Bryant BW9 Installation, Start-Up, And Operating Instructions Manual
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Bryant BW9 Installation, Start-Up, And Operating Instructions Manual

Bryant BW9 Installation, Start-Up, And Operating Instructions Manual

Gas-fired direct vent condensing hot water boiler sizes 50,000 through 100,000 series a
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Installation, Start-up, and Operating Instructions
Gas-Fired Direct Vent Condensing
Hot Water Boiler
Sizes 50,000 through 100,000
Series A
CERTIFIED
NOTE: Read the entire instruction manual before starting the installation.
This symbol → indicates a change since the last issue.
SAFETY CONSIDERATIONS.....................................................................................................................................................................................2
INTRODUCTION..........................................................................................................................................................................................................3
Boiler Ratings and Capacities..................................................................................................................................................................................3
Boilers for use at High Altitude.........................................................................................................................................................................3
INSTALLATION...........................................................................................................................................................................................................5
Before Installing the Boiler......................................................................................................................................................................................5
Codes ...................................................................................................................................................................................................................5
Boiler Sizing........................................................................................................................................................................................................6
Considerations for Boiler Locations...................................................................................................................................................................6
Locating the Boiler .............................................................................................................................................................................................6
Combustion Air and Vent Pipe Requirements...................................................................................................................................................7
Condensate Drain Requirements ........................................................................................................................................................................7
Foundation Requirements ...................................................................................................................................................................................7
Removal of Existing Boiler from Common Vent System ................................................................................................................................8
Placing the Boiler.....................................................................................................................................................................................................8
Near Boiler Piping....................................................................................................................................................................................................8
Supply and Return Lines ....................................................................................................................................................................................8
Pressure Relief Valve..........................................................................................................................................................................................8
Expansion Tank and Make-Up Water................................................................................................................................................................8
Condensate Drain Piping ....................................................................................................................................................................................9
Filling Condensate Trap with Water ..................................................................................................................................................................9
Chilled Water Piping ..........................................................................................................................................................................................9
Combustion Air and Vent Pipe................................................................................................................................................................................9
Connections and Termination.............................................................................................................................................................................9
Installation .........................................................................................................................................................................................................11
Concentric Vent Installation ..................................................................................................................................................................................12
Concentric Vent/Air Termination Kit ..............................................................................................................................................................13
Gas Supply Piping..................................................................................................................................................................................................15
Connecting the Gas Piping ...............................................................................................................................................................................16
Checking the Gas Piping ..................................................................................................................................................................................17
Electrical Wiring ....................................................................................................................................................................................................17
Electrical Power Supply....................................................................................................................................................................................17
Install Your Thermostat ....................................................................................................................................................................................19
Connect Circulator Pump Wiring.....................................................................................................................................................................19
Controls and Accessories .......................................................................................................................................................................................19
Intergrated Boiler Control (IBC) ......................................................................................................................................................................19
Gas Control Valve ............................................................................................................................................................................................19
Hot Surface Ignitor ...........................................................................................................................................................................................19
Form: IM-BW9A-03
ASME
1

TABLE OF CONTENTS

Cancels: IM-BW9A-02
®
Printed in U.S.A.
8-03
ama
Catalog No. 63BW-9A4
BW9

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Summary of Contents for Bryant BW9

  • Page 1: Table Of Contents

    Installation, Start-up, and Operating Instructions Gas-Fired Direct Vent Condensing Hot Water Boiler Sizes 50,000 through 100,000 Series A CERTIFIED ® ASME NOTE: Read the entire instruction manual before starting the installation. This symbol → indicates a change since the last issue. TABLE OF CONTENTS SAFETY CONSIDERATIONS.....................................2 INTRODUCTION..........................................3...

