OIL FIRED CAST IRON

HOT WATER BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Models (Series C)

BW4BAH-91

BW4RAH-91

BW5BAH-91

BW5RAH-91

BW4BAH-126

BW4RAH-126

BW5BAH-126

BW5RAH-126

BW4BAH-168

BW4RAH-168

BW5BAH-168

BW5RAH-168

BW4BAH-105

BW4RAH-105

BW5BAH-105

BW5RAH-105

BW4BAH-175

BW5RAH-175

BW5BAH-175

BW5RAH-175

BW4BAH-245

BW4RAH-245

BW5BAH-245

BW5RAH-245

BW4BAH-140

BW4RAH-140

BW5BAH-140

BW5RAH-140

BW4BAH-210

BW4RAH-210

BW5BAH-210

BW5RAH-210

Select Models

CAC/BDP

7310 WEST MORRIS ST.

INDIANAPOLIS, IN 46231

P/N# IM-BW4-01

[240009548, Rev. C [12/2012]

SAFETY NOTICES

Safety Notices .....................................................3

Boiler Ratings And Capacities ................................4

Fresh Air For Combustion......................................8

System Piping ...................................................10

Chimney And Chimney Connections .....................17

Typical Chimney Connection ................................18

Electrical Connections ........................................19

Filling The Boiler ..............................................20

Operating The Boiler ........................................21

Checking And Adjusting Controls .........................24

Maintenance .....................................................25

Oil Boiler / Burner Cleaning Instructions ..............26

Oil Burner Cleaning ............................................27

Service Hints ....................................................28

Electrical Wiring ................................................31

Equipment And Optional Accessories ....................32

Introduction

Boiler is a natural draft oil fi red hot water boiler comprised of cast iron sections. Boiler is available with 3, 4, or 5 cast iron sections. These sections are held together by cast iron push nipples.

Boiler is capable of fi ring #2 fuel oil from 0.65 gph up to 1.75 gph. All packaged boilers include a swing door,

Honeywell limit, temperature and pressure gauge, safety relief valve, drain valve, fl ue brush, and extra boiler tap for expansion tank or air elimination.

Boiler installation shall be completed by qualifi ed agency.

Become familiar with symbols identifying potential hazards.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

!

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury

!

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

!

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

2

Figure 1 - Dimensions

BOILER RATINGS AND CAPACITIES

BOILER RATINGS AND CAPACITIES

BOILER MODEL NO.

INPUT

+gph *Mbh

»BW(4,5)(B,R)AH-91 0.65

91

»BW(4,5)(B,R)AH-105 0.75

105

BW(4,5)(B,R)AH-140

»BW(4,5)(B,R)AH-126

1.00

0.90

140

126

»BW(4,5)(B,R)AH-175 1.25

175

BW(4,5)(B,R)AH-210 1.50

210

»BW(4,5)(B,R)AH-168 1.20

168

**HEATING

CAPACITY

*Mbh

80

92

120

111

151

179

147

‡NET

AHRI

RATING

WATER

*Mbh

70

80

104

97

131

156

128

A.F.U.E.

++

86.3

85.2

84.0

86.0

85.0

84.0

86.5

NO.

SEC.

3

3

3

4

4

4

5

Boiler

Water

Capacity

(US Gal.)

9.6

9.6

9.6

11.6

11.6

11.6

13.7

DIMENSIONS

A

(inches)

14½

14½

14½

17¾

B

6

6

6

6

C

8

8

8

9⅝

17¾ 6 9⅝

17¾ 6 9⅝

21 6 11½

BW(4,5)(B,R)AH-245 1.75

245 210 183 84.3

5 13.7

21 6 11½

* Mbh = 1,000 BTU per hour [BTU = British Thermal Unit]

**Heating Capacity based on 13% CO

2

with a 0.02” w.c. draft over fi re, 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 oil at 140,000 BTU per gallon

++A.F.U.E. = Annual Fuel Utilization Effi ciency based upon D.O.E. test procedure.

‡ Net AHRI Water Ratings based on piping and pickup allowance of 1.15. Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

>> As Energy Star Partner, manufacturer has determined this product meets Energy Star guidelines for energy effi ciency.

3

SAFE INSTALLATION AND OPERATION

!

WARNING

Fire, explosion, burn, scald hazard. Use only number 2 fuel oil. Do not use gasoline, kerosene, crankcase oil or any oil containing gasoline. Failure to follow these instructions could result in death or serious injury.

!

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation.

Install discharge piping per these instructions.

NOTICE

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 modifi cations.

Manufacturer is not responsible for any changes to the original design.

1. Read the Owner’s Manual for Safe Operation. Failure to follow rules for safe operation and instructions can cause malfunction of boiler and result in death, serious bodily injury, and/or property damage.

2. Check your local codes and utility requirements before installation. 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.

4. Inspect oil line and connections for leaks.

5. Be certain oil burner nozzle is the size required. Overfi ring will result in early failure of the boiler sections.

This will cause dangerous operation.

6. Never vent this boiler into enclosed space. Always vent to outside. Never vent to another room or inside a building.

7. Be sure there is adequate air supply for complete combustion.

8. Follow regular service and maintenance schedule for effi cient and safe operation.

9. Keep boiler area clean and free of combustible material, gasoline and other fl ammable vapors and liquids.

10. Oil burners are not do-it-yourself items. This boiler must be installed and serviced by qualifi ed professionals using combustion test instruments.

11. Be aware when piping the safety relief valve if system pressure exceeds safe limit of 30 pounds per square inch, the safety relief valve will automatically lift open. Lifting of the safety relief valve can discharge large quantities of steam and hot water, which may damage the surroundings. Before installing the safety relief valve read the manufacturer’s instructions and maintenance section of the manual on safety relief valves.

12.

