CAC / BDP BW4BAH-105 Installation, Operation & Maintenance Manual Download

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OIL FIRED CAST IRON

HOT WATER BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

BW4BAH-91

BW4RAH-91

BW5BAH-91

BW5RAH-91

BW4BAH-105

BW4RAH-105

BW5BAH-105

BW5RAH-105

BW4BAH-140

BW4RAH-140

BW5BAH-140

BW5RAH-140

BW4BAH-126

BW4RAH-126

BW5BAH-126

BW5RAH-126

BW4BAH-175

BW5RAH-175

BW5BAH-175

BW5RAH-175

BW4BAH-210

BW4RAH-210

BW5BAH-210

BW5RAH-210

Models

(Series C)

BW4BAH-168

BW4RAH-168

BW5BAH-168

BW5RAH-168

BW4BAH-245

BW4RAH-245

BW5BAH-245

BW5RAH-245

CAC/BDP

7310 WEST MORRIS ST.

INDIANAPOLIS, IN 46231

P/N# IM-BW4-01

[240009548, Rev. C [12/2012]

Select Models

Summary of Contents for BW4BAH-105

Page 1: ...40 BW4RAH 140 BW5BAH 140 BW5RAH 140 BW4BAH 126 BW4RAH 126 BW5BAH 126 BW5RAH 126 BW4BAH 175 BW5RAH 175 BW5BAH 175 BW5RAH 175 BW4BAH 210 BW4RAH 210 BW5BAH 210 BW5RAH 210 Models Series C BW4BAH 168 BW4RAH 168 BW5BAH 168 BW5RAH 168 BW4BAH 245 BW4RAH 245 BW5BAH 245 BW5RAH 245 CAC BDP 7310 WEST MORRIS ST INDIANAPOLIS IN 46231 P N IM BW4 01 240009548 Rev C 12 2012 Select Models ...

Page 2: ...afety relief valve drain valve flue brush and extra boiler tap for expansion tank or air elimination SAFETY NOTICES Boiler installation shall be completed by qualified agency NOTICE Used to address practices not related to personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury WARNING Indicates a hazardous situation which if not avoide...

Page 3: ...0 183 84 3 5 13 7 21 6 11 Mbh 1 000 BTU per hour BTU British Thermal Unit Heating Capacity based on 13 CO2 with a 0 02 w c draft over fire and a 1 smoke or less Testing was done in accordance with the D O E Department of Energy test procedure gph Gallons per hour oil at 140 000 BTU per gallon A F U E Annual Fuel Utilization Efficiency based upon D O E test procedure Net AHRI Water Ratings based on...

Page 4: ...ies of steam and hot water which may damage the surroundings Before installing the safety relief valve read the manufacturer s instructions and maintenance section of the manual on safety relief valves 12 Installation and sizing of the expansion tank must consider heating systems total water volume temperature boiler initial fill pressure and system arrangement Improperly installed and sized expan...

Page 5: ... where passage is required for access to another side for cleaning servicing inspection or replacement of any parts that normally may require such attention Boilers must be installed at least 6 from combustible material on all sides and above Allow at least 24 front clearance for servicing 5 Fresh air for combustion must be available at front of the boiler Fresh air for ventilation must be availab...

Page 6: ...CIRCULATING PUMP IN RETURN LINE OR AFTER THE EXPANSION TANK SHUT OFF VALVE OIL FILTER OIL LINES FOUNDATIONS TO OUTSIDE LINES TO OTHER APPLIANCES SERVICE LINE OVERCURRENT PROTECTED SAFETY SWITCH 2 FILL PIPE MIN 2 I D VENT PIPE ENTRANCE SWITCH OIL BURNER GENERAL PRINCIPAL REQUIREMENTS FOR A TYPICAL INSTALLATION LOCATING THE BOILER Figure 3 Boiler With Piping System ...

Page 7: ...ets the criteria for unconfined space Total input of all combustion equipment installed in combined space shall be considered in making this determination Each opening shall have minimum free area of one square inch per 1 000 Btu per hour of total input rating of all combustion equipment in the confined space but not less than 100 square inches One opening shall be within 12 inches of top and one ...

