Manuals / A.O. Smith / Household Appliance / Boiler

A.O. Smith HW 610 warranty MODELS HW 300, 399, 420, 520, 610, Up-Flow Models

Models: HW 610

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MODELS HW 300, 399, 420, 520, 610, 670

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.

—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.

500 Tennessee Waltz Parkway

Ashland City, TN 37015

www.hotwater.com

PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND

NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE

PRINTED 0210

317693-000

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A.O. Smith HW 610 warranty MODELS HW 300, 399, 420, 520, 610, Up-Flow Models

Contents

MODELS HW 300, 399, 420, 520, 610 INSTALLATION OPERATION MAINTENANCE LIMITED WARRANTY INDOOR ONLYUP-FLOW MODELS DANGER SAFE INSTALLATION, USE AND SERVICEIMPORTANT DEFINITIONS GENERAL SAFETY TROUBLESHOOTING TABLE OF CONTENTSREMOVAL OF EXISTING BOILER FROM A COMMON VENTING SYSTEM EXTRA OPENING FOR THERMOMETER AND RELIEF VALVE HW-520 AND HW--670 DIMENSIONS AND CAPACITY DATACOMPONENT LOCATION TABLE 2, RECOVERY CAPACITIESHIGH ALTITUDE INSTALLATIONS INTRODUCTIONPRECAUTIONS GROUNDING INSTRUCTIONSHIGH ALTITUDE INSTALLATIONS IN CANADA CONTROLS AND FUNCTIONAUTO RESET HIGH LIMIT IN THE U.S.AHIGH LIMIT SWITCH MANUAL RESET HIGH LIMITSAFETY FLOW SWITCH TABLE 3 - SAFETY FLOW SWITCH Minimum Pipe RateSAFETY RELIEF VALVES DANGER TANK TEMPERATURE CONTROLWater Temperature GENERALTime to Produce 2nd & 3rd Degree Burns on Adult Skinb Canadian Installations Confined Space a U. S. InstallationsAIR REQUIREMENTS Unconfined SpaceINSTALLATION CLEARANCES VENTINGA TYPICAL BOILER INSTALLATION VENTING THE BOILER - STANDARD VENTINGVENT PIPE INSTALLATION VENTING - SIDEWALL OPTIONAL POWER VENT SYSTEM VENTING MAINTENANCE - STANDARD VENTINGEXAMPLE SHOWING USE OF THE HW-610 COMBINED VENT SIZING TABLE VENTING SYSTEMTABLE 5, COMBINED VENT SIZING TABLES 1. CONVENTIONAL INSTALLATIONS SYSTEM INSTALLATIONS2. LINEAR-TEMP INSTALLATIONS ONE BOILER INSTALLED INDEPENDENT OF THE PRIMARY SYSTEMSCHEMATIC OF THE LINEAR-TEMP SYSTEM NO. SUGGESTED ITEMS FOR INSTALLATIONBOILER INLET - OUTLET SIZES MINIMUM BRANCH SIZES TO BOILERSSCHEMATIC SHOWING PROPER PIPING ISOLATION GAS CONNECTIONS5. VENT VALVES 6. MANIFOLD HEADERSMAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS PER PURGING AND SIZINGMultiplier SpecificSpecific MultiplierWIRING CONNECTIONS WIRINGSCHEMATIC DIAGRAM CONNECTION DIAGRAMHW 300 TO I.I.D. SYSTEM SINGLE STAGE I.I.D. - HONEYWELL GAS VALVE2. LINEAR-TEMP INSTALLATIONS Dual Bulb, Dual Switch Controller Main Water Temperature Dual Bulb, Dual Switch Controller Staging and Outdoor Reset ofBoilers and Secondary Circulator are Controlled by CER-TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION CER-TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATIONCANADIAN MODELS, JUNCTION BOX W/6 TERMINALS U.S. MODELS, JUCNTION BOX W/4 TERMINALSCANADIAN MODELS, JUNCTION BOX W/6 TERMINALS CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS SCHEMATICFOR HOT WATER SUPPLY APPLICATION CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAMU.S. MODELS, JUNCTION BOX W/4 TERMINALS FOR HOT WATER SUPPLY