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