MODELS HW/HWB 300, 399, 420, 520, 610, 670 GAS-FIRED COMMERCIAL COPPER BOILERS FOR HYDRONIC HEATING AND HOT WATER SUPPLY UP-FLOW MODELS • INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY • INDOOR ONLY 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.
ROUGH-IN DIMENSIONS EXTRA OPENING FOR THERMOMETER AND RELIEF VALVE HW/HWB-520, 610 AND HW--670 HW/HWB-610 AND HW-670 NATURAL GAS ONLY TABLE 1 MODELS HWB/ HWB/ DIMENSIONS IN INCHES HW-300 HW-399 A Overall height 65 (1651) 57-1/8 (1451) B Height to top of jacket 43-1/4 (1099) 45-1/8 (1146) C Floor to center line water inlet 36 (914) 38-3/4 (984) D Diameter of jacket 25-1/4 (641) 27 (686) E Floor to center line water outlet 12 (305) 12 (305) F Draft diverter outlet diameter 8 (203) 10 (254) G Floor to cen
TABLE 3, RECOVERY CAPACITIES - CANADIAN MODELS ONLY Input Temp. (C) 11 17 22 26 Model (Btu/Hr.
FOREWORD the locations indicated in the diagrams as these are necessary for checking the operation of the boiler. CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE USING APPLIANCE. MAKE SURE THE GAS ON WHICH THE BOILER WILL OPERATE IS THE SAME AS THAT SPECIFIED ON THE UNIT RATING PLATE. The boiler installation must conform to these instructions and the requirements of the local authority having jurisdiction.
LOCATION 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. When installing the boiler, consideration must be given to proper location.
TABLE 4 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 OF ASPHYXIATION. TOP SIDES REAR VENT CHEMICAL VAPOR CORROSION HWB/HW 300 28" (711.2) 6" (152.4) 6" (152.4) 6" (152.4) HWB/HW 399 32" (812.8) 6" (152.4) 6" (152.4) 6" (152.4) HWB/HW HWB/HW HWB/HW 420 520 610 & 670 24" (609.
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 100C (200F) drop in systems for a fully loaded boiler will maintain the following approximate flow rates: U.S.
NO. SUGGESTED ITEMS FOR INSTALLATION 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 above. 3 Boiler circulator. See pump sizing data above. 4 Thermometer. 5 Theraltimeter. 6 Plug cock to control flow rate. 7 Safety flow switches. For interlock with other systems or instead of low water cutoff. 8 Relief valve. 9 With one -300, -399 or -420 item 9 is - sensing element of remote control.
If the boiler is connected to chilled water piping or its heating coils are exposed to refrigerated air, the boiler piping system must be equipped with flow valves or other automatic means to prevent gravity circulation through the boiler during the cooling cycle. Excessive pressure may develop causing premature tank failure or intermittent relief valve operation. This is not a warranty failure.
IT IS IMPORTANT TO GUARD AGAINST GAS VALVE FOULING FROM CONTAMINANTS IN THE GAS WAYS. SUCH FOULING MAY CAUSE IMPROPER OPERATION, FIRE OR EXPLOSION. 2A. SIZING GAS SUPPLY LINE (For single boiler installations and for installations of multiples of two or three of same size boilers). Use table 6, or CAN/CSA B149.1-00 (latest recent edition) to size iron pipe or equivalent gas supply line. Table 6 is based on a pressure drop of 0.3 inches of water and a specific gravity of 0.
• • In table 6, 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 6 are multiplied by the appropriate multiplier from table 7. TABLE 7 MULTIPLIERS TO BE USED WITH TABLE 6 WHEN APPLYING THE GRAVITY FACTOR TO OTHER THAN .
7. Set primary system temperature control dial (thermostat) to desired setting. WARNING DO NOT INCREASE GAS PRESSURE ABOVE THAT SPECIFIED ON THE RATING PLATE, AS OVERFIRING WILL RESULT IN DAMAGE TO THE BOILER, AS WELL AS INCREASED RISK OF FIRE, SOOTING AND ASPHYXIATION. If gas pressure regulator cannot be adjusted to correct pressure with sufficient gas pressure at the valve, replace with new gas valve.
