A.O. Smith HW 300 Instruction Manual
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A.O. Smith HW 300 Instruction Manual

Gas fired commercial copper boilers for hydronic heating and hot water supply up - flow models
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See also: User Manual , Installation Operation & Maintenance
GAS FIRED COMMERCIAL COPPER BOILERS
25589, Highway 1
McBee, SC 29101
WARNING: If the information in these
instructions 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.
WHAT TO DO IF YOU SMELL GAS:
•
Do not try to light any appliance.
•
Do not touch any electrical switch; do
not use any phone in your building.
•
Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
•
If you cannot reach your gas supplier,
call the fire department.
Installation
performed by a
service agency or the gas supplier.
Thank you for buying this energy efficient boiler.
We appreciate your confidence in our products.
PRINTED 0213
H
and
service
must
qualified
installer,
MAINTENANCE - LIMITED WARRANTY
be
Instruction Manual
300, 399, 420, 520, 670
FOR HYDRONIC HEATING AND
HOT WATER SUPPLY
UP - FLOW MODELS
INSTALLATION - OPERATION
INDOOR ONLY
MODELS: HW
321078-002

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  • Page 1 Instruction Manual GAS FIRED COMMERCIAL COPPER BOILERS MODELS: HW 300, 399, 420, 520, 670 FOR HYDRONIC HEATING AND HOT WATER SUPPLY UP - FLOW MODELS 25589, Highway 1 McBee, SC 29101 INSTALLATION - OPERATION MAINTENANCE - LIMITED WARRANTY INDOOR ONLY WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS ................2 System Connections ................ 16 SAFE INSTALLATION, USE AND SERVICE.......... 3 Air Requirements ................16 GENERAL SAFETY................4 Unconfined Space ................16 INTRODUCTION ..................5 Fresh Air Openings for Confined Spaces ........17 Abbreviations Used ................

  • Page 3: Safe Installation, Use And Service

    SAFE INSTALLATION, USE AND SERVICE The proper installation, use and servicing of this boiler is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your boiler to warn you and others of a potential injury hazard.

  • Page 4: General Safety

    GENERAL SAFETY GROUNDING INSTRUCTIONS HIGH ALTITUDE INSTALLATIONS This boiler must be grounded in accordance with the National Electrical Code, Canadian Electrical Code and/or local codes. Boiler is polarity sensitive; correct wiring is imperative for proper operation. This boiler must be connected to a grounded metal, permanent wiring system, or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the boiler.

  • Page 5: Introduction

    INTRODUCTION This design complies with the current edition of the ANSI Z21.13 QUALIFICATIONS low-pressure boiler standard. QUALIFIED INSTALLER OR SERVICE AGENCY Compliance under this standard implies that when the boiler Installation and service of this boiler requires ability equivalent underwent test, the gas manifold and control assembly pro vided to that of a Qualified Agency, as defined by ANSI below.

  • Page 6: Dimensions And Capacity Data

    RISE MODELS INPUT RATING BTU/HR OUTPUT RATING BTU/HR PD-FT PD-FT PD-FT NATURAL & PROPANE (LP) GAS NATURAL & PROPANE (LP) GAS HEAD HEAD HEAD HW 300 300,000 240,000 HW 399 399,000 319,200 HW 420 420,000 336,000 HW 520 520,000 416,000...
  • Page 7 TABLE 3. RECOVERY CAPACITIES INPUT °F TYPE OF MODELS BTU/HR °C (11) (22) (28) (33) (39) (44) Natural 1,455 HW 300 300,000 Propane 5,506 2,753 2,202 1,835 1,573 1,377 Natural 1,935 HW 399 399,000 Propane 7,323 3,662 2,929 2,441 2,092...

