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A.O. Smith Burkay HW-300 Instruction Manual

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

    Gas fired commercial copper boilers instruction manual printed 0213 321078-002 thank you for buying this energy efficient boiler. We appreciate your confidence in our products. Models: hw 300, 399, 420, 520, 670 for hydronic heating and hot water supply up - flow models installation - operation main...

  • Page 2: Table of Contents

    2 system connections ........................................................................ 16 air requirements ............................................................................. 16 unconfined space ........................................................................... 16 fresh air...

  • Page 3: Warning

    3 the proper installation, use and servicing of this boiler is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your boiler to warn you and others of a potential injury hazard. Read and obey all safety...

  • Page 4: General Safety

    4 grounding instructions this boiler must be grounded in accordance with the national electrical code, canadian electrical code and/or local codes. Boiler is polarity sensitive; correct wiring is imperative for proper operation. This boiler must be connected to a grounded metal, permanent wiring sys...

  • Page 5: Introduction

    5 this design complies with the current edition of the ansi z21.13 low-pressure boiler standard. Compliance under this standard implies that when the boiler underwent test, the gas manifold and control assembly pro vided on the boiler met safe lighting and other performance criteria. Detailed instal...

  • Page 6

    6 dimensions and capacity data extra opening for thermometer a n d p r e s s u r e relief valve hw-520 and hw--670 dimensions in inches models hw-300 hw-399 hw-420 hw-520 hw-670 a overall height 65 (1651) 57-1/8 (1451) 57-1/8 (1451) 68-5/16 (1735) 67-1/2 (1715) b height to top of jacket 43-1/4 (1099...

  • Page 7: Electrical Requirements

    7 table 3. Recovery capacities models type of gas input °f 20 40 50 60 70 80 btu/hr kw °c (11) (22) (28) (33) (39) (44) hw 300 natural 300,000 88 gph 1,455 727 582 485 416 364 propane lph 5,506 2,753 2,202 1,835 1,573 1,377 hw 399 natural 399,000 117 gph 1,935 967 774 645 553 484 propane lph 7,323 3...

  • Page 8: Control Components

    8 figure 2. Component locations control components.

  • Page 9

    9 thermal balancer figure 5 shows the internal wiring of the thermal balancer. The device may be tested after disconnecting the four leads from their respective terminals on the unit. 1. Apply a test light to the yellow and red leads. • the lamp should light as the contact in this circuit is normall...

  • Page 10: Caution

    10 pressure relief valve an asme rated pressure relief valve is furnished with the boiler. A fitting for the pressure relief valve is provided in the top of the boiler. Never operate the heating elements without being certain the boiler is filled with water and a properly sized pressure relief valve...

  • Page 11

    11 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 contacts and conseq...

  • Page 12

    12 boiler installation considerations hydronic system 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 coppe...

  • Page 13

    13 cooling piping when the boiler is used in conjunction with a refrigeration system it must be installed so that the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler, see figure 7. Water temperature in the heating sys...

  • Page 14

    14 flow switch the flow switch is a safety device which must be installed at the water outlet of the unit to prevent main burner operation in the event of inadequate water flow through the unit. An accessory package containing a flow switch is available for this application. This switch may be mount...

  • Page 15: General Requirements

    15 general requirements required ability installation or service of this boiler requires ability equivalent to that of a qualified service technician in the field involved. Plumbing, air supply, venting, gas supply, and electrical work are re quired. Location when installing the boiler, consideratio...

  • Page 16

    16 air requirements for safe operation an adequate supply of fresh uncontaminated air for combustion and ventilation must be provided. An insufficient supply of air can cause recirculation of combustion products resulting in contamination that may be hazardous to life. Such a condition often will re...

  • Page 17

    17 confined space a confined space is one whose volume is less than 50 cubic feet per 1,000 btu/hr (4.8 cubic meters per kw) of the total input rating of all appliances installed in the space. Openings must be installed to provide fresh air for combustion, ventilation and dilution in confined spaces...

  • Page 18

    18 the confined space shall be provided with two permanent vertical ducts, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. The vertical ducts shall communicate directly with the outdoors. See figure 13. Each duct openin...

  • Page 19

    19 fittings and unions in gas line must be of metal to metal type. Apply joint compounds (pipe dope) sparingly and only to the male threads of pipe joints. Do not apply compound to the first two threads. Use compounds resistant to the action of liquefied petroleum gases. The boiler and its gas conne...

  • Page 20

    20 table 12. S uggested p ipe s ize f or m ul tiple g as a ppliances (n atural g as ) nominal maximum capacity of pipe in btu/hr and kw for gas pressures of 14 in. W .C. (0.5 psi) or less and iron pipe a pressure drop of 0.5 in. W .C. (based on 0.60 specific gravity gas w/heating v alue of 1,000 btu...

  • Page 21: Venting

    21 venting standard venting type b venting may be used with these boilers. All local utility regulations on venting should be followed. Vent sizing, installation and termination shall be in accordance with the current edition of the national fuel gas code, ansi z223.1, or can/csa b149.1, installatio...

