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A.O. Smith HW 610 User's Manual

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1. 45 Cleaning Flushing t 46 06 46 TPODEPE III u ee ee ence N E E ee 47 54 uuu anun ot ee erence eee oes Soe ere 55 F F EXTRA OPENING FOR THERMOMETER M AND RELIEF VALVE H HW 520 610 i gt ET AND HW 670 F N C GAS INLET HW 300 MALE NPT aol INLET LOCATION OF MANUAL NPT MAIN SHUTOFF VALVE OUTSIDE JACKET WHEN CODE REQUIRE NOT SUPPLIED TABLE 1 MODELS DIMENSIONS IN INCHES PROPANE NATURAL HW 610 670 HW 610 670 65 1651 65 1651 B Heightto Top of Jacket 43 1 4 1099 45 1 8 1146 45 1 8 1146 56 1 4 1429 56 1 4 1429 56 1 4 1429 D Diameterof Jacket 25 1 4 641 27 686 27 686 27 686 27 686 27 686 E Floorto Center Line Water Outlet 1 12 305 12 305 12 305 12 305 12 305 12 305 F Draft Diverter Outlet Diameter 1 8 203 10 254 10 254 10 254 12 305 12 305 G Floorto Center Line Gas Inlet 16 1 2 419 16 3 4 425 16 3 4 425 18 457 18 457 18 457 H J K Width of Control St
2. 5 ly gps c ana 7 Grounding u 7 m 7 7 Liquid Petroleum Gas Models a s 7 loh A lid m alip uuu uuu au E 7 CONTROLS AND UNC HON ces uu u R A 8 Ro BA Mm 8 onion mi u u u eta artubus 8 uisi c a TE sE 9 AUO Re Mog aide MIO uuu omen 9 mee i MET m mmm 9 orsi i i 10 TTE E eee 11 Thermometers not i stallegy u uuu uuu m o mM 12 ON pu 12 GENERAL 12 M c 12
3. A A WITH TERMINAL STRIP IGNITION WHITE GAS VALVE MODULE FUSED 71 THERMAL BROWN DISCONNECT ERATES SWITCH WHITE MV PV TRANSFORMER WATER PUMP z z SE LLI LLI TANK TEMP PROBE S A of BLACK COM NO SAFETY FLOW COIL TO SWITCH REQUIRED LIMIT PILOT SCHEMATIC DIAGRAM L1 HOT L2 NEUTRAL 5 120 VAC 60 HZ A FUSED T DISCONNECT B 111 a SWITCH GND TANK TEMP PROBE SAFETY FLOW SWITCH 120V O A el IGNITION MODULE CHASSIS GROUND IGNITOR WIRE TO PILOT GAS VALVE 0 0 NOTE IF REPLACING ANY FACTORY WIRING USE THESE COMPONENTS o UWIRING 105 C WIRE OR EQUIVALENT EXCEPT FOR ARE NOT FACTORY BY FACTORY THE IGNITION WIRE WHICH USES 250 C WIRE INSTALLED AND MUST BE BYINSTALLER AND THE COIL LIMIT WHICH USES 200 C WIRE SUPPLIED BY THE INSTALLER 192359 000 Rev 3 SINGLE STAGE 1 1 0 HONEYWELL GAS VALVE HW 300 thru 670 NATURAL AND PROPANE GAS U S amp CANADA FIGURE 16 24 WIRING DIAGRAM Example of Boiler LINEAR TEMP 120 VAC 60 Hz installations with building space temperature primary controlling BY FACTORY BY INSTALLER L L i i 2 we and main temperature controller as secondary boiler control FLOW CLOSES CIRCUIT FUSED TRANSFORMER EE en 4 X 4 JUNCTION BOX GAS VALVE IGNITION MODULE WITH TERM
4. RECOVERY ONE HW 300 HW 399 HW 420 HW 520 HW 610 OR ONE HW 670 UP FLOW MODEL COMMERCIAL BOILER WITH HORIZONTAL TANK DANGER WATER SUPPLIED TO FIXTURES HOT WATER TO FIXTURES AND MIXING VALVE THERMOMETER TEMPERATURE amp PRESSURE RELIEF VALVE PIPE TO DRAIN RETURN LINE COLD WATER SUPPLY TANK TEMP CONTROL LOCATE TEE AS CLOSE TO TANK AS POSSIBLE LOOP IF USED a kx a PRESSURE RELIEF VALVE GATE VALVE ALL BRONZE CIRCULATING PUMP THERMOMETER SAFETY PIPE TO FLOW P gt OPEN DRAIN SWITCH p PLUG OR SM BALL VALVE amp Gh gt GATE VALVE UNION LOW WATER CUTOFF SWITCH A IF USED WIRING FIGURES 16 and 17 on pages 24 and 25 INSTALL INACCORDANCE WITH ALL LOCAL CODES USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE Model Armstrong Number Pipe size Pump Pump Size Inches Size p HW 399 1 1 2 1 1 2 HV HW 420 1 1 2 1 1 2 HV V HW 520 1 1 2 1 1 2 H Assumes 50 equivalent feet of piping or less FIGURE 29 34 TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE TANK TEMPERATURE SYSTEM VACUUM CONTROL WARNING ON PAGE 11 IF HIGHER PREHEAT BREAKER TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT TWO HW 399 s HW 420 s HW 520
5. 80 2 OR 3 UNIT INSTALLATION FOR HOT WATER SUPPLY APPLICATION CANADIAN MODELS JUNCTION BOX W 6 TERMINALS 120 VAC 50 60 Hz 4 X 4 JUNCTION BOX NEU PEE WITH TERMINAL STRIP FUSED DISCONNECT 2 CONNECT WHITE TRANSFORMER WIRE SWITCH PE xd THERMAL SEE RESPECTIVE UNIT DIAGRAM W UNIT 1 FOR FACTORY INSTALLED WIRING lt 2 CONTROL R CONNECT TO BLACK TRANSFORMER WIRE ee es Y NC _ L NO SAFETY FLOW SWITCH REQUIRED 4 X 4 JUNCTION BOX WITH TERMINAL STRIP CONNECT TO WHITE TRANSFORMER WIRE gt THERMAL SEE RESPECTIVE UNIT DIAGRAM W PAEANCER UNIT 2 FACTORY INSTALLED WIRING 77752 CONNECT TO BLACK TRANSFORMER WIRE NO SAFETY FLOW SWITCH REQUIRED 4 4 BOX WITH TERMINAL STRIP CONNECT WHITE TRANSFORMER WIRE 1 x ee IDEE SEE RESPECTIVE UNIT DIAGRAM BALANCER UNIT 3 FACTORY INSTALLED WIRING CONNECT TO BLACK TRANSFORMER WIRE sus NC WIRING e COM BY FACTORY BY INSTALLER 8 FLOW CLOSES CIRCUIT SAFETY FLOW SWITCH REQUIRED FIGURE 24 29 SCHEMATIC CANADIAN MODELS JUNCTION BOX W 6 TERMINALS L1 HOT 120 VAC L2 NEU
6. DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 11 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES WIRING FIGURES 21 to 27 on pages 28 to 32 HEATERS SPACED 30 APART INSTALL IN ACCORDANCE WITH ALL LOCAL CODES USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE Minimum Model Pipe Size Armstrong Number Inches 2 aT 2 102 HW 610 670 S 45 2 1 2 Assumes 50 equivalent feet of piping or less FIGURE 30 35 TWO HW 300 s HW 399 s HW 420 s HW 520 s HW 610 s HW 670 s UP FLOW MODEL COMMERCIAL BOILER WITH HORIZONTAL TANK IMPORTANT THE INSTALLATION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE PIPING AND FITTINGS BETWEEN GATE VALVES AND BOILERS SHOULD BE BRASS OR BRONZE OTHER PIPING SHOULD CONFORM TO LOCAL CODES GATE VALVES ARE SHOWN FOR SERVICING BOILER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT A O SMITH GO RECOVERY SY STEM VACUUM HOT WATER 4 BREAKER TO FIXTURES AND MIXING VALVE THERMOMETER ERE s M amp PRESSURE LOOP IF USED VALVE IN THE SYSTEM
7. Os 20 4o so so 100 Combined MODEL HW 520 BOILER Required Connector or Smoke Pipe Diameter si Ria roe 15 20 40 so 100 Connector Diameter in Inches Number Total Input Total Vent Height Measured in Feet Above Draft Hood Units 20 15 20 so 4o so 100 Combined Manifold and Common Vent Diameter in Inches 6 3120 2 26 24 22 22 20 20 18 18 8 4160 32 30 28 26 24 24 22 22 20 17 MODEL HW 610 BOILER Required Connector or Smoke Pipe Diameter Total Vent Height Measured in Feet Above Draft Hood 15 20 30 40 so 100 Number Tota gory toon 20 so 4o T so 00 Combined 6 so 2s 28 26 24 24 22 22 20 8 s 3 32 3o 28 26 26 24 24 9 so 36 34 30 30 28 28 26 24 MODEL HW 670 BOILER Required Connector or Smoke Pipe Diameter Total Vent Height Measured in Feet Above Draft Hood Connector is 20 so 40 so 00 Number Total Input Combined 6 360 32 28 28 26 24 24 22 22 20 8 480 36 34 32 30 28 26 26 24 24 9 5490 38 36 34 30 30 28 28 26 24 Known 5 model HW 610 boilers See illustration Connector rise 2 Note 1 is minimum Total vent height 30
8. BULBS HONEYWELL T678B 8 0 ANIPS FULL LOAD EACH SWITCH e Boilers and Secondary Circulator are Controlled by Dual Bulb Dual Switch Controller Staging and Outdoor Reset of Main Water Temperature BOILER 1 4 e A a l L L BOILER 3 BOILER 2 OUTDOOR RELAY RATED _ BULBS TO CARRY ALL MOTORS GAS VALVES BUILDING CIRCULATOR ECT 120 VAG FROM BUILDING HONEYWELL CONTROL SYSTEM T6788 8 0 AMPS FULL LOAD EACH SWITCH LOW WATER CUT OFF IF REQUIRED LINEAR TEMP CIRCULATOR THERMAL BALANCER SAFETY FLOW SWITCH MAIN WATER FLOW SWITCH OUTDOOR THERMOSTAT IF REQUIRED JUNCTION BOX ON BOILERS HONEYWELL 67 BOILER 4 CONTROL APPLICATION DIAGRAM FOUR BOILER LINEAR TEMP INSTALLATION WITH TWO CIRCULATORS FIGURE 20 27 80 1 UNIT INSTALLATION FOR HOT WATER SUPPLY APPLICATION CANADIAN MODELS JUNCTION BOX W 6 TERMINALS 120 VAC 50 60 Hz L2 NUETRAL L1 HOT FUSED GND DISCONNECT lt lt em ES NN em TANK 7 F CIRCULATING TEMPERATURE PUMP _CONTROL __ WIRING BY FACTORY BY INSTALLER NC SAFETY FLOW SWITCH REQUIRED m 4 X 4 JUNCTION BOX WITH TERMINAL STRIP CONNECT TO WHITE TRANSFORMER WIRE 222 DN B THERMAL UNIT 1 w BALANCER SEE RESPECTIVE UNIT DIAGRAM FOR FACTO
9. CANIM 12 Di E I u NA Eoo u u eee ee 13 lt i O u uuu su 14 uuu T TET 14 14 u mnm 14 voir f LOL E m T mmt 14 16 VG Oy u uu usa 16 baee 16 p aupeMIo M T TT 17 Sro INST IN E 18 RON uuu u 18 C Ol 18 Fi l T PEA A A E A E OAE A AE a 18 Waer EIE eea E A E E E ANEA 19 a ESE E mkuu x u A EEE T N E A E AE E N E E E E E E A TE 19 LETEN e m NER E ET awakuna ET 20 Man 6 0 F O uu mun ee E 20 Cocina
10. H 120 VAC U FROM BUILDING HONEYWELL CONTROL SYSTEM T6788 HONEYWELL 8 0 AMPS 475 FULL LOAD 8 0 AMPS EACH SWITCH FULL LOAD gt gt d gt LINEAR TEMP CIRCULATORS p E OUTDOOR THERMOSAT THERMAL MAIN WATER IF REQUIRED E p BALANCERS FLOW SWITCH HONEYWELL T675A SAFETY FLOW SWITCHES LOW WATER CUT OFF JUNCTION BOXES ON BOILERS BOILER NO 1 BOILER NO 2 BOILER NO 3 NOTE Boilers and Secondary Circulator are Controlled by 1 Building temperature controls supply electric power to building circulator 2 Main flow switch proves main water flow before energizing One Dual Bulb Dual Switch Mechanical Controller and sequencing and resetting controls One Dual Bulb single Switch Mechanical Controller 3 Outdoor thermostat required if building controls do not provide automatic shutdown of reset controls during warm weather Sequencing and Outdoor Reset of Main Water Temperature CONTROL APPLICATION DIAGRAM THREE BOILER LINEAR TEMP INSTALLATION WITH THREE CIRCULATORS FIGURE 19 26 1 Building temperature controls supply electric power to building circulator 2 Main flow switch proves main water flow before energizing sequencing and resetting controls 3 Outdoor thermostat required if building controls do not provide automatic shutdown of reset controls during warm weather MAIN WATER
11. THERMAL BALANCER CIRCULATING uf TANK TEMPERATURE CONTROL T SAFETY FLOW SWITCH T SAFETY FLOW SWITCH T SAFETY FLOW SWITCH UNITS t FLOW CLOSES CIRCUIT WIRING BY FACTORY BY INSTALLER CONNECT TO BLACK TRANSFORMER WIRE CONNECT TO BLACK TRANSFORMER WIRE CONNECT TO BLACK TRANSFORMER WIRE DIAGRAM FOR FACTORY INSTALLED WIRING SEE RESPECTIVE UNIT DIAGRAM FOR FACTORY INSTALLED WIRING SEE RESPECTIVE UNIT DIAGRAM FOR FACTORY INSTALLED WIRING NOTE CONNECT TO WHITE TRANSFORMER WIRE gt UNTH 2 K SEE RESPECTIVE UNIT CONNECT TO WHITE TRANSFORMER WIRE CONNECT TO WHITE TRANSFORMER WIRE 9 gt UNIT 2 lt 7777777777 gt UNIT 3 sss DISCONNECT THE THERMAL BALANCERS ON UNITS 2 AND 3 NOTE IF ANY OF THE ORIGINAL WIRE AS SUPPLIED MUST BE REPLACED USE ONLY TYPE 105 C WIRE OR EQUIVALENT EXCEPT THE FLAME SENSOR AND IGNITION CABLE MUST BE 250 C AND WIRES CONNECTED TO THE COIL PROTECTOR WHICH ARE 200 C FIGURE 25 30 CER TEMP 80 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM FOR HOT WATER SUPPLY APPLICATION U S MODELS JUNCTION BOX W 4 TERMINALS 4 X 4 JUMCTION BOX WITH TERMINAL STRIP 120 VAC 50 60 Hz L4 HOT L2 NEUTRAL CONNECT TO WHITE TRANSFORMER FUSED pe m CONNECT n SWITCH CIRCULATING UNIT 1 PUMP THERMAL SEE RES
12. Test for spillage 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 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 2223 1 and or CAN CSA B 149 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 Appendix F in the National Fuel Gas Code ANSI Z223 1 and or CAN CSA B149 Installation Codes k MANUAL RESET HIGH LIMIT SWITCH CONTINUITY TEST Do not depress the switch reset button prior to testing With the unit 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 Protector switch contacts open Depress reset button on switch switch cannot be reset until water temperature in the boiler coils drop below 200 F Meter should read zero Defective switch or bad leads With le
13. Problem Determine diameter of connector manifold and common vent Procedure Enter the top of the HW 610 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 1 CONVENTIONAL INSTALLATIONS All modern hydronic type boilers are 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 209 109 drop in systems for a fully loaded boiler will maintain the following approximate flow rates MODELS GPM LPM HW 610 670 46 175 Figure 7 on page 14 shows a typical installation of the boiler with pipe sizing and circulator 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 Figure 7 The balancer connects between the system supply and the return line before the circulator inlet Adjustment of the balancing cock should permit adequate boiler flow rate when only the smallest zone is in oper
14. e O e e NINININ S O o O ad dd oN O O OI IO OI IO O O o O O A ua O O Co C 6 je e 1 700 3 500 Where itis 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 2B SIZING GAS SUPPLY LINE For multiples of over three boilers of same size or for multiple installations of two or more mixed sizes Capacities in cubic feet per hour of 0 60 specific gravity gas for different sizes and lengths are shown in table 7 No additional allowance is necessary for an ordinary number of fittings Applications of the gravity factor converts the figures given in table 7 to capacities with another gas of different specific gravity Such application is accomplished by multiplying the capacities given in table 7 by the multipliers shown in table 8 on page 22 To determine the size of each section of gas piping in a system within the range of table 7 proceed as follows Determine the gas demand of each appliance to be attached to the piping system When table 7 is to be used to select the piping size calculate the gas demand in terms of cubic feet per hour for each piping system outlet The gas demand for an appliance
