CAC / BDP BW4RAH-126 Instruction manual

Oil---Fired Cast Iron
Hot Water Boilers
Sizes 140,000 through 280,000
BW4
BW5
Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
ama
TABLE OF CONTENTS
PAGE
ASME
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Explanation of Model Numbers and Rating Plate . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Locating the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fresh Air for combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Boilers with Tankless Heater Coil . . . . . . . . . . . . . . . . . . . . . 7
Installation System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chimney and Chimney Connection . . . . . . . . . . . . . . . . . . . 10
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Equipment and Optional Accessories . . . . . . . . . . . . . . . . . . 10
Filling Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATING BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
To Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel Units and Oil Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air Supply for Combustion . . . . . . . . . . . . . . . . . . . . . . . . . 13
Draft Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Final Burner Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Oil Burner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Checking and Adjusting Controls . . . . . . . . . . . . . . . . . . . . 16
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Conventional Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . 16
Diaphragm Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . 16
Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tankless Coil (or Cover Plate Gasket) . . . . . . . . . . . . . . . . . 16
Oil Boiler/Burner Cleaning Instructions . . . . . . . . . . . . . . . . 17
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
®
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due
to oil 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. When working on
heating equipment, observe precautions in literature, on tags, and
on labels attached to or shipped with unit and other safety
precautions that may apply. Recognize safety information. This is
the safety--alert symbol . When you see this symbol on unit or in
instructions and manuals, be alert to potential for personal injury.
Understand the signal words DANGER, WARNING,
CAUTION, and NOTE. These words are used with the
safety--alert symbol. DANGER identifies the most serious
hazards which will result in severe personal injury or death.
WARNING signifies hazards which could result in personal
injury or death. CAUTION is used to identify unsafe practices
which may result in minor personal injury or product and
property damage. NOTE is used to highlight suggestions which
will result in enhanced installation, reliability, or operation. Read
and obey the following rules to ensure safe installation and
operation:
1. Read the Owner’s Manual carefully for safe operation.
Failure to follow the rules of safe operation and the
instructions can cause a
malfunction of the boiler and result in death, serious
bodily injury, and/or property damage.
2. Check local codes and utility requirements before
installation. The installation must be in accordance with
their directives, or follow NFPA 31–Installation of Oil
Burning Equipment, latest revision.
3. Before servicing, allow boiler to cool. Always shut off any
electricity and oil to boiler when working on it. This
prevents any electrical shocks or burns.
4. Inspect oil line and connections for leaks.
5. Be certain oil burner nozzle is size required. Overfiring
will result in early failure of boiler sections. This causes
dangerous operation.
6. Never vent this boiler into an enclosed space. Always vent
to the outside. Never vent to another room or inside a
building.
BW4 / BW5
A02217
Fig. 1 -- Model BW4/BW5
7. Be sure there is adequate air supply for complete
combustion.
8. Follow a regular service and maintenance schedule for
efficient and safe operation.
9. Keep boiler area clean and free from combustible
materials, gasoline, and other flammable vapors and
liquids.
10. Oil Burners are not do--it yourself items. This boiler must
be installed and serviced by qualified professionals using
combustion test instruments.
11. Be aware when piping the relief valve that if the system
pressure exceeds the safe limit of 30 pounds per square
inch, the relief valve will automatically lift open. Lifting of
the relief valve can discharge large quantities of steam and
hot water, which may damage the surroundings. Before
installing the relief valve read the manufacturer’s
instructions and maintenance section of the manual on
relief valves.
12. Installation and sizing of the expansion tank must consider
the heating systems total water volume, temperature, boiler
initial fill pressure, and system arrangement. An
improperly installed and sized expansion tank may result
in frequent lifting of the relief valve or other heating
system problems. For proper installation, sizing, and
maintenance of the expansion tank follow the guidelines
established by the boiler manufacturer and the expansion
tank manufacturer.
13. Expansion tank performance and life expectancy can be
hindered by overfilling the boiler. An initial fill pressure of
10.12 psig is recommended. For higher fill pressures the
expansion tank’s air charge will need to be increased to
match the fill pressure. Consult the manufacturer’s
guidelines for sizing and selection.
14. Purging the heating system of air and gases when first
putting the boiler into service is critical for proper
circulation and quiet performance. Once the air and gases
are purged, for boiler installations using float type vents,
the air vents should be closed for normal operation. If air
is heard or noticed by loss of heat, purge the system and
open the vents for a short period of time.
!
WARNING
FIRE, EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death and or property damage.
Use only number 1 or number 2 fuel oil having commercial
standard grade CS 12--48. Do not use gasoline, kerosene,
crankcase oil, or any oil containing gasoline.
!
WARNING
OPERATION AND WARRANTY HAZARD
Failure to follow this warning could result in personal
injury, death and or property damage.
This boiler has been designed for residential installations. If
used for commercial applications, all jurisdictional
requirements must be met. This may require wiring and/or
piping modifications. The manufacturer is not responsible
for any changes to original design.
2
GAGE
1 1Ú4 IN. SUPPLY
C
B
AQUASTAT
CONTROL
(WITHOUT COIL)
AQUASTAT
CONTROL
(WITH COIL)
TANKLESS
HEATER
1Ú2 IN. N.P.T.
1 1Ú4 IN.
RETURN
19 5Ú8″
3Ú IN.
4
ASME
RELIEF
VALVE
A
9″
FRONT
SIDE
REAR
A96152
Fig. 2 -- Dimensional Drawing (See Table 1 for additional information)
!
WARNING
!
FIRE, EXPLOSION HAZARD
WARNING
FIRE, EXPLOSION, ELECTRICAL,
MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury, death and or property damage
CARBON
Failure to follow this warning could result in property
damage, personal injury, or death.
DO NOT USE GASOLINE CRANKCASE DRAININGS
OR ANY OIL CONTAINING GASOLINE.
Improper installation, adjustment, alteration, service
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a
qualified installer, service agency, fuel oil supplier, or your
distributor or branch for information or assistance. The
qualified installer or agency must use only
factory--authorized and listed kits or accessories when
modifying this product.
INTRODUCTION
Check to be sure boiler size is correct before starting installation.
See rating and capacity table shown in Fig. 2 and Table 1a and
1b. Check rating plate on right side of boiler.
The boiler must be supplied with the proper oil, fresh air for
combustion, and a suitable electrical supply. Boiler must also be
connected to a suitable venting system and an adequate piping
system. Finally, a properly located thermostat is needed for
control of heating system. If there are any doubts as to the various
requirements, check with local authorities and obtain professional
help where needed. The Operating Boiler Instructions and Final
Checks and Adjustments sections later in this document are vital
to the proper and safe operation of the heating system. Take time
to be sure they are all done.
The following steps are all necessary for proper installation and
safe operation of boiler:
1. LOCATING THE BOILER
2. OIL SUPPLY AND PIPING
3. FRESH AIR FOR COMBUSTION
4. PIPING CONNECTIONS
5. CHIMNEY AND VENT PIPE CONNECTIONS
6. ELECTRICAL WIRING
7. THERMOSTAT LOCATION
8. CHECKING AND ADJUSTING
9. MAINTENANCE
Explanation of Model Numbers and Rating Plate
Each model number except for the BW4(5)RAH280ABAA has 3
possible firing rates depending on which nozzle or burner is
installed. The model number represents the burner installed in the
boiler and the largest possible input for the boiler. The
BW4(5)RAH280ABAA can only be fired at an input of 280,000
Btuh or 245,000 Btuh.
For example, a BW4BAH000140ABAA has a Beckett burner
and a maximum input of 140,000 Btuh. A BW4RAH000140 has
a Riello burner and a maximum input of 140,000 Btuh. The
rating plate for each model shows the three possible firing rates.
Boilers come shipped with the largest nozzle installed. By
changing nozzles, the BW4BAH000140ABAA firing rate can be
changed to 91,000 or 105,000 Btuh input.
For BW4BAH models equipped with Beckett burners:
The BW4BAH000280ABAA is shipped with 2 additional
nozzles to fire the Beckett burner at the alternate inputs listed on
the rating plate. The BW4BAH000210ABAA and
BW4BAH000140ABAA are shipped with one additional nozzle
each, to fire the Beckett burner at the next lowest inputs listed on
the rating plate. To fire the BW4BAH000210ABAA and
BW4BAH000140ABAA at the lowest inputs listed on the rating
plate, an accessory low--fire kit for each boiler, not included with
the boiler, is required. The low--fire kits include the alternate size
nozzle and the alternate burner end cone to fire the burners on
these models at the lowest inputs for those models.
3
BW4 / BW5
36″
For BW4RAH models equipped with Riello burners:
There are two different Riello burners used on the BW4RAH
boilers, the F--5 and F--10 burner. The BW4RAH000280AAAA
is shipped with 1 additional nozzles to fire the F--10 burner at the
next alternate lower input listed on the rating plate. The
BW4RAH000210AAAA and BW4RAH000140AAAA are
equipped with F--5 burners and shipped with two additional
nozzles to fire the boilers at the next lowest inputs listed on the
rating plate.
The BW5B and BW5R models are the same as the BW4B and
BW5B models, except the tankless water heater is factory
installed.
Refer to Tables 1a, 1b, and Table 7a,7b for additional oil burner
information. Refer to the boiler product data sheet for the correct
accessory low--fire kit.
1. The boiler must be level.
2. Use a raised base if floor can become wet or damp.
3. These boilers must have a non--combustible base if
installed on a combustible floor. Two inch concrete patio
blocks or a 2--in. Cladlite--pad may be used.
4. The vent pipe connection should be as short as possible.
5. Maintain clearances for fire safety as well as servicing.
Refer to Fig. 3 for minimum clearances. An 18--in.
clearance must be maintained at a side where passage is
required to access another side for cleaning, servicing,
inspection, or replacement of any parts that normally may
require such attention. Boilers must be installed at least
6--in. from combustible materials on all sides and above.
