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PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND

NOTIFY OWNER TO KEEP FOR FUTURE REFERENCE

PRINTED 0210 

317693-000 

GAS-FIRED COMMERCIAL COPPER BOILERS FOR 

HYDRONIC HEATING AND HOT WATER SUPPLY

•  INSTALLATION  •

  

OPERATION

  •

  MAINTENANCE  •  LIMITED WARRANTY

•  INDOOR ONLY

 

MODELS HW 300, 399, 420, 520, 610, 670

 

UP-FLOW MODELS

WARNING: If the information in this manual 

is not followed exactly, a fire or explosion 

may  result  causing  property  damage, 

personal injury or death.

—  Do  not  store  or  use  gasoline  or  other 

flammable  vapors  and  liquids  in  the 

vicinity of this or any other appliance.

—  WHAT TO DO IF YOU SMELL GAS

 

•  Do not try to light any appliance.

 

•  Do not touch any electrical 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, 

call the fire department.

—  Installation  and  service  must  be 

performed  by  a  qualified  installer, 

service agency or the gas supplier.

500 Tennessee Waltz Parkway

Ashland City, TN 37015

www.hotwater.com

Summary of Contents for Burkay HW-300

Page 1: ...rty damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light an...

Page 2: ...s Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and...

Page 3: ...3 GENERAL SAFETY...

Page 4: ...ns 14 VENTING 14 Venting the Boiler 14 Venting Maintenance 16 Venting Sidewall 16 Venting System 16 Venting Tables 17 SYSTEM INSTALLATIONS 18 Installations 18 Conventional 18 Linear Temp 18 Water Supp...

Page 5: ...to Center Line Gas Inlet 16 1 2 419 16 3 4 425 16 3 4 425 18 457 18 457 18 457 H Overall Depth 29 5 8 753 31 1 2 800 31 1 2 800 36 1 2 927 36 1 2 927 36 1 2 927 J Support Height 9 229 9 229 9 229 9 2...

Page 6: ...765 638 547 478 LPH 7245 3623 2898 2415 2070 1811 HW 420 420 000 123 GPH 2014 1007 806 671 576 504 LPH 7627 3813 3051 2542 2179 1907 HW 520 520 000 152 GPH 2494 1247 998 831 713 624 LPH 9443 4721 3777...

Page 7: ...onnected to the equipment grounding terminal or lead on the boiler CORRECT GAS MAKE SURE THE GAS ON WHICH THE BOILER WILL OPERATE IS THE SAME AS THAT SPECI FIED ON THE BOILER RATING PLATE DO NOT INSTA...

Page 8: ...stment to the gas pressure regulator is required See CHECKING AND ADJUSTING THE INPUT in this manual for inlet and manifold pressure requirements Also due to the input rating reduction required at hig...

Page 9: ...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 cont...

Page 10: ...NG THE PURPOSE OF A SAFETY RELIEF VALVE IS TO AVOID EXCESSIVE PRESSURE OR TEMPERATURE INTO THE STEAM RANGE WHICH MAY CAUSE SCALDING AT FIXTURES TANK EXPLOSION SYSTEM OR BOILER DAMAGE TO AVOID SCALDING...

Page 11: ...CAN CSA B149 TANK TEMPERATURE CONTROL The water temperature in the storage tank is controlled by the Tank Temperature Control The sensing element is mounted inside the hot water storage tank DANGER H...

Page 12: ...iler and tank for draining purposes see installation diagrams in this manual REQUIRED ABILITY Installation or service of this boiler requires ability equivalent to that of a licensed tradesman in the...

Page 13: ...struction air for combustion ventilation and draft hood dilution must be obtained from outdoors When directly communicating with the outdoors or communicating with the outdoors through vertical ducts...

Page 14: ...nd to the requirements of the local code authority having jurisdiction Good practice requires that all heavy piping be supported VENTING A TYPICAL BOILER INSTALLATION FIGURE 7 VENTING THE BOILER STAND...