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 draft cannot be obtained, a blower type flue gas exhauster may be employed to ensure proper venting and correct combustion if permitted by local codes.
TABLE 9, COMBINED VENT SIZING TABLES MODEL HW/HWB-300 BOILER MODEL HW/HWB-610 BOILER Input: 300,000 Btuh Draft Hood Outlet 8" Required Connector or Smoke Pipe Diameter Connector Total Vent Height(Measured in Feet Above Draft Hood) Rise in 10 15 20 30 40 50 60 80 100 Feet 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 10 10 10 10 10 10 10 10 4 or more Number Total Total Vent Height(Measured in Feet Above Draft Hood) if Units Input 10 15 20 30 40 50 60 80 100 C
VENTING MAINTENANCE - STANDARD VENTING gas vent properly by passing a lighted match or taper around the edge of the relief opening of the draft hood. If the chimney or gas vent is drawing properly, the match flame will be drawn into the draft hood. If not, the combustion products will tend to extinguish this flame.
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.
CONNECTION DIAGRAM HWB & HW-300, -399, -420, -500 & -610 (NATURAL GAS) SINGLE STAGE I.I.D. - ROBERTSHAW® GAS VALVE HWB & HW-300, -399, -420, -520, -610 (NATURAL GAS ONLY) - CANADIAN MODELS FIGURE 10 ® Robertshaw is a registered trademark of Fulton Controls Corp.
CONNECTION DIAGRAM HWB, HW-420,-520, -610 (PROPANE GAS) SINGLE STAGE PROPANE - ROBERTSHAW GAS VALVE 24 VOLT -HW, HWB-420, -520, -610 CANADIAN MODELS FIGURE 11 18
CONNECTION DIAGRAM HWB & HW 300, 399 (PROPANE GAS) FIGURE 13 SINGLE STAGE PROPANE ROBERTSHAW GAS VALVE 24 VOLT - HWB, HW-300, 399 CANADIAN MODELS FIGURE 11A 19
HW-300, HW-399, HW-420, HW-500 & HW-670 (NATURAL GAS) SINGLE STAGE I.I.D. - ROBERTSHAW GAS VALVE HW-300, -399, -420, -520 & 670 (NATURAL GAS ONLY) - U.S.
HW-300, HW-399, HW-420, HW-500 & HW-670 (PROPANE GAS) FIGURE 12 SINGLE STAGE I.I.D. - ROBERTSHAW GAS VALVE HW-300, -399, -420, -520 & 670 (PROPANE GAS ONLY) - U.S.
TYPICAL WIRING DIAGRAM (IID NATURAL GAS) FOR SINGLE BOILER LINEAR-TEMP® INSTALLATION FOR CANADIAN MODELS FIGURE 12 2. 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.
NOTE: 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.
NOTE: 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.
CER-TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 17 CER-TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION U.S.
CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 20 26
SCHEMATIC CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 21 27
CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM (FOR HOT WATER SUPPLY APPLICATION) U.S.
CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM (FOR HOT WATER SUPPLY APPLICATION) U.S.
BOOSTER - RECOVERY WIRING DIAGRAM CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 24 SHURE-TEMP BOOSTER - RECOVERY WIRING DIAGRAM (TWO TEMPERATURE SYSTEM) CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 25 30
BOOSTER - RECOVERY WIRING DIAGRAM U.S. MODELS, JUNCTION BOX W/4 TERMINALS FIGURE 26 SHURE - TEMP BOOSTER - RECOVERY WIRING DIAGRAM TWO-TEMPERATURE SYSTEM U.S.
WATER LINE CONNECTIONS TANK TEMPERATURE CONTROL This section provides detailed installation diagrams for typical methods of application for the unit using a Cer-Temp 80 Recovery System (for one temperature water), and either Booster-Recovery or the Shure-Temp Booster-Recovery System (for two temperature water). 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, see fig's. 31-38.
Temperature Setting 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) A float type or an electronic probe type low water cutoff may be used. The manufacturer's installation instructions must be followed. Time to Produce 2nd & 3rd Degree Burns on Adult Skin Nearly instantaneous About 1/2 second About 1-1/2 seconds Less than 5 seconds About 30 seconds More than 5 minutes THERMOMETERS Thermometers should be obtained and field installed as shown in the installation diagrams.
