Instruction/ maintenance manual of the product HWB-399 A.O. Smith
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1 1 1 1 1 PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE A DIVISION OF A.O. SMITH CORPORATION MC BEE, SC SEA TTLE, W A STRA TFORD, ONT ARIO VELDHOVEN, THE NETHERLANDS w w w .hotwater .com P ART NO. 21 1683-000 REV .
2 2 2 2 2 ROUGH-IN DIMENSIONS T ABLE 2, SPECIFICA TIONS - CANADIAN MODELS ONL Y Maximum Maximum I.A.S. Maximum Max. Heat T ransfer Max. Heat T ransfer Model T ype of Gas BTUH(KW) BTUH(KW) Heat Loss Load Surface Area (Sq. Ft.) Surface Area (Sq. Ft.) HWB-300 Natural & Propane 300,000 (88) 247,200 (72) 210,120 (62) 1,410 (.
3 3 3 3 3 T ABLE 3, RECOVERY CAP ACITIES - CANADIAN MODELS ONL Y Input T emp. (C) 1 1 1 7 22 2 6 3 3 39 4 4 5 0 56 6 1 6 7 7 2 78 Model (Btu/Hr .) Rise (F) 2 0 30 40 50 60 70 80 90 100 1 10 120 130 14.
4 4 4 4 4 CAUTION TEXT PRINTED OR OUTLINED IN RED CONT AINS INFORMA TION RELA TIVE TO YOUR SAFETY . PLEASE READ THOROUGHL Y BEFORE USING APPLIANCE. Detailed installation diagrams are in this manual. These diagrams will serve to provide the installer with a reference for the materials and method of piping suggested.
5 5 5 5 5 LOCA TION When installing the boiler , consideration must be given to proper location. Location selected should be as close to the stack or chimney as practicable with adequate air supply and as centralized with the piping system as possible.
6 6 6 6 6 Where an exhaust fan is installed in the same room with a boiler , sufficient openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE CHIMNEY , CAUSING POOR COMBUSTION. SOOTING MA Y RESUL T WITH AN INCREASED RISK OF ASPHYXIA TION.
7 7 7 7 7 1. CONVENTIONAL INST ALLA TIONS All modern hydronic type boilers are exceptionally fast heating units. The low water volumes in relation to firing rates require special attention to water flow rates for smooth, efficient operation. These considerations for the A.
8 8 8 8 8 N O . SUGGESTED ITEMS FOR INST ALLA TION 1 Short pipe nipple and pair of boiler loop tees in piping between system supply and return. One set per each group of boilers 2 Boiler pipe loop. See piping sizing data above. 3 Boiler circulator . See pump sizing data above.
9 9 9 9 9 Excessive pressure may develop causing premature tank failure or intermittent relief valve operation. This is not a warranty failure. An expansion tank or a similar device may be required in.
10 10 10 10 10 2A. SIZING GAS SUPPL Y LINE (For single boiler installations and for installations of multiples of two or three of same size boilers). Use table 6, or CAN/CSA B149.1-00 (latest recent edition) to size iron pipe or equivalent gas supply line.
11 11 11 11 11 • In table 6, select the row showing the distance to the most remote outlet or the next longer distance if the table does not give the exact length.
12 12 12 12 12 7. Set primary system temperature control dial (thermostat) to desired setting. W ARNING DO NOT INCREASE GAS PRESSURE ABOVE THA T SPECIFIED ON THE RA TING PLA TE, AS OVERFIRING WILL RESUL T IN DAMAGE TO THE BOILER, AS WELL AS INCREASED RISK OF FIRE, SOOTING AND ASPHYXIA TION.
13 13 13 13 13 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use.
14 14 14 14 14 MODEL HW/HWB-610 BOILER Input: 610,000 Btuh Draft Hood Outlet 12" Required Connector or Smoke Pipe Diameter Connector T otal V ent Height(Measured in Feet Above Draf t Hood) Rise i.
15 15 15 15 15 VENTING MAINTENANCE - ST ANDARD VENTING It is recommended that the heating surfaces and vent piping of the appliance be checked every six months for dust, deterioration and carbon deposits. Remove all soot or other obstructions from chimney and flue which will retard free draft.
16 16 16 16 16 The storage tank temperature and pressure (T & P) relief valve must comply with the applicable construction provisions of the S tandard for Relief V alves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, Z21.22 and/or CAN1-4.
17 17 17 17 17 CONNECTION DIAGRAM HWB & HW-300, -399, -420, -500 & -610 (NA TURAL GAS) SINGLE ST AGE I.I.D. - ROBERTSHAW ® GAS V A L VE HWB & HW-300, -399, -420, -520, -610 (NA TURAL GAS ONL Y) - CANADIAN MODELS FIGURE 10 ® Robertshaw is a registered trademark of Fulton Controls Corp.
