OIL FIRED CAST IRON HOT WATER BOILER INSTALLATION, OPERATION & MAINTENANCE MANUAL Models (Series C) BW4BAH-91 BW4RAH-91 BW5BAH-91 BW5RAH-91 BW4BAH-126 BW4RAH-126 BW5BAH-126 BW5RAH-126 BW4BAH-168 BW4RAH-168 BW5BAH-168 BW5RAH-168 BW4BAH-105 BW4RAH-105 BW5BAH-105 BW5RAH-105 BW4BAH-175 BW5RAH-175 BW5BAH-175 BW5RAH-175 BW4BAH-245 BW4RAH-245 BW5BAH-245 BW5RAH-245 BW4BAH-140 BW4RAH-140 BW5BAH-140 BW5RAH-140 BW4BAH-210 BW4RAH-210 BW5BAH-210 BW5RAH-210 Select Models CAC/BDP 7310 WEST MORRIS ST.
SAFETY NOTICES Introduction Safety Notices .....................................................3 Boiler is a natural draft oil fired hot water boiler comprised of cast iron sections. Boiler is available with 3, 4, or 5 cast iron sections. These sections are held together by cast iron push nipples. Boiler Ratings And Capacities ................................4 Fresh Air For Combustion......................................8 System Piping ...................................................
BOILER RATINGS AND CAPACITIES Figure 1 - Dimensions BOILER RATINGS AND CAPACITIES BOILER MODEL NO. INPUT +gph *Mbh »BW(4,5)(B,R)AH-91 »BW(4,5)(B,R)AH-105 BW(4,5)(B,R)AH-140 »BW(4,5)(B,R)AH-126 »BW(4,5)(B,R)AH-175 BW(4,5)(B,R)AH-210 »BW(4,5)(B,R)AH-168 BW(4,5)(B,R)AH-245 0.65 0.75 1.00 0.90 1.25 1.50 1.20 1.75 91 105 140 126 175 210 168 245 **HEATING CAPACITY *Mbh 80 92 120 111 151 179 147 210 ‡NET AHRI RATING WATER *Mbh 70 80 104 97 131 156 128 183 A.F.U.E. ++ NO. SEC.
SAFE INSTALLATION AND OPERATION ! WARNING ! WARNING Fire, explosion, burn, scald hazard. Use only number 2 fuel oil. Do not use gasoline, kerosene, crankcase oil or any oil containing gasoline. Failure to follow these instructions could result in death or serious injury. Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. 11.
LOCATING THE BOILER Complete Prior To Installing Boiler. 1. Place boiler in location centralized with the piping system and as close to chimney as possible. A. Verify you have selected the right size boiler with proper capacity. AHRI rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. See boiler rating and capacity table previously listed in this manual.
OIL LINES OIL FILTER SHUT OFF VALVE OIL TANK 2" FILL PIPE MIN. 2" I.D.
FRESH AIR FOR COMBUSTION EXAMPLE 2: Boiler Located in Confined Space ! WARNING Asphyxiation, fire hazard. Do not obstruct air openings to combustion area. Follow instructions below, to maintain adequate combustion air. All Air from Inside the Building: Confined space shall be provided with two permanent openings communicating directly with additional room(s) of sufficient volume so the combined volume of all spaces meets the criteria for unconfined space.
FRESH AIR FOR COMBUSTION B. All Air from Outdoors: Confined space shall be provided with two permanent openings, one commencing within 12 inches of top and commencing within 12 inches of bottom of enclosure. Openings shall communicate directly, or by ducts, with outdoors or spaces (crawl or attic) that freely communicate with outdoors. 1.
SYSTEM PIPING 1. Installation of boiler for new heating system, Figure 6a - Safety Relief Valve Installation Install all of radiation units (panels, radiators, baseboard, or tubing) and supply and return mains first. After all heating system piping and components have been installed, make final connection of system piping to boiler. It is recommended to mount circulating pump on supply side piping, such that it pumps away from expansion tank. Refer to figures on next pages. 2.
SYSTEM PIPING Low Design Water Temperature Systems (Below 140° F) And Large Water Content Systems Figure 7 - Bypass Piping Arrangement Diagram > LOW DESIGN WATER TEMPERATURE SYSTEMS • Significant condensation may form in this boiler and/ or venting system if boiler is operated with return temperatures of less than 120°F. • Condensation is corrosive and can eventually cause damage to boiler and venting system.
SYSTEM PIPING Figure 8 - System Piping Arrangement Zoning With Zone Valves > CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK NOTE: CIRCULATOR CAN ALSO BE INSTALLED ON RETURN PIPING.
SYSTEM PIPING Figure 9 - System Piping Arrangement Zoning With Circulators > CIRCULATOR ON SUPPLY PIPING PUMPS 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 12
SYSTEM PIPING Figure 10 - System Piping Arrangement Alternate Near Boiler Piping > > DIAPHRAGM EXPANSION TANK MOUNTED OFF THE BOILER > CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK 13 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 Tankless Coil Piping Arrangement Boilers may be factory packaged with tankless heater coil see figure below. Coil provides instantaneous heating of water for domestic use if proper burner and water supply 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.