ONE HW-300, HW-399, HW-420, HW-520, HW-610 OR ONE HW-670 UP-FLOW MODEL COMMERCIAL BOILER WITH VERTICAL TANK DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 32. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
ONE HW-300, HW-399, HW-420, HW-520, HW-610 OR ONE HW-670 UP-FLOW MODEL COMMERCIAL BOILER WITH HORIZONTAL TANK DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 32. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
TWO HW-399's, HW-420's, HW-520's, HW-610's or HW-670's UP-FLOW MODEL COMMERCIAL BOILER WITH VERTICAL TANK, CER-TEMP 80 IMPORTANT THE INSTALLATION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCULATOR FAILURE (A.O. SMITH PKG. NO. 211480). + 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.
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 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 (A.O. SMITH PKG. NO.211480). + 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.
THREE HW-520's, HW-610's OR HW-670's UP-FLOW MODEL COMMERCIAL BOILER WITH VERTICAL TANK, CER-TEMP 80 WIRING - FIGURES 20, 21, 22 OR 23 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 32. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
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 TEMPERATURE AT FIXTURES. SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 32. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
BOOSTER RECOVERY SYSTEM (PATENTED) TWO TEMPERATURE SYSTEM WITHOUT RECIRCULATION ONE HW-300, HW-399, HW-420, HW-520, HW-610 OR HW-670 UP-FLOW MODEL COMMERCIAL BOILER WITH VERTICAL TANK DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 32. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
BOOSTER RECOVERY SYSTEM (PATENTED) TWO TEMPERATURE SYSTEM WITHOUT RECIRCULATION ONE HW-300, HW-399, HW-420, HW-520, HW-610 OR HW-670 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 (A.O. SMITH PKG. NO. 211480). DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 32.
BOOSTER RECOVERY SYSTEM (PATENTED) - TWO TEMPERATURE SYSTEM WITHOUT RECIRCULATION ONE HW-300, HW-399, HW-420, HW-520, HW-610 OR HW-670 UP-FLOW MODEL COMMERCIAL BOILER WITH HORIZONTAL TANK + DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 32. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
BOOSTER RECOVERY SYSTEM (PATENTED) TWO TEMPERATURE SYSTEM WITHOUT RECIRCULATION ONE HW-300, HW-399, HW-420, HW-520,HW-610 OR HW-670 UP-FLOW MODEL COMMERCIAL BOILER WITH VERTICAL TANK WIRING - FIGURE 24 OR 26 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 32.
WITH TWO VERTICAL TANKS DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 32. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
TWO HORIZONTAL TANK INSTALLATION THREE HORIZONTAL TANK INSTALLATION DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES. SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 32. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES. FIGURE 40 START-UP AND OPERATING INSTRUCTIONS 4. Reset System Controller and High Limit Temperature Control to desired temperature.
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 AND VENTING 1. 2. Fast fill system through bypass until pressure approaches desired system pressure. Close bypass valve and permit pressure to be established by the pressure reducing valve.
LIGHTING AND OPERATING INSTRUCTIONS (NATURAL AND PROPANE GAS WITH I.I.D.) FOR YOUR SAFETY READ BEFORE OPERATING WARNING : IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY. A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. WARNING: HOT WATER CAN PRODUCE 3rd DEGREE BURNS IN 6 SECONDS AT 140° F. (60° C). IN CASE OF POWER FAILURE DO NOT ATTEMPT TO OPERATE APPLIANCE.
LIGHTING AND OPERATING INSTRUCTIONS PROPANE (LP) STANDING PILOT MODELS FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY. A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. WARNING: HOT WATER CAN PRODUCE 3rd DEGREE BURNS IN 6 SECONDS AT 140° F. (60° C). IN CASE OF POWER FAILURE DO NOT ATTEMPT TO OPERATE APPLIANCE.
(Continued from Page 46) 4. Adjust pilot flame. • To adjust the pilot flame, remove the cap screw from the pilot adjusting valve and turn to deliver a sufficient flame at the pilot burner to cover 3/8" to 1/2" (10-12mm) of the sensing probe tip. See fig. 42. The pilot flame should envelop 3/8 to 1/2 inch of the tip of the thermocouple. Remove pilot adjustment cover screw, fig. 43b. Turn inner adjustment screw or pilot adjusting valve clockwise to decrease, or counterclockwise to increase pilot flame.
