197373-004 BTH 300-500 Instruction Manual

Instruction Manual
GAS FIRED COMMERCIAL COPPER BOILERS
MODELS: HW
300, 399, 420, 520, 670
FOR HYDRONIC HEATING AND
HOT WATER SUPPLY
UP - FLOW MODELS
INSTALLATION - OPERATION
MAINTENANCE - LIMITED WARRANTY
INDOOR ONLY
500 Tennessee Waltz Parkway
Ashland City, TN 37015
H
WARNING: If the information in these
instructions 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.
Thank you for buying this energy efficient boiler.
We appreciate your confidence in our products.
PRINTED 1115
321078-004
TABLE OF CONTENTS
TABLE OF CONTENTS�������������������������������������������������������������������������� 2
Air Requirements����������������������������������������������������������������������������� 16
SAFE INSTALLATION, USE AND SERVICE����������������������������������������� 3
Unconfined Space��������������������������������������������������������������������������� 16
GENERAL SAFETY������������������������������������������������������������������������������� 4
Fresh Air Openings for Confined Spaces���������������������������������������� 17
INTRODUCTION������������������������������������������������������������������������������������ 5
VENTING���������������������������������������������������������������������������������������������� 21
Abbreviations Used��������������������������������������������������������������������������� 5
Standard Venting����������������������������������������������������������������������������� 21
Qualifications������������������������������������������������������������������������������������� 5
Sidewall Venting������������������������������������������������������������������������������ 22
DIMENSIONS AND CAPACITY DATA���������������������������������������������������� 6
Venting System�������������������������������������������������������������������������������� 22
CONTROL COMPONENTS������������������������������������������������������������������� 8
GAS SUPPLY CONNECTIONS����������������������������������������������������������� 24
BOILER INSTALLATION CONSIDERATIONS������������������������������������� 12
Gas Manifold Pressure Regulators�������������������������������������������������� 25
Hydronic System����������������������������������������������������������������������������� 12
BOILER START UP AND OPERATIONS��������������������������������������������� 26
Hot Water Supply Boiler System - General Water Line Connections
��������������������������������������������������������������������������������������������������������� 12
Filling the System���������������������������������������������������������������������������� 26
Precautions�������������������������������������������������������������������������������������� 26
Closed Water Systems�������������������������������������������������������������������� 13
Thermal Expansion�������������������������������������������������������������������������� 13
Pilot and Main Burner���������������������������������������������������������������������� 26
Vent Valves�������������������������������������������������������������������������������������� 13
Checking and Adjusting Input���������������������������������������������������������� 28
Manifold Headers���������������������������������������������������������������������������� 13
TROUBLESHOOTING������������������������������������������������������������������������� 32
Cooling Piping��������������������������������������������������������������������������������� 13
GENERAL MAINTENANCE����������������������������������������������������������������� 40
Circulating Pump����������������������������������������������������������������������������� 13
Manual Reset High Limit Switch Continuity Test����������������������������� 40
GENERAL REQUIREMENTS�������������������������������������������������������������� 15
Pressure Relief Valve Test��������������������������������������������������������������� 40
Required Ability�������������������������������������������������������������������������������� 15
Cleaning and Flushing Instructions������������������������������������������������� 40
Location������������������������������������������������������������������������������������������� 15
Venting Maintenance����������������������������������������������������������������������� 41
Replacing Existing Common Vented Boiler������������������������������������� 15
WIRING������������������������������������������������������������������������������������������������ 42
Chemical Vapor Corrosion��������������������������������������������������������������� 16
Wiring Connections������������������������������������������������������������������������� 42
Installation Clearances�������������������������������������������������������������������� 16
PIPING DIAGRAMS����������������������������������������������������������������������������� 47
Leveling������������������������������������������������������������������������������������������� 16
LIMITED WARRANTY�������������������������������������������������������������������������� 61
System Connections������������������������������������������������������������������������ 16
NOTES������������������������������������������������������������������������������������������������� 63
2
SAFE INSTALLATION, USE AND SERVICE
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 messages and instructions throughout this manual. It is very important that the
meaning of each safety message is understood by you and others who install, use, or service this boiler.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
IMPORTANT DEFINITIONS
Gas Supplier: The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within
this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including
the Natural Gas meter or Propane storage tank of a building. Many gas suppliers also offer service and inspection of appliances
within the building.
APPROVALS
H
3
GENERAL SAFETY
GROUNDING INSTRUCTIONS
HIGH ALTITUDE INSTALLATIONS
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 system, or an equipment grounding conductor must be
run with the circuit conductors and connected 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 speci­fied on the boiler rating plate. Do not install the boiler if
equipped for a different type of gas; con­sult your supplier.
PRECAUTIONS
If the unit is exposed to the following, do not operate until
all corrective steps have been made by a qualified service
technician:
1.
2.
3.
4.
Exposure to fire.
If damaged.
Firing without water.
Sooting.
Rated inputs are suitable up to 2000 feet (610 m) elevation.
Consult the factory for installation at altitudes over 2000 feet
(610 m).
If the boiler has been exposed to flooding, it must be replaced.
PROPANE OR LIQUEFIED PETROLEUM (LP) GAS
MODELS
Boilers for propane (LP) gas are different from natural gas models.
A natural gas boiler will not function safely on propane (LP) gas
and no attempt should be made to convert a boiler from natural
gas to propane (LP) gas.
Propane (LP) gas must be used with great caution. It is highly
explosive and heavier than air. It collects first in the low areas
making its odor difficult to detect at nose level. If propane (LP)
gas is present or even suspected, do not attempt to find the cause
yourself. Leave the building, leaving doors open to ventilate, then
call your gas supplier or service agent. Keep area clear until a
service call has been made.
At times you may not be able to smell an propane (LP) gas
leak. One cause is odor fade, which is a loss of the chemical
odorant that gives propane (LP) gas its distinctive smell. Another
cause can be your physical condition, such as having a cold or
diminishing sense of smell with age. For these reasons, the use
of a propane gas detector is recommended.
If you experience an out of gas situation, do not try to relight
boilers yourself. Call your local service agent. Only trained propane
(LP) professionals should conduct the required safety checks in
accordance with industry standards.
4
INTRODUCTION
QUALIFICATIONS
This design complies with the current edition of the ANSI Z21.13
low-pressure boiler standard.
QUALIFIED INSTALLER OR SERVICE AGENCY
Compliance under this standard implies that when the boiler
underwent test, the gas manifold and control assembly pro­vided
on the boiler met safe lighting and other performance criteria.
Installation and service of this boiler requires ability equivalent
to that of a Qualified Agency, as defined by ANSI below. In the
field involved. Installation skills such as plumbing, air supply,
venting, gas supply and electrical supply are required in addition
to electrical testing skills when performing service.
Detailed installation diagrams are found in this manual. These
diagrams will serve to provide the installer a reference for the
materials and methods of piping necessary. It is essential that
all water, gas piping and wiring be installed as shown on the
diagrams. You should thoroughly read and understand this
manual before installation and/or operation of this boiler.
ANSI Z21.13 - CSA 4.9: “Qualified Agency” - “Any individual,
firm, corporation or company that either in person or through
a representative is engaged in and is responsible for (a) the
installation, testing or replacement of gas piping or (b) the
connection, installation, testing, repair or servicing of appliances
and equipment; that is experienced in such work; that is familiar
with all precautions required; and that has complied with all the
requirements of the authority having jurisdiction.”
The factory warranty will be void if the boiler(s) have been
improperly installed or operated.
In addition to these instructions, the boiler(s) shall be installed
in accordance with those installation regulations in force in the
local area where the installation is to be made. These shall be
carefully followed in all cases. Authorities having jurisdiction
should be consulted before installations are made.
If you are not qualified (as defined by ANSI above) and licensed
or certified as required by the authority having jurisdiction
to perform a given task do not attempt to perform any of the
procedures described in this manual. If you do not understand
the instructions given in this manual do not attempt to perform
any procedures outlined in this manual.
In the absence of local codes, the installation must comply
withthe current editions, as follows:
In the United States:
The National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the
National Electric Code, NFPA 70.
In Canada:
Installation Code CAN/CSA B149.1 and Canadian Electrical
Code, CSA C22.1.
Thank you for purchasing this boiler. Properly installed and
maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
• CSA - Canadian Standards Association
5
DIMENSIONS AND CAPACITY DATA
EXTRA OPENING
FOR THERMOMETER
AND PRESSURE
RELIEF VALVE
HW-520 AND
HW--670
Figure 1. DIMENSIONS
Table 1. DIMENSIONS AND CAPACITY DATA
MODELS
DIMENSIONS IN INCHES
A
Overall height
B
Height to Top of Jacket
C
Floor to Center Line Water Inlet
D
Diameter of Jacket
E
Floor to Center Line Water Outlet
HW-300
HW-399
HW-420
HW-520
HW-670
65 (1651)
57-1/8 (1451)
57-1/8 (1451)
68-5/16 (1735)
67-1/2 (1715)
43-1/4 (1099)
45-1/8 (1146)
45-1/8 (1146)
56-1/4 (1429)
56-1/4 (1429)
36 (914)
38-3/4 (984)
38-3/4 (984)
46 (1168)
46 (1168)
25-1/4 (641)
27 (686)
27 (686)
27 (686)
27 (686)
12 (305)
12 (305)
12 (305)
12 (305)
12 (305)
F
Draft Diverter Outlet Diameter
8 (203)
10 (254)
10 (254)
10 (254)
12 (305)
G
Floor to Center Line Gas Inlet
16-1/2 (419)
16-3/4 (425)
16-3/4 (425)
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)
J
Support Height
9 (229)
9 (229)
9 (229)
9 (229)
9 (229)
K
Width of Control String (approx.)
14 (356)
14 (356)
14 (356)
11 (279)
11 (279)
L
Pipe Size of Water Inlet (NPT)
1-1/4
1-1/2
1-1/2
2
2
M
Pipe Size of Water Outlet (NPT)
1-1/4
1-1/2
1-1/2
2
2
N
Pipe Size of Gas Inlet (NPT)
3/4
3/4
1
1
1
P
Control String Plus 1/2 Jacket Diameter (approx.)
26-5/8 (676)
27-1/2 (699)
27-1/2 (699)
24-1/2 (622)
24-1/2 (622)
S
Horizontal Length between Water Inlet and Outlet
5-3/8 (137)
5-1/2 (140)
5-1/2 (140)
5-3/4 (146)
5-3/4 (146)
T
Control String from Jacket
Approximate shipping weight lbs. (Kilograms)
5 (127)
5 (127)
5 (127)
7 (178)
7 (178)
250 (113)
301 (137)
301 (137)
381 (173)
381 (173)
NOTE: All dimensions in inches (millimeters) except pipe size which is NPT
Table 2. FLOW, HEAD AND TEMPERATURE RISE
TEMPERATURE RISE AND PRESSURE DROP
BTU INPUT/OUTPUT
MODELS
20 DEG. F
RISE
30 DEG. F
RISE
40 DEG. F
RISE
INPUT RATING BTU/HR
NATURAL & PROPANE (LP) GAS
OUTPUT RATING BTU/HR
NATURAL & PROPANE (LP) GAS
GPM
PD-FT
HEAD
GPM
PD-FT
HEAD
GPM
PD-FT
HEAD
HW 300
300,000
240,000
24
8
16
3
12
2
HW 399
399,000
319,200
32
16
21
7
16
5
HW 420
420,000
336,000
34
18
22
8
17
5.5
HW 520
520,000
416,000
42
12
28
5
21
4
HW 670 Nat
660,000
528,000
53
22
35
10
26
5.5
HW 670 Prop
670,000
536,000
54
22
36
10
27
5.5
6
Table 3. RECOVERY CAPACITIES
MODELS
HW 300
HW 399
HW 420
HW 520
TYPE OF
GAS
Natural
Propane
Natural
Propane
Natural
Propane
Natural
Propane
INPUT
BTU/HR
KW
300,000
88
399,000
117
420,000
123
520,000
152
HW 670
Natural
660,000
193
HW 670
Propane
670,000
196
°F
20
40
50
60
70
80
°C
(11)
(22)
(28)
(33)
(39)
(44)
GPH
1,455
727
582
485
416
364
LPH
5,506
2,753
2,202
1,835
1,573
1,377
GPH
1,935
967
774
645
553
484
LPH
7,323
3,662
2,929
2,441
2,092
1,831
GPH
2,036
1,018
815
679
582
509
LPH
7,708
3,854
3,083
2,569
2,202
1,927
GPH
2,521
1,261
1,008
840
720
630
LPH
9,544
4,772
3,818
3,181
2,727
2,386
GPH
3,200
1,600
1,280
1,067
914
800
LPH
12,113
6,057
4,845
4,038
3,461
3,028
GPH
3,248
1,624
1,299
1,083
928
812
LPH
12,297
6,148
4,919
4,099
3,513
3,074
ELECTRICAL REQUIREMENTS
Table 4. ELECTRICAL REQUIREMENTS
MODELS
SUPPLY VOLTAGE
(VOLTS)
FREQUENCY
(HZ)
CURRENT
(AMPS)
HW 300
120
60
12
HW 399
120
60
12
HW 420
120
60
12
HW 520
120
60
12
HW 670
120
60
12
7
CONTROL COMPONENTS
Figure 2. COMPONENT LOCATIONS
8
AUTO RESET HIGH LIMIT
THERMAL BALANCER
The high limit is a safety device wired in series with the ignition
system. Set the high limit control to approximately 100°F above
the maximum designed system temperature. If the boiler outlet
water temperature should exceed the high limit setting, the main
gas control valve will close but the circulating pump will continue
to operate. Maximum adjustable setting is 115°C (239°F) cutout with a 3°C (5°F) to 25°C (45°F) adjustable differential, see
Figure 3.
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
normally closed when the resistor is cool.
2. Apply a light to the black and yellow leads.
• The lamp should not light as the contact in this circuit is
normally open when the resistor is cool.
3. Remove the test light.
4. Apply 120 volts to the white and red leads which power the
1900 ohm resistor. After a warming period the contacts of
the thermal balancer should operate.
5. Remove the test light.
6. Apply the test light as described in steps 1 and 2.
While the resistor is still warm the lamp indications should be the
opposite as described previously.
Figure 3. AUTO RESET HIGH LIMIT
INTERMITTENT IGNITION CONTROL MODULE
The Honeywell S-8600 control module contains the electronic
components of the system and also serves as a control wiring
system for the controls mounted on the boiler. The control
module performs the following functions:
1. Checks for safe-start by sensing for a false flame condition
on start-up.
2. Generates a potential of 15,000 volts for spark ignition of the
pilot burner.
