MODELS HW 300, 399, 420, 520, 610
INSTALLATION OPERATION MAINTENANCE LIMITED WARRANTY INDOOR ONLY
UP-FLOW MODELS
DANGER
SAFE INSTALLATION, USE AND SERVICE
IMPORTANT DEFINITIONS
GENERAL SAFETY
TROUBLESHOOTING
TABLE OF CONTENTS
REMOVAL OF EXISTING BOILER FROM A COMMON VENTING SYSTEM
EXTRA OPENING FOR THERMOMETER AND RELIEF VALVE HW-520 AND HW--670
DIMENSIONS AND CAPACITY DATA
COMPONENT LOCATION
TABLE 2, RECOVERY CAPACITIES
GROUNDING INSTRUCTIONS
INTRODUCTION
HIGH ALTITUDE INSTALLATIONS
PRECAUTIONS
IN THE U.S.A
CONTROLS AND FUNCTION
HIGH ALTITUDE INSTALLATIONS IN CANADA
AUTO RESET HIGH LIMIT
TABLE 3 - SAFETY FLOW SWITCH Minimum Pipe Rate
MANUAL RESET HIGH LIMIT
HIGH LIMIT SWITCH
SAFETY FLOW SWITCH
SAFETY RELIEF VALVES
DANGER
TANK TEMPERATURE CONTROL
Degree Burns on Adult Skin
GENERAL
Water Temperature
Time to Produce 2nd & 3rd
Unconfined Space
Confined Space a U. S. Installations
b Canadian Installations
AIR REQUIREMENTS
VENTING THE BOILER - STANDARD VENTING
VENTING
INSTALLATION CLEARANCES
A TYPICAL BOILER INSTALLATION
VENT PIPE INSTALLATION
VENTING SYSTEM
VENTING MAINTENANCE - STANDARD VENTING
VENTING - SIDEWALL OPTIONAL POWER VENT SYSTEM
EXAMPLE SHOWING USE OF THE HW-610 COMBINED VENT SIZING TABLE
TABLE 5, COMBINED VENT SIZING TABLES
ONE BOILER INSTALLED INDEPENDENT OF THE PRIMARY SYSTEM
SYSTEM INSTALLATIONS
1. CONVENTIONAL INSTALLATIONS
2. LINEAR-TEMP INSTALLATIONS
MINIMUM BRANCH SIZES TO BOILERS
NO. SUGGESTED ITEMS FOR INSTALLATION
SCHEMATIC OF THE LINEAR-TEMP SYSTEM
BOILER INLET - OUTLET SIZES
6. MANIFOLD HEADERS
GAS CONNECTIONS
SCHEMATIC SHOWING PROPER PIPING ISOLATION
5. VENT VALVES
MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS PER
PURGING AND SIZING
Multiplier
Specific
Multiplier
Specific
WIRING CONNECTIONS
WIRING
SINGLE STAGE I.I.D. - HONEYWELL GAS VALVE
CONNECTION DIAGRAM
SCHEMATIC DIAGRAM
HW 300 TO I.I.D. SYSTEM
2. LINEAR-TEMP INSTALLATIONS
Dual Bulb, Dual Switch Controller
Main Water Temperature
Dual Bulb, Dual Switch Controller Staging and Outdoor Reset of
Boilers and Secondary Circulator are Controlled by
U.S. MODELS, JUCNTION BOX W/4 TERMINALS
CER-TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION
CER-TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION
CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS
CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS
CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS
SCHEMATIC
FOR HOT WATER SUPPLY APPLICATION
CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM
U.S. MODELS, JUNCTION BOX W/4 TERMINALS
FOR HOT WATER SUPPLY APPLICATION
CER-TEMP 80 - 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM
U.S. MODELS, JUNCTION BOX W/4 TERMINALS
USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE
PIPING
WIRING - FIGURES 16 and 17 on pages 24 and
COMMERCIAL BOILER WITH VERTICAL TANK
COMMERCIAL BOILER WITH HORIZONTAL TANK
WIRING - FIGURES 16 and 17 on pages 24 and
USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE
USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE
WIRING - FIGURES 21 to 27 on pages 28 to
TWO HW-399s, HW-420s, HW-520s, HW-610s or HW-670s UP-FLOW MODEL
COMMERCIAL BOILER WITH VERTICAL TANK, CER-TEMP
Model
WIRING - FIGURES 21 to 27 on pages 28 to
COMMERCIAL BOILER WITH HORIZONTAL TANK
USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE
USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE
WIRING - FIGURES 21 to 27 on pages 28 to
THREE HW-520s, HW-610s OR HW-670s UP-FLOW MODEL
COMMERCIAL BOILER WITH VERTICAL TANK, CER-TEMP
Pipe Size
WIRING - FIGURES 21 to 27 on pages 28 to
USE THIS TABLE FOR CORRECT PUMP AND WATER PIPE SIZE
Model
PILOT AND MAIN BURNER
OPERATION AND START-UP INSTRUCTIONS
PRECAUTIONS
FILLING THE SYSTEM
OUTLET
PILOT ADJUSTMENT
Check for gas leaks and proper boiler and vent operation
The pilot will now ignite provided the system is calling for heat
CONSUMPTION RATE Refer to Operating at Full Input or Full Capacity
CHECKING AND ADJUSTING THE INPUT
POWER INTERRUPTION System shuts off, restarts when power is restored
TO TURN OFF GAS TO APPLIANCE
FOR YOUR SAFETY READ BEFORE LIGHTING
fire or explosion may result causing property damage, personal
LIGHTING INSTRUCTIONS
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING
T URN OFF ALL ELECTRICAL POWER T O APPLIANCE
SET T HE THERMOSTAT TO LOWWEST SETTING
RELIEF VALVE
GENERAL MAINTENANCE
MANUAL RESET HIGH LIMIT SWITCH CONTINUITY TEST
REMOVAL OF EXISTING BOILER FROM A COMMON VENTING SYSTEM
INTERNAL CONTAMINANTS
CLEANING AND FLUSHING INSTRUCTIONS
PRE-TROUBLESHOOTING
HOT WATER SUPPLY BOILERS PREVENTIVE MAINTENANCE
System Operation
TROUBLESHOOTING
CER-TEMP 80 RECOVERY SYSTEM CHECKOUT PROCEDURE
Checkout Sequence
Securely connect cable
CHECKING HONEYWELL S-8600H OR S-8610M INTERMITTENT IGNITION CONTROLS
NO SPARK AT PILOT BURNER
NO NO
Is ceramic insulator surrounding the electrode in good
burner ignition problems?
CHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLS
SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT
NO NO
CHECKING HONEYWELL S-8600H OR S8610M INTERMITTENT IGNITION CONTROLS
PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT
NO NO
NO SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT
CHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLS
NO NO NO NO NO NO NO
Status LED Green
LED STATUS AND TROUBLESHOOTING
Service Action
Location of LEDs Flame LED Yellow
Flash Code
Recommended Service Action
Continuous Retry Models C, M, E, and K Only - Green LED Status Codes
Green LED
Flash Code
Recommended Service Action
Lockout Models B, H, D and J Only - Green LED Status Codes
Green LED
2. CONDITIONS AND EXCEPTIONS
LIMITED WARRANTY
3. SERVICE AND REPAIR EXPENSE
5. CLAIM PROCEDURE
Technical Support 800-527-1953 Parts 800-433-2545 Fax
500 Tennessee Waltz Parkway, Ashland City, TN