PROTECTOR SWITCH CONTINUITY TEST Do not depress the protector switch reset button prior to testing. The leads from the switch are removed from the thermocouple function block and attached to the leads from a test flashlight. The model N22T test kit (combination flashlight and continuity tester) is manufactured by the RAY-O-Vac Company, Madison, WI and available through local suppliers. With the flashlight turned on, the lamp should light.
IMPORTANT • If lamp does not light when reset button is depressed, attach the test flashlight leads to the protector switch terminals. If lamp does not light, switch is defective and must be replaced. UNDER NO CIRCUMSTANCES SHOULD THE GAS INPUT EXCEED THE INPUT SHOWN ON THE BOILER MODEL AND RATING PLATE. OVERFIRING COULD RESULT IN DAMAGE OR SOOTING OF THE BOILER.
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. NORMAL OPERATING SEQUENCE WITH INTERMITTENT IGNITION CONTROLS (I.I.D.) 1. System control calls for boiler operation. 2. Spark begins at pilot burner. 3.
For proper performance mount the switch in a section of pipe where there is a straight run of at least 5 pipe diameters on each side of the flow switch (i.e. do not locate adjacent to valves, elbows, orifices, etc.). The flow switch shall be mounted in a standard 1-1/2" x 1-1/2" x 1" tee for a 1-1/2" pipe application. For larger pipe sizes use a reducing tee in order to keep the switch as close to the pipe as possible.
To adjust the flow rate setting: 1. Remove the flow switch cover. 2. For higher flow rate—turn the range adjusting screw clockwise. 3. For lower flow rate—turn the range adjusting screw counter-clockwise. Thermal expansion is the normal response of water when it is heated. In a closed system, thermal expansion will cause the system pressure to build until the relief valve actuation pressure is equaled. Then, the relief valve will open, allowing some water to escape, slightly lowering the pressure.
GENERAL MAINTENANCE More frequent inspections may be necessary depending on water conditions. These boilers are designed to give many years of efficient and satisfactory service when properly operated and maintained. To assure continued good performance, the following recommendations are made. The 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.
The time between cleaning will vary from two to six months depending upon water conditions and usage. A change of approximately 50F 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 “A” and “B” and the boiler, see fig. 51. 9.
— Gas supply pressure is within the maximum and minimum operating ranges listed on the appliance rating plate/label. PRE-TROUBLESHOOTING Before any extensive trouble-shooting, perform the following: Ensure That: — Voltage (24 vac) is supplied by transformer. — Appliance is wired according to wiring diagram. — Voltage (120 vac) is supplied to the appliance. Note: Cross wiring the 24 volt circuit of the relay will short the transformer. — System control (tank temperature control, thermostat, etc.
CHECKING HONEYWELL S-8600H OR 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 & 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.
CHECKING HONEYWELL S8600H OR S-8610M 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.
CHECKING HONEYWELL S-8600H OR S8610M INTERMITTENT IGNITION CONTROLS PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT Correct the situation by consulting the installation or user’s manual on how to adjust pilot flame. NO Does the pilot flame cover 3/8” to 1/2” of ingniter/sensor rod? YES Replace ignition module. NO NO Is voltage (24 Vac) across terminals MV & MV/PV? Does spark stay on for more than 15 seconds after the pilot is “proven” (lit)? YES Attach wires firmly.
CHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLS NO SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT Turn off gas supply. Fix connection and/or tighten module to the appliance NO Check the circuit providing 24 VAC. NO Is there a good connection between terminals? Is module securely attached to appliance for good ground connection? YES Is voltage (24VAC across transformer positive terminal and GND with "call for heat"?? YES NO Replace ignition module.
LIMITED WARRANTY A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this hydronic 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.
REPLACEMENT PARTS 5621 W. 115TH STREET, ALSIP, IL 60803 PHONE: 1-800-433-2545 FAX: 1-800-433-2515 E-MAIL: parts@hotwater.com • www.hotwater.