BCS Boiler Oil-Fired User manual
To the Installer:
.
To the Consumer:
Please attach these instructions
next to the water heater.
(OPTIONAL)
BACKFLOW
PREVENTER
Please read these and all component
instructions and keep for future reference.
OIL-FIRED BCS
Instruction Manual
EXPANSION TANK
Warranty, Registration Card and Parts List are included.
Homeowner: Please remember to return the Registration Card!
WARNING
Improper installation, adjustment, alteration,
service or maintenance can cause serious injury or property damage. Refer to this manual.
For assistance or additional information, consult a qualified installer or service agency.
WARNING
If the information in these instructions is not
followed exactly, a fire or explosion may result
causing property damage, personal injury or
death.
WARNING
Do not install on combustible flooring. Install
in accordance with all local codes. In the
absence of local codes, refer to NFPA 31 or
ANSI Z21.10.1.
CAUTION
The recommended temperature for normal
residential use is 120°F. The dial on the aquastat
does not always reflect the out-coming water
temperature and it could occasionally exceed
120°F. Variation in out-coming temperature
could be based on factors including but not
limited to usage patterns and type of installation. Test water at the tap nearest to the water
heater. (See page 8 for measuring the outcoming water temperature.)
BCS AND RADIANT HEAT
Radiant heating: An in-floor hot water space heating system
WARNING
A Bock high-efficiency water heater and zoned radiant heating—Bock&Radiant—make perfect
partners for cost-effective personal comfort that heats both space and water.
Hotter water increases the risk of scald injury.
Before adjusting the water temperature setting,
read this instruction manual. Temperatures at
which injury occurs vary with the person’s age
and the length of exposure. The slower reaction time of children, elderly or physically or
mentally challenged persons increases the
scalding hazard to them. It is recommended
that lower water temperatures be used where
these exposure hazards exist. Households with
small children or invalids may require a temperature setting less than 120°F to prevent accidental contact with hot water. To produce
less than 120°F, use point-of-use temperature limiting devices.
Bock&Radiant uses functional hot water and avoids boiler-type overheating that wastes energy.
Bock&Radiant eliminates using a boiler during warm months and lets ecomonic domestic hot
water work all year around.
Bock&Radiant maximizes Bock’s better heating efficiency as compared to a traditional boiler.
Bock&Radiant cuts overhead costs—simple water heater maintenance is much less expensive
than boiler maintenance.
Page 16
Oil-Fired BCS
Form # 23390
Rev 1
3/2006
If higher water temperature is needed in part
of the water system, automatic temperature
limiting devices must be used on all lines to
water taps.
WARNING
Flammable vapors may be drawn to this water
heater from other areas of the structure by air
currents. Do not store or use any flammable
liquids in the vicinity of this heater.
WARNING
Water heater blankets may restrict air flow to
the water heater and cause fire, asphyxiation,
personal injury or death.
THIS MANUAL HAS BEEN PREPARED
TO ACQUAINT YOU WITH THE INSTALLATION,
OPERATION, AND MAINTENANCE OF YOUR
WATER HEATER AND TO PROVIDE
IMPORTANT SAFETY INFORMATION.
Read all instructions thoroughly before attempting installation or operation of your
water heater. Keep these instructions for future
reference.
Local plumbing and electrical codes must be
followed in the installation of this water
heater. In the absence of a local code use the
UNIFORM PLUMBING CODE and the NFPA
Code. Local codes may supersede instructions
in this installation manual.
These instructions are a guide for the correct
installation of the water heater. The manufacturer will not be liable for damages caused by
failure to comply with the installation and
operating instructions outlined on the
following pages.
If you lack the necessary skills required or have
difficulty following the directions, seek help
from a qualified person for that part of the
installation you do not understand.
FAILURE TO FOLLOW THESE INSTRUCTIONS
OR ALL APPLICABLE BUILDING CODES
AND REGULATIONS VOIDS THE WARRANTY
ON THIS WATER HEATER.
HOT OUTLET
COLD INLET
D
IF ANY OF THESE DEVICES ARE USED,
A PROPERLY SIZED EXPANSION TANK
MUST BE INSTALLED.
C
HIGH LIMIT 120, 190
(OPTIONAL)
AVERAGER (190 ONLY)
HOT OUTLET
C
AUXILIARY OUTLET
(COMBINED APPLIANCE)
32, 51
EXPANSION TANK
AQUASTAT
AUXILIARY OUTLET
(COMBINED APPLIANCE)
B
A
RETURN
120, 190
B
A
D
AQUASTAT
RETURN
32, 51
COLD INLET
E
RETURN
E
40E-BCS
32, 51, 120, 190E-BCS
OIL-FIRED BCS
We
i
(inc ght (
lb
. bu
rne s.)
r&
con
trol
s)
System Plus is a combined appliance (space and water heating) based on a Bock highefficiency water heater and an air handler (available from various manufacturers) to heat the
entire home.
System Plus replaces the traditional furnace, cuts heat loss, and:
n Combines both primary space- and water heating
n Significantly lowers monthly fuel bills
n Creates an even temperature range—won’t dry out room air
32E-BCS
32
104
.75
3⁄4''
3⁄4''
1''
90°
114
51''
20''
6'' 11''
17'' 120/60
312
n Utilizes existing ductwork
40E-BCS
40
126
.9
3⁄4''
3⁄4''
1''
90°
136
61''
20''
6'' 54''
18'' 120/60
344
n Provides easy access for service
51E-BCS
50
152
1.1
1''
1''
1''
90°
161
59''
24''
6'' 11''
18'' 120/60
370
n Features low maintenance
120E-BCS
113 155
1.1
1''
2''
2''
90°
163
67'' 311⁄2'' 6'' 19''
22'' 120/60
751
n Extends the life of the water heater
190E-BCS
113 190 1.35
1''
2''
2''
90°
199
67'' 311⁄2'' 6'' 19''
22'' 120/60
751
n Reduces equipment costs for new construction projects—no chimney is needed for the
air handler
E
B
D
BCS AND SYSTEM PLUS™
A
C
Dimensions
Vol
tag
e (V
/Hz
)
PH)
Tem
per
atu
re R
ise
Rec
(F)
ove
ry (
G
hou
san
d
s)
Firi
ng
Rat
e (G
PH)
Col
d In
let
Hot
Out
let
Ret
urn
Sto
rag
eC
apa
city
(ga
BTU
l.)
H (T
Instruction Manual
n Generates more immediately-available hot water
n Accommodates central air
Page 2
Oil-Fired BCS
Oil-Fired BCS
Page 15
WHEN YOU RECEIVE YOUR NEW WATER HEATER
Check the new equipment to see if all components are in good condition and were not
damaged in shipment. The water heater and burner may be shipped as separate units. The
aquastat and immersion well are packed with the burner. If damage is observed or parts
appear to be missing, contact your wholesaler.
WHEN THE WATER HEATER IS USED IN A COMBINED APPLIANCE APPLICATION, PLEASE CONTACT
YOUR LOCAL DISTRIBUTOR OR THE FACTORY FOR INSTALLATION INSTRUCTIONS ON “SYSTEM PLUS”.