18 18 18 18 18 CONNECTION DIAGRAM HWB, HW-420,-520, -610 (PROP ANE GAS) SINGLE ST AGE PROP ANE - ROBERTSHAW GAS V AL VE 24 VOL T -HW , HWB-420, -520, -610 CANADIAN MODELS FIGURE 1 1.
19 19 19 19 19 SINGLE ST AGE PROP ANE ROBERTSHA W GAS V AL VE 24 VOL T - HWB, HW -300, 399 CANADIAN MODELS FIGURE 1 1A CONNECTION DIAGRAM HWB & HW 300, 399 (PROP ANE GAS) FIGURE 13.
20 20 20 20 20 HW-300, HW-399, HW-420, HW-500 & HW-670 (NA TURAL GAS) SINGLE ST AGE I.I.D. - ROBERTSHAW GAS V AL VE HW-300, -399, -420, -520 & 670 (NA TURAL GAS ONL Y) - U.
21 21 21 21 21 HW-300, HW-399, HW-420, HW-500 & HW-670 (PROP ANE GAS) FIGURE 12 SINGLE ST AGE I.I.D. - ROBERTSHAW GAS V AL VE HW -300, -399, -420, -520 & 670 (PROP ANE GAS ONL Y) - U.
22 22 22 22 22 2. LINEAR-TEMP INST ALLA TIONS Control for these systems is decided mainly by the type of building system controlling that is desired. A single boiler installation might be controlled directly from space temperature thermostat(s).
23 23 23 23 23 NOTE: 1 . Building temperature controls supply electric power to building circulator . 2. Main flow switch proves main water flow before energizing sequencing and resetting controls. 3. Outdoor thermostat required if building controls do not provide automatic shut down of reset controls during warm weather.
24 24 24 24 24 NOTE: 1. Building temperature controls supply electric power to building circulator. 2. Main flow switch proves main water flow before energizing sequencing and resetting controls. 3. Outdoor thermostat required if building controls do not provide automatic shutdown of reset controls during warm weather .
25 25 25 25 25 CER-TEMP 80 - 1 UNIT INST ALLA TION - FOR HOT W A TER SUPPL Y APPLICA TION CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 17 FIGURE 19 CER-TEMP 80 - 1 UNIT INST ALLA TION - FOR HOT W A TER SUPPL Y APPLICA TION U.
26 26 26 26 26 CER-TEMP 80 - 2 OR 3 UNIT INST ALLA TION - FOR HOT W A TER SUPPL Y APPLICA TION CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS FIGURE 20.
27 27 27 27 27 FIGURE 21 SCHEMA TIC CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS.
28 28 28 28 28 CER-TEMP 80 - 2 OR 3 UNIT INST ALLA TION CONNECTION DIAGRAM (FOR HOT W A TER SUPPL Y APPLICA TION) U.S. MODELS, JUNCTION BOX W/4 TERMINALS FIGURE 22.
29 29 29 29 29 CER-TEMP 80 - 2 OR 3 UNIT INST ALLA TION SCHEMA TIC DIAGRAM (FOR HOT W A TER SUPPL Y APPLICA TION) U.S. MODELS, JUNCTION BOX W/4 TERMINALS FIGURE 23.
30 30 30 30 30 FIGURE 24 BOOSTER - RECOVER Y WIRING DIAGRAM CANADIAN MODELS, JUNCTION BOX W/6 TERMINALS SHURE-TEMP BOOSTER - RECOVER Y WIRING DIAGRAM (TWO TEMPERA TURE SYSTEM) CANADIAN MODELS, JUNCTIO.
31 31 31 31 31 BOOSTER - RECOVERY WIRING DIAGRAM U.S. MODELS, JUNCTION BOX W/4 TERMINALS FIGURE 26 SHURE - TEMP BOOSTER - RECOVER Y WIRING DIAGRAM TWO-TEMPERA TURE SYSTEM U.
32 32 32 32 32 W A TER LINE CONNECTIONS This section provides detailed installation diagrams for typical methods of application for the unit using a Cer-T emp 80 Recovery System (for one temperature water), and either Booster-Recovery or the Shure-T emp Booster-Recovery System (for two temperature water).
33 33 33 33 33 USE ANTI-SCALD V AL VE(S) in the hot water system to reduce the risks of scalds at points of use such as lavatories, sinks and bathing facilities. A change in water temperature in the storage tank lower than the T ank T emperature Control setting will cause the sensor to close its contact s and consequently energize the boiler .
34 34 34 34 34 FIGURE 29 IMPORT ANT THE INST ALLA TION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED T O PROTECT THE BOILER IN CASE OF W A TER SERVICE INTERRUPTION OR CIRCULA TOR F AILURE (A.O. SMITH PKG . NO. 21 1480). + PIPING AND FITTINGS BETWEEN GA TE V AL VES AND BOILERS SHOULD BE BRASS OR BRONZE.
