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Fig. 30—Troubleshooting Chart No. 2

A99352

CHECK THAT CIRCUIT BREAKERS IS ON OR

FUSES ARE OK AT THE ELECTRICAL PANEL

CHECK THAT SERVICE SWITCH IS ON

CHART 1

CHECK CASTING TEMPERATURE SAFETY

SWITCH. PUSH RESET BUTTON ON SWITCH.

CONTACTS OPEN (BUTTON UP) OR CLOSED

(BUTTON DOWN)?

CLOSED

CHECK WIRING TO IBC. I20 VAC BETWEEN

TERMINALS 1 AND 3 AT WIRING HARNESS

PLUG CN7?

YES

120 VAC BETWEEN TERMINALS 1 AND 3 AT

CONNECTOR CN3 OR IBC?

YES

120 VAC AT TRANSFORMER PRIMARY

TERMINALS?

YES

24 VAC AT TRANSFORMER SECONDARY

TERMINALS?

YES

24 VAC AT WIRING HARNESS PLUG CN2?

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

YES

CHART 1

CHECK FOR 120 VAC BETWEEN TERMINALS 1

AND 3 AT CONNECTOR CN5 ON IBC?

CHECK FOR 120 VAC AT CIRCULATOR

REPAIR/REPLACE CIRCULATOR

TROUBLESHOOTING CHART 2

OPEN

REPLACE/REPAIR WIRING FROM SERVICE

SWITCH TO IBC

CHECK WATER LEVEL IN BOILER. CHECK

FOR AIR TRAPPED IN TOP OF BOILER.

CONTACTS WILL NOT STAY CLOSED UNTIL

BOILER COOLS OFF.

TROUBLESHOOTING

—38—

Содержание BW9

Страница 1: ... 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 ...

Страница 2: ... Season 28 Daily During Heating Season 29 Monthly During Heating Season 29 Periodically During Heating Season 30 End of Each Heating Season Annual Shut Down Procedure 30 Annual Examination and Cleaning of Boiler Components 30 Differential Air Pressure Switch Check 31 Service Hints 31 Repair Parts 44 SAFETY CONSIDERATIONS Recognize safety information This is the safety alert symbol When you see thi...

Страница 3: ...raws in the outside combustion air then takes the cooler flue gases from the heat exchanger and provides a positive removal of the flue gases from the building through inexpensive and readily available PVC and CPVC pipes PROCEDURE 1 BOILER RATINGS AND CAPACITIES These low pressure gas fired hot water boilers are design certified by CSA AGA and CGA for use with natural and propane gases The boiler ...

Страница 4: ...GAUGE FRONT PANEL DOOR PULL LEVELING FEET CONDENSATE DRAIN FITTING 1 2 PVC 12 7mm OPENING FOR RELIEF VALVE DISCHARGE PIPE OPENING FOR AIR VENT AND EXPANSION TANK CONNECTION ALTERNATE BOILER WATER SUPPLY AND RETURN 31 75mm CONNECTIONS 1 1 4 NPT BOILER CABINET PROVIDED INSIDE DRAIN VENT CONNECTION 2 CPVC 50 8mm 5 127mm JUNCTION BOX FOR 120 V POWER 120 V CIRCULATOR BEADS AND 24 V THERMOSTAT LEADS VEN...

Страница 5: ...60 0760 0760 0760 Manifold Pressure Inches Water Column 2 5 2 7 2 8 3 0 2 8 2 6 2 3 2 1 Pressure Switch Setpoint Inches Water Column 1 35 1 35 1 35 1 35 1 35 1 35 1 35 1 35 BW9 100 Normal Input MBH 100 0 97 0 96 0 95 0 90 0 84 0 82 0 76 0 Heating Capacity MBH 90 0 87 3 86 4 85 5 81 0 75 6 73 8 68 4 Net I B R Rating MBH 78 0 75 7 74 9 74 1 70 2 65 5 64 0 59 3 Gas Orifice Drill Size 0860 0860 0860 0...

Страница 6: ...al to the piping systems served and as close to the vent and air intake terminals as possible 2 Accessibility clearances if more stringent i e larger clearances than required fire protection clearances must be used for the boiler installation Accessibility clearances may be achieved with the use of removable walls or partitions 3 The boiler is approved for installation in closets and on combustibl...

Страница 7: ...ing solvents salts air fresheners paints adhesives and other household products Locate combustion air inlet as far away as possible from swimming pool and swimming pool pump house All combustion air and vent pipes must be airtight and watertight Combustion air and vent piping must also terminate exactly as shown in Fig 10 11 12 and 13 Vent connections serving appliances vented by natural draft sha...

