A.O. Smith HW 300 Installation & Operation Manual
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A.O. Smith HW 300 Installation & Operation Manual

Gas-fired commercial copper boilers for hydronic heating and hot water supply up-flow models
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See also: Instruction Manual , User Manual
MODELS HW 300, 399, 420, 520, 610, 670
GAS-FIRED COMMERCIAL COPPER BOILERS FOR
HYDRONIC HEATING AND HOT WATER SUPPLY
• INSTALLATION • OPERATION • MAINTENANCE • LIMITED WARRANTY
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.
— 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 and service must be
performed by a qualified installer,
service agency or the gas supplier.
PRINTED 0210
UP-FLOW MODELS
• INDOOR ONLY
PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND
NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE
500 Tennessee Waltz Parkway
Ashland City, TN 37015
www.hotwater.com
317693-000

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  • Page 1 MODELS HW 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.

  • Page 2: Safe Installation, Use And Service

    SAFE INSTALLATION, USE AND SERVICE The proper installation, use and servicing of this water heater 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 own water heater to warn you and others of a potential injury hazard.

  • Page 3: General Safety

    GENERAL SAFETY...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE..................................2 GENERAL SAFETY..........................................3 TABLE OF CONTENTS .......................................... 4 DIMENSIONS AND CAPACITY DATA ....................................5 INTRODUCTION ............................................ 7 Grounding Instructions ........................................7 Correct Gas ............................................ 7 Precautions ............................................ 7 Liquid Petroleum Gas Models ......................................7 High Altitude Installations .......................................

  • Page 5: Dimensions And Capacity Data

    DIMENSIONS AND CAPACITY DATA EXTRA OPENING FOR THERMOMETER AND RELIEF VALVE HW-520, 610 AND HW--670 TABLE 1 MODELS DIMENSIONS IN INCHES PROPANE NATURAL HW-300 HW-399 HW-420 HW-520 HW-610/670 HW-610/670 Overall height 65 (1651) 57-1/8 (1451) 57-1/8 (1451) 68-5/16 (1735) 67 (1702) 64-3/4 (1645) Height to Top of Jacket 43-1/4 (1099)
  • Page 6 TABLE 2, RECOVERY CAPACITIES Input °F Model BTUH (kW) °C 11.1 22.2 27.7 33.3 38.8 44.4 1439 HW 300 300,000 (88) 5448 2724 2179 1816 1556 1362 1914 HW 399 399,000 (117) 7245 3623 2898 2415 2070 1811 2014 1007 HW 420 420,000 (123) 7627...

  • Page 7: Introduction

    INTRODUCTION This design complies with the current edition of the ANSI Z21.13 IF THE BOILER HAS BEEN EXPOSED TO FLOODING, IT low-pressure boiler standard. MUST BE REPLACED. Compliance under this standard implies that when the boiler LIQUEFIED PETROLEUM GAS MODELS underwent test, the gas manifold and control assembly pro vided on the boiler met safe lighting and other performance criteria.

  • Page 8: Controls And Function

    HIGH ALTITUDE INSTALLATIONS Ratings specified by manufacturers for most boilers apply for elevations up to 2000 feet (600 m). For elevations above 2000 feet IN CANADA (600 m) ratings must be reduced by a rate of 4% for each 1000 feet (300 m) above sea level.

  • Page 9: Thermal Balancer

    THERMAL BALANCER Figure 4 shows the internal wiring of the thermal balancer. The device may be tested after disconnecting the four leads from their respective terminals on the unit. 1. Apply a test light to the yellow and red leads. •...

  • Page 10: Safety Relief Valves

    To adjust the flow rate setting: CAUTION The switch is factory set at approximately the minimum flow rate, see 1. Remove the flow switch cover. Table 3 on page 9. It must not be set lower than the factory setting as this may result in the switch failing to return at 'no flow' condition.

