A.O. Smith HW 610 User Manual

PLACE THESE INSTRUCTIONS ADJACENT TO BOILER ANDNOTIFY OWNER TO KEEP FOR FUTURE REFERENCEPRINTED 0210 317693-000 GAS-FIRED COMMERCIAL COPPER BOILERS F

10 CAUTIONPaddle must be trimmed at the dotted arc. It must not touch the pipe or have any restriction when installed.FIGURE 6.To adjust the ow rat

11Code, 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 exceed

12Water TemperatureTime to Produce 2nd & 3rd Degree Burns on Adult SkinOVER: 170°F (77°C)160°F (71°C)150°F (65°C)140°F (60°C)130°F (54°C)120°F (49

13PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18 INCHES OR MORE ABOVE THE FLOOR. THIS MAY REDUCE THE RISK IF LOCATION IN SUCH AN A

14INSTALLATION CLEARANCESThese boilers are approved for installation on combustible ooring in an alcove with minimum clearance to combustibles of:TAB

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

164. MULTIPLE VENT TABLETable 5 on page 17 has been compiled to show the material sizes in a Type B doublewall combined vent system

17TABLE 5, COMBINED VENT SIZING TABLESMODEL HW-300 BOILERInput: 300,000 Btuh Draft Hood Outlet 8"Required Connector or Smoke Pipe DiameterConnect

181. CONVENTIONAL INSTALLATIONSAll modern hydronic type boilers are exceptionally fast heating units. The low water volumes in relation to ri

19NO. SUGGESTED ITEMS FOR INSTALLATION1Short pipe nipple and pair of boiler loop tees in piping between system supply and return. One set pe

2IMPORTANT DEFINITIONS• Qualied Installer: A qualied installer must have ability equivalent to a licensed tradesman in the elds of plumbing, air

20 5. VENT VALVESIt is recommended that automatic, loose key or screwdriver type vent valves be installed at each convector or radiator.6. MAN

21Use tab l e 7, or CA N / C S A B14 9 .1 (cur r e n t ed i t i o n) to size iro n pip e or equiva l e nt ga s supply li n e. T

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 e

23Adjustment, if required, is performed as follows:1. Set primary system temperature control dial (thermostat) at lowest setting so that boile

24120 VAC 60 HZL1 (HOT) L2 (NEUTRAL)L1 (HOT) L2 (NEUTRAL)120 VAC 60 HZ120V24VHIGH LIMITIGNITION MODULECHASSISGROUNDIGNITOR WIRE TOPILOTNOTE: IF R

252. LINEAR-TEMP INSTALLATIONSControl for these systems is decided mainly by the type of building system controlling that is desired. A single boiler

26NOTE:1. Building temperature controls supply electric power to building circulator.2. Main ow switch proves main water ow before energiz

27NOTE:1. Building temperature controls supply electric power to building circulator.2. Main ow switch proves main water ow before energizing

28CER-TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATIONCANADIAN MODELS, JUNCTION BOX W/6 TERMINALSFIGURE 21.FIGURE 23.CER-TEMP 80 - 1 U

29CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATIONCANADIAN MODELS, JUNCTION BOX W/6 TERMINALSFIGURE 24.

3GENERAL SAFETY

30SCHEMATICCANADIAN MODELS, JUNCTION BOX W/6 TERMINALSFIGURE 25.

31CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM (FOR HOT WATER SUPPLY APPLICATION)U.S. MODELS, JUNCTION BOX W/4 TERMINALSFIGURE 26.

32CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM (FOR HOT WATER SUPPLY APPLICATION)U.S. MODELS, JUNCTION BOX W/4 TERMINALSFIGURE 27.