15. PIPE TO STORAGE eo OPEN DRAIN INSTALL THERMOMETER AND PRESSURE RELIEF IN 2 OPENINGS PROVIDED HW 520 HW 610 amp HW 670 Q TANK TEMPERATURE CONTROL PRESSURE RELIEF COLD WATER VALVE SUPPLY SEDIMENT CHECK VALVE dd SAFETY FLOW SWITCH DRAIN HEATERS SPACED 30 APART PIPE TO OPEN DRAIN GATE EP THERMOMETER LOCATE TEE AS CLOSE TO TANK PLUG OR PRESSURE RELIEF AS POSSIBLE BALL VALVE s VALVE 4 THERMOMETER CATE VALVE SAFETY PIPE TO ALL BRONZE FLOW OPEN DRAIN CIRCULATING GATE VALVE SWITCH PUMP PLUG OR BALL VALVE WIRING FIGURES 21 to 27 on pages 28 to 32 t INSTALL IN ACCORDANCE WITH ALL LOCAL CODES DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 11 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE Minimum Pipe Size Inches Armstrong Pump Size 2 2 HW 610 670 2 1 2 1 1 2 2 1 2 Assumes 50 equivalent feet of piping or less S 45 2 1 2 FIGURE 31 36 THREE HW 520 s HW 610 s HW 670 s UP FLOW MODEL COMMERCIAL BOILER WITH VERTICAL TANK CER TEMP 80 SMITH RECOVER
16. eoan ene r EEE NEE 20 o pes FEUD ERR TT 20 Gres NEQOE oO mmc 20 Gas Supply Line Purging and SIZING E o AO o 0mm 21 Gas Pressure Tee u S u u M 22 E H 23 24 33 sean do aes scent 34 39 OPERATION AND START UP INS TRUC TIONS ivit uu 39 lli L NET Oc a 39 Pili ie mmc 39 FOr Pui 39 L IOP MAS IPC HOTYS TES GT REDDAM Ea Rub NRI EO aspas asss ushanaka sasa PURO RED 43 44 Checking and Adjusting npuy u DULL 41 SS aka h E 42 REMOVAL OF EXISTING BOILER FROM COMMON VENTING SYSTEM ERU n met 45 AIG 5
17. 520 HW 610 amp HW 670 SMITH VACUUM emp 8O D HOT WATER FIXTURES RECOVERY SYSTEM RETURN LINE AND MIXING VALVE FROM CIRCULATING LOOP IF USED fa PRESSURE RELIEF VALVE STORAGE TANK THERMOMETER SAFETY FLOW THERMOMETER PIPE TO OPEN DRAIN PIPE TO OPEN DRAIN HUNE T TEMPERATURE amp PRESSURE RELIEF VALVE a LA W P SS COLD WATER SUPPLY TANK TEMPERATURE THERMOMETER SAFETY PIPE SEDIMENT FLOW OPEN DRAIN b A SWITCH PRESSURE RELIEF RISER ara a lt GATE VALVE 225 VALVE g lt m 3 Or LOCATE TEE AS x x CLOSE TO TANK 2 AS POSSIBLE OR qe PLUG OR BALL VALVE A FLOW PIPE TO 4 GATE VALVE SWITCH DRAIN Ab lt lt TG HEATERS SPACED 30 APART GATE VALVE 3 WS PUMP AF PLUG OR BALL VALVE M e 32 SY USE THIS TABLE FOR CORRECT C PUMP AND WATER PIPE SIZE Minimum Pipe Size paG Armstrong Inches Pump Pump Size WIRING FIGURES 21 to 27 on pages 28 to 32 Size B HEATERS SPACED 24 APART Assumes 50 equivalent feet of piping or less WITH ALL LOCAL CODES INSTALL IN ACCORDANCE FIGURE 33 38 ANL
18. ANY PART HAS BEEN a 7 UNDER WATER IMMEDIATELY CALL A QUALIFIED TADO WEE OL ONTAN SERVICE TECHNICIAN TO INSPECT THE APPLIANCE DO NOT TOUCH ANY ELECTRIC SWITCH AND TO REPLACE ANY PART OF THE CONTROL DO NOT USE ANY PHONE IN YOUR BUILDING SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN IMMEDIATELY CALL YOUR GAS SUPPLIER FROM UNDER WATER A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CANNOT REACH YOUR GAS DO NOT OPERATE APPLIANCE UNLESS UNIT IS FILLED SUPPLIER CALL THE FIRE DEPARTMENT WITH WATER AND INLET LINES ARE FULLY OPEN GAS VALVE GUE FIGURE FIGURE D HANDLE OFF POSITION FIGURE A FIGURE B FIGURE D 2 Q HANDLE ON HANDLE OFF HANDLE POSITION OFF POSITION ON POSITION POSITION POSITION PILOT HONEYWELL GAS VALVE MANUAL SHUTOFF VALVE PILOT FIRING VALVE OPERATING INSTRUCTIONS STOP READ THE SAFETY INFORMATION 11 SET THERMOSTAT TO DESIRED SETTING PILOT ABOVE ON THIS LABEL BURNER WILL BE IGNITED BY ELECTRONIC SPARK SET THE THERMOSTAT TO LOWEST SETTING 12 LOCATE PEEP HOLE IN FRONT OF THE PILOT TURN OFF ALL ELECTRIC POWER TO THE BURNER MAKE SURE PILOT IS BURNING APPLIANCE ADVISORY THERE IS AFIFTEEN 15 SECOND TRIAL THIS APPLIANCE IS EQUIPPED WITH AN IGNITION PERIOD FOR PILOT IGNITION WHICH IS TIME ENOUGH DEVICE WHICH AUTOMATICALLY LIGHTS THE FOR IGNITION WHEN AIR HAS BEEN BLED FROM GAS PILOT D
19. C AND TURN PILOT FIRING VALVE COUNTERCLOCKWISE OFF FIG SET THE THERMOSTAT TO LOWWEST SETTING 44 VIC 9 N At the time of removal of 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 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 V 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 D k The area around the unit should be kept clean and f
20. CAN PRODUCE 3rd DEGREE BURNS IN 6 SECONDS AT 140 F 60 C IN CASE OF POWER FAILURE DO NOT ATTEMPT TO OPERATE APPLIANCE IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE REFER TO THE USER S INFORMATION MANUAL PROVIDED WITH THIS APPLIANCE INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT DO NOT TRY TO LIGHT THE PILOT BY HAND BEFORE OPERATING SMELL ALL AROUND THE APPLI 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 GAS VALVE CONTROL KNOB HONEYWELL GAS VALVE FIGURE OFF OFF POSITION 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 e IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT C USE ONLY YOUR HAND TO TURN THE GAS CONTROL KNOB NEVER USE TOOLS IF THE KNOB WILL NOT TURN BY HAND DON T TRY TO REPAIR IT CALL A QUALIFIED SERVICE TECHNICIAN FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER
21. California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances listed in the Act IMPORTANT DEFINITIONS e Qualified Installer A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code or the Natural Gas and Propane Installation Code as it relates to the installation of gas fired boilers The qualified installer must have a thorough understanding of this instruction manual e Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired boilers The service agency must also have a thorough understanding of this instruction manual and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer e 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 se
22. DAMAGE OR SOOTING OF THE BOILER Minor variances from input on rating plate can be corrected by adjustment of gas pressure regulators described in GAS PRESSURE REGULATORS section of this manual The inlet gas pressure must not exceed or be less than the values shown on rating plate START STAGE 1 TRIAL FOR IGNITION STAGE 2 MAIN BURNER OPERATION END 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 Response flame current 5 8600 After 15 sec ignition shut down 5 minute time delay before re try 5 8600 After 15 sec ignition system locks out must be manually reset FLAME CURRENT SENSED Spark generator off 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 42 LIGHTING AND OPERATING INSTRUCTIONS NATURAL AND PROPANE FOR HW300 HW399 FOR YOUR SAFETY READ BEFORE LIGHTING WARNING you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life y warnine HOT WATER
23. Flame or Flame Signal below minimum threshold for system operation Perform routine maintenance to assure optimum flame signal Check gas supply pilot burner flame sense wiring contamination of flame rod burner ground connection not applicable Table 12 Continuous Retry Models E K Only Green LED Status Codes Green LED Flash Code X Y OFF Flash Fast Heartbeat 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 6 2 Onevery third retry on the same Call for Heat 643 On every 6th flame failure during run on the same Call for Heat 644 Flame sensed out of sequence longer than 10 seconds Soft lockout due to error detected on during self check sequences Flash Code Descriptions Flash Fast rapid blinking No Startup Flame sense calibration not applicable Next System Action 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
24. 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 FIGURE C EA HANDLE OFF POSITION FIGURE B wel FIGURE D HANDLE ON ofr EA ces ON POSITION PILOT FIRING VALVE LIGHTING INSTRUCTIONS STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL MAKE SURE BOILER AND SYSTEM ARE FILLED WITH WATER AND ALL AIR HAS BEEN EXPELLED FROM APPLIANCE TURN OFF ALL ELECTRIC POWER TO THE APPLIANCE SET SYSTEM TEMPERATURE CONTROLLER TO LOWEST SETTING PURGE ALL GAS LINES OF AIR DO NOT ATTEMPT TO LIGHT THE PILOT BY HAND REFER TO DIAGRAMS ABOVE TURN TOP KNOB OF GAS CONTROL amp PILOT VALVE FIG C CLOCKWISE y TO OFF POSITION FIG A WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS THEN SMELL FOR GAS INCLUDING NEAR THE FLOOR IF YOU SMELL GAS STOP FOLLOW B IN THE SAFETY INFORMATION ABOVE ON THIS LABEL IF YOU DON T SMELL GAS GO TO THE NEXT STEP 7 TURN TOP KNOB OF GAS CONTROL COUNTER CLOCKWISE f TO ON FIG B OPEN PILOT MANUAL VALVES COUNTER CLOCKWISE FIGURE D 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 B
25. ONE FOOT MINIMUM CONNECT OR RISE VENT TOP OR CAP N TOTAL HEIGHT MANIFOLD SEE NOTE T CAP CONNECTOR RISE NOTE MANIFOLD LENGTH FROM THE BASE OF THE VERTICAL VENT TO THE NEAREST APPLIANCE SHOULD NOT EXCEED 10 FEET OR 50 OF THE TOTAL VENT HEIGHT WHICHEVER IS GREATEST FIGURE 9 VENTING MAINTENANCE STANDARD VENTING It is recommended that the heating surfaces and vent piping of the appliance be checked every six months for dust deterioration and carbon deposits Remove all soot or other obstructions from chimney and flue which will retard free draft Replace any damaged or deteriorated parts of the venting system Qualified servicers should follow this procedure when the boiler s external heating surfaces and vent pipe need cleaning CAUTION DO NOT USE 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 USEAMETAL BRUSH TO MINIMIZE THE DANGER OF EXPLOSION Turn off the electrical power main manual gas shutoff and pilot valves if applicable Allow boiler parts and vent to cool before disassembly Remove the boiler draft diverter and vent pipe running to the chimney e Check parts and chimney for obstructions and clean as necessary Remove burner from boiler and other metal parts as required to clean and vacuum the heat exchanger and combustion coils e R
26. The gas pressure regulator is included in the combination gas valve Figure 15 and is set to operate on the gas specified on the boiler model and rating plate WIRING TERMINALS 3 PRESSURE REGULATOR ADJUSTMENT PRESSURE TAP UNDER CAP SCREW INLET PRESSURE TAP GROUND TERMINALS 2 GAS VALVE KNOB PRESSURE REGULATOR ADJUSTMENT L PILOT OUTLET PILOT ADJUSTMENT GAS UNDER CAP SCREW CONTROL OUTLET PILOT SUPPLY PILOT ADJUSTMENT UNDER SCREW FIGURE 15 Periodically check main burner Figure 34 on page 39 and pilot flame Figure 35 on page 40 for proper operation This should be checked every six months Do not subject the gas valve to inlet gas pressures of more than 14 W C 1 2 P S I If higher gas pressures are encountered a service regulator is necessary TABLE 9 CORRECT MANIFOLD PRESSURE FOR FULL BOILER INPUT IN INCHES OF WATER COLUMN Number Input Propane 3 5 10 0 Manifold Pressure HW 520 520 000 HW 610 610 000 HW 670 Nat 660 000 670 Prop 670 000 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
27. WARNING After placing boiler into operation the ignition system safety shutoff device must be tested by the following test method 1 Reset High Limit Temperature Control to lowest setting See figure 2 on page 8 2 Reset System Controller to maximum setting causing 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 relief valves should be inspected and manually operated at least twice a year IMPORTANT IT IS RECOMMENDED THAT A QUALIFIED PERSON PERFORM THE INITIAL FIRING OF THE BOILER AT THIS TIME THE USER SHOULD NOT HESITATE TO ASK THE INDIVIDUAL ANY QUESTIONS WHICH HE MAY HAVE IN REGARD TO THE OPERATION AND MAINTENANCE OF THE UNIT FILLING THE SYSTEM 1 Fast fill system through bypass until pressure approaches desi
28. WATER SERVICE PIPING AND FITTINGS BETWEEN GATE VALVES AND BOILERS SHOULD BE BRASS OR BRONZE OTHER PIPING SHOULD GATE VALVES ARE SHOWN FOR SERVICING BOILER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE WIRING FIGURES 16 and 17 on pages 24 and 25 INSTALL IN ACCORDANCE WITH ALL LOCAL CODES USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE B amp G Pump Size Minimum Pipe Size Inches Model Number HW 300 HW 399 HW 420 HW 520 HW 610 670 5 Assumes 50 equivalent feet of piping or less FIGURE 28 33 PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM INSTALL THERMOMETER AND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 amp HW 670 Armstrong Pump Size 4 2 2 2 5 25 1 1 32 1 1 32 1 1 32 1 1 5 35 SMITH THE INSTALLATION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE GATE VALVES ARE SHOWN FOR SERVICING BOILER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE PIPING AND FITTINGS BETWEEN GATE VALVES AND BOILERS SHOULD BE BRASS OR BRONZE OTHER PIPING SHOULD CONFORM TO LOCAL CODES PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM INSTALL THERMOMETER AND PRESSURE RELIEF IN pRAIN OPENINGS PROVIDED ON HW 520 HW 610 amp HW 670
29. and process chemicals are typical compounds which are corrosive These materials are corrosive at very low concentration levels with little or no odor to reveal their presence Products of this sort must not be stored near the boiler Also air which is brought in contact with the water boiler should not contain any of these chemicals If necessary uncontaminated air should be obtained from remote or outside sources INSTALLATION CLEARANCES These boilers are approved for installation on combustible flooring in an alcove with minimum clearance to combustibles of TABLE 4 o 59 Q s Two inch 50 8mm clearance is allowable from combustible construction for hot water pipes HW 610 amp 670 609 6 609 6 TANK FITTING PRESSURE REDUCING VALVE BY PASS FOR FAST FILL MAKE UP WATER AIR SEPARATOR IF USED SYSTEM SUPPLY LINE SYSTEM RETURN LINE MA CIRCULATOR DRAIN VALVE AND GATE VALVE SHOWN BELOW CIRCULATOR ARE FOR PRESSURE PURGING IF DESIRED DRAIN VALVE TEMPERATURE PRESSURE GAUGE GATE VALVE IMPORTANT THE INSTALLATION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE SMITH NO 211480 THERMOMETER DRAIN VALVE Sufficient area should be provided at the front and rear of the unit for proper servicing Clearances of 24 inches 609 4mm in the rear and 48 inches 1 219mm in
