Operating instructions

ManualsBrandsCAC / BDP ManualsHeating SystemBW4BAH-245

NOTE: Read the entire instruction manual before starting the installation.

This symbol → indicates a change since the last issue.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS.....................................................................................................................................................................................2

INTRODUCTION..........................................................................................................................................................................................................4

Explanation of Model Numbers and Rating Plate ..................................................................................................................................................4

General Information .................................................................................................................................................................................................4

LOCATION ...................................................................................................................................................................................................................4

Before You Start ......................................................................................................................................................................................................4

Locating the Boiler...................................................................................................................................................................................................5

INSTALLATION...........................................................................................................................................................................................................6

Installation Requirements.........................................................................................................................................................................................6

Fresh Air for Combustion........................................................................................................................................................................................6

Boiler Located in Unconfined Space .................................................................................................................................................................6

Boiler Located in Confined Space .....................................................................................................................................................................6

Boilers With Tankless Heater Coil..........................................................................................................................................................................7

Mounting Aquastat Control ................................................................................................................................................................................8

Tankless Coil Piping...........................................................................................................................................................................................8

Installation System Piping........................................................................................................................................................................................8

Chimney and Chimney Connection.........................................................................................................................................................................9

Checking Chimney..............................................................................................................................................................................................9

Chimney Connector and Draft Regulator ........................................................................................................................................................11

Minimum Vent Pipe Clearance ........................................................................................................................................................................11

Electrical Wiring ....................................................................................................................................................................................................11

Installing Thermostat (Not Provided)...............................................................................................................................................................11

Grounding..........................................................................................................................................................................................................11

Electrcial Power Supply....................................................................................................................................................................................11

Connecting 115–V Electrical Wiring to Boiler ...............................................................................................................................................12

Thermostat Connections....................................................................................................................................................................................12

Thermostat Heat Anticipator Adjustment ........................................................................................................................................................12

Equipment and Optional Accessories....................................................................................................................................................................12

Relief Valve (Required, Provided)...................................................................................................................................................................12

Expansion Tank (Not Provided).......................................................................................................................................................................12

Diaphragm-Type Expansion Tank (Not Provided)..........................................................................................................................................13

Air Eliminating Fitting (Air Purger) (Not Provided) ......................................................................................................................................13

Main Air Vent for Downflow Systems or Diaphragm-Type Expansion Tank (Not Provided).....................................................................13

Aquastat Relay Control (Provided) ..................................................................................................................................................................14

Automatic Fill Valve (Not Provided)...............................................................................................................................................................14

Drain Valve (Provided).....................................................................................................................................................................................14

Circulating Pump (Provided)............................................................................................................................................................................14

Oil Solenoid Valve............................................................................................................................................................................................14

Filling Boiler ..........................................................................................................................................................................................................14

How a Hot Water System Operates.................................................................................................................................................................14

Filling System With Water...............................................................................................................................................................................14

OPERATING BOILER ...............................................................................................................................................................................................14

To Start...................................................................................................................................................................................................................15

Fuel Units and Oil Lines........................................................................................................................................................................................15

Air Supply for Combustion....................................................................................................................................................................................15

Draft Regulators (Provided)...................................................................................................................................................................................15

Nozzles (Provided).................................................................................................................................................................................................15

Final Burner Adjustments ......................................................................................................................................................................................15

Installation, Startup, and Operating Instructions

BW4B

BW5B

Oil-Fired

Cast Iron Hot Water Boilers

Sizes 140,000 through 280,000

Form: IM-BW4B-02 Cancels: IM-BW4B-01 Printed in U.S.A. 8-02 Catalog No. 63BW-4B1

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Summary of content (24 pages)

