A.O. Smith DB/DW-720-1810 manual

1 WITH ELECTRONIC INTERMITTENT PILOT IGNITION AND INST ALLA TIONS W ARNING: If the information in this manual is not followed exactly , a fire or explosion may result causing property damage, personal injury or loss of life. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. — W [...]

2 FOREWORD CA UTION TEXT PRINTED OR OUTLINED IN RED CONT AINS INFORMA TION RELA TIVE TO YOUR SAFETY . PLEASE READ THOROUGHL Y BEFORE USING APPLIANCE. Detailed installation diagrams are in this manual. These diagrams will serve to provide the installer with a reference for the materials and method of piping suggested. IT IS NECESSARY THA T ALL W A T[...]

3 W ARNING AN AMPLE SUPPL Y OF AIR MUST BE PROVIDED FOR PROPER COMBUSTION AND VENTILA TION. Minimum Clearances T o Combustibles Water Blank T op Side Side Rear V ent Front All Models 12" (305mm) 18" (457mm) 6" (155mm) 6" (155mm) 6" (155mm) Alcove CAUTION Label all wires prior to disconnection when servicing controls. Wiring[...]

4 W ARNING Y our Dura-Max boiler is not designed to operate with a boiler inlet water temperature of less than 100 ° F (38 ° C). Colder inlet water temperatures will result in significant condensation developing on the heat exchanger . This situation can cause a corrosive environment for the heat exchanger , burners and venting resulting in prema[...]

5 FEA TURES IMPORT ANT Only qualified personnel shall perform the initial firing of the heater . At this time the user should not hesitate to ask the individual any questions regarding the operation and maintenance of the unit. Lighting and Operating instructions are included at the rear of this manual. By using this checklist the user may be able [...]

6 AUT OMA TIC RESET HIGH TEMPERA TURE LIMIT CONTROL CAUTION LIMIT CONTROLS ARE NOT TO BE USED AS THERMOST A TS. ALL MODELS - This limit is a safety device wired in series with the ignition system. Set the limit control dial to a minimum of 10 ° F (6 ° C) above the maximum designed system temperature. If the boiler outlet water temperature should [...]

7 INST ALLA TION INSTRUCTIONS REQUIRED ABILITY INST ALLA TION OR SERVICE OF THIS BOILER REQUIRES ABILITY EQUIV ALENT TO THA T OF A LICENSED TRADESMAN IN THE FIELD INVOL VED. PLUMBING, AIR SUPPL Y , VENTING, GAS SUPPL Y AND ELECTRICAL WORK ARE REQUIRED. W ARNING THE INLET/OUTLET W A TER MANIFOLD ON YOUR A. O. SMITH UNIT INCORPORA TES AN "O RING[...]

8 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 aforementioned manner , shall be provided. Each o[...]

9 W ARNING F AILURE TO CORRECT BACK DRAFTS MA Y CAUSE AIR CONT AMINA TION AND UNSAFE CONDITIONS. V ent 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 chimne[...]

10 T ABLE 5 Multipliers T o Be Used W ith T able 1 When Applying The Gravity Factor T o Other Than .60 Specific Gravity Specific Specific Gravity Multiplier Gravity Multiplier .35 1.31 1.00 .78 .40 1.23 1.10 .74 .45 1.16 1.20 .71 .50 1.10 1.30 .68 .55 1.04 1.40 .66 *.60 (Nat.) 1.00 *1.50 (Prop.) .63 .65 .96 1.60 .61 .70 .93 1.70 .59 .75 .90 1.80 .5[...]

11 Applications of the gravity factor converts the figures given in table 1 to capacities with another gas of different specific gravity . Such application is accomplished by multiplying the capacities given in table 1 by the multipliers shown in table 5. T o determine the size of each section of gas piping in a system within the range of table 4 p[...]

12 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 EQUIV ALENT , EXCEPT FOR THE FLAME SENSOR AND IGNITION CABLE WHICH ARE 250 ° C. SERVICING WIRING AND/OR CONTROL CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper[...]

13 The flow switch shall be mounted in the 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 the paddle segments as supplied. For other pipe sizes (i.e. 2-1/2") trim the paddle to the p[...]

14 Thereafter , during the heating season, lubricate the three oil cups at least once every four months. Combination heating/cooling systems or water heating (Cer-temp) systems should be lubricated every four months year-round. Use 2 or 3 teaspoonfuls in bearing oil cups, fig. 9, and 10 or 12 drops in the motor oil cups. Use No. 20 non-detergent mo[...]

15 A system bypass should be installed as shown in fig. 10 to prevent boiler circulation starvation when the system zones call for reduced flow . This bypass may also be used with multiple boilers manifolded for reverse-return flow . The system bypass would be installed from boiler outlet to suction side of pump. Standard Dura-Max models are factor[...]