  • Page 11: Tank Temperature Control

    Code, Section IV or CSA B51, as applicable. Select a relief valve with TANK TEMPERATURE CONTROL a discharge NOT less than the boiler input, and a pressure rating NOT exceeding the working pressure of any component in the system. The water temperature in the storage tank is controlled by the Tank Temperature Control.

  • Page 12: Thermometers (Not Installed)

    THERMOMETERS Time to Produce 2nd & 3rd Water Temperature Degree Burns on Adult Skin Thermometers should be obtained and field installed as shown in the installation diagrams. OVER: 170°F (77°C) Nearly Instantaneous 160°F (71°C) About 1/2 second Thermometers are installed in the system as a means 150°F (65°C) About 1-1/2 seconds of detecting a possible liming condition in the boiler.

  • Page 13: Air Requirements

    PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED If the confined space is within a building of tight construction, 18 INCHES OR MORE ABOVE THE FLOOR. THIS MAY air for combustion, ventilation, and draft hood dilution must be REDUCE THE RISK IF LOCATION IN SUCH AN AREA CANNOT obtained from outdoors.

  • Page 14: Installation Clearances

    INSTALLATION CLEARANCES Sufficient area should be provided at the front and rear of the unit for proper servicing. Clearances of 24 inches (609.4mm) in the rear and 48 inches (1,219mm) in the front are required by code. These boilers are approved for installation on combustible flooring In a utility room installation, the door shall be wide enough to allow in an alcove with minimum clearance to combustibles of: the boiler to enter or to permit the replacement of another appliance...
  • Page 15 Building materials must not come in contact with combustion Vent connectors serving appliances vented by natural draft shall not products from stack or chimney, due to the degradating properties be connected into any portion of mechanical draft systems operating of flue products. under positive pressure.

  • Page 16: Venting Maintenance

    4. MULTIPLE VENT TABLE 1. Turn off the electrical power (main manual gas shutoff and pilot valves, if applicable). Table 5 on page 17 has been compiled to show the material sizes in a Type B doublewall combined vent system. Refer to Allow boiler parts and vent to cool before disassembly.

  • Page 17: Venting Tables

    TABLE 5, COMBINED VENT SIZING TABLES MODEL HW-610 BOILER MODEL HW-300 BOILER Input: 610,000 Btuh Draft Hood Outlet 12" Input: 300,000 Btuh Draft Hood Outlet 8" 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 18: System Installations

    SYSTEM INSTALLATIONS 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.

  • Page 19: Water Supply Line

    SUGGESTED ITEMS FOR INSTALLATION Short pipe nipple and pair of boiler loop tees in piping between system supply and return. One set per each group of boilers. Boiler pipe loop. See piping sizing data. Boiler circulator. See pump sizing data. Thermometer.

  • Page 20: Vent Valves

    5. VENT VALVES If the boiler is connected to chilled water piping or its heating coils are exposed to refrigerated air, the boiler piping system must be It is recommended that automatic, loose key or screwdriver type equipped with flow valves or other automatic means to prevent gravity vent valves be installed at each convector or radiator.

  • Page 21: Gas Supply Line Purging And Sizing

    TO TRAP ANY DIRT OR FOREIGN MATERIAL IN THE GAS U s e t a b l e 7, o r C A N / C S A B14 9 .1 (c u r r e n t e d i t i o n) t o SUPPLY LINE, A DIRT LEG (SOMETIMES CALLED DRIP s i ze i r o n p i p e o r e q u i va l e n t g a s s u p p l y l i n e.

  • Page 22: Gas Pressure Regulators

    • In table 7 on page 21, select the row showing the distance to TABLE 8. the most remote outlet or the next longer distance if the table MULTIPLIERS TO BE USED WITH TABLE 7 WHEN APPLYING does not give the exact length. This is the only distance used in THE GRAVITY FACTOR TO OTHER THAN .60 SPECIFIC GRAVITY determining the size of any section of gas piping.

