Installation, Start-Up, and Operating Instructions Gas-Fired Natural Draft Steam Boilers Sizes 70,000 through 299,000 BS1 and BS2 Series B ama ® ASME NOTE: Read the entire instruction manual before starting the installation. These instructions must be affixed on or adjacent to the boiler. This symbol → indicates a change since the last issue. MODEL BS2 MODEL BS1 Electronic Intermittent Ignition Continuous Pilot A95139 A90003 Index Page SAFETY CONSIDERATIONS.........................................
LOCATING THE BOILER...........................................................................................................................................................................................4 FRESH AIR FOR COMBUSTION ...........................................................................................................................................................................5-6 Boiler Located in Unconfined Space .....................................................................
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.
BOILER RATINGS AND CAPACITIES VENT DAMPER PRESSURE GAGE RELIEF VALVE 26 1⁄2″ 4 3⁄4″ 2 1⁄2″ TRANSFORMER GLASS GAGE PRESSURE LIMIT CONTROL LOW WATER CUT-OFF 2 1⁄2″ N.P.T. 29″ LOW WATER CUT-OFF PROBE 36 3⁄8″ 12 1⁄4″ WATER LINE S86 2 1⁄2″ 24″ GAS VALVE GAS LINE A LEFT SIDE FRONT RIGHT SIDE A90064 Natural Gas-Fired Steam Boilers BOILER MODEL NUMBER Intermittent Ignition with Vent Damper Standing Pilot with Vent Damper NO.
Table 1—Room Large In Comparison With Boiler BOILER SIZE (SECTIONS) BOILER VOLUME (CU FT) 3 4 5 6 7 8 9 6.3 8.1 9.9 11.7 13.5 15.3 17.2 MINIMUM ROOM VOLUME REQUIRED TO BE LARGE ROOM (CU FT)* 100.4 129.4 158.4 187.4 216.4 245.4 274.5 * For room with single boiler only. Table 2—Minimum Clearances From Combustible Materials and For Servicing PART OF BOILER Top Rear Control Side Opposite Control Side Front Flue/Vent Connector Boiler Piping ALCOVE OR ROOM NOT LARGE IN COMPARISON WITH BOILER (IN.
PROCEDURE 2—BOILER LOCATED IN CONFINED SPACE EXAMPLE 2A: ALL AIR FROM INSIDE THE BUILDING The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination.
STEAM MAINS 15″ MIN. PIPE FULL SIZE SAME AS BOILER TAPPING (2 1/2″) POP SAFETY VALVE REDUCING ELL POINTING DOWN 6″ TO 10″ DRY RETURN MAIN 24″ MIN. FLUE COLLAR MAIN VENT 1 1/2″ MIN. PIPE SIZE 15″ MIN. E R E AT LIN W 2 1/2″ MIN. TEE WITH PLUG FOR SKIMMING 6″ 28″ MIN.
STEAM MAINS PIPE FULL SIZE SAME AS BOILER TAPPING (2 1/2") 15″ MIN. POP SAFETY VALVE CONNECT RISER TO BOILER WITH 2 1/2″ ELBOW AND NIPPLE (NOT SHOWN) REDUCING ELL POINTING DOWN 6″ TO 10″ DRY RETURN MAIN 24″ MIN. FLUE COLLAR MAIN VENT 1 1/2″ MIN. PIPE SIZE 15″ MIN. E R E AT LIN W 2 1/2″ TEE WITH PLUG FOR SKIMMING 6″ 28″ MIN.
THIS PIPING CONFIGURATION IS INCORRECT TO SHOW COMMON MISTAKES WRONG WAY DO NOT BULLHEAD, USE 2 TAKE OFFS WRONG WAY TAKE OFFS MUST BE BETWEEN RISER & EQUALIZER WRONG WAY SWING JOINTS ARE MISSING WRONG WAY MISSING TEE FOR SKIMMING E R E AT LIN W A95495 Fig.
TO SYSTEM A B C D WATER CHILLER VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING A95143 Fig. 6—Chilled Water Piping IMPORTANT: The damper blade on factory-supplied vent damper has a 1/2-sq in. hole (approximately 3/4-in. diameter). On boilers equipped with standing pilot, the hole MUST be left open. On boilers equipped with intermittent ignition, the hole should be plugged using plug supplied with vent damper. 1.
2-FT MIN HT 3-FT MIN ROOF RIDGE 3/4 HT MAXIMUM MUST SLOPE UP AT LEAST 1/4 IN. PER FT OF HORIZONTAL RUN A95144 Fig. 7—Typical Masonry Chimney Requirements At the time of removal of an existing boiler, the following items shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. 1. Seal any unused openings in the common venting system. 2.
