A.O. Smith HW 610 manual

PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE PRINTED 0210 317693-000 GAS-FIRED COMMERCIAL COPPER BOILERS FOR HYDRONIC HEA TING AND HOT W A TER SUPPL Y • INST ALLA TION • OPERA TION • MAINTENANCE • LIMITED W ARRANTY • INDOOR ONL Y MODELS HW 300, 399, 420, 520, 610, 670 UP-FLOW MODELS W ARNING: I[...]

2 IMPORT ANT DEFINITIONS • Qualied Installer: A qualied installer must have ability equivalent to a licensed tradesman in the elds 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 in[...]

3 GENERAL SAFETY[...]

4 SAFE INST ALLA TION, USE AND SER VICE.......................................................................................................................................................................... 2 GENERAL SAFETY............................................................................................................................[...]

5 EXTRA OPENING FOR THERMOMETER AND RELIEF V AL VE HW-520, 610 AND HW--670 DIMENSIONS AND CAP ACITY DA T A T ABLE 1 DIMENSIONS IN INCHES MODELS HW-300 HW-399 HW-420 HW -520 PROP ANE HW-610/670 NA TURAL HW-610/670 A Overall height 65 (1651) 57-1/8 (1451) 57-1/8 (1451) 68-5/16 (1735) 67 (1702) 64-3/4 (1645) B Height to T op of Jacket 43-1/4 (1099) 45[...]

6 T ABLE 2, RECOVERY CAP ACITIES Model Input °F 20 40 50 60 70 80 BTUH (kW) °C 1 1.1 22.2 27.7 33.3 38.8 44.4 HW 300 300,000 (88) GPH 1439 719 576 480 41 1 360 LPH 5448 2724 2179 1816 1556 1362 HW 399 399,000 (1 17) GPH 1914 957 765 638 547 478 LPH 7245 3623 2898 2415 2070 181 1 HW 420 420,000 (123) GPH 2014 1007 806 671 576 504 LPH 7627 3813 305[...]

7 INTRODUCTION This design complies with the current edition of the ANSI Z21.13 low-pressure boiler standard. Compliance under this standard implies that when the boiler underwent test, the gas manifold and control assembly pro vided on the boiler met safe lighting and other performance criteria. Detailed installation diagrams are found in this man[...]

8 HIGH AL TITUDE INST ALLA TIONS IN CANADA Acceptance of these models for use at altitudes above 2000 feet (600 m) is based on eld test of the individual installation by the provincial/state authority having jurisdiction. IN THE U.S.A. W ARNING INST ALLA TIONS ABOVE 2000 FEET REQUIRE REPLACEMENT OF THE BURNER ORIFICES IN ACCORDANCE WITH THE CURR[...]

9 THERMAL BALANCER Figure 4 shows the internal wiring of the thermal balancer . The device may be tested after disconnecting the four leads from their respective terminals on the unit. 1. Apply a test light to the yellow and red leads. • The lamp should light as the contact in this circuit is normally closed when the resistor is cool. 2. Apply a [...]

10 CAUTION Paddle must be trimmed at the dotted arc. It must not touch the pipe or have any restriction when installed. FIGURE 6. T o adjust the ow rate setting: 1. Remove the ow switch cover . 2. For higher ow rate - turn the range adjusting screw clockwise. 3 . For lower flow rate - turn the range adjusting screw counterclockwise. CAUTIO[...]

11 Co de, S ect ion IV o r CSA B51 , as ap pli cab le . Sel ect a r el ie f val ve wi th 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. Sm ith su ppl ie s a 125 psi re lief v al ve for h ot wat er su pply s ys tems and 50 psi rel ief val ve for space h eatin[...]

12 W ater T emperature T ime to Produce 2nd & 3rd Degree Burns on Adult Skin OVER: 170°F (77°C) 160°F (71°C) 150°F (65°C) 140°F (60°C) 130°F (54°C) 120°F (49°C) Nearly Instantaneous About 1/2 second About 1-1/2 seconds Less than 5 seconds About 30 seconds More than 5 minutes USE A NTI- SCA LD VAL V E( S) in the hot water system to r[...]

13 P ER MI T O PE RATI ON O F G AS A PP LI AN CE S I F I NS T AL LE D 18 INCHES OR MORE ABOVE THE FLOOR. THIS MA Y REDUCE THE RISK IF LOCA TION IN SUCH AN AREA CANNOT BE A VOIDED. W ARNING FLAMMABLE ITEMS, PRESSURIZED CONT AINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE BOILER. OPEN CONT AINERS OF FL[...]

14 INST ALLA TION CLEARANCES These boilers are approved for installation on combustible ooring in an alcove with minimum clearance to combustibles of: T ABLE 4 HW 300 HW 399 HW 420 HW 520 HW 610 & 670 TOP 28" (71 1.2) 32" (812.8) 24" (609.6) 24" (609.6) 24" (609.6) SIDES 6" (152.4) 6" (152.4) 24" (609.[...]

