A.O. Smith HW 610 Cleaning and Flushing Instructions, Pre-Troubleshooting, Internal Contaminants

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CLEANING AND FLUSHING INSTRUCTIONS

INTERNAL CONTAMINANTS

The hydronic system must be internally cleaned and flushed after a new or replacement boiler has been installed to remove contaminants that may have accumulated during installation. This is doubly important when a replacement boiler is installed into an existing system where Stop Leak or other boiler additives have been used.

Failure to clean and flush the system can produce acid concentrations that become corrosive, cause gases to form that block water circulation or lead to formation of deposits on the boiler surfaces, any of which could result in damage to the system and circulator.

All hot water heating systems should be completely flushed with a grease removing solution to assure trouble-tree operation.

Pipe joint compounds, soldering paste, grease on tubing and pipe all tend to contaminate a system.

Failure to flush contaminates from a system can cause solids to form on the inside of boiler exchangers, create excessive amounts of air and other gases to block circulation, foul various system accessories and even deteriorate circulation seals and impellers.

It is recommended that after installation, the boiler and system when filled should include the proper percentage of cleaning solution related to approximate water volume of the system. Fire and circulate for about one hour and then flush clean with fresh water. Commercial grease removing solutions are available from your distributor.

HOT WATER SUPPLY BOILERS PREVENTIVE MAINTENANCE

For care of the HW water system please refer to the A. O. Smith Users Information Manual supplied with the Boiler.

PRE-TROUBLESHOOTING

Before any extensive troubleshooting, perform the following:

Ensure that:

–Voltage (120 vac) is supplied to the appliance.

–System control (tank temperature control, thermostat, etc.) is calling for appliance operation (call for heat).

–Other contacts (switches) are closed (relay, low water cutoff, flow switch, coil protector, pressure switch, etc.).

–Gas supply pressure is within the maximum and minimum operating ranges listed on the appliance rating plate/label.

–Voltage (24 vac) is supplied by transformer.

–Appliance is wired according to wiring diagram.

Note: Cross wiring the 24 volt circuit of the relay will short the transformer.

–All wire terminals/connectors are firmly attached to valves, modules, switches, limit controls, etc.

–For LP models only check for possible lockout condition of the the ignition module.

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Contents Models HW 300, 399, 420, 520, 610 Tennessee Waltz Parkway Ashland City, TNSafe INSTALLATION, USE and Service Important DefinitionsGeneral Safety Table of Contents Dimensions and Capacity Data Propane NaturalRecovery Capacities 27.7 33.3Introduction High Altitude InstallationsLIQUefied petroleum gas models Controls and Function Thermal Balancer Manual Reset High LimitHigh Limit Switch Safety Flow Switch GPM LPMSafety Relief Valves Tank Temperature Control Drain Valve Not Supplied GeneralThermometers Required AbilityAIR Requirements Confined Space S. InstallationsCanadian Installations Unconfined SpaceVenting Installation ClearancesTypical Boiler Installation LevelingDraft Hood Vent Pipe InstallationConnecting Boiler to a Common Vent Vent ConnectionMultiple Vent Table Venting Sidewall Optional Power Vent SystemVenting System Combined Vent Sizing Tables Model HW-300 BoilerLINEAR-TEMP Installations System InstallationsConventional Installations ONE Boiler Installed Independent of the Primary SystemBoiler Inlet Outlet Sizes NO. Suggested Items for InstallationSchematic of the LINEAR-TEMPSYSTEM Minimum Branch Sizes to BoilersGAS Connections Purging and Sizing Correct GASGAS Pressure Regulators ExampleSpecific Multiplier Gravity Model Rated Manifold Pressure Number Input Natural PropaneWiring Wiring ConnectionsSingle Stage I.I.D. Honeywell GAS Valve HW 300 toD. System HW 300 thru 670. Natural and Propane GAS U.S. & CanadaLINEAR-TEMP Installations Boilers and Secondary Circulator are Controlled by Page Canadian MODELS, Junction BOX W/6 Terminals MODELS, Jucntion BOX W/4 TerminalsCanadian MODELS, Junction BOX W/6 Terminals Schematic MODELS, Junction BOX W/4 Terminals MODELS, Junction BOX W/4 Terminals Commercial Boiler with Vertical Tank Wiring Figures 16 and 17 on Pages 24Piping USE this Table for Correct Pump and Water Pipe SizeCommercial Boiler with Horizontal Tank Wiring Figures 21 to 27 on Pages 28 to Commercial Boiler with Vertical TANK, CER-TEMPHW-300 HW-399 HW-420 HW-520 Three HW-520s, HW-610s or HW-670s UP-FLOW Model USE this Table for Correct Pump and Water Pipe Size Pilot and Main Burner Operation and START-UP InstructionsFilling the System Main BurnerPilot Burner Electronic Ignition Consumption Rate Checking and Adjusting the InputRefer to Operating at Full Input or Full Capacity Stage Main Burner Operation Flame Current Sensed For Your Safety Read Before Lighting SET T HE Thermostat to Lowwest Setting URN Pilo T Firing VA LVE CounterclockwiseManual Reset High Limit Switch Continuity Test General MaintenanceRelief Valve HOT Water Supply Boilers Preventive Maintenance Cleaning and Flushing InstructionsPRE-TROUBLESHOOTING Internal ContaminantsTroubleshooting CER-TEMP 80 Recovery System Checkout ProcedureYES Condition not cracked or broken? Burner ignition problems?Is ceramic insulator surrounding the electrode in good Is there excessive draft conditions that may cause pilotMV & MV/PV? Replace pilot burner assembly Status LED Green LED Status and TroubleshootingLocation of LEDs Flame LED Yellow OFFNo Call for Heat Not applicable None OFF Limited Warranty Conditions and Exceptions
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