PAGE 1
Installation, Startup, and Operating Instructions Oil-Fired Cast Iron Hot Water Boilers Sizes 140,000 through 280,000 BW4B BW5B NOTE: Read the entire instruction manual before starting the installation. This symbol → indicates a change since the last issue. TABLE OF CONTENTS SAFETY CONSIDERATIONS.....................................................................................................................................................................................2 INTRODUCTION..................
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Oil Burner Maintenance .........................................................................................................................................................................................15 Oil Burner Motor...............................................................................................................................................................................................15 Fuel Filter ...............................................................................
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A02217 → Fig. 1—Model BW4B/BW5B 7. Be sure there is adequate air supply for complete combustion. 8. Follow a regular service and maintenance schedule for efficient and safe operation. 9. Keep boiler area clean and free from combustible materials, gasoline, and other flammable vapors and liquids. 10. Oil Burners are not do-it yourself items. This boiler must be installed and serviced by qualified professionals using combustion test instruments. 11.
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14. Purging the heating system of air and gases when first putting the boiler into service is critical for proper circulation and quiet performance. Once the air and gases are purged, for boiler installations using float type vents, the air vents should be closed for normal operation. If air is heard or noticed by loss of heat, purge the system and open the vents for a short period of time. WARNING: Use only number 1 or number 2 fuel oil having commercial standard grade CS 12-48.
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→ Table 1a—Boiler Ratings and Capacities NO. SEC INPUT *MBH NET **HEATING FIRING MIN. TANKLESS I=B=R SHIPPING CAPACITY RATE ++A.F.U.E. CHIMNEY DIMENSIONS-IN. HEATER RATING WEIGHT *MBH +GPH SIZE/HEIGHT G.P.M.## *MBH Without Tankless Coil BW4BAH140 BW4BAH210 BW4BAH280 3 3 3 4 4 4 5 5 5 91 105 140 126 175 210 168 245 280 80 92 119 111 150 178 147 209 236 70 80 103 97 130 155 128 182 205 0.65 0.75 1.00 0.90 1.25 1.50 1.20 1.75 2.00 #86.3 #85.2 83.4 #86.0 83.9 82.4 #86.5 83.6 82.
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GAGE 1 1⁄4 IN. SUPPLY C B AQUASTAT CONTROL (WITHOUT COIL) AQUASTAT CONTROL (WITH COIL) 36″ TANKLESS HEATER 1⁄2 IN. N.P.T. 1 1⁄4 IN. RETURN 19 5⁄8″ 9″ FRONT 3⁄4 IN. ASME RELIEF VALVE A SIDE REAR A96152 Fig. 2—Dimensional Drawing 4. The vent pipe connection should be as short as possible. 5. Maintain clearances for fire safety as well as servicing. Refer to Fig. 3 for minimum clearances. An 18-in.
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;;;;; ;;;;; ;;;;; 6″ MIN 24″ MIN BOILER FRONT 6″ 6″ MIN 18″ WITH COIL A95592 Fig. 3—Minimum Clearance Dimensions CIRCULATING PUMP IN SUPPLY LINES SERVICE LINE ELECTRIC LINE AUTOMATIC FILL VALVE AND SHUTOFF ENTRANCE SWITCH 2 IN. FILL PIPE DIAPHRAGM EXPANSION TANK OVERCURRENT PROTECTED SAFETY SWITCH VENT PIPE MINIMUM 2 IN.
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VENTILATING GRILLE COMBUSTION AIR GRILLE A95594 Fig. 5—Air Openings for Closet of Utility Room Installations FRESH AIR DUCT BOILER A95595 Fig. 6—Fresh Air Duct for Tightly Sealed House Table 2—Fresh Air Duct Capacities for Ducts Supplying Fresh Air to Boiler in Tightly Constructed Houses (Btuh)* FRESH AIR DUCT SIZE (IN.) 3-1/2 X 12 8X8 8 X 12 8 X 16 1/4–IN.