HORIZONTAL INSTALLATION FLOW NO YES YES NO TO FURNACE VENT TO CHIMNEY OR BOILER DAMPER INSTALL VENT DAMPER WITH ACTUATOR TO SIDES OF VENT ONLY. DO NOT MOUNT ABOVE OR BELOW VENT. CAUTION: Do not install the vent damper within 6 in. (152 mm) of combustible material. NOT HERE INSTALL DAMPER HERE VERTICAL INSTALLATION TO CHIMNEY 2 1 VENT DAMPER FLOW ACTUATOR MAY BE INSTALLED IN ANY POSITION TO FURNACE OR BOILER CHIMNEY 3 A95145 Fig.
Table 4—Gas Pipe Sizes Length of Pipe (Ft) 20 40 60 Length of Pipe (Ft) 20 40 60 NATURAL GAS Pipe Capacity—Btuh Input Includes Fittings 1/2 in. 3/4 in. 1 in. 1-1/4 in. 92,000 190,000 350,000 625,000 63,000 130,000 245,000 445,000 50,000 105,000 195,000 365,000 LP GAS Pipe Capacity—Btuh Input Includes Fittings Copper Tubing* Iron Pipe 5/8 in. 3/4 in. 1/2 in. 3/4 in.
VENT DAMPER MOLEX PLUG 4 115V/60HZ/1Ø POWER SUPPLY 1 BK 2 BR 3 O Y O NEUT THERMOSTAT HOT OVERCURRENT PROTECTED DISCONNECT t´ BK BT BK PRESSURE LIMIT W R H W N G B 1 2 3 N H LOW WATER CUT OFF C W Y B BK OPTIONAL WF-2U-24 WATER FEEDER BK BLOCKED VENT SAFETY SHUT OFF NOTE: TERMINAL NO. 3 APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON.
VENT DAMPER MOLEX PLUG 4 115V/60HZ/1Ø POWER SUPPLY BK 1 2 3 O BR Y O NEUT THERMOSTAT HOT OVERCURRENT PROTECTED DISCONNECT BT t´ BK W BK PRESSURE LIMIT Y BK R W H N G B 1 2 3 LOW WATER CUT OFF N H C W B OPTIONAL WF-2U-24 WATER FEEDER BK J7 BT NOTE: LWCO PROBE TERMINAL NO. 3 APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON.
VENT DAMPER MOLEX PLUG 4 24 VOLT TRANSFORMER BK 1 2 3 O BR Y 115V/60HZ/1Ø POWER SUPPLY HOT - WIRE NUT O BK THERMOSTAT BK COLOR CODE BK - BLACK BR - BROWN 0 - ORANGE Y - YELLOW R - RED BT - BLACK WITH TRACER W - WHITE G - GREEN PRESSURE LIMIT BT Y BK 4 1 3 LOW WATER CUT OFF UT 1003-620 SERIES INTERMITTENT PILOT CONTROL BK (24V) NOTE: TERMINAL NO. 3 APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON.
VENT DAMPER MOLEX PLUG 4 24 VOLT TRANSFORMER BK 1 2 3 O BR Y 115V/60HZ/1Ø POWER SUPPLY HOT - WIRE NUT O BK THERMOSTAT 2 3 1 t´ BK OVERCURRENT PROTECTED DISCONNECT W NEUT BK PRESSURE LIMIT BT Y BK OPTIONAL WF-2U-24 WATER FEEDER NOTE: TERMINAL NO. 3 APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON.
VENT DAMPER 4 PIN MOLEX PLUG VENT DAMPER 4 PIN MOLEX PLUG 4 1 BL BR 2 O ISOLATION RELAY 24V SPST N.O. HONEYWELL R8222A OR EQUIVALENT 3 Y 24 VOLT TRANSFORMER 4 1 2 BK BR O 3 ISOLATION RELAY 24V SPST N.O. HONEYWELL R8222A OR EQUIVALENT Y 24 VOLT TRANSFORMER O O BL BK PRESSURE LIMIT PRESSURE LIMIT BT ELECTRONIC THERMOSTAT W BT t° t° G B TERMINAL B OF LWCO ELECTRONIC THERMOSTAT TO LWCO & IGNITION SYSTEM TO LWCO & IGNITION SYSTEM FIELD WIRING FIELD WIRING A96054 A96055 Fig.
