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  4. Burkay HW-300
  5. Installation Operation & Maintenance

A.O. Smith Burkay HW-300 Installation Operation & Maintenance

Manual is about: UP-FLOW MODELS GAS-FIRED COMMERCIAL COPPER BOILERS FOR HYDRONIC HEATING AND HOT WATER SUPPLY

Summary of Burkay HW-300

  • Page 1

    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 seattle, wa stratford, ontario veldhoven, the netherlands w w w.Hotwater.Com part no. 211683-000 rev.02 printed in u.S.A. 0905 supersedes part no's, 210...

  • Page 2: Rough-In Dimensions

    2 2 2 2 2 rough-in dimensions table 2, specifications - canadian models only maximum maximum i.A.S. Maximum max. Heat transfer max. Heat transfer model type 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) 210,1...

  • Page 3

    3 3 3 3 3 table 3, recovery capacities - canadian models only input temp. (c) 11 17 22 26 33 39 44 50 56 61 67 72 78 model (btu/hr.) rise (f) 20 30 40 50 60 70 80 90 100 110 120 130 140 hw-300 300,000 lph 5,505 3,670 2,753 2,202 1,835 1,573 1,376 1,223 1,001 1,001 918 847 786 gph 1,455 970 727 582 4...

  • Page 4: Foreword

    4 4 4 4 4 caution text printed or outlined in red contains information relative to your safety. Please read thoroughly 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...

  • Page 5

    5 5 5 5 5 location 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. This location should also be such that the gas ig...

  • Page 6

    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 may result with an increased risk of asphyxiation....

  • Page 7

    7 7 7 7 7 1. Conventional installations 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. O. Smith copper heat exchang...

  • Page 8

    8 8 8 8 8 no. Suggested items for installation 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. 4 thermometer. 5 theraltime...

  • Page 9

    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 the inlet supply line between the appliance and the meter or valve to compensate for the thermal ex...

  • Page 10

    10 10 10 10 10 2a. Sizing gas supply 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. Table 6 is based on a pressure drop of 0.3 i...

  • Page 11

    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. This is the only distance used in determining the size of any section of gas piping. If the gravity factor is to be applied, the values ...

  • Page 12

    12 12 12 12 12 7. Set primary system temperature control dial (thermostat) to desired setting. Warning do not increase gas pressure above that specified on the rating plate, as overfiring will result in damage to the boiler, as well as increased risk of fire, sooting and asphyxiation. If gas pressur...

  • Page 13

    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. Any improper ...

  • Page 14

    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 total vent height(measured in feet above draft hood) rise in 10 15 20 30 40 50 60 80 100 feet connector diameter (in inches) 1 16 14 14 14 14 14 14 14 14 2 14 14 14 14...

  • Page 15

    15 15 15 15 15 venting maintenance - standard 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. Replac...

  • Page 16

    16 16 16 16 16 the storage tank temperature and pressure (t & p) relief valve must comply with the applicable construction provisions of the standard for relief valves and automatic gas shutoff devices for hot water supply systems, z21.22 and/or can1-4.4. The t & p valve must be of the automatic res...

  • Page 17

    17 17 17 17 17 connection diagram hwb & hw-300, -399, -420, -500 & -610 (natural gas) single stage i.I.D. - robertshaw ® gas valve hwb & hw-300, -399, -420, -520, -610 (natural gas only) - canadian models figure 10 ® robertshaw is a registered trademark of fulton controls corp..

  • Page 18

    18 18 18 18 18 connection diagram hwb, hw-420,-520, -610 (propane gas) single stage propane - robertshaw gas valve 24 volt -hw, hwb-420, -520, -610 canadian models figure 11.

  • Page 19

    19 19 19 19 19 single stage propane robertshaw gas valve 24 volt - hwb, hw-300, 399 canadian models figure 11a connection diagram hwb & hw 300, 399 (propane gas) figure 13.

  • Page 20

    20 20 20 20 20 hw-300, hw-399, hw-420, hw-500 & hw-670 (natural gas) single stage i.I.D. - robertshaw gas valve hw-300, -399, -420, -520 & 670 (natural gas only) - u.S. Models figure 11b.

  • Page 21

    21 21 21 21 21 hw-300, hw-399, hw-420, hw-500 & hw-670 (propane gas) figure 12 single stage i.I.D. - robertshaw gas valve hw-300, -399, -420, -520 & 670 (propane gas only) - u.S. Models figure 11c.

