Behler-Young BWBCAN000060 Installation, Operation & Maintenance Manual Download Page 1

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Cast Iron Gas Boiler

For Forced Hot Water

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Models

BWBCAN000060

BWBCAN000095

BWBCAN000120

BWBCAN000150

BWBCAN000175

BWBCAN000205

BWBCAN000235

PN IM-BWBC-01

[240012884 REV C, 11/15/2020]

Summary of Contents for BWBCAN000060

Page 1: ...Gas Boiler For Forced Hot Water INSTALLATION OPERATION MAINTENANCE MANUAL Models BWBCAN000060 BWBCAN000095 BWBCAN000120 BWBCAN000150 BWBCAN000175 BWBCAN000205 BWBCAN000235 PN IM BWBC 01 240012884 REV C 11 15 2020 ...

Page 2: ...re Diagrams Document Package Junction Box Circulator Harness Items found in parts box included with your boiler Information and specifications outlined in this manual in effect at the time of printing of this manual Manufacturer reserves the right to discontinue change specifications or system design at any time without notice and without incurring any obligation whatsoever For Parts lists see man...

Page 3: ...rical 24 10 1 Electrical Wiring 24 10 2 Thermostat Installation 24 11 Wiring Diagram 25 12 Lighting Instructions 27 12 1 Lighting Procedure For Boiler With Intermittent Pilot System 27 12 2 Operating Instructions For Intermittent Pilot System 27 12 3 To Turn Off Gas To The Appliance 27 13 Normal Sequence Of Operation 28 14 General Maintenance And Care Instructions 29 14 1 Seasonal Startup 29 14 2 ...

Page 4: ... 8 24 1 8 24 1 8 613 mm 613 mm 613 mm 613 mm 613 mm 613 mm 613 mm H Flue Diameter 4 5 6 6 7 7 7 102 mm 127 mm 153 mm 153 mm 178 mm 178 mm 178 mm Supply Return Tappings 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT Natural Gas Inlet 1 2 NPT 1 2 NPT 1 2 NPT 1 2 NPT 1 2 NPT 3 4 NPT 3 4 NPT Relief Valve NPT 3 4 NPT 3 4 NPT 3 4 NPT 3 4 NPT 3 4 NPT 3 4 NPT 3 4 NPT Drain Valve NPT...

Page 5: ... all requirements before beginning installation FOR YOUR SAFETY READ BEFORE OPERATING Hot Water Can Scald Water heated to temperature for clothes washing dish washing and other sanitizing needs can scald and cause permanent injury Children elderly and infirm or physically handicapped persons are more likely to be permanently injured by hot water Never leave them unattended in bathtub or shower Nev...

Page 6: ...ne numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to prevent dust Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air 2 SAFETY SYMBOLS AND WARNINGS 2 2 For Your Safety 2 2...

Page 7: ...l solid base as near chimney as possible and centrally located with respect to heat distribution system as practical 6 Horizontal vent run to chimney shall be as short as practicable Refer to NFPA 54 to determine maximum permissible horizontal run for chimney type and height 7 Verify floor will support weight of boiler water and equipment 8 May be installed on combustible floor Do not install boil...

Page 8: ...etc Cleaning Solvents Hydrochloric acid muriatic acid Cements adhesives and glues Photo processing plants Garages with workshops Furniture refinishing areas and establishments Laundry Chemicals Laundry detergents bleaches fabric softeners etc Antistatic fabric softeners dryer sheets Dry cleaning laundry areas and establishments Other Permanent wave solutions Refrigerants Freon etc only where the r...

Page 9: ... or hot water during operation Discharge line shall A connect to relief valve outlet and piped down to safe point of disposal Check local codes for maximum distance from floor or allowable safe point of discharge B be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge line C have no intervening shutoff valve between safety relief valve and dis...

Page 10: ...luid used NOTICE If damage due to frozen pipes is a possibility install appropriate safeguards and alarms on the heating system to prevent property damage due to frozen and burst pipes should the boiler heating system become inoperative due to a power outage safety lockout or component failure 4 4 Water Treatment Manufacturer recommends a water analysis be done on water used to fill the system Tre...

Page 11: ...ycle Do not expose boiler and piping to freezing temperatures Note WARNING Asphyxiation hazard Gradual flueway blocking resulting from condensate induced corrosion may block boiler passages resulting in carbon monoxide and or flame rollout Install bypass piping if return temperature is under 130 F Failure to follow these instructions could result in death or serious injury 4 Boiler connected to he...

Page 12: ...ed water heating system Do not use automotive or ethylene glycol Do not expose boiler and piping to freezing temperatures Note Boiler installed above radiation level or as required by authority having jurisdiction Integral low water switch is provided in boiler Boiler used in connection with refrigeration system Install piping in parallel with boiler with appropriate valves to prevent chilled medi...

Page 13: ...NNECTING SUPPLY RETURN PIPING Figure 4 3 Bypass Piping With Automatic Mixing Valve BACK FLOW VALVE PIPING LEGEND PURGE VALVE DRAIN VALVE ASME RELIEF VALVE Back Flow Valve IM BWBC 01 240012884 REV C 11 15 2020 ...

