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

Page 1: ...ONTAINS INFORMATION RELATIVE TO YOUR SAFETY PLEASE READ THOROUGHLY BEFORE USING APPLIANCE WARNING If the information in this manual is not followed exactly a fire or explosion may result causing prope...

Page 2: ...1451 68 5 16 1735 67 1702 64 3 4 1645 B Height to top of jacket 43 1 4 1099 45 1 8 1146 45 1 8 1146 56 1 4 1429 56 1 4 1429 56 1 4 1429 C Floor to center line water inlet 36 914 38 3 4 984 38 3 4 984...

Page 3: ...831 1 627 1 464 1 331 1 220 1 127 1 046 GPH 1 935 1 290 967 774 645 553 484 430 387 352 322 298 276 HW 420 420 000 LPH 7 708 5 138 3 854 3 083 2 569 2 202 1 927 1 713 1 542 1 401 1 285 1 186 1 101 GPH...

Page 4: ...MMON VENTINGSYSTEM 54 GENERALMAINTENANCE 55 Relief Valve 55 CLEANINGANDFLUSHINGINSTRUCTIONS 55 Internal Contaminants 55 Hot Water Supply Boilers Preventive Maintenance 55 Deliming 55 56 Deliming Solve...

Page 5: ...OF AIR WILL CAUSE RECIRCULATION OF COMBUSTION PRODUCTS RESULTING IN AIR CONTAMINATION THAT MAY BE HAZARDOUS TO LIFE SUCH A CONDITION OFTEN WILL RESULT IN A YELLOW LUMINOUS BURNER FLAME CAUSING CARBONI...

Page 6: ...y uncontaminated air should be obtained from remote or outside sources INSTALLATION CLEARANCES These boilers are approved for installation on combustible flooring in an alcove with minimum clearance t...

Page 7: ...w Installations A O Smith LINEAR TEMP systems have been designed to provide efficient trouble free operation of the boiler sizes covered in this manual with any of the following conditions a Unknown s...

Page 8: ...stallation is an excellent way to modernize the system The A O Smith boiler s should be installed on a pipe loop with a separate circulating pump selected from PUMPAND PIPE SIZING DATATABLE Figure 3 s...

Page 9: ...PIPINGISOLATION OFTHEBOILERFROMTHECHILLER FIGURE4 If the boiler is connected to chilled water piping or its heating coils are exposed to refrigerated air the boiler piping system must be equipped with...

Page 10: ...ched to the piping system When table 6 is to be used to select the piping size calculate the gas demand in terms of cubic feet per hour for each piping system outlet The gas demand for an appliance ca...

Page 11: ...ith a cubic foot per hour demand of 2 060 and with 50 lineal feet of gas supply line table 6 shows a pipe size of 3 76mm is required NOTE For other than 60 specific gravity apply multiplier factor as...

Page 12: ...or chimney must be a minimum height of 12 305mm above the annual snow fall to prevent blockage Building materials must not come in contact with combustion products from stack or chimney due to the de...

Page 13: ...NAND UNSAFE CONDITIONS Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure 3 CONNECTING BOI...

Page 14: ...12 12 12 12 12 12 12 2 12 12 12 10 10 10 10 10 10 3 12 10 10 10 10 10 10 10 10 4 or more 10 10 10 10 10 10 10 10 10 Number Total Total Vent Height Measured in Feet Above Draft Hood if Units Input 10...

Page 15: ...he combustion products are going up the chimney or gas vent properly by passing a lighted match or taper around the edge of the relief opening of the draft hood If the chimney or gas vent is drawing p...

Page 16: ...L REGULATIONS The boiler when installed must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the N...

Page 17: ...ECTIONDIAGRAM HWB HW 300 399 420 500 610 NATURALGAS SINGLESTAGEI I D ROBERTSHAW GASVALVE HWB HW 300 399 420 520 610 NATURAL GAS ONLY CANADIAN MODELS FIGURE10 Robertshaw is a registered trademark of Fu...