Figure 5. THERMAL BALANCER
3. Opens the pilot valve.
MANUAL RESET HIGH LIMIT
4. Discontinues ignition spark when the pilot flame is
established. The S-8600 control used on propane
gas models provides safety lockout if the pilot
fails to ignite within the pilot flame establishing
period. The S-8600 control used on natural gas
models continues trial for ignition until pilot flame
is established.
This boiler is equipped with a manual reset high limit switch,
located under the small cover on the side of the jacket, see
Figure 6. This device provides positive shutdown of the boiler
in the event of boiler or system malfunction. Should the surface
temperature of the copper tubing heat exchanger reach 250°F
(120°C), the high limit switch will activate, the gas control valve
will close, the pilot and main burners will be extinguished. If
the high limit switch should shut off unit, check the following
conditions:
5. After proof of pilot flame, opens then main valve.
6. On a power loss, shuts the boiler down. When power is
restored it will begin a new ignition cycle.
• No water in boiler.
• Restricted water flow through the boiler.
• Improper wiring (boiler firing without circulating pump
operating).
• Pump failure.
7. On a loss of flame, shuts off main gas and starts trial for pilot
ignition.
Please refer to TROUBLESHOOTING SECTION for more
information.
After correcting failure condition remove the protector switch
cover and push the reset button. The high limit switch may be
reset after the coil surface cools to 6°F (3.3°C) below the trip
setting.
Figure 4. S-8600 INTERMITTENT IGNITION CONTROL
MODULE (IID)
Figure 6. HIGH LIMIT SWITCH
9
PRESSURE RELIEF VALVE
If any pressure relief valve is replaced, the replacement valve
must comply with the current editions of the ASME Boiler and
Pressure Vessel Code, Section IV or CSA B51, as applicable.
Select a pressure relief valve with a discharge NOT less than the
boiler input, and a pressure rating NOT exceeding the working
pressure of any component in the system.
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 is installed in the pressure relief valve opening provided.
All HW models ship factory standard with a 125 psi relief valve
for hot water supply applications an optional 50 psi relief valve
is available for units to be used for space heating applications.
The pressure rating of the pressure relief valve should be equal
to or less than the rated pressure capacity of any component
in the system including the boiler. Should the valve need to be
replaced, call the toll free phone number listed on the back of this
manual for further technical assistance.
An ASME rated temperature and pressure relief valve must be
installed on each and every water storage tank in a hot water
supply system.
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 - CSA 4.4. The T & P
valve must be of the automatic reset type and not embody a
single-use type of fusible plug, cartridge or linkage.
Explosion Hazard
Pressure Relief Valve must
comply with ASME code.
The T & P relief valve should have a maximum temperature
rating of 100°C (210°F), a pressure rating NOT exceeding the
lowest rated working pressure of any system component, and a
discharge capacity exceeding the total input of the water boilers
supplying water to the storage tank.
Properly sized Pressure Relief
Valve must be installed in
opening provided.
Can result in overheating and
excessive tank pressure.
Locate the T & P relief valve (a) in the top of the storage tank or
(b) in the side of the tank on centerline within upper 6 inches from
the top of the tank. See Figure 30 to Figure 43 on Pages 47 to 60.
Tapping shall be threaded in accordance with the latest version
of the Standard for Pipe Threads, General Purpose (inch), ANSI/
ASME B.120.1.
Can cause serious injury or death.
A discharge pipe from the pressure relief valve should terminate
at an adequate floor drain. Do not thread, plug, or cap the end of
the drain line.
CAUTION
Water Damage Hazard
• Pressure Relief Valve discharge pipe must
terminate at adequate drain.
The Discharge Pipe:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall not be exposed to freezing temperatures.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both
the pressure relief valve and the discharge pipe.
• Must terminate a maximum of six inches above a floor
drain or external to the building. In cold climates, it is
recommended that the discharge pipe be terminated at an
adequate drain inside the building.
• Shall not have any valve or other obstruction between the
pressure relief valve and the drain.
Once the boiler is installed and filled with water and the system
is pressurized, manually test the operation of the pressure relief
valve.
10
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.
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.
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 consequently energize the boiler.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
If the Tank Temperature Control is out of calibration, replace it
with a new one; do not attempt to fix this control.
THERMOMETERS
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Thermometers should be obtained and field installed as
shown in the installation diagrams.
Feel water before bathing or
showering.
Thermometers are installed in the system as a means of
detecting a possible liming condition in the boiler. An
increase of 5°F (3°C) over the normal temperature rise
through the boiler is an indication that lime is present. The
term "temperature" designates the difference between the
boiler inlet and outlet water temperature.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
An increase of 5°F (3°C) above the recorded temperature
rise may signify a liming condition in the coils or heat
exchanger. Refer to Cleaning and Flushing Instructions on
Page 40 for deliming instructions.
The tank temperature control is adjustable from 100°F (37.7°C)
to 220°F (104.4°C). It is recommended that lower water
temperatures be used to avoid the risk of scalding. It is further
recommended, in all cases, that the water temperature be set
for the lowest temperature which satisfies the user’s hot water
needs. This will also provide the most energy efficient operation
of the boiler and minimize scale formation.
Record temperature rise at initial start-up for future
reference.
DRAIN VALVE (NOT SUPPLIED)
The boiler should be located in an area where the general public
does not have access to set temperatures. Setting the water
temperature at 120°F (49°C) will reduce the risk of scalds.
A drain valve must be obtained and installed on each boiler
and tank for draining purposes.
Some people are more likely to be permanently injured by
hot water than others. These include the elderly, children, the
infirm and the physically/mentally disabled. Table 5 shows the
approximate time-to-burn relationship for normal adult skin. If
anyone using hot water provided by the boiler being installed fits
into one of these groups or if there is a local code or state law
requiring a certain water temperature at the point of use, then
special precautions must be taken. Contact a qualified service
technician or qualified agency.
Table 5. TEMPERATURE AND TIME TO PRODUCE BURNS
Water Temperature
°F (°C)
Time for 1st Degree Burn
(Less Severe Burns)
110 (43)
(normal shower temp.)
116 (47)
(pain threshold)
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
116 (47)
35 minutes
45 minutes
122 (50)
1 minute
5 minutes
131 (55)
5 seconds
25 seconds
140 (60)
2 seconds
5 seconds
149 (65)
1 second
2 seconds
154 (68)
instantaneous
1 second
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15, 1978)
11
BOILER INSTALLATION CONSIDERATIONS
HYDRONIC SYSTEM
Pipe sizing and boiler loop pump selection data are shown in
Table 8 for several different temperature rises across the boilers.
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
exchanger boilers are covered below.
Table 8. PUMP AND PIPE SIZING DATA
(PIPING FROM TEES IN MAIN TO BOILER BRANCHES)
Conventional 20 ºF (10 ºC) drop in systems for a fully loaded
boiler will maintain the following approximate flow rates:
MODEL
Table 6. WATER FLOW RATES
MODELS
HW-300
HW-399
HW-420
HW-520
HW-670
HW-300
GPM (LPM)
24 (91)
32 (121)
34 (127)
42 (158)
54 (203)
HW-399
HW-420
Figure 30 to Figure 43 on Pages 47 to 60 show typical installations
of the boiler with pipe sizing and circulating pump selected by the
installer to provide adequate water flow whenever the boiler is
firing.
HW-520
In a system with several large zones of which any might be
smaller than approximately 1/3 of the system should include a
hydronic balancer as shown in the piping diagrams. The balancer
connects between the system supply and the return line before
the circulating pump inlet. Adjustment of the balancing cock
should permit adequate boiler flow rate when only the smallest
zone is in operation.
HW-670
20 (10)
30 (15)
30 (15)
40 (20)
20 (10)
35 (15)
40 (20)
40 (20)
20 (10)
35 (15)
40 (20)
40 (20)
20 (10)
20 (10)
35 (17)
40 (20)
20 (10)
30 (15)
35 (17)
40 (20)
GPM
24
16
16
12
32
18
16
16
34
19
17
17
42
42
24
21
54
36
31
27
*PUMP
SIZE
1-1/2" PR
150
125
100
60-13
1-1/2" HV
150
125
60-13
1-1/2" HV
150
125
2-1/2"
1-1/2" HV
1-1/2" HV
150
60-13
2-1/2"
2"
1-1/2" HV
PIPE
SIZE
2"
1-1/2"
1-1/4"
1"
2"
1-1/2"
1-1/2"
1-1/4"
2"
1-1/2"
1-1/2"
1-1/4"
2-1/2"
2"
1-1/2"
1-1/2"
3"
2-1/2"
2"
1-1/2"
NOTE: Pipe loop sizes and pump selections based on 50
equivalent feet of pipe and fittings.
Attention should be given to balancing inputs and water flow
rates where wide variations of system flow rates can occur.
*All pump sizes listed are B & G model numbers.
The recommended minimum flow rates that will result in
approximately 50 ºF (30 ºC) temperature rise across the boiler
are as follows:
HOT WATER SUPPLY BOILER SYSTEM - GENERAL
WATER LINE CONNECTIONS
Piping diagrams will serve to provide the installer with a
reference for the materials and methods of piping necessary for
installation. It is essential that all water piping be installed and
connected as shown on the diagrams. Check the diagrams to
be used thoroughly before starting installation to avoid possible
errors and to minimize time and material cost. It is essential that
all water piping be installed and connected as shown on the
diagrams. Figure 30 to Figure 43 on Pages 47 to 60.
Table 7. MINIMUM WATER FLOW RATES RESULTING IN
TEMPERATURE RISE
MODELS
HW-300
HW-399
HW-420
HW-520
HW-670
TEMP. RISE °F
(°C)
GPM (LPM)
10 (36)
13 (49)
13 (49)
17 (63)
21 (81)
These boilers can be used ONLY in a forced circulation hot water
heating system. Since most forced circulation systems will be of
the closed type, install the water supply line as shown on piping
diagrams, Fast filling of large pipe, old radiator installations and
pressure purging of series loop systems (where high pressures
are not available) requires bypassing of the pressure reducing
valve. Generally, pressure purging is not possible with a well
pump system. High point air venting is essential.
If the system is of the open type, a pressure reducing valve
will not be required as the water supply to the system will be
controlled by a manually operated valve. An overhead surge tank
is required.
12
CLOSED WATER SYSTEMS
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 supply systems may, because of code requirements
or such conditions as high line pressure, among others, have
installed devices such as pressure reducing valves, check
valves, and back flow preventers. Devices such as these cause
the water system to be a closed system.
Water temperature in the heating system must be reduced to less
than 1000F (38°C) before cooling system is started, or damage to
the chiller unit may occur.
THERMAL EXPANSION
As water is heated, it expands (thermal expansion). In a closed
system the volume of water will grow when it is heated. As the
volume of water grows there will be a corresponding increase
in water pressure due to thermal expansion. Thermal expansion
can cause premature tank failure (leakage). This type of failure
is not covered under the limited warranty. Thermal expansion
can also cause intermittent Temperature-Pressure Relief Valve
operation: water discharged from the valve due to excessive
pressure build up. This condition is not covered under the limited
warranty. The Temperature-Pressure Relief Valve is not intended
for the constant relief of thermal expansion.
Figure 7. SCHEMATIC SHOWING PROPER PIPING
ISOLATION OF THE BOILER FROM THE CHILLER
A properly sized thermal expansion tank must be installed on
all closed systems to control the harmful effects of thermal
expansion. Contact a local plumbing service agency to have a
thermal expansion tank installed. An expansion tank or a similar
device may be required in the inlet supply line between the boiler
and the meter or valve to compensate for the thermal expansion
of water under supply pressure, see Piping Diagrams section on
Page 47.
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 flow valves or other automatic means to prevent
gravity circulation through the boiler during the cooling cycle.
CIRCULATING PUMP
Constant circulating pump operation of the boiler voids 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
circulating operation is used per the recommended installation
procedure. Constant circulation of water through the building’s
system main is permissible as long as the water does not
constantly flow through the boiler. Only all bronze or stainless
steel circulating pumps are to be used with the unit when it is
installed in hot water supply systems.
An air separator as shown in the piping diagrams is recommended
especially for modern commercial hydronic systems.
VENT VALVES
It is recommended that automatic, loose key or screwdriver type
vent valves be installed at each convector or radiator.
MANIFOLD HEADERS
Split systems with individual supply and return lines from the boiler
room should normally have this piping connected to supply and
return manifold headers near the boiler. To achieve good water
distribution with maximum pressure drop for several circuits,
manifolds of at least 2-1/2" (64 mm) diameter are suggested on
HW-399, HW-420, HW-520 and HW-670 units. HW-300 units
should have 1-1/2" (38 mm) diameter manifolds.
The circuits should be spaced on the header at a minimum of
3" (76 mm) center to center. Install a balancing cock in each
return line.
Manifold headers are recommended for split systems with
or without zone valves and also those installations with zone
circulating pumps. If the system is to be split at remote points,
good practice requires special attention be given to main pipe
sizing to allow balancing of water flow.
Figure 8. A TYPICAL CIRCULATING PUMP
Although each circulating pump that requires oiling is oiled and
operated by the manufacturer, It must be oiled again before
operated. See Figure 8 above.
The boiler piping system of a hot water boiler connected to
heating coils located in air handling units where they may be
exposed to refrigerated air circulation must be equipped with
flow control valves or other automatic means to prevent gravity
circulation of the boiler water during the cooling cycle.
Refer to the pump manufacturer’s instructions for lubrication
requirements.
13
FLOW SWITCH
Table 9. FLOW SWITCH
Minimum Pipe Rate
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.
Model Number
An accessory package containing a flow switch is available for
this application.
Contacts Closed
(Flow)
Contacts Open
(No Flow)
GPM
LPM
GPM
LPM
HW-300
5.8
22.0
3.7
14.0
This switch may be mounted in a horizontal pipe line or a vertical
pipe line with upward water flow. Do not install the switch where
the water flow is downward.
HW-399
7.5
28.4
5.0
18.9
HW-420
7.5
28.4
5.0
18.9
For proper performance mount the switch in a section of pipe where
there is a straight run of at least 5 pipe diameters on each side
of the flow switch (i.e. do not locate adjacent to valves, elbows,
orifices, etc.).
HW-520
13.7
51.9
9.5
36.0
HW-670
13.7
51.9
9.5
36.0
The flow switch may be field adjusted to obtain higher minimum
flow rates than those shown inTable 9.
The flow switch shall be mounted in a standard 1-1/2" 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 of
the reducing tee and provide adequate paddle length in the flow
stream. For example in a 2" pipe installation use a 2" x 2" x 1"
reducing tee. For 2", or 3" pipe use paddle segments as supplied.
For other pipe sizes (i.e. 1-1/4", 1-1/2" and 2-1/2") trim the paddle
to the proper pipe size, see Figure 9 below. If a standard tee is
used, install a face or hex bushing in the top opening. The paddle
must be adjusted or trimmed to the size of the pipe in which it will
be installed.