35 35 35 35 35 FIGURE 30 ONE HW-300, HW-399, HW-420, HW-520, HW-610 OR ONE HW-670 UP-FLOW MODEL COMMERCIAL BOILER WITH HORIZONT AL T ANK WIRING - FIGURES 17, 18, 19 INST ALL IN ACCORDANCE WITH ALL LOC.
36 36 36 36 36 TWO HW-399's, HW-420's, HW-520's, HW-610's or HW-670's UP-FLOW MODEL COMMERCIAL BOILER WITH VERTICAL T ANK, CER-TEMP 80 IMPORT ANT THE INST ALLATION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED T O PROTECT THE BOILER IN CASE OF W ATER SERVICE INTERRUPTION OR CIRCULA T OR FAILURE (A.
37 37 37 37 37 FIGURE 32 TWO HW-300's, HW-399's, HW-420's, HW-520's, HW-610's OR HW-670's UP-FLOW MODEL COMMERCIAL BOILER WITH HORIZONT AL T ANK IMPORT ANT THE INST ALLA TION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF W A TER SERVICE INTERRUPTION OR CIRCULA TOR F AILURE (A.
38 38 38 38 38 THREE HW-520's, HW-610's OR HW-670's UP-FLOW MODEL COMMERCIAL BOILER WITH VERTICAL T ANK, CER-TEMP 80 IMPORT ANT THE INST ALLA TION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED TO PROTECT THE BOILER IN CASE OF WA TER SERVICE INTERRUPTION OR CIRCULA TOR F AILURE (A.
39 39 39 39 39 THREE HW-520's, HW-610's OR HW-670's UP-FLOW MODEL COMMERCIAL BOILER WITH HORIZONT AL T ANK, CER-TEMP 80 IMPORT ANT THE INST ALLA TION OF SAFETY FLOW SWITCH AS SHOWN IS REQUIRED T O PROTECT THE BOILER IN CASE OF W A TER SERVICE INTERRUPTION OR CIRCULA T OR F AILURE (A.
40 40 40 40 40 FIGURE 35 WIRING - FIGURE 25 OR 27 INST ALL IN ACCORDANCE WITH ALL LOCAL CODES BOOSTER RECOVER Y SYSTEM (P A TENTED) TWO TEMPERA TURE SYSTEM WITHOUT RECIRCULA TION ONE HW-300, HW-399, H.
41 41 41 41 41 FIGURE 36 BOOSTER RECOVERY SYSTEM (P A TENTED) TWO TEMPERA TURE SYSTEM WITHOUT RECIRCULATION ONE HW-300, HW-399, HW-420, HW-520, HW-610 OR HW-670 UP-FLOW MODEL COMMERCIAL BOILER WITH HO.
42 42 42 42 42 FIGURE 37 BOOSTER RECOVER Y SYSTEM (P A TENTED) - TWO TEMPERA TURE SYSTEM WITHOUT RECIRCULA TION ONE HW-300, HW-399, HW-420, HW-520, HW-610 OR HW-670 UP-FLOW MODEL COMMERCIAL BOILER WITH HORIZONT AL T ANK + PIPING AND FITTINGS BETWEEN GA TE V AL VES AND BOILERS SHOULD BE BRASS OR BRONZE.
43 43 43 43 43 4 FLOW REGULA TING PLUG COCK (For Boiler Flow Rate Adjustment) A slight closing of this valve may be necessary to set proper water flow rate for 40°F temperature rise through the boiler . T emperature rise is observed between the boiler inlet and outlet thermometers.
44 44 44 44 44 FIGURE 39 WITH TWO VERTICAL T ANKS WITH THREE VERTICAL T ANKS DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES.
45 45 45 45 45 TWO HORIZONT AL T ANK INST ALLA TION THREE HORIZONT AL T ANK INST ALLA TION FIGURE 40 DANGER TEMPERA TURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERA TURE A T FIXTURES.
46 46 46 46 46 IMPORT ANT IT IS RECOMMENDED THA T A QUALIFIED PERSON PERFORM THE INITIAL FIRING OF THE BOILER. A T THIS TIME THE USER SHOULD NOT HESIT A TE T O ASK THE INDIVIDUAL ANY QUESTIONS WHICH HE MA Y HA VE IN REGARD T O THE OPERA TION AND MAINTENANCE OF THE UNIT .
47 47 47 47 47 LIGHTING AND OPERA TING INSTRUCTIONS (NA TURAL AND PROP ANE GAS WITH I.I.D.) W ARNING: HOT W A TER CAN PRODUCE 3rd DEGREE BURNS IN 6 SECONDS A T 140° F .