Installation and sizing of the expansion tank must consider heating systems total water volume, temperature, boiler initial fi ll pressure, and system arrangement. Improperly installed and sized expansion tank may result in frequent lifting of the safety relief valve or other heating system problems. For proper installation, sizing, and maintenance of the expansion tank follow guidelines established by tank manufacturer.

13. Expansion tank performance and life expectancy can be hindered by overfi lling the boiler. Recommend initial fi ll pressure of 10-12 psig. For higher fi ll pressures expansion tank’s air charge will need to be increased to match fi ll pressure. Consult manufacturer’s guidelines for sizing and selection.

14. Purging the heating system of air and gases when fi rst putting boiler into service is critical for proper circulation and quiet performance. Once air and gases are purged, for boiler installations using fl oat type vents, air vents should be closed for normal operation.

If air is heard or noticed by loss of heat, purge system and open vents for short period of time.

4

LOCATING THE BOILER

Complete Prior To Installing Boiler.

A. Verify you have selected the right size boiler with proper capacity. AHRI rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. See boiler rating and capacity table previously listed in this manual. Any heat loss calculations used should be based on approved methods.

B. Boiler must be supplied with proper oil supply and oil piping, suffi cient fresh combustion air, and suitable electrical supply.

1. Place boiler in location centralized with the piping system and as close to chimney as possible.

2.

Boiler must be level. If necessary use metal shims beneath boiler’s feet.

3. Use raised base if fl oor can become wet or damp.

4.

Maintain clearances for fi re safety as well as servicing. 18” clearance must be maintained at a side where passage is required for access to another side for cleaning, servicing, inspection, or replacement of any parts that normally may require such attention. Boilers must be installed at least 6” from combustible material on all sides and above.

Allow at least 24” front clearance for servicing.

C. Boiler must be connected to suitable venting system and piping system adequate to distribute heating load.

D. Properly locate and install thermostat for heating system control.

5. Fresh air for combustion must be available at front of the 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.

Any doubts as to requirements, check with local authorities and obtain professional help where needed. OPERATING

INSTRUCTIONS, FINAL CHECKS AND ADJUSTMENTS, and

MAINTENANCE sections in this manual are vital to the proper and safe operation of the heating system.

!

WARNING

Fire hazard. Do not install boiler on combustible fl ooring or carpeting. Failure to follow these instructions could result in death or serious injury.

Figure 2 - Clearances

6. Floor supporting boiler must be noncombustible and suffi ciently stable. If it is combustible, place boiler on 2” concrete patio blocks or 2” Cladlite Pad™.

Blocks or pad must be under entire boiler to protect the fl oor.

7.

Installation shall be in accordance with the requirements of the local authorities having jurisdiction. Compliance with these regulations is required. In the absence of local codes, follow NFPA

31 Installation of Oil Burning Equipment, latest revision.

6”

Min.

Boiler

Front

6”

Min.

6” Min./18”

With Coil

24” Min.

BOILER CLEARANCES

Unit

Combustible

Clearance

Top

Left Side

Right Side

6”

24”

6”

Base non-combustible

Front 18”

Back 6”

Accessibility,

Cleaning, and

Servicing

Flue to

Combustible

Clearance

18”

24”

18”

All distances measured from the cabinet of the boiler.

5

Figure 3 - Boiler With Piping System

LOCATING THE BOILER

C H I M N E Y

VENT PIPE

PUMP IN RE

ENTRANCE SWIT

6

FRESH AIR FOR COMBUSTION

EXAMPLE 2: Boiler Located in Confi ned Space

!

WARNING

Asphyxiation, fi re hazard. Do not obstruct air openings to combustion area. Follow instructions below, to maintain adequate combustion air.

NOTICE

Install outside air intake if you use fi replace or kitchen or bathroom exhaust fan. These devices rob boiler and water heater of combustion air.

Provide enough fresh air to assure proper combustion.

Fire in the boiler uses oxygen. It must have continuous supply. Air in the house contains only enough oxygen to supply burner for short time. Outside air must enter the house to replace air used by the burner. Study the following examples 1 and 2 to determine your fresh air requirements.

EXAMPLE 1: Boiler Located in Unconfi ned Space

If your boiler is in an open area (un-partitioned basement) in conventional house, air that leaks through cracks around doors and windows will usually be adequate to provide air for combustion. Doors should not fi t tightly. Do not caulk cracks around windows.

An unconfi ned space is defi ned as space whose volume is not less than 50 cubic feet per 1,000 Btu per hour of total input rating of all appliances installed in that space.

A.

All Air from Inside the Building: Confi ned space shall be provided with two permanent openings communicating directly with additional room(s) of suffi cient volume so the combined volume of all spaces meets the criteria for unconfi ned space. Total input of all combustion equipment installed in combined space shall be considered in making this determination. Each opening shall have minimum free area of one square inch per 1,000 Btu per hour of total input rating of all combustion equipment in the confi ned space, but not less than 100 square inches. One opening shall be within 12 inches of top and one within 12 inches of bottom of the enclosure.

Example: Your boiler is rated at 100,000 Btu per hour.

Water heater is rated at 30,000 Btu per hour. Total is

130,000 Btu per hour. You need two grilles, each with 130 square inches of FREE opening. Metal grilles have about

60% FREE opening. To fi nd louvered area needed, multiply free opening required by 1.7 (130 x 1.7 = 221.0 sq. in. louvered area). In this example, two grilles each having 8” x 30” (240 sq. in.) louvered area would be used.

Figure 4 - Air Openings For Boiler Located In

Confi ned Space (Utility Room )

7

FRESH AIR FOR COMBUSTION

B. All Air from Outdoors: Confi ned space shall be provided with two permanent openings, one commencing within 12 inches of top and commencing within 12 inches of bottom of enclosure. Openings shall communicate directly, or by ducts, with outdoors or spaces (crawl or attic) that freely communicate with outdoors.

