 ft Ibs 10 Connect element wiring as necessary 11 Follow FILLING instructions to restore boiler to service Check for water leaks around elements and proper operation when boiler is filled Replace insulation and cabinet panel Before calling for service check the following points to see if the cause of trouble can be identified and corrected Reviewing this checklist may eliminate the need of a service call and quickly restore the boiler to service The illustration on page 5 identifies the location of most of the boiler components BE SURE TO TURN OFF THE ELECTRICITY WHEN CHECKING EQUIPMENT Not enough or no hot water 1 Be certain the electrical disconnect switch serving the boiler is in the ON position The pilot switch es on the cabinet front should be on n some installations the boiler electrical service may be limited by the power company or boiler controls If the boiler operates on a controlled circuit heat may be effected Check the fuses T
39. t regulations prohibit sale of a model of equivalent size and construction State Water Heaters will provide a model which complies with the regulations of your area in which case the consumer will be charged the difference in price between the like replacement and the energy efficient model required The warranty on the repair or replacement of the part portion or tank will be limited to the unexpired term of the original warranty 2 ALL OTHER PARTS If within ONE year after initial installation of this boiler any part or portion shall prove upon examination by the warrantor to be defective in material or workmanship the warrantor will repair or replace such part or portion at its option 3 CONDITIONS AND EXPECTATIONS This warranty shall 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 approved by the American Society of Mechanical Engineers must have been installed This warranty shall apply only when the boiler is used 1 at temperatures not exceeding the maximum setting of its control 2 at water pressure not exceeding the working pressure shown on the boiler 3 when filled with water free to circulate at all times and with the tank free of damaging scale deposits 4 in a noncorrosive and non contaminated atmosphere 5 in its original installation locat
40. the automatic high limits mentioned above The manual reset button is located on the high limit switch which is located in the control panel 15 ADANGER Full power is present whenever the cabinet door is opened even with the pilot switch turned off FILLING THE BOILER Refer to SYSTEM CLEANING section for preparing the system prior to final filling and operation CAUTION Property Damage Hazard In order to avoid boiler damage fill tank with water before operating Hard Water in areas which have hard water it may be desirable to fill the system with soft water and or provide water treatment as recommended by a consultant familiar with local conditions In this way harmful water scale build up on the heating elements is minimized Close the boiler drain valve and system valves as necessary Open a vent in the highest point of the system to allow the air to escape Fully open the make up water inlet valve Fill the boiler and piping Close the vent as water starts to flow from the opening Place the make up water valve in the desired position The boiler is now ready for START UP and TEMPERATURE REGULATION if being placed in operation for the first time INITIAL START UP The following checks should be made by the installer when the boiler is placed into operation for the first time 1 Check all factory and field made water and electrical connections for tightness Repair water leaks
41. the elements and tank cleanout for gasket leakage Tighten the bolts or if necessary follow the WATER AND LIME SCALE REMOVAL procedure to replace the gaskets SYSTEM WATER TEST System water test Review SYSTEM CLEANING section for a description of six problems which result from loss of system chemical stability Chemical stability is checked by 1 Draw off water from system Is it dirty discolored or odorous 2 What is the pH of the system water It should be neutral or slightly alkaline 3 Does air purged from system vents burn actually gas If so the air is If any of the above conditions are present all waterways should be cleaned and the water adjusted to an alkaline condition If you cannot identify or correct the source of malfunction 1 Place the boiler electrical disconnect switch in the OFF position 2 Close the make up water inlet valve to the boiler 3 Contact your servicer State Water Heaters the warrantor extends the following LIMITED WARRANTY to the owner of this boiler 1 THE TANK If the tank in this boiler shall prove upon examination by the warrantor to have leaked due to natural corrosion from water therein during the FIRST year after initial installation the warrantor will at its option repair it or provide a replacement tank less elements and controls of equivalent size and then current model Some government agencies are requiring energy efficient standards for boilers In the even
Download Pdf Manuals
Related Search