State SW 37-670 User Manual

COMMERCIAL ELECTRIC BOILERS

A DIVISION OF A. O. SMITH CORPORATION

RENTON, WASHINGTON

www.statewaterheaters.com

Instruction Manual

MODELS SW 37-670

INSTALLATION - OPERATION - SERVICE -

MAINTENANCE - LIMITED WARRANTY

ASME

Thank you for buying this energy efficient boiler from us. We appreciate your confidence in our products.

PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE.

PRINTED 0110 316393-000

SAFE INSTALLATION, USE AND SERVICE

Your safety and the safety of others is extremely important in the installation, use, and servicing of this boiler.

Many safety-related messages and instructions have been provided in this manual and on your own boiler to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, or service this boiler.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous

DANGER

WARNING

CAUTION

situation which, if not avoided, will result in death or injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION used without the safety alert symbol

CAUTION

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and how to avoid the risk of injury.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This appliance can cause low level exposure to some of the substances listed.

•  QualiedInstallerorServiceAgency:

Installation and service of this boiler requires ability equivalent to that of a Qualied Agency (as dened by ANSI below) in the eld

involved. Installation skills such as plumbing and electrical supply are required in addition to electrical testing skills when performing service.

indicates a potentially hazardous situation which, if not avoided, could result in property damage.

IMPORTANT DEFINITIONS

•  ANSIZ223.12006Sec.3.3.83:

“Qualied Agency” - “Any individual, rm, corporation or company that either in person or through a representative is engaged in and is

responsible for (a) the installation, testing or replacement of gas piping or (b) the connection, installation, testing, repair or servicing of

appliances and equipment; that is experienced in such work; that is familiar with all precautions required; and that has complied with all

the requirements of the authority having jurisdiction.”

GENERAL SAFETY INFORMATION

PRECAUTIONS

DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER

WATER. Immediately call a qualied service technician to inspect

the appliance and to replace any part of the control system which has been under water.

If the unit is exposed to the following, do not operate boiler until all

corrective steps have been made by a qualied service agency.

1. External re.

2. Damage.

3. Firing without water.

GROUNDING INSTRUCTIONS

This boiler must be grounded in accordance with the National Electrical Code and/or local codes. These must be followed in all cases. Failure to ground this boiler properly may also cause erratic control system operation on ELECTRONIC CONTROL models.

This boiler must be connected to a grounded metal, permanent wiring system, or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the boiler.

When servicing this unit, verify the power to the unit is turned off prior to opening the control cabinet door.

HYDROGEN GAS (FLAMMABLE)

Hydrogen gas can be produced in a hot water system served by this boiler

that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely ammable. To reduce the risk of injury

under these conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system. If hydrogen is present there will probably be an unusual sound such as air escaping through the pipe

as the water begins to ow. THERE SHOULD BE NO SMOKING OR

OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE...........................................................2

GENERAL SAFETY INFORMATION .......................................................................3

Precautions ....................................................................................................3

Hydrogen Gas (Flammable) ...........................................................................3

TABLE OF CONTENTS ...........................................................................................4

INTRODUCTION .....................................................................................................4

Preparing for the Installation ..........................................................................4

DIMENSIONS AND CAPACITIES DATA .................................................................5

FEATURES AND COMPONENTS ..........................................................................8

APPROVALS ...........................................................................................................9

MODEL AND RATING .............................................................................................9

LOCATING THE NEW BOILER ...............................................................................9

Facts to Consider About the Location ............................................................9

INSTALLATION .....................................................................................................10

Required Ability ............................................................................................10

General ........................................................................................................10

Pressure Relief Valve ...................................................................................10

Water Line Connections ...............................................................................10

Closed Water Systems ................................................................................. 11

Thermal Expansion ......................................................................................11

ELECTRICAL DATA ...............................................................................................12

General ........................................................................................................12

Branch Circuit ...............................................................................................12

Calculating Amperage/Overcurrent Protection .............................................12

Boiler Circuits ...............................................................................................12

Control Circuits .............................................................................................12

WIRING DIAGRAMS .............................................................................................13

OPERATION ..........................................................................................................15

Important ......................................................................................................15