Allow at least 24--in. front clearance for servicing. Allow
at least 18--in. right--side clearance for servicing boilers
equipped with a tankless coil.
6. Fresh air for combustion must be available at front of
boiler. Fresh air for ventilation must be available to front
AND rear of boiler. Air passages must be free of
obstructions at all times. Ventilating and combustion air
must enter boiler room without restrictions.
7. Be sure installation is in accordance with the requirements
of local authorities having jurisdiction. Compliance with
these regulations is required. In the absence of local codes,
follow NFPA 31--Installation of Oil Burning Equipment.
BW4 / BW5
General Information
Boilers with the same number of sections are identical to each
other except for their firing rate and/or type of burner. The firing
rate is determined by the nozzle size used in the oil burner and the
oil pressure at the nozzle. For example, models BW4RAH091,
BW4RAH105, and BW4RAH140 are the same boiler, without a
tankless coil. They all have a Riello oil burner fired at a different
input rate. Models BW5RAH245 and BW4RAH280 are the same
boiler, with a tankless coil. They both have a Riello oil burner
fired at a different input rate.
1. Check to be sure you have selected the right size boiler
with the proper capacity. The I=B=R rating of the boiler
selected should be greater than or equal to the calculated
peak heating load (heat loss) for the building or area(s)
served by the boiler and associated hot water heating
systems. (See Fig. 2.) Any heat loss calculations used
should be based on approved methods.
2. Boiler must be supplied with the proper oil supply and oil
piping, sufficient fresh combustion air, and a suitable
electrical supply.
3. Boiler must be connected to a suitable venting system and
a piping system adequate to distribute the heating load.
4. A thermostat must be properly located and installed for
control of the heating system.
If there are any doubts as to the various requirements, check with
local authorities and obtain professional help where needed. The
Operation Instructions, Final Checks and Adjustments and
Maintenance sections in this manual are vital to the proper and
safe operation of the heating system. Take the time to be sure they
are all done.
Locating the Boiler
If boiler is part of a planned heating system, locate it as close as
possible to where it is shown on plan. If boiler is to be part of an
existing system, it is usually best to put it where the old one was.
If location is to be changed, additional materials as well as an
adequate base will be required. The following rules apply:
INSTALLATION
Installation Requirements
Refer to Fig. 4 for the basic requirements of a typical installation.
NOTE: Always keep manual fuel supply valve shut off if burner
is shut down for an extended period of time.
;;;;;
;;;;;
;;;;;
Fresh Air for Combustion
6″ MIN
24″ MIN
BOILER
FRONT
6″
6″ MIN
18″ WITH COIL
A95592
Fig. 3 -- Minimum Clearance Dimensions
4
CIRCULATING PUMP
IN SUPPLY LINES
ELECTRIC LINE
SERVICE LINE
AUTOMATIC
FILL VALVE
AND SHUTOFF
ENTRANCE
SWITCH
DIAPHRAGM
EXPANSION TANK
OVERCURRENT
PROTECTED
SAFETY SWITCH
VENT PIPE
MINIMUM 2 IN. ID
DRAFT
REGULATOR
VENT PIPE
LINES TO OTHER
APPLIANCES
RELIEF VALVE
TO OUTSIDE
SHUTOFF
VALVE
C
H
I
M
N
E
Y
BW4 / BW5
2 IN. FILL PIPE
TO RADIATION
OIL
TANK
FROM RADIATION
OIL BURNER
FOUNDATIONS
OIL
FILTER
OIL LINES
A02230
Fig. 4 -- General Principal Requirements for a Typical Installation
Table 1 – Boiler Ratings and Capacities
WITHOUT
TANKLESS
COIL
NO.
INPUT
SEC
*MBH
**HEATING
CAPACITY
*MBH
NET
I=B=R
RATING
*MBH
FIRING
RATE
GPH
DIMENSIONS --- IN
MIN.
A.F.U.E.
CHIMNEY
SIZE/HEIGHT
H
W
SHIPPING
D
WEIGHT
TANKLESS
HEATER
G.P.M.
3
91
80
70
0.65
#86.3
8” X8” X15’
14 1/2
6
8
460
N/A
3
105
92
80
0.75
#85.2
8” X8” X15’
14 1/2
6
8
460
N/A
3
140
119
103
1.00
83.4
8” X8” X15’
14 1/2
6
8
460
N/A
4
126
111
97
0.90
#86.0
8” X8” X15’
17 3/4
6
9 5/8
533
N/A
BW4BAH210
4
175
150
130
1.25
83.9
8” X8” X15’
17 3/4
6
9 5/8
533
N/A
BW4RAH210
4
210
178
155
1.50
82.4
8” X8” X15’
17 3/4
6
9 5/8
533
N/A
5
}168
147
128
1.20
#86.5
8” X8” X15’
21
6
11 1/2
620
N/A
BW4BAH280
5
245
209
182
1.75
83.6
8” X8” X15’
21
6
11 1/2
620
N/A
BW4RAH280
5
280
236
205
2.00
82.0
8” X8” X20’
21
6
11 1/2
620
N/A
Shaded areas are as shipped. Alternate inputs require a field---installed alternate oil nozzle supplied with base model.
* MBH = 1,000 BTU per hour/BTU=British Thermal Unit
** Heating Capacity is based on a 13 percent CO2 with a ---0.02 in. wc draft over fire and a #1 smoke or less. Testing was done in accordance with the D.O.E.
(Department
of Energy) test procedure.
+ GPH = Gallons per hour of oil at 140,000 BTU per gallon
++ A.F.U.E. = Annual Fuel Utilization Efficiency based upon D.O.E. test procedure
# As an Energy Star Partner, the manufacturer has determined that this product meets Energy Star guidelines for Energy Efficiency
# # Gallons of water per minute, heated from 40˚F to 140˚F, with 200˚F boiler water temperature, intermittent draw.
} The 168,000 Btuh input is only available with a Beckett burner.
BW4BAH140
BW4RAH140
5
Table 1 -- Boiler Ratings and Capacities (Cont.)
WITH TANK-
NO.
INPUT
LESS COIL
SEC
*MBH
**HEATING
CAPACITY
*MBH
NET
I=B=R
RATING
*MBH
FIRING
RATE
MIN.
DIMENSIONS--- IN
CHIMNEY
A.F.U.E
GPH
SIZE/HEIGHT
H
W
D
SHIPPING
WEIGHT
TANKLESS
HEATER
G.P.M.
3
91
80
70
0.65
#86.3
8” X8” X15’
14 1/2
6
8
470
2.90
3
105
92
80
0.75
#85.2
8” X8” X15’
14 1/2
6
8
470
3.00
3
140
119
103
1.00
83.4
8” X8” X15’
14 1/2
6
8
470
3.25
4
126
111
97
0.90
#86.0
8” X8” X15’
17 3/4
6
9 5/8
545
3.15
BW5BAH210
4
175
150
130
1.25
83.9
8” X8” X15’
17 3/4
6
9 5/8
545
3.50
BW5RAH210
4
210
178
155
1.50
82.4
8” X8” X15’
17 3/4
6
9 5/8
545
3.75
5
}168
147
128
1.20
#86.5
8” X8” X15’
21
6 11 1/2
620
N/A
BW5BAH280
5
245
209
182
1.75
83.6
8” X8” X15’
21
6 11 1/2
630
4.00
BW5RAH280
5
280
236
205
2.00
82.0
8” X8” X20’
21
6 11 1/2
630
4.25
Shaded areas are as shipped. Alternate inputs require a field---installed alternate oil nozzle supplied with base model.
* MBH = 1,000 BTU per hour/BTU=British Thermal Unit
** Heating Capacity is based on a 13 percent CO2 with a ---0.02 in. wc draft over fire and a #1 smoke or less. Testing was done in accordance with the D.O.E.
(Department
of Energy) test procedure.
+ GPH = Gallons per hour of oil at 140,000 BTU per gallon
++ A.F.U.E. = Annual Fuel Utilization Efficiency based upon D.O.E. test procedure
# As an Energy Star Partner, the manufacturer has determined that this product meets Energy Star guidelines for Energy Efficiency
# # Gallons of water per minute, heated from 40˚F to 140˚F, with 200˚F boiler water temperature, intermittent draw.
} The 168,000 Btuh input is only available with a Beckett burner.
BW5BAH140
BW4 / BW5
BW5RAH140
Table 2 – Fresh Air Duct for Tightly Sealed House
FRESH AIR DUCT SIZE (IN.)
1/4–IN. MESH SCREEN
WOOD LOUVERS
METAL LOUVERS
3---1/2 X 12
144,000
36,000
108,000
8X8
256,000
64,000
192,000
8X12
384,000
96,000
288,000
8X16
512,000
128,000
384,000
!
WARNING
!
WARNING
FIRE AND CARBON MONOXIDE POISONING
HAZARD
CARBON MONOXIDE POISONING AND UNIT
OPERATION HAZARD
Failure to follow this warning can cause personal injury or
death.
Failure to follow this warning could result in personal
injury, death and or property damage.
Be sure to provide enough fresh air for combustion.
Enough air ensures proper combustion and ASSURES
THAT NO HAZARD WILL DEVELOP DUE TO LACK
OF OXYGEN.
If a fireplace or a kitchen or bathroom exhaust fan is used,
an outside air intake should be installed. These devices rob
the boiler and water heater of combustion air.
!
A. Boiler Located in Unconfined Space
An unconfined space is defined as a space with volume not less
than 50 cu ft.. per 1000 Btuh of total input rating of all appliances
installed in that space.
If boiler is in an open area (unpartitioned basement) in a
conventional house, air that leaks through cracks around doors
and windows will usually be adequate to provide air for
combustion. The doors should not fit tightly. Cracks around
windows should not be caulked.