  • Page 2: Safety Considerations

    A99365 Fig. 1—BW9 Boiler L4006A High Limit Aquastat Control................................20 Draft Inducer Temperature Safety Switch................................23 Casting Temperature Safety Switch..................................23 Differential Pressure Air Proving Switch.................................23 Draft Inducer........................................23 Circulator Pump.........................................23 Drain Valve........................................23 ASME Rated Pressure Relief Valve.................................23 Flame Rollout Safety Shutoff ...................................23 (Optional) External Condensate Pump ................................23 START-UP PROCEDURES......................................24...

  • Page 3: Introduction

    INTRODUCTION The BW9 is a gas-fired direct vent condensing hot water boiler with cast aluminum heat exchanger sections. A revolutionary cast aluminum heat exchanger means better heat transfer and thermal storage than similarly sized cast iron boilers, which results in higher efficiency. The heating system water absorbs large amounts of heat from the cast aluminum heat exchanger, cooling the flue gases and causing condensation.
  • Page 4 BACK STANDARD BOILER WATER SUPPLY & RETURN OPENINGS (1-1/4" NPT (31.75mm) CONNECTIONS PROVIDED INSIDE BOILER CABINET) A99156 Fig. 2—BW9 Boiler Detail Table 1—Sea Level Ratings (Natural and Propane Gases) NATURAL AND PROPANE GAS A.G.A. Heating BOILER MODEL NUMBER SHIPPING WEIGHT (LBS.)

  • Page 5: Installation

    → Table 2—Natural Gas High Altitude Ratings ELEVATION (FT.) 0–2000 3000 4000 5000 6000 7000 7500 8500 BW9–50 Normal Input (MBH) 50.0 48.0 47.8 47.5 46.0 44.0 43.5 42.0 Heating Capacity (MBH) 45.0 43.2 43.0 42.8 41.4 39.6 39.2 37.8 Net I=B=R Rating (MBH) 39.0...

  • Page 6: Boiler Sizing

    B. Boiler Sizing 1. Check to be sure you have selected the BW9 boiler with the proper capacity before starting the installation. 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.

  • Page 7: Combustion Air And Vent Pipe Requirements

    E. Combustion Air and Vent Pipe Requirements This boiler requires a dedicated direct vent system. In a direct vent system, all air for combustion is taken directly from outside atmosphere, and all flue products are discharged to outside atmosphere. Combustion air and vent pipe connections must terminate together in the same atmospheric pressure zone, either through the roof or sidewall (roof termination preferred).

  • Page 8: Removal Of Existing Boiler From Common Vent System

    H. Removal of Existing Boiler from Common Vent System → When an existing Category I furnace is removed or replaced, the original venting system may no longer be sized to properly vent the remaining attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, spillage of combustion products into the living space, etc.

  • Page 9: Condensate Drain Piping

    SERVICE SUPPLY TO VALVE* RADIATION RETURN FROM CIRCULATOR RADIATION PURGE (DRAIN) VALVE SERVICE VALVE* RELIEF VALVE (NOT SHOWN) TEMPERATURE/ PRESSURE DISCONNECT WITH GAUGE SERVICE OUTLET EXHAUST TEE WITH DRAIN *FIELD INSTALLED A99157 Fig. 3—Single Zone Boiler Piping D. Condensate Drain Piping Condensate trap is built into boiler.
  • Page 10 ZONE SERVICE VALVE ZONE SUPPLY TO VALVE ZONES ZONE SERVICE VALVE CIRCULATOR RETURN FROM ZONES PURGE (DRAIN) VALVES ZONE SERVICE VALVE ZONE SERVICE VALVE A99158 Fig. 4—Multizone Boiler Piping with Zone Valves → 1. See Fig. 10, 11, 12 and 13 for combustion air and vent pipe roof and sidewall termination. (Roof termination is preferred). Combustion air and vent pipes must terminate together in same atmospheric pressure zone as shown.

