Page 4 - CAUTION; FOREWORD; TABLE OF CONTENTS; INSTALLATION INSTRUCTIONS; REQUIRED ABILITY
4 4 4 4 4 CAUTION TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVETO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE USINGAPPLIANCE. Detailed installation diagrams are in this manual. These diagrams will serveto provide the installer with a reference for the materials and method ofpiping sug...
Page 5 - LOCATION; THE BOILER MUST NOT BE INSTALLED ON CARPETING.; AIR REQUIREMENTS; WARNING; / K W ) u p t o a n d i n c l u d i n g
5 5 5 5 5 LOCATION When installing the boiler, consideration must be given to properlocation. Location selected should be as close to the stack orchimney as practicable with adequate air supply and as centralizedwith the piping system as possible. This location should also besuch that the gas igniti...
Page 6 - CHEMICAL VAPOR CORROSION; INSTALLATION CLEARANCES; TABLE 4; TOP; LEVELLING; A TYPICAL BOILER INSTALLATION
6 6 6 6 6 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 INTOT H E R O O M T H R O U G H T H E C H I M N E Y, C A U S I N G P O O RCOMBUSTION. SOOTING MAY RESULT WITH AN INCREA...
Page 8 - SUGGESTED ITEMS FOR INSTALLATION; BOILER INLET - OUTLET SIZES; SCHEMATIC OF THE LINEAR-TEMP
8 8 8 8 8 NO. SUGGESTED ITEMS FOR INSTALLATION 1 Short pipe nipple and pair of boiler loop tees in pipingbetween system supply and return. One set per eachgroup of boilers 2 Boiler pipe loop. See piping sizing data above. 3 Boiler circulator. See pump sizing data above. 4 Thermometer. 5 Theraltimete...
Page 9 - SCHEMATIC SHOWING PROPER PIPING ISOLATION; CIRCULATING PUMP; A TYPICAL CIRCULATING PUMP; GAS CONNECTIONS
9 9 9 9 9 Excessive pressure may develop causing premature tank failureor intermittent relief valve operation. This is not a warranty failure.An expansion tank or a similar device may be required in the inletsupply line between the appliance and the meter or valve tocompensate for the thermal expans...
Page 10 - A. SIZING GAS SUPPLY LINE (For single boiler installations and; TABLE 6; B. SIZING GAS SUPPLY LINE (For multiples of over three boilers; PURGING; CORRECT GAS
10 10 10 10 10 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 sizeiron pipe or equivalent gas supply line. Table 6 is based on apressure drop of 0.3 inc...
Page 11 - GAS PRESSURE REGULATORS
11 11 11 11 11 • In table 6, select the row showing the distance to the mostremote outlet or the next longer distance if the table does notgive the exact length. This is the only distance used indetermining the size of any section of gas piping. If the gravityfactor is to be applied, the values in t...
Page 12 - VENTING THE BOILER - STANDARD VENTING; FIGURE 6; DRAFT HOOD; VENT PIPE INSTALLATION
12 12 12 12 12 7. Set primary system temperature control dial (thermostat) todesired setting. WARNING DO NOT INCREASE GAS PRESSURE ABOVE THAT SPECIFIEDON THE RATING PLATE, AS OVERFIRING WILL RESULT INDAMAGE TO THE BOILER, AS WELL AS INCREASED RISK OFFIRE, SOOTING AND ASPHYXIATION. If gas pressure re...
Page 13 - MULTIPLE VENT TABLE; FIGURE 8; CONNECTING BOILER TO A COMMON VENT
13 13 13 13 13 After it has been determined that each appliance remainingconnected to the common venting system properly vents whentested as outlined above, return doors, windows, exhaust fans,fireplace dampers and any other gas burning appliance to theirprevious conditions of use. Any improper oper...
Page 14 - TABLE 9, COMBINED VENT SIZING TABLES
14 14 14 14 14 MODEL HW/HWB-610 BOILER Input: 610,000 Btuh Draft Hood Outlet 12" 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 16 14 14 14 14 14 14 14 14 2 14 14 1...
Page 15 - VENTING MAINTENANCE - STANDARD VENTING; VENTING SYSTEM; FIGURE 9; SAFETY RELIEF VALVES
15 15 15 15 15 VENTING MAINTENANCE - STANDARD VENTING It is recommended that the heating surfaces and vent piping ofthe appliance be checked every six months for dust, deteriorationand carbon deposits. Remove all soot or other obstructions fromchimney and flue which will retard free draft. Replace a...
Page 16 - WIRING CONNECTIONS
16 16 16 16 16 The storage tank temperature and pressure (T & P) relief valvemust comply with the applicable construction provisions of theStandard for Relief Valves and Automatic Gas Shutoff Devices forHot Water Supply Systems, Z21.22 and/or CAN1-4.4. The T & Pvalve must be of the automatic...
