Carrier B Series Installation, Start-Up, And Operating Instructions Manual Download Page 29

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REPAIR PARTS

KEY NO.

DESCRIPTION

PART NO.

3/4-in. Relief Valve

157-00-01

3/4-in. Coupling

115-00-01

3/4-in. X 6-1/2-in. Nipple

146-07-002

Steam Pressure Gauge

146-23-005

1/4-in. Coupling

146-93-054

1/4-in. X 3-in. Nipple

146-07-001

AT-140D Transformer, 24v

146-62-045

PA-404A Pressuretrol

146-62-015

Glass Water Gauge Set (Used with PS-802 LWCO)

146-22-005

Glass Water Gauge Set (Used with 67D-1 LWCO)

146-22-010

90° Pigtail (Used with PS-802 LWCO)

146-43-004

180° Pigtail (Used with 67D-1 LWCO)

146-43-005

PS-802 Low Water Cut-Off

128-00-01

67D-1 Low Water Cut-Off

146-26-042

Control, Intermittent Pilot UT 1003-620

146-62-070

S8600M Intermittent Pilot Control, Liquified Petroleum Gas

146-62-071

1/2-in. X 3-in. Brass Nipple (PS-802 only)

131-00-03

1/2-in. X 1/2-in. X 1/4-in. Brass Tee (PS-802 only)

146-93-051

1/2-in. Brass Coupling (PS-802 only)

146-93-052

1/2-in. X 3 1/2-in. Brass Nipple (PS-802 only)

146-07-024

3/4-in. Drain Valve

146-22-000

WF-2U-24 Water Feeder (Optional)

163-00-01

Rollout Switch

146-29-002

Spill Switch (36TX16-6282) 280°F

146-60-002

5-in. Vent Damper (3 Section Boilers)

118-20-05

6-in. Vent Damper (4, 5 Section Boilers)

118-20-06

7-in. Vent Damper (6, 7, 8, 9 Section Boilers)

118-20-07

400°F Black Silicone Rubber Adhesive Sealant (10.3 oz cartridge)

146-06-024

Vent Damper Operator (Motor)

114-00-02

Not illustrated.

A03137

BOILER CONTROLS AND PIPING

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Summary of Contents for B Series

Page 1: ... Index Page SAFETY CONSIDERATIONS 3 INTRODUCTION 3 BOILER RATINGS AND CAPACITIES 4 ama ASME A95139 Continuous Pilot MODEL BS1 A90003 Electronic Intermittent Ignition MODEL BS2 Installation Start Up and Operating Instructions BS1 and BS2 Series B Gas Fired Natural Draft Steam Boilers Sizes 70 000 through 299 000 Form IM BS1A 05 Cancels IM BS1A 04 Printed in U S A 8 03 Catalog No 63BS 1A3 ...

Page 2: ...trol 19 Low Water Cut Off LWCO 19 Water Feeder Optional 19 Vent Damper 19 Rollout Switch Flame Rollout Safety Shutoff 19 Spill Switch Blocked Vent Safety Shutoff 19 FOR YOUR SAFETY READ BEFORE OPERATING 19 20 GAS VALVE OPERATING INSTRUCTIONS 20 21 Intermittent Ignition Boiler VR8204A VR8304M Gas Valve 20 Continuous Pilot Boiler VR8200A VR8300A Gas Valve 20 21 OPERATING BOILER 21 22 How a Steam Sys...

Page 3: ...re are any doubts as to the various requirements check with local authorities and obtain professional help where needed Take time to complete all the steps for SAFE and PROPER operation of heating system If this boiler is installed in a building under construction special care must be taken to insure a clean combustion air supply during the construction process Airborne particulates such as from d...

Page 4: ...An 18 inch clearance should be maintained on any side where passage is required to access another side for cleaning servicing inspecting or replacement of any part that may need attention An 18 inch clearance is recommended on the control side for servicing 6 Determine boiler room size Rooms that are large in comparison with the size of boiler are defined as rooms having a volume equal to or great...

Page 5: ...ust fan is used an outside air intake should be installed These devices rob the boiler and water heater of combustion air which can cause fire personal injury or death PROCEDURE 1 BOILER LOCATED IN UNCONFINED SPACE EXAMPLE 1 An unconfined space is defined as a space whose volume is not less than 50 cubic feet per 1 000 Btu per hour of the total input rating of all appliances installed in that spac...

Page 6: ...cate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors and shall have a minimum free area of a 1 sq inch per 3000 Btu per hour of total input of all equipment located in enclosure see Table 3C and b Not less than the sum of the areas of all vent connectors in the confined space Table 3A Fresh Air Duct Capacities for Vertical Du...

Page 7: ...or each main 7 All boilers in gravity return systems MUST be equipped with a Hartford Loop as shown in Fig 4 and 5 8 When piping vertical risers from boiler to header bottom of header must be a minimum of 24 in above water level line on right side of boiler 9 Steam riser s and header shall be 2 1 2 in pipe size 10 Equalizer line shall be a minimum 1 1 2 in pipe size 11 The near boiler piping shall...

