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Carrier BW9 Series, Installation Instructions Manual

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BW9

Installation Instructions

Gas---Fired, Direct Vent, Condensing

Hot Water Boiler

Sizes 125,000 Through 200,00

Series A

NOTE

: Read the entire instruction manual before starting the

installation.

PAGE

SAFETY CONSIDERATIONS

1

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INTRODUCTION

2

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INSTALLATION

3

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Rules for Safe Installation and Operation

3

. . . . . . . . . . . . .

Before Installing the Boiler

3

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Placing the Boiler

5

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Near Boiler Piping

5

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Combustion Air and Vent Pipe

6

. . . . . . . . . . . . . . . . . . . . .

Gas Supply Piping

10

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Controls and Accessories

14

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START--UP AND CHECK--OUT PROCEDURES

15

. . . . . . . .

Water Treatment and Freeze Protection

15

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Filling Boiler With Water and Purging Air for
Systems With Diaphragm Type Expansion Tanks

17

. . . . . .

Filling Boiler With Water and Purging Air for
Systems With Conventional Closed Type

Expansion Tanks

17

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Placing Boiler in Operation

18

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Check Out Procedures and Adjustments

18

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CARE AND MAINTENANCE

20

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SERVICE HINTS AND TROUBLESHOOTING

23

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REPAIR PARTS

35

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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. When working on

heating equipment, observe precautions in literature, on tags, and
on labels attached to or shipped with unit and other safety

precautions that may apply.
Recognize safety information. This is the safety--alert symbol

. When you see this symbol on the unit and in instruction

manuals, be alert to the potential for personal injury.
Understand

the

signal

words

DANGER,

WARNING,

CAUTION, and NOTE. These words are used with the

safety--alert symbol. DANGER identifies the most serious
hazards which

will

result in severe personal injury or death.

WARNING signifies hazards which

could

result in personal

injury or death. CAUTION is used to identify unsafe practices

which

may

result in minor personal injury or product and

property damage. NOTE is used to highlight suggestions which

will

result in enhanced installation, reliability, or operation.

ama

CERTIFIED

®

ASME

Read and obey the following rules to ensure safe installation and

operation:

1. Read the entire installation manual before beginning the

installation.

Failure to follow these rules of safe

installation and operation and these instructions could

cause a malfunction of the boiler and result in death,
serious bodily injury, and/or property damage.

2. Check all applicable state and local building codes and

utility company requirements before installation. The
installation must conform with these requirements in their

entirety. In the absence of these codes, use NFPA
Installation Codes and good industry practices.

3. Before servicing the boiler, allow boiler to cool. Always

shut off any electricity and gas supply connected to the
boiler prior to servicing.

4. Inspect gas line for leaks.
5. Be certain gas input rate is correct. Overfiring may result

in early failure of boiler sections. This may cause
dangerous operation. Underfiring may result in too much

air for the pre--mix burner causing poor combustion or
loss of combustion.

6. Never vent the products of combustion from this boiler to

an enclosed space. Always vent to the outdoors. Never
vent to another room or to inside a building.

7. Be sure there is adequate air supply to boiler 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 and

flammable materials.

Summary of Contents for BW9 Series

Page 1: ...used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installatio...

Page 2: ...tion also known as direct vent is the safest and best way to obtain plenty of clean combustion air The forced draft fan draws in the outside combustion air to mix with gas which flows into the pre mix burner and combusts The fan then forces the resulting flue gases from the boiler unit and provides a positive removal of the flue gases from the building through inexpensive and readily available PVC...

Page 3: ...on must comply with local codes 11 This boiler and related hot water heating systems are not do it yourself items They must be installed and serviced by qualified professionals STEP 2 Before Installing the Boiler Complete all of the following prior to installing the boiler CODES This boiler product is a gas fired direct vent condensing boiler and must be installed in accordance with all applicable...

Page 4: ...e space are always at or above 32 degrees F to prevent freezing of liquid condensate COMBUSTION AND VENT PIPE REQUIREMENTS This boiler requires a dedicated direct vent system In a direct vent system all air for combustion is taken directly from outside atmosphere and all flue products are discharged to outside atmosphere Combustion air and vent pipe connections must terminate together in the same ...

Page 5: ...er exhaust fan 6 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliances will operate continuously 7 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 the smoke a cigarette cigar or pipe 8 Any improper operation of the common venting system should be corrected s...

Page 6: ...ed schedule 40 PVC or CPVC drain pipe and cement A condensate pump with a reservoir not furnished may be used to remove condensate to a drain line sanitary line above boiler if a floor drain is not available or is inaccessible FILLING CONDENSATE TRAP WITH WATER NOTE On the initial start up the condensate trap must be manually filled with water The following are the steps required to initially fill...