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
counterclockwise.
The switch is factory set at approximately the minimum flow rate,
refer to Table 9. It must not be set lower than the factory setting
as this may result in the switch failing to return at a 'no flow'
condition.
Any part of the paddle must not touch the pipe or any restrictions
in the pipe. Screw the flow switch in position so the flat of the
paddle is at right angles to the flow. The arrow on the side case
must point in the direction of the flow.
4. Replace flow switch cover. Where units are installed in
multiples, each boiler must be individually protected by a flow
switch.
Figure 9. FLOW SWITCH
14
GENERAL REQUIREMENTS
REQUIRED ABILITY
REPLACING EXISTING COMMON VENTED BOILER
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
re­quired.
When an existing boiler is removed from a common venting
system, the common venting system is likely to be too large
for proper venting of the appliances remaining connected to it.
At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected to
the common venting system placed in operation, while the other
appliances remaining connected to the common venting system
are not in operation.
LOCATION
When installing the boiler, consideration must be given to proper
location. The location selected should provide ade­quate air
supply and be as centralized with the piping system as possible.
This location should also be such that the gas ignition system
components are protected from water dripping, spraying,
etc.) during boiler operation and service (circulating pump
replacement, control replacement, etc.).
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies which
could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows
and all doors between the space in which the appliances
remaining connected to the common venting system are
located and other spaces of the building. Turn on clothes
dryers and any appliance not connected to the common
venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at
maximum speed. Do not operate a summer exhaust fan.
Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance will
operate continuously.
5. Test for spillage at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a match
or candle, or smoke from a cigarette, cigar or pipe.
6. 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 condition of use.
7. Any improper operation of the common venting system should
be corrected so the installation conforms with the National
Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1,
Installation Codes. When resizing any portion of the common
venting system, the common venting system should be
resized to approach the minimum size as determined using
the appropriate tables in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CSA B149 .1, Installation Codes.
Some local codes permit operation of gas appliances if installed 18
inches or more above the floor. This may reduce the risk if location in
such an area cannot be avoided.
A hot water boiler installed above radiation level or as required by
the authority having jurisdiction, must be provided with a low water
cutoff device at the time of boiler installation.
15
AIR REQUIREMENTS
CHEMICAL VAPOR CORROSION
Boiler corrosion and component failure can be caused by the
heating and breakdown of airborne chemical vapors. Spray can
propellants, cleaning sol­vents, refrigerator and air conditioning
refrig­erants, swimming pool chemicals, calcium and sodium
chloride (water softener salt), waxes, and process chemicals
are typical compounds which are potentially corrosive. These
materials are corrosive at very low concentration levels with little
or no odor to reveal their presence.
Breathing Hazard - Carbon Monoxide Gas
Install appliance in accordance with
the Instruction Manual and NFPA 54 or
CAN/CSA-B149.1.
To avoid injury, combustion and ventilation
air must be taken from outdoors.
Do not place chemical vapor emitting
products near the boiler.
Products of this sort should not be stored near boiler. Also, air
which is brought in contact with boiler should not contain any
of these chemicals. If necessary, uncontaminated air should be
obtained from remote or outside sources. Failure to observe this
requirement will void warranty.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
INSTALLATION CLEARANCES
For safe operation an adequate supply of fresh uncontaminated
air for combustion and ventilation must be provided.
These boilers are approved for installation on combustible
flooring in an alcove with minimum clearance to combustibles of:
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 result in a yellow, luminous burner
flame, causing sooting of the combustion chamber, burners and
flue tubes and creates a risk of asphyxiation.
Table 10. INSTALLATION CLEARANCES
HW
300
TOP
HW
399
HW
420
HW
520
HW
670
Do not install the boiler in a confined space unless an adequate
supply of air for combustion and ventilation is brought in to that
space using the methods described in the Confined Space
section that follows.
28" (711.2) 28" (711.2) 24" (609.6) 24" (609.6) 24" (609.6)
SIDES
6" (152.4)
6" (152.4) 24" (609.6) 24" (609.6) 24" (609.6)
REAR
6" (152.4)
6" (152.4) 24" (609.6) 24" (609.6) 24" (609.6)
VENT
6" (152.4)
6" (152.4)
6" (152.4)
6" (152.4)
Never obstruct the flow of ventilation air. If you have any doubts
or questions at all, call your gas supplier. Failure to provide the
proper amount of combustion air can result in a fire or explosion
and cause property damage, serious bodily injury or death.
6" (152.4)
2 inches (51 mm) clearance is allowable from combustible
construction for hot water pipes.
UNCONFINED SPACE
Sufficient area should be provided at the front and rear of the unit for
proper servicing. Clearances of 24 inches (609.4 mm) in the rear and
48 inches (1,219 mm) in the front are required by code. In a utility
room installation, the door shall be wide enough to allow the boiler
to enter or to permit the replacement of another appliance such as
a boiler.
An unconfined space is one whose volume is not 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. Rooms
communicating directly with the space, in which the appliances
are installed, through openings not furnished with doors, are
considered a part of the unconfined space.
LEVELING
Makeup air requirements for the operation of exhaust fans,
kitchen ventilation systems, clothes dryers and fireplaces shall
also be considered in determining the adequacy of a space to
provide combustion, ventilation and dilution air.
Each unit should be checked after installation to be certain that it
is level prior to starting the unit.
If the unit is not level, obtain and insert shims under the legs of
the unit to correct this condition.
UNUSUALLY TIGHT CONSTRUCTION
In unconfined spaces in buildings, infiltration may be adequate
to provide air for combustion, ventilation and dilution of flue
gases. However, in buildings of unusually tight construction (for
example, weather stripping, heavily insulated, caulked, vapor
barrier, etc.) additional air must be provided using the methods
described in the Confined Space section that follows.
SYSTEM CONNECTIONS
The system installation must conform to these instructions and to
the requirements of the local code authority having jurisdiction. Good
practice requires that all heavy piping be supported.
16
CONFINED SPACE
OUTDOOR AIR THROUGH TWO OPENINGS
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. The required size for
the openings is dependent on the method used to provide fresh
air to the confined space and the total Btu/hr input rating of all
appliances installed in the space.
DIRECT VENT BOILERS
Boilers installed in a direct vent configuration that derive all air
for combustion from the outdoor atmosphere through sealed
intake air piping are not factored in the total boiler input Btu/hr
calculations used to determine the size of openings providing
fresh air into confined spaces.
Figure 10. OUTDOOR AIR THROUGH TWO OPENINGS
EXHAUST FANS
The confined space shall be provided with two permanent
openings, 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 openings shall communicate directly with the
outdoors. See Figure 10.
Where exhaust fans are installed, additional air shall be provided
to replace the exhausted air. When an exhaust fan is installed
in the same space with a boiler, sufficient openings to provide
fresh air must be provided that accommodate the requirements
for all appliances in the room and the exhaust fan. Undersized
openings will cause air to be drawn into the room through the
boiler’s vent system causing poor combustion. Sooting, serious
damage to the boiler and the risk of fire or explosion may result.
It can also create a risk of asphyxiation.
Each opening shall have a minimum free area of 1 square inch
per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure. Each opening shall
not be less than 100 square inches (645 cm2).
OUTDOOR AIR THROUGH ONE OPENING
LOUVERS AND GRILLES
The free areas of the fresh air openings in the instructions that
follow do not take in to account the presence of louvers, grilles or
screens in the openings.
The required size of openings for combustion, ventilation and
dilution air shall be based on the “net free area” of each opening.
Where the free area through a design of louver or grille or screen
is known, it shall be used in calculating the size of opening
required to provide the free area specified. Where the louver and
grille design and free area are not known, it shall be assumed
that wood louvers will have 25% free area and metal louvers and
grilles will have 75% free area. Non motorized louvers and grilles
shall be fixed in the open position.
FRESH AIR OPENINGS FOR CONFINED SPACES
The following instructions shall be used to calculate the size,
number and placement of openings providing fresh air for
combustion, ventilation and dilution in confined spaces. The
illustrations shown in this section of the manual are a reference
for the openings that provide fresh air into confined spaces
only. Do not refer to these illustrations for the purpose of vent
installation. See Venting section on Page 21 for complete venting
installation instructions.
Figure 11. OUTDOOR AIR THROUGH ONE OPENING
Alternatively a single permanent opening, commencing within 12
inches (300 mm) of the top of the enclosure, shall be provided.
See Figure 11. The boiler shall have clearances of at least 1
inch (25 mm) from the sides and back and 6 inches (150 mm)
from the front of the appliance. The opening shall directly
communicate with the outdoors or shall communicate through
a vertical or horizontal duct to the outdoors or spaces that freely
communicate with the outdoors and shall have a minimum free
area of the following:
1. 1 square inch per 3000 Btu/hr (700 mm2 per kW) of the total
input rating of all appliances located in the enclosure, and
2. Not less than the sum of the areas of all vent connectors in
the space.
17
OUTDOOR AIR THROUGH TWO HORIZONTAL DUCTS
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 opening shall have a minimum free area of 1 square
inch per 4,000 Btu/hr (550 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall be not less
than 3 inches.
AIR FROM OTHER INDOOR SPACES
Figure 12. OUTDOOR AIR THROUGH TWO HORIZONTAL
DUCTS
The confined space shall be provided with two permanent
horizontal 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 horizontal ducts shall communicate
directly with the outdoors. See Figure 12.
Each duct opening shall have a minimum free area of 1 square
inch per 2,000 Btu/hr (1100 mm2 per kW) of the aggregate input
rating of all appliances installed in the enclosure.
When ducts are used, they shall be of the same cross sectional
area as the free area of the openings to which they connect.
The minimum dimension of rectangular air ducts shall be not less
than 3 inches.
Figure 14. AIR FROM OTHER INDOOR SPACES
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (300 mm) of the top
and one commencing within 12 inches (300 mm) of the bottom of
the enclosure. See Figure 14.
OUTDOOR AIR THROUGH TWO VERTICAL DUCTS
The illustrations shown in this section of the manual are a
reference for the openings that provide fresh air into confined
spaces only.
Each opening shall communicate directly with an additional
room(s) of sufficient volume so that the combined volume of all
spaces meets the criteria for an Unconfined Space.
Do not refer to these illustrations for the purpose of vent
installation.
Each opening shall have a minimum free area of 1 square inch
per 1,000 Btu/hr (1100 mm2 per kW) of the aggregate input rating
of all appliances installed in the enclosure. Each opening shall
not be less than 100 square inches (645 cm2).
Figure 13. OUTDOOR AIR THROUGH TWO VERTICAL
DUCTS
18
GAS CONNECTIONS
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 connection must be leak
tested before placing the boiler in operation.
SIZING GAS SUPPLY LINE (FOR SINGLE BOILER
INSTALLATIONS AND FOR INSTALLATIONS OF MULTIPLES
OF TWO OR THREE OF SAME SIZE BOILERS).
Use Table 11 or CAN/CSA B149.1 (current edition) to size
iron pipe or equivalent gas supply line. Table 11 is based on a
pressure drop of 0.3 inches of water and a specific gravity of 0.60
approximately that of natural gas. (Propane (LP) gas has an S.G.
of about 1.53). If the service pressure is five inches water column
or less, use one pipe size larger in order to minimize pressure
drop in the line.
Table 11. MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS
PER HOUR (BASED UPON A PRESSURE DROP OF 0.3
INCH WATER COLUMN AND 0.6 SPECIFIC GRAVITY GAS)
Make sure the gas on which boiler is to operate is same as that
specified on the rating plate. Do not install boiler if equipped for
a different type of gas. Consult your gas supplier.
This boiler is not intended to operate at gas supply pressure
other than shown on the rating plate. A lock-up or positive shutoff type regulator must be installed in gas supply line. For proper
gas regulation the lock-up style regulators must be installed no
closer than a minimum of 3 feet from the boiler and a maximum
of 8 feet away from the boiler. Exposure to higher gas supply
pressure may cause damage to gas control valves which can
result in fire or explosion. If overpressure has occurred such as
through improper testing of gas lines or emergency malfunction
of supply system, the gas control valves must be checked for safe
operation. Make sure that the outside vents on supply regulators
and the safety vent valves are protected against blockage. These
are parts of the gas supply system, not boiler. Vent blockage may
occur during ice build-up or snowstorms.
Distance
from Gas
Meter
Nominal Iron Pipe Size (Inches)
1/2 3/4
1
1 1/4 1 1/2
2
2 1/2
3
4
10 (3) 132 278 520 1,050 1,600 3,050 4,800 8,500 17,500
20 (6)
92 190 350 730 1,100 2,100 3,300 5,900 12,000
30 (9)
73 152 285 590 890 1,650 2,700 4,700 9,700
40(12) 63 130 245 500 760 1,450 2,300 4,100 8,300
50 (15) 56 115 215 440 670 1,270 2,000 3,600 7,400
60 (18) 50 105 195 400 610 1,150 1,850 3,250 6,800
70 (21) 46 96 180 370 560 1,050 1,700 3,000 6,200
80 (24) 43 90 170 350 530 990 1,600 2,800 5,800
90 (27) 40 84 160 320 490 930 1,500 2,600 5,400
100 (30) 38 79 150 305 460 870 1,400 2,500 5,100
125 (38) 34 72 130 275 410 780 1,250 2,200 4,500
150 (45) 31 64 120 250 380 710 1,130 2,000 4,100
175 (53) 28 59 110 225 350 650 1,050 1,850 3,800
200 (60) 26 55 100 210 320 610
980 1,700 3,500
The boiler must be isolated from the gas supply piping system by
closing its main manual gas shut off valve during any pressure
testing of the gas supply piping system at test pressures equal
to or less than 1/2 psig.
Disconnect the boiler and its main manual gas shut-off valve
from the gas supply piping during any pressure testing of the gas
supply system over 1/2 psig. The gas supply line must be capped
when not connected to the boiler.
*The heating value of Natural Gas is approximately 1,050 Btu/Ft.3.
Propane (LP) Gas has a heating value of approximately 2,500 Btu/Ft3.
It is important to guard against gas control valve fouling from
contaminants in the gas ways. Such fouling may cause improper
operation, fire or explosion. If copper supply lines are used they
must be approved for gas service.
1 cu. meter=35.31 cu. feet.
Where it is necessary to use more than the average number of
pipe fittings i.e. elbows, tees, and valves in gas supply line, use a
pipe larger than specified to compensate for increased pressure
drop.
When local codes require a main manual shut-off valve outside
the boiler jacket, a suitable main manual shut-off valve must be
installed in a location complying with those codes.