1. When directly communicating with outdoors, each opening shall have minimum free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the enclosure.

2. When communicating with outdoors through vertical ducts, each opening shall have minimum free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the enclosure.

3. When communicating with outdoors through horizontal ducts, each opening shall have minimum free area of one square inch per 2,000

Btu per hour of total input rating of all equipment in the enclosure.

4. When ducts are used, they shall be of same cross sectional area as free area of openings to which they connect. Minimum dimension of rectangular air ducts shall be not less than three inches.

Figure 5 - Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In

Tightly Constructed Houses

FRESH AIR DUCT CAPACITIES

THROUGH LOUVERS

Fresh Air

Duct Size

¼” Mesh

Screen

(Btuh)*

Wood

Louvers

(Btuh)*

Metal

Louvers

(Btuh)*

3 ½” x 12”

8” x 8”

8” x 12”

8” x 16”

144,000

256,000

384,000

512,000

36,000

64,000

96,000

128,000

108,000

192,000

288,000

384,000

*Btuh = British Thermal Units per hour based on opening covered by ¼” mesh screen , wood louvers, or metal louvers.

8

SYSTEM PIPING

1. Installation of boiler for new heating system,

Install all of radiation units (panels, radiators, baseboard, or tubing) and supply and return mains fi rst. After all heating system piping and components have been installed, make fi nal connection of system piping to boiler. It is recommended to mount circulating pump on supply side piping, such that it pumps away from expansion tank. Refer to fi gures on next pages.

2. Equip hot water boiler installed above radiation

level with low water cut off device. Periodic inspection is necessary, as is fl ushing of fl oat type devices, per low water cut off manufacturer’s specifi c instructions.

Figure 6a - Safety Relief Valve Installation

3. Packaged boiler is set up with 1¼” NPT supply

and return piping from front of boiler. Boiler supply and return piping can be moved to rear of boiler. Boiler should not be piped return line to front, supply line to rear, or vice versa, will cause boiler water to short circuit heat exchanger. Piping connections may require additional fi ttings and parts.

4. Install drain valve provided with boiler in return tee. .

5. Install Safety Relief Valve in rear section using ¾” nipple and street elbow provided with boiler. See fi gure

6a.

A. Install safety relief valve with spindle in vertical position.

B. Do not install shutoff valve between boiler and safety relief valve.

C. Install discharge piping from safety relief valve.

• Use ¾” or larger pipe. See fi gure 6b.

• Use pipe suitable for temperatures of 375°F

(191°C) or greater.

• Individual boiler discharge piping shall be independent of other discharge piping.

• Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

6. Verify clean cold water supply is available when connecting to pressure reducing valve. When water supply is from well or pump, a sand strainer should be installed at the pump.

Figure 6b - Discharge Piping From Safety Relief

Valve

SAFETY RELIEF VALVE

Follow Instructions to install discharge piping from safety relief valve to drain.

DISCHARGE

LINE

Check local codes for maximum distance from fl oor or allowable safe point of discharge .

9

SYSTEM PIPING

Figure 7 - Bypass Piping Arrangement Diagram

Low Design Water Temperature Systems (Below

140° F) And Large Water Content Systems

> LOW DESIGN WATER TEMPERATURE

SYSTEMS

> LARGE WATER CONTENT SYSTEMS

> PIPING ARRANGED FOR “POWER

PURGING” AIR OUT OF THE SYSTEM

PIPING, REFER TO THIS MANUAL’S

SECTION ON “FILLING THE SYSTEM

WITH WATER” OPTION #1

• Signifi cant condensation may form in this boiler and/ or venting system if boiler is operated with return temperatures of less than 120°F.

• Condensation is corrosive and can eventually cause damage to boiler and venting system. Minimum design return water temperature to prevent this condensation in boiler and venting is 120°F.

• Boiler used in heating system where design water temperatures below 140°F are desired (e.g. radiant fl oor heating), a 3-way or 4-way mixing valve or suitable alternative (e.g. Bypass Piping Arrangement shown in diagram on following page) is required to prevent low temperature (below return 120°F) return water from entering boiler. When using mixing valve, follow manufacturer’s installation instructions.

• Boiler connected to system having large water content

(such as former gravity system), use of Bypass Piping

Arrangement shown in diagram on following page is suggested.

Adjust two throttling valves to maintain at least 120°F in boiler return.

Throttling valves are used for bypass piping, if required.

10

SYSTEM PIPING

Figure 8 - System Piping Arrangement Zoning With Zone Valves

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

NOTE: CIRCULATOR CAN ALSO BE INSTALLED

ON RETURN PIPING.

> PIPING ARRANGED FOR “POWER PURGING”

AIR OUT OF SYSTEM PIPING, REFER TO

THIS MANUAL’S SECTION ON “FILLING THE

SYSTEM WITH WATER” OPTION #1

11

SYSTEM PIPING

Figure 9 - System Piping Arrangement Zoning With Circulators

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

> PIPING ARRANGED FOR “POWER PURGING”

AIR OUT OF SYSTEM PIPING, REFER TO

THIS MANUAL’S SECTION ON “FILLING

THE SYSTEM WITH WATER” OPTION #1

12

SYSTEM PIPING

Figure 10 - System Piping Arrangement Alternate Near Boiler Piping

> PER THIS MANUAL, USE OPTION #2 IN

“FILLING THE SYSTEM WITH WATER”

> DIAPHRAGM EXPANSION TANK MOUNTED

OFF THE BOILER

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

> THIS PIPING ARRANGEMENT CAN BE USED

WITH ZONE VALVES OR ZONE

CIRCULATORS

13

SYSTEM PIPING

Tankless Coil Piping Arrangement

Boilers may be factory packaged with tankless heater

coil see fi gure below. Coil provides instantaneous heating of water for domestic use if proper burner and water supply line controls are used. Tankless coils are meant to provide domestic hot water for intermittent draws, not continuous fl ow.