FLUE OUTLET PLACEMENT AND INSTALLATION
Flue outlet placement is of utmost importance for maximizing the performance of your Bock
Balanced Combustion System (BCS). Please see page 13 for unit dimensions. The following
instructions are recommended and may be code mandated for BCS installation:
n The wall opposite to prevailing winds
(east or south wall, if prevailing winter
winds are typically out of the west or
north) is the preferred wall for installation. This reduces the likelihood that
the Balanced Flue™ application will be
operating against high winds and
severe cold when it is cycling the
most often.
n The flue outlet must be placed at least
one (1) foot above the highest anticipated snow load to prevent flue
blockage.
n Use a flat wall for the flue outlet and
stay a minimum of three feet from corners or any structure to reduce eddy
currents.
n The flue outlet should be located even
with or above the top of the water
heater and in a location requiring the
fewest inlet and outlet elbows possible.
n To reduce frosting effects, place the outlet as far as possible from windows,
doors and other structural openings
such as eave vents—four feet is the recommended minimum.
n A minimum distance of three feet from
the outlet to plants and shrubs is suggested; a greater distance is preferred, as
moisture and frost effects can result in
damage or loss.
n The Balanced Flue should be located
away from high traffic areas to prevent
damage to wall outlet and human contact with the hot exhaust surfaces.
Page 14
Oil-Fired BCS
Oil-Fired BCS
Page 3
1. Cut a 7" O.D. opening in the preferred wall and provide a minimum of 1⁄2" clearance
of non-combustible space around the Balanced Flue. The opening should allow for a
1⁄2" downward pitch to the outside for drainage of any condensate in the Balanced Flue.
2. Insert the Balanced Flue from the
inside through the wall. Check the
outside extension to be sure air inlet
holes are exposed and will not be
covered by the flashing ring. Fasten
the assembly to the inside wall with
the tabs provided (see installation
detail drawing). On the outside
wall, install the flashing ring provided. Caulk around the outer and
inner rim of the flashing ring to
prevent moisture from entering
through the wall.
BOCK OIL-FIRED WATER HEATER
2 Mounting Tabs:
Attach to vent with
4 metal screws
supplied.
Bock Tank Assembly Parts List
When ordering repair parts, always give
the part name, model number, size and
serial number.
ITEM DESCRIPTION
1. Cold Water Inlet Dip Tube
2. Plastic Cap
3. Magnesium Rod
Installation Detail
4. Top Pan
Attach vent to
building structure
with 4 appropriate screws.
(customer supplied)
5. Hot Out Nipple 3⁄4"
6. Tank
7. Heater Jacket
8. Temperature & Pressure Relief Valve
9. Immersion Well & Aquastat
WATER HEATER PLACEMENT
10. Drain Valve
11. Burner Mounting Bracket (part of jacket
assembly—32, 40, 51, BCS)
NOTE: Locate the heater so it is not subject to physical
damage from moving vehicles or flooding.
12. Mounting Bracket Gasket
DO NOT INSTALL THE WATER HEATER ON COMBUSTIBLE FLOORING. Place on noncombustible
flooring and maintain clearances prescribed by this
manufacturer and per code NFPA 31. If the water heater
must be located on combustible flooring it should be
raised off the floor with a layer of 4" concrete block laid
so the air holes are aligned as shown in the drawing at
left. Please contact Bock Water Heaters or consult NFPA
31 with questions concerning proper flooring materials.
Leave adequate room for periodic maintenance of
heater and burner. The heater should be placed as near to the Balanced Flue as convenient in
order to keep vent connector length to a minimum, with a maximum horizontal run length of
15 feet.
13. Bottom Pan
14. Combustion Chamber Sleeve
15. Combustion Chamber
16. Sight Glass
17. Inspection Door
18. Not Used
19. Burner
20. Primary Relay
21. Cad Cell
Minimum clearance to combustible construction is: SIDES 6"; BACK 6"; FRONT 24". The installation
of this water heater must conform with local codes and ordinances. In the absence of local
codes, the installation must comply with the National Fire Protection Association (NFPA 31) Code.
Page 4
Oil-Fired BCS
Oil-Fired BCS
Page 13
OUR TOTAL WARRANTY COMMITMENT
CONNECT WATER PIPING
We will not assume, nor authorize any person to assume for us, any other liability in connection with the sale or operation of Bock Water Heaters. Any implied warranties, including merchantability or fitness for a particular application, imposed on the sale of this heater under
laws of the state of sale are limited to one year. Some states do not allow limitations on how
long an implied warranty lasts, or for the exclusion of incidental or consequential damages, so
the above limitations or exclusions may not apply to you. This warranty gives you specific
legal rights, and you may also have other rights which vary from state to state.
Be careful not to apply any heat to the water heater nipples. Install dielectric unions and shut
off valves on both hot and cold water lines.
40 BCS models are equipped with a brass inlet bushing installed in the tank. Heaters equipped with this bushing are
marked next to the inlet by the decal shown on the left.
The purpose of this bushing is to help keep the tank bottom free of sediment by aiding tank flushing. This bushing must be located as shown on the decal to function
properly. Do not allow the bushing to rotate out of position when tightening the inlet fittings.
WARRANTY REGISTRATION CARD
The attached warranty registration card should be returned within 30 (thirty) days of the date
of installation, otherwise the date of manufacture will be recorded as the date of installation
for the purpose of this warranty.
An approved pressure and temperature relief valve is factory installed in the opening provided
in the upper right-hand side of the water heater. Pipe the T&P to within 6" of the floor or to a
floor drain with a free flowing drain pipe.
CAUTION: Scalding injury and/or water damage can occur from either the manual
lifting of the lever or the normal operation of the T&P valve if it is not piped to a proper
drain. If the valve fails to flow water or reseat, call your plumber.
TO MAKE A CLAIM
Contact your nearest Bock distributor or:
Bock Water Heaters, Inc. • 110 South Dickinson Street • Madison, WI 53703
Telephone 608-257-2225 • Fax 608-257-5304
www.bockwaterheaters.com
Check incoming water line for backflow preventers or water pressure reducing valves, as these
may cause pressure to build up in the water heater and result in tank failure. If this water
heater is installed in a closed system or if backflow preventers and pressure regulators are
installed, a properly sized expansion tank must be installed.
Note: Do not try to heat hard water as this will drastically reduce heater life. Install a water
softener if the water heater is being installed in a hard water area (water hardness higher than
seven grains).
EXHAUST VENT
Where clearances to combustibles are a concern use double wall venting. Venting approved for Category III applicances is ideal but not required, single wall venting may be used
if allowed by local code. Caution: Do not use B-vent. The vent connector from the heater to
the rear of the Balanced Flue should be made using galvanized or stainless (preferred) vent material with a 4'' minimum diameter. A 6" × 4" reducer is placed on top of the heater flue. Note:
For 190E-BCS, a 6" vent pipe is preferred. Use one elbow to connect the heater to the venting.
An additional elbow may be used if the maximum horizontal distance from the BCS outlet to
the heater is reduced three feet. Maximum horizontal distance is 15 feet.
Venting from the heater to the Balanced Flue should be sealed but does not have to be pressure
tight. High temperature stainless sealing tape (2" wide) or high temperature (+500°F) RTV silicon sealants are recommended. Make certain the flue connector is removable for servicing.
Page 12
Oil-Fired BCS
Oil-Fired BCS
Page 5
COMPANY’S RESPONSIBILITY
FRESH AIR INTAKE VENT
Proper sealing of the fresh air intake vent material is important, but temperature is not an
issue. Failure to properly seal the inlet venting subjects the burner to possible reverse drafts
after burner shutdown—a hazardous condition with the possibility of creating a fire.
Use only solid or flexible metal duct, rigid plastic, or similar material of 4" diameter. Note: Do
not use flexible plastic dryer vent hose. Avoid tight turns with flexible ducting and limit
length. If using solid ducting, use a maximum of two elbows and 15' horizontal length. One
additional elbow may be used if horizontal distance from the BCS outlet to the heater is reduced three feet.
BURNER
The BCS burner is a custom burner equipped with an outside fresh air receiver, nozzle preheater, fuel oil solenoid valve and a custom electronic primary control having a 15-minute
post-purge timer. Do not use burner controls with shorter post-purge times as burner damage
may result.