  • Page 22

    22 sidewall venting the optional sidewall power vent system is certified for maximum 100' equivalent venting. The power vent kits p/n for hw300, 399- 420, 520, 670 are 325614-000, 325614-001, 325614-002 and 325614-003 respectively. If you are installing the optional power vent kit, refer to your hw ...

  • Page 23

    23 model hw-300 boiler input: 300,000 btuh draft hood outlet 8" required connector or smoke pipe diameter connector rise in feet total vent height (measured in feet above draft hood) 10 15 20 30 40 50 60 80 100 connector diameter (in inches) 1 10 10 10 10 10 10 10 10 10 2 10 10 10 10 10 10 10 10 10 ...

  • Page 24: Gas Supply Connections

    24 4. When installing multiple boilers in the same gas supply system it is recommended that individual positive lock-up gas pressure regulators be installed at each unit. Pipe sizes for propane gas make sure to contact the gas supplier for pipe sizes, tanks, and 100% lockup gas pressure regulator. P...

  • Page 25

    25 adjustment, if required, is performed as follows: 1. Set primary system temperature control dial (thermostat) at lowest setting so that boiler will not call for heat. 2. Attach a pressure gauge to the tapping in the control string elbow. 3. Reset primary system temperature control dial (thermosta...

  • Page 26

    26 boiler start up and operations after placing the boiler into operation, the ignition system safety shutoff device must be tested by the following test method . 1. Reset high limit temperature control to lowest setting. (see figure 3 on page 9). 2. Reset system controller to maximum setting, causi...

  • Page 27

    27 figure 20. Spark ignition pilot burner and burner flame figure 21. Adjusting pilot flame 2. Pilot burner - electronic ignition to establish pilot flame without main burner operation, it will be necessary to perform the following steps: servicing of the pilot burner (every six months) includes kee...

  • Page 28

    28 6. Remove the pressure gauge or manometer from the manifold pressure tapping. Replace the screw-in plug in the manifold pressure tap. 7. Repeat steps 7 thru 11 of the operating instructions on page 31. The boiler will resume normal operation. When the boiler is operating at full capacity, or full...

  • Page 29

    29 start stage 1 trial for ignition stage 2 main burner operation end thermostat (controller) calls for heat spark generator powered first valve (pilot) operator opens pilot burner operation pilot burner lights. Pilot burner does not light module senses module response flame current. S-8600m after 1...

  • Page 30

    30 lighting and operating instructions (natural and propane for hw300 - hw399).

  • Page 31

    31 lighting and operating instructions (natural and propane with i.I.D. For hw420 & up).

  • Page 32: Troubleshooting

    32 table 17. Cer-temp 80 recovery system checkout procedure before any extensive troubleshooting, perform the following: ensure that: • voltage (120 vac) is supplied to the boiler. • system control (tank temperature control, thermostat, etc.) is calling for boiler operation (call for heat). • other ...

  • Page 33

    33 checking honeywell s-8600h or s-8600m 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 attached to pilot...

  • Page 34

    34 checking honeywell s-8600h or s-8600m 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 orifice is un...

  • Page 35

    35 checking honeywell s-8600h or s-8600m intermittent ignition controls pilot burner lights but main burner does not light does the pilot flame cover 3/8” to 1/2” of igniter/sensor rod? Does spark stay on for more than 15 seconds after the pilot is “proven” (lit)? Ensure the ground wire and ignition...

  • Page 36

    36 checking honeywell s8600h or s-8600m 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 boiler for good ground connection? Is voltage (24vac) across transformer positive...

  • Page 37

    37 figure 22. Location of led's yellow led flash code a indicates recommended service action heartbeat normal flame signal not applicable 2 weak flame signal- system will operate reliably but flame signal is less than desired. Note: this indication may flash temporarily during or shortly after light...

  • Page 38

    38 green led flash code (x+y) a indicates next system action recommended service action off no "call for heat" not applicable none flash fast startup - flame sense calibration not applicable none heartbeat normal operation not applicable none 2 5 minute retry delay • pilot flame not detected during ...

  • Page 39

    39 green led flash code (x+y) a indicates next system action recommended service action off no "call for heat" not applicable none flash fast startup - flame sense calibration not applicable none heartbeat normal operation not applicable none 3 recycle • flame failed during run initiate new trial fo...

  • Page 40: General Maintenance

    40 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 boiler should be kept clean and free from lint and debri...

  • Page 41

    41 venting maintenance it is recommended that the heating surfaces and vent piping of the boiler 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. Replace any damaged or deteriorated part...

  • Page 42: Wiring

    42 the electrical connections must be made so that the circulating pump will operate before the gas control valve opens. At no time may the controlling system allow the burner to fire when there is no water flow through the boilers. Refer to the diagram in figure 24 on pages 43 for proper wiring seq...