Page 15: ...lid fuel burning equipment This practice is prohibited by many local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems Where a separate vent conn...

Page 16: ...verter and vent pipe running to the chimney Check parts and chimney for obstructions and clean as necessary 3 Remove burner from boiler and other metal parts as required to clean and vacuum the heat e...

Page 17: ...ld and Common Vent Diameter in Inches 2 1040 16 16 14 14 14 14 12 12 12 3 1560 20 18 18 16 16 14 14 14 14 4 2080 22 22 20 18 18 18 16 16 14 5 2600 26 24 22 20 20 18 18 18 18 6 3120 28 26 24 22 22 20 2...

Page 18: ...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 system flow rate b Varying flow rate as...

Page 19: ...installed with the replacement boiler s Make up water connections and accessories are not shown SCHEMATIC OF THE LINEAR TEMP SYSTEM FIGURE 12 Supply and return headers of the old system should be con...

Page 20: ...THE WARRANTY Constant water flow through the unit will wash away the copper s natural protective coating This is called velocity erosion This erosion is not as great a problem when intermittent circul...

Page 21: ...iping system When table 7 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 can be found by...

Page 22: ...e of 1 000 Btu per cubic foot Solution 2 HW 420 Boilers 840 000 Btuh 2 HW 610 Boilers 1 220 000 Btuh Total Btuh Input 2 060 000 Btuh Total Btuh Input 2 060 000 Btuh 2 060 cf h Btu per Cubic Foot of Ga...

Page 23: ...LOCAL 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 t...

Page 24: ...VALVE COIL LIMIT GND 4 X 4 JUNCTION BOX WITH TERMINAL STRIP WHITE GAS VALVE BROWN IGNITION MODULE WHITE YELLOW WHITE RED MV MV PV PV 24V GND GND GND SPARK TO PILOT 24V MV PV MV PV MV PV MV PV THERMAL...

Page 25: ...will normally require an automatic shutdown control if there is a continuous recirculating main and or if the entire building is not under control of space temperature thermostats A single bulb outdo...

Page 26: ...BOILER LINEAR TEMP INSTALLATION WITH TWO CIRCULATORS FIGURE 18 CONTROL APPLICATION DIAGRAM THREE BOILER LINEAR TEMP INSTALLATION WITH THREE CIRCULATORS FIGURE 19 NOTE 1 Building temperature controls...

Page 27: ...ng controls 3 Outdoor thermostat required if building controls do not provide automatic shutdown of reset controls during warm weather Boilers and Secondary Circulator are Controlled by Dual Bulb Dual...

Page 28: ...INSTALLATION FOR HOT WATER SUPPLY APPLICATION CANADIAN MODELS JUNCTION BOX W 6 TERMINALS FIGURE 21 FIGURE 23 CER TEMP 80 1 UNIT INSTALLATION FOR HOT WATER SUPPLY APPLICATION U S MODELS JUCNTION BOX W...

Page 29: ...29 CER TEMP 80 2 OR 3 UNIT INSTALLATION FOR HOT WATER SUPPLY APPLICATION CANADIAN MODELS JUNCTION BOX W 6 TERMINALS FIGURE 24...

Page 30: ...30 SCHEMATIC CANADIAN MODELS JUNCTION BOX W 6 TERMINALS FIGURE 25...

Page 31: ...31 CER TEMP 80 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM FOR HOT WATER SUPPLY APPLICATION U S MODELS JUNCTION BOX W 4 TERMINALS FIGURE 26...

Page 32: ...32 CER TEMP 80 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM FOR HOT WATER SUPPLY APPLICATION U S MODELS JUNCTION BOX W 4 TERMINALS FIGURE 27...

Page 33: ...ES 16 and 17 on pages 24 and 25 INSTALL IN ACCORDANCE WITH ALL LOCAL CODES ONE HW 300 HW 399 HW 420 HW 520 HW 610 OR ONE HW 670 UP FLOW MODEL COMMERCIAL BOILER WITH VERTICAL TANK USE THIS TABLE FOR CO...