  • Page 8: Control Components

    CONTROL COMPONENTS FIGURE 2. COMPONENT LOCATIONS...
  • Page 9 THERMAL BALANCER AUTO RESET HIGH LIMIT Figure 5 shows the internal wiring of the thermal balancer. The The high limit is a safety device wired in series with the ignition device may be tested after disconnecting the four leads from system.
  • Page 10 PRESSURE RELIEF VALVE If any pressure relief valve is replaced, the replacement valve must comply with the current editions of the ASME Boiler and Pressure Vessel Code, Section IV or CSA B51, as applicable. An ASME rated pressure relief valve is furnished with the boiler. Select a pressure relief valve with a discharge NOT less than the A fitting for the pressure relief valve is provided in the top of the boiler input, and a pressure rating NOT exceeding the working...
  • Page 11 USE ANTI-SCALD VALVE(S) in the hot water system to reduce TANK TEMPERATURE CONTROL the risks of scalds at points of use such as lavatories, sinks and bathing facilities. The water temperature in the storage tank is controlled by the Tank Temperature Control. The sensing element is mounted A change in water temperature in the storage tank lower than the inside the hot water storage tank.

  • Page 12: Boiler Installation Considerations

    BOILER INSTALLATION CONSIDERATIONS HYDRONIC SYSTEM Pipe sizing and boiler loop pump selection data are shown in Table 8 for several different temperature rises across the boilers. All modern hydronic type boilers are exceptionally fast heating units. The low water volumes in relation to firing rates require TABLE 8.

  • Page 13: Closed Water Systems

    CLOSED WATER SYSTEMS COOLING PIPING When the boiler is used in conjunction with a refrigeration system Water supply systems may, because of code requirements it must be installed so that the chilled medium is piped in parallel or such conditions as high line pressure, among others, have with the boiler with appropriate valves to prevent the chilled installed devices such as pressure reducing valves, check medium from entering the boiler, see Figure 7.
  • Page 14 FLOW SWITCH TABLE 9. FLOW SWITCH Minimum Pipe Rate The flow switch is a safety device which must be installed at the Contacts Closed Contacts Open water outlet of the unit to prevent main burner operation in the (Flow) (No Flow) Model Number event of inadequate water flow through the unit.

  • Page 15: General Requirements

    GENERAL REQUIREMENTS REQUIRED ABILITY REPLACING ExISTING COMMON VENTED BOILER Installation or service of this boiler requires ability equivalent When an existing boiler is removed from a common venting to that of a qualified service technician in the field involved. system, the common venting system is likely to be too large Plumbing, air supply, venting, gas supply, and electrical work are for proper venting of the appliances remaining connected to it.

  • Page 16: Chemical Vapor Corrosion

    CHEMICAL VAPOR CORROSION AIR REQUIREMENTS Boiler corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors. Spray can propellants, cleaning sol vents, refrigerator and air conditioning refrig erants, swimming pool chemicals, calcium and sodium Breathing Hazard - Carbon Monoxide Gas chloride (water softener salt), waxes, and process chemicals are typical compounds which are potentially corrosive.

  • Page 17: Fresh Air Openings For Confined Spaces

    CONFINED SPACE OUTDOOR AIR THROUGH TWO OPENINGS A confined space is one whose volume is less than 50 cubic feet per 1,000 Btu/hr (4.8 cubic meters per kW) of the total input rating of all appliances installed in the space. Openings must be installed to provide fresh air for combustion, ventilation and dilution in confined spaces.
  • Page 18 OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS The confined space shall be provided with two permanent vertical ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure.
  • Page 19 GAS CONNECTIONS Fittings and unions in gas line must be of metal to metal type. Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compound to the first two threads. Use compounds resistant to the action of liquefied petroleum gases.

  • Page 21: Venting

    VENTING STANDARD VENTING FIGURE 15. VENT PIPE INSTALLATION Where a continuous or intermittent back draft is found to exist the Type B venting may be used with these boilers. All local utility cause must be determined and corrected. A special vent cap may regulations on venting should be followed.