B. Boiler Located in Confined Space
ALL AIR FROM INSIDE BUILDING
The confined space shall be provided with 2 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 combustion
equipment installed in the combined space shall be considered in
making this determination. Each opening shall have a minimum
free area of 1 sq.. in. per 1000 Btuh of total input rating for all
combustion equipment in the confined space, but not less than
100 sq. in. One opening shall be within 12 in. of the top and 1
within 12 in. of the bottom of the enclosure. (See Fig. 5.)
WARNING
UNIT LIFE REDUCTION HAZARD
Failure to follow this warning could result in personal
injury, death and or property damage.
Air for combustion must not be contaminated by halogen
compounds, which include fluoride, chloride,bromide, and
iodide. These elements are found in aerosol sprays,
detergents, bleaches, cleaning solvents, salts, air fresheners,
and other household products.
Enough fresh air must be provided to assure proper combustion.
The fire in the boiler uses oxygen. It must have a continuous
supply. The air in a house contains only enough oxygen to supply
the burner for a short time. Outside air must enter the house to
replace that used by the burner. The exact fresh air requirements
depend on whether the boiler is located in an unconfined or
confined space.
6
area of 1 sq. in. per 2000 Btuh of total input rating of all
equipment in the enclosure.
4. When ducts are used, they shall be of the same
cross--sectional area as the free area of the openings to
which they connect. The minimum dimension of
rectangular air ducts shall not be less than 3--in.
VENTILATING
GRILLE
Boilers may be factory packaged with a tankless heater coil. The
use of this coil eliminates the need for a hot water storage tank.
Instantaneous heating of water in the coil provides a flow of hot
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 flows.
IMPORTANT:
Do not use a tankless coil if water is
excessively hard with lime or other deposits which will
accumulate inside coil.
C. Mounting Aquastat Control
The control configuration on this boiler has been set up so that
the Honeywell L8124C Combination Hi/Low Limit Aquastat
Relay mounts on the tankless coil. This maximizes tankless coil
performance by making the burner respond more quickly to a call
for domestic hot water. The boiler is completely wired according
to schematic wiring diagram. (See Fig. 14.) The installer must
mount the L8124C Aquastat on control well in 3/4--in. tapping
on tankless coil. (See Fig. 7.)
D. Tankless Coil Piping
COMBUSTION
AIR GRILLE
A95594
Fig. 5 -- Air Openings for Closet or Utility
Room Installations
FRESH AIR
DUCT
BOILER
IN
1⁄2 IN.
A95595
NPT
3⁄4 IN. NPT
CONTROL WELL
Fig. 6 -- Fresh Air Duct for Tightly Sealed House
Example: The boiler is rated at 100,000 Btuh. The water heater is
rated at 30,000 Btuh. The total is 130,000 Btuh. Two grilles are
needed, each with 130 sq. in. of FREE opening. Metal grilles
have about 60 percent FREE area. To find the louvered area
needed, multiply the FREE area required by 1.7 (130 X 1.7 =
221.0 sq. in. louvered area). In this example, 2 grilles each having
an 8 in. X 30 in. (240 sq. in.) louvered area would be used. Fig. 5
shows grille locations.
ALL AIR FROM OUTDOORS
The confined space shall be provided with 2 permanent openings,
1 commencing within 12--in. of the top and 1 commencing within
12--in. of the bottom of the enclosure. The openings shall
communicate directly, or by ducts, with the outdoors or spaces
(crawl or attic) that freely communicate with the outdoors.
1. When directly communicating with the outdoors, each
opening shall have a minimum free area of 1 sq. in. per
4000 Btuh of total input rating of all equipment in the
enclosure.
2. When communicating with the outdoors through vertical
ducts, each opening shall have a minimum free area of 1
sq. in. per 4000 Btuh of total input rating of all equipment
in the enclosure.
3. When communicating with the outdoors through
horizontal ducts, each opening shall have a minimum free
A95596
Fig. 7 -- Tankless Heater Coil
Piping is as shown in Fig. 8. A tempering valve (mixing valve) is
recommended. A flow restrictor may be required on tankless coil
inlet piping so that flow rates are matched to boiler heat input.
See Table 3.
7
BW4 / BW5
Boilers With Tankless Heater Coil
Table 3 – Boiler Rating Information
BOILER MODEL
BW4 / BW5
BURNER FIRING RATE
INPUT (MBH)
TANKLESS RATING (GPM)
BW4BAH091
BW4RAH091
BW5BAH091
BW5RAH091
0.65
91
2.90
BW4BAH105
BW4RAH105
BW5BAH105
BW5RAH105
0.75
105
3.00
BW4BAH140
BW4RAH140
BW5BAH140
BW5RAH140
1.00
140
3.25
BW4BAH126
BW4RAH126
BW5BAH126
BW5RAH126
0.90
126
3.15
BW4BAH175
BW4RAH175
BW5BAH175
BW5RAH175
1.25
175
3.50
BW4BAH210
BW5BAH210
1.50
210
3.75
BW4BAH245
BW4RAH245
BW5BAH245
BW5RAH245
1.75
245
4.00
BW4BAH280
BW4RAH280
BW5BAH280
BW5RAH280
2.00
280
4.25
* Gallon of water per minute heated from 40_ F to 140_
installed accessory on BW4 models.
UNTEMPERED
HOT WATER
(TO AUTOMATIC
DISHWASHER, ETC.)
F with 200_
F boiler water, intermittent draw. Tankless heater is factory installed on BW5 models, field
responsible for any water damage. Connect a drain line of
the same pipe size (3/4--in.) to carry any water away to a
drain.
3. Connect the 1 1/4--in. NPT supply and return lines to
boiler. Both supply and return lines should be piped to the
front section or both to the rear section. The boiler should
NOT be piped return line to the front, supply line to the
rear, or vice versa, as this will cause boiler water to short
circuit heat exchanger. The connections may require
certain additional fittings and parts as shown on diagrams.
(See Fig. 9, 10, and 11.)
If installing an entire new heating system, first install all radiation
units (panels, radiators, or cabinets) and supply and return mains,
then make connections to boiler.
In connecting cold water supply to reducing valve, make sure that
a clean water supply is available. When water supply is from a
well or pump, a sand stainer should be installed at pump.
When boiler is used in connection with refrigeration systems, it
shall be installed so that chilled medium is piped in parallel with
the heating boiler with appropriate valves to prevent chilled
medium from entering the heating boiler.
The minimum boiler supply water temperature setting on the
aquastat is 140_F. If the boiler is used in a heating system where
supply water temperatures below 140_F are desired, a suitable
method, such as, the use of bypass piping shown in the figure 10,
a 3 way or 4 way mixing valve, or some other means needs to be
used to ensure return water temperatures to the boiler are no less
than 120_F. When the boiler is operated with return water
temperatures less than 120_F, condensation may form in the
boiler and venting. This condensation is corrosive and can
eventually cause severe damage to the boiler and venting system.
Antifreeze added to boilers must be non--toxic and must be of a
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
percent 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 on next page.
TEMPERED
HOT WATER
TANKLESS COIL
OUT
CENTER LINE
OF COLD TAP
IN
8 IN. TO
12 IN.
LIMIT
CONTROL
TEMPERING
VALVE
COLD WATER
INLET
SHUTOFF
VALVE
A98269
Fig. 8 -- Recommended Piping with Tankless Heater Coil
Installation System Piping
1. Place boiler in selected location as close to flue as
possible. (See Fig. 4.) Boiler is shipped assembled. Only
the factory--supplied relief valve needs be installed.
2. Install relief valve in rear section on 3/4--in. nipple and
street ell. Do not connect directly to a drain, but leave an
air gap. No shutoff of any description shall be placed
between safety relief valve and boiler, or on discharge
pipes between such safety valves and the atmosphere.
Installation of safety relief valve shall conform to
requirements of the ANSI/ASME Boiler and Pressure
Vessel Code, Section IV. The manufacturer is not
8
RETURN FROM SYSTEM
DRAIN VALVE
FOR POWER
PURGING
MAIN SHUTOFF
VALVE
AUTOMATIC
FILL VALVE
SUPPLY TO
SYSTEM
SHUTOFF VALVE
BOILER SERVICE
FILTROL WITH
AIR PURGER
FILL LINE WITH SHUT OFF VALVE
BOILER
DRAIN
VALVE
R
A01032
Fig. 9 -- Circulator on Supply Pumping Away
ADJUST THE TWO THROTTLINE VALVES TO
MAINTAIN AT LEAST 120 OF IN THE
BOILER RETURN. THE THROTTLING VALVES
ARE USED FOR BYPASS PIPING, IF REQUIRED.
RETURN FROM SYSTEM
THROTTLING VALVE
DRAIN VALVE
FOR POWER MAIN SHUTOFF
VALVE
PURGING
CIRCULATOR
PUMP
AUTOMATIC
FILL VALVE
THROTTLING VALVE
SUPPLY TO
SYSTEM
SHUTOFF VALVE
BOILER SERVICE
S
AQUASTAT
BOILER
DRAIN
VALVE
FILTROL WITH
AIR PURGER
ISOLATION VALVES
FILL LINE WITH SHUT OFF VALVE
R
A01034
Fig. 10 -- Bypass Piping Circulator on Supply
RETURN FROM SYSTEM
SHUTOFF VALVE
BOILER SERVICE
SUPPLY TO
SYSTEM
ISOLATION
VALVES
*
CIRCULATOR
PUMP
AUTOMATIC
FILL VALVE
FILL LINE WITH
SHUT OFF VALVE
SHUTOFF VALVE
BOILER SERVICE
AQUASTAT
FILTROL WITH
AIR PURGER
*
LOCATE CIRCULATOR PUMP HERE WHEN SYSTEM
PIPING USES ZONE VALVES. IF SYSTEM PIPING
USES ZONE CIRCULATORS, USE THIS CIRCULATOR
AS A ZONE CIRCULATOR
BOILER
DRAIN
VALVE
A01035
Fig. 11 -- Piping Circulator on Supply Side
9
BW4 / BW5
S
AQUASTAT
Table 4 – Recommended Minimum Chimney Sizes
FIRING RATE
(GPH)
0.60 to 1.30
1.31 to 1.80
1.81 to 2.00
CHIMNEY HEIGHT
(FT.)