NOTICE

Do not use tankless coil if your water is excessively hard with lime or other deposits which will accumulate inside the coil.

When using tankless coil, boiler is confi gured so Honeywell

L7248 operates with Honeywell L4006 low limit mounted on well installed in tankless heater. Mount factory wired low limit on well.

Tempering valve (mixing valve) is required as shown below.

Flow restrictor may be required on tankless coil inlet piping so that fl ow rates are matched to boiler heat input (see table).

Boiler

Model

BW5(B,R)AH-91

BW5(B,R)AH-105

BW5(B,R)AH-140

BW5(B,R)AH-126

BW5(B,R)AH-175

BW5(B,R)AH-210

BW5(B,R)AH-168

BW5(B,R)AH-245

Burner

Input

Rate (gph)

0.65

0.75

1.00

0.90

1.25

1.50

1.20

1.75

Input

(MBH)

91

105

140

126

175

210

168

245

Tankless

Rating

(gpm)‡

2.90

3.00

3.25

3.15

3.50

3.75

3.45

4.00

‡ Gallons of water per minute heated from 40°F to 140°F with

200°F boiler water temperature, intermittent draw

!

DANGER

Water temperatures exceeding 125°F will cause severe burns instantly or death by scalding.

Figure 11 -Tankless Coil Piping Arrangement

14

SYSTEM PIPING ARRANGEMENT

Antifreeze added to boilers must be nontoxic, and must be of type specifi cally intended for use in closed hydronic heating systems. Under no circumstances should automotive antifreeze be used. Antifreeze used in any boiler may reduce capacity by 10% or more and increase fuel consumption. Tankless coil performance will fall as concentration of antifreeze is increased. Refer to boiler and piping water volumes tables.

PIPING WATER VOLUMES

PIPE SIZE

½”

¾”

1”

1 ¼”

COPPER PIPE

FACTOR

82.5

40.0

23.3

15.3

STEEL PIPE

FACTOR

63.5

36.0

22.2

12.8

1 ½”

2”

10.8

6.2

9.5

5.8

Divide total length of piping in feet by appropriate factor in table to determine volume in gallons.

BOILER WATER VOLUMES

Number of

Boiler Section

3

4

5

Total Volume

(Gallons)

9.6

11.6

13.7

15

CHIMNEY AND CHIMNEY CONNECTIONS

For oil fi red boilers for connections to vents or chimneys, vent installations shall be in accordance with applicable provisions of INSTALLATION OF OIL BURNING EQUIPMENT,

NFPA31 latest revision, and applicable provisions of local building codes.

NOTICE

Fresh air (ventilation) is important to proper venting. Ventilation and venting are two parts of the same system. Inadequate ventilation will result in inadequate venting. Always be sure to have enough ventilation to support proper venting.

Check your chimney to make certain that it is right size, properly constructed and in good condition.

See Table “Recommended Minimum Chimney Sizes”.

For additional chimney design and sizing information, consult the National Standard for Chimneys, Fireplaces,

Vents and Solid Fuel Burning Appliances, ANSI/NFPA 211.

!

WARNING

Fire Hazard. Maintain minimum vent pipe clearance of 18” from surface of vent to wood and other combustible materials. Failure to comply may result in death or serious injury.

Chimney Connector And Draft Regulator

• Venting the boiler requires 6” diameter chimney connector pipe and use of manufacturer provided draft regulator.

• Regulator, when properly installed, automatically controls the draft.

• Install in horizontal section of pipe, may also be installed in angled or vertical section of pipe.

• Verify “top” of regulator is at the top and short pipe section which holds the vane is horizontal.

• Even though locating draft regulator close to chimney reduces noise, install draft regulator as close as practicable to the boiler.

• Install chimney connector, start at boiler with vertical pipe, elbow, then install draft regulator horizontally.

• When regulator is in place, start at chimney and work back to the regulator.

• Join the two sections with draw-band.

• Horizontal pipe must slope up toward the chimney at least 1/4 inch per linear foot of venting.

• Chimney connector must not leak and must be fi rmly supported.

• Join each section with at least two sheet metal screws.

Support every second section with a stovepipe wire.

NFPA RECOMMENDED MINIMUM CHIMNEY SIZES

FIRING RATE

(gph)

0.60 - 1.30

1.31 - 1.80

1.81 - 2.00

CHIMNEY

HEIGHT (ft)

15

15

20

NOMINAL

CHIMNEY

8” x 8”

8” x 8”

8” x 8”

ROUND

LINER INSIDE

For elevations above 2,000 feet above sea level, add 3 feet to the chimney heights.

6”

7”

8”

SQUARE

LINER INSIDE

6 ¾” x 6 ¾”

6 ¾” x 6 ¾”

6 ¾” x 6 ¾”

16

TYPICAL CHIMNEY CONNECTION

Figure 12 -Typical Chimney Connection

Minimum height:

• Must be at least 3ft. (.9m) higher than highest part of passage through roof.

• Must be at least 2ft. (.7m) higher than any neighboring object within 10ft. (3m).

• Must have unobstructed top opening.

Must be at least 4 in.

(101mm) thick

- and be tight

17

ELECTRICAL CONNECTIONS

!

WARNING

Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections.

Failure to do so could result in death or serious injury.

Thermostat

Install 24 Volt thermostat (not provided) in proper location.

Location of thermostat has effect on boiler system operation.

Follow instructions included with thermostat.

Grounding

Permanently ground boiler according to local codes and latest revision of the National Electrical Code. Run 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod.

Electric Power Supply

Installation must comply with the latest revision of the

National Electrical Code, any other national, state, or local codes or regulations.