Страница 8: ...ide the boiler for a short distance on a smooth floor or surface NOTE Refer to manual section Locating the Boiler for required clearances for servicing and maintenance PROCEDURE 3 NEAR BOILER PIPING CAUTION Copper supply and return piping must NOT be installed directly into aluminum boiler section castings due to galvanic corrosion between dissimilar metals Iron or steel bushings or pipe nipples s...

Страница 9: ...ternal condensate pump if used 4 Reinstall the vent drain line F Chilled Water Piping The boiler when used in connection with a refrigeration system must be installed so the chiller medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water boiler connected to heating coils located in air handli...

Страница 10: ... 2 in CPVC coupling are furnished with the boiler NOTE The transition from 2 in pipe to 3 in pipe must be made in a vertical run See Fig 13 5 Combustion air and vent piping lengths See Table 5 6 Combustion air and vent piping to be pitched back to boiler at minimum 1 4 in per foot from intake and vent terminals so that all moisture in combustion air and vent piping drains to boiler Pipes must be p...

Страница 11: ... maintained from electric meters gas meters regulators and relief equipment Maintain 3 ft horizontal distance from dryer vents B Installation 1 Attach combustion air intake piping to factory supplied Fernco 2 in rubber coupling on mixer Attach vent piping to factory supplied 2 in CPVC vent tee on draft inducer outlet NOTE All pipe joints are to be water tight 2 Working from the boiler to the outsi...

Страница 12: ...uctions differ from those packaged with termination kit follow kit instructions Combustion air and vent pipes must terminate outside structure A factory accessory termination kit must be installed in one of the installations shown in Fig 10 or Fig 11 Four termination kits are available 1 The 2 in termination bracket kit is for 1 in 1 1 2 in and 2 in diameter 2 pipe termination systems 50 000 and 7...

Страница 13: ...as stones balls etc e Termination kit should be positioned where vent vapors are not objectionable 2 Cut one 4 in diameter hole for 2 in kit or one 5 in diameter hole for 3 in kit 3 Loosely assemble concentric vent air termination components together using instructions in kit 4 Slide assembled kit with rain shield REMOVED through hole a Roof terminations Locate assembly through roof to appropriate...

Страница 14: ...PATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER COMBUSTION AIR VENT 1 MAXIMUM ROOF OVERHANG 12 MINIMUM RAINSHIELD Table 5 BW9 Vent Table MODEL VENT DIAMETER MINIMUM LENGTH MAXIMUM LENGTH OF PIPE PER NUMBER OF ELBOWS Number of 90 Degree Elbows 0 1 2 3 4 5 6 BW9 100 2 in 7 ft 16 ft 14 1 2 ft 13 ft 11 1 2 ft 10 ft 8 1 2 ft 7 ft 3 in 15 ft 83 ft 80 ft 77 ft 74 ft 71 ft 68 ft 65 ft BW9 075 2 in 7 ft 21 ...

Страница 15: ...bustion air opening 1 1 For furnaces with an input capacity greater than 100 000 Btuh from any non mechanical air supply windows or doors which can be opened or combustion air opening 1 3 From service regulator vent electric and gas meters and relief equipment See Note 6 See Note 6 Above grade when adjacent to public walkway See Note 3 See Note 3 18 in above roof surface in Canada NOTES 1 If insta...

Страница 16: ... Code NFPA 54 2002 ANSI Z223 1 2002 In Canada follow the CAN CGA B149 1 and 2 installation Codes for Gas Burning Appliances and Equipment 2 Use pipe joint compound suitable for propane gas on male threads only 3 Use ground joint unions 4 Install a sediment trap upstream of gas controls Fig 13 Sidewall Vent Intake Terminations A99165 OVERHANG 12 MINIMUM 12 SEPARATION BETWEEN BOTTOM OF COMBUSTION AI...

Страница 17: ...s the National Electrical Code ANSI NFPA 70 In Canada electrical wiring shall comply with the Canadian Electrical Codes CSA C22 1 and 2 A Electrical Power Supply Prior to making any line voltage connections service switch at boiler should be in the off position and the power turned off at the fuse box Run a separate 120 volt circuit from a separate over current protection device in the electrical ...