30. fault corrects control resumes normal operation after a one minute delay Control remains in wait mode When the fault corrects control resumes normal operation after a one minute delay Initiate new trial for ignition after retry delay completed 5 minute retry delay then initiate new trial for ignition Control waits until flame is no longer sensed and then goes to soft lockout Flash code continues Control auto resets from soft lockout after one hour Heartbeat Constant 1 2 second bright 1 2 second dim cycles A single flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence Recommended Service Action If system fails to light on next trial for ignition check gas supply pilot burner spark and flame sense wiring flame rod 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 rod burner ground connection Check for pilot flame Replace gas 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 rod is in proper position Check flame rod ceramic for cracks damage or tracking Check transformer and AC line for proper input voltage to the control Check with full system
31. is adjusted to a position that will permit gas to flow Is pilot gas flowing during ignition attempt YES Turn on power supply Turn off power supply YES NO Is ignition cable firmly plugged into pilot assembly and module Securely connect Is ground wire firmly attached to pilot assembly and GND cable and or ground terminal on module wire YES 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 th ilot ilot shiel J Carefully bend down other metal parts pilot screen pilot shield etc wards top of ground Ignition cable must not touch metal surfaces or current strap to achieve carrying wires 1 8 spark gap Is there a 1 8 gap between ground strap and electrode YES Is ceramic insulator surrounding the electrode good Replace pilot burner 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 49 HONEYWELL 5 8600 58610 INTERMITTENT IGNITION CONTROLS PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT C
32. lighting present at the valve and the pilot does not operate when system instructions in this manual or on the lighting and calls for heat replace valve operating label on the boiler See pages 43 44 5 Low gas pressure e Check for gas leaks and proper boiler and vent operation Adjust pilot flame by means of the pilot gas adjustment 2 PILOT BURNER ELECTRONIC IGNITION n iie cas valve To establish pilot flame without main burner operation it will be The pilot flame should envelop 3 8 to 1 2 inch of the tip necessary to perform the following steps of the thermocouple Remove pilot adjustment cover screw Figure 36 Turn inner adjustment screw pilot servicing of the pilot burner every six months includes adjusting valve clockwise to decrease or counterclockwise keeping pilot shield not shown free of lint cleaning the burner to increase pilot flame Be sure to replace cover screw on head the primary air opening and the orifice of the pilot burner combination gas valve after adjustment to prevent Figure 35 possible gas leakage 1 Open fused disconnect switch or shut off electrical power to the boiler WIRING TERMINALS 3 PRESSURE REGULATOR STMENT OUTLET UNDER CAP SCREW PRESSURE TAP 2 Disconnect wire from MV wire on valve INLET PRESSURE TAP GROUND 3 Close fused disconnect switch to restore electrical power e to the boiler 6 GAS VALVE PRESSURE REGUL
33. 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 ESCAPING 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 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 DRAFT PROPER DRAFT FIGURE 10 TABLE 5 COMBINED VENT SIZING TABLES MODEL HW 300 BOILER Required Connector or Smoke Pipe Diameter Total Vent Height Measured in Feet Above Draft Hood Risen Feat 10 15 20 40 so eo T 100 4ormoe PO Number Total Input Total Vent Height Measured in Feet Above Draft Hood fUnts 20 so 40 so 60 100 Combined 2 60 14 12 12 12 10 10 10 10 10 900 16 14 14 14 12 12 12 12 12 MODEL HW 399 BOILER Required Connector or Smoke Pipe Diameter Rise nFoct L ts D 20 40 so so 100 Connector Diameter in Inches Number Total Input fUnts 1000 115 20 so 4o so eo 100 Combined MODEL HW 420 BOILER Required Connector or Smoke Pipe Diameter RiseinFeat 10 15 20 so 40 so 100 Number Total Input fUnits
34. 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 water heater 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 WARNING situation which if not avoided could result in injury or death CAUTION indicates a potentially hazardous AX CAUTION situation which if not avoided could result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous CAUTION situation which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to 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
35. requirements not covered below THE PURPOSE SAFETY RELIEF VALVE IS TO AVOID EXCESSIVE PRESSURE OR TEMPERATURE INTO THE STEAM RANGE WHICH MAY CAUSE SCALDING AT FIXTURES TANK EXPLOSION SYSTEM OR BOILER DAMAGE TO AVOID SCALDING OR WATER DAMAGE A DRAIN LINE MUST BE CONNECTED A RELIEF VALVE TO DIRECT DISCHARGE TOASAFELOCATION ADRAIN LINE MUST NOT BE REDUCED FROM THE SIZE OF THE VALVE OUTLET AND IT MUST NOT CONTAIN ANY VALVES BETWEEN THE BOILER AND THE RELIEF VALVE OR THE RELIEF VALVE AND THE DRAIN EXIT IN ADDITION THERE SHOULD NOT BE ANY RESTRICTIONS IN A DRAIN LINE NOR SHOULD IT BE ROUTED THROUGH AREAS WHERE FREEZING CONDITIONS MIGHT OCCUR DO NOT THREAD OR CAP THE DRAIN LINE EXIT RESTRICTING OR BLOCKING A DRAIN LINE WILL DEFEAT THE PURPOSE OF THE RELIEF VALVE AND MAY CREATE AN UNSAFE CONDITION INSTALLA DRAIN LINE WITH A DOWNWARD SLOPE SUCH THAT IT NATURALLY DRAINS ITSELF If any safety 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 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 relief valve for hot water supply systems and 50 psi relief valve for space heating application An ASME rated temperature and pressure relief valve must be instal
36. 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 water heater LEVELING Each unit should be checked after installation to be certain that it is level If the unit is not level insert metal 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 PIPE HANGERS INSTALL IN ACCORDANCE WITH LOCAL CODES HYDRONIC BALANCER VALVE IF LOCAL CODES REQUIRE A LOW WATER CUTOFF INSTALL HERE 4 RELIEF VALVE MAIN MANUAL GAS SHUTOFF VALVE SAFETY FLOW SWITCH WATER OUTLET HEIGHT FOLLOW LOCAL CODES 6 MINIMUM DIRT LEG WATER INLET PIPED TO OPEN DRAIN A TYPICAL BOILER INSTALLATION FIGURE 7 VENTING VENTING THE BOILER STANDARD VENTING THE INSTRUCTIONS THIS SECTION ON VENTING THE BOILER MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR 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 For boilers for connection to gas vents or chimneys vent sizing installation and terminati
37. time of boiler installation AIR REQUIREMENTS Provisions for combustion and ventilation air in accordance with the current edition of the National Fuel Gas Code ANSI Z223 1 CAN CSA B149 1 Installation Codes or applicable provisions of the local building codes Provisions for vent bleed and gas relief lines when applicable Keep appliance area free of combustible or flammable liquids Do not obstruct the flow of combustion or ventilating air WARNING FOR SAFE OPERATION PROVIDE ADEQUATE AIR FOR COMBUSTION AND VENTILATION AN INSUFFICIENT SUPPLY OF AIR WILL CAUSE RECIRCULATION OF COMBUSTION PRODUCTS RESULTING IN AIR CONTAMINATION THAT MAY BE HAZARDOUS TO LIFE SUCH A CONDITION OFTEN WILL RESULT IN A YELLOW LUMINOUS BURNER FLAME CAUSING CARBONING OR SOOTING OF THE COMBUSTION CHAMBER BURNERS AND FLUE TUBES AND CREATES A RISK OF ASPHYXIATION Unconfined Space In buildings of conventional frame brick or stone construction unconfined spaces may provide adequate air for combustion and draft hood dilution If the unconfined space is within a building of tight construction buildings using the following construction weather stripping heavy insulation caulking vapor barrier etc air for combustion ventilation and draft hood dilution must be obtained from outdoors or spaces freely communicating with the outdoors The installation instructions for confined spaces in tightly constructed buildings must be followed to ens
38. 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 Recommended Service Action If system fails to light on next trial for ignition check gas supply pilot burner flame sense wiring contamination of flame rod burner ground connection Check for pilot flame Replace gas 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 rod is in proper position Check flame rod 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 rod contaminated or out of position burner ground connection Check gas supply pilot burner flame sense wiri
39. ACTORY 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 26 31 80 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM 14 HOT TEMPERATURE CONTROL SAFETY FLOW SWITCH SAFETY FLOW SWITCH SAFETY FLOW SWITCH FLOW CLOSES CIRCUIT WIRING BY FACTORY BY INSTALLER FOR HOT WATER SUPPLY APPLICATION U S MODELS JUNCTION BOX W 4 TERMINALS NEUTRAL 120 VAC THERMAL BALANCER CIRCULATING PUMP RH1 1900 OHM CONNNECT TO BLACK CONNECT TO WHITE TRANSFORMER WIRE TRANSFORMER WIRE os SEE RESPECTIVE UNIT DIAGRAM FOR FACTORY INSTALLED WIRING CONNECT TO BLACK CONNECT TO WHITE TRANSFORMER WIRE TRANSFORMER WIRE UNIT 2 SEE RESPECTIVE UNIT DIAGRAM FOR FACTORY INSTALLED WIRING DELETE UNIT 3 IF ONLY 2 UNITS l l l ARE DESIRED WIRE ACCORDINGLY CONNECT TO BLACK CONNECT TO WHITE TRANSFORMER WIRE TRANSFORMER WIRE O inn UNIT 3 TL SEE RESPECTIVE UNIT DIAGRAM FOR FACTORY INSTALLED WIRING NOTE IF ANY OF THE ORIGIN
40. AKE 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 SERVICEMAN EXPOSURE TO FIRE IF DAMAGED FIRING WITHOUT WATER SOOTING Aa ON IF THE BOILER HAS BEEN EXPOSED TO FLOODING IT MUST BE REPLACED LIQUEFIED PETROLEUM GAS MODELS Boilers for propane or liquefied petroleum gas LPG are different from natural gas models A natural gas boiler will not function safely on LP gas and no attempt should be made to convert a boiler from natural gas to LP gas 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 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 smell an LP gas leak One cause is odor fade which is a loss of the chemical odorant that gives 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 pr
41. AL WIRE AS SUPPLIED WITHTHE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C WIRE OR EQUIVALENT EXCEPT FOR THE FLAME 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 32 ONE HW 300 HW 399 HW 420 HW 520 HW 610 OR ONE HW 670 UP FLOW MODEL COMMERCIAL BOILER WITH VERTICAL TANK VACUUM BREAKER HOT WATER TO FIXTURES AND MIXING VALVE TEMPERATURE amp PRESSURE RELIEF VALVE 4 PIPETO OPEN DRAIN PRESSURE VALVE STORAGE TANK SMITH SY STEM GATE VALVE PLUG OR TANK BALL VALVE TEMPERATURE CONTROL ALL BRONZE CIRCULATING SW PUMP NY LOCATE TEE AS CLOSE TO TANK DRAIN AS POSSIBLE COLD WATER SUPPLY IMPORTANT THE INSTALLATION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT INTERRUPTION OR CIRCULATOR FAILURE CONFORM TO LOCAL CODES 5 GATE VALVE AN 45 lt DRAIN SJ DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 11 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES RELIEF SAFETY FLOW SWITCH Des GATE VALVE THE BOILER IN CASE OF
42. ATOR 5 ADJUSTMENT 7 PILOT The pilot will now ignite provided the system is calling for heat OUTLET PILOT ADJUSTMENT GAS UNDER CAP SCREW CONTROL 4 Adjust pilot flame To adjust the pilot flame remove the cap screw from the pilot adjusting screw Figure 36 and turn to deliver a sufficient PILOT ADJUSTMENT ee flame at the pilot burner to cover 3 8 to 1 2 10 12mm of the sensing probe tip See Figure 35 FIGURE 36 6 Clogged pilot burner orifice IGNITOR GROUND STRAP SENSOR ROD PROPER PILOT FLAME e Clean or replace orifice A clogged orifice will restrict ADJUSTMENT PILOT BURNER gas flow and result in low thermocouple output GROUND WIRE TO ELECTRONIC IGNITION 42 dM 7 Incorrectorifice BURNER HEAD Replace The Orifice size is stamped on the INSULATED IGNITION CABLE ELECTRODE wrench flats E 8 Clogged primary air opening SPARK IGNITION TYPICAL PILOT Restricted air passages will soften the pilot flame and result in poor thermocouple flame FIGURE 35 impingement PILOT BURNER BURNER FLAME 40 CHECKING AND ADJUSTING THE INPUT 1 Follow steps 1 thru 6 of the OPERATING INSTRUCTIONS 2 Attach a pressure gauge or a manometer to the manifold pressure tapping and refer to table 10 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 consumi
43. Code applies in Canada 1 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 2 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 non combustible 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 21mm m per foot from the boiler to the vent terminals see Figure 8 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 CORRECT METHOD OF VENT PIPE INSTALLATION INCORRECT INSTALLATION WITH NO UPWARD ANGLE FOR ONE BOILER MINIMUM UPWARD PITCH 1 4 TO THE FOOT 21mm m FOR TWO BOILERS VENT PIPE INSTALLATION FIGURE 8 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 normal methods or if a suitable dra
44. ILER 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 valve k The electrical connections must be made so that the circulator will operate before the gas 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 diagrams in Figures 16 and 17 on pages 24 and 25 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 negligible 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 APPLIANCE 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 C AND WIRES CONNECTED TO THE COIL PROTECTOR WHICH ARE 200 C HW 300 670 I I D SYSTEM CONNECTION DIAGRAM 120 VAC 60 HZ L1 HOT 12 NEUTRAL GND 4 X 4 JUNCTION BOX