33FIGURE 28.IMPORTANTTHE INSTALLATION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF WATER SERVICE INTERRUPTION OR CIRCUL

34FIGURE 29.ONE HW-300, HW-399, HW-420, HW-520, HW-610 OR ONE HW-670 UP-FLOW MODELCOMMERCIAL BOILER WITH HORIZONTAL TANKWIRING - FIGURES 16 and 17 on

35TWO HW-399's, HW-420's, HW-520's, HW-610's or HW-670's UP-FLOW MODELCOMMERCIAL BOILER WITH VERTICAL TANK, CER-TEMP 80IMPORT

36FIGURE 31.TWO HW-300's, HW-399's, HW-420's, HW-520's, HW-610's OR HW-670's UP-FLOW MODELCOMMERCIAL BOILER WITH HORIZO

37THREE HW-520's, HW-610's OR HW-670's UP-FLOW MODELCOMMERCIAL BOILER WITH VERTICAL TANK, CER-TEMP 80IMPORTANTTHE INSTALLATION OF SA

38THREE HW-520's, HW-610's OR HW-670's UP-FLOW MODELCOMMERCIAL BOILER WITH HORIZONTAL TANK, CER-TEMP 80IMPORTANTTHE INSTALLATION OF

39 WARNINGAfter placing boiler into operation, the ignition system safety shutoff device must be tested by the following test method.1. Reset High

4 SAFE INSTALLATION, USE AND SERVICE...

40 4. Reinstall the burner manifold assembly on boiler. 5. Restore electrical power and gas supply to boiler. • Put the boiler back in operation

41CHECKING AND ADJUSTING THE INPUT1. Follow steps 1 thru 6 of the OPERATING INSTRUCTIONS.2. Attach a pressure gauge or a manometer to the m

42STARTSTAGE 1TRIAL FORIGNITIONSTAGE 2MAIN BURNEROPERATIONENDTHERMOSTAT (CONTROLLER) CALLS FOR HEATSPARK GENERATOR POWEREDFirst valve (pilot) operator

43FOR YOUR SAFETY READ BEFORE LIGHTINGWARNING:FLAMMABLEIf you do not follow these instructions exactly, afire or explosion may result causing property

44FOR YOUR SAFETY READ BEFORE OPERATINGWARNING:FLAMMABLEIf you do not follow these instructions exactly, afire or explosion may result causing propert

45At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to th

46CLEANING AND FLUSHING INSTRUCTIONSINTERNAL CONTAMINANTSThe hydronic system must be internally cleaned and flushed after a new or replacement

47TROUBLESHOOTINGCER-TEMP 80 RECOVERY SYSTEM CHECKOUT PROCEDUREUse this checkout for Cer-Temp 80 Recovery Systems. (For hot water supply application o

48CHECKING HONEYWELL S-8600H OR S-8610MINTERMITTENT IGNITION CONTROLSTurn off gas supply.Is voltage (24 Vac) across the 24 V terminals on module durin

49CHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLS SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHTEnsure all manual shutoff valves a

5EXTRA OPENINGFOR THERMOMETERAND RELIEF VALVEHW-520, 610AND HW--670DIMENSIONS AND CAPACITY DATATABLE 1DIMENSIONS IN INCHESMODELSHW-300 HW-399 HW-420 H

50CHECKING HONEYWELL S-8600H OR S8610M INTERMITTENT IGNITION CONTROLSPILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHTDoes the pilot ame cover 3/8”

51CHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLS NO SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHTTurn off gas supply.Is there a

52The following procedures are provided as a general guide.Any module should be replaced if it does not perform properly on checkout or troubleshootin

53Table 12.Continuous Retry Models C, M, E, and K Only - Green LED Status CodesGreen LEDFlash Code (X+Y)aIndicates Next System Action Recommended Serv

54Table 13.Lockout Models B, H, D and J Only - Green LED Status CodesGreen LEDFlash Code (X+Y)aIndicates Next System Action Recommended Service Action

55A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this boiler.1. If within TEN years after initial ins

500 Tennessee Waltz Parkway, Ashland City, TN 37015Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306www.hotwater.com

6TABLE 2, RECOVERY CAPACITIESModelInput °F 20 40 50 60 70 80BTUH (kW) °C 11.1 22.2 27.7 33.3 38.8 44.4HW 300 300,000 (88)GPH 1439 719 576 480 411 360L

7INTRODUCTIONThis design complies with the current edition of the ANSI Z21.13 low-pressure boiler standard.Compliance under this standard impli

8HIGH ALTITUDE INSTALLATIONSIN CANADAAcceptance of these models for use at altitudes above 2000 feet (600 m) is based on eld test of the individua

9THERMAL BALANCERFigure 4 shows the internal wiring of the thermal balancer. The device may be tested after disconnecting the four leads from