48 48 48 48 48 LIGHTING AND OPERA TING INSTRUCTIONS PROP ANE (LP) ST ANDING PILOT MODELS W ARNING: HOT W A TER CAN PRODUCE 3rd DEGREE BURNS IN 6 SECONDS A T 140° F .
49 49 49 49 49 4. Adjust pilot flame. T o adjust the pilot flame, remove the cap screw from the pilot adjusting valve and turn to deliver a sufficient flame at the pilot burner to cover 3/8" to 1/2" (10-12mm) of the sensing probe tip. See fig.
50 50 50 50 50 FIGURE 43D The purpose of checking the current ahead and after the protector switch is to measure the millivolt drop across the contacts. This drop should be between 4 and 6 millivolts. PROTECTOR SWITCH CONTINUITY TEST Do not depress the protector switch reset button prior to testing.
51 51 51 51 51 • If lamp does not light when reset button is depressed, attach the test flashlight leads to the protector switch terminals. If lamp does not light, switch is defective and must be replaced. • If lamp does light, the leads are bad and must be repaired or replaced.
52 52 52 52 52 NORMAL OPERA TING SEQUENCE WITH INTERMITTENT IGNITION CONTROLS (I.I.D.) 1. System control calls for boiler operation. 2. S park begins at pilot burner . 3. Pilot gas control valve is energized. Gas flows to pilot burner . 4. Pilot burner gas ignites.
53 53 53 53 53 PROTECTOR SWITCH FIGURE 48 PRESSURE REDUCING V A L V E The screen in the pressure reducing valve may require occasional cleaning due to foreign material in the water supply . This will restrict the flow and could reduce the effectiveness of purging and prolong filling time.
54 54 54 54 54 T o adjust the flow rate setting: 1. Remove the flow switch cover . 2. For higher flow rate—turn the range adjusting screw clockwise. 3 . For lower flow rate—turn the range adjusting screw counter-clockwise. CAUTION The switch is factory set at approximately the minimum flow rate, see T able II.
55 55 55 55 55 GENERAL MAINTENANCE These boilers are designed to give many years of efficient and satisfactory service when properly operated and maintained. T o assure continued good performance, the following recommendations are made. The area around the unit should be kept clean and free from lint and debris.
56 56 56 56 56 The time between cleaning will vary from two to six months depending upon water conditions and usage. A change of approximately 5 0 F in the normal temperature rise through the boiler is usually an indication that scale should be removed.
57 57 57 57 57 TROUBLESHOOTING CER-TEMP 80 RECOVERY SYSTEM CHECKOUT PROCEDURE Use this checkout for Cer-T emp 80 Recovery Systems. (For hot water supply application only) SYSTEM OPERA TION Checkout Sequence Contact Incorrect Cause Remedy Set tank temperature Circulating pump Pump and burner T ank temperature control Replace.
58 58 58 58 58 CHECKING HONEYWELL S-8600H OR S-8610M INTERMITTENT IGNITION CONTROLS T urn off gas supply . Is voltage (24 V ac) across the 24 V terminals on module during “Call for heat”? T urn off power supply .
59 59 59 59 59 CHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLS SP ARK A T PILOT BURNER BUT PILOT WILL NOT LIGHT Ensure all manual shutoff valves are fully open; All filters are clean; All gas connections are gas tight; Pilot tubing is not damaged, obstructed or kinked; and pilot orifice is unclogged.
60 60 60 60 60 CHECKING HONEYWELL S-8600H OR S8610M INTERMITTENT IGNITION CONTROLS PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT Does the pilot flame cover 3/8” to 1/2” of ingniter/sensor rod.
61 61 61 61 61 CHECKING HONEYWELL S8600H OR S-8610M INTERMITTENT IGNITION CONTROLS NO SP ARK A T PILOT BURNER BUT PILOT WILL NOT LIGHT T urn of f gas supply .
62 62 62 62 62 LIMITED WARRANTY A. O. Smith Corporation, the warrantor, extends the following LIMITED W ARRANTY to the owner of this hydronic boiler . 1.
63 63 63 63 63.
64 64 64 64 64 5621 W . 1 15TH STREET , ALSIP , IL 60803 PHONE: 1-800-433-2545 F AX: 1-800-433-2515 E-MAIL: part s@hotwater .com • w w w .hotwater .com REPLACEMENT P ARTS.
An important point after buying a device A.O. Smith HWB-399 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought A.O. Smith HWB-399 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data A.O. Smith HWB-399 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, A.O. Smith HWB-399 you will learn all the available features of the product, as well as information on its operation. The information that you get A.O. Smith HWB-399 will certainly help you make a decision on the purchase.
If you already are a holder of A.O. Smith HWB-399, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime A.O. Smith HWB-399.
However, one of the most important roles played by the user manual is to help in solving problems with A.O. Smith HWB-399. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device A.O. Smith HWB-399 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