Page 8: ...the enclosure 3 When communicating with outdoors through horizontal ducts each opening shall have minimum free area of one square inch per 2 000 Btu per hour of total input rating of all equipment in the enclosure 4 When ducts are used they shall be of same cross sectional area as free area of openings to which they connect Minimum dimension of rectangular air ducts shall be not less than three in...

Page 9: ...iler See figure 6a A Install safety relief valve with spindle in vertical position B Do not install shutoff valve between boiler and safety relief valve C Install discharge piping from safety relief valve Use or larger pipe See figure 6b Use pipe suitable for temperatures of 375 F 191 C or greater Individual boiler discharge piping shall be independent of other discharge piping Size and arrange di...

Page 10: ...temperatures of less than 120 F Condensation is corrosive and can eventually cause damage to boiler and venting system Minimum design return water temperature to prevent this condensation in boiler and venting is 120 F Boiler used in heating system where design water temperatures below 140 F are desired e g radiant floor heating a 3 way or 4 way mixing valve or suitable alternative e g Bypass Pipi...

Page 11: ...OM EXPANSION TANK NOTE CIRCULATORCANALSOBEINSTALLED ON RETURN PIPING PIPING ARRANGED FOR POWER PURGING AIR OUT OF SYSTEM PIPING REFER TO THIS MANUAL S SECTION ON FILLING THE SYSTEM WITH WATER OPTION 1 Figure 8 System Piping Arrangement Zoning With Zone Valves ...

Page 12: ...UMPS AWAY FROM EXPANSION TANK PIPING ARRANGED FOR POWER PURGING AIR OUT OF SYSTEM PIPING REFER TO THIS MANUAL S SECTION ON FILLING THE SYSTEM WITH WATER OPTION 1 SYSTEM PIPING Figure 9 System Piping Arrangement Zoning With Circulators ...

Page 13: ... ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK PER THIS MANUAL USE OPTION 2 IN FILLING THE SYSTEM WITH WATER THIS PIPING ARRANGEMENT CAN BE USED WITH ZONE VALVES OR ZONE CIRCULATORS SYSTEM PIPING Figure 10 System Piping Arrangement Alternate Near Boiler Piping ...

Page 14: ...line controls are used Tankless coils are meant to provide domestic hot water for intermittent draws not continuous flow NOTICE Do not use tankless coil if your water is excessively hard with lime or other deposits which will accumulate inside the coil When using tankless coil boiler is configured so Honeywell L7248 operates with Honeywell L4006 low limit mounted on well installed in tankless heat...

Page 15: ...umption Tankless coil performance will fall as concentration of antifreeze is increased Refer to boiler and piping water volumes tables BOILER WATER VOLUMES Number of Boiler Section Total Volume Gallons 3 9 6 4 11 6 5 13 7 PIPING WATER VOLUMES PIPE SIZE COPPER PIPE FACTOR STEEL PIPE FACTOR 82 5 63 5 40 0 36 0 1 23 3 22 2 1 15 3 12 8 1 10 8 9 5 2 6 2 5 8 Divide total length of piping in feet by app...

Page 16: ... SIZES FIRING RATE gph CHIMNEY HEIGHT ft NOMINAL CHIMNEY ROUND LINER INSIDE SQUARE LINER INSIDE 0 60 1 30 15 8 x 8 6 6 x 6 1 31 1 80 15 8 x 8 7 6 x 6 1 81 2 00 20 8 x 8 8 6 x 6 For elevations above 2 000 feet above sea level add 3 feet to the chimney heights CHIMNEY AND CHIMNEY CONNECTIONS For oil fired boilers for connections to vents or chimneys vent installations shall be in accordance with app...

Page 17: ...y Connection Minimum height Must be at least 3ft 9m higher than highest part of passage through roof Must be at least 2ft 7m higher than any neighboring object within 10ft 3m Must have unobstructed top opening Must be at least 4 in 101mm thick and be tight ...

Page 18: ... regulations Connect 115 volt electrical supply to L1 and L2 terminals on limit and two thermostat wires to T and T terminals on same limit See wiring diagram page 28 Run separate circuit from separate over current protection device in your electrical service entrance panel Minimum 15 ampere circuit Locate shutoff switch at boiler Turn off during any maintenance Solder and tape or securely fasten ...