General ........................................................................................................15

High Temperature Limit ................................................................................15

Filling the Boiler ............................................................................................15

Initial Start Up ...............................................................................................15

Temperature Regulation ...............................................................................15

Temperature Controls ...................................................................................16

Draining ........................................................................................................16

MAINTENANCE ....................................................................................................17

Schedule ......................................................................................................17

System Cleaning ..........................................................................................17

Flushing ........................................................................................................17

Sediment Removal .......................................................................................17

Lime Scale Removal ....................................................................................17

TROUBLESHOOTING CHECKLIST .....................................................................18

Not Enough or No Hot Water .......................................................................18

Water is Too Hot ...........................................................................................18

Boiler Makes Strange Sounds ......................................................................18

Leakage Checkpoints ...................................................................................18

WARRANTY ..........................................................................................................19

INTRODUCTION

Thank You for purchasing this boiler. Properly installed and maintained, it should give you years of trouble free service.

Abbreviations Found In This Instruction Manual:

• ANSI - American National Standards Institute

• ASME - American Society of Mechanical Engineers

• GAMA - Gas Appliance Manufacturer’s Association

• NEC - National Electrical Code

• NFPA - National Fire Protection Association

• UL - Underwriters Laboratory

PREPARING FOR THE INSTALLATION

1. Read the “General Safety” section of this manual rst and then the entire manual carefully. If you don’t follow the safety

rules, the boiler may not operate safely. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

This manual contains instructions for the installation, operation,

and maintenance of the electric boiler. It also contains warnings throughout the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the boiler and your safety. READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE BOILER.

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. IT IS NECESSARY THAT ALL WATER PIPING AND THE ELECTRICAL WIRING BE INSTALLED AND CONNECTED AS SHOWN IN THE DIAGRAMS.

Particular attention should be given to the installation of

thermometers at the locations indicated in the diagrams as these are necessary for checking the operation of the heater.

fuses always use the correct size for the circuit. See page 12 through 14.

The principal components of the heater are identied on page 8.

The model and rating plate on page 9 interprets certain markings into useful information. Both of these references should be used to identify the heater, its components and optional equipment.

2. The installation must conform with these instructions and the local code authority having jurisdiction and the requirements of the power company. In the absence of code requirements,

follow NFPA-70 (current edition). The National Electrical Code

may be ordered from: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

3. If after reading this manual you have any questions or do not understand any portion of the instructions, call the toll free number on the back cover for further assistance.

A sample rating plate and barcode tag are shown on page 9 of

this manual. In order to expedite your request, please have the serial number and item ID from the barcode tag available for the technician.

4. Carefully plan your intended placement of the boiler. Examine the location to ensure the boiler complies with the “Locating the

New Boiler” section in this manual.

Installation and service of this boiler requires ability equivalent

to that of a licensed tradesman or qualied agency (page 2) in the eld involved. Plumbing and electrical work are required.

5. For installation in California this boiler must be braced or anchored to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may

be obtained from California Ofce of the State Architect, 1102 Q

Street, Suite 5100, Sacramento, CA 95811.

Be sure to turn off power when working on or near the electrical

system of the heater. Never touch electrical components with wet hands or when standing in water. When replacing

6. Massachusetts Code requires this boiler to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5.00.

DIMENSION DATA

SIZES AND DATA NW37 THRU NW150

Model Number

Prex Gal. Cap. Std. KW Input

SW SW SW SW SW SW SW SW

SW SW SW SW

SW SW SW SW SW

SW SW SW SW

* All ttings under 4” will be threaded type. All ttings 4” and larger will be anged. 3” ttings extend 4” beyond jacket.

** Where overall height is a problem a larger diameter vessel with a reduced height may be furnished.

Lifting lugs and channel skid base on 96 gallon and larger units.