  • Page 43

    43 120 vac 60 hz l1 (hot) l2 (neutral) ) l a r t u e n ( 2 l ) t o h ( 1 l 120 vac 60 hz 120v 24v high limit ignition module chassis ground igniter wire to pilot note: if replacing any factory wiring, use type 105°c wire or equivalent, except for the ignition wire which uses 250°c wire and the coil ...

  • Page 44

    44 figure 25. Cer - temp 80 - 1 unit installation - for hot water supply application figure 26. Schematic: cer - temp 80 - 1 unit installation - for hot water supply application.

  • Page 45

    45 figure 27. Cer - temp 80 - 2 or 3 unit installation connection diagram - for hot water supply application.

  • Page 46

    46 figure 28. Cer - temp 80 - 2 or 3 unit installation schematic diagram - for hot water supply application.

  • Page 47: Piping Diagrams

    47 n otes : 1. P re ferred piping diagram . 2. The tempera ture and pre ssure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. S ervi ce val ves are shown for servicing uni t. Howeve r, local codes s hall govern their usage . 4. A. O. S mi th piping me...

  • Page 48

    48 n ot es : 1. Pr ef err ed piping diag ra m . 2. The te m pe ra tu re and p re ss ur e relie f v al ve s ett ing s hall no t e xc eed p re ss ur e ra ting o f an y co m ponen t in the syst em . 3. Se rv ic e val ve s ar e shown fo r s erv ic ing uni t. Howe ve r, lo cal c ode s shall go ve rn thei...

  • Page 49

    49 n otes : 1. Pre ferred piping diagram . 2. The tempera ture and pressure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. Service valves are shown for s ervicing uni t. Howeve r, local codes shall govern their usage . 4. A. O. S mi th piping me thod...

  • Page 50

    50 n otes : 1. Pre ferred piping diagram . 2. The tempera ture and pressure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. Service valves are shown for s ervicing uni t. Howeve r, local codes shall govern their usage . 4. A. O. S mi th piping me thod...

  • Page 51

    51 n otes : 1. Pre ferred piping diagram . 2. The tempera ture and pressure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. Service valves are shown for s ervicing uni t. Howeve r, local codes shall govern their usage . 4. A. O. S mi th piping me thod...

  • Page 52

    52 n otes : 1. Pre ferred piping diagram . 2. The tempera ture and pressure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. Service valves are shown for s ervicing uni t. Howeve r, local codes shall govern their usage . 4. A. O. S mi th piping me thod...

  • Page 53

    53 n otes : 1. P re ferred piping layou t. 2. The tempera ture and pres sure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. S er vi ce v alve s are s hown for s ervicing boile r. Howeve r, local codes shall govern their usage . Hw b urk a y boiler (3...

  • Page 54

    54 figure 36. Two boilers primar y/ secondar y hydronic piping system n otes : 1. Pre ferred piping layou t. 2. The tempera ture and pres sure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. Ser vi ce v alve s are s hown for s ervicing boile r. Howeve...

  • Page 55

    55 figure 37. Three boilers primar y/ secondar y hydronic piping system n otes : 1. Pre ferred piping la you t. 2. The tempera ture and pre ssure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. Servi ce v al ves are s hown for servicing boile r. Howev...

  • Page 56

    56 figure 38. Four boilers primar y/ secondar y hydronic piping system n otes : 1. Pre ferred piping la you t. 2. The tempera ture and pre ss ure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. Ser vice valve s are shown for s ervicing boile r. Howeve...

  • Page 57

    57 figure 39. Zone pumping/ horizont al buffer t ank hea ting system ex pansion t ank make-u p w ater zone pumps zone loo p supplies zone returns air se par at or thermal accumul at or (buffer t ank) finished floor aos st orage t ank n otes : 1. Pre ferred piping layou t. 2. The tempera ture and pre...

  • Page 58

    58 figure 40. Zone pumping/ vertical buffer t ank hea ting system n otes : 1. Pre ferred piping la you t. 2. The tempera ture and pre ss ure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. Ser vice valve s are shown for s ervicing boile r. Howeve r, l...

  • Page 59

    59 figure 41. Boiler/ vertical buffer t ank hea ting system n otes : 1. Pre ferred piping layou t. 2. The tempera ture and pres sure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. Servi ce v alve s are s hown for s ervicing boile r. Howeve r, lo cal ...

  • Page 60

    60 figure 42. Boiler/ vertical buffer t ank, 3 w ay mi xing v al ve hea ting system n otes : 1. Pre ferred piping la you t. 2. The tempera ture and pre ssure relie f valve se tting shall no t exceed pressure ra ting o f any componen t in the sys tem . 3. Servi ce val ves are shown for servicing boil...

  • Page 61: Limited Warranty

    61 limited warranty a. O. Smith corporation, the warrantor, extends the following limited warranty to the owner of this boiler: 1. If within ten years after initial installation of the boiler, a heat exchanger or gas burner should prove upon examination by the warrantor to be defective in material o...

  • Page 62

    62 25589 highway 1, mcbee, sc 29101 technical support: 800-527-1953 • parts: 800-433-2545 • fax: 800-644-9306 www.Hotwater.Com.