Before attaching gas line be sure that all gas pipe is clean
on inside. To trap any dirt or foreign material in the gas supply
line, a sediment trap must be incorporated in piping. The
sediment trap must be readily accessible and not subject to
freezing conditions. Install in accordance with recommendations
of serving gas supplier. Refer to the current edition of the National
Fuel Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas and
Propane Installation Code, CAN/CSA B149.1
Size of gas supply piping may be larger than heater connection
on installations where a significant run of piping is required.
To prevent damage, care must be taken not to apply too much
torque when attaching gas supply pipe to boiler gas inlet. When
installing and tightening gas piping use a second wrench to hold
the gas control valve to keep the valve from turning. To prevent
damage to the gas control valve do not use pipe wrench on the
valve body.
19
20
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 Value of 1,000 BTU’s/Ft3)
Size
Length of Pipe in Feet (Meters)
(Inches)
10 (3.05) 20 (6.1) 30 (9.14) 40 (12.19) 50 (15.24) 60 (18.29)70 (21.34) 80 (24.38)90 (27.43)100 (30.48) 125 (38.1)
150
1 1/2 BTU/hr 3,276,000 2,277,600 1,840,800 1,544,400 1,404,000 1,263,6001,170,000 1,076,4001,014,000 967,200 858,000 780,000
kW
959
667
539
452
411
370
343
315
297
283
251
228
2 BTU/hr 6,162,000 4,290,000 3,432,000 2,964,000 2,620,800 2,371,2002,184,000 2,028,0001,903,200 1,794,000 1,591,200 1,482,000
kW
1,805
1,256
1,005
868
768
694
640
594
557
525
466
434
2 1/2 BTU/hr 9,828,000 6,786,000 5,491,200 4,680,000 4,134,000 3,744,0003,510,000 3,198,0003,042,000 2,886,000 2,574,000 2,340,000
kW
2,878
1,987
1,608
1,371
1,211
1,097
1,028
937
891
845
754
685
3 BTU/hr 17,160,00012,012,000 9,750,000 8,268,000 7,410,000 6,708,0006,084,000 5,772,0005,382,000 5,070,000 4,602,000 4,134,000
kW
5,026
3,518
2,856
2,421
2,170
1,965
1,782
1,690
1,576
1,485
1,348
1,211
4 BTU/hr 35,880,00024,648,00019,968,00017,004,00015,132,00013,728,00012,636,00011,700,00011,232,00010,452,000 9,360,000 8,580,000
kW
10,508
7,219
5,848
4,980
4,432
4,021
3,701
3,427
3,290
3,061
2,741
2,513
Table 13. SUGGESTED PIPE SIZE FOR MULTIPLE GAS APPLIANCES (PROPANE GAS)
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 Value of 1,000 BTU’s/Ft3)
Size
Length of Pipe in Feet (Meters)
(Inches)
10 (3.05) 20 (6.1) 30 (9.14) 40 (12.19) 50 (15.24) 60 (18.29)70 (21.34) 80 (24.38)90 (27.43)100 (30.48) 125 (38.1)
150
1 1/2 BTU/hr 2,100,000 1,460,000 1,180,000 990,000 900,000 810,000 750,000 690,000 650,000 620,000 550,000 500,000
kW
615
428
346
290
264
237
220
202
190
182
161
146
2 BTU/hr 3,950,000 2,750,000 2,200,000 1,900,000 1,680,000 1,520,0001,400,000 1,300,0001,220,000 1,150,000 1,020,000 950,000
kW
1,157
805
644
556
492
445
410
381
357
337
299
278
2 1/2 BTU/hr 6,300,000 4,350,000 3,520,000 3,000,000 2,650,000 2,400,0002,250,000 2,050,0001,950,000 1,850,000 1,650,000 1,500,000
kW
1,845
1,274
1,031
879
776
703
659
600
571
542
483
439
3 BTU/hr 11,000,000 7,700,000 6,250,000 5,300,000 4,750,000 4,300,0003,900,000 3,700,0003,450,000 3,250,000 2,950,000 2,650,000
kW
3,222
2,255
1,830
1,552
1,391
1,259
1,142
1,084
1,010
952
864
776
4 BTU/hr 23,000,00015,800,00012,800,00010,900,000 9,700,000 8,800,0008,100,000 7,500,0007,200,000 6,700,000 6,000,000 5,500,000
kW
6,736
4,627
3,749
3,192
2,841
2,577
2,372
2,197
2,109
1,962
1,757
1,611
Table 12. SUGGESTED PIPE SIZE FOR MULTIPLE GAS APPLIANCES (NATURAL GAS)
175
717,600
210
1,326,000
388
2,137,200
626
3,822,000
1,119
7,800,000
2,284
175
460,000
135
850,000
249
1,370,000
401
2,450,000
718
5,000,000
1,464
200
670,800
196
1,248,000
366
1,999,800
585
3,556,800
1,042
7,176,000
2,102
200
—
—
800,000
234
1,280,000
375
2,280,000
668
4,600,000
1,347
VENTING
STANDARD VENTING
Figure 16. VENT PIPE INSTALLATION
Type B venting may be used with these boilers. All local utility
regulations on venting should be followed.
Where a continuous or intermittent back draft is found to exist the
cause must be determined and corrected. A special vent cap may
be required. If the back draft cannot be corrected by the normal
methods or if a suitable draft cannot be obtained, a blower type
flue gas exhauster may be employed to ensure proper venting
and correct combustion if permitted by local codes.
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, Installation Codes, or applicable
provisions of the local building codes.
Vent connectors serving appliances vented by natural draft shall
not be connected into any portion of mechanical draft systems
operating under positive pressure.
Vent connectors serving appliances vented by natural draft shall
not be connected into any portion of mechanical draft systems
operating under positive pressure.
The minimum distance from adjacent public walkways, adjacent
buildings, openable windows and building openings shall not be
less than those values specified in the National Fuel Gas Code,
ANSI Z223.1 or CAN/CSA B149.1, Installation Codes;
CONNECTING BOILER TO A COMMON VENT
Do not connect the boiler to a common vent or chimney with solid
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.
DRAFT HOOD
The draft hood furnished with this boiler must be installed without
alteration. The draft hood must be installed using a minimum of
two #12 x 3/4" self drilling screws, see Figure 15. Provision must
be made if the boiler is installed in confined space or a small
boiler room to accommodate draft hood spillage and avoid risks
described above. The upper air opening called for in the AIR
REQUIREMENTS section of this manual is for this purpose.
Where a separate vent connection is not available and the vent
pipe from the boiler must be connected to a common vent with
oil burning equipment, the vent pipe should enter the common
vent or chimney at a point ABOVE the flue pipe from the oil
fired unit.
Where two or more appliances vent into a common vent connector
or manifold, the area of the common vent or vent connector
should at least equal the area of the largest vent connector plus
50% of the areas of the additional draft hood outlets.
When removing a boiler from a system with a common vent, use
the following steps:
Be sure the other appliances connected to the common vent are
not in operation.
Seal any unused openings in the common venting system.
Visually inspect the venting system for proper size and horizontal
pitch and determine there is no blockage or restriction, leakage,
corrosion and other deficiencies which could cause an unsafe
condition.
Figure 15. VENT PIPE INSTALLATION
VENT CONNECTION
Insofar as is practical, close all building doors and windows and
all doors between the space in which the appliances remaining
connected to the common venting system are located and other
spaces of the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom exhausts, so
they will operate at maximum speed. Close fireplace dampers.
Size and install proper size vent pipe. Do not reduce pipe size to
less than that of the draft hood outlet.
Horizontal runs of vent pipe shall be securely supported by
adequately placed (approximately every 4 feet or 1 meter),
noncombustible hangers and/or slip joints suitable for the weight
and design of the materials employed to prevent sagging and to
maintain a minimum upward slope of 1/4" (21 mm/m) per foot from
the boiler to the vent terminals, see Figure 16. Dampers or other
obstructions must not be installed in the vent. Be sure that the
vent pipe does not extend beyond the inside wall of the chimney.
Place in operation the appliance being inspected. Follow the
lighting instructions. Adjust thermostat so appliance will operate
continuously.
21
Test for spillage at the draft hood relief opening after five minutes
of main burner operation. Use the flame of a match or candle.
SIDEWALL VENTING
The optional sidewall power vent system is certified for maximum
100' equivalent venting. The power vent kits p/n for HW300, 399420, 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 Power Vent Kit Installation Instructions
for proper wiring and installation procedures. Contact your local
A.O.Smith representative for details.
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 operation of the common venting system should be
corrected so the installation conforms with the current edition of
National Fuel Gas Code, ANSI Z223.1 or CAN/CSA B149.1. When
resizing any portion of the common venting system, the common
venting system should be resized to approach the minimum size
as determined using the appropriate tables in the National Fuel
Gas Code, ANSI Z223.1 or CAN/CSA B149.1.
VENTING SYSTEM
Have venting system checked every six months for
obstructions and/or deterioration in vent piping. Refer to
Venting Maintenance on Page 41.
MULTIPLE VENT TABLE
1. Insofar as is practical, close all doors, windows and air
inlets to the building. Turn on all exhaust fans (range
hood, bathroom exhaust, etc.) so they will operate at their
maximum speed. Close fireplace dampers.
Table 14 on Page 23 has been compiled to show the material
sizes in a Type B doublewall combined vent system. Refer to
the current edition of NFPA 54 or CAN/CSA B140.1 for further
information.
2. After allowing the boiler to operate for five minutes, test for
spillage at the draft hood relief opening.
A combined vent system is one in which two or more boilers at
one level are attached to a common vent.
3. “Checking the draft. Operate vent connected gas utilization
equipment for several minutes and check to see that the
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 properly, the match flame will be drawn
into the draft hood. If not, the combustion products will tend
to extinguish this flame.
In order to use Table 14, the connector rise and total vent height
must be known. Connector rise is vertical distance from the draft
hood outlet to the point where the manifold connection is made. Total
vent height is the least vertical distance from a draft hood outlet to
the top of the vent. Local codes or utility requirements often govern
termination height. ULC listed doublewall gas vents, up through 24"
(610 mm) diameter, can be installed in heated and unheated areas
and can pass through floors, ceilings, partitions, walls and roofs,
provided the required one inch clearance is observed. These vents
should be installed in accordance with National Fuel Gas Code,
ANSI Z223.1 or CAN/CSA B149.1.
If the combustion products are escaping from the relief opening
of the draft hood, do not operate the equipment until proper
adjustment or repairs are made to provide adequate draft through
the chimney or gas vent.”
EXAMPLE SHOWING USE OF THE HW-670 COMBINED
VENT SIZING TABLE
4. Next, turn on all other fuel burning appliances within the
same room so they will operate at their full input.
Repeat step C above, checking the draft on each appliance.
Figure 18. VENTING SYSTEM
Figure 17. EXAMPLE FOR COMBINED VENT SIZING
TABLE
22
Table 14. COMBINED VENT SIZING TABLES
MODEL HW-300 BOILER
Input: 300,000 Btuh
Draft Hood Outlet 8"
Required Connector or Smoke Pipe Diameter
Total Vent Height (Measured in Feet Above Draft Hood)
Connector
10
15
20
30
40
50
60
80
100
Rise in Feet
Connector Diameter (in Inches)
1
10
10
10
10
10
10
10
10
10
2
10
10
10
10
10
10
10
10
10
3
10
10
10
10
10
10
10
10
10
4 or more
Total Vent Height (Measured in Feet Above Draft Hood)
Number
Total Input
if Units
10
15
20
30
40
50
60
80
100
Btuh x 1000
Combined
Manifold and Common Vent Diameter (in Inches)
2
600
14
12
12
12
10
10
10
10
10
3
900
16
14
14
14
12
12
12
12
12
4
1200
18
16
16
14
14
14
14
12
12
MODEL HW-520 BOILER
Input: 520,000 Btuh
Draft Hood Outlet 10"
Required Connector or Smoke Pipe Diameter
Total Vent Height (Measured in Feet Above Draft Hood)
Connector
10
15
20
30
40
50
60
80
100
Rise in Feet
Connector Diameter (in Inches)
1
14
14
14
12
12
12
12
12
12
2
12
12
12
12
12
12
12
12
12
3
12
12
12
12
10
10
10
10
10
4 or more
12
12
12
12
10
10
10
10
10
Total Vent Height (Measured in Feet Above Draft Hood)
Number
Total Input
if Units
10
15
20
30
40
50
60
80
100
Btuh x 1000
Combined
Manifold 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
20
18
18
7
3640
30
28
26
24
24
22
22
20
20
8
4160
32
30
28
26
24
24
22
22
20
MODEL HW-399 BOILER
Input: 399,000 Btuh
Draft Hood Outlet 10"
Required Connector or Smoke Pipe Diameter
Total Vent Height (Measured in Feet Above Draft Hood)
Connector
10
15
20
30
40
50
60
80
100
Rise in Feet
Connector Diameter (in Inches)
1
12
12
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
Total Vent Height (Measured in Feet Above Draft Hood)
Number
Total Input
10
15
20
30
40
50
60
80
100
if Units
Btuh x 1000
Combined
Manifold and Common Vent Diameter (in Inches)
2
798
14
14
14
12
12
12
12
12
12
3
1197
18
16
16
14
14
14
14
14
12
4
1596
20
20
18
16
16
16
14
14
14
MODEL HW-670 BOILER
Input: 660,000 or 670,000 Btuh
Draft Hood Outlet 12"
Required Connector or Smoke Pipe Diameter
Total Vent Height (Measured in Feet Above Draft Hood)
Connector
10
15
20
30
40
50
60
80
100
Rise in Feet
Connector Diameter (in Inches)
1
16
14
14
14
14
14
14
14
14
2
14
14
14
14
14
12
12
12
12
3
14
14
12
12
12
12
12
12
12
4 or more
12
12
12
12
12
12
12
12
12
Total Vent Height (Measured in Feet Above Draft Hood)
Number
Total Input
10
15
20
30
40
50
60
80
100
if Units
Btuh x 1000
Combined
Manifold and Common Vent Diameter (in Inches)
2
1220
18
18
16
16
14
14
14
14
14
3
1830
22
20
20
18
18
16
16
16
14
4
2440
26
24
22
20
20
18
18
18
16
5
3050
28
26
26
24
22
22
20
20
18
6
3660
32
28
28
26
24
24
22
22
20
7
4270
34
32
30
28
26
24
24
22
22
8
4880
36
34
32
30
28
26
26
24
24
9
5490
38
36
34
30
30
28
28
26
24
10
6100
40
38
36
32
30
30
28
26
26
11
6710
42
38
38
34
32
30
28
28
26
12
7320
46
44
40
38
36
34
34
32
30
MODEL HW-420 BOILER
Input: 420,000 Btuh
Draft Hood Outlet 10"
Required Connector or Smoke Pipe Diameter
Total Vent Height (Measured in Feet Above Draft Hood)
Connector
10
15
20
30
40
50
60
80
100
Rise in Feet
Connector Diameter (in Inches)
1
12
12
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
Total Vent Height (Measured in Feet Above Draft Hood)
Number
Total Input
10
15
20
30
40
50
60
80
100
if Units
Btuh x 1000
Combined
Manifold and Common Vent Diameter (in Inches)
2
840
14
14
14
12
12
12
12
12
12
3
1260
18
16
16
14
14
14
14
14
12
4
1680
20
20
18
16
16
16
14
14
14
Example: Known:(5) model HW-670 boilers. (See illustration).