15
15
20
NORMAL CHIMNEY AREA (IN.)
ROUND LINER INSIDE
DIAMETER (IN.)
6
7
8
8X8
8X8
8X8
SQUARE LINER INSIDE
DIMENSIONS (IN.)
6--- 3/4 X 6--- 3/4
6--- 3/4 X 6--- 3/4
6--- 3/4 X 6--- 3/4
---For elevations above 2000 ft. above sea level, add 3 ft. to chimney heights. (See figure 12.)
BW4 / BW5
Chimney and Chimney Connection
Follow local codes. In the absence of local codes, follow
ANSI/NFPA 31 Installation of Oil Burning Equipment, latest
revision.
A. Checking Chimney
The chimney is a very important part of the heating system. No
boiler, however efficient its design, can perform satisfactorily if
the chimney serving it is inadequate. Check chimney to make
certain it is the right size, properly constructed, and in sound
condition.
B. Chimney Connector and Draft Regulator
Boiler requires 6--in. diameter chimney connector pipe. The draft
regulator shipped with boiler must also be used. When properly
installed, the regulator controls the draft automatically. It is best to
install it in a horizontal section of the pipe, but it may be in an
angled or vertical section. Make certain that the “top” is at top and
that the short pipe section which holds vane is horizontal. Install
it as close as practicable to boiler. (See Fig. 12.)
Install chimney connector as follows:
1. Start at boiler with a vertical pipe, at least 1 foot tall, and
then an elbow.
2. Install draft regulator making it horizontal.
3. When regulator is in place, start at chimney and work back
to regulator.
4. Join the 2 sections with a drawband. The horizontal pipe
must slope up toward chimney at least 1/4--in. per ft.. It
must not leak and must be firmly supported.
5. Join sections with at least 3 sheet metal screws. Space
evenly around the pipe.
6. Support every 5 feet with metal straps or stove pipe wire.
C. Minimum Vent Pipe Clearance
Wood and other combustible materials must not be closer than
18--in. from any surface of vent pipe.
Electrical Wiring
See Fig. 14 for wiring diagrams for the various models.
A. Installing Thermostat (Not Provided)
The 24--v thermostat location has an important effect on
operation of boiler system. BE SURE TO FOLLOW
INSTRUCTIONS INCLUDED WITH THERMOSTAT.
B. Grounding
Permanently ground boiler according to local codes and the
current edition of The National Electrical Code. Run a 14 gage or
heavier copper wire from boiler to a grounded connection in
service panel or a properly driven and electrically grounded
ground rod.
C. Electrical Power Supply
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Turn off electric power at fuse box before making any line
voltage connections. Follow local electric codes
All electrical work must conform to local codes as well as the
National Electrical Code. If not familiar with wiring and codes in
general, have a competent electrician do this job.
Boiler controls are all wired at the factory. All that is required is
to connect a 115--v electric supply and thermostat wires to
aquastat relay.
Run a separate circuit from a separate overcurrent protective
device in electrical service entrance panel. This should be a
15--amp circuit. Locate a shutoff switch at boiler. It must be
turned OFF during any maintenance. Solder and tape or securely
fasten these connections with wire nuts.
D. Connecting 115--V Electrical Wiring to Boiler
Connect 115--v electric supply wires to terminals L1 and L2 on
aquastat relay. (See Fig. 14.)
E. Thermostat Connections
The 2 wires from thermostat connect to terminals T and T on
L8148A and L8124C aquastat relay (See Fig. 14.)
F. Thermostat Heat Anticipator Adjustment
Set heat anticipator at 0.2 amps. Measure the AMP draw of the
thermostat circuit and adjust the anticipator setting if necessary.
Equipment and Optional
Accessories
A. Relief Valve (Required, Provided)
Each low--pressure hot water heating boiler is provided with a
relief valve for over--pressure protection of boiler and heating
system. The relief valve opens when pressure in boiler rises to 30
psig. Each relief valve is provided with a lifting device for testing
and should be tested monthly during heating season. Escape
piping should be provided from discharge side of relief valve so
as to prevent scalding or other hazardous situations. The escape
piping must remain full size and end at a safe point of discharge.
B. Expansion Tank (Not Provided)
In a properly assembled system, expanding water flows into an
expansion tank. This tank should be of the correct size.
The tank is filled with air. As the water expands, it compresses the
air in tank to form an air pressure cushion. This “spring--like”
cushion serves s to maintain correct operating water pressure
regardless of water temperature. This assures a “full measure” of
water even in the highest radiation unit of system. It also prevents
blowing off the relief valve.
The air in tank in the beginning (with system filled with cold
water) is sufficient for proper operation. The tank also serves as a
trap for excess s air in system. This air would cause gurgling in
pipes and inefficient circulation in radiators if left in system.
10
line. It is recommended to locate the diaphragm type expansion
tank (a) in the supply line with the circulator located after the
expansion tank or (b) off the e3/4--in. tapping provided on the top
of the rear casting with the circulator mounted directly off the
boiler’s supply piping connection. This configuration allows the
circulator to “pump away” from the expansion tank for improved
air elimination and system performance. The air reliminator
fitting or air purger is not provided. The air eliminator fitting or
air purger is used to help remove air from the system before it
reaches the radiators. It should be installed in the supply line. Air
left in the system can cause noises in the pipes and inefficient
circulation in the radiators. .
D. Air Eliminating Fitting (Air Purger) (Not Provided)
Table 5 – Boiler Water Volumes
NUMBER OF BOILER SECTIONS
TOTAL VOLUME (GALLONS)
3
4
5
9.6
11.6
13.7
BW4 / BW5
It is possible for a tank to become “water--logged” (filled with
water). It can also become overfilled with air. This can happen
after filling system with new water. Fittings are provided on tank
and in line to tank for bleeding off excess water or air.
When installing this tank, the following are important: :
1. Tank should be higher than boiler top.
2. Pipe to tank should continuously rise up to tank (so that
air can “bubble“ up through it).
C. Diaphragm--Type Expansion Tank (Not Provided)
The diaphragm--type expansion tank takes the place of a
conventional expansion tank. Read instructions packed with tank
assembly carefully. The tank comes with a 10--12 psi air charge.
This is the same as the pressure produced in system by automatic
fill valve. When system is first filled, ,tank contains little or no
water. .As water is heated, its pressure increases. It expands into
tank compressing the air in tank. This compressed air cushion
permits water in system m to expand as temperature changes. The
diaphragm--type expansion tank can be mounted on the air purger
fitting or at any other convenient place in the supply or return
MUST BE REQUIRED MINIMUM
HEIGHT. MUST BE AT LEAST
3 FT HIGHER THAN HIGHEST
PART OF PASSAGE THROUGH
ROOF. MUST BE AT LEAST 2 FT
HIGHER THAN ANY NEIGHBORING
OBJECT. MUST HAVE AN
UNOBSTRUCTED TOP OPENING.
MUST BE AT LEAST
4 IN. THICK AND BE TIGHT.
DRAFT REGULATOR
VANE
TIGHT, SMOOTH,
CORRECTLY SIZED.
MUST SLOPE UP AT
LEAST 1/4 IN. PER FOOT
OF HORIZONTAL RUN.
DRAWBAND LAST
PIECE INSTALLED
SEALED IN
THIMBLE
TIGHT CLEAN-OUT
DOOR
BALANCED
WEIGHT
CRIMPED
END
ALTERNATE POSITIONS
TOP
TOP
A95601
Fig. 12 -- Typical Chimney Requirements
11
Table 6 – Piping Water Volumes
PIPE SIZE
COPPER PIPE FACTOR
STEEL PIPE FACTOR
1/2--- IN.
82.5
63.5
3/4--- IN.
40.0
36.0
1--- IN.
23.3
22.2
1--- 1/4--- IN.
15.3
12.8
1--- 1/2--- IN.
10.8
9.5
2--- IN.
6.2
5.8
BW4 / BW5
---Divide total length of piping in feet by appropriate factor in table to determine volume in gallons.
An air purger is used to remove air from system. It is installed in
supply line. It eliminates air from water before it reaches radiators
and bleeds off this air.
E. Main
Air Vent
for Downflow
Systems or
Diaphragm--Type Expansion Tank (Not Provided)
Before a system is filled with water, there is air in pipes and
radiation units. Some of it will be trapped as system fills. It is
possible to eliminate most of this air through air vents on
radiation units. A main air vent speeds and simplifies this process.
It should be installed on highest point in supply main when all
radiation is below top of boiler.
F. Aquastat Relay Control (Provided)
The water temperature limit control in aquastat relay is adjustable
and may be set as necessary. It may be set as low as 140_F or as
high as 240_F. This depends on type and amount of radiation
involved and weather conditions.
G. Automatic Fill Valve (Not Provided)
For safe, efficient operation, a hot water system must be filled
with water. Adding new water when needed can be done
manually (by use of a hand valve in water supply line). This
requires regular attention to system’s needs. An automatic fill
valve accomplishes this without attention. It is installed in supply
line on hot water boilers only. The valve operates through water
pressure differentials. It does not require electrical connection.
H. Drain Valve (Provided)
This manual valve provides a means of draining all water from
boiler and system. It is installed in a tee where return line enters
boiler.
I. Circulating Pump (Provided)
Every forced hot water system requires a circulating pump. A
separate pump or zone valve is required for each zone if there are
2 or more zones. The circulator must have the capacity to provide
the circulation required by the heating system. The circulator
should be connected to the supply main and must be wired into
the boiler’s electrical system. See the prior pages of installation
section for piping configurations with the circulator located on
the supply main piping using zone circulators or zone valves.