  • Page 23: Wiring

    Adjustment, if required, is performed as follows: 5. Set primary system temperature control dial (thermostat) to lowest setting. Set primary system temperature control dial (thermostat) at lowest setting so that boiler will not call for heat. 6. Remove pressure gauge and replace sealing plug. Attach a pressure gauge to the tapping in the control string 7.

  • Page 24: Wiring Diagrams

    HW 300 TO 670 I.I.D. SYSTEM CONNECTION DIAGRAM 120 VAC 60 HZ L1 (HOT) L2 (NEUTRAL) 4 X 4 JUNCTION BOX WITH TERMINAL STRIP IGNITION WHITE MODULE GAS VALVE ** FUSED THERMAL BROWN DISCONNECT BALANCER SWITCH WHITE MV/PV MV/PV YELLOW TRANSFORMER 120/24V ** WATER PUMP...
  • Page 25 TYPICAL WIRING DIAGRAM (IID SYSTEM) FOR SINGLE BOILER LINEAR-TEMP INSTALLATION ® FIGURE 17. LINEAR-TEMP INSTALLATIONS building is not under control of space temperature thermostats. A single bulb outdoor sensing control will prevent overheating of halls, Control for these systems is decided mainly by the type of building stairways or other uncontrolled areas.
  • Page 26 NOTE: Outdoor thermostat required if building controls do not provide Building temperature controls supply electric power to building automatic shutdown of reset controls during warm weather. circulator. Boilers and Secondary Circulator are Controlled by Main flow switch proves main water flow before energizing •...
  • Page 27 NOTE: Building temperature controls supply electric power to building circulator. Main flow switch proves main water flow before energizing sequencing and resetting controls. Outdoor thermostat required if building controls do not provide automatic shutdown of reset controls during warm weather. Boilers and Secondary Circulator are Controlled by Dual Bulb, Dual Switch Controller...
  • Page 28 CER-TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 21. CER-TEMP 80 - 1 UNIT INSTALLATION FOR HOT WATER SUPPLY APPLICATION U.S. MODELS, JUCNTION BOX W/4 TERMINALS FIGURE 22. FIGURE 23.
  • Page 29 CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 24.
  • Page 30 SCHEMATIC CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 25.
  • Page 31 CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM (FOR HOT WATER SUPPLY APPLICATION) U.S. MODELS, JUNCTION BOX W/4 TERMINALS FIGURE 26.
  • Page 32 CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM (FOR HOT WATER SUPPLY APPLICATION) U.S. MODELS, JUNCTION BOX W/4 TERMINALS FIGURE 27.

  • Page 33: Piping

    PIPING 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 11. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
  • Page 34 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 11. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.
  • Page 35 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. PIPING AND FITTINGS BETWEEN GATE VALVES AND BOILERS SHOULD BE BRASS OR BRONZE.
  • Page 36 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. PIPING AND FITTINGS BETWEEN GATE VALVES AND BOILERS SHOULD BE BRASS OR BRONZE.
  • Page 37 THREE HW-520's, HW-610's OR HW-670's UP-FLOW MODEL COMMERCIAL BOILER WITH VERTICAL TANK, CER-TEMP 80 WIRING - FIGURES 21 to 27 on pages 28 to 32. INSTALL IN ACCORDANCE WITH ALL LOCAL CODES DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES.
  • Page 38 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. IF HIGHER PREHEAT TEMPERATURES ARE NECESSARY TO OBTAIN ADEQUATE BOOSTER OUTPUT, ADD AN ANTI-SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES.

  • Page 39: Operation And Start-Up Instructions

    OPERATION AND START-UP INSTRUCTIONS WARNING CAUTION After placing boiler into operation, the ignition system safety shutoff SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY device must be tested by the following test method. FAIL TO SHUT OFF, DO NOT TURN OFF OR DISCONNECT THE ELECTRICA L SUPPLY TO THE PUM P.
  • Page 40 4. Reinstall the burner manifold assembly on boiler. Check for good terminal connection at the sensing probe at the pilot burner assembly if pilot does not light. 5. Restore electrical power and gas supply to boiler. Check for electrical power to the valve. If electrical power and gas •...