Page 18: ...18 18 18 18 18 CONNECTIONDIAGRAM HWB HW 420 520 610 PROPANEGAS SINGLESTAGEPROPANE ROBERTSHAWGASVALVE 24 VOLT HW HWB 420 520 610 CANADIAN MODELS FIGURE11...

Page 19: ...19 19 19 19 19 SINGLESTAGEPROPANEROBERTSHAWGASVALVE 24 VOLT HWB HW 300 399 CANADIAN MODELS FIGURE11A CONNECTION DIAGRAM HWB HW 300 399 PROPANEGAS FIGURE13...

Page 20: ...20 20 20 20 20 HW 300 HW 399 HW 420 HW 500 HW 670 NATURALGAS SINGLESTAGEI I D ROBERTSHAWGASVALVE HW 300 399 420 520 670 NATURAL GAS ONLY U S MODELS FIGURE11B...

Page 21: ...21 21 21 21 21 HW 300 HW 399 HW 420 HW 500 HW 670 PROPANEGAS FIGURE12 SINGLESTAGEI I D ROBERTSHAWGASVALVE HW 300 399 420 520 670 PROPANE GAS ONLY U S MODELS FIGURE11C...

Page 22: ...emperature thermostats A single bulb outdoor sensing control will prevent overheating of halls stairways or other uncontrolled areas There are occasions when outdoor temperatures are temporarily too w...

Page 23: ...IAGRAM TWO BOILER LINEAR TEMP INSTALLATION WITH TWO CIRCULATORS FIGURE13 CONTROLAPPLICATIONDIAGRAM THREEBOILERLINEAR TEMP INSTALLATIONWITHTHREECIRCULATORS FIGURE14 NOTE 1 Building temperature controls...

Page 24: ...ATION WITH TWO CIRCULATORS FIGURE15 NOTE 1 Building temperature controls supply electric power to building circulator 2 Main flow switch proves main water flow before energizing sequencing and resetti...

Page 25: ...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...

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 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...

Page 31: ...1 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 FIGUR...

Page 32: ...nt is recommended This will protect the dishwashers coffee urns water boilers water piping and other equipment When water softening or water treatment is not practical a comparatively easy method of p...

Page 33: ...as shown in the installation diagrams Thermometers are installed in the system as a means of detecting a possible liming condition in the boiler An increase of 3 C 5 F over the normal temperature rise...

Page 34: ...ON HW 520 HW 610 HW 670 WIRING FIGURES 17 18 19 INSTALLINACCORDANCE WITH ALL LOCAL CODES ONE HW 300 HW 399 HW 420 HW 520 HW 610 OR ONE HW 670 UP FLOW MODEL COMMERCIALBOILERWITHVERTICALTANK USETHISTAB...

Page 35: ...EIR USAGE PRESSURE RELIEF VALVE RATING SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM INSTALL THERMOMETER AND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 HW 670 USETHISTA...

Page 36: ...F ANY COMPONENT IN THE SYSTEM INSTALL THERMOMETER AND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 HW 670 WIRING FIGURES 20 21 22 OR 23 HEATERS SPACED 30 APART INSTALLINACCORDANCE WITH ALL LO...

Page 37: ...ED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM INSTALL THERMOMETER AND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 HW 670 WIRING FIGURES 20 21 22 or 23 INSTALLINACCORDANCE WITH ALL LOCA...

Page 38: ...SHOULD NOT EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM INSTALLTHERMOMETER AND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 HW 670 FIGURE 33 USETHISTABLEFORCORRECT PUMPAND WATER PI...

Page 39: ...EXCEED PRESSURE CAPACITY OF ANY COMPONENT IN THE SYSTEM INSTALLTHERMOMETERAND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 HW 670 WIRING FIGURES 20 21 22 OR 23 HEATERS SPACED 24 APART INSTAL...

Page 40: ...F IN OPENINGS PROVIDED ON HW 520 HW 610 HW 670 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...

Page 41: ...E BOOSTER OUTPUT ADD ANANTI SCALD VALVE FOR HOT WATER SUPPLIED TO FIXTURES USETHISTABLEFORCORRECT PUMPAND WATER PIPE SIZE Minimum B G Armstrong Model Pipe Size Pump Pump Number Inches Size Size HW 300...