Connector rise - 2' (Note 1' is minimum). Total vent height 30'.
Problem: Determine diameter of connector, manifold and common
vent.
Procedure: Enter the top of the HW-670 table (total vent
height) at 30' and the side at 2' (connector rise). A 14"
connector diameter is indicated for each connector rise.
To determine the manifold and common vent size, enter table
on this page (total vent height) at 30 and the side at 5 boilers. A
manifold diameter of 24" (610 mm) is indicated.
23
GAS SUPPLY CONNECTIONS
GAS SUPPLY PIPE CONNECTIONS
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.
1. Make sure to install ground joint union for servicing.
In Canada – When using manual main shutoff to support the
weight of the piping with valves, ensure that it is identified by the
installer.
PIPE SIZES FOR PROPANE GAS
Make sure to contact the gas supplier for pipe sizes, tanks, and
100% lockup gas pressure regulator.
2. Install sediment trap per NFPA 54 for US and CAN B149.1
for Canada.
PURGING GAS LINE
3. Support the piping with hangers, not by the boiler or its
accessories. The gas control valve and blower will not
support the weight of the piping. Failure to comply could
result in severe personal injury, death, or substantial
property damage.
Gas line purging is required with new piping or systems in which
air has entered. Gas purging should be performed per NFPA 54
for US and CAN B149.1 for Canada.
4. Purge all air from the gas supply piping.
CHECK GAS SUPPLY INLET PRESSURE
5. Before setting the boiler in operation, check the boiler and its
gas connection for leaks.
• Disconnect the boiler from the gas supply piping system
during any pressure testing, at a test pressure in excess
of 1/2 PSIG (3.5 kPa)
• The boiler must be isolated from the gas supply piping
system by closing a manual shutoff valve during any
pressure testing, at test pressures equal to or less than
1/2 PSIG (3.5 kPa).
CSA or UL listed flexible gas connections are acceptable, but
make sure that the line has adequate capacity to allow your boiler
to fire at full rate. Consult with local codes for proper installation
or service procedures.
Do not adjust or attempt to measure gas control valve outlet
pressure. Attempting to alter or measure the outlet pressure
could result in damage to the valve, causing potential severe
personal injury, death, or substantial property damage.
Do not check for gas leaks with an open flame, instead use the
bubble test. Failure to use the bubble test or check for gas leaks
can cause severe personal injury, death, or substantial property
damage.
Make sure the gas piping are sized for the proper flow and length
of pipe, to avoid excessive pressure drop. The gas meter and
the gas regulator must be properly sized for the total gas load.
Perform the below steps when checking inlet gas supply:
6. Use pipe sealing compound compatible with propane gases.
Apply sparingly only to male threads of the pipe joints so that
pipe dope does not block gas flow.
1. Turn the main power switch to the “OFF” position.
2. Shut off gas supply.
3. Remove the 1/8" pipe plug on the main gas shutoff valve
and install a suitable 1/8" fitting (field supplied) for the
manometer tubing. Place the tubing of the manometer over
the tap once the 1/8" fitting is installed.
Failure to apply pipe sealing compound as detailed in this
manual can result in severe personal injury, death, or substantial
property damage.
7. Make sure the maximum inlet gas pressure do not exceed
the value specified. Minimum value specified is for input
adjustment only.
4. Slowly turn on the gas supply.
5. Ensure inlet pressure is within specified range.
Make sure to use two wrenches when tightening gas piping at the
boiler, using one wrench to prevent the boiler gas line connection
from turning. Failure to support the boiler gas connection pipe to
prevent it from turning could damage gas line components. Do
not use wrench on valve body as damage would occur.
6. If the gas pressure is out of range, contact the gas utility, gas
supplier, qualified installer or service agency to determine
the necessary steps to provide proper gas pressure to the
control.
CHECK FOR GAS LEAKS
GAS PRESSURE REQUIREMENTS
If a positive lock-up regulator is required follow these instructions:
Before operating the boiler, make sure to check the floor near and
around the boiler for gas odorant or any unusual odor. Remove
the top access panel and check for odor in the interior of the
boiler enclosure. Do not start the boiler if there is any indication
of a gas leak. Use an approved leak detection solution and repair
any leaks at once.
1. Positive lock-up gas pressure regulators must be rated at or
above the input Btu/hr rating of the boiler they supply.
2. Positive lock-up gas pressure regulator(s) should be
installed no closer than 3 feet (1 meter) and no farther than
8 feet (2.4 meters) from the boiler’s inlet gas connection.
In the case of propane boilers, the supplier mixes an odorant
with the propane to make its presence detectable. But in some
instances, the odorant can fade, and the gas may no longer have
an odor. Before operating the boiler, make sure the propane
supplier verify the correct odorant level in the gas.
3. After installing the positive lock-up gas pressure regulator(s),
an initial nominal supply pressure setting of 7 inches w.c.
(1.7 kPa) while the boiler is operating is recommended and
will generally provide good boiler operation. Some addition
adjustment maybe required later to maintain a steady gas
supply pressure.
Do not adjust or attempt to measure the outlet pressure. The
gas valve is factory set for the correct outlet pressure. This
setting is suitable for natural gas and propane, equiring no field
adjustment. Attempting to alter or measure the outlet pressure
could result in damage to the valve, causing potential severe
personal injury, death, or substantial property damage.
The maximum allowable gas supply pressure for this boiler is
14 inches w.c. (3.5 kPa). Install a positive lock-up gas pressure
regulator in the gas supply line if inlet gas pressure can exceed
14 inches w.c. (3.5 kPa) at any time.
24
GAS MANIFOLD PRESSURE REGULATORS
Adjustment, if required, is performed as follows:
The gas manifold pressure regulator is included in the
combination gas control valve, Figure 19, and is set to operate
on the gas specified on the boiler model and rating plate.
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.
Periodically check main burner, Figure 20 on Page 26, and
pilot flame, Figure 21 on Page 27, for proper operation. This
should be checked every six months.
3. Reset primary system temperature control dial (thermostat)
to highest setting. Main burner will now ignite.
4. With main burner firing, adjust pressure, if necessary, by
turning pressure regulator adjusting screw with a screwdriver.
Do not subject the gas control valve to inlet gas pressures of
more than 14" W.C. (1/2 P.S.I.). If higher gas pressures are
encountered, a service regulator is necessary.
• • Table 15. CORRECT MANIFOLD PRESSURE FOR FULL BOILER
INPUT (IN INCHES OF WATER COLUMN)
Model
Rated
Manifold Pressure
Natural
Propane
Number
Input
HW-300
300,000
3.5
10.0
HW-399
399,000
3.5
10.0
HW-420
420,000
3.5
10.0
HW-520
520,000
3.5
10.0
HW-670 Nat.
660,000
3.5
HW-670 Prop.
670,000
10.0
Clockwise to increase pressure.
Counterclockwise to decrease pressure.
5. Set primary system temperature control dial (thermostat) to
lowest setting.
6. Remove pressure gauge and replace sealing plug.
7. Set primary system temperature control dial (thermostat) to
desired setting.
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 pressure regulator cannot be adjusted to correct pressure
with sufficient gas pressure at the valve, replace with new gas
control valve.
Figure 19. GAS CONTROL VALVES (NATURAL GAS & PROPANE)
25
BOILER START UP AND OPERATIONS
PILOT AND MAIN BURNER
After placing the boiler into operation, the ignition system safety
shutoff device must be tested by the following test method.
To maintain safe operation of the boiler, check the pilot and
the main burner once every six months for proper flame
characteristics.
1. Reset High Limit Temperature Control to lowest setting.
(See Figure 3 on Page 9).
2. Reset System Controller to maximum setting, causing a call
for heat and allowing unit to run until High Limit Temperature
Control trips.
1. MAIN BURNER
The main burner, Figure 20, should display the following
characteristics:
3. Resetting the High Limit Temperature Control to a higher
setting, unit should run.
• 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.
4. Reset System Controller and High Limit Temperature Control
to desired temperature. If unit fails to run, see TroubleShooting in this manual.
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.
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.
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.
Also check for good flow of combustion and ventilating air to the
unit. Maintain a clear area around the boiler at all times.
Figure 20. MAIN BURNER
FILLING THE SYSTEM
The boiler should be periodically inspected by a qualified servicer
for continuous safe operation.
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.
Qualified servicers should follow this procedure when the boiler’s
burners need cleaning.
2. Vent all high points in system to purge system of air.
a. Turn off the electrical power and close the main manual gas
shutoff valve. Refer to Lighting & Operating Instructions on
Pages 30 and 31.
If pressure bleeding of system is desired, install valves as shown
in Figure 30 to Figure 43 on Pages 47 to 60.
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.
• 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.
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:
•
•
•
•
•
d. Reinstall the burner manifold assembly on boiler.
Flooding to level of burner or controls or higher.
Exposure to fire.
If damaged.
Firing without water.
Sooting.
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 30 and 31.
• Check for gas leaks and proper boiler and vent operation.
26
2. PILOT BURNER - ELECTRONIC IGNITION
Check for electrical power to the valve. If electrical power and
gas are present at the valve and the pilot does not operate when
system calls for heat, replace valve.
To establish pilot flame without main burner operation, it will be
necessary to perform the following steps:
e. Low gas pressure
Servicing of the pilot burner (every six months) includes
keeping pilot shield (not shown) free of lint, cleaning the burner
head, the primary air opening and the orifice of the pilot burner,
Figure 21.
a. Open fused disconnect switch or shut off electrical power to
the boiler.
b. Disconnect wire from MV wire on valve.
c. Close fused disconnect switch to restore electrical power to
the boiler.
f.
The pilot will now ignite provided the system is calling for heat.
d. Adjust pilot flame.
• Adjust pilot flame by means of the pilot gas adjustment
located in the gas control valve.
• The pilot flame should envelop 3/8 to 1/2 inch (1012 mm) of the tip of the thermocouple. Remove pilot
adjustment cover screw, Figure 22. Turn inner adjustment
screw or pilot adjusting valve clockwise to decrease,
or counterclockwise to increase pilot flame. Be sure to
replace cover screw on combination gas control valve
after adjustment to prevent possible gas leakage.
Clogged pilot burner orifice.
• Clean or replace orifice. A clogged orifice will restrict gas
flow and result in low thermocouple output.
g. Incorrect orifice.
To adjust the pilot flame, remove the cap screw from the pilot
adjusting screw (Figure 22) and turn to deliver a sufficient flame
at the pilot burner to cover 3/8" to 1/2" (10-12 mm) of the sensing
probe tip. See Figure 21.
• Replace. The Orifice size is stamped on the wrench flats.
h. Clogged primary air opening.
Check for good terminal connection at the sensing probe at the
pilot burner assembly if pilot does not light.
• Restricted air passages will soften the pilot flame and
result in poor thermocouple flame impingement.
Figure 21. SPARK IGNITION PILOT BURNER AND BURNER FLAME
Figure 22. ADJUSTING PILOT FLAME
27
CHECKING AND ADJUSTING INPUT
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.
Fire and Explosion Hazard
When the boiler is operating at full capacity, or full gas input,
it should consume 1 cu. ft. of gas in approximately the time
indicated in Table 16.
Under no circumstances should the
input exceed the rate shown on the
boiler’s rating label.
Overfiring could result in fire or
explosion.
Gas and carbon monoxide detectors are
available.
Table 16. CONSUMPTION RATE (REFER TO OPERATING
AT FULL INPUT OR FULL CAPACITY)
TYPE
GAS
Breathing Hazard - Carbon Monoxide Gas
Under no circumstances should
the input exceed the rate shown
on the boiler’s rating label.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
1. Follow steps 1 thru 6 of the OPERATING INSTRUCTIONS
on Page 31.
2. Attach a pressure gauge or a manometer to the manifold
pressure tapping and refer to Table 16 for correct manifold
pressure.
3. Follow steps 7 thru 11 of the OPERATING INSTRUCTIONS.
4. Use this formula to “clock” the meter. Be sure that other gas
consuming appliances are not ON during this interval.
Btuh = The approximate actual input rate.
T =
Time in seconds to burn one cubic foot of gas.
H =
Heating value of the fuel gas in Btu per cubic foot of gas.
EXAMPLE:
T = 9.0 seconds/ft3
H = 1050 Btu/ft3(natural gas)
Btuh = ?
Gas flow through meter:
3600
9.0
1050
12.6
9.5
9.0
7.3
5.7
Propane
2500
30.0
22.6
21.4
17.3
13.4
The inlet gas pressure must not exceed or be less than the
values shown on rating plate.
Gas and carbon monoxide detectors
are available.
3600 x H = Btuh
T
Natural
Minor variances from input on rating plate can be corrected by
adjustment of gas pressure regulators. Refer to Gas manifold
pressure regulators on Page 25.
Overfiring could result in damage to
the boiler’s and sooting.
TIME TO CONSUME 1 CU. FT. OF GAS
(SECONDS)
HEATING
VALUE
BTU/FT. HW-300 HW-399 HW-420 HW-520 HW-670
x 1050 = 420,000 Btuh
Small changes in the input rate may be made by adjusting the
manifold pressure, refer to Gas manifold pressure regulators
on Page 25. Under no circumstances should you exceed the
maximum input rate for the boiler given in Table 3 on Page 7.
5. Repeat steps 1 thru 6 of the OPERATING INSTRUCTIONS.
28
START
STAGE 1
TRIAL FOR
IGNITION
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 15 sec. ignition
shut-down. 5 minute
time delay before re-try.
S-8600H
STAGE 2
MAIN BURNER
OPERATION
After 15 sec. ignition
system locks out
must be manually reset.
FLAME CURRENT SENSED
• Spark generator off.
• Second valve operator (main) opens.
MAIN BURNER OPERATION
Module monitors pilot flame current.
END
POWER INTERRUPTION
System shuts off, restarts
when power is restored.
PILOT FLAME FAILURE
Main valve closes.
Module starts trial for
ignition.
THERMOSTAT (CONTROLLER) SATISFIED
Valves close, pilot and main burners are off.