  • Page 22: Sidewall Venting

    Test for spillage at the draft hood relief opening after five minutes SIDEWALL VENTING of main burner operation. Use the flame of a match or candle. The optional sidewall power vent system is certified for maximum After it has been determined that each appliance remaining 100' equivalent venting.
  • Page 23 TABLE 14. COMBINED VENT SIZING TABLES MODEL HW-300 BOILER MODEL HW-520 BOILER Input: 300,000 Btuh Draft Hood Outlet 8" Input: 520,000 Btuh Draft Hood Outlet 10" Required Connector or Smoke Pipe Diameter Required Connector or Smoke Pipe Diameter Total Vent Height (Measured in Feet Above Draft Hood) Total Vent Height (Measured in Feet Above Draft Hood) Connector Connector...

  • Page 24: Gas Supply Connections

    GAS SUPPLY CONNECTIONS GAS SUPPLY PIPE CONNECTIONS When installing multiple boilers in the same gas supply system it is recommended that individual positive lock-up Make sure to install ground joint union for servicing. gas pressure regulators be installed at each unit. In Canada –...

  • Page 25: Gas Manifold Pressure Regulators

    GAS MANIFOLD PRESSURE REGULATORS Adjustment, if required, is performed as follows: 1. Set primary system temperature control dial (thermostat) at The gas manifold pressure regulator is included in the lowest setting so that boiler will not call for heat. combination gas control valve, Figure 18, and is set to operate 2.

  • Page 26: Boiler Start Up And Operations

    BOILER START UP AND OPERATIONS PILOT AND MAIN BURNER After placing the boiler into operation, the ignition system safety shutoff device must be tested by the following test method. To maintain safe operation of the boiler, check the pilot and 1.
  • Page 27 2. PILOT BURNER - ELECTRONIC IGNITION Check for electrical power to the valve. If electrical power and gas are present at the valve and the pilot does not operate when To establish pilot flame without main burner operation, it will be system calls for heat, replace valve.

  • Page 28: Checking And Adjusting Input

    CHECKING AND ADJUSTING INPUT 6. Remove the pressure gauge or manometer from the manifold pressure tapping. Replace the screw-in plug in the manifold pressure tap. 7. Repeat steps 7 thru 11 of the OPERATING INSTRUCTIONS on Page 31. The boiler will resume normal operation. Fire and Explosion Hazard When the boiler is operating at full capacity, or full gas input, Under no circumstances should the...
  • Page 29 START THERMOSTAT (CONTROLLER) CALLS FOR HEAT STAGE 1 SPARK GENERATOR POWERED TRIAL FOR First valve (pilot) operator opens IGNITION PILOT BURNER OPERATION Pilot burner lights. Pilot burner does not light Module senses Module Response flame current. S-8600M After 15 sec. ignition shut-down.
  • Page 30 LIGHTING AND OPERATING INSTRUCTIONS (NATURAL AND PROPANE FOR HW300 - HW399)
  • Page 31 LIGHTING AND OPERATING INSTRUCTIONS (NATURAL AND PROPANE WITH I.I.D. FOR HW420 & UP)