15 Building materials must not come in contact with combustion products from stack or chimney , due to the degradating properties of ue 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 met[...]

16 4. MUL TIPLE VENT T ABLE T able 5 on page 17 has been compiled to show the material sizes in a T ype B doublewall combined vent system. Refer to CAN/CSA B149 .1 (current edition), or the ASHRAE 1983 Equipmen t V olume for further information. A combined vent system is one in which two or more boilers at one level are attached to a common vent. I[...]

17 T ABLE 5, COMBINED VENT SIZING T ABLES MODEL HW-300 BOILER Input: 300,000 Btuh Draft Hood Outlet 8" Required Connector or Smoke Pipe Diameter Connector Rise in Feet T otal Vent Height (Measured in Feet Above Draft Hood) 10 15 20 30 40 50 60 80 100 Connector Diameter (in Inches) 1 10 10 10 10 10 10 10 10 10 2 10 10 10 10 10 10 10 10 10 3 10 [...]

18 1. CONVENTIONAL INST ALLA TIONS All modern hydronic type boilers are exceptionally fast heating units. The low water volumes in relation to ring rates require special attention to water ow rates for smooth, efcient operation. These considerations for the A. O. Smith copper heat exchanger boilers are covered below . Conventional 20 0 F ([...]

19 NO. SUGGESTED ITEMS FOR INST ALLA TION 1 Short pipe nipple and pair of boiler loop tees in piping between system supply and return. One set per each group of boilers. 2 Boiler pipe loop. See piping sizing data. 3 Boiler circulator . See pump sizing data. 4 Thermometer . 5 Theraltimeter . 6 Plug cock to control ow rate. 7 Safety ow switches[...]

20 5. VENT V AL VES 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 . T o achieve goo[...]

21 U s e t a b l e 7, o r C A N / C S A B 1 4 9 .1 ( c u r r e n t e d i t i o n ) t o s i z e i r o n p i p e o r e q u i v a l e n t g a s s u p p l y l i n e . Ta b l e 7 i s b a s e d o n a p r e s s u r e d r o p o f 0 . 3 i n c h e s o f w a t e r a n d a s p e c i f i c g r a v i t y o f 0 . 6 0 a p p r o x i m a t e l y t h a t o f n a t u [...]

22 • In 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 [...]

23 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 ignit[...]

24 120 VA C 60 HZ L1 (HOT) L2 (NEUTRAL) L1 (HOT) L2 (NEUTRAL) 120 VA C 60 HZ 120V 24V HIGH LIMIT IGNITION MODULE CHASSIS GROUND IGNITOR WIRE TO PILOT NOTE: IF REPLACING AN Y FA CTOR Y WIRING, USE TYPE 105°C WIRE OR EQUI VA LENT , EXCEPT FOR THE IGNITION WIRE WHICH USES 250°C WIRE AND THE COIL LIMI T WHICH USES 200°C WIRE. 192359-000 Rev . 3 %%UW[...]

25 2. LINEAR-TEMP INST ALLA TIONS Cont rol for t hese systems i s de cided mainly by t he t ype of b uilding system co ntrolling t hat is desired. A sing le boiler ins tallati on might b e c o nt r o ll e d d i re c t ly f r o m s p ac e t em p e ra tu r e t h er m o s ta t (s ) . Mult iple b oiler installat ions a re mo re ef fect ive when the boi[...]

26 NOTE: 1. Building temperature controls supply electric power to building circulator . 2. Main ow switch proves main water ow before energizing sequencing and resetting controls. 3. Outdoor thermostat required if building controls do not provide automatic shutdown of reset controls during warm weather . Boilers and Secondary Circulator are [...]

27 NOTE: 1. Building temperature controls supply electric power to building circulator . 2. Main ow switch proves main water ow before energizing sequencing and resetting controls. 3. Out door the rmostat require d if build ing control s do not provide automatic shutdown of reset controls during warm weather . Boilers and Secondary Circulator[...]

28 CER-TEMP 80 - 1 UNIT INST ALLA TION - FOR HOT W A TER SUPPL Y APPLICA TION CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 21. FIGURE 23. CER-TEMP 80 - 1 UNIT INST ALLA TION - FOR HOT W A TER SUPPL Y APPLICA TION U.S. MODELS, JUCNTION BOX W/4 TERMINALS FIGURE 22.[...]

29 CER-TEMP 80 - 2 OR 3 UNIT INST ALLA TION - FOR HOT W A TER SUPPL Y APPLICA TION CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 24.[...]