Connect 115 volt electrical supply to L1 and L2 terminals on limit and two thermostat wires to T and T terminals on same limit. See wiring diagram page 28.

Run separate circuit from separate over current protection device in your electrical service entrance panel. Minimum

15 ampere circuit. Locate shutoff switch at boiler. Turn off during any maintenance. Solder and tape or securely fasten connections with wire nuts.

Oil Burner Wiring

For boilers packaged with oil burners, burners are wired at the factory. For boilers shipped without a burner, wiring connections are shown in the electrical wiring diagrams of this manual.

18

How A Hot Water System Operates

Entire heating system (boiler, piping, and radiation units) is fi lled with water. As water in the boiler is heated, it is circulated from top of boiler through supply main to radiation units. Cooler water in radiation units fl ows back through return piping through return main into the boiler.

This arrangement provides positive and rapid response to the thermostat.

Filling The System With Water

FILLING THE BOILER

OPTION #1 This method utilizes boiler piping as shown in fi gure on page 6.

OPTION #2

• Close air vents on all radiation units.

• Open valves to radiation units. Verify boiler drain valve, expansion tank drain cock, and air bleed screw on expansion tank drain fi tting are closed.

• Open fi ll valve on piping to expansion tank.

• Open water inlet to boiler and leave it open.

• Open air vent on lowest radiation unit.

• When all air has escaped and water starts to fl ow from vent, close it.

• Go to next radiation unit, and repeat this process until fi nishing with highest radiation unit.

• If heating system has automatic vents, this manual venting is unnecessary but it will speed up proper fi lling of the system.

A. Close main shutoff valve, isolation valves, and zone valves (if applicable). If bypass piping is installed, also close two throttling valves. Leave boiler service shutoff valve (if installed) and balancing valves to each heating zone fully open.

B. Open following valves in order: drain valve for power purging, isolating valves before and after boiler circulator (if applicable), both throttling valves (if applicable), and then open fi ll line shutoff valve. Water will fi ll bypass piping and push air through piping and out power purging drain valve. When power purging drain valve runs air free, close bypass piping throttling valve (leaving throttling valve to supply piping fully open).

If system is a closed expansion tank system, automatic fi ll valve is needed. Leave automatic fi ll valve open to refi ll system automatically as needed.

Note initial fi ll pressure on boiler’s temperature / pressure gauge, which should be 10-15 psig. Any lowering of pressure from its initial fi ll pressure indicates loss of water due to leakage. Automatic fi ll valve should then compensate for this water pressure loss. If it does not, manually open this valve to refi ll system until needle is again pointing to same pressure reading. Instructions are packaged with valve.

C. Next, open isolation valve (or zone valve) to fi rst zone. Water will fi ll piping and push any air out power purging drain valve. When power purging drain valve runs air free, close isolation valve or zone valve).

Repeat this procedure for remaining heating zones.

D. Once all zones are fi lled with water and purged of air,

close power purging drain valve and fi ll line shut off valve, open main shutoff valve, and adjust throttling valves and balancing valves as required.

19

Start: Fill entire system with water. Vent all air from system following section for Filling The Boiler.

OPERATING THE BOILER

• Room used for supplying combustion air should be isolated from any area served by exhaust fans.

• Refer back to the section on Fresh Air For Combustion for additional sizing guidelines.

Fuel Units And Oil Lines:

• Install oil line(s) to oil burner.

• Recommend using heavy wall copper tubing and fl ared fi ttings, not compression fi ttings.

• All connections and joints must be absolutely airtight.

Use an appropriate non-hardening thread sealing compound on the threaded connections, not Tefl on tape.

• See fuel unit data sheet furnished with the burner for sizing, lift, and length of tubing recommendations.

Draft Regulators: Barometric draft regulator is required for controlling draft through boiler. Mount barometric draft regulator in chimney connector. Refer back to section on

“Chimney And Chimney Connections”. Once draft regulator is installed, use draft gauge to adjust to proper opening:

A. Combustion chamber over fi re draft will be approximately -0.01” WC to -0.02” WC.

B. Stack draft will be approximately -0.02” WC. to

-0.04” WC.

C. Larger installation, greater draft will be required in stack to obtain desired over fi re draft.

Oil burner is equipped with single stage fuel unit with bypass plug removed for single pipe installation.

Satisfactory where fuel supply is on same level as or above burner permitting gravity fl ow of oil. Per NFPA 31 requirements, never exceed 3 psig pressure to inlet side of fuel unit.

When necessary to lift oil to burner, two pipe installation is required. Run return line between fuel unit and oil supply. When two pipe installation is used, bypass plug

(furnished with burner) must be installed in fuel unit. Refer to fuel unit instructions furnished with burner for specifi c instructions on installing bypass plug. Do not exceed fuel unit manufacturer’s recommendations for running vacuum.

Nozzles And Electrodes : Use proper size, spray angle, and spray pattern nozzle. Refer to recommended nozzle selection charts.

To install nozzle, remove nozzle line electrode assembly, if necessary remove retention ring assembly, and install and tighten nozzle. Take care not to damage electrode insulators or bend electrode tips.

After installing nozzle, reassemble nozzle line electrode assembly and set electrode tip spacing.

Depending on burner type, electrode tip spacing may need to be set prior to reassembling nozzle line electrode assembly.

Refer to following pages for setting electrode tip spacing.

NOTICE

If lift exceeds 14 feet for Beckett burners or 11 feet for Riello burners, two stage fuel unit is required with return line.

Refer to Oil Burner Specifi cations chart for proper pump pressure and head adjustment.

Install oil fi lter of adequate size inside building between tank shutoff valve and oil burner. For ease of servicing, locate shutoff valve and fi lter near oil burner.

Air Supply For Combustion:

• Do not install boiler in rooms with insuffi cient air, unless corrective steps are taken.