When the piping is arranged with zone circulators and no bypass
piping, the circulator provided with the boiler may be used as a
zone circulator. Both piping arrangements allow the circulator to
pump away from the expansion tank and show how the piping
should be arranged to allow the heating system to be easily
purged of air.
J. Oil Solenoid Valve
The Beckett oil burner uses a standard solenoid valve. Upon
burner shutdown, a standard solenoid valve stops the flow of oil
to the nozzle. Without the solenoid valve, the oil pump continues
to pump oil to the burner nozzle until the motor winds down
below the pump cut--off speed. The Riello oil burner has a delay
oil solenoid valve. The delay solenoid valve provides the same
shut down action of the standard solenoid valve, plus on burner
start--up, the delay solenoid valve remains closed for an
additional 15 seconds. This allows the burner fan motor to
pre--purge the combustion chamber and the oil pump to bring the
supply oil pressure up to its set point helping to provide a clean
light off.
Filling Boiler
OPTION #1
A. How a Hot Water System Operates
The entire heating system (boiler, piping, and radiation units) is
filled with water. As water in boiler is heated, it is pumped from
top of boiler through supply main to radiation units. The cooler
water in them flows back through return main to boiler. This
provides positive and rapid response to thermostat.
B. Filling System With Water
a. Close the main shutoff valve, isolation valves, and
zone valves (if applicable). If bypass piping is
installed, also close the two throttling valves. Leave
the boiler service shutoff valve (if installed) and the
balancing valves to each heating zone fully open.
b. Open the following valves in order: the drain valve for
power purging, isolating valves before and after the
boiler circulator (if applicable), both throttling valves
(if applicable), and then open the fill line shutoff
valve. Water will fill the bypass piping and push air
through the piping and out the power purging drain
valve. When the power purging drain valve runs air
free, close the bypass throttling valve (leaving the
throttling valve to the supply piping fully open)
c. Next, open the isolation valve (or zone valve) to the
first zone. Water will fill the piping and push any air
out the power purging drain valve. When the power
purging drain valve runs air free, close the isolation
valve or zone valve. Repeat this procedure for the
remaining heating zones.
d. Once all of the zones are filled with water and purged
of air, close the power purging drain valve and fill line
shut off valve, open the main shutoff valve, and adjust
the throttling valves and balancing valves as required.
OPTION #2
1. Close air vents on all radiation units. Open valves to these
units.
2. Make sure boiler and expansion tank drain cocks are
closed. The air bleed screw on tank drain fitting should be
closed.
3. Open valve in line from boiler to expansion tank.
4. Open water inlet to boiler and leave it open.
5. Start with the LOWEST radiation unit. Open the air vent
on this radiation unit. When all air has escaped and water
starts to flow from vent, close air vent.
6. Proceed to next lowest radiation unit and repeat process
outlined in item 5. Repeat until every radiation unit in
system has been covered. End with the highest unit in
system.
If units have automatic vents, this manual venting is unnecessary
but will speed up proper filling of system.
If system is a closed expansion tank system, there should be an
automatic fill valve. It may be left open to refill system
automatically as needed.
Check temperature--pressure gage. Note position of hand
indicating pressure. This should be between 10 and 15 psi. Any
lowering of this movable hand below 10 psi indicates loss of
water due to leakage. The automatic fill valve should compensate
for this. If it does not, manually open this valve to refill system
12
room. See Fresh Air for Combustion section earlier in this
document.
Draft Regulators (Provided)
OPERATING BOILER
!
WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal
injury, death and or property damage.
Do not tamper with unit or controls.
IMPORTANT: Follow these instructions carefully.
To Start
Fill entire system with water. Vent all air from system. Refer to
instructions included with oil burner.
Fuel Units and Oil Lines
Install oil line(s) to the oil burner. Recommend using heavy wall
copper tubing and flared fittings, not compression fittings. All
connections and joints must be absolutely airtight. Use an
appropriate non--hardening thread sealing compound on the
threaded connections, not Teflon tape. See fuel unit data sheet
furnished with the burner for sizing, lift, and length of tubing
recommendations.
The original equipment oil burner (when furnished) is equipped
with a single--stage fuel unit with the by--pass plug removed for
single pipe installation. This is satisfactory where the fuel supply
is on the same level as, or above the burner, permitting gravity
flow of oil. Per NFPA--31 requirements, never exceed 3 psig
pressure to the inlet side of the fuel unit. When it is necessary to
lift the oil to the burner, a two--pipe installation is required. Run
a return line between the fuel unit and the oil supply. When a
two--pipe installation is used, the by--pass plug (furnished with
the burner) must be installed in the fuel unit. Refer to the fuel
unit instructions furnished with the burner for specific
instructions on installing the by--pass plug. Do not exceed the
fuel unit manufacturer’s recommendations for running vacuum.
(Note: If lift exceeds 14 feet for Beckett or Carlin burners or 11
feet for Riello burners, a two--stage fuel unit is required with a
return line.)
Install an oil filter of adequate size inside the building between
tank shutoff valve and the oil burner. For ease of servicing, locate
the shutoff valve and filter near the oil burner.
A draft regulator is required. It should preferably be mounted in
smoke pipe. Use a draft gage to adjust to proper opening. When
burner air supply and draft are properly adjusted, combustion
chamber draft will be approximately --0.01 to --0.02 in. wc and
stack draft will be --0.02 to --0.04 in. wc. The larger the
installation, the greater the draft required at stack to obtain --0.01
to --0.02 in. wc at combustion chamber.
Nozzles (Provided)
Use the proper size, type, and spray pattern nozzle, refer to Table
6. To install nozzle, loosen clamping screw on retention ring
assembly and slide assembly off adapter. Install and tighten
nozzle in adapter. Be careful not to damage electrode insulators or
bend electrodes. Replace retention ring assembly on adapter.
Make sure clamp is tight against shoulder on adapter. Tighten
clamping screw. Check electrode setting. (See Fig. 17--19.)
Final Burner Adjustments
A final adjustment must be made with the use of a
COMBUSTION TEST KIT. Initial settings for burner are shown
on label on top of ignition transformer and Table 7. Set burner
accordingly. After operating 10 minutes to warm unit up, a smoke
tester should be used to take a smoke reading in flue pipe
between boiler and draft regulator. Smoke should be zero (Shell
Bacharach Scale). At times a new boiler requires more time than
this to burn clean due to oil film on a new heat exchanger. Check
draft over the fire. This should be --0.01 to --0.02 in. wc as
previously stated. Adjust draft if necessary. Gradually close air
shutter, and if necessary the air band, to obtain a smoke reading
showing a trace of smoke. Measure CO2 at this point. Increase air
sufficiently to reduce CO2 by 0.5 to 1 percent as an insurance
margin. Smoke should be zero. If a clean fire cannot be obtained,
it will be necessary to verify head and electrode alignment. (See
Fig. 15--17.) If fire is still smoky, replace nozzle with a correct
replacement. Record nozzle size, oil pressure, combustion
readings and air settings then place a tag or label on boiler or
burner with this information. Units should be cycled several times
to assure good operation with no fluttering or rumbling. Check
for oil leaks.
DIMENSION “H”
SEE BELOW
5/32
GAP
ELECTRODE
Air Supply for Combustion
Do not install in rooms with insufficient air to supply
combustion. Occasionally, it is necessary to install windows or
cut holes in a door to these rooms to obtain sufficient air and to
prevent less than atmospheric air pressure in the room. If there is
a lack of combustion air, the burner flame will be yellow and
formation of soot will occur in heating unit. In buildings of
conventional frame, brick, or stone construction without utility
rooms, basement windows, or stair doors, infiltration is normally
adequate to provide air for combustion and operation of
barometric draft control. The room should be isolated from any
area served by exhaust fans. Do not install exhaust fans in this
5/16 ABOVE
L1 OR V1 HEAD
NOZZLE
DIMENSION “N”
SEE FIG 18
A01064
Fig. 13 -- Beckett Burner Electrode Adjustments
13
BW4 / BW5
until hand is again pointing to same pressure reading. Instructions
are packaged with valve.
DIMENSION "Z"
1 3⁄4″ ± 1⁄32″
WITNESS
MARK
LOCATION OF HEAD
AT "0" POSITION
ON ADJUSTING PLATE
BW4 / BW5
"V1" ADJUSTABLE
HEAD
"MD" AIR
TUBE COMBINATION
HOLD DOWN
SCREW
5/32
GAP
PRIMARY
ADJUSTING
PLATE
SECONDARY
ADJUSTING
PLATE
7/16 ABOVE
ELECTRODE
NOZZLE
DIMENSION “N”
SEE FIG 15
KNURLED
NUT
ACORN NUT/
LOCK WASHER
A02245
Fig. 15 -- Beckett Burner Setting Fixed (F) Head -- 140, 210
A95604
Fig. 14 -- Beckett Burner Setting Variable (V1) Head
A06506
Fig. 16 -- Riello 40--F5 Burner Electrode Adjustments
14
BW4 / BW5
A06507
Fig. 17 -- Riello 40--F10 Burner Electrode Adjustments
Oil Burner Maintenance
The following preventative maintenance items should be
performed annually, preferably prior to the heating season.
A. Oil Burner Motor
Add 2--3 drops of non--detergent electric motor oil to each oil cup
located at front and rear of motor. Excessive oiling will shorten
the life expectancy of motor.
B. Fuel Filter
This should be replaced so as to prevent contaminated fuel from
reaching the nozzle. A partially blocked fuel filter can cause
premature failure of fuel pump unit.
C. Fuel Pump Unit
Replace pump screen and clean pump unit to maintain reliable
fuel delivery to nozzle.
D. Ignition Electrods
Clean and adjust as per manufacturer’s recommendations so as to
maintain reliable ignition of oil.