16 NOTES: 1. BUILDING TEMPERA TURE CONTROLS SUPPLY ELECTRIC POWER T O BUILDING CIRCULA T OR. 2. MAIN FLOW SWITCH PROVES MAIN W A TER FLOW BEFORE ENERGIZING, SEQUENCING AND RESETTING CONTROLS. 3. OUTDOOR THERMOST A T REQUIRED IF BUILDING CONTROLS DO NOT PROVIDE AUTOMA TIC SHUT-DOWN OF RESET CONTROLS DURING W ARM WEA THER.[...]

17 BYP ASS BALANCING With systems where water temperature can be expected to drop appreciably due to long standby periods, or heavy draw down, a bypass pipe of at least 1" size with a balancing cock should be installed between the boiler inlet and outlet (see fig. 10). When the system first starts, the valve should be slowly opened until the c[...]

18 generator type boilers establish temperature rises. The deciding factor in choice of boiler temperature rise relates to the boiler inlet temperature. Boiler outlet, minus system temperature drop, is boiler inlet temperature. THE BOILER TEMPERA TURE RISE SHOULD NOT RAISE THE OUTLET TEMPERA TURE UP TO THE MAXIMUM 250 ° F (1 15 ° C) SETTING OF TH[...]

19 FIGURE 14 NO . SUGGESTED ITEMS FOR INST ALLA TION 1. SHORT PIPE NIPPLE AND P AIR OF BOILER LOOP TEES IN PIPING BETWEEN SYSTEM SUPPL Y AND RETURN - ONE SET PER EACH BOILER 2. BOILER PIPE LOOP (See Piping Sizing Data T able 3.) 3. BOILER CIRCULA TING PUMP (See Piping Sizing Data T able 3.) 4. THERMOMETER 5. PRESSURE GAUGE 6. LOW W A TER CUT-OFF (I[...]

20 USE ONY TYPE 105 ° C THERMOPLASTIC OR ITS EQUIV ALENT IF ANY OF THE ORIGINAL WIRES AS SUPPLIED MUST BE REPLACED. USE ONY TYPE 105 ° C THERMOPLASTIC OR ITS EQUIV ALENT IF ANY OF THE ORIGINAL WIRES AS SUPPLIED MUST BE REPLACED. BOILER CONVENTIONAL SYSTEM FIGURE 15 ONE BOILER LINEAR-TEMP SYSTEM FIGURE 16[...]

21 DURA-MAX - PUMP MOUNT - SINGLE ST AGE - SCHEMA TIC DIAGRAM DURA-MAX - SINGLE ST AGE FIRING - UNITED ST A TES MODELS WITH PUMP . 120 VOL T SYSTEM CONTROLLER[...]

22 DURA-MAX - PUMP MOUNT - DUAL ST AGE - SCHEMA TIC DIAGRAM DURA-MAX - DUAL ST AGE FIRING - UNITED ST A TES MODELS WITH PUMP . 120 VOL T SYSTEM CONTROLLER[...]

23 DURA-MAX - PUMP MOUNTED - MODULA TING - SCHEMA TIC DIAGRAM DURA-MAX - MODULA TED FIRING - UNITED ST A TES MODELS WITH PUMP . 120 VOL T SYSTEM CONTROLLER[...]

24 DURA-MAX - SINGLE ST AGE FIRING - SCHEMA TIC DIAGRAM DURA-MAX - SINGLE ST AGE FIRING - UNITED ST A TES & CANADIAN MODELS WITHOUT PUMP . 120 VOL T SYSTEM CONTROLLER[...]

25 DURA-MAX - DUAL ST AGE FIRING - SCHEMA TIC DIAGRAM DURA-MAX - DUAL ST AGE FIRING - UNITED ST A TES & CANADIAN MODELS WITHOUT PUMP . 120 VOL T SYSTEM CONTROLLER[...]

26 DURA-MAX - MODULA TED FIRING - SCHEMA TIC DIAGRAM DURA-MAX - MODULA TED FIRING - UNITED ST A TES & CANADIAN MODELS WITHOUT PUMP . 120 VOL T SYSTEM CONTROLLER[...]

27 HOT W A TER SUPPL Y APPLICA TIONS Cer-T emp 80 Recovery Systems W A TER LINE CONNECTIONS This section provides detailed installation diagrams for typical methods of application for the unit using a Cer-T emp 80 Recovery System (for one temperature water). This equipment must be protected against loss of water or loss of water flow by the install[...]

28 ONE DURA-MAX (MODEL DW) COMMERCIAL BOILER WITH HORIZONT AL T ANK CAUTION TO PREVENT CONDENSA TION THE MINIMUM BOILER INLET TEMPERA TURE IS 100 ° F (38 ° C) IMPORT ANT SAFETY FLOW SWITCH AS SHOWN TO PROTECT THE BOILER IN CASE OF WA TER SERVICE INTERRUPTION OR CIRCULA TOR F AILURE. CAUTION PUMP MUST BE RA TED FOR SYSTEM OPERA TING TEMPERA- TURES[...]