MOUNT THE OIL BURNER
An aquastat with immersion well is packed with the burner. The thermostat is factory set at
120°F for residential use. The maximum setting for 32, 40, and 51E-BCS models is 160°F; for 120
and 190E-BCS models the maximum setting is 180°F. The adjustable differential on 120E-BCS
models is shipped at 15°. Lower differentials can be used for water temperatures under 160°F.
(See the caution on page 2 regarding temperature variations.) Install the immersion well with
the aquastat and verify that the sensing bulb may be fully inserted into the well. (Refer to
“Controls” section on page 10.)
Remove the cardboard core from the burner opening in the water heater. Mount the burner on
stud bolts, making sure to place the supplied gasket between the burner flange and heater.
Secure the burner to the heater with the 1⁄4-20 nuts or 3⁄8" @ 16 cap screws supplied.
The company’s responsibility is to repair or replace, at our option, with the prevailing comparable Bock model, any part of the equipment, including the tank, sold by the company which
proves to be defective in material or workmanship during the warranty period, when installed
in accordance with applicable codes and ordinances, and operated and maintained in accordance with our instructions, subject to the conditions and exceptions indicated below. Our liability, in the event of leakage or other malfunction, is strictly limited to repair or replacement
of the defective heater or part, as provided herein. We are not responsible hereunder for incidental property damage or personal injury, consequential costs or damage. Equipment that is
repaired or replaced will carry the unexpired portion of the original equipment warranty.
BURNER AND CONTROLS
Any burner and/or controls used on a Bock water heater other than the ones recommended by
Bock Water Heaters, and listed by Underwriters Laboratories, Inc., will void the water
heater warranty. Bock Water Heaters specifies burners and controls on the basis of safety, reliability and performance. Only the following burners and controls have been tested and approved by Bock Water Heaters and Underwriters Laboratories, Inc., to meet the stringent
standards required by both: 32E-BCS: Carlin 0.75 x 70A; 40E-BCS: Carlin 0.85 x 70A;
51E-BCS and 120E-BCS: Carlin 1.1 x 70A; 190E-BCS: Carlin 1.35 x 70B.
The only controls acceptable for use with these models are as follows:
For normal household applications:
Burner: Carlin EZ1 with 15-minute post-purge and nozzle heater.
Temperature Control (aquastat): 32, 40, 51E-BCS—Carlin EZ-Temp 90000B
120E-BCS—Carlin EZ-Temp 90000C
190E-BCS—Carlin EZ-Temp 90300B
OWNER’S RESPONSIBILITY
CONNECT THE ELECTRICITY
REFER TO BURNER WIRE DIAGRAM (page 4). All wiring must comply with applicable codes
and ordinances. The primary relay and aquastat are wired to the burner at the factory. Install
the aquastat well in the 3⁄4" tapping at the front of the heater. Be sure the sensing bulb is all
the way in. Tighten the aquastat retaining screws to secure the control to the well. Connect
the power supply to the aquastat, being sure to run through a fused disconnect switch (to be
attached to heater in the field).
At the company’s request, the owner is to return to the factory at Madison, WI, any part, including the tank, defective in material or workmanship, and pay all transportation charges for
such return parts and for replacement parts sent from the factory to the owner. The owner will
pay all labor charges for the removal and installation of such parts, including the tank. Any
replacement water heater furnished under this warranty shall remain in warranty only for the
unexpired portion of the original warranty. The owner will have annual inspections of the
anode rods. Bock Water Heaters requires paid receipts to show maintenance of anodes on glass
lined tank claims.
EXCEPTIONS
This warranty will not apply to tanks or parts subject to misuse, abuse, neglect, alteration,
accident, excessive temperature, excessive pressure, lime, silt or sediment accumulation,
corrosive atmosphere, the removal of the magnesium anode rods, noise, odor, rusty water,
the installation of an insulation blanket, installation outside of the United States (excluding
Canada), or on which the serial numbers have been altered. The warranty also does not apply
when the water heater is installed without a new temperature and pressure relief valve and is
not installed in accordance with local codes and ordinances.
Page 6
Oil-Fired BCS
Oil-Fired BCS
Page 11
SERVICE
CONNECT THE OIL LINE
1. Check the fuel supply, electrical wiring, fuses, and make sure the temperature control is
calling for heat.
2. If the motor runs but there is no flame, remove the electrode assembly, clean, readjust, and
check the porcelain for cracks. Replace if necessary. Check the ignitor to see if it is producing a spark. (Use extreme caution—the ignitor has 14,000 volt output.) Make sure the
coupling between the motor and pump shaft is not slipping. Check the set screw on the
blower wheel for tightness. Clean or replace the nozzle with the correct size and spray
angle.
3. Bleed the pump and check for clear, air-free oil. If oil is milky or frothy, check the line for
air leaks at fittings. Tighten all fittings again. Check filter gaskets and make sure the cartridge is clean.
4. If the burner motor fails to start, reset the control and check for voltage on the burner lead.
If no voltage, replace control. If there is power to the motor connect a pig tail and 100 watt
bulb to the capacitor leads. If the motor starts, replace the capacitor. If not, check for thermal lock out. Note: The BCS burner is equipped with a split capacitor motor containing an
automatic reset thermal cut-out. If the motor cuts out because of overheating, it will reset
when the motor cools. Make certain that air can flow freely around burner. If motor locks
out repeatedly, check capacitor and the fuel pump turning torque before replacing motor.
5. If the burner ignites, runs for a short time (10–20 seconds), and then goes out on safety,
replace the flame detector. If the burner still runs only a short time, replace the control.
6. If you smell oil or combustion products, remove and clean the electrode assembly, readjust
combustion settings, and insure that the joints on the flue connections are sealed (see “Exhuast Vent” and “Fresh Air Intake Vent” installation, page 6).
Gravity System: The oil burner is normally equipped with a single-stage pump equipped
for one line (gravity) flow. Use 3⁄8" O.D. or larger soft copper tubing and attach with flared
fittings. DO NOT USE COMPRESSION FITTINGS. Install the shut off valve and oil filter in the
oil line. Follow instructions from the pump manufacturer (attached to pump).
Lift System: Run a two-line system (suction and return lines) for lifts over 8 feet. Install a
bypass plug if required according to the instructions attached to the pump. (Plug is in bag
with instruction sheet.) The burner may be ordered with a two-stage pump for high lifts or
longer runs.
WARNING!!! When you install the bypass plug you MUST run a two-line system!
For any horizontal run or lift that exceeds the maximum length specified in the chart below,
a booster pump must be used. Booster pumps may be obtained from Sun Tec Hydraulics, Rockford, Illinois. Booster pumps must be installed as close to the oil supply tank as possible. Suction and return lines should be the same diameter and both go within 6" of the bottom of the
tank. The return line should stop slightly above the suction line. Use a minimum of fittings.
Make tubing bends with as large a radius as possible. DO NOT USE COMPRESSION FITTINGS.
Use caution in the final connection to the burner. Do not put strain on the fuel unit. Before
attaching tubing to the burner, form a coil in the tubing to minimize any vibration. Bury oil
lines in the floor for quiet operation, making sure there are NO CONNECTIONS OR FITTINGS
UNDER THE FLOOR.
MAXIMUM LIFT AND HORIZONTAL RUN (Refer to pump manufacturer’s instructions)
Maximum Lift & Horizontal Run for Oil Units
7. The internal high limit located in the thermostat will break the circuit to the burner if
water overheating occurs. When this happens, the burner will not go into post purge or
may stop post purge prematurely. Replace the thermostat, if necessary.