  • Page 22

    22 22 22 22 22 2. Linear-temp installations 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). Multiple boiler installations are more effective when th...

  • Page 23

    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 shutdown of reset controls ...

  • Page 24

    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 ...

  • Page 25

    25 25 25 25 25 cer-temp 80 - 1 unit installation - for hot water supply application canadian models, junction box w/6 terminals figure 17 figure 19 cer-temp 80 - 1 unit installation - for hot water supply application u.S. Models, jucntion box w/4 terminals figure 18.

  • Page 26

    26 26 26 26 26 cer-temp 80 - 2 or 3 unit installation - for hot water supply application canadian models, junction box w/6 terminals figure 20

  • Page 27

    27 27 27 27 27 figure 21 schematic canadian models, junction box w/6 terminals.

  • Page 28

    28 28 28 28 28 cer-temp 80 - 2 or 3 unit installation connection diagram (for hot water supply application) u.S. Models, junction box w/4 terminals figure 22.

  • Page 29

    29 29 29 29 29 cer-temp 80 - 2 or 3 unit installation schematic diagram (for hot water supply application) u.S. Models, junction box w/4 terminals figure 23.

  • Page 30

    30 30 30 30 30 figure 24 booster - recovery wiring diagram canadian models, junction box w/6 terminals shure-temp booster - recovery wiring diagram (two temperature system) canadian models, junction box w/6 terminals figure 25.

  • Page 31

    31 31 31 31 31 booster - recovery wiring diagram u.S. Models, junction box w/4 terminals figure 26 shure - temp booster - recovery wiring diagram two-temperature system u.S. Models, junction box w/4 terminals figure 27.

  • Page 32

    32 32 32 32 32 water line connections this section provides detailed installation diagrams for typical methods of application for the unit using a cer-temp 80 recovery system (for one temperature water), and either booster-recovery or the shure-temp booster-recovery system (for two temperature water...

  • Page 33

    33 33 33 33 33 use anti-scald valve(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 tank temperature control setting will cause the sensor to close its contact...

  • Page 34

    34 34 34 34 34 figure 29 important the installation of safety flow switch as shown is required to protect the boiler in case of water service interruption or circulator failure (a.O. Smith pkg. No. 211480). + piping and fittings between gate valves and boilers should be brass or bronze. Other piping...

  • Page 35

    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 horizontal tank wiring - figures 17, 18, 19 install in accordance with all local codes important the installation of safety flow switch as shown is required to protect the boiler in...

  • Page 36

    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 tank, cer-temp 80 important the installation of safety flow switch as shown is required to protect the boiler in case of water service interruption or circulator failure (a.O. Smith pk...

  • Page 37

    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 horizontal tank important the installation of safety flow switch as shown is required to protect the boiler in case of water service interruption or circulator failure (a.O....

  • Page 38

    38 38 38 38 38 three hw-520's, hw-610's or hw-670's up-flow model commercial boiler with vertical tank, cer-temp 80 important the installation of safety flow switch as shown is required to protect the boiler in case of water service interruption or circulator failure (a.O. Smith pkg. No. 211480). + ...

  • Page 39

    39 39 39 39 39 three hw-520's, hw-610's or hw-670's up-flow model commercial boiler with horizontal tank, cer-temp 80 important the installation of safety flow switch as shown is required to protect the boiler in case of water service interruption or circulator failure (a.O. Smith pkg. No. 211480). ...

  • Page 40

    40 40 40 40 40 figure 35 wiring - figure 25 or 27 install in accordance with all local codes booster recovery system (patented) two temperature system without recirculation one hw-300, hw-399, hw-420, hw-520, hw-610 or hw-670 up-flow model commercial boiler with vertical tank + piping and fittings b...

  • Page 41

    41 41 41 41 41 figure 36 booster recovery system (patented) two temperature system without recirculation one hw-300, hw-399, hw-420, hw-520, hw-610 or hw-670 up-flow model commercial boiler with horizontal tank wiring - figure 25 or 27 install in accordance with all local codes important the install...

  • Page 42

    42 42 42 42 42 figure 37 booster recovery system (patented) - two temperature system without recirculation one hw-300, hw-399, hw-420, hw-520, hw-610 or hw-670 up-flow model commercial boiler with horizontal tank + piping and fittings between gate valves and boilers should be brass or bronze. Other ...