E. Nozzle
Replace so as to maintain safe and reliable combustion efficiency.
Always replace with the exact nozzle as required in Table 7.
These must be kept clean and free of dirt, lint, and oil so as to
maintain proper amount of air the fuel requires to burn.
NOTE: If any component parts must be replaced, always use
parts recommended by burner manufacturer.
F. Fan and Blower Housing
Check burner blower wheel for dirt, grease and grime. Clean as
necessary. Check motor is attached to burner housing and wheel
is attached tightly to motor shaft. Check pump coupling for wear
and damage.
Table 7 – Beckett Oil Burner Specifications
BASE
BOILER IN -
DELEVAN OIL
MODEL
PUT (BTUH)
NOZZLE
140
210
280
FIRING
RATE
(GPM)
HEAD--- ADJUSTMENT
LOW FIRE
OR SETTING
BAFFLE
AIR SHUTTER
AIR
STATIC
BAND
PLATE (IN.)
PUMP PRESSURE
91,000*
0.50–80 B
0.65
F0 1--- 1/8
YES
10
0
3--- 5/8
175 PSIG
105,000
0.65–70 B
0.75
F3 1--- 1/8
YES
10
0
3--- 1/2
140 PSIG
140,000
0.85–70 B
1
F3 1--- 1/8
NO
10
2
3--- 1/2
140 PSIG
126,000*
0.75–80 A
0.9
F3 1--- 1/8
NO
8
0
3--- 1/2
140 PSIG
175,000
1.00–80 A
1.25
F6 1--- 1/8
NO
10
0
3--- 3/8
140 PSIG
210,000
1.25–80 A
1.5
F6 1--- 1/8
NO
10
2
3--- 3/8
140 PSIG
168,000
1.00–60 B
1.2
V1--- 0
NO
10
1.5
2--- 3/4
140 PSIG
245,000
1.50–45 B
1.75
V1--- 2
NO
10
4
2--- 3/4
140 PSIG
280,000
1.65–60 B
2
V1--- 4
NO
10
5
2--- 3/4
140 PSIG
15
BW4 / BW5
Table 8 – Riello Oil Burner Specifications
BOILER
DELEVAN
FIRING
TURBULATOR/AIR
OIL PUMP PRESSURE
OIL
INPUT (BTUH)
OIL NOZZLE
RATE (GPM)
SHUTTER SETTING
(PSIG)
BURNER
91,000
0.50--- 70ºW
0.65
0.5 / 2.0
155
F--- 5
105,000
0.65--- 70ºW
0.75
2.0 / 2.2
150
F--- 5
140,000
0.85--- 70ºW
1.00
2.0 / 3.2
170
F--- 5
126,000
0.75--- 70ºW
0.9
1.5 / 2.6
160
F--- 5
175,000
1.00--- 70ºW
1.25
2.5 / 3.8
170
F--- 5
210,000
1.25--- 70ºW
1.5
4.0 / 7.0
175
F--- 5
245,000
1.50--- 70ºW
1.75
2.0 / 3.8
155
F--- 10
280,000
1.75--- 70ºW
2.00
2.5 / 4.1
155
F--- 10
Note: All Riello 40 F ---5 and F ---10 oil burners are factory preset at 145
psig.
!
Checking and Adjusting Controls
!
WARNING
FIRE, EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury or death.
WARNING
Never burn garbage or paper in the unit, and never leave
combustible material around it.
FIRE, EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury or death.
Do not attempt to start the burner when excess oil has
accumulated, when unit if full of vapor, or when the
combustion chamber is very hot.
IMPORTANT: These instructions must be followed carefully.
A. Adjusting Operating Controls
Instructions for each control are included. Refer to Table 8 for
recommended settings for the first adjustment:
These settings can be changed after gaining familiarity with how
system responds. If system does not give quite enough heat in
very cold weather, ,the high limit setting can be raised to 220_F.
If more domestic hot water is required, the low limit setting can
also be raised
B. Checking Thermostat Opeation
When set above temperature indicated on thermometer, boiler
burner should start. Make certain thermostat shuts boiler down
when room temperature reaches selected setting and starts boiler
operating when room temperature falls a few degrees.
NOTE: Do not start burner unless all cleanout doors are secured
in place.
MAINTENANCE
To assure trouble--free operation, we recommend that flue
passages, burner, combustion chamber area (target wall and fire
door insulation), burner adjustment, operation of controls, and
boiler seals (door gasket or silicone seal, cast iron seals and flue
collector) be checked ONCE EACH YEAR by a competent
service technician.
BEFORE THE START OF EACH SEASON (or whenever
system has been shut down for some time), recheck the whole
system for leaks and recheck boiler and vent pipe for leaks.
Replace or patch any boiler seals that are faulty.
Relief Valve
This valve should open automatically when system pressure
exceeds the safe limit (30 psi). Should it ever fail to open under
this condition, shut system down. Drain it until pressure is
reduced below safe limit, then have valve replaced immediately.
The relief valve should be tested monthly during heating season.
Prior to testing, make certain a discharge pipe is properly
connected to the valve outlet and arranged so as to contain and
safely dispose of boiler discharge. Hold the trip lever fully open
for at least five seconds in order to flush free any sediment that
may lodge on the valve seat. Then permit the valve to snap shut.
Conventional Expansion Tank
As previously noted, this tank may become waterlogged or may
receive an excess of air. Frequent automatic opening of relief
valve indicates waterlogging. A high boiler temperature
accompanied by unusually low radiation unit temperature (and
“knocking”) indicates excess air in tank. To correct either
condition, close valve between boiler and tank. Drain tank until it
is empty. Check all tank plugs and fittings. Tighten as necessary.
Open valve between boiler and tank. Water will rise to normal
height in tank if automatic fill valve is installed, otherwise,
manually refill system.
Diaphragm Expansion Tank
As previously noted, this tank may become waterlogged or may
receive an excess of air. Frequent automatic opening of relief
valve indicates waterlogging. A high boiler temperature
accompanied by unusually low radiation unit temperature (and
“knocking”) indicates excess air in tank. To correct this condition,
replace the diaphragm expansion tank.
Water System
If system is to remain out of service during freezing weather,
always DRAIN IT completely. Water left in to freeze will crack
pipes and/or boiler.
Tankless Coil (or Cover Plate Gasket)
The tankless coil gasket should be checked at least twice a year
for leakage and replaced if necessary.
16
OIL BOILER CLEANING
1. Shut off all electrical power to the boiler/burner and shut
off fuel oil supply.
2. Remove the vent pipe from the top of the boiler. Inspect
the pipe and chimney for signs of corrosion and
deterioration. Clean out the base of the chimney. If the
vent pipe shows any signs of corrosion or deterioration,
replace it immediately. If chimney damage or deterioration
is discovered, contact a competent professional.
3. Remove the top jacket panel screws (5), the brass wing
nuts (2) holding the flue collector top, and then the flue
collector top. Inspect the gasket on the underside of the
flue collector and replace as necessary.
4. Before beginning to clean the flue passageways, ensure
that the combustion chamber blanket is covered. If the
blanket is not covered prior to cleaning, replace the
blanket once cleaning is complete.
5. Now with access to the flue passageways, remove the soot
from the fireside surfaces by brushing diagonally through
the flue passages (See Fig. 18). Brushing can be made
easier by cutting the end of the flue brush off and inserting
it into a drill. When brushing, care should be taken so as
not to damage the target wall with the flue brush.
6. Carefully vacuum the soot accumulations from the
combustion chamber area, being particularly careful to not
damage any of the refractory or blanket insulation. To gain
access to the combustion chamber first double check that
the shut off valve on the fuel line is closed and then
disconnect the fuel oil line. Then open the swing door by
simply removing the whiz lock nut holding the door shut.
7. Now inspect the target wall, fire door refractory, and
combustion chamber blanket (when included) for cracking
and deterioration. If there is any signs of cracking or
deterioration, replace the refractory or blanket before
reassembling the burner/front plate.
8. Inspect the door’s braided gasket for wear and damage.
Replace when necessary with braided gasket of the same
material and size. See repairs parts section of this manual.
9. Now inspect and clean the oil burner.
A95609
Fig. 18 -- Removing Soot
OIL BOILER CLEANING
NOTE: These are general instructions for cleaning an oil burner.
For specifics, consult the burner manufacturer’s instructions
1. Make sure all electrical power to the boiler/burner and the
fuel supply to the burner are shut off.
2. With the swing door open, clean any soot accumulations
from the end of the burner and if applicable burner head.
3. Remove the burner drawer assembly, clean the electrodes
and then reset the electrode spark gap per the
manufacturer’s recommendations.
4. Replace the oil nozzle with the exact same size and type
recommended for use on this boiler.
5. Reinstall the burner drawer assembly making sure the
head location (and size if applicable) are per the
manufacturer’s recommendations. If the burner being used
has a damaged head, replace the head with the exact same
head recommended for use on this boiler.
6. Inspect and clean the oil burner blower wheel.
7. Remove the oil pump cover and clean/replace the pump
screen. Carefully reassemble ensuring the pump cover
makes a good seal.
8. Securely fasten the swing door shut.
9. Replace the fuel filter (if applicable).
10. Reconnect the electrical and fuel supplies.
11. Fire the burner, checking for proper combustion using
combustion test equipment and making adjustments as
necessary.
12. Ensure that all safety controls and operating controls are
functionally properly.
IMPORTANT: KEEP BOILER AND AREA AROUND IT
CLEAN. NEVER BURN REFUSE OR ANY MATERIAL
OTHER THAN THE SPECIFIED FUEL IN BOILER. HAVE
BOILER CHECKED EACH YEAR BY A QUALIFIED
TECHNICIAN.
Sequence of Operation
Refer to Fig. 19 and the wiring diagram shown in Fig. 14 while
reviewing sequence of operation.