• It may be necessary to install windows or cut holes in a door to rooms used for supply air to obtain suffi cient combustion air and prevent less than atmospheric air pressure in that room.

• If there is a lack of combustion air, burner fl ame will be dark orange and formation of soot will occur in heating unit.

• In buildings of conventional frame, brick, or stone construction that do not have utility rooms, basement windows, or stair doors, air infi ltration is normally adequate to provide enough air for combustion and for operation of barometric draft control.

20

OPERATING THE BOILER

Final Burner Adjustments: Final burner adjustments must be made using combustion test instruments. Refer to

“Burner Settings”. Set burner accordingly.

• Check draft over fi re to verify it is between -0.01” WC and -0.02” WC, adjust draft as necessary.

• After operating 10 minutes to warm up boiler, use combustion test equipment to take smoke reading in fl ue pipe between boiler and draft regulator.

• Smoke reading should be zero to trace (Shell Bacharach

Scale).

• A new boiler requires more than 10 minutes to burn clean due to oil fi lm on new heat exchanger.

• If smoke reading is zero, gradually close burner’s air adjustment to obtain smoke reading showing trace smoke reading. Once smoke reading is trace, measure

CO

2

and as insurance margin increase air to suffi ciently reduce CO

2

by ½% to 1%.

If clean fi re cannot be obtained, it is necessary to verify burner head and electrode alignment. Proper electrode alignment fi gures are presented on following pages.

If fi re continues to be smoky, replace nozzle with correct replacement.

Once burner is completely adjusted, burner should be started and stopped several times to assure good operation with no fl uttering or rumbling. Verify there are no oil leaks and record nozzle size, oil pressure, combustion readings, and air settings on tag or label attached to burner or, boiler.

Oil Burner Maintenance : For Beckett AFG, and Riello

40 F5, or F10 perform following preventative maintenance annually, preferably prior to heating season. Refer to burner manual provided with boiler.

1. Fuel Filter Replace to prevent contaminated fuel from reaching nozzle. Partially blocked fuel fi lter can cause premature failure of fuel pump.

2. Fuel Pump Unit Replace pump screen and clean pump unit to maintain fuel delivery to nozzle.

3. Ignition Electrodes Clean and adjust per manufacturer’s recommendations, to maintain reliable ignition of oil.

4. Nozzle Replace to maintain safe and reliable combustion effi ciency. Replace with nozzle as required in charts located in this manual.

5. Fan and Blower Housing Must be kept clean, free of dirt, lint and oil to maintain proper amount of air fuel requires to burn.

6. Check Final Burner Adjustments.

If any component parts must be replaced, always use parts recommended by burner manufacturer.

BOILER

MODEL

DELEVAN

OIL NOZZLE

BW(4,5) BAH-91* 0.50-80º B

BW(4,5) BAH-105 0.65-70º B

BW(4,5) BAH-140 0.85-70º B

BECKETT OIL BURNER SPECIFICATIONS

INPUT

RATE

(gph)

HEAD-ADJ.

OR SETTING

LOW FIRE

BAFFLE

AIR

SHUTTER/

BAND

STATIC

PLATE

0.65

0.75

F0 - 1 ⅛

F3 - 1 ⅛

YES

YES

10/0

10/0

3 ⅝

3 ½

1.00

F3 - 1 ⅛ NO 10/2 3 ½

BURNER

MODEL

AFG F-HEAD

AFG F-HEAD

AFG F-HEAD

OIL PUMP

PRESSURE

(PSIG)

175

140

140

BW(4,5) BAH-126

BW(4,5) BAH-175

0.75-80º A

1.00-80º A

BW(4,5) BAH-210 1.25-80º A

BW(4,5) BAH-168 1.00-60º B

BW(4,5) BAH-245 1.50-45º B

0.90

1.25

1.50

1.20

1.75

F3 - 1 ⅛

F6 - 1 ⅛

F6 - 1 ⅛

0

2

*To fi re the 3 section 91 on rate, the oil pressure must be increased to 175 psig. All Beckett oil burners for the BW boilers are factory preset at 140 psig.

REILLO OIL BURNER SPECIFICATIONS

BOILER

MODEL

DELEVAN

OIL NOZZLE

INPUT

RATE (gph)

TURBULATOR/AIR

SHUTTER SETTING

OIL PRESSURE

(PSIG)*

BURNER

MODEL

OIL PUMP

PRESSURE

(PSIG)

BW(4,5) RAH-91*

BW(4,5) RAH-105

BW(4,5) RAH-140

0.50-70° W

0.65-70° W

0.85-70° W

0.65

0.75

1.00

0.50/2.0

2.0/2.2

2.0/3.2

155

150

170

F5

F5

F5

155

150

150

BW(4,5) RAH-126

BW(4,5) RAH-175

BW(4,5) RAH-210

BW(4,5) RAH-245

0.75-70° W

1.00-70° W

1.25-70° W

1.50-70° W

0.90

1.25

1.50

1.75

1.5/2.6

2.5/3.8

4.0/7.0

2.0/3.8

160

170

175

155

F5

F5

F5

F10

150

170

175

155

*All Riello 40 F5 and F10 oil burner are factory preset at 145 psig.

NO

NO

NO

NO

NO

8/0

10/0

10/2

10/1.5

10/4

3 ½

3 ⅜

3 ⅜

2 ¾

2 ¾

AFG F-HEAD

AFG F-HEAD

AFG F-HEAD

AFG 50 MD

AFG 50 MD

140

140

140

140

140

21

OPERATING THE BOILER

Figure 13 -Burner Adjustments and Settings

22

You or your installer must follow these instructions carefully.

!

NOTICE

CHECKING AND ADJUSTING CONTROLS

WARNING

Burn, scald hazard. Do not attempt to start the burner when excess oil has accumulated, when the unit is full of vapor, or when the combustion chamber is very hot.