Page 8: ...tant part of the heating system It must be clean the right size properly constructed and in GOOD CONDITION No boiler can function properly with a bad chimney Inspect chimney and verify that construction and size of chimney meet all applicable provisions of the NFGC and local building codes Fig 7 gives an idea how a boiler might be vented to a chimney Note that height HT is measured from vent pipe ...

Page 9: ...Y TAKE OFFS MUST BE BETWEEN RISER EQUALIZER WRONG WAY SWING JOINTS ARE MISSING WRONG WAY DO NOT BULLHEAD USE 2 TAKE OFFS WATER LINE THIS PIPING CONFIGURATION IS INCORRECT TO SHOW COMMON MISTAKES A95495 Fig 5 Common Near Boiler Piping Mistakes 9 ...

Page 10: ... per ft 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 must be flush with inside face of chimney flue Use a sealed in thimble for chimney connection 10 Horizontal run should not be longer than 3 4 the chimney height HT See Fig 7 The sections of vent pipe should be fastened with at least 3 sheet metal screws to make the piping...

Page 11: ...djust thermostat so appliance will operate continuously 5 Test for spillage at 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 common venting system properly vents when tested as outlined above return doors windows exhaust fans fire...

Page 12: ... damper open manually or motor damage will result Set switch to AUTOMATIC OPERATION to close vent damper during burner off cycle For further information and for a vent damper troubleshooting guide refer to the manual packaged with vent damper GAS SUPPLY PIPING PROCEDURE 1 CHECKING GAS SUPPLY The gas pipe to boiler must be correct size for length of run and Btuh input of all gas utilization equipme...

Page 13: ...a leak CORRECT EVEN THE SMALLEST LEAK AT ONCE WARNING Never use a match or open flame to test for leaks Use a soap and water solution A failure to follow this warning could result in fire explosion personal injury or death ELECTRICAL WIRING See Fig 12 15 for wiring diagrams of the various models PROCEDURE 1 ELECTRIC POWER SUPPLY WARNING Turn off electric power at fuse box before making any line vo...

Page 14: ...PV MV MV GAS VALVE VR8204A VR8304M UT 1003 620 SERIES INTERMITTENT PILOT CONTROL R G W BK BT BK MV MV PV PV GND 24V GND 24V SPARK TO PILOT BURNER W G R BL BK TO VENT DAMPER LOW WATER CUT OFF VENT DAMPER MOLEX PLUG 4 1 2 3 115V 60HZ 1Ø POWER SUPPLY NEUT HOT W BK BT OVERCURRENT PROTECTED DISCONNECT BK BR O Y t THERMOSTAT BK O PRESSURE LIMIT 1 3 2 LWCO PROBE BK BT G W R J7 C H N W B N H B BK Y NOTE T...

Page 15: ... ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON OPTIONAL WF 2U 24 WATER FEEDER COLOR CODE BK BR 0 Y R BT W G B BLACK BROWN ORANGE YELLOW RED BLACK WITH TRACER WHITE GREEN BLUE BLOCKED VENT SAFETY SHUT OFF FLAME ROLLOUT SAFETY SHUTOFF WIRE NUT GAS VALVE TH TR OVERCURRENT PROTECTED DISCONNECT FLAME ROLLOUT SAFETY SHUTOFF BLOCKED VENT SAFETY SHUTOFF P1 01 W LWCO 24 V SECONDARY BK BK BT Y P1 04 N...

Page 16: ...620 SERIES INTERMITTENT PILOT CONTROL COLOR CODE BK BR 0 Y R BT W G BLACK BROWN ORANGE YELLOW RED BLACK WITH TRACER WHITE GREEN WIRE NUT OVERCURRENT PROTECTED DISCONNECT FLAME ROLLOUT SAFETY SHUTOFF BLOCKED VENT SAFETY SHUTOFF P1 01 W 24 V SECONDARY BK BK BT Y P1 04 NOTE 1 S1A AND S1B ARE THE AUTOMATIC OPERATION HOLD DAMPER OPEN SWITCH SWITCH SHOWN IN AUTOMATIC POSITION S2 S3 AND S4 ARE CAM ACTUAT...

Page 17: ...ROLLOUT SAFETY SHUTOFF BLOCKED VENT SAFETY SHUTOFF NOTE TERMINAL NO 3 APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON COLOR CODE BK BR 0 Y R BT W G BLACK BROWN ORANGE YELLOW RED BLACK WITH TRACER WHITE GREEN WIRE NUT TR BT BK TH GAS VALVE OVERCURRENT PROTECTED DISCONNECT FLAME ROLLOUT SAFETY SHUTOFF BLOCKED VENT SAFETY SHUTOFF P1 01 W 24 V SECONDARY BK BK BT Y P1 04 NOTE 1 S1A AND...