SYSTEM PIPING ARRANGEMENT Antifreeze added to boilers must be nontoxic, and must be of type specifically intended for use in closed hydronic heating systems. Under no circumstances should automotive antifreeze be used. Antifreeze used in any boiler may reduce capacity by 10% or more and increase fuel consumption. Tankless coil performance will fall as concentration of antifreeze is increased. Refer to boiler and piping water volumes tables.
CHIMNEY AND CHIMNEY CONNECTIONS For oil fired boilers for connections to vents or chimneys, vent installations shall be in accordance with applicable provisions of INSTALLATION OF OIL BURNING EQUIPMENT, NFPA31 latest revision, and applicable provisions of local building codes. ! WARNING Fire Hazard. Maintain minimum vent pipe clearance of 18” from surface of vent to wood and other combustible materials. Failure to comply may result in death or serious injury.
TYPICAL CHIMNEY CONNECTION Figure 12 -Typical Chimney 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.
ELECTRICAL CONNECTIONS ! WARNING Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. Thermostat Install 24 Volt thermostat (not provided) in proper location. Location of thermostat has effect on boiler system operation. Follow instructions included with thermostat. Grounding Permanently ground boiler according to local codes and latest revision of the National Electrical Code.
FILLING THE BOILER How A Hot Water System Operates Entire heating system (boiler, piping, and radiation units) is filled with water. As water in the boiler is heated, it is circulated from top of boiler through supply main to radiation units. Cooler water in radiation units flows back through return piping through return main into the boiler. This arrangement provides positive and rapid response to the thermostat. OPTION #2 • Close air vents on all radiation units. • Open valves to radiation units.
OPERATING THE BOILER • Room used for supplying combustion air should be isolated from any area served by exhaust fans. • Refer back to the section on Fresh Air For Combustion for additional sizing guidelines. Start: Fill entire system with water. Vent all air from system following section for Filling The Boiler. Fuel Units And Oil Lines: • Install oil line(s) to oil burner. • Recommend using heavy wall copper tubing and flared fittings, not compression fittings.
OPERATING THE BOILER Final Burner Adjustments: Final burner adjustments Oil Burner Maintenance: For Beckett AFG, and Riello 40 F5, or F10 perform following preventative maintenance annually, preferably prior to heating season. Refer to burner manual provided with boiler. must be made using combustion test instruments. Refer to “Burner Settings”. Set burner accordingly. • Check draft over fire to verify it is between -0.01” WC and -0.02” WC, adjust draft as necessary.
OPERATING THE BOILER Figure 13 -Burner Adjustments and Settings 22
CHECKING AND ADJUSTING CONTROLS NOTICE You or your installer must follow these instructions carefully. Locate thermostat five feet above the floor on inside wall.
MAINTENANCE Annually: Recommend flue passages, combustion chamber area (target wall, fire door insulation, durablanket), burner adjustment, control operation, and boiler seals (fire door gasket or silicone seal, cast iron sectional seals, flue collector) be checked once each year by trained Service Technician. Diaphragm Expansion Tank: Tank may become water logged. Frequent automatic opening of safety relief valve indicates water logging.
OIL BOILER / BURNER CLEANING INSTRUCTIONS Oil Boiler Cleaning: 6. Carefully vacuum soot accumulations 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. 1. Shut off all electrical power to boiler / burner and shut off fuel oil supply. 2. Remove vent pipe from top of boiler.
OIL BURNER CLEANING These are general instructions for cleaning an oil burner. For specifics, consult burner manufacturer’s instructions. ! WARNING Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. 1. Verify all electrical power to boiler / burner and fuel supply to burner are shut off. 2.
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service: IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . . POSSIBLE CAUSE WHAT TO DO Thermostat is not set correctly Reset thermostat Burner is not operating properly Check flame. If it is yellow, the burner is not getting enough air. Or, if flame is blue and noisy and seems to lift off the burner, the burner is getting too much air. Contact your service technician.
ELECTRICAL WIRING Figure 16 - Honeywell L7248L Control With Beckett AFG Burner 28
ELECTRICAL WIRING Figure 17 - Honeywell L7248L Control With Riello F5/F10 Burner 29
EQUIPMENT AND OPTIONAL ACCESSORIES MAIN AIR VENT: for down flow systems or diaphragm type expansion tanks (not provided) Before system is filled with water, there is air in pipes and radiation units. Some air will be trapped as system is filled. It is possible to eliminate most of this air through air vents on radiation units. Main air vent will speed and simplify this process. Install main air vent on highest point in supply main when all radiation is below top of boiler.
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CAC/BDP 7310 West Morris St. Indianapolis, IN.