  • Page 43

    43 43 43 43 43 4 flow regulating 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. Temperature rise is observed between the boiler inlet and outlet thermometers. 5 flow regulating pl...

  • Page 44

    44 44 44 44 44 figure 39 with two vertical tanks with three vertical tanks danger temperature setting should not exceed safe use temperature at fixtures. See tank temperature control warning on page 32. If higher preheat temperatures are necessary to obtain adequate booster output, add an anti-scald...

  • Page 45

    45 45 45 45 45 two horizontal tank installation three horizontal tank installation figure 40 danger temperature setting should not exceed safe use temperature at fixtures. See tank temperature control warning on page 32. If higher preheat temperatures are necessary to obtain adequate booster output,...

  • Page 46

    46 46 46 46 46 important it is recommended that a qualified person perform the initial firing of the boiler. At this time the user should not hesitate to ask the individual any questions which he may have in regard to the operation and maintenance of the unit. Filling and venting 1. Fast fill system...

  • Page 47

    47 47 47 47 47 lighting and operating instructions (natural and propane gas with i.I.D.) warning: hot water can produce 3rd degree burns in 6 seconds at 140° f. (60° c). In case of power failure do not attempt to operate appliance. Improper installation, adjustment, alteration, service or maintenanc...

  • Page 48

    48 48 48 48 48 lighting and operating instructions propane (lp) standing pilot models warning: hot water can produce 3rd degree burns in 6 seconds at 140° f. (60° c). In case of power failure do not attempt to operate appliance. Improper installation, adjustment, alteration, service or maintenance c...

  • Page 49

    49 49 49 49 49 4. Adjust pilot flame. To 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. 42. Figure 42 if the pilot burner ignites but the main bu...

  • Page 50

    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....

  • Page 51

    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. Checking and adjusti...

  • Page 52

    52 52 52 52 52 normal operating sequence with intermittent ignition controls (i.I.D.) 1. System control calls for boiler operation. 2. Spark begins at pilot burner. 3. Pilot gas control valve is energized. Gas flows to pilot burner. 4. Pilot burner gas ignites. The sensing probe on the pilot burner ...

  • Page 53

    53 53 53 53 53 protector switch figure 48 pressure reducing valve 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. To inspect the ...

  • Page 54

    54 54 54 54 54 to 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 ta...

  • Page 55

    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. To assure continued good performance, the following recommendations are made. The area around the unit should be kept clean and free from lint...

  • Page 56

    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. For long life, copper or brass is recommended ...

  • Page 57

    57 57 57 57 57 troubleshooting cer-temp 80 recovery system checkout procedure use this checkout for cer-temp 80 recovery systems. (for hot water supply application only) system operation checkout sequence contact incorrect cause remedy set tank temperature circulating pump pump and burner tank tempe...

  • Page 58

    58 58 58 58 58 checking honeywell s-8600h or s-8610m intermittent ignition controls turn off gas supply. Is voltage (24 vac) across the 24 v terminals on module during “call for heat”? Turn off power supply. Is ignition cable firmly plugged into pilot assembly and module? Is ground wire firmly attac...

  • Page 59

    59 59 59 59 59 checking honeywell s8600h or s-8610m intermittent ignition controls spark at 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 or...

  • Page 60

    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? Does spark stay on for more than 15 seconds after the pilot is “proven” (lit)? Ensure the ground wire ...

  • Page 61

    61 61 61 61 61 checking honeywell s8600h or s-8610m intermittent ignition controls no spark at pilot burner but pilot will not light turn off gas supply. Is there a good connection between terminals? Is module securely attached to appliance for good ground connection? Is voltage (24vac across transf...

  • Page 62

    62 62 62 62 62 limited warranty a. O. Smith corporation, the warrantor, extends the following limited warranty to the owner of this hydronic boiler. 1. If within ten years after initial installation of the boiler, a heat exchanger, coil or gas burner shall prove upon examination by the warrantor to ...

  • Page 63

    63 63 63 63 63.

  • Page 64

    64 64 64 64 64 5621 w. 115th street, alsip, il 60803 phone: 1-800-433-2545 fax: 1-800-433-2515 e-mail: parts@hotwater.Com • www.Hotwater.Com replacement parts.