29
LIGHTING AND OPERATING INSTRUCTIONS (NATURAL AND PROPANE FOR HW300 - HW399)
30
LIGHTING AND OPERATING INSTRUCTIONS (NATURAL AND PROPANE WITH I.I.D. FOR HW420 & UP)
31
TROUBLESHOOTING
Before any extensive troubleshooting, perform the following:
• Voltage (24 vac) is supplied by transformer.
• Boiler is wired according to wiring diagram.
Note: Cross wiring the 24 volt circuit of the relay will short the
transformer.
• All wire terminals/connectors are firmly attached to
valves, modules, switches, limit controls, etc.
• For Propane (LP) models only check for possible lockout
condition of the ignition module.
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 contacts (switches) are closed (relay, low water
cutoff, flow switch, coil protector, pressure switch, etc.).
• Gas supply pressure is within the maximum and minimum
operating ranges listed on the boiler rating plate/label.
Table 17. CER-TEMP 80 RECOVERY SYSTEM CHECKOUT PROCEDURE
Use this checkout for Cer-Temp 80 Recovery Systems. (For hot water supply application only)
CHECKOUT SEQUENCE
Set tank temperature
control (thermostat)
20°F (10°C) below tank
water temperature.
SYSTEM OPERATION
CORRECT
Circulating pump and
burner shut off.
With thermal balancer,
pump off delay of
approximately 2 minutes.
INCORRECT
CAUSE
Tank temperature control
Replace.
Pump and burner remain (thermostat) defective.
on.
System wiring is
Correct wiring.
incorrect.
Circulating pump on.
Burner on.
Pump wired for
continuous operation.
Correct wiring.
Gas control valve stuck
or defective.
Correct or replace
valve.
System wiring is
incorrect.
Correct wiring.
High limit control set too
low.
High limit control
differential too wide.
Circulating pump on.
Set tank temperature
control (thermostat)
20°F (10°C) above tank
water temperature.
Circulating pump and
burner on.
Circulating pump and
burner off.
Boiler outlet
temperature exceeds
210°F (100°C).
Circulating pump on.
Set tank temperature
control (thermostat)
for desired water
temperature.
System maintains desired
water temperature.
REMEDY
Replace. (If
problem proven to
be at this control by
applying jumper to
terminals.)
System wiring is
incorrect.
Correct wiring.
Coil protector switch has
activated.
Remove control
cover, depress
reset button.
Gas control valve or
wiring defective.
Check wiring.
Repair or replace
valve.
Power off or system
wiring is incorrect.
Check power supply
and wiring.
Tank temperature control
Replace.
(thermostat) defective.
Burner on.
System wiring is
incorrect.
Correct wiring.
Circulating pump and
burner on.
High limit control
defective, or set too high
(max. should be set at
200°F).
Replace.
32
CHECKING HONEYWELL S-8600H OR S-8600M
INTERMITTENT IGNITION CONTROLS
NO SPARK AT PILOT BURNER
Turn off gas supply.
Replace ignition module.
NO
Is voltage (24 Vac) across the 24 V terminals
on module during “Call for heat”?
YES
Is voltage (24 Vac) across the PV & MV/PV terminals on
“call for heat”?
YES
NO
NOTE: S-8600M will automatically reset every 5 minutes. S8600H pilot
valve will be de-energized if module goes into lockout condition. Reset
system by turning electrical power off or by turning system controller to
off or down below "call for heat". Wait one minute, then turn system on.
YES
Turn on gas supply.
Turn on power supply.
Securely connect cable
and/or ground wire.
Turn off power supply.
NO
Is ignition cable firmly plugged into pilot
assembly and module?
Is ground wire firmly attached to pilot assembly and GND terminal
on module?
YES
Replace pilot burner
and/or ground wire.
NO
Are ignition cable and ground wire in good condition
(not brittle, burnt or cracked)?
YES
Carefully bend downward
top of ground strap
to achieve 1/8”
spark gap.
NO
Ensure ground strap is the closest metal to the igniter/sensor
rod (electrode) to prevent the spark from shorting out to other metal
parts (pilot screen, pilot shield, etc.).
Ignition cable must not touch metal surfaces or current
carrying wires.
Is there a 1/8” gap between ground strap and electrode?
YES
Replace Ignition
Module.
NO
Is the ceramic insulator surrounding the electrode cracked or broken?
YES
Replace pilot burner assembly.
33
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 unclogged. Check for air in gas
line, purge (bleed) line if necessary.
YES
NO
Attach wires firmly.
Are the wires securely attached to the pilot operator on the gas control
and to the PV & MV/PV terminals on the ignition module?
YES
NO
Replace gas control valve.
Install a pressure gauge in the pilot tubing line between the gas control
and the pilot burner assembly. Ensure that the pilot adjustment screw
(under cap) is adjusted to a position that will permit gas to flow.
Is pilot gas flowing during ignition attempt?
YES
Turn on power supply.
Turn off power supply.
YES
NO
Securely connect
cable and/or ground
wire.
Is ignition cable firmly plugged into pilot assembly and module?
Is ground wire firmly attached to pilot assembly and GND terminal on
module?
YES
Replace pilot burner
and/or ground wire.
NO
Are ignition cable and ground wire in good condition (not brittle, burnt, or cracked)?
YES
Carefully bend downwards top of ground
strap to achieve
1/8” spark gap.
Ensure ground strap is the closest metal to the igniter/sensor
rod (electrode) to prevent the spark from shorting out to
other metal parts (pilot screen, pilot shield, etc.).
NO
Ignition cable must not touch metal surfaces or current
carrying wires.
Is there a 1/8” gap between ground strap and electrode?
YES
Replace pilot burner.
NO
Is ceramic insulator surrounding the electrode in good
condition (not cracked or broken)?
YES
Replace ignition
module.
NO
Is there excessive draft conditions that may cause pilot
burner ignition problems?
YES
Correct draft problems in a manner that would ensure
adequate combustion and ventilation air and proper
pilot burner performance.
34
CHECKING HONEYWELL S-8600H OR S-8600M
INTERMITTENT IGNITION CONTROLS
PILOT BURNER LIGHTS BUT MAIN BURNER DOES NOT LIGHT
Correct the situation by consulting the
installation or user’s manual on how to
adjust pilot flame.
NO
Does the pilot flame cover 3/8” to 1/2”
of igniter/sensor rod?
YES
Replace
ignition
module.
NO
NO
Is voltage (24 Vac) across terminals
MV & MV/PV?
Does spark stay on for more than
15 seconds after the pilot is “proven” (lit)?
YES
Attach
wires
firmly.
NO
Are the wires securely attached to the main
valve operator on the gas control and to
terminals MV & MV/PV on ignition module?
YES
YES
Replace main gas control valve.
NO
Replace pilot burner
and/or ground wire.
Ensure the ground wire and ignition cable are
separate from each other (prevents shorting
out).
Are they in good condition (not brittle, burnt or
cracked)?
YES
NO
Replace pilot burner.
Is the ceramic insulator surrounding the
igniter/sensor rod in good condition
(not broken or cracked)?
YES
NO
Clean rod or replace
pilot burner if necessary.
Is the igniter/sensor rod in good
condition (not worn, corroded, sooted
or damaged)?
YES
Replace ignition module.
35
CHECKING HONEYWELL S8600H OR S-8600M
INTERMITTENT IGNITION CONTROLS
NO SPARK AT PILOT BURNER BUT PILOT WILL NOT LIGHT
Turn off gas supply.
Fix connection and/or
tighten module to the
boiler.
NO
Is there a good connection between terminals?
Is module securely attached to boiler for good ground
connection?
YES
Check the circuit providing
24 VAC.
NO
Is voltage (24VAC) across transformer positive terminal and
GND with "call for heat"?
YES
Replace ignition module.
NO
Is voltage (24VAC) across ignition module terminals 24 Volt and GND on
"call for heater"?
NOTE: (For Propane (LP) models only) Pilot Valve will be de-energized
if module goes into lockout condition. Reset system by turning electrical
power off or by turning system controller down below "call for heat". Wait
one minute then turn system on.
Turn on gas supply and/or
power supply.
YES
Securely connect cable
and/or ground wire.
NO
Turn off power supply.
Is high voltage cable assembly firmly plugged into module?
Is pilot ground wire firmly attached to the pilot assembly and GND
terminal on module?
YES
Replace pilot burner and/
or ground wire.
NO
Are high voltage cable and ground wire in good condition (not brittle,
burnt or cracked)?
YES
Carefully bend downwards top of ground
strap to achieve
1/8” spark gap.
Make sure pilot flame spreader (hood) is the closest metal to
the electrode to prevent the spark from shorting out to other metal parts
(pilot screen, pilot shield, etc).
NO
High voltage cable must not touch metal surfaces or current carrying
wires.
Is there a 7/64" spark gap between the tip (edge) of the hood and
electrode, and is the gap located in the pilot gas stream?
YES
Replace ignition module.
NO
Is the ceramic insulator surrounding the electrode in good
condition (not cracked or broken)?
YES
Replace pilot burner assembly.
36
Table 18. YELLOW LED FLAME CODES
The following procedures are provided as a general guide.
Any module should be replaced if it does not perform properly on
checkout or troubleshooting.
In addition, replace any module if it is wet or looks like it has ever
been wet.
YELLOW LED
FLASH CODEA
INDICATES
RECOMMENDED
SERVICE ACTION
Heartbeat
Normal Flame Signal
not applicable
LED STATUS AND TROUBLESHOOTING
The control has two LEDs; one for flame sensing and one for
system status:
2
Weak Flame SignalSystem will operate
reliably but flame
signal is less than
desired.
NOTE: This indication
may flash temporarily
during or shortly
after lightoff on some
applications.
Perform routine
maintenance to
assure optimum
flame signal.
Marginal Flame Signal
(less than 1.1µA)System may not
operate reliably over
time.
1
Figure 23. LOCATION OF LED'S
•
Flame LED (Yellow)
Indicates flame presence and strength. Refer to Table 18.
•
Status LED (Green)
Indicates system operation status and error conditions. Refer
to Table 19 and Table 20 on Pages 38 and 39 for status
specific to each model.
OFF
Check gas supply,
pilot burner, flame
sense wiring,
Service call
contamination
recommended.
of flame sensor,
burner ground
NOTE: This indication
connection.
may flash temporarily
during or shortly
after lightoff on some
applications.
No Flame or Flame
Signal below minimum
not applicable
threshold for system
operation.
Flash Code Descriptions:
A
• Heartbeat: Constant 1/2 second bright 1/2 second dim
cycles.
• The flash code number signifies that the LED flashes X
times at 2Hz, remains off for two seconds, and then repeats
the sequence.
37
Table 19. CONTINUOUS RETRY MODELS C, M, E AND K ONLY - GREEN LED STATUS CODES
GREEN LED
FLASH CODE
(X+Y)A
OFF
INDICATES
No "Call for Heat"
NEXT SYSTEM ACTION
not applicable
RECOMMENDED SERVICE
ACTION
none
Flash Fast
Startup - Flame sense calibration
not applicable
none
Heartbeat
Normal operation
not applicable
none
5 minute Retry Delay
• Pilot flame not detected during
trial for ignition
Initiate new trial for ignition after
retry delay completed.
If system fails to light on next
trial for ignition check gas supply,
pilot burner, spark and flame
sense wiring, flame sensor
contaminated or out of position,
burner ground connection.
Recycle
• Flame failed during run
Initiate new trial for ignition. Flash
code will remain through the ignition
trial until flame is proved.
If system fails to light on next trial
for ignition, check gas supply,
pilot burner, flame sense wiring,
contamination of flame sensor,
burner ground connection.
Flame sensed out of sequence
If situation self corrects within 10
seconds, control returns to normal
sequence. If flame out of sequence
remains longer than 10 seconds,
control goes to Flash code 6+4 (see
below).
Check for pilot flame. Replace
gas control valve if pilot flame is
present. If no pilot flame, cycle
"Call for Heat." If error repeats,
replace control.
7
Flame sense leakage to ground
Check flame sense lead wire for
Control remains in wait mode. When damage or shorting. Check that
flame sensor is in proper position.
the fault corrects, control resumes
normal operation after a one minute
delay.
Check flame sensor ceramic for
cracks, 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 and AC line
for proper input voltage to the
control. Check with full system
load on the transformer.
6+2
5 minute Retry Delay
• On every third retry on the same
"Call for Heat"
Initiate new trial for ignition after
retry delay completed.
Check gas supply line, pilot
burner, spark and flame
sense wiring, flame sensor
contaminated or out of position,
burner ground connection.
6+3
On every 6th flame failure during run
on the same "Call for Heat"
5 minute retry delay, then initiate
new trial for ignition.
Check gas supply, pilot burner,
flame sense wiring, contamination
of flame sensor, burner ground
connection.
6+4
Flame sensed out of sequencelonger than 10 seconds
Control waits until flame is no
longer sensed and then goes to
soft lockout. Flash code continues.
Control auto resets from soft lockout
after one hour.
Check for pilot flame. Replace
gas control valve if pilot flame
present. If no pilot flame, cycle
"Call for Heat." If error repeats,
replace control.
ON
Soft lockout due to error detected
during self check sequences
Control auto resets from soft lockout Reset by cycling "Call for Heat." If
after one hour.
error repeats, replace the control.
2
3
4
Flash Code Descriptions:
• Flash Fast: rapid blinking.
• Heartbeat: Constant 1/2 second bright 1/2 second dim cycles.
• A single flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then repeats the
sequence.
• X+Y flash codes signify that the LED flashes X times at 2Hz, remains off for two seconds, flashes Y times at 2Hz, remains off
for three seconds, and then repeats the sequence.
A
38
Table 20. LOCKOUT MODELS B, H, D AND J ONLY - GREEN LED STATUS CODES
GREEN LED
FLASH CODE
(X+Y)A
OFF
INDICATES
No "Call for Heat"
NEXT SYSTEM ACTION
not applicable
RECOMMENDED SERVICE
ACTION
none
Flash Fast
Startup - Flame sense calibration
not applicable
none
Heartbeat
Normal operation
not applicable
none
Recycle
• Flame failed during run
Initiate new trial for ignition. Flash
code will remain through the ignition
trial until flame is proved.
If system fails to light on next
trial for ignition, check gas
supply, pilot burner, flame
sense wiring, contamination of
flame sensor, burner ground
connection.
Flame sensed out of sequence
If situation self corrects within 10
seconds, control returns to normal
sequence. If flame out of sequence
remains longer than 10 seconds,
control goes to Flash code 6+4 (see
below).
Check for pilot flame. Replace
gas control valve if pilot flame is
present. If no pilot flame, cycle
"Call for Heat." If error repeats,
replace control.