Page 42: ...STALLATION 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 WIRING FIGURE 24 OR 26 INSTALLINACCORDAN...

Page 43: ...160 F with 20 F differential minimum Right Dial Tank Temperature Adjust to 140 F with 8 F differential minimum May be adjusted slightly higher if total demand of 180 F water requires higher tank tempe...

Page 44: ...TANKS DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEE TANK TEMPERATURE CONTROL WARNING ON PAGE 32 IF HIGHER PREHEATTEMPERATURESARENECESSARYTO OBTAIN ADEQUATE BOOSTER...

Page 45: ...ng causing a call for heat and allowing unit to run until High Limit Temperature Control trips 3 Resetting the High Limit Temperature Control to a higher setting unit should run 4 Reset System Control...

Page 46: ...ics are not evident check for accumulation of lint or other foreign material that restricts or blocks the air openings to the burner or boiler Also check for good flow of combustion and ventilating ai...

Page 47: ...OUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THEFIREDEPARTMENT C USE ONLY YOUR HAND TO PUSH IN OR TURN THE GAS CONTROL KNO...

Page 48: ...UCH ANY ELECTRIC SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CANNOT REACH YOUR GAS SUPPLIER CA...

Page 49: ...ot gas adjustment located in the gas valve The pilot flame should envelop 3 8 to 1 2 inch of the tip of the thermocouple Remove pilot adjustment cover screw fig 43b Turn inner adjustment screw or pilo...

Page 50: ...eads from a test flashlight The model N22T test kit combination flashlight and continuity tester is manufactured by the RAY O Vac Company Madison WI and available through local suppliers With the flas...

Page 51: ...S SECONDS Type Value HWB HWB HWB HWB HWB HWB Gas Btu Ft 3 HW 300 HW 399 HW 420 HW 520 HW 610 HW 670 Natural 1050 12 6 9 5 9 0 7 3 6 2 5 7 Propane 2500 30 0 22 6 21 4 17 3 14 8 13 4 IMPORTANT UNDER NO...

Page 52: ...e check the rating plate before making changes The input reduction is primarily achieved by reducing the size of the main burner orifices To do this the main burner orifices require replacement with o...

Page 53: ...2 x 1 1 2 x 1 tee for a 1 1 2 pipe application For larger pipe sizes use a reducing tee in order to keep the switch as close to the pipe as possible Install the flow switch in the branch top opening...

Page 54: ...rdered through A O Smith dealers authorized servicers or distributors Refer to the Yellow Pages for where to call or contact the A O Smith Enterprises Ltd P O Box 310 768 Erie St Stratford Ontario N5A...

Page 55: ...at may have accumulated during installation This is doubly important when a replacement boiler is installed into an existing system where Stop Leak or other boiler additives have been used Failure to...

Page 56: ...inue to fill until foaming action stops 9 When foaming action has stopped completely allow 10 to 15 minutes for the solvent to dissolve any remaining scale in the unit 10 Open the drain cock and drain...

Page 57: ...wiring Repair or defective replace valve Circulating pump Power off or system Check power supply and burner off wiring is incorrect and wiring Tank temperature control Replace thermostat defective Bur...

Page 58: ...s the ceramic insulator surrounding the electrode cracked or broken Replace pilot burner assembly Replace ignition module Turn on gas supply turn on power supply Securely connect cable and or ground w...

Page 59: ...e firmly attached to pilot assembly and GND terminal on module Are ignition cable and ground wire in good condition not brittle burnt or cracked Ensure ground strap is the closest metal to the igniter...

Page 60: ...he igniter sensor rod in good condition not broken or cracked Is the igniter sensor rod in good condition not worn corroded sooted or damaged Replace ignition module Correct the situation by consultin...

Page 61: ...pilot ground wire firmly attached to the pilot assembly and GND terminal on module Are high voltage cable and ground wire in good condition not brittle burnt or cracked Make sure pilot flame spreader...

Page 62: ...dministrative charges for forwarding the replacement part from the nearest distributor and returning the claimed defective part to such distributor c All cost necessary or incidental for any materials...

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...