A. Boiler with Tankless Coil
HIGH LIMIT CONTROLLER
The high limit contacts open and turn burner off when boiler
water temperature reaches high limit set point. The high limit
automatically resets after boiler water temperature drops past set
point and through fixed 10_ differential.
LOW LIMIT AND CIRCULATOR CONTROLLER
On a boiler water temperature rise, with the adjustable differential
set at the minimum setting of 10_, burner circuit contacts RB
break and circulator circuit contacts RW make at low limit set
point. On a boiler water temperature drop of 10_ below set point,
the RB circuit makes and RW circuit breaks
At any differential setting greater than 10_, the RB make and
RW break temperature remains the same (control setting minus
10_). The RB break and RW make temperature is the set point
temperature plus the difference between differential setting and
10_.
The low limit control fires burner to maintain boiler water
temperature at low limit setting (set point plus adjustable
differential setting minus 10_).
While boiler water temperature is below low limit setting,
circulator is prevented from operating, giving preference to
domestic hot water requirements. Once boiler water temperature
rises to low limit setting, thermostat controls firing of burner and
operation of circulator pump as follows:
17
BW4 / BW5
Oil Boiler/Burner Cleaning Instructions
N H
115V 60 CYCLE
SUPPLY
24 VOLT
THERMOSTAT
TO
115V
SUPPLY
TO
24V
L1L2 T T THERM
AQUASTAT
RELAY
A95602
BW4 / BW5
Fig. 19 -- Wiring Connections to Aquastat Relay
Table 9 – Recommended Operating Control Settings
OPERATING CONTROL
Standing Radiators
Baseboard and
Convectors
Low Limit (When Used)
Differential (When Used)
High Limit
CONTROL
SETTING
180°F
200°F
140°F
10°F
1. Thermostat calls for heat completing circuit between
terminals T and T on L8124C aquastat controller
energizing the 1K relay coil.
2. With 1K relay coil energized, contacts 1K1 and 1K2 are
closed. Terminal B1 is energized providing power to
R4184 oil burner primary control. This in turn powers
ignition coil and burner motor.
3. With R4184 primary control energized, burner operation
starts and burner remains running as long as cad cell
senses flame. In the event of a flame failure or if flame is
not fully proven within 45 sec of initial start--up, the
R4184 primary control locks out and opens burner circuit.
This requires a manual start--up of burner.
4. As long as flame is proven through cad cell relay, burner
remains on until circuit is interrupted by boiler water
temperature reaching high limit setting (opening high limit
contacts BR), or thermostat is satisfied breaking T--T
circuit.
5. Circulator pump is powered through terminal C1 and runs
when boiler water temperature is above low limit setting.
6. If boiler water temperature reaches high limit setting, high
limit contacts BR open de--energizing terminal B1 and
shutting off burner. Circulator pump remains running as
long as thermostat calls for heat.
7. If boiler water temperature falls 10_ below high limit
setting, contacts BR close energizing burner.
8. Thermostat is satisfied terminating call for heat. Relay coil
1K is de--energized opening 1K1 and 1K2 contacts. Both
burner and circulator pump cease operation.
NOTE: The high limit setting must be set a minimum of 20_
higher than low limit setting.
B. Boiler Without Tankless Coil
AQUASTAT HIGH LIMIT CONTROLLER
The aquastat control’s high limit contacts open and turn off the
burner when the boiler water temperature reaches the control’s
high limit set point. The high limit contracts automatically reset
after the boiler water temperature drops past the set point by 10_
F, which is a fixed differential. When the thermostat controls call
for domestic space heating, the sequence of operation for the
burner and circulator is as follows:
1. Thermostat calls for heat, completing the circuit between
terminals T and T on the aquastat controller, energizing
the 1K relay coil.
2. With the 1K relay coil energized, contacts 1K1 and 1K2
are closed. Terminals C1 and C2 are energized providing
power to the circulator. Terminal B1 is energized,
providing power to the oil burner primary control. This in
turn powers the ignition coil and burner motor.
3. With the primary control energized, the burner operation
starts and remains running as long as the cad cell senses
flame. In the event of flame failure or the flame is not fully
proven within the trial for ignition period, the primary
control will lockout and open the burner circuit. This will
require a manual startup of the burner.
4. As long as flame is proven through the cad cell relay, the
burner will remain on unit the circuit is interrupted by the
boiler water temperature reaching the aquastat’s high limit
setting (opening high limits contracts BR), or the
thermostat is satisfied breaking the T—T circuit.
5. If the boiler water temperature reaches the aquastat’s high
limit setting, the high limit contact BR is de--energized
turning the burner off. However, the circulator pump will
continue to run, as long as, the thermostat calls for heat.
6. After the high limit contact BR is de--energized, the boiler
water temperature must fall 10_ F below the aquastat’s
high limit setting for the high limit contacts BR to close
and energize the burner.
7. When the thermostat is satisfied, the call for domestic
space heating is ended. Relay coil 1K is de--energized,
opening 1K1 and 1K2 contacts. Both the burner and
circulator pump operation stop.
18
BOILER WITH TANKLESS HEATER COIL
BOILER WITHOUT TANKLESS HEATER COIL
COLOR CODE
120/60/1 OVERCURRENT PROTECTED DISCONNECT
B=BLACK
W=WHITE
O=ORANGE
Y=YELLOW
LINE
NEUT
120V HOT
POWER
SUPPLY
OVERCURRENT
PROTECTED
DISCONNECT
BK
A
W
L2
L1
T
NEUTRAL
L8124C
AQUASTAT
T
24 V THERMOSTAT
FIELD WIRING
B2
R C1
ZC
ZR
B1
C2
G
BK
BK
W
W
BK
F
F
O
OIL
VALVE
R
CIRCULATOR
PUMP
L1
L2
T
T
L8148A
AQUASTAT
3
R4184
RELAY
W
OIL BURNER
MOTOR
CAD CELL
Y
B
R
OIL
VALVE
Y
IGN
TRANS
BK
BK
C1
IGNITION
OIL BURNER
TRANSFORMER MOTOR
C2
B
B1
B
B2
B
W
W
G
B
B
W
GND
COLOR CODE
BK=BLACK
O=ORANGE
Y=YELLOW
R=RED
W=WHITE
LINE
VOLTAGE
CLASS II
24 VOLTS
T
T
L1
L2
1K
W
R
B
LOW LIMIT/
CIRCULATOR
O
L1
(HOT)
L2
CIRCULATOR
R4184D
RELAY
W
1K1
F
ZR
F
B
ZC
Y
CAD
CEL
Y
B
HIGH LIMIT
1K2
R
B1
B2
L1
JUMPER
T
C1
T
3
B
R
IK1
C2
IK
IK2
C1
L2
BW4B
C2
B2
B1
BW5B
A02231
Fig. 20 -- Wiring Diagrams for Boilers With and Without Tankless Heaters and Beckett Burners
19
BW4 / BW5
24 VOLT THERMOSTAT
FIELD WIRING
BW4 / BW5
A06504
Fig. 21 -- Boilers Without Tankless Coil and Honeywell L8148 Aquastat Control
20
BW4 / BW5
A06505
Fig. 22 -- Boilers With Tankless Coil and Honeywell L8124C Aquastat Control and Riello Burners
21
Service Hints
240 F (116 C)
HI LIMIT
SETTING
10 F (5.6 C)
DIFF
SWITCH BREAKS ON
RISE, TURNS BURNER
OFF. CIRCULATOR
OPERATES ON CALL
FOR HEAT.
SWITCH MAKES ON
FALL. BURNER
OPERATES ON
CALL FOR HEAT.
BW4 / BW5
25 F (13.9 C)
DIFF
LOW LIMIT
AND
CIRCULATOR
SETTING
10 F (5.6 C)
DIFF
Avoid inconvenience and service calls by checking these points
before calling for service.
have your service technician check any problem you are
unable to correct.
Parts List
All parts are listed in the following Parts Lists. Parts may be
ordered through nearest supplier When ordering parts, first obtain
the Model No. from the name plate on boiler, then determine the
Part No. (not the Key No.) and the Description of each part from
the following appropriate illustration and list. Parts for which no
Part No. is given are standard items which can be procured
locally. Be sure to give all this information: The Part No., The
Part Description, The Boiler Model No.
SWITCH MAKES R-W,
BREAKS R-B ON RISE
(25 F [13.9 C]
DIFFERENTIAL).
SWITCH MAKES R-W,
BREAKS R-B ON RISE
(10 F [5.6 C]
DIFFERENTIAL).
SWITCH MAKES R-B
ON FALL, BREAKS
R-W. BURNER ON,
CIRCULATOR OFF.
110 F (43 C)
A956111
Fig. 23 -- Relationship of Set Points and Differential
Table 10 – Service Hints
IF SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT. . .
POSSIBLE CAUSE
WHAT TO DO
Thermostat is not set correctly
Reset thermostat above room temperature.
Boiler and/or burner may be dirty
Clean all flue passages and vent pipe. Have burner cleaned and readjusted.
Burner may not be firing at proper rate
Check nozzle size it there is any doubt. Have burner adjusted.
Burner may be short--- cycling Short--- cycling (too frequent off and
on) of burner causes sooting. If boiler and/or burner becomes
Burner may be short--- cycling
dirty at frequent intervals, correct the .dirt condition,. then also correct the control
setting (or other cause of short--- cycling).
Check thermostat heat anticipator and correct setting, if neces--sary, per instruction sheet packed with thermostat.
No power to boiler
Controls out of adjustment
Radiators not heating
Circulator pump not running
Poor electrical contact
POSSIBLE CAUSE
Oil burner fan wheel may be dirty
Draft regulator may be stuck
POSSIBLE CAUSE
Air in system
POSSIBLE CAUSE
Dirt on seat
Waterlogged expansion tank
Check overcurrent protection. Check to be sure power supply circuit is on.
Reset according to instructions packed with controls.