Adjust Operating Controls : Use the following settings for fi rst adjustment:

Locate thermostat fi ve feet above the fl oor on inside wall.

Locate thermostat to sense average room temperature, avoid the following:

THERMOSTAT LOCATIONS TO AVOID

DEAD

SPOTS

HOT SPOTS COLD SPOTS

Behind doors

Corners & alcoves

Concealed pipes Concealed pipes

Fireplace or ducts

TV sets

Radios

Stairwells drafts

Doors drafts

Lamps

Direct sunlight

Kitchens

Unheated room on other side of wall

High Limit:

Baseboard and Convectors 200°F

Standing Radiators 180°F

Low Limit (when used) 140º ( increase if hotter domestic water is required, low limit set point must be at least 20°F less than high limit set point)

When temperature on thermostat is set above indicated thermostat temperature, boiler’s burner should start. Verify that when room temperature reaches selected temperature setting, thermostat should turn boiler’s burner off, and once room temperature falls few degrees boiler starts operating again.

Do not start burner unless all cleanout doors are secured in place.

Adjust Thermostat Heat Anticipator To: 0.2

Amp s

Check Thermostat Operation:

Follow instructions included with your thermostat.

23

MAINTENANCE

Annually : Recommend fl ue passages, combustion chamber area (target wall, fi re door insulation, durablanket), burner adjustment, control operation, and boiler seals (fi re door gasket or silicone seal, cast iron sectional seals, fl ue collector) be checked once each year by trained Service Technician.

Diaphragm Expansion Tank : Tank may become water logged. Frequent automatic opening of safety relief valve indicates water logging. High boiler temperature accompanied by unusually low radiation unit temperature

(and “knocking” noises) indicates excess air in the tank. To correct this condition, replace diaphragm expansion tank.

Before The Start Of Each Heating Season system has been shut down for extended periods of time) recheck whole system for water, oil, and vent piping leaks.

Replace or patch any leaks or faulty seals.

Vent Pipe:

(or when

Visually inspect entire venting system once a month for any signs of leakage, deterioration, or soot build up. If vent pipe shows any signs of leaking or deterioration, replace it immediately. If it shows any signs of soot build up, clean vent pipe and have burner settings and combustion checked by trained Service Technician.

Water System: If system is to remain out of service during freezing weather, drain it completely (water left in system may freeze and will crack pipes and/or boiler).

Tankless Coil (Or Cover Plate) Gasket: Gasket should be checked at least twice year for leakage, replace if necessary. If gasket is replaced, make sure that when coil plate (or cover plate) is reattached, ten nuts are torqued in alternating pattern to insure equal force is applied to entire gasket creating good seal. Nuts should be torqued so gasket does not squeeze out from behind the plate.

Oil Burner: Oil burner maintenance is listed in this manual under “Operating The Boiler”.

Safety Relief Valve: Valve should open automatically when system pressure exceeds pressure rating (usually 30 psi) of safety relief valve. Should valve ever fail to open under this condition, shut down the system. Drain system until system pressure is reduced below safety relief valve pressure rating. Contact Service Technician to replace the valve and inspect heating system to determine cause, may indicate equipment malfunction. Safety relief valve should be tested monthly during heating season. Prior to testing, make certain discharge pipe is properly connected to valve outlet and arranged so as to contain and safely dispose of boiler discharge. Hold trip lever fully open for at least fi ve seconds in order to fl ush free any sediment that may lodge on valve seat. Permit valve to snap shut. Refer to valve manufacturer’s instructions packaged for more details.

Conventional Expansion Tank : Tank may become water logged or may receive excess air. Frequent automatic opening of safety relief valve indicates water logging. High boiler temperature accompanied by unusually low radiation unit temperature (and “knocking” noises) indicates excess air in the tank. To correct either condition, close valve between boiler and tank. Drain tank until empty. Check all tank plugs and fi ttings, tighten as necessary. Open valve between boiler and tank. Water will rise to normal height in tank if system has automatic fi ll valve, otherwise manually refi ll system.

Never burn garbage or paper in the unit, never leave combustible material around it.

24

OIL BOILER / BURNER CLEANING INSTRUCTIONS

Oil Boiler Cleaning:

1.

Shut off all electrical power to boiler / burner and shut off fuel oil supply.

2.

3.

Remove vent pipe from top of boiler. Inspect pipe and chimney for signs of corrosion and deterioration. Clean out base of chimney. If vent pipe shows any signs of corrosion or deterioration, replace it immediately. If chimney damage or deterioration is discovered, contact a service technician.

Remove top jacket panel screws (5), brass wing nuts

(2) holding fl ue collector top, and fl ue collector top.

Inspect gasket on underside of fl ue collector and replace as necessary.

6.

7.

8.

Carefully vacuum soot accumulations from combustion chamber area, take care to not damage any of refractory or blanket insulation. To gain access to combustion chamber fi rst check that shut off valve on fuel oil line is closed and disconnect fuel oil line. Open swing door by removing whiz lock nut holding door shut.

Inspect target wall, fi re door refractory, and combustion chamber blanket (when included) for cracking and deterioration. If there are signs of cracking or deterioration, replace refractory or blanket before reassembling burner / front plate.

Inspect door’s braided gasket for wear and damage.

Replace when necessary with braided gasket of same material and size.

4. Before beginning to clean fl ue passageways, insure combustion chamber blanket is covered. If blanket is not covered prior to cleaning, replace blanket once cleaning is completed.

9.

10.

Inspect and clean oil burner.

Reinstall burner.

5.

With access to fl ue passageways, remove soot from fi reside surfaces by brushing diagonally through fl ue passages (see drawing below). Brushing can be made easier by cutting end of fl ue brush off and inserting it into drill. When brushing, take care to not damage target wall with fl ue brush.