If any other service problems arise, you may obtain more information by contacting your
installer or nearest Bock distributor; or write, call, or fax:
Bock Water Heaters, Inc. • 110 South Dickinson Street • Madison, WI 53703
Telephone 608-257-2225 • Fax 608-257-5304
Horizontal Run
Lift
3⁄8"
0'
4'
7'
8'
O.D. Tube
65'
45'
31'
16'
1⁄2"
100'
100'
100'
64'
This warranty covers “Bock” water heater models 32E-BCS, 40E-BCS, 51E-BCS, 120E-BCS and
190E-BCS. Bock Water Heaters, a division of Bock Corporation—a Wisconsin corporation—at
110 S. Dickinson Street, Madison, Wisconsin 53703 (“Company”), warrants to the owner, the
tank of this water heater will not leak due to defective materials or workmanship for FIVE (5)
years from the date of original installation. If the water heater is installed in other than a
single family dwelling, this warranty is limited to THREE (3) years from the date of original
installation. The company also warrants that no other part of this water heater will fail due to
a defect in material or workmanship for one (1) year.
Oil-Fired BCS
Oil-Fired BCS
3450 RPM
Lift
3⁄8"
O.D. Tube
Inlet vacuum must not exceed 6 inHG
on a one-pipe system
LIMITED WARRANTY
Page 10
Two-pipe System with
Single-Stage pump*
One-pipe System
0'
1'
2'
3'
4'
5'
6'
7'
8'
9'
10'
11'
12'
13'
14'
O.D. Tube
84'
78'
73'
68'
63'
57'
52'
47'
42'
36'
31'
26'
21'
—
—
1⁄2"
Two-pipe System with
Two-Stage pump**
3450 RPM
Lift
O.D. Tube
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
83'
62'
41'
3⁄8"
O.D. Tube
1⁄2"
0'
93'
2'
85'
4'
77'
6'
69'
8'
60'
10'
52'
12'
44'
14'
36'
16'
27'
—
18'
*Suntec A Series pumps
**Suntec B Series pumps
O.D. Tube
100'
100'
100'
100'
100'
100'
100'
100'
100'
76'
Inlet vacuum must not exceed 6 inHG
on a one-pipe system. On a two-pipe
system, inlet vacuum must be less than
12 inHG for “A” model pumps and
17 inHG for “B” model pumps.
Page 7
MEASURING THE OUTCOMING WATER TEMPERATURE, CON’T
PLACE WATER SYSTEM IN OPERATION
1. Fill the tank with water, opening a hot water faucet to allow trapped air to escape from the
heater. Open the cold water inlet valves. Shut off each faucet as it delivers water that is free
of air. Inspect for leaks. Never operate an empty or partially full heater.
Date
Time
Person running test
Set temp °F
Outlet temp °F
2. Be sure the oil tank is filled with #1 or #2 heating oil. Loosen the ignitor hold down screw
and swing the ignitor back open on the hinge. Rotate the blower wheel a few times to
loosen the pump shaft. Swing the ignitor closed and fasten.
3. Bleed air from the oil line by opening the bleed valve on the fuel pump. Attach a small
plastic tube to the bleed valve fitting on the pump and run to a gallon container. Turn on
the electricity and set the thermostat so the burner motor runs. The heater will not ignite
when the bleed valve is open. Bleed the line until the oil is completely clear, not milky or
opaque. The oil must be transparent and free of air bubbles and froth. To keep the burner
control from locking out while bleeding the pump, attach a jumper between the flame
detector terminals after starting the burner. Remove the jumper when finished. Shut the
bleed valve and the burner will ignite. Remove the plastic tubing. Set the pump pressure to
100 PSI.
4. Adjust the burner combustion air in accordance with the burner manufacturer’s instructions. Using combustion instruments, check the CO2 and smoke. The CO2 should be at least
101⁄2% with 0-to-trace smoke on the Bacharach scale (see burner installation manual.) No
draft adjustment is required. Your Bock BCS water heater will operate under draft or low
positive pressure depending on installation.
5. While the burner is operating, disconnect one of the yellow cad cell wires. Check to see
that the burner control locks out in the time specified on the control. Reattach the wire
and reset the control. The burner should restart. Note: You may have to wait a minute
before resetting the control.
WARNING: Hydrogen gas can be produced in a hot water system served by
a heater that has not been used for a long period of time (generally two
weeks or more). Hydrogen gas is extremely flammable. To reduce the risk
of injury, open the hot water faucet at the highest location in the house for several
minutes before using any electrical appliance connected to the
hot water system. If hydrogen is present, there may be an unusual sound
similar to air escaping through the pipe as the water begins to flow. Do
not smoke or allow an open flame near the faucet at the time it is open.
MAINTENANCE
Annual service of the BCS is suggested and biannual service is recommended. For
burner maintenance, follow the manufacturer’s instructions supplied with the burner.
1. Install a new burner nozzle of the correct rate and angle.
2. Clean and adjust the electrodes and inspect for cracks in the porcelain. Check for corrosion on the buss bars and ignitor terminals.
3. Change the fuel oil filter and have the oil tank checked for sediment. Clean the tank, if
necessary.
INSPECT THE INSTALLATION AND ADJUST THE CONTROLS
The thermostat has been adjusted to 120°F at the factory. Wait until thermostat has shut off
fuel to the burner. Wait 30 seconds following shut-off of fuel, then set thermostat to the highest temperature. The burner should relight. Set thermostat to the lowest temperature; the
burner should go out. The thermostat should be adjusted to the minimum setting that will
meet the hot water needs of the homeowner or commercial application.
CAUTION: There is a scald potential if the thermostat is set too high. The recommended
temperature setting for normal residential use is 120°F. If higher temperature settings
are needed for combined appliance applications or commercial use, an automatic
tempering valve must be installed on all domestic hot water lines. Should overheating
occur, or the fuel supply fail to shut off, turn off the electricity to the water heater.
MEASURING THE OUTCOMING WATER TEMPERATURE
The thermostat is factory set at 120°F for residential use. (See the caution above regarding temperature variations.) It is the responsibility of the homeowner and installer to verify that the
installer follows the recommended quantitative testing for measuring the out-coming water
temperature. To make sure that the system works properly after installation and in the future,
it is recommended that the heater’s performance be measured and monitored. Run water out
of the tap nearest the heater until it comes out warm. Using a calibrated thermometer, take a
measurement. If the water is not at a suitable temperature for the installation, have a qualified
service person adjust the aquastat. Contact Bock for further information if needed.
4. The system should be checked with combustion instruments for safe and efficient
operation.
5. Keep the oil tank full to prevent water vapor from collecting (especially during the
summer).
6. Regularly check the Balanced Flue for obstructions such as hornets’ nests. The end caps
are removable for cleaning. Check the inlet and outlet tubes for any blockage and make
sure the joints are sealed.
7. EVERY SIX TO 12 MONTHS: Drain the heater tank and inspect for sediment or lime accumulation. Flush if necessary. If lime has accumulated, remove with a commercial compound. Check your water softening equipment if lime is found. DO NOT ATTEMPT TO
HEAT HARD WATER. (See maintenance label on heater.)
8. Change the magnesium anode rods every six to 12 months or when they are
reduced to 3⁄8" diameter. (See maintenance label on heater.) It is recommended that
your installer use PermaBond LH-050. Teflon tape should not be used when installing
magnesium or aluminum anode rods.