30 SCHEMA TIC CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 25.[...]

31 CER-TEMP 80 - 2 OR 3 UNIT INST ALLA TION CONNECTION DIAGRAM (FOR HOT W A TER SUPPL Y APPLICA TION) U.S. MODELS, JUNCTION BOX W/4 TERMINALS FIGURE 26.[...]

32 CER-TEMP 80 - 2 OR 3 UNIT INST ALLA TION SCHEMA TIC DIAGRAM (FOR HOT W A TER SUPPL Y APPLICA TION) U.S. MODELS, JUNCTION BOX W/4 TERMINALS FIGURE 27.[...]

33 FIGURE 28. IMPORT ANT THE INST ALL A TION OF SAFET Y FLOW SWIT CH AS SH OWN IS REQUI RED TO PROT ECT THE BOIL ER IN CASE OF W A TE R SER VIC E INTERRUPTION OR CIRCULA TOR F AILURE. + P IPIN G AND FITT INGS BET WEEN GA TE V AL VES A ND B OILE RS SHO ULD BE BRAS S O R BR ONZE . OTHE R P IPI NG SHOU LD CONFORM T O LOCAL CODES. GA TE V AL VES ARE SH[...]

34 FIGURE 29. ONE HW-300, HW -399, HW-420, HW-520, HW -610 OR ONE HW-670 UP-FLOW MODEL COMMERCIAL BOILER WITH HORIZONT AL T ANK WIRING - FIGURES 16 and 17 on pages 24 and 25. INST ALL IN ACCORDANCE WITH ALL LOCAL CODES IMPORT ANT THE INST ALLA TION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED T O PROTECT THE BOILER IN CASE OF W A TER SERVICE INTERRUP[...]

35 TWO HW-399's, HW -420's, HW-520's, HW-610's or HW -670's UP-FLOW MODEL COMMERCIAL BOILER WITH VERTICAL T ANK, CER-TEMP 80 IMPORT ANT THE INST ALLA TION OF SAFETY FLOW SWITCH AS SHOWN IS REQU IRED TO PRO TECT THE BOILER IN CASE OF W A TER SER VICE INTERRUPTION OR CIRCULA TOR F AILURE. + PIPING AND FITTINGS BETWEEN GA TE V[...]

36 FIGURE 31. TWO HW-300's, HW -399's, HW-420's, HW-520's, HW -610's OR HW-670's UP-FLOW MODEL COMMERCIAL BOILER WITH HORIZONT AL T ANK IMPORT ANT THE INST ALLA TION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED T O PROTECT THE BOILER IN CASE OF W A TER SERVICE INTERRUPTION OR CIRCULA T OR F AILURE. + PIPING AND FITTINGS [...]

37 THREE HW-520's, HW -610's OR HW-670's UP-FLOW MODEL COMMERCIAL BOILER WITH VERTICAL T ANK, CER-TEMP 80 IMPORT ANT THE INST ALLA TION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF WA TER SERVICE INTERRUPTION OR CIRCULA TOR F AILURE. + PI PING A ND FI TTIN GS BE TWE EN GA TE V AL VES AN D BOI LER S SHO [...]

38 THREE HW-520's, HW -610's OR HW-670's UP-FLOW MODEL COMMERCIAL BOILER WITH HORIZONT AL T ANK, CER-TEMP 80 IMPORT ANT THE INST ALLA TION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF WA TER SERVICE INTERRUPTION OR CIRCULA TOR F AILURE. + PIPING AND FITTINGS BETWEEN GA TE V AL VES AND BOILERS SHOULD BE [...]

39 W ARNING After placing boiler into operation, the ignition system safety shutoff device must be tested by the following test method. 1 . Reset High Limit T emperature Control to lowest setting. (See gure 2 on page 8). 2. Reset System Controller to maximum setting, causing a call for heat and allowing unit to run until High Limit T emperature [...]

40 4. Reinstall the burner manifold assembly on boiler . 5. Restore electrical power and gas supply to boiler . • Put the boiler back in operation by following the lighting instructions in this manual or on the lighting and operating label on the boiler . See pages 43 - 44. • Check for gas leaks and proper boiler and vent operation. 2. PILOT BU[...]

41 CHECKING AND ADJUSTING THE INPUT 1. Follow steps 1 thru 6 of the OPERA TING INSTRUCTIONS. 2 . At t ac h a p re ss ur e g au ge o r a m an o met er to t he m an if ol d p re ss ur e t ap pi ng an d r ef er to ta bl e 10 fo r c or r ec t ma ni fo l d pressure. 3. Follow step s 7 thru 1 1 of the OPER A TI NG INSTRU CTIONS . 4. Use this formula to ?[...]

42 ST ART ST AGE 1 TRIAL FOR IGNITION ST AGE 2 MAIN BURNER OPERA TION END THERMOST A T (CONTROLLER) CALLS FOR HEA T SP ARK GENERA TOR POWERED First valve (pilot) operator opens PILOT BURNER OPERA TION Pilot burner lights. Pilot burner does not light Module senses Module Response ame current. S-8600M After 15 sec. ignition shut-down. 5 minute tim[...]