45. INAL STRIP HONEYWELL HONEYWELL HE WIGREEN GND _ 4 av e MV CIRCULATOR CIRCULATING 6 MVIPV WHITE K MVIPV ao d 108 com 4 W YELLOW 5 I SYSTEM MAIN TEMP THERMAL CONTROLLER CONTROLLER z BALANCER Paavon 675 BLACK WITAN RED EM 2 l ee __ NC COIL LIMIT CONTROLLED SAFETY FLOW SWITCH LIMIT HOT REQUIRED PLOT f BURNER NOTE f mE f GROUND If any of the original wire as supplied with the appliance WIRE SENSOR IGNITION must be replaced it must be replaced with Type 105 C wire or equivalent except for the wire connected to the coil protector which are 200 C CABLE af aft E PILOT BURNER HONEYWELL TYPICAL WIRING DIAGRAM SYSTEM FOR SINGLE BOILER LINEAR TEMP INSTALLATION FIGURE 17 2 LINEAR TEMP INSTALLATIONS Control for these systems is decided mainly by the type of building system controlling that is desired A single boiler installation might be controlled directly from space temperature thermostat s Multiple boiler installations are more effective when the boilers are sequenced in and out of operation by some form of main water temperature controller With one to three boilers individual controls set at progressive temperatures may be used For more than three or four boilers a step controller is recommended Individual boiler cont
46. LL RESULT IN IMPROPER AND INEFFICIENT OPERATION OF THE APPLIANCE RESULTING IN THE PRODUCTION OF INCREASED LEVELS OF CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS WHICH COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH For specific orifice requirements please refer to the appropriate section of the National Fuel Gas Code ANSI Z223 1 You should contact your gas supplier for any specific changes which may be required in your area Ratings specified by manufacturers for most boilers apply for elevations up to 2000 feet 600 m For elevations above 2000 feet 600 m ratings must be reduced by a rate of 496 for each 1000 feet 300 m above sea level Example If a boiler is rated at 610 000 Btu hr at sea level to operate the boiler at 5000 feet 1500 m it must be derated by 2096 496 x 5 to a new rating of 488 000 Btu hr A O Smith does build some models specifically for high altitude service Please check the rating plate before making changes The input reduction is primarily achieved by reducing the size of the main burner orifices To do this the main burner orifices require replacement with orifices sized for the particular installation elevation When ordering be sure to state the model number and the altitude of the location where the boiler is being installed Upon field deration of the boiler adjustment to the gas pressure regulator is required See CHECKING AND ADJUSTING THE INPUT in this manual for inlet and manifold pr
47. MODELS HW 300 399 420 520 610 670 GAS FIRED COMMERCIAL 5 FOR HYDRONIC HEATING AND HOT WATER SUPPLY UP FLOW MODELS INSTALLATION OPERATION MAINTENANCE LIMITED WARRANTY INDOOR ONLY Burkay APPROVED SMITH v WARNING If the information in this manual 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 Do not try to light any appliance Do touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer 500 Tennessee Waltz Parkway Ashland City TN 37015 service agency or the gas supplier WWW bo ie cont PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE PRINTED 0210 317693 000 a ANEL lt proper installation use and servicing of this water heater 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 own water heater to warn you and others of a
48. O NOT TRY TO LIGHT THE PILOT BY HAND LINES PRIOR TO IGNITIION ATTEMPT IF PILOT FAILS _ REFER TO DIAGRAMS ABOVE TURN TOP KNOB OF TO IGNITE AND YOU SUSPECT THAT IT IS DUE TO AIR GAS CONTROL CLOCKWISE TO OFF IN THE LINES CLOSE PILOT MANUAL VALVE AND POSITION FIG A i REPEAT LIGHTING PROCEDURE STEPS 1 THRU 12 TURN MANUAL SHUTOFF VALVE COUNTERCLOCK 13 WITH PILOT FLAME ESTABLISHED TURN MANUAL WISE TO OFF FIG TURN PILOT MANUAL VALVE 21 Mena 2 co COUNTERCLOCKWISE OFF FIG E THE REDUNDANT MAIN COMBINATION VALVE WILL WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS ALREADY BE OPEN AND MAIN BURNER WILL IGNITE THEN SMELL FOR GAS INCLUDING 2 ADVISORY IF MAIN BURNER FAILS TO IGNITE MAKE FLOOR IF YOU SMELL GAS FOLLOW SURE PILOT IS BURNING IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS BELOW TIT PTI Mn E T ON THIS LABEL TO TURN OFF GAS TO APPLIANCE LABEL IF YOU DON T SMELL GAS GO TO THE NEXT STEP CALL YOUR SERVICE TECHNICIAN OR GAS TURN TOP KNOB OF GAS CONTROL COUNTER SUPPLIER CLOCKWISE TO ON FIG B TURN PILOT FIRING VALVE CLOCKWISE FIG F PILOT BURNER TURN ON ALL ELECTRIC POWER TO THE APPLIANCE TO TURN OFF GAS TO APPLIANCE TURN OFF ALL ELECTRICAL POWER TO APPLIANCE TURN TOP KNOB OF GAS CONTRO L VALVE CLOCKWISE YTO OFF FIG A TURN MAINFIRING VALVE COUNTERCLOCKWISE f TO OFF FIG
49. OILER IS NOT INTENDED TO OPERATE AT GAS SUPPLY PRESSURE OTHER THAN SHOWN ON THE RATING PLATE EXPOSURE TO HIGHER GAS SUPPLY PRESSURE MAY CAUSE DAMAGE TO GAS VALVES WHICH CAN RESULT IN FIRE OR EXPLOSION IF OVERPRESSURE HAS OCCURRED SUCH AS THROUGH IMPROPER TESTING OF GAS LINES OR EMERGENCY MALFUNCTION OF THE SUPPLY SYSTEM THE GAS VALVES MUST BE CHECKED FOR SAFE OPERATION MAKE SURE THAT THE OUTSIDE VENTS ON THE SUPPLY REGULATORS AND THE SAFETY VENT VALVESARE PROTECTEDAGAINST BLOCKAGE THESEARE PARTS OF THE GAS SUPPLY SYSTEM NOT THE BOILER VENTBLOCKAGE MAY OCCUR DURING ICE BUILD UP OR SNOW STORMS 20 LU IN WHEN LOCAL CODES REQUIRE A MAIN MANUAL SHUTOFF VALVE OUTSIDE THE BOILER JACKET A SUITABLE MAIN MANUAL SHUTOFF VALVE MUST BE INSTALLED IN ALOCATION COMPLYING WITH THOSE CODES IT IS IMPORTANT TO GUARD AGAINST GAS 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 CERTIFIED FOR GAS SERVICE BEFORE ATTACHING THE GAS LINE BE SURE THAT ALL GAS PIPE IS CLEAN ON THE INSIDE DIRT FOREIGN MATERIAL IN THE GAS SUPPLY LINE A DIRT LEG SOMETIMES CALLED DRIP LEG or sediment trap MUST BE INCORPORATED IN THE PIPING see Figure 1 on page 6 The dirt leg must be readily accessible and not subject to freezing conditions INSTALL IN ACCORDANCE WITH RECOMMENDATIONS OF SERVING GAS SUPPLIERS Refer to National Fuel Ga
50. PECTIVE UNIT DIAGRAM lt W BALANCER FOR FACTORY INSTALLED WIRING GND i Ri BLACK TRANSFORMER WIRE EI pes 1 TEMPERATURE CONTROL lt e NO ae SAFETY FLOW SWITCH CHEM JE NEN A ee id 4X4JUMCTION BOX J TERMINAL STRIP CONNECT TO WHITE TRANSFORMER m L UNIT 2 AN SEE RESPECTIVE UNIT DIAGRAM cee 4 e 1 FOR FACTORY INSTALLED WIRING 1 a 4 Y l L R CONNECT TO BLACK TRANSFORMER WIRE f _ FH 7d I l J 1 71 NC MEE L COM i e 1 DELETE UNIT 3 IF ONLY 2 UNITS SAFETY FLOW SWITCH ARE DESIRED WIRE ACCORDINGLY NOTE DISCONNECT THE THERMAL i rod BALANCERS ON UNITS 2 AND 3 4 X 4 JUNCTION BOX j WITH TERMINAL STRIPS CONNECT TO WHITE TRANSFORMER WIRE I ME i 1 _ UNIT 3 E mm acca SEE RESPECTIVE UNIT DIAGRAM DISCONNECTED FOR FACTORY INSTALLED WIRING ce 4 e I L 1 9R CONNECT TO BLACK TRANSFORMER WIRE 2 B NC L ecoM 1 J NO SAFETY FLOW SWITCH FLOW CLOSES CIRCUIT WIRING NOTE BY F
51. RY INSTALLED WIRING R CONNECT TO BLACK TRANSFORMER WIRE Y FIGURE 21 CER TEMP 80 1 UNIT INSTALLATION FOR HOT WATER SUPPLY APPLICATION U S MODELS JUCNTION BOX W 4 TERMINALS 120 VAC 50 60 Hz L4 HOT L NEUTRAL FUSED DISCONNECT SWITCH CIRCULATING PUMP GND 22 2 an 4 X 4 JUNCTION BOX WITH TERMINAL STRIP CONNECT TO WHITE TRANSFORMER WIRE E UNIT 1 T THERMAL SEE RESPECTIVE UNIT DIAGRAM BALANCER FOR FACTORY INSTALLED WIRING pose CONNECT TO BLACK TRANSFOMER WIRE l TANK TEMPERATURE i CONTROL Loc d FLOW SWITCH ee PPS Em 21 FIGURE 22 SCHEMATIC 120 L2 NEU 4 L2 GND l THERMAL BALANCER uis CIRCULATING CANADIAN PUMP I MODELS iH I g y 4 uf TEMPERATURE GND CONTROL LUGIN J BOX I U S 190000 MODELS s RE CONNECT TO WHITE TRAN TRANSFORMER WIRE gt UNIT431 lt K SEE RESPECTIVE UNIT i DIAGRAM FOR FACTORY INSTALLED WIRING tFLOW CLOSES CIRCUIT WIRING BY FACTORY BY INSTALLER NOTE IF ANY OF THE ORIGINAL WIRE AS SUPPLIED MUST BE REPLACED USE ONLY TYPE 105 C WIRE OR EQUIVALENT EXCEPT THE FLAME SENSOR AND IGNITION CABLE MUST BE 250 C AND WIRES CONNECTED TO THE COIL PROTECTOR WHICH ARE 2002 FIGURE 23 28
52. ST 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 2 CONDITIONS AND EXCEPTIONS 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 an appropriately sized safety relief valve certified to the ASME Boiler and Pressure Vessel Code must have been installed and fresh clean water used for filling and make up purposes a This warranty shall apply only when the boiler is 1 used at temperatures not exceeding the maximum setting of its operative and or high limit control 2 used at water pressure not exceeding the working pressure shown on the boiler 3 used when filled with potable water free to circulate at all times and with the heat exchanger s and coil s free of damaging scale deposits 4 in a non corrosive and non contaminated atmosphere 5 owned by the original purchaser 6 it s original installation location 7 is sized in accordance with proper sizing techniques for commercial boilers 8 bearing a rating plate which has not been altered defaced or removed except as required by the warrantor 9 fired at the factory rated input using the fuel stated on the rating plate 10 maintained in accordance with the instructions print
53. TER CONFINED AREAS OR SPACES WHERE IGNITION CAN OCCUR THE AREA MUST BE WELL VENTILATED AND ALL SOURCES OF IGNITION MUST BE INACTIVATED OR REMOVED 1 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 gas consult your supplier 2A SIZING GAS SUPPLY LINE For single boiler installations and for installations of multiples of two or three of same size boilers 21 Use table 7 or CAN CSA B149 1 current edition to size iron pipe or equivalent gas supply line Table 7 is based on a pressure drop of 0 3 inches of water and a specific gravity of 0 60 approximately that of natural gas 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 7 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 Distance from Gas Nominal Iron Pipe Size Inches Meter 114 112 2 2421 L 4 2 700 70 21 46 96 180 370 seo 1 050 1 700 3 RU 2D 1 050 980 heating value of Natural Gas is approximately 1 050 Btu Ft Propane LP Gas has a heating value of approximately 2 500 Btu Ft 1 cu meter 35 31 cu feet e
54. ULT IN DAMAGE TO THE ADJACENT AREA OR TO LOWER FLOORS OF THE STRUCTURE WHEN SUCH LOCATIONS CANNOT BE AVOIDED A METAL DRAIN PAN SHOULD BE INSTALLED UNDER THE BOILER Such pans should be fabricated with sides at least 60mm 2 1 2 deep with length and width at least 50mm 2 greater than the diameter of the boiler and must be piped to an adequate drain The pan must not restrict combustion air flow WARNING KEEPING BOILERAREACLEARAND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS THERE IS A RISK IN USING FUEL BURNING APPLIANCES SUCH AS BOILERS IN ROOMS OR AREAS WHERE GASOLINE OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED OPERATED OR REPAIRED FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOORAND MAY BE IGNITED BY THEIGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION 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 WARNING FLAMMABLE ITEMS PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE BOILER OPEN CONTAINERS OF FLAMMABLE MATERIAL MUST NOT BE STORED OR USED IN THE SAME ROOM WITH THE BOILER 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
55. URNER WILL THEN IGNITE NOTE IF PILOT FAILS TO IGNITE TURN OFF APPLIANCE AND CONSULT YOUR INSTALLATION AND USER S MANUAL FOR ADJUSTMENTS AND TROUBLE SHOOTING IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE AND CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER TO TURN OFF GAS TO APPLIANCE A SETTHESYSTEMCONTROLLER TO THE LOWESTSETTING B TURNOFFELECTRICA L POWER TO APPLIANCE C TURN TOP OF GAS VALVE CLOCKWISE Y D OFF POSITION SEE FIGA CLOSE FIRINGAND PILOT MANUAL VALVES CLOCKWISE SEEABOVE 211686 000 REV XX LIGHTING AND OPERATING INSTRUCTIONS NATURAL AND PROPANE GAS WITH 1 0 FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly fire or explosion may result causing property damage personal Injury or 1055 of life FLAMMABLE A THIS APPLIANCE IS EQUIPPED WITH AN IGNITION C USE ONLY YOUR HAND TO TURN THE GAS CONTROL DEVICE WHICH AUTOMATICALLY LIGHTS THE PILOT KNOB NEVER USE TOOLS IF THE KNOB WILL NOT DO NOT TRY TO LIGHT THE PILOT BY HAND TURN BY HAND DON T TRY TO REPAIR IT CALL A B BEFORE LIGHTING SMELL ALL AROUND THE QUALIFIED SERVICE TECHNICIAN FORCE OR APPLIANCE AREA FOR GAS BE SURE TO SMELL ATTEMPTED REPAIR MAY RESULT IN AFIRE OR NEXT TO THE FLOOR BECAUSE SOME GAS IS HEAVIER EXPLOSION THAN AIR AND WILL SETTLE ON THE FLOOR WHAT TO DO IF YOU SMELL GAS DO NOT USE THIS APPLIANCE IF
56. VES ARE SHOWN FOR SERVICING BOILER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE E PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM INSTALL THERMOMETER AND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 amp HW 670 USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE Model Pipe Size Armstrong Number Inches Pump Size HW 520 2 4 2 4 4 2 S 45 2 1 2 HW 610 670 1 1 2 3 HD 3 S 46 Assumes 50 equivalent feet of piping or less FIGURE 32 37 THREE HW 520 s HW 610 s OR HW 670 s UP FLOW MODEL COMMERCIAL BOILER WITH HORIZONTAL TANK CER TEMP 80 DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATUREAT FIXTURES SEE TANK TEMPERATURE CONTROL WARNING IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES IMPORTANT THE INSTALLATION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE PIPING AND FITTINGS BETWEEN GATE VALVES AND BOILERS SHOULD BE BRASS OR BRONZE OTHER PIPING SHOULD CONFORM TO LOCAL CODES GATE VALVES ARE SHOWN FOR SERVICING BOILER HOWEVER LOCAL CODES SHALL GOVERN THEIR USAGE PRESSURE RELIEF VALVE RATING SHOULD EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM INSTALL THERMOMETER AND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW
57. Y SYSTE PRESSURE RELIEF VALVE INSTALL IN ACCORDANCE WITH ALL LOCAL CODES THERMOMETER SAFETY FLOW SWITCH 7 WIRING FIGURES 21 to 27 on pages 28 to 32 GATE VALVE PLUG OR BALL VALVE PRESSURE RELIEF VALVE INSTALL INACCORDANCE WITH ALL LOCAL CODES THERMOMETER SAFETY FLOW SWITCH PIPETO 1 OPEN DRAIN PRESSURE RELIEF VALVE THERMOMETER OPEN DRAIN PLUG OR OPEN DRAIN SAFETY FLOW HOT WATER SWITCH TO FIXTURES AND MIXING VALVE TANK TEMPERATURE CONTROL ALL BRONZE CIRCULATING PUMP mur y P C ul STORAGE Y san 2 COLD WATER lt L SUPPLY LOCATE TEE AS CLOSE TO TANK 7 AS POSSIBLE PLUG OR BALL VALVE 4 GATE VALVE GATEVALVE HEATERS SPACED 30 z DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 11 IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT ADD AN ANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES IMPORTANT THE INSTALLATION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE PIPING AND FITTINGS BETWEEN GATE VALVES AND BOILERS SHOULD BE BRASS OR BRONZE OTHER PIPING SHOULD CONFORM TO LOCAL CODES GATE VAL
58. YELLOW RED FIGURE 4 MANUAL RESET HIGH LIMIT This boiler is equipped with a manual reset high limit switch located under the small cover on the side of the jacket see Figure 5 This device provides positive shutdown of the boiler in the event of boiler or system malfunction Should the surface temperature of the copper tubing heat exchanger reach 250 F 120 C the high limit switch will activate the gas 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 circulator operating e Pump failure After correcting failure condition remove the protector switch cover and push the reset button The high limit switch may be reset after the coil surface cools to 6 F 3 3 C below the trip setting RESET BUTTON HIGH LIMIT SWITCH COVER PROTECTOR SWITCH HIGH LIMIT SWITCH FIGURE 5 SAFETY FLOW SWITCH The safety 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 of inadequate water flow through the unit An accessory package containing a safety 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
59. ads attached depress the switch button If the meter does not read zero the switch is defective and must be replaced RELIEF VALVE The safety relief valve should be opened at least twice a year to check its working condition This will aid in assuring proper pressure relief protection Lift the lever at the top of the valve several times until the valve seats properly and operate freely DANGER THE WATER PASSING OUT OF THE VALVE DURING CHECKING OPERATION MAY BE EXTREMELY HOT BEFORE OPERATING RELIEF VALVE MAKE SURE DRAIN LINE IS INSTALLED TO DIRECT DISCHARGE TOA SAFE LOCATION SUCHASAN OPEN DRAIN TO AVOID SCALDING OR WATER DAMAGE WARNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE INTERNAL CONTAMINANTS The hydronic system must be internally cleaned flushed after a new or replacement boiler has been installed to remove contaminants that may have accumulated during installation This is doubly important when a replacement boiler is installed into an existing system where Stop Leak or other boiler additives have been used Failure to clean and flush the system can produce acid concentrations that become corrosive cause gases to form that block water circulation or lead to formation of deposits on the boiler surfaces any of which could result in damage to the system and circulator All hot water heating systems should be completely flushed wit
60. age 24 vac is supplied by transformer Appliance is wired according to wiring diagram Note Cross wiring the 24 volt circuit of the relay will short the transformer A All wire terminals connectors are firmly attached to valves modules switches limit controls etc For LP models only check for possible lockout condition of the the ignition module 618 6010 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 comet _ Tank temperature control Replace Pump and burner remain thermostat defective on System wiring is Circulating pump and Set tank temperature burner shut off incorrect control thermostat 20 F Pump wired for 10 below tank water With thermal balancer temperature pump off delay of Gas valve stuck or Correct or replace approximately 2 minutes defective valve urner on incorrect High limit control set too low Correct wiring Replace If problem proven to be at this control by applying jumper to terminals High limit control differential too wide dieu wiring is Coil protector switch has Remove control cover activated depress reset button Gas valve or wiring Check wiring Repair or defective replace valve Power off or system Check power sup
61. al area be less than 10 square inches 6500 mm In additional to the above there shall be permanent air supply opening s having a cross sectional area of not less than 1 square inch per 7 000 BTUH 310 mm KW up to and including 1 000 000 BTUH plus 1 square inch per 14 000 BTU in excess of 1 000 000 BTUH This opening s shall be located at or ducted to a point neither more than 18 450 mm nor less than 6 inches 150 mm above the floor level Where power vented equipment is used in the same room as the boiler sufficient air openings must be supplied UNDERSIZED OPENINGS MAY RESULT IN INSUFFICIENT AIR FOR COMBUSTION WHERE AN EXHAUST FAN IS INSTALLED IN THE SAME ROOM WITH A BOILER SUFFICIENT OPENINGS FOR AIR MUST BE PROVIDED IN THE WALLS UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE CHIMNEY CAUSING POOR COMBUSTION SOOTING MAY RESULT WITH AN INCREASED RISK O F ASPHYXIATION CHEMICAL VAPOR CORROSION WARNING CORROSION OF THE FLUEWAYS AND VENT SYSTEM MAY OCCUR IF AIR FOR COMBUSTION CONTAINS CERTAIN CHEMICAL VAPORS WHICH BREAK DOWN INTO ACIDS AT HIGH TEMPERATURE SUCH CORROSION MAY RESULT IN FAILURE AND RISK OF ASPHYXIATION Water 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 waxes
62. alls stairways or other uncontrolled areas There are occasions when outdoor temperatures are temporarily too warm for even a moderate amount of heating in these areas Space temperature controlling can be varied to meet the building requirements Either the single thermostat as shown or multiple zone thermostats should control a common relay This relay controls electric power to the system primary circulator and to the main water temperature controller This provides for water movement in the system before the main temperature controller can start the secondary circulating pump or fire the boiler Figure 17 shows a typical wiring diagram for a single boiler space heating installation The boiler may be controlled by a main temperature controller as shown or may include outdoor reset if desired Figure 18 on page 26 shows a layout for various choices of controls often found in commercial heating These layouts are not intended to be wiring diagrams and only show the relation of one device to another in the system Figure 18 is a typical layout of controls for two boilers with one circulator and including optional outdoor reset and thermal balancer If a secondary circulator is used with each boiler arrangement for boiler no 2 will be as shown for boiler no 1 Commercial size installations are always best when designed to individual building requirements The layout in figure 18 is typical of many combination possibilities to meet
63. apors A WARNING e Overheated water can cause watertank explosion Properly sized temperature and pressure relief valve must be installed A WARNING Breathing Hazard Carbon Monoxide Gas Special consideration must be taken with installations above 2 000 feet Please contact an A O Smith qualified service agent to obtain the proper setup and instructions before lighting Failure to implement the proper setup will result in improper and inefficient operation of the appliance resulting in production of increased levels of carbon monoxide gas in excess of the safe limits which could result in serious personal injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual CAUTION Improper installation and use may result in property damage Donotoperate boiler ifflood damaged nstallinlocation with drainage Fill boiler with water before operation Bealertforthermal expansion Refer to instruction manual for installation and service SAFE TNSTALPATION USEATDSERUVIGE MEME IM E IN EE ME 2 GENERAL AFET een HH 3 TABERE C ONTE NE u u usual E u een eee 4 DIMENSIONS AND CAPACITY DATA
64. ation 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 509F 30 temperature rise across the boiler are as follows MODELS HW 300 HW 399 12 45 If system flow rate is unknown or if zoning creates extreme variations in flow rates the boiler should be installed as shown in Figure 11 on this page for A O Smith LINEAR TEMP installations 2 LINEAR TEMP INSTALLATIONS A New Installations A O Smith LINEAR TEMP systems have been designed to provide efficient trouble free operation of the boiler sizes covered in this manual with any of the following conditions a Unknown system flow rate b Varying flow rate as with zoned systems c Multiple boiler installations Figure 11 on this page shows piping and accessory arrangement for a boiler pumped independent of the primary system mains Pipe sizing and boiler loop pump selection data are shown in Table 6 for several different temperature rises across the boilers 18 ANELON MAKE UP WATER RSEN PRESSURE REDUCING VALVE BY PASS FOR FAST FILL A gt iw SYSTEM SUPPLY UA T a ESS BUILDING ogy CIRCULATOR n SECONDARY PIPE LOOP BOILER BRANCHES ONE BOILER INSTALLED INDEPENDENT OF THE PRIMARY SYSTEM FIGURE 11 Total heating requirements for the building can
65. be supplied by a series of boiler loops all connecting to a common pipe joining the system supply and return mains The supply and return branches of each boiler loop must join the common pipe only a short nipple length apart The different sets of branches should be installed reasonably close together but not necessarily to the short nipple length as required for the supply and return of each set These branches may be made with tees or with welded connections The installer is reminded that the total boiler flow rates need not match the system flow rate TABLE 6 PUMP AND PIPE SIZING DATA PIPING FROM TEES IN MAIN TO BOILER BRANCHES Temp Rise F C 1 1 2 PR 150 125 100 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 HW 610 670 NOTE Pipe loop sizes and pump selections based on 50 equivalent feet of pipe and fittings pump sizes listed B 8 model numbers SUGGESTED ITEMS FOR INSTALLATION Short pipe nipple and pair of boiler loop tees in piping between system supply and return One set per each group data data i ipe loop ipin Boiler circulator See pump sizing Thermometer Theraltimeter Plug cock to control flow rate Safety flow switches For interlock with other systems or instead of low water cutoff Relief valve With one 300 399 or 420 item 9 is sensing element of remote control With a group of 300
66. can be found by dividing its heat input rate by the gas s heating value Obtain or determine the length of piping from the gas meter or service regulator to the appliance s e n table 7 on page 21 select the row showing the distance to the most remote outlet or the next longer distance if the table does not give the exact length This is the only distance used in determining the size of any section of gas piping If the gravity factor is to be applied the values in the selected row of table 7 are multiplied by the appropriate multiplier from table 8 Total the gas demands of all appliances on the piping system Enter table 7 on the left hand side at the row equal to or just exceeding the distance to the most remote outlet Select the pipe size in the row with a capacity equal to or just exceeding the total gas demand This is the required main gas supply line size leading away from the gas meter or regulator To determine the pipe size required for each branch outlet leading away from the main supply line determine the gas demand for that outlet Enter table 7 on the same row and select the branch pipe size for a capacity equal to or just exceeding the demand at that outlet The main line can be resized for a lesser capacity after each branch outlet since the gas demand is reduced Total the gas demands of all remaining appliances branching off downstream on the main gas line Re enter table 8 in the same row and select the appropriat
67. d to pilot assembly and GND terminal on module YES 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 Carefully bend downward metal parts pilot screen pilot shield etc 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 Ignition Is the ceramic insulator surrounding the electrode Module cracked or broken YES Replace pilot burner assembly 48 HONEYWELL 58600 OR 5 8610 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 YES NO Attach wires firmly Are the wires securely attached to the pilot operator on the gas control and to the PV amp MV PV terminals on the ignition module YES Install a pressure gauge in the pilot tubing line between the NO gas control and the pilot burner assembly Ensure that the pilot Replace gas valve adjustment screw under cap