Page 14: ...PING Figure 4 4 Bypass Piping Fixed Low Temp Only With Zone Valve BACK FLOW VALVE PIPING LEGEND ASME RELIEF VALVE Manually adjust until proper system temperature is reached Drain Valve Drain Valve IM BWBC 01 240012884 REV C 11 15 2020 ...

Page 15: ...G SUPPLY AND RETURN PIPING Figure 4 5 Bypass Piping 4 Way Valve Option With Circulator On Supply side BACK FLOW VALVE PIPING LEGEND ASME RELIEF VALVE Back Flow Valve Drain Valve IM BWBC 01 240012884 REV C 11 15 2020 ...

Page 16: ...ure 4 6 Single Zone System With DHW Priority BACK FLOW VALVE PIPING LEGEND 4 CONNECTING SUPPLY AND RETURN PIPING ASME RELIEF VALVE Back Flow Valve Drain Valve Purge Valve IM BWBC 01 240012884 REV C 11 15 2020 ...

Page 17: ...es all domestic hot water DHW installations use an anti scald valve Local codes may require additional equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements Note Refer to pump manufacturer literature for proper pump sizing 1 4 CONNECTING SUPPLY AND RETURN PIPING BACK FLOW VALVE PIPING LEGEND Figure 4 7 Multi Zone System With Zone Valve...

Page 18: ...Infiltration Rate See Table 5 1 for space with boiler only Use equation for multiple appliances Do not use an air infiltration rate ACH greater than 0 60 Volume 21 ft3 ACH x Total Input BTU HR 1 000 C Refer to National Fuel Gas Code for opening requirements between connected indoor spaces All Outdoor Air Provide permanent opening s communicating directly or by ducts with outdoors A Two Permanent O...

Page 19: ...haust 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 Minimum draft should be 02 w c 7 After it has been det...

Page 20: ... good condition Installation must conform to requirements of the authority having jurisdiction or in absence of such requirements to The National Fuel Gas Code ANSI Z223 1 NFPA 54 7 4 Vent Pipe Connect draft hood to boiler using 2 screws provided onto flue collector Connect two safety circuit wires attached to vent damper harness to blocked vent switch See Figure 13 1 Fasten sections of vent pipe ...

Page 21: ...damper so it is accessible for servicing See Figure 8 2 4 Damper must be in the open position when appliance main burners are operating 5 Boiler is equipped with factory wired harness that plugs into vent damper 6 Slope pipe up from boiler to chimney not less than 1 4 per foot 7 Run pipe as directly as possible with as few elbows as possible 8 Do not connect to fireplace flue 9 End of vent pipe mu...

Page 22: ...22 Figure 8 2 Vent Damper Placement Figure 8 3 Vent Damper Position Indicator 8 VENT DAMPER INSTALLATION INSTRUCTIONS IM BWBC 01 240012884 REV C 11 15 2020 ...

Page 23: ...call the fire department DANGER Fire Hazard Do not use matches candles open flames or other methods providing ignition source Failure to comply will result in death or serious injury WARNING Fire explosion asphyxiation and burn hazard Boiler piping and gas connections shall be leak tested before placing boiler in operation Failure to follow these instructions and or improper installation could res...

Page 24: ...nductors only for all connections to the boiler 10 2 Thermostat Installation 1 Use a thermostat with dry contacts which does not pull any load from the control Use a separate transformer for zone valve wiring 2 Thermostat should be installed on inside wall about four feet above floor 3 NEVER install thermostat on outside wall 4 Do not install thermostat where it will be affected by drafts hot or c...

Page 25: ...fication substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life Figure 11 1 Integrated High Limit Electronic Ignition Control IM BWBC 01 240012884 REV C 11 15 2020 ...

Page 26: ...26 11 WIRING DIAGRAM Figure 11 2 Integrated High Limit Electronic Ignition Control IM BWBC 01 240012884 REV C 11 15 2020 ...

Page 27: ...d service technician or your gas supplier 12 3 TO TURN OFF GAS TO THE APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Push in gas control knob slightly and turn clockwise to OFF DO NOT FORCE 4 Call qualified service technician WARNING If you do not follow these instructions exactly a fire or explosion may result causin...

Page 28: ...h or serious injury A Power remains off until boiler water temperature drops below high limit setting B Circulator continues to operate under this condition until thermostat is satisfied 3 In event the flow of combustion products through boiler venting system becomes blocked A Blocked vent safety switch shuts main burner gas off B If boiler flue way becomes blocked flame rollout safety switch shut...

Page 29: ...mp in flue collector through draft relief opening or flue inspection cover With mirror positioned above burners flue gas passageways can be checked for soot or scale Follow this procedure to clean flue gas passageways 1 Remove burner tray from heat exchanger by disconnecting gas valve remove two 2 nuts and pull out the assembly See Figure 14 1 page 30 2 Remove top jacket panel 3 Remove flue inspec...