3
4
7
8
Flame sense leakage to ground
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 flame sense lead wire
for damage or shorting. Check
that flame sensor is in proper
position.
Check flame sensor ceramic for
cracks, damage or tracking.
Control remains in wait mode. When
the fault corrects, control resumes
normal operation 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.
Remain in lockout until "Call for
Heat" is cycled.
Check gas supply line, pilot
burner, spark and flame
sense wiring, flame sensor
contaminated or out of position,
burner ground connection.
6+2
Failed trial for ignition resulting in
lockout
6+3
More than 5 flame failures during run
Remain in lockout until "Call for
on the same "Call for Heat" resulting
Heat" is cycled.
in lockout
6+4
Flame sensed out of sequencelonger than 10 seconds
Control waits until flame is no
longer sensed and then goes to
soft lockout. Flash code continues.
Control auto resets from soft lockout
after one hour.
ON
Soft lockout due to error detected
during self check sequences
Control auto resets from soft lockout
after one hour.
Check gas supply, pilot
burner, flame sense wiring,
contamination of flame sensor,
burner ground connection.
Check for pilot flame. Replace
gas control valve if pilot flame
present. If no pilot flame, cycle
"Call for Heat." If error repeats,
replace control.
Reset by cycling "Call for Heat."
If error repeats, replace the
control.
Flash Code Descriptions:
• Flash Fast: rapid blinking.
• Heartbeat: Constant 1/2 second bright 1/2 second dim cycles.
• A single flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then repeats the
sequence.
• X+Y flash codes signify that the LED flashes X times at 2Hz, remains off for two seconds, flashes Y times at 2Hz, remains off
for three seconds, and then repeats the sequence.
A
39
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 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
and sooting.
The flow of combustion and ventilation air to the boiler must not
be obstructed. The boiler area must be kept clear and free from
combustible materials, gasoline, and other flammable vapors
and liquids.
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. More frequent inspections may be necessary
depending on water conditions.
Figure 24. PRESSURE RELIEF VALVE TEST
If after manually operating the valve, it fails to completely reset
and continues to release water, turn off power to the boiler at
the main disconnect switch or breaker. Close the cold water inlet
to the boiler and follow the draining instructions in this manual
to drain the boiler. Should the pressure relief valve need to be
replaced, call the toll free phone number listed on the back of this
manual for further technical assistance.
Periodic checks, at least twice a year, should be made for water
and/or gas leaks.
The boiler mounted gas and electrical controls have been
designed to give both dependable service and long life.
However, malfunction can occur, as with any piece of equipment.
It is therefore recommended that all components be checked
periodically by a qualified service technician for proper operation.
CLEANING AND FLUSHING INSTRUCTIONS
INTERNAL CONTAMINANTS
The hydronic system must be internally cleaned and flushed
after a new or replacement boiler has been installed to remove
contaminants that 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.
MANUAL RESET HIGH LIMIT SWITCH CONTINUITY
TEST
Do not depress the switch reset button prior to testing. With the
boiler being cold, disconnect the leads from the switch. With a
multimeter place a probe on each side of the switch. If the meter
reads zero the switch is good. If you receive an infinite or OL
signal, the reason could be:
Failure to clean and flush the system can produce acid
concentrations that become corrosive, cause gases to form
that block water circulation or lead to formation of deposits on
the boiler surfaces, any of which could result in damage to the
system and circulating pump.
1. Switch contacts open.
• Depress reset button on switch (switch cannot be reset
until water temperature in the boiler coils drop below
200°F). Meter should read zero.
2. Defective switch or bad leads.
All hot water heating systems should be completely flushed with
a grease removing solution to assure trouble-tree operation.
Pipe joint compounds, soldering paste, grease on tubing and
pipe all tend to contaminate a system.
• With leads attached, depress the switch button. If the
meter does not read zero, the switch is defective and
must be replaced.
Failure to flush contaminates from a system can cause solids to
form on the inside of boiler heat exchangers, create excessive
amounts of air and other gases to block circulation, foul various
system accessories and even deteriorate circulation seals and
impellers.
PRESSURE RELIEF VALVE TEST
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. Fire
and circulate for about one hour and then flush clean with fresh
water. Commercial grease removing solutions are available from
your distributor.
Burn hazard.
Hot water discharge.
HOT WATER SUPPLY BOILERS PREVENTIVE
MAINTENANCE
Keep clear of Pressure
Relief Valve discharge outlet.
For care of the HW water system please refer to the A. O. Smith
Users Information Manual supplied with the boiler.
40
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 parts of the venting system.
Qualified servicers should follow this procedure when the boiler’s
external heating surfaces and vent pipe need cleaning.
1. Turn off the electrical power (main manual gas shutoff and
pilot valves, if applicable).
Allow boiler parts and vent to cool before disassembly.
2. Remove the boiler draft diverter 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 exchanger and combustion
coils.
• Refer to parts list supplied with this manual for
disassembly aid.
4. Reinstall the parts removed in steps 2 and 3.
• Be sure the vent pipe has a minimum upward pitch of
one quarter inch per foot of length (21 mm/m) and is
sealed as necessary.
5. Restore electrical power and gas supply to boiler.
• Place boiler in operation by following the lighting
instructions in this manual.
• Check for gas leaks and proper boiler and vent
operation.
41
WIRING
WIRING CONNECTIONS
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 25 on Pages 43 for proper wiring
sequence with conventional single boiler installations.
The thermal balancer shown is factory included by A. O. Smith.
This device serves as a pump shutdown delay switch to balance
the rising boiler water temperature to system temperature
before the pump stops. Overshooting of boiler temperature is
prevented and stack loss after shutdown is negligible.
CONVENTIONAL INSTALLATIONS
All electrical work must be installed in accordance with current
editions National Electrical Code, ANSI/NFPA 70 and/or the
Canadian Electrical Code, PART 1, CSA C22.1, Electrical Code
and must conform to 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 the
current editions National Electrical Code, ANSI/NFPA 70 and/
or the Canadian Electrical Code Part 1, CSA C22.1, Electrical
Code.
If any of the original wire, as supplied with the boiler, must
be replaced, it must be replaced with type 1050c wire or its
equivalent, except for the flame sensor and ignition cable
which are 250 0c and wires connected to the coil protector
which are 2000c.
Strict adherence to piping and wiring diagrams is required to
prevent constant pump operation when system temperature
control is satisfied. Otherwise the warranty is void as stipulated
in the limited warranty on the instructions manual.
42
CONNECTION DIAGRAM
GND
4 X 4 JUNCTION BOX
WITH TERMINAL STRIP
** FUSED
DISCONNECT
SWITCH
GAS
CONTROL
VALVE
WHITE
THERMAL
BALANCER
MV/PV
W
4
3
1
PV
TRANSFORMER
120/24V
Y
B
BROWN
WHITE
YELLOW
RED
R
HIGH
LIMIT
BLACK
MV
MV/PV
PV
24V GND
24V
GND
GREEN
2
** TANK TEMP
PROBE
IGNITION
MODULE
WHITE
WHITE/TAN
** WATER PUMP
MV
WHITE/TAN
120 VAC 60 HZ
L1 (HOT)
L2 (NEUTRAL)
SPARK
COM NO
COIL
LIMIT
** SAFETY FLOW
SWITCH (REQUIRED)
TO
PILOT
SCHEMATIC DIAGRAM
L1 (HOT)
L2 (NEUTRAL)
120 VAC 60 HZ
FUSED
DISCONNECT
SWITCH
THERMAL
BALANCER
GND
WATER PUMP
TANK TEMP
PROBE
SAFETY FLOW
SWITCH
120V
24V
HIGH LIMIT
COIL
LIMIT
IGNITION MODULE
CHASSIS
GROUND
MV
MV/PV
PV
IGNITER WIRE TO
PILOT
GAS CONTROL VALVE
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 LIMIT WHICH USES 200°C WIRE.
** THESE COMPONENTS
ARE NOT FACTORY
INSTALLED AND MUST BE
SUPPLIED BY THE
INSTALLER.
Figure 25. WIRING DIAGRAMS
43
%%UWIRING
BY FACTORY
BY INSTALLER
Figure 26. CER - TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION
Figure 27. SCHEMATIC: CER - TEMP 80 - 1 UNIT INSTALLATION - FOR HOT WATER SUPPLY APPLICATION
44
Figure 28. CER - TEMP 80 - 2 OR 3 UNIT INSTALLATION CONNECTION DIAGRAM - FOR HOT WATER SUPPLY
APPLICATION
45
Figure 29. CER - TEMP 80 - 2 OR 3 UNIT INSTALLATION SCHEMATIC DIAGRAM - FOR HOT WATER SUPPLY
APPLICATION
46
HOT WATER
TO FIXTURES
AOS
STORAGE TANK
47
EXPANSION
TANK
COLD WATER
SUPPLY
ALTERNATE COLD WATER CONNECTION
FOR OLD STYLE TANK
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
Figure 30. ONE TEMPERATURE - ONE BOILER/ VERTICAL STORAGE TANK RECOVERY SYSTEM
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. A. O. Smith piping method is based on 50 equivalent feet of piping. Boiler placement shall be as close as practical to the
storage tank. Applications in excess of these recommendations shall require a licensed engineer for design assistance.
FINISHED FLOOR
DE-LIMING TEE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
BURKAY HW(300-670) - ONE TEMPERATURE-ONE BOILER/VERTICAL STORAGE TANK
RECOVERY SYSTEM
LEGEND
SYSTEM
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
PIPING DIAGRAMS
48
HOT WATER
TO FIXTURES
AOS
STORAGE TANK
ALTERNATE
LOCATION
DRAIN
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LOCATE ELBOW AS CLOSE
TO TANK AS POSSIBLE
Figure 31. ONE TEMPERATURE - ONE BOILER/ HORIZONTAL STORAGE TANK RECOVERY SYSTEM
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. A. O. Smith piping method is based on 50 equivalent feet of piping. Boiler placement shall be as close as practical to the
storage tank. Applications in excess of these recommendations shall require a licensed engineer for design assistance.
FINISHED FLOOR
DE-LIMING TEE
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
BURKAY HW(300-670) - ONE TEMPERATURE-ONE BOILER/HORIZONTAL STORAGE TANK
RECOVERY SYSTEM
LEGEND
EXPANSION
TANK
COLD WATER
SUPPLY
SYSTEM RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
49
DE-LIMING TEE
2 1/2
2
2
MANIFOLD
PIPING SIZE
“B” (INCH)
B
LEGEND
DRAIN
Figure 32. ONE TEMPERATURE - TWO BOILERS/ VERTICAL STORAGE TANK RECOVERY SYSTEM
EXPANSION
TANK
SYSTEM RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
COLD WATER
SUPPLY
ALTERNATE COLD WATER CONNECTION
FOR OLD STYLE TANK
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. A. O. Smith piping method is based on 50 equivalent feet of piping. Boiler placement shall be as close as practical to the
storage tank. Applications in excess of these recommendations shall require a licensed engineer for design assistance.
FINISHED FLOOR
2
520-670
A
1 1/2
399-420
DE-LIMING TEE
1 1/4
300
B
BOILER
PIPING SIZE
“A” (INCH)
BOILER
MODEL (HW)
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
BURKAY HW(300-670) - ONE TEMPERATURE-TWO BOILER/VERTICAL STORAGE TANK
RECOVERY SYSTEM
AOS
STORAGE TANK
50
DE-LIMING TEE
DE-LIMING
TEE
2 1/2
A
2
520-670
A
1 1/2
B
DRAIN
AOS
STORAGE TANK
Figure 33. ONE TEMPERATURE - TWO BOILERS/ HORIZONTAL STORAGE TANK RECOVERY SYSTEM
SEDIMENT RISER
ALTERNATE
LOCATION
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
HOT WATER
TO FIXTURES
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. A. O. Smith piping method is based on 50 equivalent feet of piping. Boiler placement shall be as close as practical to the
storage tank. Applications in excess of these recommendations shall require a licensed engineer for design assistance.
FINISHED FLOOR
B
2
1 1/4
300
399-420
2
MANIFOLD
PIPING SIZE
“B” (INCH)
BOILER
MODEL (HW)
BOILER
PIPING SIZE
“A” (INCH)
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
BURKAY HW(300-670) - ONE TEMPERATURE-TWO BOILER/HORIZONTAL STORAGE TANK
RECOVERY SYSTEM
LEGEND
EXPANSION
TANK
COLD WATER
SUPPLY
SYSTEM
RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
51
2
520-670
DE-LIMING TEE
1 1/2
399-420
A
1 1/4
300
A
3
2 1/2
2
MANIFOLD
PIPING SIZE
“B” (INCH)
A
B
DRAIN
HOT WATER
TO FIXTURES
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
B
EXPANSION
TANK
COLD WATER
SUPPLY
SYSTEM RETURN
ALTERNATE COLD WATER CONNECTION
FOR OLD STYLE TANK
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
LEGEND
Figure 34. ONE TEMPERATURE - THREE BOILERS/ VERTICAL STORAGE TANK RECOVERY SYSTEM
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. A. O. Smith piping method is based on 50 equivalent feet of piping. Boiler placement shall be as close as practical to the
storage tank. Applications in excess of these recommendations shall require a licensed engineer for design assistance.
FINISHED FLOOR
B
BOILER
PIPING SIZE
“A” (INCH)
BOILER
MODEL (HW)
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
BURKAY HW(300-670) - ONE TEMPERATURE-THREE BOILER/VERTICAL STORAGE TANK
RECOVERY SYSTEM
AOS
STORAGE TANK
52
A
2
520-670
A
DE-LIMING
TEE
1 1/2
3
A
B
AOS
STORAGE TANK
HOT WATER
TO FIXTURES
DRAIN
SEDIMENT RISER
ALTERNATE
LOCATION
TANK TEMPERATURE CONTROL
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
Figure 35. ONE TEMPERATURE - THREE BOILERS/ HORIZONTAL STORAGE TANK RECOVERY SYSTEM
NOTES:
1. Preferred piping diagram.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing unit. However, local codes shall govern their usage.
4. A. O. Smith piping method is based on 50 equivalent feet of piping. Boiler placement shall be as close as practical to the
storage tank. Applications in excess of these recommendations shall require a licensed engineer for design assistance.
FINISHED FLOOR
B
2
1 1/4
300
399-420
2 1/2
MANIFOLD
PIPING SIZE
“B” (INCH)
BOILER
MODEL (HW)
BOILER
PIPING SIZE
“A” (INCH)
WARNING: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
BURKAY HW(300-670) - ONE TEMPERATURE-THREE BOILER/HORIZONTAL STORAGE TANK
RECOVERY SYSTEM
LEGEND
EXPANSION
TANK
COLD WATER
SUPPLY
SYSTEM RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
53
NA
1.25”
1.50”
2.00”
300
399-420
520-670
EXPANSION TANK
MAKE-UP WATER
AIR SEPARATOR
PLACES TEES AS CLOSE
TOGETHER AS PRACTICAL
SYSTEM RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
FINISHED FLOOR
LOOP TEMPERATURE PROBE
DRAIN
TEMPERATURE CONTROL PROBE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
Figure 36. ONE BOILER PRIMARY/ SECONDARY HYDRONIC PIPING SYSTEM
NOTES:
1. Preferred piping layout.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing boiler. However, local codes shall govern their usage.