Page 7: ... maximum vent length 5 feet per each additional elbow 1 Combustion air and vent piping to be pitched back to boiler at minimum 1 4 per foot from intake and vent terminals so that all moisture in combustion air and vent piping drains to boiler Pipes must be pitched continuously with no sags or low spots where moisture can accumulate and block the flow of air or flue gas Combustion air and vent pipe...

Page 8: ...PARTS BAG A04054 Fig 6 Diaphragm Type Expansion Tank Piping TO EXHAUST VENT 2 CPVC 1 2 ADAPTER MALE NPT X SOCKET WELD PVC PIPING 1 3 8 LONG TO BOILER FLUE OUTLET 2 CPVC 2 UNTHREADED MALE X 2 NPT MALE PVC BUSHING 2 NPT MALE PVC BUSHING 1 2 UNTHREADED PVC ELBOW 1 2 UNTHREADED PVC PIPING 3 3 4 LONG 1 2 UNTHREADED PVC ELBOW 1 2 UNTHREADED PVC PIPING 2 LONG 1 2 UNTHREADED PVC PIPING 3 3 4 LONG 1 2 UNTH...

Page 9: ...tee on draft inducer outlet NOTE All pipe joints are to be watertight 2 Working from the boiler to the outside cut pipe to required length s 3 Deburr inside and outside of pipe Remove all chips and shavings 4 Chamfer outside edge of pipe for better distribution of primer and cement 5 Clean and dry all surfaces to be joined 6 Check dry fit of pipe and mark insertion depth on pipe NOTE It is recomme...

Page 10: ...opane gas after the ball cock to facilitate service on the unit CHECKING THE GAS PIPING After all connections have been made check immediately for leaks Open the manual shutoff valve Test for leaks by applying soap suds or a liquid detergent to each joint Bubbles forming indicate leak CORRECT EVEN THE SMALLEST LEAK AT ONCE FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in pe...

Page 11: ...TICIPATED SNOW LEVEL OR GRADE 12 MINIMUM VENT 18 MAXIMUM 3 MAXIMUM SEPARATION 90 BRACKET 12 OR MORE CLEARANCE A99165 Fig 9 Sidewall Vent Intake Terminations MAINTAIN 12 IN CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER COMBUSTION AIR VENT 1 MAXIMUM ROOF OVERHANG 12 MINIMUM RAINSHIELD A01382 Fig 10 Concentric Vent Terminations VENT COMBUSTION AIR ELBOW FIELD SUPPLIED S...

Page 12: ...ted directly on the wall or on a vertically mounted outlet box It should be sensing average room temperature Avoid the following DEAD SPOTS COLD SPOTS HOT SPOTS Behind doors Concealed pipes or ducts Concealed pipes Lamps Corners and alcoves Stairwells drafts Fireplace Direct sunlight Unheated rooms on oth er side of wall TV sets Kitchens Radios Set heat anticipator at 0 7 amps Connect 24 volt ther...

Page 13: ... Field Wiring Connections If any of the original wire as supplied wiht this appliance must be replaced it must be replaced with type 150_C Thermoplastic wire or its equivalent A06089 Fig 16 Schematic Wiring Connections ...

Page 14: ...agnostic indicator lamps lamp D and E on the IBC see Fig 18 will blink indicating the failure mode as a lack of flame signal The IBC is manually reset from lockout by either removing and reestablishing the thermostat s call for heat or by turning the service switch off then back on L4006A HIGH LIMIT AQUASTAT CONTROL The High Limit Aquastat Control determines the maximum boiler water temperature an...

Page 15: ...tacts are normally open and close when the draft inducer is running and causing the differential pressure at the switch to exceed its setting The closed switch proves there is adequate air flow for combustion The pressure switch shuts off the main burner if the differential pressure is inadequate due to a blocked vent pipe a blocked air intake a blocked boiler section or a blocked air inducer Afte...

Page 16: ...cated by the illumi nation of Lamp D Two seconds later Lamp C will extinguish X X X when the integrated boiler control stops sending power to the hot surface igniter The integrated boiler control then enters a 6 second trial for ignition mode This is indicated by a low level illumination of Lamp E During the last 2 seconds of this trial for ignition mode main burner flame is proven by flame rectif...

Page 17: ...th water Make sure air vent is open Hold relief valve open until water runs air free for five seconds to rapidly bleed air from boiler then let the relief valve snap shut 2 Open the zone service valve on the supply pipe for the first zone Open the purge valve on the first zone Feed water will fill the zone pushing air out the purge valve Close the purge valve when the water runs air free Close the...