9. Open the relief valve test lever to flush out. Make sure it reseats itself.
10. If the heater is shut off in cold weather, drain the tank to prevent freezing.
This log (or a similar one) should be filled out as follows:
Page 8
Oil-Fired BCS
Oil-Fired BCS
Page 9
MEASURING THE OUTCOMING WATER TEMPERATURE, CON’T
PLACE WATER SYSTEM IN OPERATION
1. Fill the tank with water, opening a hot water faucet to allow trapped air to escape from the
heater. Open the cold water inlet valves. Shut off each faucet as it delivers water that is free
of air. Inspect for leaks. Never operate an empty or partially full heater.
Date
Time
Person running test
Set temp °F
Outlet temp °F
2. Be sure the oil tank is filled with #1 or #2 heating oil. Loosen the ignitor hold down screw
and swing the ignitor back open on the hinge. Rotate the blower wheel a few times to
loosen the pump shaft. Swing the ignitor closed and fasten.
3. Bleed air from the oil line by opening the bleed valve on the fuel pump. Attach a small
plastic tube to the bleed valve fitting on the pump and run to a gallon container. Turn on
the electricity and set the thermostat so the burner motor runs. The heater will not ignite
when the bleed valve is open. Bleed the line until the oil is completely clear, not milky or
opaque. The oil must be transparent and free of air bubbles and froth. To keep the burner
control from locking out while bleeding the pump, attach a jumper between the flame
detector terminals after starting the burner. Remove the jumper when finished. Shut the
bleed valve and the burner will ignite. Remove the plastic tubing. Set the pump pressure to
100 PSI.
4. Adjust the burner combustion air in accordance with the burner manufacturer’s instructions. Using combustion instruments, check the CO2 and smoke. The CO2 should be at least
101⁄2% with 0-to-trace smoke on the Bacharach scale (see burner installation manual.) No
draft adjustment is required. Your Bock BCS water heater will operate under draft or low
positive pressure depending on installation.
5. While the burner is operating, disconnect one of the yellow cad cell wires. Check to see
that the burner control locks out in the time specified on the control. Reattach the wire
and reset the control. The burner should restart. Note: You may have to wait a minute
before resetting the control.
WARNING: Hydrogen gas can be produced in a hot water system served by
a heater that has not been used for a long period of time (generally two
weeks or more). Hydrogen gas is extremely flammable. To reduce the risk
of injury, open the hot water faucet at the highest location in the house for several
minutes before using any electrical appliance connected to the
hot water system. If hydrogen is present, there may be an unusual sound
similar to air escaping through the pipe as the water begins to flow. Do
not smoke or allow an open flame near the faucet at the time it is open.
MAINTENANCE
Annual service of the BCS is suggested and biannual service is recommended. For
burner maintenance, follow the manufacturer’s instructions supplied with the burner.
1. Install a new burner nozzle of the correct rate and angle.
2. Clean and adjust the electrodes and inspect for cracks in the porcelain. Check for corrosion on the buss bars and ignitor terminals.
3. Change the fuel oil filter and have the oil tank checked for sediment. Clean the tank, if
necessary.
INSPECT THE INSTALLATION AND ADJUST THE CONTROLS
The thermostat has been adjusted to 120°F at the factory. Wait until thermostat has shut off
fuel to the burner. Wait 30 seconds following shut-off of fuel, then set thermostat to the highest temperature. The burner should relight. Set thermostat to the lowest temperature; the
burner should go out. The thermostat should be adjusted to the minimum setting that will
meet the hot water needs of the homeowner or commercial application.
CAUTION: There is a scald potential if the thermostat is set too high. The recommended
temperature setting for normal residential use is 120°F. If higher temperature settings
are needed for combined appliance applications or commercial use, an automatic
tempering valve must be installed on all domestic hot water lines. Should overheating
occur, or the fuel supply fail to shut off, turn off the electricity to the water heater.
MEASURING THE OUTCOMING WATER TEMPERATURE
The thermostat is factory set at 120°F for residential use. (See the caution above regarding temperature variations.) It is the responsibility of the homeowner and installer to verify that the
installer follows the recommended quantitative testing for measuring the out-coming water
temperature. To make sure that the system works properly after installation and in the future,
it is recommended that the heater’s performance be measured and monitored. Run water out
of the tap nearest the heater until it comes out warm. Using a calibrated thermometer, take a
measurement. If the water is not at a suitable temperature for the installation, have a qualified
service person adjust the aquastat. Contact Bock for further information if needed.
4. The system should be checked with combustion instruments for safe and efficient
operation.
5. Keep the oil tank full to prevent water vapor from collecting (especially during the
summer).
6. Regularly check the Balanced Flue for obstructions such as hornets’ nests. The end caps
are removable for cleaning. Check the inlet and outlet tubes for any blockage and make
sure the joints are sealed.
7. EVERY SIX TO 12 MONTHS: Drain the heater tank and inspect for sediment or lime accumulation. Flush if necessary. If lime has accumulated, remove with a commercial compound. Check your water softening equipment if lime is found. DO NOT ATTEMPT TO
HEAT HARD WATER. (See maintenance label on heater.)
8. Change the magnesium anode rods every six to 12 months or when they are
reduced to 3⁄8" diameter. (See maintenance label on heater.) It is recommended that
your installer use PermaBond LH-050. Teflon tape should not be used when installing
magnesium or aluminum anode rods.
9. Open the relief valve test lever to flush out. Make sure it reseats itself.
10. If the heater is shut off in cold weather, drain the tank to prevent freezing.
This log (or a similar one) should be filled out as follows:
Page 8
Oil-Fired BCS
Oil-Fired BCS
Page 9
SERVICE
CONNECT THE OIL LINE
1. Check the fuel supply, electrical wiring, fuses, and make sure the temperature control is
calling for heat.
2. If the motor runs but there is no flame, remove the electrode assembly, clean, readjust, and
check the porcelain for cracks. Replace if necessary. Check the ignitor to see if it is producing a spark. (Use extreme caution—the ignitor has 14,000 volt output.) Make sure the
coupling between the motor and pump shaft is not slipping. Check the set screw on the
blower wheel for tightness. Clean or replace the nozzle with the correct size and spray
angle.
3. Bleed the pump and check for clear, air-free oil. If oil is milky or frothy, check the line for
air leaks at fittings. Tighten all fittings again. Check filter gaskets and make sure the cartridge is clean.
4. If the burner motor fails to start, reset the control and check for voltage on the burner lead.
If no voltage, replace control. If there is power to the motor connect a pig tail and 100 watt
bulb to the capacitor leads. If the motor starts, replace the capacitor. If not, check for thermal lock out. Note: The BCS burner is equipped with a split capacitor motor containing an
automatic reset thermal cut-out. If the motor cuts out because of overheating, it will reset
when the motor cools. Make certain that air can flow freely around burner. If motor locks
out repeatedly, check capacitor and the fuel pump turning torque before replacing motor.
5. If the burner ignites, runs for a short time (10–20 seconds), and then goes out on safety,
replace the flame detector. If the burner still runs only a short time, replace the control.
6. If you smell oil or combustion products, remove and clean the electrode assembly, readjust
combustion settings, and insure that the joints on the flue connections are sealed (see “Exhuast Vent” and “Fresh Air Intake Vent” installation, page 6).
Gravity System: The oil burner is normally equipped with a single-stage pump equipped
for one line (gravity) flow. Use 3⁄8" O.D. or larger soft copper tubing and attach with flared
fittings. DO NOT USE COMPRESSION FITTINGS. Install the shut off valve and oil filter in the
oil line. Follow instructions from the pump manufacturer (attached to pump).
Lift System: Run a two-line system (suction and return lines) for lifts over 8 feet. Install a
bypass plug if required according to the instructions attached to the pump. (Plug is in bag
with instruction sheet.) The burner may be ordered with a two-stage pump for high lifts or
longer runs.