Page 18: ...essure limit control PROCEDURE 3 ELECTRONIC THERMOSTATS Certain types of electronic thermostats may lose their memory or shut down With PS 802 probe type low water cut offs this may occur each time the low water cut off detects a low water condition With 67D 1 float type low water cut offs this may occur each time thermostat calls for heat due to the internal circuit in vent damper If this is the ...

Page 19: ...job is to maintain a safe minimum water level It is used to keep boiler running by compensating for minor evaporative steam leaks and to prevent freeze ups if the homeowners are away and a return line springs a leak McDonnell and Miller Model 101 water feeders may be used however the water feed rates are too high and need to be regulated or throttled and wiring must be revised Consult boiler manuf...

Page 20: ...n device which automatically lights the pilot Do NOT try to light pilot by hand 5 Remove lower front panel 6 Turn gas control knob clockwise to OFF position See Fig 18 7 Wait 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in safety information in For Your Safety Read Before Operating section 8 Turn gas control knob counterclockwise to ON p...

Page 21: ...be performed 3 Turn gas control knob clockwise to OFF position See Fig 19 Do not force OPERATING BOILER PROCEDURE 1 HOW A STEAM SYSTEM OPERATES The water in boiler is heated until it reaches boiling point As water boils it turns into steam The steam rises from top of water through supply main to radiation units As it passes through radiators it releases its heat and condenses into water The water ...

Page 22: ...burners do not require primary air adjustment and are not equipped with primary air shutters Main burner flames should form sharp blue inner cones in a softer blue out mantel with no yellow Puffs of air from blowing on the flame or stamping on the floor will cause the flames to turn orange momentarily This is not unusual Remain still when observing the main burner flames If the flame appearance is...

Page 23: ...rmostat for desired temperature Special conditions in home and location of thermostat govern this setting CLEANING BOILER It is very important to clean a new steam boiler after it has been installed and put into continuous operation This must be done to remove any accumulation of oil grease sludge etc that may be present in system These substances may cause boiler water to foam and surge producing...

Page 24: ...rsonnel PROCEDURE 3 LOW WATER CUT OFF LWCO The low water cut off interrupts electrical current to burner when water line in boiler drops to a low level A Float Type Low Water Cut Offs It is very important to keep float chamber free of sediment a condition essential to dependability To keep any accumulation from interfering with float action blow down or flush out control regularly This must be dow...

Page 25: ...d Loop Generally a 15 in horizontal run between riser and main takeoff allows entrained water to fall out of steam vapor so it can return to boiler See Fig 3 4 and 5 4 Adjustment of steam limit control to a wide differential increases difficulty if quick vents are old style slow releasing type or dirty Always set steam limit control differential as low as possible 5 Soap and detergents in boiler w...

Page 26: ... vents are not operating properly Check flow control valve if used It may be in closed position Poor electrical contact Check all control terminals and wire joints Rollout switch blown Have your service technician check heat exchanger for blockage Replace rollout switch with exact replace ment Chimney flue is blocked Spill switch contacts are open requiring manual reset of spill switch Have your s...

Page 27: ...5 001 146 05 002 146 05 051 146 05 053 146 05 005 146 05 007 146 05 009 15 Boiler Section Left 410 00 013 410 00 013 410 00 013 410 00 013 410 00 013 410 00 013 410 00 013 16 Boiler Section Middle 410 00 015 410 01 015 410 01 015 410 01 015 410 01 015 410 01 015 410 01 015 17 Jacket Top Panel 425 00 843 425 00 844 425 00 845 425 00 846 425 00 847 425 00 848 425 00 849 18 Draft Diverter 425 00 673 ...

Page 28: ... 532 146 15 532 146 15 532 146 15 532 146 15 532 146 15 532 146 15 532 6A Main Burner Pilot Mount 146 15 531 146 15 531 146 15 531 146 15 531 146 15 531 146 15 531 146 15 531 7 Pilot Burner 146 62 092 146 62 092 146 62 092 146 62 092 146 62 092 146 62 092 146 62 092 Rollout Shield 42500933 934 935 936 937 938 939 ALTERNATE PARTS FOR CONTINUOUS PILOT 24V 1 24 v Gas Valve Continuous Pilot 146 62 051...

Page 29: ...ttent Pilot UT 1003 620 146 62 070 S8600M Intermittent Pilot Control Liquified Petroleum Gas 146 62 071 13 1 2 in X 3 in Brass Nipple PS 802 only 131 00 03 14 1 2 in X 1 2 in X 1 4 in Brass Tee PS 802 only 146 93 051 15 1 2 in Brass Coupling PS 802 only 146 93 052 16 1 2 in X 3 1 2 in Brass Nipple PS 802 only 146 07 024 3 4 in Drain Valve 146 22 000 WF 2U 24 Water Feeder Optional 163 00 01 Rollout...

Page 30: ... 30 ...

Page 31: ...roduct theory and skills programs is available using popular video based formats and materials All include video and or slides plus companion book Classroom ServiceTraining plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 644 5544...

Page 32: ... 2003 CAC BDP 7310 W Morris St Indianapolis IN 46231 imbs1a05 32 Catalog No 63BS 1A3 ...

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