43 FOR YOUR SAFETY READ BEFORE LIGHTING W ARNING : FLAMMABL E If you do not fo ll ow these instr uctions e xactly , a fire or e xplosion may result causing prope rt y damag e, personal inju ry or loss of li fe . C. D. WHA T TO DO IF Y OU SMELL GAS DO NOT T RY TO LIGHT A NY APPLIANCE. DO NOT TOUCH A NY ELECTRIC SWITCH; DO NOT USE A NY PHONE IN YOUR [...]

44 FOR YOUR SAFETY READ BEFORE OPER AT ING W ARNING: FLAMMABLE If you do not fo ll ow these instr uctions e xactly , a fire or ex plosion ma y result causing prope rt y damag e, personal inju ry or loss of li fe . A. B. THIS APPLIANCE IS EQUIPPED WIT H AN IGNITION DEVICE WHICH A UT OM AT ICAL LY LIGHTS THE PILO T. DO NOT T RY TO LIGHT THE PILOT BY [...]

45 At the time of removal of an existing boiler , the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. Seal any unused openings in the common venting system. Visually inspect th[...]

46 CLEANING AND FLUSHING INSTRUCTIONS INTERNAL CONT AMINANTS T he h yd r on i c s ys te m m u st b e i n te r na l ly c l e an e d a nd f l us h ed a f te r a n e w o r r ep l ac e m en t b o i le r h a s b e en in st a l le d to r e m ove contaminants t hat may have ac cumulated during installati on. T hi s is do u bl y i m po r t a nt wh e n a r [...]

47 TROUBLESHOOTING CER-TEMP 80 RECOVER Y SYSTEM CHECKOUT PROCEDURE Use this checkout for Cer-T emp 80 Recovery Systems. (For hot water supply application only) Checkout Sequence System Operation Cause Remedy Contact Incorrect Set tank temperature control (thermostat) 20°F (10°C) below tank water temperature. Circulating pump and burner shut off. [...]

48 CHECKING HONEYWELL S-8600H OR S-8610M INTERMITTENT IGNITION CONTROLS T urn off gas supply . Is voltage (24 V ac) across the 24 V terminals on module during “Call for heat”? T urn off power supply . Is ignition cable rmly plugged into pilot assembly and module? Is gro und wire rm ly a tta ch ed t o pi lot asse mbl y and GND term inal on[...]

49 CHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLS SP ARK A T PILOT BURNER BUT PILOT WILL NOT LIGHT Ensure all manual shutoff valves are fully open; all lters are clean; all gas connections are gas tight; pilot tubing is not damaged, obstructed or kinked; and pilot orice is unclogged. Check for air in gas line, purge (blee[...]

50 CHECKING HONEYWELL S-8600H OR S8610M INTERMITTENT IGNITION CONTROLS PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT Does the pilot ame cover 3/8” to 1/2” of ingniter/sensor rod? Does spark stay on for more than 15 seconds after the pilot is “proven” (lit)? Ensure the ground wire and ignition cable are separate from each other (prev[...]

51 CHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLS NO SP ARK A T PILOT BURNER BUT PILOT WILL NOT LIGHT T urn off gas supply . Is there a good connection between terminals? Is module securely attached to appliance for good ground connection? Is voltage (24V AC) across transformer positive terminal and GND with "call for heat[...]

52 The following procedures are provided as a general guide. Any module should be replaced if it does not perform properly on checkout or troubleshooting. In addition, replace any module if it is wet or looks like it has ever been wet. LED ST A TUS AND TROUBLESHOOTING The control has two LEDs; one for ame sensing and one for system status: FIGUR[...]

53 T able 12. Continuous Retry Models C, M, E, and K Only - Green LED Status Codes Green LED Flash Code (X+Y) a Indicates Next System Action Recommended Service Action OFF No "Call for Heat" not applicable none Flash Fast Startup - Flame sense calibration not applicable none Heartbeat Normal operation not applicable none 2 5 minute Retry [...]

54 T able 13. Lockout Models B, H, D and J Only - Green LED Status Codes Green LED Flash Code (X+Y) a Indicates Next System Action Recommended Service Action OFF No "Call for Heat" not applicable none Flash Fast Startup - Flame sense calibration not applicable none Heartbeat Normal operation not applicable none 3 Recycle - Flame failed du[...]

55 A. O. Smith Corporation, the warrantor , extends the following LIMITED WARRANTY to the owner of this boiler . 1. If within TEN years after initial installation of the boiler, a heat exchanger , 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 [...]

500 T ennessee W altz Parkway , Ashland City , TN 37015 T echnical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306 www .hotwater.com[...]