37 37 37 37 37 37 37 37

60 60 60 60

96 96 96 96 96

150 150 150 150

45K 60K 75K

90K 105K 120K 150K 180K

210K 240K 270K 300K

330K 390K 420K 450K 480K

540K 600K 660K 720K

D E F G** H J K S T

42 32 32 32 32 32 32 32

32 32 32 32

36 36 36 36 36

46 46 46 46

30 30 30 30 30 30 30

30 30 30 30

38 38 38 38 38

44 44 44 44

12 12 12 12 12 12 12

12 12 12 12

16 16 16 16 16

19 19 19 19

69 1/2 69 1/2 69 1/2 69 1/2 69 1/2

69 1/2 69 1/2 69 1/2 69 1/2

12 1/2 12 1/2 12 1/2 12 1/2 12 1/2 12 1/2 12 1/2 12 1/2

12 1/2 12 1/2 12 1/2 12 1/2

17 17 17 17 17

20 20 20 20

1 1/2 1 1/2 1 1/2 1 1/2 1 1/2

2 2 2 2

17 17 17 17 17

20 20 20 20

22 22 22 22 22

27 27 27 27

Inlet* &

Outlet*

4 4 4 4 4 4 4 4

4 4 4 4

5 5 5 5 5

5 1/2 5 1/2 5 1/2 5 1/2

Boiler

Drain

3 3 2 3 3 3 3 3

3 3 3 3

4 4 4 4 4

5 5 5 5

1 1 1 1 1 1 1 1

1 1 1 1

1 1/4 1 1/4 1 1/4 1 1/4 1 1/4

1 1/2 1 1/2 1 1/2 1 1/2

SIZES AND DATA NW220 THRU 670

Model Number

Prex Gal. Cap.

SW SW SW SW SW SW SW

SW SW SW SW SW SW

SW SW SW SW

SW SW SW SW SW SW

NOTE: For boilers 3400KW to 6000KW, consult factory. * All ttings under 4” will be threaded type. All ttings 4” and larger will be anged.

** Where overall height is a problem a larger diameter vessel with a reduced height may be furnished.

220 220 220 220 220 220 220

334 334 334 334 334 334

400 400 400 400

500 500 500 500

670 670 670 670 670 670

Std. KW

Input

780K 840K 900K

960K 1020K 1080K 1140K

1200K 1260K 1380K 1500K 1620K 1740K

1800K 1860K 1980K 2100K

2200K 2340K 2460K 2580K

2700K 2820K 2940K 3060K 3180K 3300K

D E F G** H J K S T

25 60 60 60 60 60 60

60 60 60 60 60 60

66 66 66 66

72 72 72 72

78 78 78 78 78 78

50 50 50 50 50 50

56 56 56 56

62 62 62 62

68 68 68 68 68 68

71 71 71 71 71 71 71

99 99 99 99 99 99

90 1/2 90 1/2 90 1/2 90 1/2

96 1/2 96 1/2 96 1/2 96 1/2 96 1/2 96 1/2

21 21 21 21 21 21 21

25 25 25 25 25 25

25 1/2 25 1/2 25 1/2 25 1/2

26 1/2 26 1/2 26 1/2 26 1/2

30 1/2 30 1/2 30 1/2 30 1/2 30 1/2 30 1/2

2 2 2 2 2 2 2

2 2 2 2 2 2

2 1/2 2 1/2 2 1/2 2 1/2

2 1/2 2 1/2 2 1/2 2 1/2 2 1/2 2 1/2

25 1/2 25 1/2 25 1/2 25 1/2 25 1/2 25 1/2 25 1/2

25 1/2 25 1/2 25 1/2 25 1/2 25 1/2 25 1/2

30 30 30 30

34 34 34 34

38 38 38 38 38 38

30 30 30 30 30 30 30

30 30 30 30 30 30

33 33 33 33

36 36 36 36

39 39 39 39 39 39

5 1/2 5 1/2 5 1/2 5 1/2 5 1/2 5 1/2 5 1/2

7 1/4 7 1/4 7 1/4 7 1/4 7 1/4 7 1/4

7 3/4 7 3/4 7 3/4 7 3/4

7 3/4 7 3/4 7 3/4 7 3/4 7 3/4 7 3/4

Inlet* &

Outlet*

5 5 5 5 5 5 5

6 6 6 6 6 6

8 8 8 8

8 8 8 8 8 8

Boiler

Drain

1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2

2 2 2 2 2 2

2 2 2 2

2 2 2 2 2 2

+ 14 hidden pages