Page 34: ...GE 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 DANGER TEMPERATU...

Page 35: ...TEM INSTALLTHERMOMETERAND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 HW 670 WIRING FIGURES 21 to 27 on pages 28 to 32 HEATERS SPACED 30 APART INSTALL IN ACCORDANCE WITH ALL LOCAL CODES FIGU...

Page 36: ...ANY COMPONENT IN THE SYSTEM INSTALL THERMOMETER AND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 HW 670 DANGER TEMPERATURE SETTING SHOULD NOT EXCEED SAFE USE TEMPERATURE AT FIXTURES SEETANKT...

Page 37: ...URE CAPACITY OF ANY COMPONENT IN THE SYSTEM INSTALLTHERMOMETERAND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 HW 670 FIGURE 32 WIRING FIGURES 21 to 27 on pages 28 to 32 INSTALL IN ACCORDANCE...

Page 38: ...ITY OF ANY COMPONENT IN THE SYSTEM INSTALLTHERMOMETERAND PRESSURE RELIEF IN OPENINGS PROVIDED ON HW 520 HW 610 HW 670 WIRING FIGURES 21 to 27 on pages 28 to 32 HEATERS SPACED 24 APART INSTALL IN ACCOR...

Page 39: ...g 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 serviceman 1 Flooding to level of burner...

Page 40: ...12mm of the sensing probe tip See Figure 35 FIGURE 35 Check for good terminal connection at the sensing probe at the pilot burner assembly if pilot does not light Check for electrical power to the val...

Page 41: ...6 of the OPERATING INSTRUCTIONS 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 OPER...

Page 42: ...M After 15 sec ignition shut down 5 minute time delay before re try S 8600H After 15 sec ignition system locks out must be manually reset FLAME CURRENT SENSED Spark generator off Second valve operator...

Page 43: ...OSITION FIGURE A ON OFF ON POSITION FIGURE B GAS VALVE CONTROL KNOB HONEYWELL GAS VALVE A B FIGURE C PILOT PILOT FIRING VALVE HANDLE OFF POSITION FIGURE D PILOT HANDLE ON POSITION LIGHTING INSTRUCTION...

Page 44: ...URN MAIN FIRING VALVE COUNTER CLOCKWISE TO OFF FIG C A ND T URN PILO T FIRING VALVE COUNTERCLOCKWISE T O OFF FIG E 4 SET T HE THERMOSTAT TO LOWWEST SETTING 1 STOP READ THE SAFETY INFORMATION ABOVE ON...

Page 45: ...ee from lint and debris Sweeping the floor around the boiler should be done carefully This will reduce the dust and dirt which may enter the burner and pilot air passages causing improper combustion a...

Page 46: ...and impellers It is recommended that after installation the boiler and system when filled should include the proper percentage of cleaning solution related to approximate water volume of the system Fi...

Page 47: ...mostat 20 F 10 C above tank water temperature Circulating pump and burner on Circulating pump on High limit control set too low Replace If problem proven to be at this control by applying jumper to te...

Page 48: ...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 wire Ca...

Page 49: ...ly 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 senso...

Page 50: ...iter 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 consulting the...

Page 51: ...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 hood i...

Page 52: ...Normal Flame Signal not applicable 2 Weak Flame Signal Sytem will operate reliably but flame signal is less than desired NOTE This indication may flash temporarily during or shortly after lightoff on...

Page 53: ...cks damage or tracking 8 Low secondary voltage supply below 15 5 Vac Control remains in wait mode When the fault corrects control resumes normal operation after a one minute delay Check transformer an...

Page 54: ...tion after a one minute delay Check transformer and AC line for proper input voltage to the control Check with full system load on the transformer 6 2 Failed trial for ignition resulting in lockout Re...

Page 55: ...part from the nearest distributor and returning the claimed defective part to such distributor c All cost necessary or incidental for any materials and or permits required for installation of the repl...

Page 56: ...500 Tennessee Waltz Parkway Ashland City TN 37015 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com...

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