Страница 18: ... ANSI NFPA 70 In Canada electrical wiring shall comply with the Canadian Electrical Codes CSA C22 1 and 2 Run a 14 gauge or heavier copper wire from the boiler to a grounded connection in the service panel or a properly driven and electrically grounded ground rod Fig 15 Combustion Air Vent 3 in A00311 Fig 16 Gas Piping A99167 GAS SUPPLY PIPING MANUAL SHUT OFF VALVE SEDIMENT TRAP GROUND JOINT UNION...

Страница 19: ...essories described A Intergrated Boiler Control IBC The Integrated Boiler Control IBC is a microprocessor based controller for a high efficiency gas boiler that monitors all safety controls and which controls the operation of the combustion air blower circulator pump burner and a combination hot surface igniter flame sensor This controller is not intended for use with a vent damper This controller...

Страница 20: ... F The field setpoint adjustment for each installation depends on heating system requirements The aquastat automatically resets when the boiler water temperature decreases 5 30 F adjustable differential The differential can be adjusted with the white Differential Adjustment Wheel on the aquastat and gives the flexibility for boiler operation The larger the differential the longer the run cycle of ...

Страница 21: ...QUASTAT CONTROL 3 2 1 4 7 5 8 6 9 HI LIMIT W R 2 1 2 1 PRESSURE SWITCH DIFFERENTIAL AIR 1 3 5 4 Y Y Y Y HOT NEUTRAL GROUND Y Y V V BR BR PUR BK BK W W PUR P10 DRAFT INDUCER PUR PUR P12 IGNITER N O ON OFF SWITCH RECEPTACLE 1 POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED NOTE P LABEL REFERENCE LOCATION OF CONNECTOR PLUG BETWEEN SCHEMATIC AND LADDER DIAGRAM AND THE UNIT US...

Страница 22: ...E AQUASTAT CONTROL MICROPROCESSOR ELECTRONIC LOGIC TIMERS INDICATOR LIGHTS VALVE IGNITER PURGE POWER 5K 4K 3K 2K 1K P3 7 W SAFETY SWITCH TRANSFORMER R P3 4 P3 6 P3 3 P3 5 4K1 3K1 P3 2 P2 1 P1 1 P1 3 P2 2 24 VAC 120 VAC P3 1 L1 HO T L2 P7 2 2K1 CIRCULATOR MOTOR 1K 1 5K1 P6 1 P6 2 5K2 HOT SURFACE IGNITER 120 VOLT POWER SUPPLY THERMOSTAT 1 DIFFERENTIAL AIR P3 9 HIGH LIMIT MANUAL RESET BLOWER TEMPERAT...

Страница 23: ...n a carton within the boiler cabinet for a single zone or zone valve controlled heating system and should be correctly located on the downstream i e pumping away side of the expansion tank For a pump controlled system where there is a circulator for each zone the circulator provided with the boiler can work for one zone For more details on piping and circulators see Near Boiler Piping section of t...

Страница 24: ...capacity f Water content of the boiler is 2 6 gallons 10 liters PROCEDURE 2 FILLING BOILER WITH WATER AND PURGING AIR FOR SYSTEMS WITH DIAPHRAGM TYPE EXTENSION TANKS Refer to appropriate Near Boiling Piping diagrams 1 Close all zone service valves on the supply and return piping Open the feed valve and fill boiler with water Make sure air vent is open Hold relief valve open until water runs air fr...

Страница 25: ...urner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone...

Страница 26: ...ected to the yellow thermostat lead wires in the furnished field wiring junction box the heat anticipator should be set at 0 7 amps For other wiring configurations refer to the instructions provided by the thermostat manufacturer regarding adjustment of heat anticipator Cycle boiler with thermostat Raise the thermostat to the highest setting and verify boiler goes through normal start up cycle Low...

Страница 27: ...5 in w c to 3 5 in w c depending on the altitude WARNING Operating this boiler with propane gas without a factory approved conversion kit may result in equipment damage fire property damage personal injury or death Restore all gas appliances that may have been shut off while measuring boiler input rate to normal operating conditions Table 9 Diagnostic Sequence SEQUENCE OF OPERATION DIAGNOSTIC DIAG...

Страница 28: ... cleaning instructions in Annual Examination and Cleaning of Boiler Components below b Visually inspect venting and air intake system for proper function deterioration or leakage If the vent or air intake show any signs of deterioration or leakage repair or replace them immediately Insure proper reassembly and resealing of the vent and air intake system c Check for and remove any obstruction to th...