WARNING!!! When you install the bypass plug you MUST run a two-line system!
For any horizontal run or lift that exceeds the maximum length specified in the chart below,
a booster pump must be used. Booster pumps may be obtained from Sun Tec Hydraulics, Rockford, Illinois. Booster pumps must be installed as close to the oil supply tank as possible. Suction and return lines should be the same diameter and both go within 6" of the bottom of the
tank. The return line should stop slightly above the suction line. Use a minimum of fittings.
Make tubing bends with as large a radius as possible. DO NOT USE COMPRESSION FITTINGS.
Use caution in the final connection to the burner. Do not put strain on the fuel unit. Before
attaching tubing to the burner, form a coil in the tubing to minimize any vibration. Bury oil
lines in the floor for quiet operation, making sure there are NO CONNECTIONS OR FITTINGS
UNDER THE FLOOR.
MAXIMUM LIFT AND HORIZONTAL RUN (Refer to pump manufacturer’s instructions)
Maximum Lift & Horizontal Run for Oil Units
7. The internal high limit located in the thermostat will break the circuit to the burner if
water overheating occurs. When this happens, the burner will not go into post purge or
may stop post purge prematurely. Replace the thermostat, if necessary.
If any other service problems arise, you may obtain more information by contacting your
installer or nearest Bock distributor; or write, call, or fax:
Bock Water Heaters, Inc. • 110 South Dickinson Street • Madison, WI 53703
Telephone 608-257-2225 • Fax 608-257-5304
Horizontal Run
Lift
3⁄8"
0'
4'
7'
8'
O.D. Tube
65'
45'
31'
16'
1⁄2"
100'
100'
100'
64'
This warranty covers “Bock” water heater models 32E-BCS, 40E-BCS, 51E-BCS, 120E-BCS and
190E-BCS. Bock Water Heaters, a division of Bock Corporation—a Wisconsin corporation—at
110 S. Dickinson Street, Madison, Wisconsin 53703 (“Company”), warrants to the owner, the
tank of this water heater will not leak due to defective materials or workmanship for FIVE (5)
years from the date of original installation. If the water heater is installed in other than a
single family dwelling, this warranty is limited to THREE (3) years from the date of original
installation. The company also warrants that no other part of this water heater will fail due to
a defect in material or workmanship for one (1) year.
Oil-Fired BCS
Oil-Fired BCS
3450 RPM
Lift
3⁄8"
O.D. Tube
Inlet vacuum must not exceed 6 inHG
on a one-pipe system
LIMITED WARRANTY
Page 10
Two-pipe System with
Single-Stage pump*
One-pipe System
0'
1'
2'
3'
4'
5'
6'
7'
8'
9'
10'
11'
12'
13'
14'
O.D. Tube
84'
78'
73'
68'
63'
57'
52'
47'
42'
36'
31'
26'
21'
—
—
1⁄2"
Two-pipe System with
Two-Stage pump**
3450 RPM
Lift
O.D. Tube
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
83'
62'
41'
3⁄8"
O.D. Tube
1⁄2"
0'
93'
2'
85'
4'
77'
6'
69'
8'
60'
10'
52'
12'
44'
14'
36'
16'
27'
—
18'
*Suntec A Series pumps
**Suntec B Series pumps
O.D. Tube
100'
100'
100'
100'
100'
100'
100'
100'
100'
76'
Inlet vacuum must not exceed 6 inHG
on a one-pipe system. On a two-pipe
system, inlet vacuum must be less than
12 inHG for “A” model pumps and
17 inHG for “B” model pumps.
Page 7
COMPANY’S RESPONSIBILITY
FRESH AIR INTAKE VENT
Proper sealing of the fresh air intake vent material is important, but temperature is not an
issue. Failure to properly seal the inlet venting subjects the burner to possible reverse drafts
after burner shutdown—a hazardous condition with the possibility of creating a fire.
Use only solid or flexible metal duct, rigid plastic, or similar material of 4" diameter. Note: Do
not use flexible plastic dryer vent hose. Avoid tight turns with flexible ducting and limit
length. If using solid ducting, use a maximum of two elbows and 15' horizontal length. One
additional elbow may be used if horizontal distance from the BCS outlet to the heater is reduced three feet.
BURNER
The BCS burner is a custom burner equipped with an outside fresh air receiver, nozzle preheater, fuel oil solenoid valve and a custom electronic primary control having a 15-minute
post-purge timer. Do not use burner controls with shorter post-purge times as burner damage
may result.
MOUNT THE OIL BURNER
An aquastat with immersion well is packed with the burner. The thermostat is factory set at
120°F for residential use. The maximum setting for 32, 40, and 51E-BCS models is 160°F; for 120
and 190E-BCS models the maximum setting is 180°F. The adjustable differential on 120E-BCS
models is shipped at 15°. Lower differentials can be used for water temperatures under 160°F.
(See the caution on page 2 regarding temperature variations.) Install the immersion well with
the aquastat and verify that the sensing bulb may be fully inserted into the well. (Refer to
“Controls” section on page 10.)
Remove the cardboard core from the burner opening in the water heater. Mount the burner on
stud bolts, making sure to place the supplied gasket between the burner flange and heater.
Secure the burner to the heater with the 1⁄4-20 nuts or 3⁄8" @ 16 cap screws supplied.
The company’s responsibility is to repair or replace, at our option, with the prevailing comparable Bock model, any part of the equipment, including the tank, sold by the company which
proves to be defective in material or workmanship during the warranty period, when installed
in accordance with applicable codes and ordinances, and operated and maintained in accordance with our instructions, subject to the conditions and exceptions indicated below. Our liability, in the event of leakage or other malfunction, is strictly limited to repair or replacement
of the defective heater or part, as provided herein. We are not responsible hereunder for incidental property damage or personal injury, consequential costs or damage. Equipment that is
repaired or replaced will carry the unexpired portion of the original equipment warranty.
BURNER AND CONTROLS
Any burner and/or controls used on a Bock water heater other than the ones recommended by
Bock Water Heaters, and listed by Underwriters Laboratories, Inc., will void the water
heater warranty. Bock Water Heaters specifies burners and controls on the basis of safety, reliability and performance. Only the following burners and controls have been tested and approved by Bock Water Heaters and Underwriters Laboratories, Inc., to meet the stringent
standards required by both: 32E-BCS: Carlin 0.75 x 70A; 40E-BCS: Carlin 0.85 x 70A;
51E-BCS and 120E-BCS: Carlin 1.1 x 70A; 190E-BCS: Carlin 1.35 x 70B.
The only controls acceptable for use with these models are as follows:
For normal household applications:
Burner: Carlin EZ1 with 15-minute post-purge and nozzle heater.
Temperature Control (aquastat): 32, 40, 51E-BCS—Carlin EZ-Temp 90000B
120E-BCS—Carlin EZ-Temp 90000C
190E-BCS—Carlin EZ-Temp 90300B
OWNER’S RESPONSIBILITY
CONNECT THE ELECTRICITY
REFER TO BURNER WIRE DIAGRAM (page 4). All wiring must comply with applicable codes
and ordinances. The primary relay and aquastat are wired to the burner at the factory. Install
the aquastat well in the 3⁄4" tapping at the front of the heater. Be sure the sensing bulb is all
the way in. Tighten the aquastat retaining screws to secure the control to the well. Connect
the power supply to the aquastat, being sure to run through a fused disconnect switch (to be
attached to heater in the field).