Page 19 - SINGLE STAGE PROPANE ROBERTSHAW GAS VALVE
19 19 19 19 19 SINGLE STAGE PROPANE ROBERTSHAW GAS VALVE 24 VOLT - HWB, HW-300, 399 CANADIAN MODELS FIGURE 11A CONNECTION DIAGRAM HWB & HW 300, 399 (PROPANE GAS) FIGURE 13
Page 22 - LINEAR-TEMP INSTALLATIONS; INSTALLATION FOR CANADIAN MODELS
22 22 22 22 22 2. LINEAR-TEMP INSTALLATIONS Control for these systems is decided mainly by the type of buildingsystem controlling that is desired. A single boiler installation mightbe controlled directly from space temperature thermostat(s).Multiple boiler installations are more effective when the b...
Page 25 - - FOR HOT WATER SUPPLY APPLICATION; CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS; FOR HOT WATER SUPPLY APPLICATION
25 25 25 25 25 CER-TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 17 FIGURE 19 CER-TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION U.S. MODELS, JUCNTION BOX W/4 TERMINALS FIGURE 18
Page 27 - SCHEMATIC
27 27 27 27 27 FIGURE 21 SCHEMATIC CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS
Page 28 - CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM
28 28 28 28 28 CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM (FOR HOT WATER SUPPLY APPLICATION) U.S. MODELS, JUNCTION BOX W/4 TERMINALS FIGURE 22
Page 29 - CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM
29 29 29 29 29 CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM (FOR HOT WATER SUPPLY APPLICATION) U.S. MODELS, JUNCTION BOX W/4 TERMINALS FIGURE 23
Page 30 - BOOSTER - RECOVERY WIRING DIAGRAM; SHURE-TEMP BOOSTER - RECOVERY WIRING DIAGRAM
30 30 30 30 30 FIGURE 24 BOOSTER - RECOVERY WIRING DIAGRAM CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS SHURE-TEMP BOOSTER - RECOVERY WIRING DIAGRAM (TWO TEMPERATURE SYSTEM) CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 25
Page 32 - DANGER; Some states; DETAIL OF TANK FITTING USED WITH MODIFIED RECOVERY
32 32 32 32 32 WATER LINE CONNECTIONS This section provides detailed installation diagrams for typicalmethods of application for the unit using a Cer-Temp 80 RecoverySystem (for one temperature water), and either Booster-Recoveryor the Shure-Temp Booster-Recovery System (for two temperaturewater). T...
Page 33 - LOW WATER CUTOFF
33 33 33 33 33 USE ANTI-SCALD VALVE(S) in the hot water system to reduce therisks of scalds at points of use such as lavatories, sinks andbathing facilities. A change in water temperature in the storage tank lower than theTank Temperature Control setting will cause the sensor to closeits contacts an...
Page 34 - *Assumes 50 equivalent feet pf piping or less.
34 34 34 34 34 FIGURE 29 IMPORTANTTHE INSTALLATION OF SAFETY FLOW SWITCH AS SHOWNIS REQUIRED TO PROTECT THE BOILER IN CASE OF WATERSERVICE INTERRUPTION OR CIRCULATOR FAILURE (A.O.SMITH PKG. NO. 211480). + PIPING AND FITTINGS BETWEEN GATE VALVES ANDBOILERS SHOULD BE BRASS OR BRONZE. OTHERPIPING SHOUL...
Page 40 - TWO TEMPERATURE SYSTEM WITHOUT RECIRCULATION
40 40 40 40 40 FIGURE 35 WIRING - FIGURE 25 OR 27 INSTALL IN ACCORDANCE WITH ALL LOCAL CODES 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 + PIPING AND FITTINGS B...
Page 43 - INSTRUCTIONS FOR NUMBERED CONTROLS SHOWN ABOVE -
43 43 43 43 43 4 FLOW REGULATING PLUG COCK (For Boiler Flow Rate Adjustment) A slight closing of this valve may be necessary to set properwater flow rate for 40°F temperature rise through the boiler.Temperature rise is observed between the boiler inlet andoutlet thermometers. 5 FLOW REGULATING PLUG ...
Page 45 - START-UP AND OPERATING INSTRUCTIONS
45 45 45 45 45 TWO HORIZONTAL TANK INSTALLATION THREE HORIZONTAL TANK INSTALLATION FIGURE 40 DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFEU S E T E M P E R AT U R E AT F I X T U R E S . S E E TA N KTEMPERATURE CONTROL WARNING ON PAGE 32. IFHIGHER PREHEAT TEMPERATURES ARE NECESSARYTO OBTAIN ADEQU...
