1. DL manuals
  2. CAC / BDP
  3. Boiler
  4. BW4BAH-105
  5. Installation, Operation & Maintenance Manual

CAC / BDP BW4BAH-105 Installation, Operation & Maintenance Manual

Manual is about: Oil Fired Cast Iron Hot Water Boiler

Summary of BW4BAH-105

  • Page 1

    Oil fired cast iron hot water boiler installation, operation & maintenance manual bw4bah-91 bw4rah-91 bw5bah-91 bw5rah-91 bw4bah-105 bw4rah-105 bw5bah-105 bw5rah-105 bw4bah-140 bw4rah-140 bw5bah-140 bw5rah-140 bw4bah-126 bw4rah-126 bw5bah-126 bw5rah-126 bw4bah-175 bw5rah-175 bw5bah-175 bw5rah-175 bw...

  • Page 2

    2 safety notices .....................................................3 boiler ratings and capacities ................................4 fresh air for combustion......................................8 system piping ...................................................10 chimney and chimney connections ...

  • Page 3

    3 boiler ratings and capacities boiler model no. Input **heating capacity *mbh ‡net ahri rating water *mbh a.F.U.E. ++ no. Sec. Boiler water capacity (us gal.) dimensions (inches) +gph *mbh a b c »bw(4,5)(b,r)ah-91 0.65 91 80 70 86.3 3 9.6 14½ 6 8 »bw(4,5)(b,r)ah-105 0.75 105 92 80 85.2 3 9.6 14½ 6 ...

  • Page 4

    4 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 b...

  • Page 5

    5 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....

  • Page 6

    6 oil t ank c h i m n e y elec tric line vent pipe draft regula to r diaphra gm exp ansion t ank au to m atic fill v al ve and shut off relief v al ve to radia tion from radia tion circula ting pump in re turn line or after the exp ansion tank shut off va lv e oil fil ter oil lines found ations to o...

  • Page 7

    7 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...

  • Page 8

    8 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...

  • Page 9

    9 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...

  • Page 10

    10 adjust two throttling valves to maintain at least 120°f in boiler return. Throttling valves are used for bypass piping, if required. > 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 sect...

  • Page 11

    11 system piping > 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 figure 8 - system piping ...

  • Page 12

    12 > 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 system piping figure 9 - system piping arrangement zoning with circulators.

  • Page 13

    13 > diaphragm expansion tank mounted off the boiler > circulator on supply piping pumps away from expansion tank > per this manual, use option #2 in “filling the system with water” > this piping arrangement can be used with zone valves or zone circulators system piping figure 10 - system piping arr...

  • Page 14

    14 boiler model burner input rate (gph) input (mbh) tankless rating (gpm)‡ bw5(b,r)ah-91 0.65 91 2.90 bw5(b,r)ah-105 0.75 105 3.00 bw5(b,r)ah-140 1.00 140 3.25 bw5(b,r)ah-126 0.90 126 3.15 bw5(b,r)ah-175 1.25 175 3.50 bw5(b,r)ah-210 1.50 210 3.75 bw5(b,r)ah-168 1.20 168 3.45 bw5(b,r)ah-245 1.75 245 ...

  • Page 15

    15 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. Tankles...

  • Page 16

    16 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...

  • Page 17

    17 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 lea...

  • Page 18

    18 electrical connections 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 natio...

  • Page 19

    19 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 throug...

  • Page 20

    20 • 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. Draft regulators: barometric draft regulator is required for controlling draft through boiler. Mount barometr...

  • Page 21

    21 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 boile...

  • Page 22

    22 operating the boiler figure 13 -burner adjustments and settings.

  • Page 23

    23 adjust operating controls : use the following settings for fi rst adjustment: 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) a...

  • Page 24

    24 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 tech...

  • Page 25

    25 oil boiler cleaning: 1. Shut off all electrical power to boiler / burner and shut off fuel oil supply. 2. 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, ...

  • Page 26

    26 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, c...

  • Page 27

    27 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 yell...

  • Page 28

    28 electrical wiring figure 16 - honeywell l7248l control with beckett afg burner.

  • Page 29

    29 figure 17 - honeywell l7248l control with riello f5/f10 burner electrical wiring.

  • Page 30

    30 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. ...

  • Page 31

    Notes.

  • Page 32

    Cac/bdp 7310 west morris st. Indianapolis, in. 46231.