At the company’s request, the owner is to return to the factory at Madison, WI, any part, including the tank, defective in material or workmanship, and pay all transportation charges for
such return parts and for replacement parts sent from the factory to the owner. The owner will
pay all labor charges for the removal and installation of such parts, including the tank. Any
replacement water heater furnished under this warranty shall remain in warranty only for the
unexpired portion of the original warranty. The owner will have annual inspections of the
anode rods. Bock Water Heaters requires paid receipts to show maintenance of anodes on glass
lined tank claims.
EXCEPTIONS
This warranty will not apply to tanks or parts subject to misuse, abuse, neglect, alteration,
accident, excessive temperature, excessive pressure, lime, silt or sediment accumulation,
corrosive atmosphere, the removal of the magnesium anode rods, noise, odor, rusty water,
the installation of an insulation blanket, installation outside of the United States (excluding
Canada), or on which the serial numbers have been altered. The warranty also does not apply
when the water heater is installed without a new temperature and pressure relief valve and is
not installed in accordance with local codes and ordinances.
Page 6
Oil-Fired BCS
Oil-Fired BCS
Page 11
OUR TOTAL WARRANTY COMMITMENT
CONNECT WATER PIPING
We will not assume, nor authorize any person to assume for us, any other liability in connection with the sale or operation of Bock Water Heaters. Any implied warranties, including merchantability or fitness for a particular application, imposed on the sale of this heater under
laws of the state of sale are limited to one year. Some states do not allow limitations on how
long an implied warranty lasts, or for the exclusion of incidental or consequential damages, so
the above limitations or exclusions may not apply to you. This warranty gives you specific
legal rights, and you may also have other rights which vary from state to state.
Be careful not to apply any heat to the water heater nipples. Install dielectric unions and shut
off valves on both hot and cold water lines.
40 BCS models are equipped with a brass inlet bushing installed in the tank. Heaters equipped with this bushing are
marked next to the inlet by the decal shown on the left.
The purpose of this bushing is to help keep the tank bottom free of sediment by aiding tank flushing. This bushing must be located as shown on the decal to function
properly. Do not allow the bushing to rotate out of position when tightening the inlet fittings.
WARRANTY REGISTRATION CARD
The attached warranty registration card should be returned within 30 (thirty) days of the date
of installation, otherwise the date of manufacture will be recorded as the date of installation
for the purpose of this warranty.
An approved pressure and temperature relief valve is factory installed in the opening provided
in the upper right-hand side of the water heater. Pipe the T&P to within 6" of the floor or to a
floor drain with a free flowing drain pipe.
CAUTION: Scalding injury and/or water damage can occur from either the manual
lifting of the lever or the normal operation of the T&P valve if it is not piped to a proper
drain. If the valve fails to flow water or reseat, call your plumber.
TO MAKE A CLAIM
Contact your nearest Bock distributor or:
Bock Water Heaters, Inc. • 110 South Dickinson Street • Madison, WI 53703
Telephone 608-257-2225 • Fax 608-257-5304
www.bockwaterheaters.com
Check incoming water line for backflow preventers or water pressure reducing valves, as these
may cause pressure to build up in the water heater and result in tank failure. If this water
heater is installed in a closed system or if backflow preventers and pressure regulators are
installed, a properly sized expansion tank must be installed.
Note: Do not try to heat hard water as this will drastically reduce heater life. Install a water
softener if the water heater is being installed in a hard water area (water hardness higher than
seven grains).
EXHAUST VENT
Where clearances to combustibles are a concern use double wall venting. Venting approved for Category III applicances is ideal but not required, single wall venting may be used
if allowed by local code. Caution: Do not use B-vent. The vent connector from the heater to
the rear of the Balanced Flue should be made using galvanized or stainless (preferred) vent material with a 4'' minimum diameter. A 6" × 4" reducer is placed on top of the heater flue. Note:
For 190E-BCS, a 6" vent pipe is preferred. Use one elbow to connect the heater to the venting.
An additional elbow may be used if the maximum horizontal distance from the BCS outlet to
the heater is reduced three feet. Maximum horizontal distance is 15 feet.
Venting from the heater to the Balanced Flue should be sealed but does not have to be pressure
tight. High temperature stainless sealing tape (2" wide) or high temperature (+500°F) RTV silicon sealants are recommended. Make certain the flue connector is removable for servicing.
Page 12
Oil-Fired BCS
Oil-Fired BCS
Page 5
1. Cut a 7" O.D. opening in the preferred wall and provide a minimum of 1⁄2" clearance
of non-combustible space around the Balanced Flue. The opening should allow for a
1⁄2" downward pitch to the outside for drainage of any condensate in the Balanced Flue.
2. Insert the Balanced Flue from the
inside through the wall. Check the
outside extension to be sure air inlet
holes are exposed and will not be
covered by the flashing ring. Fasten
the assembly to the inside wall with
the tabs provided (see installation
detail drawing). On the outside
wall, install the flashing ring provided. Caulk around the outer and
inner rim of the flashing ring to
prevent moisture from entering
through the wall.
BOCK OIL-FIRED WATER HEATER
2 Mounting Tabs:
Attach to vent with
4 metal screws
supplied.
Bock Tank Assembly Parts List
When ordering repair parts, always give
the part name, model number, size and
serial number.
ITEM DESCRIPTION
1. Cold Water Inlet Dip Tube
2. Plastic Cap
3. Magnesium Rod
Installation Detail
4. Top Pan
Attach vent to
building structure
with 4 appropriate screws.
(customer supplied)
5. Hot Out Nipple 3⁄4"
6. Tank
7. Heater Jacket
8. Temperature & Pressure Relief Valve
9. Immersion Well & Aquastat
WATER HEATER PLACEMENT
10. Drain Valve
11. Burner Mounting Bracket (part of jacket
assembly—32, 40, 51, BCS)
NOTE: Locate the heater so it is not subject to physical
damage from moving vehicles or flooding.
12. Mounting Bracket Gasket
DO NOT INSTALL THE WATER HEATER ON COMBUSTIBLE FLOORING. Place on noncombustible
flooring and maintain clearances prescribed by this
manufacturer and per code NFPA 31. If the water heater
must be located on combustible flooring it should be
raised off the floor with a layer of 4" concrete block laid
so the air holes are aligned as shown in the drawing at
left. Please contact Bock Water Heaters or consult NFPA
31 with questions concerning proper flooring materials.
Leave adequate room for periodic maintenance of
heater and burner. The heater should be placed as near to the Balanced Flue as convenient in
order to keep vent connector length to a minimum, with a maximum horizontal run length of
15 feet.
13. Bottom Pan
14. Combustion Chamber Sleeve
15. Combustion Chamber
16. Sight Glass
17. Inspection Door
18. Not Used
19. Burner
20. Primary Relay
21. Cad Cell
Minimum clearance to combustible construction is: SIDES 6"; BACK 6"; FRONT 24". The installation
of this water heater must conform with local codes and ordinances. In the absence of local
codes, the installation must comply with the National Fire Protection Association (NFPA 31) Code.
Page 4
Oil-Fired BCS
Oil-Fired BCS
Page 13
WHEN YOU RECEIVE YOUR NEW WATER HEATER
Check the new equipment to see if all components are in good condition and were not
damaged in shipment. The water heater and burner may be shipped as separate units. The
aquastat and immersion well are packed with the burner. If damage is observed or parts
appear to be missing, contact your wholesaler.
WHEN THE WATER HEATER IS USED IN A COMBINED APPLIANCE APPLICATION, PLEASE CONTACT
YOUR LOCAL DISTRIBUTOR OR THE FACTORY FOR INSTALLATION INSTRUCTIONS ON “SYSTEM PLUS”.
