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