APPLICATION CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAMU.S. MODELS, JUNCTION BOX W/4 TERMINALS WIRING - FIGURES 16 and 17 on pages 24 and PIPINGCOMMERCIAL BOILER WITH VERTICAL TANK USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZECOMMERCIAL BOILER WITH HORIZONTAL TANK WIRING - FIGURES 16 and 17 on pages 24 andUSE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE TWO HW-399s, HW-420s, HW-520s, HW-610s or HW-670s UP-FLOW MODEL WIRING - FIGURES 21 to 27 on pages 28 toCOMMERCIAL BOILER WITH VERTICAL TANK, CER-TEMP USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZECOMMERCIAL BOILER WITH HORIZONTAL TANK WIRING - FIGURES 21 to 27 on pages 28 toUSE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE ModelTHREE HW-520s, HW-610s OR HW-670s UP-FLOW MODEL WIRING - FIGURES 21 to 27 on pages 28 toCOMMERCIAL BOILER WITH VERTICAL TANK, CER-TEMP USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZEUSE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE WIRING - FIGURES 21 to 27 on pages 28 toModel Pipe SizePRECAUTIONS OPERATION AND START-UP INSTRUCTIONSFILLING THE SYSTEM PILOT AND MAIN BURNERCheck for gas leaks and proper boiler and vent operation PILOT ADJUSTMENTThe pilot will now ignite provided the system is calling for heat OUTLETCONSUMPTION RATE Refer to Operating at Full Input or Full Capacity CHECKING AND ADJUSTING THE INPUTPOWER INTERRUPTION System shuts off, restarts when power is restored fire or explosion may result causing property damage, personal FOR YOUR SAFETY READ BEFORE LIGHTINGLIGHTING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCET URN OFF ALL ELECTRICAL POWER T O APPLIANCE FOR YOUR SAFETY READ BEFORE OPERATINGSET T HE THERMOSTAT TO LOWWEST SETTING OPERATING INSTRUCTIONSMANUAL RESET HIGH LIMIT SWITCH CONTINUITY TEST GENERAL MAINTENANCEREMOVAL OF EXISTING BOILER FROM A COMMON VENTING SYSTEM RELIEF VALVEPRE-TROUBLESHOOTING CLEANING AND FLUSHING INSTRUCTIONSHOT WATER SUPPLY BOILERS PREVENTIVE MAINTENANCE INTERNAL CONTAMINANTSCER-TEMP 80 RECOVERY SYSTEM CHECKOUT PROCEDURE TROUBLESHOOTINGCheckout Sequence System OperationNO SPARK AT PILOT BURNER CHECKING HONEYWELL S-8600H OR S-8610M INTERMITTENT IGNITION CONTROLSNO NO Securely connect cableCHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLS burner ignition problems?SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT Is ceramic insulator surrounding the electrode in goodPILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT CHECKING HONEYWELL S-8600H OR S8610M INTERMITTENT IGNITION CONTROLSNO NO NO NONO SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT CHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLSNO NO NO NO NO NO NO Service Action LED STATUS AND TROUBLESHOOTINGLocation of LEDs Flame LED Yellow Status LED GreenContinuous Retry Models C, M, E, and K Only - Green LED Status Codes Recommended Service ActionGreen LED Flash CodeLockout Models B, H, D and J Only - Green LED Status Codes Recommended Service ActionGreen LED Flash Code3. SERVICE AND REPAIR EXPENSE LIMITED WARRANTY5. CLAIM PROCEDURE 2. CONDITIONS AND EXCEPTIONSTechnical Support 800-527-1953 Parts 800-433-2545 Fax 500 Tennessee Waltz Parkway, Ashland City, TN