Страница 29: ...er to unit Turn off gas supply to unit at the gas supply shutoff Failure to do so could result in fire personal injury property damage or death 1 Remove jacket front and top panels and check for piping leaks around relief valve and other fittings If found contact a qualified service agency to repair WARNING DO NOT use stop leak compounds Failure to do so could result in fire personal injury proper...

Страница 30: ...c Remove air baffle from 1 1 2 in X 2 in flexible coupling and clean air baffle if necessary Refer to repair parts diagram mixer and pressure switch assembly d Confirm that manual gas valve is closed and disconnect gas line to gas valve at union Disconnect wires to gas valve and igniter e Loosen but do not remove 5 nuts attaching mixer assembly to boiler Remove 2 igniter screws and very carefully ...

Страница 31: ...switch e Connect the 2 in flexible coupling to the draft inducer outlet 5 Follow start up and check out procedures to verify proper operation PROCEDURE 7 DIFFERENTIAL AIR PRESSURE SWITCH CHECK The following steps and diagram indicate the locations of the connection points required to check the differential air pressure The differential air pressure switch is a safety device which will prevent the ...

Страница 32: ...PURGE LIGHT ON AIRFLOW PROVED DRAFT INDUCER RUNS FOR 15 SEC PREPURGE CONTROL LOCKOUT PURGE LIGHT BLINKS RESET REQUIRED CIRCULATOR REMAINS ENERGIZED AS LONG AS THERMOSTAT CONTINUES TO CALL FOR HEAT OPEN IBC WAITS FOR UP TO 5 MINUTES FOR AIR PRESSURE SWITCH CONTACTS TO CLOSE INDICATING FAN SUCTION PRESENT CLOSED DRAFT INDUCER ENERGIZES THRU 1K1 CONTACTS CLOSED OPEN OPEN CLOSED YES NO DOES MAIN BURNE...

Страница 33: ...ONTROL LOCKOUT PROBLEM WITH COMBUSTION AIRFLOW PURGE LIGHT BLINKS SAFETY SEQUENCES DURING OPERATION DRAFT INDUCER TEMPERATURE SAFETY SWITCH D E DRAFT INDUCER RUNS THRU 30 SECOND POST PURGE AND SWITCHES OFF CIRCULATOR RUNS WITH THERMOSTAT ON CALL FOR HEAT WHEN TEMPERATURE SAFETY SWITCH CONTACTS REMAKE BEFORE END OF CALL FOR HEAT CONTROL GOES INTO NORMAL LIGHT OFF SEQUENCE LOSS OF FLAME SIGNAL DRAFT...

Страница 34: ...GIZED VALVE LIGHT GOES OUT DRAFT INDUCER RUNS FOR 30 SECOND POSTPURGE PURGE LIGHT ON DRAFT INDUCER IS DE ENERGIZED AFTER 30 SECONDS PURGE LIGHT SHUTS OFF THERMOSTAT ENDS CALL FOR HEAT BOILER STANDS BY FOR NEXT CALL FOR HEAT END OF NORMAL SEQUENCE OF OPERATION DETAILED SEQUENCE OF OPERATION 34 ...

Страница 35: ...HAT EITHER THERE IS NOTHING WRONG WITH THE CONTROL OR IT IS BEING DAMAGED BY SOME OTHER PROBLEM A SHORT BURNIGN OUT A TRANSFORMER FOR EXAMPLE 1 BEFORE TROUBLESHOOTING A MAKE SURE THAT CIRCUIT BREAKER IS ON OR FUSE IS OK AT ELECTRICAL PANEL B MAKE SURE THAT SERVICE SWITCH IS ON C MAKE SURE THAT GAS IS ON AT THE GAS METER AT ALL APPROPRIATE MANUAL SHUTOFF VALVES AND AT THE GAS CONTROL VALVE D MAKE S...

Страница 36: ...ER AND AIR 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 BALVE TO OPEN GAS CONTROL ...

Страница 37: ...Fig 29 Troubleshooting Chart No 1 A00318 37 ...

Страница 38: ...HARNESS PLUG CN2 REPLACE IBC NO NO NO 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...

Страница 39: ...Fig 31 Troubleshooting Chart No 3 A00319 39 ...

Страница 40: ...Fig 32 Troubleshooting Chart No 4 A00320 40 ...

Страница 41: ...Fig 33 Troubleshooting Chart No 5 A00321 41 ...

Страница 42: ...Fig 34 Troubleshooting Chart No 6 A00322 42 ...