  • Page 32: Troubleshooting

    TROUBLESHOOTING Before any extensive troubleshooting, perform the following: • Voltage (24 vac) is supplied by transformer. • Boiler is wired according to wiring diagram. Ensure that: Note: Cross wiring the 24 volt circuit of the relay will short the • Voltage (120 vac) is supplied to the boiler. transformer.
  • Page 33 CHECKING HONEYWELL S-8600H OR S-8600M INTERMITTENT IGNITION CONTROLS NO SPARK AT PILOT BURNER Turn off gas supply. Is voltage (24 Vac) across the 24 V terminals Replace ignition module. on module during “Call for heat”? Is voltage (24 Vac) across the PV & MV/PV terminals on “call for heat”? NOTE: S-8600M will automatically reset every 5 minutes.
  • Page 34 CHECKING HONEYWELL S-8600H OR S-8600M 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;...
  • Page 35 CHECKING HONEYWELL S-8600H OR S-8600M INTERMITTENT IGNITION CONTROLS PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT Correct the situation by consulting the Does the pilot flame cover 3/8” to 1/2” installation or user’s manual on how to of igniter/sensor rod? adjust pilot flame.
  • Page 36 CHECKING HONEYWELL S8600H OR S-8600M INTERMITTENT IGNITION CONTROLS NO SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT Turn off gas supply. Fix connection and/or Is there a good connection between terminals? tighten module to the Is module securely attached to boiler for good ground boiler.
  • Page 37 The following procedures are provided as a general guide. TABLE 18. YELLOW LED FLAME CODES Any module should be replaced if it does not perform properly on YELLOW LED RECOMMENDED INDICATES checkout or troubleshooting. FLASH CODE SERVICE ACTION In addition, replace any module if it is wet or looks like it has ever Heartbeat Normal Flame Signal not applicable...
  • Page 38 TABLE 19. CONTINUOUS RETRY MODELS C, M, E AND K ONLY - GREEN LED STATUS CODES GREEN LED RECOMMENDED SERVICE FLASH CODE INDICATES NExT SYSTEM ACTION ACTION (x+Y) No "Call for Heat" not applicable none Flash Fast Startup - Flame sense calibration not applicable none Heartbeat...
  • Page 39 TABLE 20. LOCKOUT MODELS B, H, D AND J ONLY - GREEN LED STATUS CODES GREEN LED RECOMMENDED SERVICE FLASH CODE INDICATES NExT SYSTEM ACTION ACTION (x+Y) No "Call for Heat" not applicable none Flash Fast Startup - Flame sense calibration not applicable none Heartbeat...

  • Page 40: General Maintenance

    GENERAL MAINTENANCE These boilers are designed to give many years of efficient and satisfactory service when properly operated and maintained. assure continued good performance, following recommendations are made. The area around the boiler should be kept clean and free from lint and debris.

  • Page 41: Venting Maintenance

    VENTING MAINTENANCE It is recommended that the heating surfaces and vent piping of the boiler be checked every six months for dust, deterioration and carbon deposits. Remove all soot or other obstructions from chimney and flue which will retard free draft. Replace any damaged or deteriorated parts of the venting system.

  • Page 42: Wiring

    WIRING WIRING CONNECTIONS The electrical connections must be made so that the circulating pump will operate before the gas control valve opens. At no time may the controlling system allow the burner to fire when there is no water flow through the boilers. Refer to the diagram in Figure 24 on Pages 43 for proper wiring sequence with conventional single boiler installations.

  • Page 43: Connection Diagram

    CONNECTION DIAGRAM 120 VAC 60 HZ L1 (HOT) L2 (NEUTRAL) 4 X 4 JUNCTION BOX WITH TERMINAL STRIP IGNITION CONTROL WHITE MODULE VALVE ** FUSED THERMAL BROWN DISCONNECT BALANCER SWITCH WHITE MV/PV MV/PV YELLOW TRANSFORMER 120/24V ** WATER PUMP WHITE 24V GND HIGH LIMIT...
  • Page 44 FIGURE 25. CER - TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION FIGURE 26. SCHEMATIC: CER - TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION...
  • Page 45 FIGURE 27. CER - TEMP 80 - 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM - FOR HOT WATER SUPPLY APPLICATION...
  • Page 46 FIGURE 28. CER - TEMP 80 - 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM - FOR HOT WATER SUPPLY APPLICATION...

  • Page 47: Piping Diagrams

    PIPING DIAGRAMS STORAGE TANK...
  • Page 49 STORAGE TANK...
  • Page 51 STORAGE TANK...
  • Page 59 STORAGE TANK...
  • Page 60 STORAGE TANK...

  • Page 61: Limited Warranty

    LIMITED WARRANTY 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 or gas burner should 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.
  • Page 62 25589 Highway 1, McBee, SC 29101 Technical Support: 800-527-1953 • Parts: 800-433-2545 • Fax: 800-644-9306 www.hotwater.com...

This manual is also suitable for:

Hw 399Hw 420Hw 520Hw 670

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