Page 18: ...and Step 5 Combustion Air and Vent Pipe located in the INSTALLATION section in this manual 2 Check for proper gas supply pressure and proper gas line sizing to the boiler by referring to Step 6 Gas Supply Piping located in the INSTALLATION section in this manual 3 Check for orifice in negative pressure hose at gas valve and 2 air intake pipe upstream of gas valve 4 Relight boiler 5 If boiler still...

Page 19: ... inch gauge in accordance with A S M E American Society of Mechanical Engineers Boiler and Pressure Vessel Code Section IV Standards for heating boilers TEST HIGH LIMIT CONTROL AND ADJUST While burner is operating Adjust setting on high limit control below actual boiler water temperature Burner should go off while circulator continues to operate Raise limit setting above boiler water temperature a...

Page 20: ...m throughout the boiler sections and represents a negligible mass of aluminum that is consumed by oxidation during the life of the boiler If left unchecked this buildup may eventually cause blockage of the flue gas passages in the boiler sections reducing efficiency and ultimately shutting down the boiler due to lack of combustion air flow Regular service and maintenance by a qualified service age...

Page 21: ... with a snorkel attachment k Inspect burner for any foreign matter in the flame ports or inside the burner Any foreign matter should be removed by blowing with compressed air or vacuuming l Reinstall burner and gaskets and position blower adapter assembly over studs Install five 5 nuts but do not tighten Reinstall igniter and igniter gasket and fasten with two 2 screws Use care when installing the...

Page 22: ...For Model 125 Closed at 3 5 1 50 For Model 150 Closed at 0 5 1 50 For Model 175 2 00 For Model 200 Running with Blockage Less Than or Equal to Setpoints Open at 3 5 Closed at 0 5 3 2 1 2 1 3 1 5 1 2 SIGHT GLASS ADAPTER 4 13 1 4 7 4 6 4 16 1 2 GAS VALVE 8 6 4 1 4 4 4 5 9 9 AIR INLET CONNECTION 2 2 EA A06107 Fig 20 Differential Air Pressure ...

Page 23: ...FAN SUCTION PRESENT CLOSED CLOSED OPEN OPEN CLOSED YES NO IBC CHECKS N O AIR PRESSURE SWITCH IBC SELF CHECK OF INTERNAL CIRCUITRY 1 2 SEC CIRCULATOR ENERGIZES THRU 2K1 CONT ACTS THERMOSTAT CALLS FOR HEAT POWER ON STANDBY NORMAL SEQUENCE OF OPERATION IF MAIN BURNER DOES NOT PROVE FLAME IN 3 TRIALS CONTROL LOCKOUT VALVE FLAME LIGHT BLINKS RESET IS REQUIRED THIS PROBLEM IS A RESULT OF NOT ESTABLISHIN...

Page 24: ...ME SIGNAL DRAFT INDUCER RUNS THRU 30 SECOND POST PURGE LOSS OF COMBUSTION AIRFLOW CONTROL WILL ATTEMPT TO RE LIGHT BOILER 3 TIMES IF FLAME IS NOT PROVEN CONTROL LOCKOUT PROBLEM ESTABLISHING A FLAME SIGNAL VALVE LIGHT IS BLINKING DRAFT INDUCER RUNS THRU 30 SECOND POST PURGE IF CALL FOR HEAT REMAINS IBC WAITS 5 MINUTES FOR AIRFLOW TO BE RE ESTABLISHED HI LIMIT CONTROL DRAFT INDUCER CONTINUES TO RUN ...

Page 25: ... CIRCULATOR PUMP ARE DE ENERGIZED VALVE LIGHT GOES OUT BLOWER RUNS FOR 30 SECOND POST PURGE PURGE LIGHT ON BLOWER IS DE ENERGIZED AFTER 30 SECONDS PURGE LIGHT SHUTS OFF A04066 Fig 23 End of Normal Sequence of Operation ...

Page 26: ...IT 7 IT IS EXTREMELY UNLIKELY THAT THE TWO CONSECUTIVE CONTROLS ARE DEFECTIVE IF IT SEEMS TO BE HAPPENING CHANCES ARE THAT EITHER THERE IS NOTHING WRONG WITH THE CONTROL OR IT IS BEING DAMAGED BY SOME OTHER PROBLEM AN ELECTRICAL SHORT BURNING OUT A TRANSFORMER FOR EXAMPLE INITIAL SERVICE CHECKS 1 BEFORE TROUBLESHOOTING A MAKE SURE THAT CIRCUIT BREAKER IS ON OR FUSE IS OK AT ELECTRICAL PANEL B MAKE...