FLUE OUTLET PLACEMENT AND INSTALLATION
Flue outlet placement is of utmost importance for maximizing the performance of your Bock
Balanced Combustion System (BCS). Please see page 13 for unit dimensions. The following
instructions are recommended and may be code mandated for BCS installation:
n The wall opposite to prevailing winds
(east or south wall, if prevailing winter
winds are typically out of the west or
north) is the preferred wall for installation. This reduces the likelihood that
the Balanced Flue™ application will be
operating against high winds and
severe cold when it is cycling the
most often.
n The flue outlet must be placed at least
one (1) foot above the highest anticipated snow load to prevent flue
blockage.
n Use a flat wall for the flue outlet and
stay a minimum of three feet from corners or any structure to reduce eddy
currents.
n The flue outlet should be located even
with or above the top of the water
heater and in a location requiring the
fewest inlet and outlet elbows possible.
n To reduce frosting effects, place the outlet as far as possible from windows,
doors and other structural openings
such as eave vents—four feet is the recommended minimum.
n A minimum distance of three feet from
the outlet to plants and shrubs is suggested; a greater distance is preferred, as
moisture and frost effects can result in
damage or loss.
n The Balanced Flue should be located
away from high traffic areas to prevent
damage to wall outlet and human contact with the hot exhaust surfaces.
Page 14
Oil-Fired BCS
Oil-Fired BCS
Page 3
HOT OUTLET
COLD INLET
D
IF ANY OF THESE DEVICES ARE USED,
A PROPERLY SIZED EXPANSION TANK
MUST BE INSTALLED.
C
HIGH LIMIT 120, 190
(OPTIONAL)
AVERAGER (190 ONLY)
HOT OUTLET
C
AUXILIARY OUTLET
(COMBINED APPLIANCE)
32, 51
EXPANSION TANK
AQUASTAT
AUXILIARY OUTLET
(COMBINED APPLIANCE)
B
A
RETURN
120, 190
B
A
D
AQUASTAT
RETURN
32, 51
COLD INLET
E
RETURN
E
40E-BCS
32, 51, 120, 190E-BCS
OIL-FIRED BCS
We
i
(inc ght (
lb
. bu
rne s.)
r&
con
trol
s)
System Plus is a combined appliance (space and water heating) based on a Bock highefficiency water heater and an air handler (available from various manufacturers) to heat the
entire home.
System Plus replaces the traditional furnace, cuts heat loss, and:
n Combines both primary space- and water heating
n Significantly lowers monthly fuel bills
n Creates an even temperature range—won’t dry out room air
32E-BCS
32
104
.75
3⁄4''
3⁄4''
1''
90°
114
51''
20''
6'' 11''
17'' 120/60
312
n Utilizes existing ductwork
40E-BCS
40
126
.9
3⁄4''
3⁄4''
1''
90°
136
61''
20''
6'' 54''
18'' 120/60
344
n Provides easy access for service
51E-BCS
50
152
1.1
1''
1''
1''
90°
161
59''
24''
6'' 11''
18'' 120/60
370
n Features low maintenance
120E-BCS
113 155
1.1
1''
2''
2''
90°
163
67'' 311⁄2'' 6'' 19''
22'' 120/60
751
n Extends the life of the water heater
190E-BCS
113 190 1.35
1''
2''
2''
90°
199
67'' 311⁄2'' 6'' 19''
22'' 120/60
751
n Reduces equipment costs for new construction projects—no chimney is needed for the
air handler
E
B
D
BCS AND SYSTEM PLUS™
A
C
Dimensions
Vol
tag
e (V
/Hz
)
PH)
Tem
per
atu
re R
ise
Rec
(F)
ove
ry (
G
hou
san
d
s)
Firi
ng
Rat
e (G
PH)
Col
d In
let
Hot
Out
let
Ret
urn
Sto
rag
eC
apa
city
(ga
BTU
l.)
H (T
Instruction Manual
n Generates more immediately-available hot water
n Accommodates central air
Page 2
Oil-Fired BCS
Oil-Fired BCS
Page 15
To the Installer:
.
To the Consumer:
Please attach these instructions
next to the water heater.
(OPTIONAL)
BACKFLOW
PREVENTER
Please read these and all component
instructions and keep for future reference.
OIL-FIRED BCS
Instruction Manual
EXPANSION TANK
Warranty, Registration Card and Parts List are included.
Homeowner: Please remember to return the Registration Card!
WARNING
Improper installation, adjustment, alteration,
service or maintenance can cause serious injury or property damage. Refer to this manual.
For assistance or additional information, consult a qualified installer or service agency.
WARNING
If the information in these instructions is not
followed exactly, a fire or explosion may result
causing property damage, personal injury or
death.
WARNING
Do not install on combustible flooring. Install
in accordance with all local codes. In the
absence of local codes, refer to NFPA 31 or
ANSI Z21.10.1.
CAUTION
The recommended temperature for normal
residential use is 120°F. The dial on the aquastat
does not always reflect the out-coming water
temperature and it could occasionally exceed
120°F. Variation in out-coming temperature
could be based on factors including but not
limited to usage patterns and type of installation. Test water at the tap nearest to the water
heater. (See page 8 for measuring the outcoming water temperature.)
BCS AND RADIANT HEAT
Radiant heating: An in-floor hot water space heating system
WARNING
A Bock high-efficiency water heater and zoned radiant heating—Bock&Radiant—make perfect
partners for cost-effective personal comfort that heats both space and water.
Hotter water increases the risk of scald injury.
Before adjusting the water temperature setting,
read this instruction manual. Temperatures at
which injury occurs vary with the person’s age
and the length of exposure. The slower reaction time of children, elderly or physically or
mentally challenged persons increases the
scalding hazard to them. It is recommended
that lower water temperatures be used where
these exposure hazards exist. Households with
small children or invalids may require a temperature setting less than 120°F to prevent accidental contact with hot water. To produce
less than 120°F, use point-of-use temperature limiting devices.
Bock&Radiant uses functional hot water and avoids boiler-type overheating that wastes energy.
Bock&Radiant eliminates using a boiler during warm months and lets ecomonic domestic hot
water work all year around.
Bock&Radiant maximizes Bock’s better heating efficiency as compared to a traditional boiler.
Bock&Radiant cuts overhead costs—simple water heater maintenance is much less expensive
than boiler maintenance.
Page 16
Oil-Fired BCS
Form # 23390
Rev 1
3/2006
If higher water temperature is needed in part
of the water system, automatic temperature
limiting devices must be used on all lines to
water taps.
WARNING
Flammable vapors may be drawn to this water
heater from other areas of the structure by air
currents. Do not store or use any flammable
liquids in the vicinity of this heater.
WARNING
Water heater blankets may restrict air flow to
the water heater and cause fire, asphyxiation,
personal injury or death.
THIS MANUAL HAS BEEN PREPARED
TO ACQUAINT YOU WITH THE INSTALLATION,
OPERATION, AND MAINTENANCE OF YOUR
WATER HEATER AND TO PROVIDE
IMPORTANT SAFETY INFORMATION.
Read all instructions thoroughly before attempting installation or operation of your
water heater. Keep these instructions for future
reference.
Local plumbing and electrical codes must be
followed in the installation of this water
heater. In the absence of a local code use the
UNIFORM PLUMBING CODE and the NFPA
Code. Local codes may supersede instructions
in this installation manual.
These instructions are a guide for the correct
installation of the water heater. The manufacturer will not be liable for damages caused by
failure to comply with the installation and
operating instructions outlined on the
following pages.
If you lack the necessary skills required or have
difficulty following the directions, seek help
from a qualified person for that part of the
installation you do not understand.
FAILURE TO FOLLOW THESE INSTRUCTIONS
OR ALL APPLICABLE BUILDING CODES
AND REGULATIONS VOIDS THE WARRANTY
ON THIS WATER HEATER.
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