Page 30: ...dup Area around boiler shall be clear and free of combustible materials gasoline and other flammable vapors and liquids Free flow of combustion and ventilating air to boiler and boiler room shall not be restricted or blocked Inspect factory supplied and field sourced low water cutoffs annually or as recommended by low water cutoff manufacturer Flush float type low water cutoffs per manufacturer s ...

Page 31: ...lumn from specified pressure listed on boiler rating plate 7 Primary air adjustment is not necessary therefore air shutters are not furnished CHECK SAFETY CONTROL CIRCUIT Test ignition system safety shutoff device after placing boiler in operation Test ignition system safety shutoff device after placing boiler in operation Blocked vent switch and rollout switch can be tested by removing one of the...

Page 32: ...ping within area to be heated boiler may be selected on basis of its heating capacity 3 Tank sized for non ferrous baseboard or radiant panel systems Increase size for cast iron baseboard and radiation STANDARD EQUIPMENT Boiler Jacket Cast Iron Boiler Battery High Limit Control Intermittent Electric Ignition Pilot System Vent Damper Relay Main Gas Burners Gas Control Includes Automatic Gas Valve I...

Page 33: ...ial 15 F default setting adjustable between 10 and 30 F о F_ Degrees Fahrenheit Press UP or DOWN button until parameter has reached desired value After 60 seconds without any button inputs control automatically returns to READ mode A 4 Display In RUN mode status items and parameters are viewable Example to display setpoint control flashes sp setpoint followed by temperature i e 135 followed by F o...

Page 34: ...closes to do this The control is waiting for this to occur This may last up to one minute If the vent damper switch has not closed after one minute ERR 55 will be displayed e 17 Diagnostics Another diagnostic check The control will also check the safety switches rollout and vent are closed This will be so quick the control may move on before the STA code is flashed Should the safety switches be de...

Page 35: ...ard lockouts on this model m 15 Wait for limit to close One of the safety limits rollout vent spill or low water cutoff has been activated Control will resume normal operation once limit is reset Underlying cause why the limit switch opened MUST be investigated n 16 Flame out of sequence Flame signal sensed before trial ignition Appropriate alarm is sent OR Flame signal sensed out of sequence duri...

Page 36: ...dels wait for retry or reset at thermostat Check for correct installation and wiring before replacing any component Control module cannot be repaired If it malfunctions it must be replaced Use only qualified service agent to service ignition systems 1 Perform checkout as first step in troubleshooting Check troubleshooting guide to pinpoint cause of problem See Table A7 2 If troubleshooting indicat...

Page 37: ... reading 1 Check sensor is plugged into control board 2 Check sensor wiring is not damaged 3 Scroll display reading to bt and hold sensor bulb securely in you hand It should read a temperature close to body temperature If not replace sensor 55 Damper end switch failed to close Vent damper must confirm it is open switch closes to do this Control did not receive this signal after waiting one minute ...

Page 38: ...eck all electrical connections are tight 3 Check pilot rod is clean 4 Check for adequate draft 5 Check for adequate combustion air 64 Soft Lockout Internal failure Control is sensing something wrong with electrical circuitry 1 Check all wiring is correct Refer to wiring diagram 2 Check there is a good ground to pilot bracket 65 Hard Lockout Temperature above limit Soft Lockout on S9361A2098 S9361A...

Page 39: ...dule and pilot burner igniter sensor Check for good metal to metal contact between pilot burner bracket and the main burner Check ground lead from GND BURNER terminal on module to pilot burner Verify connections are clean and tight If wire is damaged or deteriorated replace with No 14 18 gauge moisture resistant thermoplastic insulated wire with 105 C 221 F minimum rating Check ceramic flame rod i...

Page 40: ...kwise to increase pilot flame Following adjustment always replace pilot adjustment cover screw and tighten firmly to assure proper gas control operation Figure 12 1 page 27 3 If pilot does not stay lit ensure adequate flame current as follows Turn off boiler at circuit breaker or fuse box Clean flame rod with emery cloth Verify electrical connections are clean and tight Replace damaged wire Check ...

Page 41: ...ns to closed position 4 Return thermostat to desired position 5 Place vent damper in open position to permit burner operation by using HOLD DAMPER OPEN switch located on damper controller 6 Thermostat controls burner firing as before while damper remains open 7 DO NOT turn damper open manually motor damage will result 8 Set switch to AUTOMATIC OPERATION to close vent damper during burner off cycle...

Page 42: ...tep v v Place jumper wire across orange and yellow wires in Molex plug see Figure 4 This will create bypass of the damper boiler should then ignite If boiler ignites Go to section B 4 Vent Damper Troubleshooting Guide If boiler does not ignite Problem is not the damper Go to Damper harness Molex on Aquastat Step C NOTE Prior to replacing the damper be sure the problem is not with wire connections ...

Page 43: ...WER Between 4 1 When calling for heat 1 Thermostat not calling for heat 2 Burned out heat anticipator 3 Loose or broken connections 4 Off On operating limit pressure control or low water cut off 5 Off On blocked vent switch or flame roll out 1 Turn thermostat up to call for heat 2 Replace thermostat 3 Tighten repair or replace connection 4 Turn operating limit pressure control or low water cutoff ...

Page 44: ...al energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 ...

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