Open radiator vents to vent excess air. Check flow control valve (if used). It may
be in closed position.
Check relay operation.
Check all control terminals and wire joints.
IF BURNER IS NOISY. .
WHAT TO DO
Clean fan wheel with a stiff brush and cleaning solvent. Readjust oil burner.
Check to see if vane swings freely. Clean if vane is stuck.
IF RADIATORS ARE NOISY. . .
WHAT TO DO
Open radiator vents to vent air. Check expansion tank.
RELIEF VALVE LEAKING. . .
WHAT TO DO
Open valve manually. Allow water to run and clear valve seat.
Drain tank. See instructions.
22
13
2
12
XXX
11
1
1
1
10
XXX
3
1
1
1
4
XXX
14
2
15
1
7
2
XXX
XXX
16
1
18
10
19
10
5
8
1
9
XXX
A01039
ITEM
DESCRIPTION
PART NUMBER
1
Section Machined Back
403--- 00--- 008
2
Section Machined Middle
403--- 00--- 007
3
Section Machined Front
403--- 00--- 006
4
Nipple Machined 2--- in. --- (2--- in. cast iron push nipple)
433--- 00--- 976
Tie Rod 1/4X10 1/4
3 section
146--- 05--- 002
4 section
146--- 05--- 051
5 section
146--- 05--- 053
6
Nuts head (Hex) ZP (Zinc Plated) 1/4--- in. --- 20
HW--- 003.02
7
Cut Rope 5/18--- in. X 70--- 1/2--- in. (NORFAB 400 Serrated Braided
Rope)
433--- 00--- 955
8
Target Wall (Gemcolite Vacuum Formed Ceramic Fiber 2300’)
146--- 19--- 003
9
Dura Blanket 3--- 8 # 1/2--- in. thick
Size --- 3 section--- 8--- in. X 12--- in., 4 section --- 8--- in. X 20--- in. 5
146--- 30--- 031
5
Collector BAse
10
3 section
425--- 00--- 279
4 section
425--- 00--- 280
5 section
425--- 00--- 281
Tape Plym Collector insulation
1--- in. X 1/16--- in. X 100
Included in Part # 425--- 00--- 279, 80, 81
12
Collector Top
Included in part # 425--- 00--- 279, 80, 81
13
Wing Nut 8/32 --- Brass
137--- 04--- 007
14
Screw #14 X 3/4 in. HWH SL S.M. SC.
(Hex Washer Head, Slotted, Sheet Metal Screw)
146--- 95--- 109
15
Gasket PF--- EV 5040--- 150A
146--- 03--- 065
16
Coil 3.7 GPM (Gallons Per Minute) CDB
146--- 27--- 020
17
Cover Plate (Not Shown)
146--- 19--- 001
18
Stud 18--- 8St. St.(Stainless Steel) 3/8--- 16X1--- 1/2--- in.
146--- 95--- 113
19
Washer Flat 18--- 8 St. St. (Stainless Steel) 3/8
146--- 95--- 114
20
Nut Top Lock 18--- 8 St. St. (Stainless Steel) 3/8
146--- 95--- 115
21
Plug Solid Black Square Head 1--- 1/4--- in. (Not Shown)
1395002
22
400_ Black Silicone Rubber Adhesive Sealant (Not Shown)
146--- 06--- 020
11
23
BW4 / BW5
20
10
XXX
2
1
3
1
12
1
11
1
10
1
4
1
4
1
8
1
6
2
BW4 / BW5
1
1
5
1
7
2
A01040
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
DESCRIPTION
Section Machined Front
Stud TFL (Threaded Full Length) 3/8–16-- in. X 2–1/2-- in.
Whizlok Nut ZP (Zinc Plated) 3/8
Insulation Swing Door (Gemoclite Vacuum Formed Ceramic Fiber 2300°)
Hinge Machined
Rivet RD (Round) HD (Head) Separated Flange ZP 3/8-- in. X 1-- in.
Bolt Hex (head) Separated Flange ZP (Zinc Plated) 1/4-- in. X 2-- in.
Cut Rope FiberFrax Round Braid 3/8-- in. X 48-- in.
Fire Door Wing Machined
Observation Door Machined
Washer Lock Plain 5/16-- in.
Bolt 5/16-- in. X 3/8-- in. Socket SH (Shoulder) BLT (Bolt) 1/4-- in. 20 TH (Thread)
Fig. 24 -- Swing Fire Door Assembly
Table 11 – Beckett Oil Burner Service Parts
OIL BURNER REPAIR PARTS-- BURNER NOT SHOWN
Burner Motor
Fuel Pump
Oil Solenoid Valve
Ignitor or Ignition Transformer
Oil Primary Control 7184B
Electrodes for V1 Head (5 section only)
Electrodes for F Head (3 and 4 section only)
Oil Burner Head, F-- 0
Oil Burner Head, F-- 3
Oil Burner Head, F-- 6
Oil Burner Head, V-- 1
Burner Mounting Gasket
Cad Cell
Oil Burner, 3 section
Oil Burner, 4 section
Oil Burner, 5 section
PART NUMBER
RP-- 015.00
RP04501
RP04601
RP02001
RY00701
146–19–105
146–19–104
1050003
1050002
1050004
Not Stocked-- Order from Beckett
14619106
14662085
146-- 19-- 355
146-- 19-- 356
146-- 19-- 357
24
PART NUMBER
403–00–006
146–95–125
146–95–126
146–14–014
403–00–010
146–95–121
146–95–124
433–00–905
403–00–009
403–00–014
146–95–123
146–95–122
Table 12 – Riello Oil Burner Service Parts
RIELLO OIL BURNER REPAIR PARTS
Oil Burner Repair Parts--- Burner Not Shown
Burner Motor
Fuel Pump *
Oil Solenoid Coil * *
Oil Primary Control 530SE
Electrodes
Photo Cell
Oil Burner, 3 section
Oil Burner, 4 section
Oil Burner, 5 section
O --- Ring Pump Press
Electric Air Shutter
Capacitor 12.5uF
Pump Drive Key
Part Number
30A065101
30A065401
30A064901
30A064801
30A065301
30A065701
1050006
1050006
14619011
30A065601
BW4 / BW5
30A065201
30A064701
3
XXX
5
1
2
1
4
XXX
6
4
8
4
1
XXX
7
21
9b
4
Item
1
2
3
4
5
6
7
8
9
Description
Complete Jacket
Panel Right Empire II
Jacket Panel, Back
Jacket Panel, Top
Panel Left Empire II
Panel Upper Front Empire II
Acorn Nut --- 5/16”
#14 Jacket Screw
Stand --- Off
Panel, Lower Front Empire II
3 Section
Part Number
42670289AB
42570244AB
42570269AB
42570254AB
42570264AB
42570267AB
146--- 95--- 042
146--- 95--- 074
146--- 95--- 103
42570268AB
25
4 Section
Part Number
42670290AB
42570245AB
42570269AB
42570255AB
42570265AB
42570267AB
146--- 95--- 042
146--- 95--- 074
146--- 95--- 103
42570268AB
5 Section
Part Number
42670291AB
42570246AB
42570269AB
42570256AB
42570266AB
42570267AB
146--- 95--- 042
146--- 95--- 074
146--- 95--- 103
42570268AB
A01042
COLLECTOR OPENING
JACKET TOP
TRIDICATOR OPENING
OPENING FOR OPTIONAL
EXPANSION TANK OR AIR
ELIMINATOR
FRONT PANEL
BOILER SUPPLY
OPENING
STAND_OFF
ACORN NUT
JACKET SCREW
BW4 / BW5
LOWER FRONT PANEL
SHOWN HERE FOR CLARITY
LEFT SIDE PANEL
RIGHT SIDE PANEL
BACK PANEL
A01041
Fig. 25 -- Jacket Parts
7
4
WATER
OUTLET
2a
3a
(WITHOUT
TANKLESS
COIL)
5
OPTIONAL
TANKLESS
COIL
WATER
HEATER
WITH 1/2” NPT
CONNECTIONS
2b
(WITH
TANKLESS
COIL)
5a, 5b
1
6
RIGHT SIDE VIEW
FRONT VIEW
A02216
ITEM
1
1
1
2a
2b
3a
3c
____
4
5a
5b
6
7
DESCRIPTION
Beckett AFG F-- Head oil Burner
Beckett AFG Variable Head Oil Burner
Riello Oil Burner
L8148A-- 1124 Aquastat Control (no tankless coil)
L8124C-- 1094 Aquastat Control (with tankless coil)
Taco 007 Circulator
Taco Circulator Gaskets
1-- 1/4” Flange set with gaskets, nuts, and bolts
Temperature/Pressure Gauge 2” Stem
1-- 1/4” x 2-- 1/2” Pipe Nipple
1-- 1/4” x 3/4” x 1-- 1/4” Reducing Tee
3/4” Drain Valve
3/4” Relief Valve
Copyright 2006 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231
3 SECTION
146-- 19-- 355
____
1050006
433-- 00-- 521
146-- 62-- 022
CI-- 001.03
146-- 26-- 050
146-- 26-- 049
1260006
146-- 07-- 044
1510001
146-- 22-- 000
146-- 22-- 011
Fig. 26 -- Repair Parts
Printed in U.S.A.
4 SECTION
146-- 19-- 356
____
1050006
433-- 00-- 521
146-- 62-- 022
CI-- 001.03
146-- 26-- 050
146-- 26-- 049
1260006
146-- 07-- 044
1510001
146-- 22-- 000
146-- 22-- 011
Edition Date: 09/06
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
26
5 SECTION
____
146-- 19-- 357
146-- 19-- 011
433-- 00-- 521
146-- 62-- 022
CI-- 001.03
146-- 26-- 050
146-- 26-- 049
1260006
146-- 07-- 044
1510001
146-- 22-- 000
146-- 22-- 011
Catalog No: IM---BW4R ---01
Replaces: New