Page 27: ...FLOW IS PROVEN OFF DURING PURGE CYCLE DRAFT INDUCER IS NOT POWERED OR AIR FLOW IS NOT PROVEN OFF DURING IGNITER AND RUN CYCLE NORMAL OPERATION PURGE CYCLE COMPLETE IBC IS LOCKED OUT PROBLEM COULD INDICATE FALSE POSITIVE PROOF OF AIR FLOW BLOCKED VENT OR INTAKE AIR PIPE OR FLUE WAY IBC IS ENERGIZING IGNITER IGNITER IS NOT ENERGIZED IBC IS ENERGIZING GAS CONTROL VALVE TO OPEN GAS CONTROL VALVE IS CL...

Page 28: ...uctions If you cannot reach your gas supplier call the fire department Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas at a location external to the appliance Do not use the boiler if any part of the gas control system has been under water A qualified service technician should inspect the boiler an...

Page 29: ...29 A04070 Fig 27 Troubleshooting Chart No 1 ...

Page 30: ...NO REPLACE IBC REPAIR WIRING TO TRANSFORMER REPLACE TRANSFORMER PUSH RESET BUTTON ON CASTING TEMP SAFETY SWITCH CHECK CONTINUITY OF CASTING TEMP SAFETY SWITCH CONTACTS CONACTS OPEN OR CLOSED CLOSED OPEN REPLACE CAST TEMP SAFETY SWITCH REPLACE REPAIR WIRING FROM TRANSFORMER TO IBC REPLACE IBC REPLACE REPAIR WIRING FROM IBC TO CIRCULATOR NO NO YES YES NO CHART 1 CHECK FOR 120 VAC BETWEEN TERMINALS 1...

Page 31: ...MAY PUDDLE AND BLOCK THE VENT CHECK AIR PRESSURE SWITCH PER INSTRUCTIONS ON FOLLOWING PAGES ARE SAMPLING LINES CLEAR AND CONNECTED PROPERLY CLEAN OUT SAMPLING LINES OR REPLACE DEFECTIVE SWITCH CHECK FLUE PASSAGES IN BOILER PER MAINTENANCE AND CLEANING ARE FLUE PASSAGES IN BOILER CLEAN CLEAN BOILER FLUE PASSAGES PER MAINTENANCE AND CLEANING INSTRUCTIONS CHECK DRAFT INDUCER MOTOR RPM IS IT 3400 3600...

Page 32: ...EPLACE WIRING FROM IBC TO IGNITER SENSOR REPLACE IGNITER SENSOR CHECK FOR 24 VAC ACROSS TERMINALS CN6 Z AND CN6 5 ON IBC WHILE THE VALVE FLAME LED IS LIT REPAIR REPLACE WIRING BETWEEN IBC AND GAS CONTROL REPLACE IBC YES YES YES YES YES YES NO NO NO NO NO NO NO NO NO CHART 5 CHART 5 YES YES YES CHECK IF IGNITER SENSOR POSITION IS OK TIP SHOULD BE SLANTED TOWARDS BURNER RESTORE IGNITER SENSOR TO COR...

Page 33: ...33 A04073 Fig 31 Troubleshooting Chart No 5 ...

Page 34: ... CHECK FIRING RATE OF UNIT IS UNIT FIRING AT THE CORRECT RATE DOES THIS UNIT USE LP GAS REPLACE GAS CONTROL CHECK GAS ORIFACE SIZE IS GAS ORIFICE SIZE CORRECT CHECK REPAIR PARTS LIST FOR CORRECT SIZE IS GAS ORIFICE CLEAR OF BLOCKAGE DOES DRAFT BLOWER STOP AFTER 30 SECOND POST PURGE A04074 Fig 32 Troubleshooting Chart No 6 ...

Page 35: ...35 REPAIR PARTS 11b 12 9 13 14 15 16 17 18 16 1 8 7 6 5 19 4 3 2 10 11a A04076 Fig 33 Jacket and Base Assembly ...

Page 36: ...ludes Items 15 and 16 1 10 750701031AB Jacket Panel Back 1 11a 2370007AB Jacket Panel Top Left 1 11b 2370008AB Jacket Panel Top Right 1 12 12695074 Screw 10 x 1 2 ZP 12 13 750001034 Jacket Tie Bar 1 14 14695060 Screw 10 x 1 2 Tech 14 15 1225013 Tap Bumper 1 16 1225012 Latch and Clip Kit 1 17 14631095 Door Pull 18 2272150AB Jacket Service Door Replacement Kit Includes Items 16 and 17 1 19 2485001 P...