29 TWO DURA-MAX (MODEL DW) HOT W A TER SUPPL Y BOILERS WITH VERTICAL T ANK CAUTION TO PREVENT CONDENSA TION THE MINIMUM BOILER INLET TEMPERA TURE IS 100 ° F (38 ° C) SEE P AGE 31 FOR ADDITIONAL PIPING INFORMA TION. CAUTION PUMP MUST BE RA TED FOR SYSTEM OPERA TING TEMPERA TURE AND PRESSURE . * SAFETY RELIEF V AL VE RA TING SHOULD NOT EXCEED PRESS[...]

30 TWO DURA-MAX (MODEL DW) HOT W A TER SUPPL Y BOILERS WITH HORIZONT AL T ANK CAUTION TO PREVENT CONDENSA TION THE MINIMUM BOILER INLET TEMPERA TURE IS 100 ° F (38 ° C) IMPORT ANT THE INST ALLA TION OF SAFETY FLOW SWITCHES AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF W A TER SERVICE INTERRUPTION OR CIRCULA TO R F AILURE. NOTE: THERMOMETE[...]

31 FIGURE 24 MANIFOLDING OF MODEL TJV-120M & TJV-200M T ANKS NOTE: PIPE SIZES BETWEEN MANIFOLDS AND BOILER(S) TO BE SELECTED FROM THE CER-TEMP 80 DIAGRAM FOR THE HEA TER MODEL TO BE INST ALLED. ALL PIPING FROM TEES TO BE EQUIDIST ANT TO T ANKS. INST ALL IN ACCORDANCE WITH ALL LOCAL CODES. PRESSURE RELIEF V AL VE RA TING SHOULD NOT EXCEED PRESSU[...]

32 ST ART-UP AND OPERA TING INSTRUCTIONS W ARNING After placing boiler into operation, the ignition system safety shutoff device must be tested by the following test method. 1. Reset Manual High T emperature Safety Limit Control (High Limit) to the lowest setting. (See figures 3 or 4, pages 5 or 6). 2. Reset System Controller to maximum setting, ca[...]

33 LIGHTING AND OPERA TING INSTRUCTIONS WARNING: HOT W A TER CAN PRODUCE 3rd DEGREE BURNS IN 6 SECONDS A T 140 ° F . (60 ° C). IN CASE OF POWER F AILURE DO NOT A TTEMPT TO OPERA TE BOILER. IMPROPER INST ALLA TION, ADJUSTMENT , AL TERA TION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. REFER TO THE USER'S[...]

34 INTERNAL CONT AMINANTS The system must be internally cleaned and flushed after a new or replacement unit has been installed to remove contaminants that may have accumulated during installation. This is doubly important when a replacement unit is installed into an existing system where Stop Leak or other boiler additives have been used. All syste[...]

35 1. Remove main burners from unit. 2. Check that burner venturi and ports are free of foreign matter . 3. Clean burners with bristle brush and/or vacuum cleaner 3/4" DO NOT distort burner ports or pilot location. 4. Reinstall burners in unit. Making sure front and rear of burners are installed correctly in burner support brackets. Also check[...]

36 CHECKING HONEYWELL S8600H OR S8610M (NA T . GAS) INTERMITTENT IGNITION CONTROLS NO SP ARK A T PILOT BURNER NO Replace ignition module Is voltage (24 V ac) across the 24 V terrminals on module during “ call for heat ” ? YES Is voltage (24 V ac) across the PV & MV/PV terminals on “ call for heat ” ? NO NOTE: S8610M will automatically r[...]

37 SP ARK A T 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 . NO Attach wires firmly. Are the wires securely [...]

38 PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT Correct the situation by consulting N O the installation or user ’ s manual Does the pilot flame cover 3/8 ° to 1/2" on how to adjust pilot flame. (10 mm to 12 mm) of igniter/sensor rod? YES Replace ignition NO NO module. Is voltage (24 V ac) across Does spark stay on for more than 30 se[...]

39 CAUTION DO NOT USE A NYLON BRUSH OR OTHER ST A TIC CREA TING MA TERIAL TO CLEAN DUST AND CARBON DEPOSITS FROM HEA TING SURFACES AND VENT . SUCH DEPOSITS ARE FLAMMABLE AND MA Y BE IGNITED BY ST A TIC ELECTRICITY . USE A MET AL BRUSH TO MINIMIZE THE DANGER OF EXPLOSION 1. Turn of f the electrical power , main manual gas shutoff and pilot valves. ?[...]

40 The time between cleaning will vary from two to six months depending upon water conditions and usage. A change of approximately 5 ° F in the normal temperature rise through the boiler is usually an indication that scale should be removed. For long life, copper or brass is recommended for all valves, pipe and fittings used between gate valves ?[...]

41 DURA-MAX LIMITED W ARRANTY A. O. Smith Corporation, the warrantor, extends the following LIMITED W ARRANTY to the owner of this hydronic boiler: 1. If within TEN years after initial installation of the boiler , the heat exchanger shall prove upon examination by the warranto r to be defective in material or workmanship, the warrantor , at his opt[...]

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44 REPLACEMENT P ARTS 5621 W . 1 15TH STREET , ALSIP , IL 60803 PHONE: 800-433-2545 F AX: 800-433-2515 ww w .hotwater .com E-Mail: parts@hotwater .com[...]