68. 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 section of this manual for deliming instructions Record temperature rise at initial start up for future reference DRAIN VALVE Not Supplied A drain valve must be obtained and installed on each boiler and tank for draining purposes see installation diagrams in this manual REQUIRED ABILITY Installation or service of this boiler requires ability equivalent to that of a licensed tradesman 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 Location selected should be as close to the stack or chimney as practicable with adequate air supply and 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 appliance operation and service circulator replacement control replacement etc THE BOILER MUST NOT BE INSTALLED ON CARPETING THE BOILER SHOULD NOT BE LOCATED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING LOCATE IT NEAR A FLOOR DRAIN THE BOILER SHOULD BE LOCATED IN AN AREAWHERE LEAKAGE FROM THE BOILER OR CONNECTIONS WILL NOT RES
69. e and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition WARNING Ensure sufficient supply and ventilation air Under no circumstances should the equipment room where the boiler is installed ever be under negative pressure Insufficient air supply can interfere with combustion and ventilation of this boiler resulting in unsafe conditions 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 ithas 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
70. e dealer who sold the boiler or with any other dealer handling the warrantor s products If this is not practicable the owner should contact U S Customers Canadian Customers A O Smith Corporation A O Smith Enterprises Ltd 500 Tennessee Waltz Parkway P O Box 310 768 Erie Street Ashland City TN 37015 Stratford Ontario N5A 6T3 Telephone 1 800 323 2636 Telephone 1 800 265 8520 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 6 DISCLAIMERS NO OTHER EXPRESS WARRANTY HAS BEEN OR WILL BE MADE IN BEHALF OF THE WARRANTOR WITH RESPECT TO THE MERCHANT ABILITY OF THE BOILER OR THE INSTALLATION OPERATION REPAIR OR REPLACEMENT OF THE BOILER THE WARRANTOR SHALL NOT BE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OF THE UNIT INCONVENIENCE LOSS OR DAMAGE TO PERSONAL PROPERT Y 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 TORT a Some states or 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 Fi
71. e pipe size with adequate capacity Repeat the branch sizing and main line re sizing for any remaining appliances in the system 15 15 DISTANCE 10 TO REMOTE 10 OUTLET 50 APPLIANCE APPLIANCE OUTLET OUTLET FARTHEST FROM METER GAS FROM BRANCH 10 10 SUPPLIER 15 15 10 MAIN LINE GAS METER APPLIANCE OUTLET EXAMPLE Job Condition Determining the required gas pipe size for a system composed of two HW 420 boilers and two HW 610 boilers to be installed as a multiple group 50 lineal feet from meter Gas to be used has a 60 specific gravity and heating value of 1 000 Btu per cubic foot Solution 2 HW 420 Boilers 2 HW 610 Boilers 840 000 Btuh 1 220 000 Btuh Total Btuh Input 2 060 000 Btuh Total Btuh Input 2 060 000 Btuh 2 060 cf h Btu per Cubic Foot of Gas 1 000 With a cubic foot per hour demand of 2 060 and with 50 lineal feet of gas supply line table 7 shows a pipe size of 3 76mm is required NOTE Forother than 60 specific gravity apply multiplier factor as shown in table 8 TABLE 8 MULTIPLIERS TO BE USED WITH TABLE 7 WHEN APPLYING THE GRAVITY FACTOR TO OTHER THAN 60 SPECIFIC GRAVITY Specific Specific uw Mule Gravity 65 096 160 75 0 180 80 87 10 90 82 2100 Use these correction factors if exact specific gravity of the gas is not known 60 Nat 1 50 Prop 9 8 8 8 GAS PRESSURE REGULATORS
72. ed by a manually operated valve An overhead surge tank is required 4 EXPANSION TANK CAUTION A closed system will exist if a check valve without bypass pressure reducing valve without bypass or a water meter without bypass is installed in the cold water line between the water heater and street main or well Excessive pressure may develop causing premature tank failure or intermittent relief valve operation This is not a warranty failure An expansion tank or a similar device may be required in the inlet supply line between the appliance and the meter or valve to compensate for the thermal expansion of water under supply pressure see Figure 7 on page 14 An air separator as shown in the piping diagrams is recommended especially for modern commercial hydronic systems 5 VENT VALVES It is recommended that automatic loose key or screwdriver type vent valves be installed at each convector or radiator 6 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 64mm diameter are suggested on HW 399 HW 420 HW 520 HW 610 and HW 670 units HW 300 units should have 1 1 2 38mm diameter manifolds The circuits should be spaced on the header at a minimum of 3 76mm center t
73. ed in the manual included with the boiler 11 in the United States its territories or possessions and Canada 12 with an intermittent circulating action and with the pump and burner operating together 13 indoor installation only b Any accident to the boiler any misuse abuse including freezing or alteration of it any operation of it in a modified form or any attempt to repair leaks in the coil or heat exchanger will void this warranty 3 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 defective part to such distributor C All cost necessary or incidental for any materials and or permits required for installation of the replacement 4 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 boiler 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 5 CLAIM PROCEDURE Any claim under this warranty should be initiated with th
74. ed the approximate time to burn relationship for normal adult skin Valves for reducing point of use temperature by mixing cold and hot water are available Also available are inexpensive devices that attach to faucets to limit hot water temperatures Contact a licensed plumber or the local plumbing authority Time to Produce 2nd amp 3rd Degree Burns on Adult Skin Water Temperature Nearly Instantaneous About 1 2 second About 1 1 2 seconds Less than 5 seconds About 30 seconds More than 5 minutes 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 SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF TURN OFF THE MANUAL GAS CONTROL VALVE TO THE APPLIANCE 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 rise
75. efer to parts list supplied with this manual for disassembly aid Reinstall the parts removed in steps 2 and 3 Be sure the vent pipe has a minimum upward pitch of one quarter inch per foot of length 21mm m and is sealed as necessary 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 VENTING SIDEWALL OPTIONAL POWER VENT SYSTEM 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 A 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 After allowing appliance to operate for five minutes test for spillage at the draft hood relief opening 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
76. essure requirements Also due to the input rating reduction required at high altitudes the output rating of the appliance is also reduced and should be compensated for in the sizing of the equipment for applications ON TRE 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 10 F above the maximum designed system temperature If the boiler outlet water temperature should exceed the high limit setting the main gas valve will close but the circulator will continue to operate Maximum adjustable setting is 115 C 239 F cut out with a 3 C 5 F to 25 C 45 F adjustable differential see Figure 2 DIFFERENTIAL ADJUSTING 02 6 Tg amp FIGURE 2 UT IN CUT OUT INDICATOR INDICATOR 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 heater 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 NL 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
77. 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 6 On a power loss shuts the heater down When power is restored it will begin a new ignition cycle 7 On a loss of flame shuts off main gas and starts trial for pilot ignition PLEASE SEE TROUBLESHOOTING SECTION FOR MORE INFORMATION Teh es 11 4 S 8600 INTERMITTENT IGNITION CONTROL MODULE IID FIGURE 3 THERMAL BALANCER Figure 4 shows the internal wiring of the thermal balancer device may be tested after disconnecting the four leads from their respective terminals on the unit 1 Apply a test light to the yellow and red leads The lamp should light as the contact in this circuit is normally closed when the resistor is cool 2 Apply a light to the black and yellow leads Thelamp should not light as the contact in this circuit is normally open when the resistor is cool 3 Remove the test light 4 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 CONTACTS C WHITE BLACK
78. flow is downward For proper performance mount the switch in a section of pipe where there is a straight run of atleast 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 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 6 on page 10 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 CAUTION 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 TABLE 3 SAFETY FLOW SWITCH Model Number HW 300 Minimum Pipe Rate Contacts Closed Flow Contacts Open No Flow 28 4 5 0 51 9 9 5 The safety flow switch may be field adjusted to obtain higher minimum flow rate
79. from PUMP AND PIPE SIZING DATA should not exceed the high limit control setting of 115 C 240 F There should be a relation of the minimum system load to the size boiler selected as the first firing or base boiler This will stabilize operation during minimum load periods B Commercial Boiler Replacements Application of LINEAR TEMP to a commercial boiler replacement with an old multiple pump installation is an excellent way to modernize the system The A O Smith boiler s should be installed on a pipe loop with a separate circulating pump selected from PUMP AND PIPE SIZING DATA TABLE Figure 12 shows a line drawing of how the system headers should be connected to the pipe loop installed with the replacement boiler s Make up water connections and accessories are not shown 19 FLOW CONTROL VALVES SUPPLY HEADER r r r AQUA STAT ZONE w CLOSE SPACED CIRCULATORS CONNECTIONS iiM j BOILER CIRCULATOR FROM BOILER S gt TO BOILER S SCHEMATIC OF THE LINEAR TEMP SYSTEM FIGURE 12 Supply and return headers of the old system should be connected to the boiler loop with a pair of tees set close together The boiler loop pump and the boiler s should be wired to operate only when any of the system pumps are in operation The number of zone pumps that may be in operation at any particular time will take their required flow rate out from the first tee in the boiler piping Th
80. ft cannot be obtained a blower type flue gas exhauster may be employed to ensure proper venting and correct combustion if permitted by local codes WARNING FAILURE TO CORRECT BACK DRAFTS WILL CAUSE AIR CONTAMINATION AND UNSAFE CONDITIONS 15 Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure 3 CONNECTING BOILER TO A COMMON VENT Do not connect the boiler to a 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 a common 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 siz
81. h a grease removing solution to assure trouble tree operation all lt e 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 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 Before any extensive troubleshooting perform the following Ensure that Voltage 120 vac is supplied to the appliance System control tank temperature control thermostat etc is calling for appliance operation call for heat A 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 appliance rating plate label 46 21010 k Volt
82. is water will be circulated through the proper branches from the supply header to the zones calling for heat The water will be brought back to the return header and then into the second tee in the boiler pipe loop There will be no conflict between the boiler pump and the zone pumps when the two tees in the boiler loop are placed close together Normal use of flow control valves is required to prevent cross circulation of zones as with any multiple pump system Flow control is not required on boiler circuit Attention should be given to balancing gas inputs and water flow rates Large systems with multiple boilers should include main water temperature control with or without outdoor reset to stage the boilers on and off in relation to the load on the system 3 WATER SUPPLY LINE 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 Figure 7 to 11 on pages 14 and 18 Fast filling of large pipe old radiator installations and pressure purging of series loop systems where high pressures 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 controll
83. led on each and every water storage tank in a hot water supply system The storage tank temperature and pressure T amp P relief valve must comply with the applicable contruction provisions of the Standard for Relief valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems Z21 22 CSA 4 4 The 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 Figures 28 to 33 Pages 34 to 38 Tapping shall be threaded in accordance with the latest version of the Standard for Pipe Threads General Purpose inch ANSI ASME B 120 1 Mark location with a class Label See ANSI Z21 10 1 Part 1 Marking See CAN CSA B149 A WARNING Temperature pressure relief valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized pressure relief valve must be installed in opening provided on the boiler Failure to install proper relief valve can result in overheating and excessive pressure which can cause seriou
84. ll in the following for your own reference Keep it Registration is not a condition of warranty The model and serial number are found on the boiler s rating plate Owner Installation Address City and State Province Postal Zip Code Date Installed Model No Serial No Dealer s Name Phone No Dealer s Address FILL IN DATA AND KEEP FOR FUTURE REFERENCE 55 x Smith 500 Tennessee Waltz Parkway Ashland City TN 37015 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com