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Table 3—Boiler Rating Information BOILER MODEL BW4BAH091 BW5BAH091 BW4BAH105 BW5BAH105 BW4BAH140 BW5BAH140 BW4BAH126 BW5BAH126 BW4BAH175 BW5BAH175 BW4BAH210 BW5BAH210 BW4BAH168 BW5BAH168 BW4BAH245 BW5BAH245 BW4BAH280 BW5BAH280 BURNER FIRING RATE (GPH) 0.65 0.75 1.00 0.90 1.25 1.50 1.20 1.75 2.00 INPUT (MBH) 91 105 140 126 175 210 168 245 280 TANKLESS RATING (GPM) 2.90 3.00 3.25 3.15 3.50 3.75 3.45 4.00 4.
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Table 4—Boiler Water Volumes NUMBER OF BOILER SECTIONS 3 4 5 TOTAL VOLUME (GALLONS) 9.6 11.6 13.7 Table 5—Piping Water Volumes PIPE SIZE 1/2-in. 3/4-in. 1-in. 1-1/4-in. 1-1/2-in. 2-in. COPPER PIPE FACTOR 82.5 40.0 23.3 15.3 10.8 6.2 STEEL PIPE FACTOR 63.5 36.0 22.2 12.8 9.5 5.8 —Divide total length of piping in feet by appropriate factor in table to determine volume in gallons.
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RETURN FROM SYSTEM SHUTOFF VALVE BOILER SERVICE SUPPLY TO SYSTEM * CIRCULATOR PUMP ISOLATION VALVES AUTOMATIC FILL VALVE FILL LINE WITH SHUT OFF VALVE SHUTOFF VALVE BOILER SERVICE AQUASTAT FILTROL WITH AIR PURGER * LOCATE CIRCULATOR PUMP HERE WHEN SYSTEM PIPING USES ZONE VALVES. IF SYSTEM PIPING USES ZONE CIRCULATORS, USE THIS CIRCULATOR AS A ZONE CIRCULATOR BOILER DRAIN VALVE A01035 Fig.
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MUST BE REQUIRED MINIMUM HEIGHT. MUST BE AT LEAST 3 FT HIGHER THAN HIGHEST PART OF PASSAGE THROUGH ROOF. MUST BE AT LEAST 2 FT HIGHER THAN ANY NEIGHBORING OBJECT. MUST HAVE AN UNOBSTRUCTED TOP OPENING. MUST BE AT LEAST 4 IN. THICK AND BE TIGHT. DRAFT REGULATOR VANE TIGHT, SMOOTH, CORRECTLY SIZED. MUST SLOPE UP AT LEAST 1/4 IN. PER FOOT OF HORIZONTAL RUN. DRAWBAND LAST PIECE INSTALLED SEALED IN THIMBLE BALANCED WEIGHT CRIMPED END TIGHT CLEAN-OUT DOOR ALTERNATE POSITIONS TOP TOP A95601 Fig.
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NH 115V 60 CYCLE SUPPLY 24 VOLT THERMOSTAT TO 115V SUPPLY TO 24V L1L2 T T THERM AQUASTAT RELAY A95602 Fig.
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F. Aquastat Relay Control (Provided) The water temperature limit control in aquastat relay is adjustable and may be set as necessary. It may be set as low as 140°F or as high as 240°F. This depends on type and amount of radiation involved and weather conditions. G. Automatic Fill Valve (Not Provided) For safe, efficient operation, a hot water system must be filled with water. Adding new water when needed can be done manually (by use of a hand valve in water supply line).
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IMPORTANT: Follow these instructions carefully. PROCEDURE 1—TO START Fill entire system with water. Vent all air from system. Refer to instructions included with oil burner. PROCEDURE 2—FUEL UNITS AND OIL LINES The oil burner is provided with a single-stage 3450 RPM fuel unit with bypass plug removed for a single-pipe installation. This is satisfactory where fuel supply is on same level or above burner, permitting gravity flow of oil. Never exceed 3 psi pressure to suction side of fuel unit.
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Table 7—Oil Burner Specifications BASE MODEL 140 210 280 BOILER INPUT (BTUH) DELEVAN OIL NOZZLE 91,000* 105,000 140,000 126,000* 175,000 210,000 168,000 245,000 280,000 0.50–80 0.65–70 0.85–70 0.75–80 1.00–80 1.25–80 1.00–60 1.50–45 1.65–60 HEADADJUSTMENT OR SETTING F0 1-1/8 F3 1-1/8 F3 1-1/8 F3 1-1/8 F6 1-1/8 F6 1-1/8 V1-0 V1-2 V1-4 FIRING RATE (GPM) B B B A A A B B B 0.65 0.75 1 0.9 1.25 1.5 1.2 1.75 2 LOW FIRE BAFFLE AIR SHUTTER AIR BAND STATIC PLATE (IN.
