Installation, Start-Up, and Operating Instructions Gas-Fired Natural Draft Hot Water Boilers Sizes 37,500 through 280,000 Series B BW1 BW2 ama CERTIFIED ® ASME NOTE: Read the entire instruction manual before starting the installation. These instructions must be affixed on or adjacent to the boiler. This symbol → indicates a change since the last issue. → MODEL BW1 MODEL BW2 Continuous Pilot Electronic Intermittent Ignition A03114 A03115 Index Page SAFETY CONSIDERATIONS..........................
INSTALLATION—SYSTEM PIPING .........................................................................................................................................................................7 For Use with Cooling Units .....................................................................................................................................................................................7 Low Design Water Temperature Systems (Below 140°F)......................................................
SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as maintaining water level. All other operations must be performed by trained service personnel.
BOILER RATINGS AND CAPACITIES ASME RELIEF VALVE 1 1⁄4† SUPPLY TEMPERATURE/ PRESSURE GAGE VENT DAMPER A AQUASTAT 26 1⁄2† 4 3⁄4† 9† 1 1⁄4† RETURN 1 1⁄4† NPT SPILL SWITCH 31 3⁄8† 23 1⁄4† 12 1⁄4† 5 3⁄8† DRAIN VALVE ROLLOUT SWITCH LEFT SIDE GAS VALVE FRONT INT. PILOT CONTROL RIGHT SIDE A02318 Gas-Fired Hot Water Boilers BOILER MODEL NUMBER Electronic Ignition with Vent Damper Continuous Pilot with Vent Damper NO.
LOCATING THE BOILER NOTE: This unit MUST be set on a concrete or other non-combustible material base or floor. 1. Select level location as centralized with piping system and as near chimney as possible. 2. Place crated boiler at selected location. Remove crate by pulling crate sides from top and bottom boards. When boiler is to be installed on a combustible floor, a combustible floor base must be used. This boiler must NOT be installed on carpeting. 3. Boiler is to be level.
FRESH AIR FOR COMBUSTION Provision for combustion and ventilation air must be in accordance with Section 5.3 of NFGC, Air for Combustion and Ventilation, of the or applicable provisions of local building codes. Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction. WARNING: Be sure to provide enough fresh air for combustion. Enough air ensures proper combustion and ASSURES THAT NO HAZARD WILL DEVELOP DUE TO LACK OF OXYGEN.
Table 3A—Fresh Air Duct Capacities for Vertical Ducts (Btuh)* 100% FREE AREA 75% FREE AREA 25% FREE AREA Fresh Air Duct Size (In.) 1/4-in. Mesh Screen Metal Louvers Wood Louvers 3" X 12" 144,000 108,000 36,000 8" X 8" 256,000 192,000 64,000 8" X 12" 384,000 288,000 96,000 8-1/2" X 16" 512,000 384,000 128,000 * 1 Square Inch per 4,000 Btuh Table 3B—Fresh Air Duct Capacities for Horizontal Ducts (Btuh)* 100% FREE AREA 75% FREE AREA 25% FREE AREA 1/4-in.
TO SYSTEM A CIRCULATOR B AIR VENT COLD WATER INLET SUPPLY MAIN RELIEF VALVE AIR PURGER GAUGE C FILTROL TANK LIMIT CONTROL D WATER CHILLER RETURN LINE VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING → VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING A03116 A95143 Fig. 3—Chilled Water Piping Fig. 2—Typical Hot Water Piping PROCEDURE 1—CHECKING CHIMNEY The chimney is a very important part of heating system. It must be clean, the right size, properly constructed, and in GOOD CONDITION.
2-FT MIN HT 3-FT MIN Table 4—Typical Chimney Sizes BOILER INPUT (BTUH) Up Up Up Up to to to to 100,000 155,000 230,000 350,000 FLUE AREA IN INCHES Height (HT)* 10-15 ft 15-25 ft 25 ft up 6X6 6X5 5X5 6X7 6X6 6X5 7X8 7X7 6X7 9X9 8X9 8X8 ROOF RIDGE * HT = top of thimble to top of flue. (See Fig. 4.) For boiler input, refer to Fig. 1. For information only — not meant to imply minimum sizes. 3/4 HT MAXIMUM MUST SLOPE UP AT LEAST 1/4 IN. PER FT OF HORIZONTAL RUN A95144 Fig.