CONTROLS AND ACCESSORIES PROCEDURE 1—RELIEF VALVE The relief valve should open automatically if boiler steam pressure exceeds pressure rating of valve (15 psig). Should it ever fail to open under this condition, shut down boiler. If valve discharge occurs or valve fails to open as described above, contact an authorized contractor or qualified service technician to replace relief valve and inspect heating system to determine the cause as this may indicate an equipment malfunction.
B. BEFORE OPERATING, smell all around 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. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the fire department. C.
PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW) WIRING TERMINALS (2) INLET PRESSURE TAP OUTLET PRESSURE TAP CONVENIENCE TERMINALS (2) (OPTIONAL) GAS INLET ON GAS OUTLET MATCH HOLDER OFF PILOT THERMOCOUPLE CONNECTION RED RESET BUTTON PILOT ADJUSTMENT (UNDER CAP SCREW) PILOT OUTLET GAS CONTROL KNOB SHOWN IN "ON" POSITION A95521 Fig. 19—VR8200A/VR8300A Continuous Pilot Gas Valve A99181 Fig. 20—Lighting Pilot 4. Remove lower front panel. 5. Turn gas control knob clockwise to OFF position.
4. Allow boiler to fill until water runs out gauge drain valve, then close gauge drain valve. 5. Continue to fill boiler until water reaches indicated water line. This is about halfway up glass tube. PROCEDURE 3—WATER LEVEL The normal water level is shown on right side of boiler and is 24 in. above the floor. The normal water level is determined when boiler is off and cold (when all of the water in system is inside boiler and return piping below water line) and everything above water line is air, no steam.
The above is an example of a typical 1-pipe system. For larger systems or other types of systems such as 2-pipe systems or systems with convectors or fan coil units, pressuretrol settings need to be determined on a system-by-system basis. The cut-in setpoint is determined by system pressure drop to furthest radiator or terminal unit. Double the system pressure drop as a safety factor, resulting in the rule that cut-in setting should never be less than twice the system pressure drop.
If cleaning is necessary, repeat skimming and blowdown procedures above. Usually a long skim is sufficient to clean boiler. In more troublesome cases, it may be desirable to flush the system as well. This is accomplished by closing gate valve in the Hartford Loop and opening drain(s) at end of wet return(s). Run a hose from drain valve on wet return to a nearby floor drain or bucket. Run boiler at 2 lb. of steam pressure.
3. Remove 2 screws attaching intermediate front panel to left and right side jacket panels. 4. Remove draft diverter and intermediate front panel as 1 unit. 5. Carefully remove cerafelt gasket strips. 6. Clean passageways between sections with a flexible handle wire brush. Remove dirt from bottom of boiler and between sections by vacuuming. 7. Make sure all flame ports in burners are open and clear. Shake out or blow out all loose dirt in burners. 8.
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service. FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS 1. 2. 3. 4. Do not try to light any appliance. Do not touch any electric switch; do not use the phone. Leave the building immediately, then call your gas supplier. If you cannot reach the gas supplier, call the fire department. IF SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT. . . What To Do Reset thermostat above room temperature. Check flame.
REPAIR PARTS GAS-FIRED STEAM BOILERS yy ;; ;; yy ;; yy ;; ;yyy 21 —IMPORTANT— READ THESE INSTRUCTIONS BEFORE ORDERING All parts listed in the following Parts List may be ordered through your nearest supplier. When ordering parts, first obtain Model No. from data plate on boiler, then determine Part No. (not the Key No.) and Description of each part from the following illustrations and lists. Be sure to give all this information: Part No. — Part Description — Boiler Model No.
REPAIR PARTS FOR USE WITH NATURAL GAS ONLY 3 6 4 5 6A 2 1 A98238 Gas Burners and Manifold Parts This is a Repair Parts List—Not a Packing List KEY NO. 1 2 3 4 5 6 6A 7 ‡ 1 3 7 ‡ PART NO. 3 Section 4 Section 5 Section 6 Section ELECTRONIC INTERMITTENT IGNITION (Shown) 24-v Gas Valve, Elect. Inter.
REPAIR PARTS → BOILER CONTROLS AND PIPING 1 4 2 6 3 8 11 5 7 13 9 12 14 10 A03137 KEY NO. 1 2 3 4 5 6 7 8 9 * 10 * 11 * 12 * 13 14 15 16 * * * * * * * * * DESCRIPTION 3/4-in. Relief Valve 3/4-in. Coupling 3/4-in. X 6-1/2-in. Nipple Steam Pressure Gauge 1/4-in. Coupling 1/4-in. X 3-in.
—30—
SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials. All include video and/or slides, plus companion book.
© 2003 CAC/BDP 7310 W. Morris St., Indianapolis, IN 46231 imbs1a05 —32— Catalog No.