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Table 8—Recommended Operating Control Settings High Limit OPERATING CONTROL Standing Radiators Baseboard and Convectors Low Limit (When Used) Differential (When Used) CONTROL SETTING 180°F 200°F 140°F 10°F B. Checking Thermostat Operation When set above temperature indicated on thermometer, boiler burner should start. Make certain thermostat shuts boiler down when room temperature reaches selected setting and starts boiler operating when room temperature falls a few degrees.
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A95609 Fig. 18—Removing Soot 8. Inspect the door’s braided gasket for wear and damage. Replace when necessary with braided gasket of the same material and size. See repairs parts section of this manual. 9. Now inspect and clean the oil burner. OIL BURNER CLEANING NOTE: These are general instructions for cleaning an oil burner. For specifics, consult the burner manufacturer’s instructions 1. Make sure all electrical power to the boiler/burner and the fuel supply to the burner are shut off. 2.
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240 F (116 C) HI LIMIT SETTING 10 F (5.6 C) DIFF SWITCH BREAKS ON RISE, TURNS BURNER OFF. CIRCULATOR OPERATES ON CALL FOR HEAT. SWITCH MAKES ON FALL. BURNER OPERATES ON CALL FOR HEAT. 25 F (13.9 C) DIFF LOW LIMIT AND CIRCULATOR SETTING 10 F (5.6 C) DIFF SWITCH MAKES R-W, BREAKS R-B ON RISE (25 F [13.9 C] DIFFERENTIAL). SWITCH MAKES R-W, BREAKS R-B ON RISE (10 F [5.6 C] DIFFERENTIAL). SWITCH MAKES R-B ON FALL, BREAKS R-W. BURNER ON, CIRCULATOR OFF. 110 F (43 C) A95611 Fig.
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Table 9—Service Hints IF SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT. . . POSSIBLE CAUSE WHAT TO DO Thermostat is not set correctly Reset thermostat above room temperature. Clean all flue passages and vent pipe. Have burner cleaned and Boiler and/or burner may be dirty readjusted. Burner may not be firing at proper rate Check nozzle size it there is any doubt. Have burner adjusted. Burner may be short-cycling Short-cycling (too frequent off and on) of burner causes sooting.
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13 2 12 XXX 11 1 1 1 10 XXX 3 1 1 1 4 XXX 14 2 15 1 7 2 XXX XXX 16 1 18 10 19 10 5 20 10 XXX 8 1 9 XXX A01039 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 → DESCRIPTION Section Machined Back Section Machined Middle Section Machined Front Nipple Machined 2-in. — (2-in. cast iron push nipple) Tie Rod 1/4 X 10 1/4 3 section 4 section 5 section Nuts head (Hex) ZP (Zinc Plated) 1/4-in. — 20 Cut Rope 5/18-in. X 70–1/2-in.
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2 1 3 1 11 1 12 1 1 1 10 1 4 1 4 1 8 1 6 2 5 1 7 2 A01040 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION Section Machined Front Stud TFL (Threaded Full Length) 3/8–16-in. X 2–1/4-in. Whizlok Nut ZP (Zinc Plated) 3/8 Insulation Swing Door (Gemoclite Vacuum Formed Ceramic Fiber 2300°) Hinge Machined Rivet RD (Round) HD (Head) Seperated Flange ZP 3/8-in. X 1-in. Bolt Hex (head) Separated Flange ZP (Zinc Plated) 1/4-in. X 2-in. Cut Rope FiberFrax Round Braid 3/8-in. X 48-in.
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3 XXX 5 1 2 1 4 XXX 6 4 8 4 1 XXX 7 21 9b 4 A01042 ITEM 1 2 3 4 5 6 7 8 9a 9b DESCRIPTION Right Side Jacket Panel Back Jacket Panel Top Jacket Panel Left Side Jacket Panel Front Jacket Panel 5/18-in.
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7 4 WATER OUTLET 2a 3a (WITHOUT TANKLESS COIL) 5 OPTIONAL TANKLESS COIL WATER HEATER WITH 1/2” NPT CONNECTIONS 2b (WITH TANKLESS COIL) 5a, 5b 1 6 FRONT VIEW ITEM 1 1 ____ ____ 2a 2b 3a 3c ____ ____ 4 5a 5b 6 7 RIGHT SIDE VIEW A02216 DESCRIPTION 3EW 4EW Beckett AFG F-Head oil Burner 146-19-355 146-19-356 Beckett AFG Variable Head Oil Burner ____ ____ Beckett AFG F-Head Low Fire Kit (0.65 gph) 433-00-015 ____ Beckett AFG F-Head Low Fire Kit (0.