HORIZONTAL INSTALLATION FLOW NO YES YES NO TO FURNACE VENT TO CHIMNEY OR BOILER DAMPER INSTALL VENT DAMPER WITH ACTUATOR TO SIDES OF VENT ONLY. DO NOT MOUNT ABOVE OR BELOW VENT. CAUTION: Do not install the vent damper within 6 in. (152 mm) of combustible material. NOT HERE INSTALL DAMPER HERE VERTICAL INSTALLATION TO CHIMNEY 2 1 VENT DAMPER FLOW ACTUATOR MAY BE INSTALLED IN ANY POSITION TO FURNACE OR BOILER CHIMNEY 3 A95145 Fig.
2. In Canada, vent damper must be attached directly to flue outlet collar, with the exception of 2-section boiler where the 3-in. to 4-in. adapter is supplied with vent damper. No other interconnecting pieces are allowed between boiler and vent damper. 3. In Canada, vent dampers are not an option. Boilers are either factory built for use with a vent damper and vent damper is supplied with boiler, or they are factory built for use without a vent damper.
→ All electrical work must conform to local codes as well as the National Electrical Code (NEC) ANSI/NFPA-70-2002. In Canada, electrical wiring shall comply with the Canadian Electrical Codes CSA C22.1 and 2. PROCEDURE 1—ELECTRIC POWER SUPPLY WARNING: Turn off electric power at fuse box before making any line voltage connections. Follow local electric codes. Failure to follow this warning could result in electrical shock, personal injury, or death.
L8148E AQUASTAT VENT DAMPER TR B TH-2 TV C1 C2 L1 L2 B1 B2 LS B1 BLUE WHITE RED 24V 24VGND PV PV/MV MV GND PV MV/PV MV VR8204A OR VR8304M 5 6 5 6 GREEN FUSE B GREEN BLUE 9 SPARK 8 SSW SSW 1 2 3 4 9 8 B2 TO PILOT RSW 1 2 34 Z W 1K 1K2 CIR 120V 60HZ SUPPLY UT 1003-620 T R TO PILOT GND PV MV/PV MV 1K1 DAMPER R 24V 24VGND L1 C2 CIR Z SPARK C1 L2 HARNESS T W TV RSW WHITE PV/MV PV RED MV VR8204A OR VR8304M UT 1003-620 COMPONENT CODE TH-1 TH-2 TH-3 TR-1 TR-2
HARNESS VENT DAMPER TH-2 L1 L2 T W TV C2 CIR C1 1K1 Z TR DAMPER B R TH-2 CIR RSW B1 W T TV C1 C2 L1 L2 1K2 B2 B2 L8148E AQUASTAT R 120V 60HZ SUPPLY LS B B1 FUSE TH SSW Z 1K LGV LGV RSW SSW TR TH TR COMPONENT CODE TH-1 TH-2 TH-3 TR-1 TR-2 MGV LGV LGV-1 PS MR-PS SD THERMOSTAT (MILLIVOLT) THERMOSTAT (24 VOLD) THERMOSTAT (LINE VOLTAGE) TRANSFORMER (120V/24V 40VA) TRANSFORMER (120V/24V 50VA) MILLIVOLT GAS VALVE 24 VOLT GAS VALVE 24 VOLT GAS VALVE PRESSURE SWITCH MANUAL RESET
EQUIPMENT AND OPTIONAL ACCESSORIES PROCEDURE 1—RELIEF VALVE A relief valve must be installed on boiler. Water expands as it is heated. If there is no place for water to expand into, water pressure builds up inside boiler and system. Should this happen, relief valve automatically opens at a predetermined pressure. This relieves strain on boiler and system.
PROCEDURE 12—SPILL SWITCH (BLOCKED VENT SHUTOFF SYSTEM) The spill switch is a manual-reset disc thermostat with a fixed set point (340°F) and normally closed contacts. It is located at relief opening of integral draft diverter. In the event of chimney or venting system blockage causing products of combustion to spill out of relief opening, the spill switch disc heats up and spill switch contacts open shutting down flow of gas to main burners by removing power to gas valve.
PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW) WIRING TERMINALS (3) INLET PRESSURE TAP GAS INLET ON OUTLET PRESSURE TAP GROUND TERMINALS (2) GAS OUTLET OFF GAS CONTROL KNOB SHOWN IN "ON" POSITION PILOT ADJUSTMENT (UNDER CAP SCREW) PILOT OUTLET A95520 Fig. 11—VR8204A/VR8304M Intermittent Ignition Gas Valve 6. Turn gas control knob clockwise to OFF position. (See Fig. 11.) 7. Wait 5 minutes to clear out any gas. Then smell for gas, including near the floor.
PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW) WIRING TERMINALS (2) INLET PRESSURE TAP OUTLET PRESSURE TAP CONVENIENCE TERMINALS (2) (OPTIONAL) GAS INLET ON GAS OUTLET MATCH HOLDER OFF PILOT THERMOCOUPLE CONNECTION RED RESET BUTTON PILOT ADJUSTMENT (UNDER CAP SCREW) PILOT OUTLET GAS CONTROL KNOB SHOWN IN "ON" POSITION A95521 A99181 Fig. 13—Lighting Pilot Fig.
3⁄8″ to 1⁄2″ OUTER MANTEL FLAME ON SENSOR SHARP INNER CONES A95160 A99182 Fig. 15—Main Burner Flame Fig. 14—Pilot Flame and Sensor PROCEDURE 3—LIMIT CONTROLS ADJUSTMENT Instructions for each control are included with controls. Table 6 shows recommended boiler water temperatures. These settings can be changed after becoming familiar with system operation. For example, if system is not giving quite enough heat in very cold weather, the limit setting can be raised to 220°F.
3. Remove 2 screws attaching intermediate front panel to left and right side jacket panels. 4. Remove draft diverter and intermediate front panel as 1 unit. 5. Carefully remove cerafelt gasket strips. 6. Clean passageways between sections with a flexible handle wire brush. Remove dirt from bottom of boiler and between sections by vacuuming. 7. Make sure all flame ports in burners are open and clear. Shake out or blow out all loose dirt in burners. 8.
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service. FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS 1. 2. 3. 4. Do not try to light any appliance. Do not touch any electric switch; do not use the phone. Leave the building immediately, then call your gas supplier. If you cannot reach the gas supplier, call the fire department.
REPAIR PARTS GAS-FIRED HOT WATER BOILERS yy ;; ;; yy ;;;yyy yy ;; 21 —IMPORTANT— READ THESE INSTRUCTIONS BEFORE ORDERING All parts listed in the following Parts List may be ordered through your nearest supplier. When ordering parts, first obtain Model No. from data plate on boiler, then determine Part No. (not Key No.) and Description of each part from the following illustrations and lists. Be sure to give all this information: Part No. — Part Description — Boiler Model No.
REPAIR PARTS FOR USE WITH NATURAL GAS ONLY 3 6 4 5 6A 2 1 A98238 Gas Burners and Manifold Parts This is a Repair Parts List—Not a Packing List KEY NO. 1 2 3 4 5 6 6A 7 ‡ 1 3 7 8 DESCRIPTION 24-v Gas Valve, Electronic Intermittent Ignition Pilot Tube 10-32 X 1/2-in. Hex Head Screw Gas Manifold Main Burner Orifice* Main Burner† Main Burner with Pilot Bracket Pilot Burner Rollout Shield PART NO.
REPAIR PARTS FOR USE WITH LIQUIFIED PETROLEUM GAS ONLY 3 6 4 5 6A 2 1 A98238 Liquified Petroleum Gas Burners and Manifold Parts This is a Repair Parts List—Not a Packing List KEY NO. 1 2 3 4 5 6 6A 7 ‡ 1 3 7 8 DESCRIPTION 24-v Gas Valve, Electronic Intermittent Ignition Pilot Tube 10-32 X 3/16-in Hex Head Screw Gas Manifold Main Burner Orifice* Main Burner† Main Burner with Pilot Bracket Pilot Burner Rollout Shield 24-v Gas Valve, Continuous Pilot 10-32 X 3/16-in.
REPAIR PARTS → BOILER CONTROLS AND PIPING 7 1 8 3 2 5 4 6 9 10 → A03108 KEY NO. 1 2 3 4 5 6 * * 7 * 8 * 9 10 * * * * * * * * DESCRIPTION 3/4-in. ASME Relief Valve 3/4-in. X 7-1/2-in. Nipple Temperature Pressure Gage—5-in. Stem 1-1/4-in. X 2-1/2-in. Nipple 1-1/4-in. X 3/4-in.
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© 2003 CAC/BDP 7310 W. Morris St., Indianapolis, IN 46231 imbw1a05 —28— Catalog No.