Страница 43: ...ARENT VINYL TUBING WHITE TRANSPARENT VINYL TUBING SILICONE TUBING TO SIGHT GLASS SUCTION PORT TO GAS VALVE VENT WHITE TRANSPARENT VINYL TUBING 4 WAY CONNECTOR TO AIR INLET SUCTION PORT WHITE TRANSPARENT VINYL TUBING TESTING LINES VINYL CAP TYP 2 TEE INCLINED MANOMETER OR DIFFERENTIAL PRESSURE GAUGE 43 ...

Страница 44: ... 14631044 PPS10111 2682 Air Pressure Switch Q90 50 1 10 14662803 UT 1013 10 Intergrated Boiler Control 1 11 14631091 CO2366 Glide 4 12 14631120 HEYCO OCB 1500 Bushing 1 13 14631316 RACO 232 4X4X2 Box 1 14 14631319 P S Switch 691 l 1 15 14631318 Cover Plate Raco 902 802 1 16 14631174 419 1AA1 2 1 2 in Plug 2 17 14631171 415 1AA1 1 1 2 in Plug 2 18 14631176 BPF 3 1 2 in Plug 1 19 14631175 421 1AA1 3...

Страница 45: ...ANTITY 1 14631035 59019 1 2 in ID X 1 8 in thick Vinyl Tubing 6 2 14631114 57134 3 4 in Snap Grid Clamp 1 3 14631320 62067 1 2 in ID Hose Tee 1 4 14631101 62017 1 2 in NPTX1 2 in ID Tube Straight 1 5 14631321 1 2 in PVC Coupling Sch 80 1 6 14631306 1 2 in X 4 in PVC Nipple Sch 80 1 7 14631110 1 2 in ID X 1 2 in ID X 1 2 in NPT Tube Tee 1 8 14631323 S S Clamp Size 16 13 16 in x 1 1 2 in 1 45 ...

Страница 46: ...Fig 38 Boiler Block and Piping Assembly A99176 46 ...

Страница 47: ...02 1 1 4 in Sq Head Solid Plug 12 15 14695040 1 4 in X 1 1 4 in Carriage Bolt 4 16 14631101 62017 1 2 in NPT X 1 2 in ID Tube Straight 1 17 14607044 1 1 4 in X 2 1 2 in Nipple Black 2 18 1510001 1 1 4 in X 3 4 in X 1 1 4 in Tee 2 19 14622000 3 4 in Drain Valve 1 20 14693056 1 in Sq Socket Plug 4 21 14619002 Empire Sight Glass 1 22 1395001 3 4 in Sq Hd Plug 1 23 14693004 3 4 in X 1 2 in Bushing 1 2...

Страница 48: ...Fig 39 Mixer and Air Pressure Switch Assembly A99177 28 16 17 20 14 13 15 4 12 11 10 5 2 7 15 15 26 6 7 4 19 21 18 28 24 20 22 20 8 9 22 23 25 20 22 3 2 1 TO SIGHT GLASS ADAPTER 48 ...

Страница 49: ... 16 24 X 1 4 Hose ID Brass Barb Fitting 1 18 14631104 62064 1 4 in ID Tube Tee 1 19 14631313 1 4 in ID Tube 4 way Connector 1 20 14631143 1 4 in ID Tube 4 way Connector3 8 in Hose Clamp HC 6ST 10 21 14631151 PC250 12 Vinyl Cap 2 22 14631033 59006 1 4 in ID X 3 8 in OD Vinyl Tubing AS REQUIRED 23 14631314 1 4 in ID X 3 8 in OD Vinyl Tubing Red AS REQUIRED 24 14629003 1 4 in ID Silicone Tubing AS RE...

Страница 50: ...4631303 36TX11 22491 Inducer Temp Safety Switch 1 4 14695808 4 20 X 1 4 in HWH Plast Form Screw 2 5 2272065 116516 11 Induced Draft Blower Kit 1 6 14631026 Blower Gasket 1 7 12101021 Flue Connector 1 8 14631027 Recovery Coil Gasket 1 9 14695810 1 4 in 20 Hex Nut w Serrated Washer Block 4 10 14693804 1 8 in NPT 1 4 Hose ID Brass Barb Fitting 1 11 14631103 62043 1 2 in NPT X 1 2 in ID Tube Elbow 1 1...

Страница 51: ... 51 ...

Страница 52: ... 2003 CAC BDP 7310 W Morris St Indianapolis IN 46231 imbw9a03 52 Catalog No 63BW 9A4 ...

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