85. load on the transformer Check gas supply line pilot burner spark and flame sense wiring flame rod contaminated or out of position burner ground connection Check gas supply pilot burner flame sense wiring contamination of flame rod burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Control auto resets from soft lockout Reset by cycling Call for Heat If after one hour error repeats replace the control X Y flash codes signify that the LED flashes X times at 2Hz remains off for two seconds flashes Y times at 2Hz remains off for three seconds and then repeats the sequence 53 Table 13 Lockout Models H D and J Only Green LED Status Codes Green LED Flash Code X Y OFF Flash Fast Heartbeat Recycle Flame failed during run Flame sensed out of sequence Flame sense leakage to ground Low secondary voltage supply below 15 5 Vac Failed trial for ignition resulting in One lockout More than 5 flame failures during run 6 3 on the same Call for Heat resulting in lockout 6 4 sensed out of sequence longer than 10 seconds No Startup Flame sense calibration not applicable Next System Action Initiate new trial for ignition Flash code will remain through the ignition trial until flame is proved If situation self corrects within
86. m 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 34 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 1 Turn off the electrical power and close the main manual gas shutoff valve See L amp O instructions on pages 43 and 44 Allow boiler parts to cool before disassembly 2 Remove main burner manifold assembly from boiler Refer to parts list supplied with this manual for disassembly aid 3 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 4 Reinstall the burner manifold assembly on boiler Check for good terminal connection at the sensing probe at the pilot burner assembly if pilot does not light 5 Restore electrical power and gas supply to boiler Check for electrical power to the valve If electrical power and gas Putthe boiler back in operation by following the
87. ng contamination of flame rod burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control O 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 eFlash Code Descriptions Flash Fast rapid blinking Heartbeat Constant 1 2 second bright 1 2 second dim cycles A single flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence X Y flash codes signify that the LED flashes X times at 2Hz remains off for two seconds flashes Y times at 2Hz remains off for three seconds and then repeats the sequence 54 Pa quA mY AN AV V 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 coil or gas burner shall prove upon examination by the warrantor to be defective in material or workmanship the warrantor at his option will exchange or repair such part or portion This term is reduced to FIVE years if this boiler is used for water heating purposes other than hydronic space heating a This warranty is extended to the owner for all other parts or portion during the FIR
88. ng appliances are not ON during this interval 3600 x H Btuh T Btuh T H The approximate actual input rate Time in seconds to burn one cubic foot of gas Heating value of the fuel gas in Btu per cubic foot of gas EXAMPLE 9 0 seconds ft Btu ft natural gas tuh as QUI on through meter 600 x 1050 420 000 Btuh 0 cO Small changes in the input rate may be made by adjusting the manifold pressure see GAS PRESSURE REGULATORS Under no circumstances should you exceed the maximum input rate for the boiler given in table 2 on page 6 5 Repeat steps 1 thru 6 of the OPERATING INSTRUCTIONS 6 Remove the pressure gauge or manometer from the manifold pressure tapping Replace the screw in plug in the manifold pressure tap 41 Repeat steps 7 thru 11 of the OPERATING INSTRUCTIONS 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 10 TABLE 10 CONSUMPTION RATE Refer to Operating at Full Input or Full Capacity Type Gas Time to Consume 1 cu ft of gas seconds Hw Hw hw HW HW 399 420 520 610 670 EEE ESE IMPORTANT Heating Value Btu Ft 300 UNDER CIRCUMSTANCES SHOULD THE GAS INPUT EXCEED THE INPUT SHOWN ON THE BOILER MODEL AND RATING PLATE OVERFIRING COULD RESULT IN
89. o 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 circulators 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 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 7 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 13 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 x meu CHILLER COOLING CIRCULATOR ee SCHEMATIC SHOWING PROPER PIPING ISOLATION OF THE BOILER FROM THE CHILLER FIGURE 13 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 thro
90. on shall be in accordance with the 14 current edition of the National Fuel Gas Code ANSI Z223 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 Code ANSI Z223 1 and or CAN CSA B149 1 Installation Codes Stack or chimney must be a minimum height of 12 305mm above the annual snow fall to prevent blockage Building materials must not come in contact with combustion products from stack or chimney due to the degradating properties of flue products Flue products must have a minimum clearance of 4 feet 1 22m horizontally from and in no case above or below unless a 4 foot 1 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment CAN CSA B149 1 Installation Code specifies a 6 foot horizontal vent terminal clearance to gas and electric meters and relief devices this clearance is specified as 4 feet in the U S under the National Fuel Gas Code ANSI Z223 1 Therefore instruction which specifies compliance with the 4 foot clearance as applies in the U S only and the CAN CSA B149 1 Installation
91. opane gas detector is recommended IF YOU EXPERIENCE AN OUT OF GAS SITUATION DO NOT TRY TO RELIGHT APPLIANCES YOURSELF Call your local service agent Only trained LP professionals should conduct the required safety checks in accordance with industry standards HIGH ALTITUDE INSTALLATIONS WARNING Special consideration must taken with installations above 2 000 feet 609m 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 HIGH ALTITUDE INSTALLATIONS IN CANADA Acceptance of these models for use at altitudes above 2000 feet 600 m is based on field test of the individual installation by the provincial state authority having jurisdiction IN THE U S A WARNING INSTALLATIONS ABOVE 2000 FEET REQUIRE REPLACEMENT OF THE BURNER ORIFICES IN ACCORDANCE WITH THE CURRENT EDITION OF THE NATIONAL FUEL GAS CODE ANSI 2223 1 FAILURE TO REPLACE THE ORIFICES WI
92. orrect the situation by consulting the installation or user s manual on how to adjust pilot flame Does the pilot flame cover 3 8 to 1 2 of ingniter sensor rod Replace ignition module Does spark stay on for more than 15 seconds after the pilot is proven lit Is voltage 24 Vac across terminals MV amp MV PV Attach 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 valve Ensure the ground wire and ignition cable are separate from each other prevents shorting 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 50 HONEYWELL 58600 OR 5 8610 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 appliance Is module securely attached to appliance for good ground connection Is voltage 24VAC across transformer positive terminal and GND with call for heat Check the circuit pr
93. oviding 24 VAC s ri Is voltage 24VAC across ignition module terminals 24 Volt and Repl le e GND for heater NOTE For models only Pilot Valve will de energized if module goes into lockout condition Reset system by turning Turn on gas supply and or electrical power off or by turning system controller down below power supply call for heat Wait one minute then turn system on Turn off power supply NO Securely connect cable 5 and or ground wire 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 NO Are high voltage cable and ground wire in good condition not and or ground wire brittle burnt or cracked YES Make sure pilot flame spreader hood is the closest metal to the electrode to prevent the spark from shorting out to other metal Carefully bend down parts pilot screen pilot shield etc wards top of ground High voltage cable must not touch metal surfaces or current strap to achieve carrying wires 1 8 spark gap Is there a 7 64 spark gap between the tip edge of the hood and electrode and is the gap located in the pilot gas stream YES Penas GB cer module NO Is the ceramic insulator surrounding the electrode in good i condition not cracked broken Replace pilot burner assembly m o 51 foll
94. owing procedures provided as general guide Any module should be replaced if it does not perform properly on checkout or troubleshooting In addition replace any module if it is wet or looks like it has ever been wet LED STATUS AND TROUBLESHOOTING The control has two LEDs one for flame sensing and one for system status V TOA Flame LED Status LED FIGURE 37 Location of LEDs Flame LED Yellow Indicates flame presence and strength See Table 11 e Status LED Green Indicates system operation status and error conditions See Table 12 and Table 13 on pages 53 and 54 for status specific to each model 52 Yellow LED Flash Codea Table 11 Yellow LED Flame Codes Recommended Service Action Heartbeat Normal Flame Signal not applicable 2 1 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 Weak Flame Signal Sytem 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 may flash temporarily during or shortly after lightoff on some applications No
95. ply Circulating pump and wiring is incorrect and wiring burner off Tank temperature control Replace thermostat defective incorrect High limit control Circulating pump and defective or set too high burner on max should be set at 200 Set tank temperature control thermostat 20 F Circulating pump and 10 C above tank water burner on temperature Boiler outlet temperature exceeds 210 F 100 C Replace Circulating pump on Set tank temperature control thermostat System maintains desired for desired water water temperature temperature 47 HONEYWELL 5 8600 S 8610M 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 S8610M 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 AES Turn on power supply Turn off power supply Is ignition cable firmly plugged into pilot Securely connect cable assembly and module and or ground wire Is ground wire firmly attache
96. red system pressure Close bypass valve and permit pressure to be established by the pressure reducing valve 2 Ventall high points in system to purge system of air If pressure bleeding of system is desired install valves as shown in Figure 7 on page 14 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 serviceman Flooding to level of burner or controls or higher Exposure to fire If damaged Firing without water Sooting QI po S 39 lt e A CAUTION SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF DO NOT TURN OFF OR DISCONNECT THE ELECTRICAL SUPPLY TO THE PUMP INSTEAD SHUTOFF THE GAS SUPPLY AT A LOCATION EXTERNAL TO THE APPLIANCE 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 34 should display the following characteristics Provide complete combustion of gas e Cause rapid ignition and carryover of flame across entire burner Givereasonably quiet operation during ignition burning and extinction e Cause no excessive lifting of flame fro
97. ree from lint and debris Sweeping the floor around the boiler should be done caretully This will reduce the dust and dirt which may enter the burner and pilot air passages causing improper combustion and sooting THE FLOW OF COMBUSTION AND VENTILATION AIR TO THE BOILER MUST NOT BE OBSTRUCTED THE BOILER AREA MUST BE KEPT CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS Any safety devices including low water cutoffs used in conjunction with this boiler should receive periodic every six months inspection to assure proper operation A low water cutoff device of the float type should be flushed every six months All 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 More frequent inspections may be necessary depending on water conditions 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 serviceman for proper operation 45 e V Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously
98. ring approx 14 356 14 356 14 356 11 279 11 279 11 279 M Size of Water Outlet 1 114 112 112 02 j 2 272 Pipe Size of 1 34 1 dd e4t d P Control String Plus 1 2 Jacket Diameter 26 5 8 676 24 1 2 622 24 1 2 622 S Depth 29 5 8 753 31 1 2 800 31 1 2 800 36 1 2 927 36 1 2 927 36 1 2 927 Horizontal Length between Water Inlet and Outlet 5 3 8 137 5 1 2 140 5 1 2 140 5 3 4 146 5 3 4 146 5 3 4 146 Control String from Jacket 5 127 5 127 5 127 7 178 7 178 7 178 Approximate shipping ight Ibs Kilograms 240 109 291 132 291 132 361 164 361 164 361 164 NOTE All dimensions in inches millimeters except pipe size which is NPT TABLE 2 RECOVERY CAPACITIES Joo UNIT SHOWN WITH CONTROL COVER REMOVED HIGH LIMIT CONTROL TRANSFORMER IGNITION MODULE PILOT BURNER OBSERVATION HOLE FIRING VALVE GAS OPERATING VALVE MANUAL SHUTOFF a VALVE COMPONENT LOCATION FIGURE 1 6 N TROL This design complies with the current edition of the ANSI 221 13 low pressure boiler standard Compliance under this standard implies that when the boiler underwent test the gas manifold and control assembly provided on the boiler met safe lighting and other performance criteria Detailed installation diagrams are found in this manual The
