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NOTE:
Read the entire instruction manual before starting the installation.
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1
TABLE OF CONTENTS
SAFETY CONSIDERATIONS.....................................................................................................................................................................................2
INTRODUCTION..........................................................................................................................................................................................................3
Boiler Ratings and Capacities..................................................................................................................................................................................3
Boilers for use at High Altitude .........................................................................................................................................................................3
INSTALLATION...........................................................................................................................................................................................................5
Before Installing the Boiler......................................................................................................................................................................................5
Codes ...................................................................................................................................................................................................................5
Boiler Sizing........................................................................................................................................................................................................6
Considerations for Boiler Locations...................................................................................................................................................................6
Locating the Boiler .............................................................................................................................................................................................6
Combustion Air and Vent Pipe Requirements...................................................................................................................................................7
Condensate Drain Requirements ........................................................................................................................................................................7
Foundation Requirements ...................................................................................................................................................................................7
Removal of Existing Boiler from Common Vent System ................................................................................................................................8
Placing the Boiler.....................................................................................................................................................................................................8
Near Boiler Piping....................................................................................................................................................................................................8
Supply and Return Lines ....................................................................................................................................................................................8
Pressure Relief Valve..........................................................................................................................................................................................8
Expansion Tank and Make-Up Water................................................................................................................................................................8
Condensate Drain Piping ....................................................................................................................................................................................9
Filling Condensate Trap with Water ..................................................................................................................................................................9
Chilled Water Piping ..........................................................................................................................................................................................9
Combustion Air and Vent Pipe................................................................................................................................................................................9
Connections and Termination.............................................................................................................................................................................9
Installation .........................................................................................................................................................................................................11
Concentric Vent Installation ..................................................................................................................................................................................12
Concentric Vent/Air Termination Kit ..............................................................................................................................................................13
Gas Supply Piping..................................................................................................................................................................................................15
Connecting the Gas Piping ...............................................................................................................................................................................16
Checking the Gas Piping ..................................................................................................................................................................................17
Electrical Wiring ....................................................................................................................................................................................................17
Electrical Power Supply....................................................................................................................................................................................17
Install Your Thermostat ....................................................................................................................................................................................19
Connect Circulator Pump Wiring.....................................................................................................................................................................19
Controls and Accessories .......................................................................................................................................................................................19
Intergrated Boiler Control (IBC) ......................................................................................................................................................................19
Gas Control Valve ............................................................................................................................................................................................19
Hot Surface Ignitor ...........................................................................................................................................................................................19
CERTIFIED
ama
ASME
®
Installation, Start-up, and Operating Instructions
BW9
Gas-Fired Direct Vent Condensing
Hot Water Boiler
Sizes 50,000 through 100,000
Series A
Form:
IM-BW9A-03
Cancels:
IM-BW9A-02
Printed in U.S.A.
8-03
Catalog No.
63BW-9A4
Summary of Contents for BW9
Page 37: ...Fig 29 Troubleshooting Chart No 1 A00318 37 ...
Page 39: ...Fig 31 Troubleshooting Chart No 3 A00319 39 ...
Page 40: ...Fig 32 Troubleshooting Chart No 4 A00320 40 ...
Page 41: ...Fig 33 Troubleshooting Chart No 5 A00321 41 ...
Page 42: ...Fig 34 Troubleshooting Chart No 6 A00322 42 ...
Page 46: ...Fig 38 Boiler Block and Piping Assembly A99176 46 ...
Page 51: ... 51 ...
Page 52: ... 2003 CAC BDP 7310 W Morris St Indianapolis IN 46231 imbw9a03 52 Catalog No 63BW 9A4 ...