Page 19: ...ging drain valve runs air free close isolation valve or zone valve Repeat this procedure for remaining heating zones D Once all zones are filled with water and purged of air close power purging drain valve and fill line shut off valve open main shutoff valve and adjust throttling valves and balancing valves as required OPTION 2 Close air vents on all radiation units Open valves to radiation units ...

Page 20: ...er must be installed in fuel unit Refer to fuel unit instructions furnished with burner for specific instructions on installing bypass plug Do not exceed fuel unit manufacturer s recommendations for running vacuum NOTICE If lift exceeds 14 feet for Beckett burners or 11 feet for Riello burners two stage fuel unit is required with return line Install oil filter of adequate size inside building betw...

Page 21: ...H 175 1 00 80º A 1 25 F6 1 NO 10 0 3 AFG F HEAD 140 BW 4 5 BAH 210 1 25 80º A 1 50 F6 1 NO 10 2 3 AFG F HEAD 140 BW 4 5 BAH 168 1 00 60º B 1 20 0 NO 10 1 5 2 AFG 50 MD 140 BW 4 5 BAH 245 1 50 45º B 1 75 2 NO 10 4 2 AFG 50 MD 140 To fire the 3 section 91 on rate the oil pressure must be increased to 175 psig All Beckett oil burners for the BW boilers are factory preset at 140 psig BOILER MODEL DELE...

Page 22: ...22 OPERATING THE BOILER Figure 13 Burner Adjustments and Settings ...

Page 23: ...he unit is full of vapor or when the combustion chamber is very hot Locate thermostat five feet above the floor on inside wall Locate thermostat to sense average room temperature avoid the following THERMOSTAT LOCATIONS TO AVOID DEAD SPOTS HOT SPOTS COLD SPOTS Behind doors Concealed pipes Concealed pipes or ducts Fireplace TV sets Stairwells drafts Corners alcoves Radios Doors drafts Lamps Unheate...

Page 24: ...ment that may lodge on valve seat Permit valve to snap shut Refer to valve manufacturer s instructions packaged for more details Conventional Expansion Tank Tank may become water logged or may receive excess air Frequent automatic opening of safety relief valve indicates water logging High boiler temperature accompanied by unusually low radiation unit temperature and knocking noises indicates exce...

Page 25: ...ations from combustion chamber area take care to not damage any of refractory or blanket insulation To gain access to combustion chamber first check that shut off valve on fuel oil line is closed and disconnect fuel oil line Open swing door by removing whiz lock nut holding door shut 7 Inspect target wall fire door refractory and combustion chamber blanket when included for cracking and deteriorat...

Page 26: ... assembly make sure head location and size if applicable are per manufacturer s recommendations If burner being used has damaged head replace head with same head recommended for use on this boiler 6 Inspect and clean oil burner blower wheel 7 Remove oil pump cover and clean replace pump screen Carefully reassemble insuring pump cover creates proper seal 8 Securely fasten swing door shut 9 Replace ...

Page 27: ...ck to be sure electric power supply circuit is ON Controls out of adjustment Reset according to instructions Radiators not heating Open radiator vents to excess air Check flow control valve if used It may be in closed position Circulating pump not running Check over current protection Check relay operation Poor electrical contact Check all control terminals and wire joints Chimney flue is blocked ...

Page 28: ...28 ELECTRICAL WIRING Figure 16 Honeywell L7248L Control With Beckett AFG Burner ...

Page 29: ...29 Figure 17 Honeywell L7248L Control With Riello F5 F10 Burner ELECTRICAL WIRING ...

Page 30: ... burner fan motor to pre purge combustion chamber and oil pump to bring supply oil pressure up to its set point helping to provide clean light off LIMIT CONTROL provided Refer to manufacturer instructions provided with limit control Water temperature limit control in limit is adjustable and may be set as low as 140 F so long as return water temperatures to boiler are no less than 120 F or as high ...

Page 31: ...NOTES ...

Page 32: ...CAC BDP 7310 West Morris St Indianapolis IN 46231 ...

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