99. rols or the separate stages of a step controller should fire a boiler and also start the boiler loop circulator whenever the first boiler of a group supplied by that boiler loop is fired Some large installations may require the firing of more than one boiler per stage The system or primary circulator may or may not be controlled by the boiler sequencer When this pump is operated through the first switch of any type of step controller care should be taken to determine if a motor starter is needed due to insufficient switch capacity If the primary pump is controlled by a manual switch or any other controllers the electric current supply to the boiler group should be through the primary pump controller The fast response of A O Smith boilers eliminates any need to maintain boiler temperature when the system is satisfied Wiring should always prevent firing of boiler s when there is no water flow in the mains Installation diagrams show flow switches in the outlet piping from each boiler as good protection against any boiler being fired when the boiler loop circulator is not in operation These flow switches will also serve as protection if there is a loss of water Outdoor vent systems will normally require an automatic shutdown control if there is a continuous recirculating main and or if the entire 25 building is not under control of space temperature thermostats A single bulb outdoor sensing control will prevent overheating of h
100. rvice and inspection of appliances within the building 2 Read understand this manual and all Warnings and Cautions within before installing and using this appliance Place these instructions adjacent to boiler and notify owner to keep for future reference DANG Untempered hotwater can cause severe burns instantly resulting Insevereinjury or death Children elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting A DANGER Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity ofthis or any other appliance Avoid all ignition sources if you smell LP gas Do not expose boiler control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use Read instruction manual before installing using or servicing AWARNING For continued protection against risk of fire e Do not install boiler on carpeted floor Do not operate boiler if flood damaged A DANGER Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Flammable V
101. s 399 s or 420 s item 9 is for 1st boiler the sensing element as above For additional boilers install a 2nd limit control if required by local codes With any 520 610 or 670 boilers install 2nd limit control here if required by local code BOILER INLET OUTLET SIZES HW 300 1 1 4 HW 399 1 1 2 HW 420 1 1 2 HW 520 amp HW 610 2 HW 300 1 1 4 HW 399 1 1 2 HW 420 1 1 2 HW 520 amp HW 670 2 MINIMUM BRANCH SIZES TO BOILERS HW 300 1 1 4 HW 520 610 Single boiler HW 399 1 1 2 per pump 2 HW 420 1 1 2 HW 300 1 1 4 HW 399 1 1 2 HW 420 1 1 2 Flow control valve Required only if flow rate of system primary is excessive for size of boiler branch tees or if chilled water main is above boilers System supply temperature thermometer Boiler headers for three 3 boilers can be larger than pipe loop if desired to aid in balancing HW 520 670 Single boiler per pump 2 The system flow rate is selected to give the desired system temperature drop depending on the design criteria The boiler generator flow rates on the other hand should be selected to give the temperature rise through the generator that is both economical and offers the best generator efficiency The boiler temperature rise is normally between 109 and 209 209 and 40 F The system temperature that will be introduced to the boiler inlet temperature plus the selected boiler temperature rise selected
102. s HW 610 s HW 670 s UP FLOW MODEL COMMERCIAL BOILER WITH VERTICAL TANK CER TEMP 80 A O SMITH IMPORTANT THE INSTALLATION OF SAFETY FLOW SWITCH AS SHOWN IS Cer cmp BO REQUIRED TO PROTECT THE BOILER IN CASE OF WATER SERVICE RECOVERY SYSTEM INTERRUPTION OR CIRCULATOR FAILURE PIPING AND FITTINGS BETWEEN GATE VALVES AND BOILERS SHOULD BE BRASS OR BRONZE OTHER PIPING SHOULD CONFORM TO LOCAL CODES GATE VALVES ARE SHOWN FOR SERVICING BOILER HOWEVER PEN 2 LOCAL CODES SHALL GOVERN THEIR USAGE TO FIXTURES AND MIXING VALVE PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED TEMPERATURE amp PRESSURE PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM RELIEF VALVE INSTALLTHERMOMETERAND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 amp HW 670 PRESSURE RELIEF VALVE THERMOMETER w SAFETY SWITCH FLOW GATE VALVE SWITCH lt ep PIPETO OPEN DRAIN a N PLUG OR gt BALL VALVE R uM kd ty M S f PLUG OR BALL VALVE 4 A e d ca Y 1 UNION A P GATE VALVE TANK TEMPERATURE CONTROL PRESSURE RELIEF VALVE GATE VALVE ALL BRONZE CIRCULATING PUMP I D ie aw 6 q iind COLD WATER LOCATE TEE AS SUPPLY CLOSE TO TANK ASPossiBLE
103. s injury or death 11 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 DANGER 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 TIME OF EXPOSURE THE SLOWER RESPONSE TIME OF CHILDREN AGED OR DISABLED PERSONS INCREASES THE HAZARDS TO THEM NEVER ALLOW SMALL CHILDREN TO USE A HOT WATER TAP OR TO DRAW THEIR OWN BATH WATER NEVER LEAVE ACHILD OR DISABLED PERSON UNATTENDED OR SHOWER DANGER 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 water heater and minimize scale formation THE WATER HEATER SHOULD BE LOCATED IN AN AREAWHERE 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 states provinces require settings at specific lower temperatures Below you will find list
104. s Code ANSI 2223 1 or CAN CSA B 149 1 Installation Codes To prevent damage care must be taken not to apply too much torque when attaching gas supply pipe to the gas valve gas inlet Fittings and unions in the gas line must be the 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 CONNECTIONS MUST BE LEAK TESTED BEFORE PLACING THE BOILER IN OPERATION Use soap and water solution or other material acceptable for the purpose in locating gas leaks DO NOT USE MATCHES CANDLES FLAME OR OTHER SOURCES OF IGNITION FOR THIS PURPOSE DISCONNECT THE BOILER AND ITS MAIN MANUAL GAS SHUTOFF VALVE FROM THE GAS SUPPLY PIPING SYSTEM DURING ANY PRESSURE TESTING OF THE GAS SUPPLY SYSTEM OVER 1 2 PSIG 3 5kPa THE GAS SUPPLY LINE MUST BE CAPPED WHEN NOT CONNECTED TO THE BOILER THE BOILER MUST BE ISOLATED FROM THE GAS SUPPLY PIPING SYSTEM BY CLOSING ITS MAIN MANUAL GAS SHUTOFF VALVE DURING ANY PRESSURE TESTING OF THE GAS SUPPLY PIPING SYSTEM AT TEST PRESSURES EQUAL TO OR LESS THAN 1 2 PSIG 3 5kPa PURGING AND SIZING Gas line purging is required with new piping or systems in which air has entered A CAUTION PURGING SHOULD BE PERFORMED BY PERSONS EXPERIENCED IN THIS TYPE GAS SERVICE TO AVOID RISK OF FIRE OR EXPLOSION PURGE DISCHARGE MUST NOT EN
105. s than those shown in table 3 22 0 28 4 HW 610 670 adjust the flow rate setting 1 Remove the flow switch cover 2 For higher flow rate turn the range adjusting screw clockwise 3 counterclockwise A CAUTION The switch is factory set at approximately the minimum flow rate see Table 3 on page 9 It must not be set lower than the factory setting as this may result in the switch failing to return at no flow condition For lower flow rate turn the range adjusting screw 4 Replace flow switch cover Where units are installed in multiples each boiler must be individually protected by a safety flow switch A CAUTION Paddle must be trimmed at the dotted arc It must not touch the pipe or have any restriction when installed 4 4 9A6 115 9mm 2 29 32 73 8mm 2 13 32 61 1mm 4 1 29 32 lt 1 11 16 42 9mm 13 8 34 5mm gt PIRE 5 17 32 140 5mm 4 3 17 32 89 7mm n SAFETY FLOW PADDLE 3 k 6 19 32 167 5mm s 4 PIPE 5 6 TO 8 WELDING HALF COUPLING FLOW DIMENSION A MUST AT LEAST 5 PIPE DIAMETERS FROM NEAREST ELBOW VALVE OR OTHER PIPE RESTRICTIONS FIGURE 6 SAFETY RELIEF VALVES Your local code authority may have other specific relief valve
106. se 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 with the current editions as follows In the United States The National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electric Code NFPA 70 In Canada Installation Code CAN CSA B149 1 and Canadian Electrical Code CSA C22 1 GROUNDING INSTRUCTIONS This boiler must be grounded in accordance with the National Electrical Code Canadian Electrical Code and or local codes Correct wiring is imperative for proper operation 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 CORRECT GAS M
107. system should be corrected so the installation conforms with the current edition of CAN CSA B149 1 current edition 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 CAN CSA B149 1 4 MULTIPLE VENT TABLE Table 5 on page 17 has been compiled to show the material sizes in a Type B doublewall combined vent system Refer to CAN CSA B149 1 current edition or the ASHRAE 1983 Equipment Volume 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 5 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 610mm 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 CAN CSA B149 1 current edition EXAMPLE SHOWING USE OF THE HW 610 COMBINED VENT SIZING TABLE NOTE MANIFOLD MAY BE SLOPED UPWARD BUT ALL BOILERS MUST HAVE REQUIRED
108. the requirements of different buildings Brand names of controls shown are suggestions and not directly related to any particular type of system THESE LAYOUTS ARE NOT WIRING DIAGRAMS OUTDOOR BULB TEMP BULB gt Ww s 5 o 5 BUILDING RELAY RATED TO CARRY CIRCULATOR ALL MOTORS GAS 4 THERMAL CIRCULATOR GHSGULATOR 252 VALVES Y 120 VAC 8 0 AMPS E P FULL LOAD FROM BUILDING Y EA SWITCH CONTROL SYSTEM e BALANCER THERMAL SAFETY BALANCER SWITCH SAFETY OUTDOOR BULB a MAIN WATER FLOW SWITCH OUTDOOR THERMOSTAT IF REQUIRED D E EN HONEYWELL T675A T sunetion T BOXES ON LOW WATER CUT OFF BOILERS IF REQUIRED BOILER 1 BOILER NO 2 NOTE 3 Outdoor thermostat required if building controls do not provide 1 Building temperature controls supply electric power to building automatic shutdown of reset controls during warm weather circulator Boilers and Secondary Circulator are Controlled by 2 Main flow switch proves main water flow before energizing Dual Bulb Dual Switch Controller sequencing and resetting controls Staging and Outdoor Reset of Main Water Temperature CONTROL APPLICATION DIAGRAM TWO BOILER LINEAR TEMP INSTALLATION WITH TWO CIRCULATORS FIGURE 18 MAIN WATER OUTDOOR TEMP BUL BULBS RELAYRATED Z E 5 TO CARRY BUILDING ALL MOTORS CIRCULATOR gt lt lt GAS VALVES ETC _ 7 c
109. turning pressure regulator adjusting screw with a screwdriver Clockwise to increase pressure Counterclockwise to decrease pressure WIRING CONNECTIONS CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING 1 CONVENTIONAL INSTALLATIONS ALL ELECTRICAL WORK MUST BE INSTALLED IN ACCORDANCE WITH 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 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 15 VOID AS STIPULATED IN THE LIMITED WARRANTY ON THE INSTRUCTIONS MANUAL 29 Set primary system temperature control dial thermostat to lowest setting Remove pressure gauge and replace sealing plug Set primary system temperature control dial thermostat to desired setting DO NOT INCREASE GAS PRESSUREABOVE THAT SPECIFIED ON THE RATING PLATE AS OVERFIRING WILL RESULT IN DAMAGE TO THE BO
110. ugh the boiler during the cooling cycle 8 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 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 circulators are to be used with the unit when it is installed in HOT WATER SUPPLY SYSTEMS BEARING OIL MOTOR OIL A TYPICAL CIRCULATING PUMP FIGURE 14 Although each circulator that requires oiling is oiled and operated by the manufacturer IT MUST BE OILED AGAIN BEFORE OPERATED Oil the three oil cups 2 on the motor 1 on the pump as instructed on the oil tube supplied with the unit see Figure 14 on this page Thereafter during the heating season lubricate the three oil cups at least once every four months Combination heating cooling systems should be lubricated every four months year round Use 2 or 3 teaspoonsful in bearing oil cups or 12 drops in the motor oil cups see Figure 14 on this page Use No 20 non detergent motor oil Follow the same oiling procedure if a replacement circulator is installed into the system WARNING THIS B
111. ure adequate air supply Confined Space a U S Installations When drawing combustion and dilution air from inside a conventionally constructed building to a confined space such a space shall be provided with two permanent openings ONE WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM Each opening shall have a free area of at least one square inch per 1000 Btuh of the total input of all appliances in the enclosure but not less than 100 square inches 13 If the confined space is within a building of tight construction air for combustion ventilation and draft hood dilution must be obtained from outdoors When directly communicating with the outdoors or communicating with the outdoors through vertical ducts two permanent openings located in the above manner shall be provided Each opening shall have a free area of not less than one square inch per 4000 Btuh of the total input of all appliances in the enclosure If horizontal ducts are used each opening shall have a free area of not less than one square inch per 2000 Btuh of the total input of all appliances in the enclosure b Canadian Installations Ventilation of the space occupied by the boiler s shall be provided by an opening for ventilation air at the highest practical point communicating with outdoors The total cross sectional area shall be at least 10 of the area of the combustion air opening but in no case shall the cross section

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