11.

12.

13.

Reinstall fl ue collector.

Reinstall top jacket panel. Reconnect fl ue pipe.

Reconnect electrical and fuel supplies.

14. Fire burner, check for proper combustion using combustion test equipment, make adjustments as necessary.

Figure 14 - Brush Diagonally Through Flue

Passages

15.

Verify all safety controls and operating controls are functioning properly.

NOTICE

Important operating and maintenance requirements:

• Keep your boiler and the area around it clean

• Never burn refuse or any material other than specifi ed fuel in your boiler

25

OIL BURNER CLEANING

These are general instructions for cleaning an oil burner. For specifi cs, consult burner manufacturer’s instructions.

!

WARNING

Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections.

Failure to do so could result in death or serious injury.

1.

Verify all electrical power to boiler / burner and fuel supply to burner are shut off.

2. With swing door open, clean any soot accumulations from end of burner and if applicable burner head.

3.

Remove burner drawer assembly, clean electrodes and then reset electrode spark gap per manufacturer’s recommendations.

4. Replace oil nozzle with same size and type recommended for use on this boiler.

5.

Install burner drawer assembly make sure head location (and size if applicable) are per manufacturer’s recommendations. If burner being used has damaged head, replace head with same head recommended for use on this boiler.

6. Inspect and clean oil burner blower wheel.

7.

Remove oil pump cover and clean / replace pump screen. Carefully reassemble insuring pump cover creates proper seal.

8. Securely fasten swing door shut.

9.

Replace fuel fi lter (if applicable).

10. Connect electrical and fuel supplies.

11.

Fire burner, check for proper combustion using combustion test equipment and making adjustments as necessary.

12. Insure all safety controls and operating controls are functioning properly.

26

SERVICE HINTS

You may avoid inconvenience and service calls by checking these points before you call for service:

IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .

POSSIBLE CAUSE WHAT TO DO

Thermostat is not set correctly Reset thermostat

Burner is not operating properly

Check fl ame. If it is yellow, the burner is not getting enough air.

Or, if fl ame is blue and noisy and seems to lift off the burner, the burner is getting too much air. Contact your service technician.

No electric power to boiler

Controls out of adjustment

Radiators not heating

Check over-current protection. Check to be sure electric power supply circuit is “ON”.

Reset according to instructions.

Open radiator vents to excess air. Check fl ow control valve (if used). It may be in closed position.

Check over-current protection. Check relay operation.

Check all control terminals and wire joints.

Circulating pump not running

Poor electrical contact

Chimney fl ue is blocked Have the chimney professionally cleaned.

RELIEF VALVE LEAKING . . .

WHAT TO DO POSSIBLE CAUSE

Corrosion and/or deposits on seat.

Open valve manually. Allow water to run and clear valve seat.

Water logged expansion tank Drain tank, see instructions.

HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU

ARE UNABLE TO CORRECT.

27

ELECTRICAL WIRING

Figure 16 - Honeywell L7248L Control With Beckett AFG Burner

28

ELECTRICAL WIRING

Figure 17 - Honeywell L7248L Control With Riello F5/F10 Burner

29

EQUIPMENT AND OPTIONAL ACCESSORIES

MAIN AIR VENT: for down fl ow systems or diaphragm type expansion tanks (not provided)

Before system is fi lled with water, there is air in pipes and radiation units. Some air will be trapped as system is fi lled.

It is possible to eliminate most of this air through air vents on radiation units. Main air vent will speed and simplify this process. Install main air vent on highest point in supply main when all radiation is below top of boiler.

AUTOMATIC FILL VALVE (not provided)

For safe, effi cient operation, hot water system must be fi lled with water. Adding new water, when needed can be done manually (by use of hand valve in water supply line). This requires regular attention to system’s needs.

Automatic fi ll valve or pressure reducing valve accomplishes this without attention. Install in supply line on hot water boilers only. Valve operates through water pressure differentials. It does not require electrical connection.

BURNER SOLENOID VALVE (provided)

Beckett and Carlin oil burner’s use standard solenoid valve.

Upon burner shut down, standard solenoid valve stops fl ow of oil to nozzle. Without solenoid valve, oil pump continues to pump oil to burner nozzle until burner motor winds down below pumps cutoff speed. Riello oil burner has delay solenoid valve. Delay solenoid valve provides same shut down action as standard solenoid valve, plus on burner start up delay solenoid valve remains closed for additional 15 seconds. Allows burner fan motor to prepurge combustion chamber and oil pump to bring supply oil pressure up to its set point helping to provide clean light off.

CIRCULATOR (provided)

Every forced hot water system requires circulator. Separate circulator or zone valve is required for each zone, if there are two or more zones. Circulator must have capacity to provide circulation required by heating system. Circulator should be connected to supply main and must be wired into boiler’s electrical system. See “System Piping” section for piping confi gurations with circulator located on supply main piping using zone circulators or zone valves. When piping is arranged with zone circulators and no bypass piping, circulator provided with boiler may be used as zone circulator. Both piping arrangements allow circulator to pump away from expansion tank and show how piping should be arranged to allow heating system to be easily purged of air.

Taco 007 Pump Curve

LIMIT CONTROL (provided) Refer to manufacturer instructions provided with limit control

Water temperature limit control in limit is adjustable and may be set: as low as 140°F so long as return water temperatures to boiler are no less than 120°F, or as high as

220°F so long as boiler and heating system have adequate circulation to remove heat from boiler otherwise steam may be created in boiler. Refer back to “System Piping” section for more information.

DRAIN VALVE (provided)

Drain valve is manually operated valve provides means of draining all water from boiler and heating system. It should be installed in reducing tee where return line enters boiler.

30

NOTES

CAC/BDP

7310 West Morris St.

Indianapolis, IN. 46231