  • Page 41: Checking And Adjusting Input

    CHECKING AND ADJUSTING THE INPUT Repeat steps 7 thru 11 of the OPERATING INSTRUCTIONS. The boiler will resume normal operation. Follow steps 1 thru 6 of the OPERATING INSTRUCTIONS. When the boiler is operating at full capacity, or full gas input, Attach a pressure gauge or a manometer to the manifold it should consume 1 cu.

  • Page 42: Operating Sequence

    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 43: Lighting Instructions

    LIGHTING AND OPERATING INSTRUCTIONS NATURAL AND PROPANE FOR HW300 - HW399 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. FLAMMABLE WHAT TO DO IF YOU SMELL GAS WARNING: HOT WATER CAN PRODUCE...
  • Page 44 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. FLAMMABLE C .USE ONLY YOUR HAND TO TURN THE GAS CONTROL THIS APPLIANCE IS EQUIPPED WITH AN IGNITION...

  • Page 45: Removal Of Existing Boiler From A Common Venting System

    REMOVAL OF EXISTING BOILER FROM A COMMON VENTING SYSTEM At the time of removal of an existing boiler, the following steps Place in operation the appliance being inspected. Follow the shall be followed with each appliance remaining connected to lighting instructions. Adjust thermostat so appliance will operate the common venting system placed in operation, while the other continuously.

  • Page 46: Cleaning And Flushing Instructions

    CLEANING AND FLUSHING INSTRUCTIONS Pipe joint compounds, soldering paste, grease on tubing and INTERNAL CONTAMINANTS pipe all tend to contaminate a system. Failure to flush contaminates from a system can cause solids The hydronic system must be internally cleaned and flushed to form on the inside of boiler exchangers, create excessive after a new or replacement boiler has been installed to remove amounts of air and other gases to block circulation, foul...

  • Page 47: Troubleshooting

    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 Cause Remedy Contact Incorrect Tank temperature control Replace. (thermostat) defective. Pump and burner remain System wiring is Circulating pump and Correct wiring.
  • Page 48 CHECKING HONEYWELL S-8600H OR S-8610M 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: S8610M will automatically reset every 5 minutes.
  • Page 49 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.
  • Page 50 CHECKING HONEYWELL S-8600H OR S8610M 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 ingniter/sensor rod? adjust pilot flame.
  • Page 51 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 Is there a good connection between terminals? tighten module to the Is module securely attached to appliance for good ground appliance.
  • Page 52 The following procedures are provided as a general guide. Table 11 Any module should be replaced if it does not perform properly on Yellow LED Flame Codes checkout or troubleshooting. Yellow LED Recommended Indicates Flash Code Service Action In addition, replace any module if it is wet or looks like it has ever been wet.
  • Page 53 Table 12. Continuous Retry Models C, M, E, and K Only - Green LED Status Codes Green LED Flash Code Indicates Next System Action Recommended Service Action (X+Y) No "Call for Heat" not applicable none Flash Fast Startup - Flame sense calibration not applicable none Heartbeat...
  • Page 54 Table 13. Lockout Models B, H, D and J Only - Green LED Status Codes Green LED Flash Code Indicates Next System Action Recommended Service Action (X+Y) No "Call for Heat" not applicable none Flash Fast Startup - Flame sense calibration not applicable none Heartbeat...

  • Page 55: Limited Warranty

    LIMITED WARRANTY A. O. Smith Corporation, the warrantor, extends the following LIMITED WARRANTY to the owner of this boiler. 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.
  • Page 56 500 Tennessee Waltz Parkway, Ashland City, TN 37015 • • Technical Support: 800-527-1953 Parts: 800-433-2545 Fax: 800-644-9306 www.hotwater.com...

This manual is also suitable for:

Hw 420Hw 399Hw 520Hw 610Hw 670Hw 610

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