SYSTEM PUMP
SYSTEM SUPPLY
NA
NA
MANIFOLD
PIPING SIZE
“B” (INCH)
HW BOILER
BOILER PIPING
SIZE “A” (INCH)
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HW BURKAY BOILER (300-670) - ONE BOILER PRIMARY/SECONDARY
HYDRONIC PIPING SYSTEM
LEGEND
54
1.50”
2.00”
520-670
AIR SEPARATOR
2.50”
EXPANSION TANK
MAKE-UP WATER
B
A
DRAIN
Figure 37. TWO BOILERS PRIMARY/ SECONDARY HYDRONIC PIPING SYSTEM
FINISHED FLOOR
TEMPERATURE CONTROL PROBE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
PLACES TEES AS CLOSE
TOGETHER AS PRACTICAL
NOTES:
1. Preferred piping layout.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing boiler. However, local codes shall govern their usage.
SYSTEM PUMP
SYSTEM SUPPLY
2.00”
1.25”
300
399-420
2.00”
MANIFOLD
PIPING SIZE
“B” (INCH)
HW BOILER
BOILER PIPING
SIZE “A” (INCH)
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HW BURKAY BOILERS (300-670) - TWO BOILERS PRIMARY/SECONDARY
HYDRONIC PIPING SYSTEM
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
SYSTEM RETURN
LOOP TEMPERATURE PROBE
LEGEND
55
1.50”
2.00”
399-420
520-670
3.00”
2.50”
2.50”
MAKE-UP
WATER
AIR SEPARATOR
EXPANSION TANK
MANIFOLD
PIPING SIZE
“B” (INCH)
A
B
DRAIN
A
PLACES TEES AS CLOSE
TOGETHER AS PRACTICAL
FINISHED FLOOR
A
SYSTEM RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
LOOP TEMPERATURE PROBE
TEMPERATURE CONTROL PROBE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
Figure 38. THREE BOILERS PRIMARY/ SECONDARY HYDRONIC PIPING SYSTEM
NOTES:
1. Preferred piping layout.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing boiler. However, local codes shall govern their usage.
4. A. O. Smith piping method is based on 50 equivalent feet of piping. Boiler placement shall be as close as practical to the
heating loop. Applications in excess of these recommendations shall require a licensed engineer for design assistance.
SYSTEM PUMP
1.25”
300
SYSTEM SUPPLY
BOILER PIPING
SIZE “A” (INCH)
HW BOILER
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HW BURKAY BOILER (300-670) - THREE BOILERS PRIMARY/SECONDARY
HYDRONIC PIPING SYSTEM
LEGEND
56
MAKE-UP
WATER
EXPANSION TANK
4.00”
3.00”
A
B
A
DRAIN
A
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
PLACES TEES AS CLOSE
TOGETHER AS PRACTICAL
FINISHED FLOOR
SYSTEM RETURN
LOOP TEMPERATURE PROBE
TEMPERATURE CONTROL PROBE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
Figure 39. FOUR BOILERS PRIMARY/ SECONDARY HYDRONIC PIPING SYSTEM
NOTES:
1. Preferred piping layout.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing boiler. However, local codes shall govern their usage.
4. A. O. Smith piping method is based on 50 equivalent feet of piping. Boiler placement shall be as close as practical to the
heating loop. Applications in excess of these recommendations shall require a licensed engineer for design assistance.
SYSTEM PUMP
SYSTEM SUPPLY
AIR SEPARATOR
2.00”
520-670
2.50”
1.25”
1.50”
300
MANIFOLD
PIPING SIZE
“B” (INCH)
BOILER PIPING
SIZE “A” (INCH)
399-420
HW BOILER
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HW BURKAY BOILER (300-670) - FOUR BOILERS PRIMARY/SECONDARY
HYDRONIC PIPING SYSTEM
LEGEND
57
EXPANSION TANK
AIR SEPARATOR
AOS
STORAGE TANK
Figure 40. ZONE PUMPING/ HORIZONTAL BUFFER TANK HEATING SYSTEM
ZONE RETURNS
DRAIN
TEMPERATURE CONTROL PROBE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
THERMAL
ACCUMULATOR
(BUFFER TANK)
NOTES:
1. Preferred piping layout.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing boiler. However, local codes shall govern their usage.
FINISHED FLOOR
MAKE-UP WATER
ZONE PUMPS
ZONE LOOP SUPPLIES
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HW BURKAY BOILER (300-670) - ZONE PUMPING/HORIZONTAL BUFFER TANK
HEATING SYSTEM
LEGEND
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
58
EXPANSION
TANK
AIR SEPARATOR
THERMAL
ACCUMULATOR
(BUFFER TANK)
ZONE RETURNS
LEGEND
DRAIN
TEMPERATURE CONTROL PROBE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
Figure 41. ZONE PUMPING/ VERTICAL BUFFER TANK HEATING SYSTEM
NOTES:
1. Preferred piping layout.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing boiler. However, local codes shall govern their usage.
FINISHED FLOOR
MAKE-UP WATER
ZONE PUMPS/
ZONE LOOP SUPPLIES
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HW BURKAY BOILER (300-670) - ZONE PUMPING/VERTICAL BUFFER TANK
HEATING SYSTEM
AOS
STORAGE TANK
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
59
EXPANSION TANK
MAKE-UP WATER
AIR SEPARATOR
DRAIN
TEMPERATURE CONTROL PROBE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
Figure 42. BOILER/ VERTICAL BUFFER TANK HEATING SYSTEM
NOTES:
1. Preferred piping layout.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing boiler. However, local codes shall govern their usage.
FINISHED FLOOR
SYSTEM PUMP
SYSTEM SUPPLY
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HW BURKAY BOILER (300-670) - BOILER/VERTICAL BUFFER TANK HEATING
SYSTEM
LEGEND
AOS
STORAGE TANK
SYSTEM RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
60
EXPANSION TANK
MAKE-UP WATER
AIR SEPARATOR
LEGEND
3-WAY MIXING VALVE
DRAIN
TEMPERATURE CONTROL PROBE
CIRCULATING PUMP
PRESSURE RELIEF VALVE
TEMPERATURE & PRESSURE
RELIEF VALVE
Figure 43. BOILER/ VERTICAL BUFFER TANK, 3 WAY MIXING VALVE HEATING SYSTEM
NOTES:
1. Preferred piping layout.
2. The temperature and pressure relief valve setting shall not exceed pressure rating of any component in the system.
3. Service valves are shown for servicing boiler. However, local codes shall govern their usage.
FINISHED FLOOR
SYSTEM PUMP
SYSTEM SUPPLY
CAUTION: THIS DRAWING SHOWS SUGGESTED
PIPING CONFIGURATION AND OTHER DEVICES;
CHECK WITH LOCAL CODES AND ORDINANCES
FOR ADDITIONAL REQUIREMENTS.
HW BURKAY BOILER (300-670) - BOILER/VERTICAL BUFFER TANK, 3-WAY
MIXING VALVE HEATING SYSTEM
AOS
STORAGE TANK
SYSTEM RETURN
WATER FLOW SWITCH
TEMPERATURE GAGE
CHECK VALVE
FULL PORT BALL VALVE
LIMITED WARRANTY
COMMERCIAL
HOT WATER SUPPLY BOILER
LIMITED WARRANTY
EFFECTIVE
WHAT'S NOT COVERED
If within FIVE years after initial installation of the boiler, a
heat exchanger or gas burner shall prove upon examination by
the warrantor to be defective in material or workmanship, the
warrantor, at his option will exchange or repair such part or
portion.
• Problems caused by improper: gas supply line sizing, gas type,
venting, connections, combustion air, voltage, wiring, or fusing
• Failure to follow applicable codes
• Failure to follow printed instructions
• Abuse, misuse, accident, fire, flood, Acts of God
• Improper installation, sizing, delivery, or maintenance
• Claims related to rust, noise, smell, or taste of water
• Failure to conduct authorized factory start up if required
• Alterations to the boiler
• Non-outdoor boilers installed outdoors
• Damages due to a failure to allow for thermal expansion
• Heat exchanger failure due to lack of adequate / proper supply
of water
• Boilers moved from their original location
• Service trips to explain proper installation, use, or maintenance
of the product/unit or to describe compliance requirements
under applicable codes and regulations
• Charges related to accessing your boiler including but not
limited to door/wall removal, equipment rental, etc.
• Replacement parts after expiration of this warranty
For 1 Year, in the event of part failure, we will repair or, at our
discretion, replace the defective part.
We warrant this product against defects in materials or
workmanship as described in this document if installed within
the United States or Canada and provided the product remains
at its original place of installation.
Warranty coverage begins the date of installation OR the date of
manufacture if installation cannot be verified.
WHAT'S COVERED
Subject to these terms, in the event of defect in materials and/
or workmanship resulting in a heat exchanger leak during the
first five years, we will:
• Replace or repair the heat exchanger.
Subject to these terms, in the event of a defect in materials and/or
workmanship appearing during the first year, we will:
• Repair or, at our discretion, replace any part of the boiler
covered under this limited warranty excluding parts subject
to normal maintenance (Example: non-electronic anode rod,
filter, etc)
LIMITATIONS
NOTWITHSTANDING ANYTHING ELSE TO THE CONTRARY,
THIS IS YOUR SOLE AND EXCLUSIVE WARRANTY.
ALL OTHER WARRANTIES INCLUDING A WARRANTY
OF MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE ARE EXPRESSLY DISCLAIMED. SELLER SHALL
NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL,
SPECIAL, PUNITIVE OR OTHER INDIRECT DAMAGES. TOTAL
LIABILITY ARISING AT ANY TIME SHALL NOT EXCEED THE
PURCHASE PRICE PAID WHETHER BASED ON CONTRACT,
TORT, STRICT LIABILITY OR ANY OTHER LEGAL THEORY.
Service / labor, shipping, delivery, installation, handling
or any other costs are not covered at any time under
this warranty.
Any replacement part or product will be warranted only for
the unexpired portion of the original boiler’s limited warranty
period.
SERVICE INQUIRIES:
For service inquiries call the telephone number listed below. Be prepared to provide the following information:
name, address, and telephone number; the model and serial number of the boiler; proof of installation; and a clear description of
the problem.
For your records, fill in the product:
Serial: ___________________
Model: ___________________
U.S. Customers:
Canadian Customers:
A. O. Smith Corporation
P. O. Box 310 – 768 Erie Street
500 Tennessee Waltz Parkway
Ashland City, Tennessee 37015
Stratford (Ontario) N5A 6T3
800-265-8520
800-527-1953
www.hotwater.com
61
COMMERCIAL
HYDRONIC HEATING BOILER
LIMITED WARRANTY
EFFECTIVE
WHAT'S NOT COVERED
If within TEN years after initial installation of the boiler,
• Problems caused by improper: gas supply line sizing, gas type,
venting, connections, combustion air, voltage, wiring, or fusing
• Failure to follow applicable codes
• Failure to follow printed instructions
• Abuse, misuse, accident, fire, flood, Acts of God
• Improper installation, sizing, delivery, or maintenance
• Claims related to rust, noise, smell, or taste of water
• Failure to conduct authorized factory start up if required
• Alterations to the boiler
• Non-outdoor boilers installed outdoors
• Damages due to a failure to allow for thermal expansion
• Heat exchanger failure due to lack of adequate / proper supply
of water
• Boilers moved from their original location
• Service trips to explain proper installation, use, or maintenance
of the product/unit or to describe compliance requirements
under applicable codes and regulations
• Charges related to accessing your boiler including but not
limited to door/wall removal, equipment rental, etc.
• Replacement parts after expiration of this warranty
a heat exchanger or gas burner shall prove upon examination
by the warrantor to be defective in material or workmanship,
the warrantor, at his option will exchange or repair such part
or portion.
For 1 Year, in the event of part failure, we will repair or, at our
discretion, replace the defective part.
We warrant this product against defects in materials or
workmanship as described in this document if installed within
the United States or Canada and provided the product remains
at its original place of installation.
Warranty coverage begins the date of installation OR the date of
manufacture if installation cannot be verified.
WHAT'S COVERED
Subject to these terms, in the event of defect in materials and/
or workmanship resulting in a heat exchanger leak during the
first five years, we will:
• Replace or repair the heat exchanger.
Subject to these terms, in the event of a defect in materials and/or
workmanship appearing during the first year, we will:
• Repair or, at our discretion, replace any part of the boiler
covered under this limited warranty excluding parts subject
to normal maintenance (Example: non-electronic anode rod,
filter, etc)
LIMITATIONS
NOTWITHSTANDING ANYTHING ELSE TO THE CONTRARY,
THIS IS YOUR SOLE AND EXCLUSIVE WARRANTY.
ALL OTHER WARRANTIES INCLUDING A WARRANTY
OF MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE ARE EXPRESSLY DISCLAIMED. SELLER SHALL
NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL,
SPECIAL, PUNITIVE OR OTHER INDIRECT DAMAGES. TOTAL
LIABILITY ARISING AT ANY TIME SHALL NOT EXCEED THE
PURCHASE PRICE PAID WHETHER BASED ON CONTRACT,
TORT, STRICT LIABILITY OR ANY OTHER LEGAL THEORY.
Service / labor, shipping, delivery, installation, handling
or any other costs are not covered at any time under
this warranty.
Any replacement part or product will be warranted only for
the unexpired portion of the original boiler’s limited warranty
period.
SERVICE INQUIRIES:
For service inquiries call the telephone number listed below. Be prepared to provide the following information:
name, address, and telephone number; the model and serial number of the boiler; proof of installation; and a clear description of
the problem.
For your records, fill in the product:
Serial: ___________________
Model: ___________________
U.S. Customers:
Canadian Customers:
A. O. Smith Corporation
P. O. Box 310 – 768 Erie Street
500 Tennessee Waltz Parkway
Ashland City, Tennessee 37015
Stratford (Ontario) N5A 6T3
800-265-8520
800-527-1953
www.hotwater.com
62
NOTES
63
www.hotwater.com
500 Tennessee Waltz Parkway, Ashland City, TN 37015
Tech Support: 800-527-1953
Parts: 800-433-2545
Copyright © 2014 A. O. Smith Corporation. All rights reserved.