Page 37: ... x 29 1 2 Long 1 2 14631305 Tee 2 CPVC SCH 80 1 3 1400008 Vent Pipe 2 CPVC SCH 40 x 7 Long 1 4 240005852 Cleanout PVC 2 1 5 1001002 PVC Fitting 1 2 NPT Male x 1 2 Slip Female 1 6 140014 Pipe 1 2 PVC SCH 40 x 1 3 8 1 7 1190005 Elbow 1 2 x 90 deg PVC SCH 40 3 8 1400014 Pipe 1 2 PVC SCH 40 x 3 3 4 2 9 1400014 Pipe 1 2 PVC SCH 40 x 2 1 10 1510012 Tee 1 2 x 1 2 x 1 2 PVC SCH 40 1 11 1400014 Pipe 1 2 PV...

Page 38: ...38 5 6 7 8 9 10 4 3 2 1 28 29 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 31 30 30 A06153 Fig 35 Boiler Block and Piping Assembly ...

Page 39: ... 1 13 1230010 Fitting Brass 1 8 NPT x 3 16 Straight Barb 1 14 14631324 Aquastat 1 15 14662804 Well Control 1 16 14693004 x Std Black Bushing 1 17 14693204 1 x 1 Std Black Bushing 1 18 PF06501 1 x 7 NPT Std Black Pipe Nipple 1 19 1260006SP Temp Pressure Gauge 2 Shank 1 20 1060002 x Std Black Iron Bushing 1 21 PF05901 1 x 1 x Std Black Tee 1 22 14693001 3 4 x 1 8 Black Bushing 1 23 1580006 Air Purge...

Page 40: ...s 2 and 3 1 2 1250009 Burner Casting Gasket 1 3 1250008 Burner Flue Adapter Gasket 1 4 1210122 Flue Adapter 1 5 14695810 Hex Nut w Serrated Washer x 20 5 6 1450011 Threaded Stud x 20 x 1 5 7 1250010 Igniter Mixer Gasket 1 8 1264005 Hot Surface Igniter 1 9 14695809 Screw 10 32 x 3 8 2 2272133 Hot Surface Igniter Kit Includes Items 7 8 and 9 1 Not Shown ...

Page 41: ...WITCH ASSEMBLY Item Item Item Part Number Description Quantity 1 14629003 Silicone Tubing 3 16 I D Varies 2 1401004 Air Pressure Switch 3 5 IWC 1 3 1401002 Air Pressure Switch Clip 2 4 1552004 Orange Silicone Tubing 3 16 I D Varies 5 1401003 Air Pressure Switch 1 2 IWC 1 6 1230006 3 16 Black Vinyl 2 7 1510009 Plastic Barbed Hose Tee 3 16 I D 5 8 1110001 Rotor Clamp 22 9 PB 002 02 Pilot Orifice BBR...

Page 42: ... 2272142 Gas Valve Replacement Kit 175 Only 1 2272143 Gas Valve Replacement Kit 200 Only 1 3 14631311 2 x 1 Flex Coupling 1 4 1570038 Ball Valve Blue 1 5 1400007 Vent Pipe 2 PVC SCH 40 8 Long 1 6 1230011 Fitting PE 1 8 NPT x 3 16 Barb 90_ 1 7 1450012 Screw T25 Torx 2 8 14693801 Elbow Street Mall Iron 90 PWX 2 9 14607301 Nipple Blk Std NPT x 3 2 10 1225015 Cap Cast Iron 1 11 14657015 Tee Black 1 12...

Page 43: ...lastic Bag 3 x 6 x 18 Orifice LP Model 150 4 2MM Label Propane Literature Conversion 125 200 Key Torx T 20 Label Propane Only Data Plate BW9AAN000175 KBANP1601DNK Plastic Bag 3 x 6 x 18 Orifice LP Model 175 5 2MM Label Propane Literature Conversion 125 200 Key Torx T 20 Label Propane Only Data Plate BW9AAN000200 KBANP1701DNK Plastic Bag 3 x 6 x 18 Orifice LP Model 200 6 0MM Label Propane Literatur...

Page 44: ...ice issues reviewed with owner maintenance person Installation booklet affixed on or adjacent to boiler Installer Company Address Phone Installer s í Name Signature A04082 Copyright 2006 CAC BDP S 7310 W Morris St S Indianapolis IN 46231 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog No IM BW9A 05 Replaces IM BW9A 04 ...

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