A.O. Smith Burkay HW-300, User Manual

10

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 2 on Page 7).

2. 

Reset System Controller to maximum setting, 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  Controller  and  High  Limit  Temperature 

Control to desired temperature. If unit fails to run, refer to 

Troubleshooting section in this manual on Page 16.

Before operating the boiler, the entire system must be filled with 

water, purged of air and checked for leaks. Do not use Stop Leak 

or other boiler compounds. The gas piping should also be leak 

tested.
Any safety devices including low water cutoffs used in conjunction 

with  this  boiler  should  receive  periodic  (every  six  months) 

inspection to assure proper operation. A low water cutoff device 

of the float type should be flushed every six months. All pressure 

relief valves should be inspected and manually operated at least 

twice a year.

IMPORTANT

It is recommended that a qualified service technician 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 THE SYSTEM

1. 

Fast fill system through bypass until pressure approaches 

desired  system  pressure.  Close  bypass  valve  and  permit 

pressure to be established by the pressure reducing valve.

2. 

Vent all high points in system to purge system of air.

If pressure bleeding of system is desired, install valves as shown 

in the Piping Diagrams of the Instruction Manual.
Where  cast  iron  radiation  and  motorized  valves  are  used, 

conventional system pressure and installation practices should 

be followed.

Provisions should be made to permit manual venting of radiators 

or convectors.

PRECAUTIONS

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

until all corrective steps have been made by a qualified service 

technician:

•  Flooding to level of burner or controls or higher.
•  Exposure to fire.
•  If damaged.
•  Firing without water.
• 

Sooting.

PILOT AND MAIN BURNER

To  maintain  safe  operation  of  the  boiler,  check  the  pilot  and 

the  main  burner  once  every  six  months  for  proper  flame 

characteristics.

1. 

MAIN BURNER

The  main  burner,  Figure  6,  should  display  the  following 

characteristics:

•  Provide complete combustion of gas.
•   Cause rapid ignition and carryover of flame across entire 

burner.

•   Give reasonably quiet operation during ignition, burning 

and extinction.

•   Cause no excessive lifting of flame from burner ports.

If the proceeding burner characteristics 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 air to the 

unit. Maintain a clear area around the boiler at all times.

The boiler should be periodically inspected by a qualified servicer 

for continuous safe operation.
Qualified servicers should follow this procedure when the boiler’s 

burners need cleaning.

a. 

Turn off the electrical power and close the main manual gas 

shutoff valve. Refer to Lighting & Operating Instructions on 

Pages 14 and 15.
•  Allow boiler parts to cool before disassembly.

b. 

Remove main burner manifold assembly from boiler.
•  Refer to parts list supplied with this manual for 

disassembly aid.

c.  Remove any loose foreign material such as dust or lint with 

a  vacuum.  Check  all  ports,  orifices,  and  air  openings  for 

blockage. Dislodge any foreign material causing blockage. 

Remove any soot or carbon deposits with a rag making sure 

to remove any lint left on burner by vacuuming again.

d.  Reinstall the burner manifold assembly on boiler.

e. 

Restore electrical power and gas supply to boiler.
•  Put the boiler back in operation by following the lighting 

instructions in this manual or on the lighting and 

operating label on the boiler. Refer to Pages 14 and 15.

•  Check for gas leaks and proper boiler and vent operation.

FIGURE 6.  MAIN BURNER