Page 46 - IMPORTANT; FILLING AND VENTING; PILOT AND MAIN BURNER
46 46 46 46 46 IMPORTANT IT IS RECOMMENDED THAT A QUALIFIED PERSON PERFORMTHE INITIAL FIRING OF THE BOILER. AT THIS TIME THE USERS H O U L D N O T H E S I TAT E TO A S K T H E I N D I V I D U A L A N YQ U E S T I O N S W H I C H H E M AY H AV E I N R E G A R D TO T H EOPERATION AND MAINTENANCE OF TH...
Page 47 - HOT WATER CAN PRODUCE 3rd DEGREE; : I F Y O U D O N O T F O L L O W T H E S E I N S T R U C T I O N S; FOR YOUR SAFETY READ BEFORE OPERATING
47 47 47 47 47 LIGHTING AND OPERATING INSTRUCTIONS (NATURAL AND PROPANE GAS WITH I.I.D.) WARNING: HOT WATER CAN PRODUCE 3rd DEGREE BURNS IN 6 SECONDS AT 140° F. (60° C). IN CASE OF POWER FAILURE DO NOT ATTEMPT TOOPERATE APPLIANCE. IMPROPER INSTALLATION,ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCEC...
Page 48 - WA R N I N G : I F Y O U D O N O T F O L L O W T H E S E I N S T R U C T I O N S; FOR YOUR SAFETY READ BEFORE LIGHTING
48 48 48 48 48 LIGHTING AND OPERATING INSTRUCTIONS PROPANE (LP) STANDING PILOT MODELS WA R N I N G : HOT WATER CAN PRODUCE 3rd DEGREE BURNS IN 6 SECONDS AT 140° F. (60° C). IN CASE OF POWER FAILURE DO NOT ATTEMPT TO OPERATEA P P L I A N C E . I M P R O P E R I N S TA L L AT I O N , A D J U S T M E N...
Page 49 - CLOSED CIRCUIT TEST
49 49 49 49 49 4. Adjust pilot flame. To adjust the pilot flame, remove the cap screw from thepilot adjusting valve and turn to deliver a sufficient flameat the pilot burner to cover 3/8" to 1/2" (10-12mm) of thesensing probe tip. See fig. 42. FIGURE 42 If the pilot burner ignites but the ma...
Page 50 - PROTECTOR SWITCH CONTINUITY TEST; Protector switch contacts open.
50 50 50 50 50 FIGURE 43D The purpose of checking the current ahead and after the protectorswitch is to measure the millivolt drop across the contacts. Thisdrop should be between 4 and 6 millivolts. PROTECTOR SWITCH CONTINUITY TEST Do not depress the protector switch reset button prior to testing.Th...
Page 51 - CONTROL SETTINGS; The high limit is a safety device; ELECTRONIC INTERMITTENT PILOT
51 51 51 51 51 • 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. • If lamp does light, the leads are bad and must be repaired or replaced. CHECKING AND ADJUSTI...
Page 52 - IN CANADA; THERMAL BALANCER
52 52 52 52 52 NORMAL OPERATING SEQUENCE WITH INTERMITTENT IGNITION CONTROLS (I.I.D.) 1. System control calls for boiler operation. 2. Spark begins at pilot burner. 3. Pilot gas control valve is energized. Gas flows to pilot burner. 4. Pilot burner gas ignites. The sensing probe on the pilot burners...
Page 54 - SAFETY RELIEF VALVE MAINTENANCE; REPLACEMENT PARTS; the complete model and serial; REMOVAL OF EXISTING BOILER FROM A COMMON VENTING SYSTEM
54 54 54 54 54 To adjust the flow rate setting: 1. Remove the flow switch cover. 2. For higher flow rate—turn the range adjusting screw clockwise. 3. F o r l o w e r f l o w r a t e — t u r n t h e r a n g e a d j u s t i n g s c r e wcounter-clockwise. CAUTION The switch is factory set at approxima...
Page 55 - GENERAL MAINTENANCE; RELIEF VALVE; CLEANING AND FLUSHING INSTRUCTIONS; HOT WATER SUPPLY BOILERS
55 55 55 55 55 GENERAL MAINTENANCE These boilers are designed to give many years of efficient andsatisfactory service when properly operated and maintained. Toa s s u r e c o n t i n u e d g o o d p e r f o r m a n c e , t h e f o l l o w i n grecommendations are made. The area around the unit shoul...
Page 56 - DELIMING SOLVENTS; HEAVY LIME DEPOSITS
56 56 56 56 56 The time between cleaning will vary from two to six monthsdepending upon water conditions and usage. A change ofapproximately 5 0 F in the normal temperature rise through the boiler is usually an indication that scale should be removed. For longlife, copper or brass is recommended for...
Page 57 - TROUBLESHOOTING; CER-TEMP 80 RECOVERY SYSTEM CHECKOUT PROCEDURE
57 57 57 57 57 TROUBLESHOOTING 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 Contact Incorrect Cause Remedy Set tank temperature Circulating pump Pump and burner Tank tempe...
Page 62 - LIMITED WARRANTY
62 62 62 62 62 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 ...