  • Page 11: Installation

    ZONE SERVICE VALVE FLOW CHECK SUPPLY TO VALVE ZONE ZONE SERVICE VALVE CIRCULATORS FLOW CHECK VALVE RETURN FROM ZONES PURGE (DRAIN) VALVES ZONE SERVICE VALVE ZONE SERVICE VALVE A99159 Fig. 5—Multizone Boiler Piping with Circulators g. Terminate the vent above normal snowline. Avoid locations where snow may drift and block the vent. Ice or snow may cause the boiler to shut down if the vent becomes obstructed.

  • Page 12: Concentric Vent Installation

    RELIEF VALVE DISCHARGE PIPING A99160 Fig. 6—Relief Valve Discharge Piping AUTOMATIC AIR VENT* 3/4” X 1/8” BUSHING* MANUAL FILL VALVE 3/4” TEE* 3/4” NIPPLE (FURNISHED COMBINATION QUICK FILL AND INSTALLED ON VALVE, STRAINER, CHECK PACKAGED BOILER) VALVE AND PRESSURE REDUCING VALVE 3/4”...

  • Page 13: Concentric Vent/Air Termination Kit

    CLOSED TYPE EXPANSION TANK EXPANSION TANK SERVICE (GATE VALVE OR FULL PORT BALL VALVE) CHECK AND PRESSURE REDUCING VALVE COLD WATER FILL MANUAL FILL VALVE A99162 Fig. 8—Conventional (closed type) Expansion Tank Piping OPEN DRAIN PIPE TO BE PITCHED DOWN TO FLOOR DRAIN AT A MINIMUM 1/4”...
  • Page 14 ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER A01382 Fig. 11—Concentric Vent and Combustion-Air Side Termination Table 5—BW9 Vent Table MAXIMUM LENGTH OF PIPE PER NUMBER OF ELBOWS MODEL VENT DIAMETER MINIMUM LENGTH Number of 90 Degree Elbows 2-in.

  • Page 15: Gas Supply Piping

    → Table 6—Combustion-Air and Vent Pipe Termination Clearances CLEARANCE (FT) LOCATION U.S.A. Canada Above grade level or above anticipated 1† snow depth Dryer/Water heater vent See Note 5 See Note 5 From plumbing vent stack From any mechanical fresh air intake See Note 4 See Note 6 For furnaces with an input capacity...

  • Page 16: Connecting The Gas Piping

    OVERHANG 12” MINIMUM 12” SEPARATION BETWEEN BOTTOM OF 90° COMBUSTION AIR INTAKE AND BOTTOM OF VENT VENT MAINTAIN 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE 3” MAXIMUM SEPARATION 15” MAXIMUM 18” MAXIMUM LESS THAN 12” CLEARANCE OVERHANG 12”...

  • Page 17: Checking The Gas Piping

    WITH 4 - 90" ELBOWS FOR BW9 - 100 5’ CPVC 20' (6.10m) MAXIMUM LENGTH TOTAL WITH 1.52m 4 - 90" ELBOWS FOR BW9 - 75 AND BW9 - 50 2' (.61m) MINIMUM LENGTH TOTAL WITH 4 - 90" ELBOWS FOR ALL *FACTORY SUPPLIED...
  • Page 18 A00311 Fig. 15—Combustion Air & Vent (3-in.) GAS SUPPLY PIPING MANUAL SHUT-OFF VALVE SEDIMENT TRAP GROUND JOINT UNION A99167 Fig. 16—Gas Piping The boiler, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code, ANSI/NFPA 70.

  • Page 19: Install Your Thermostat

    C. Hot Surface Igniter The 120 volt Hot Surface Igniter heats up to 1800°F to initiate combustion of the gas in the BW9 burner. The igniter is mounted next to the burner through the gas/air mixer. The igniter also serves as a means for proving the main burner flame by flame rectification. In the event of a lack of flame signal on 3 consecutive trials for ignition, the IBC will lockout.

  • Page 20: L4006A High Limit Aquastat Control

    WIRE COLOR CODE 120 VOLT CIRCULATOR BK = BLACK W = WHITE G = GREEN Y = YELLOW 24 VOLT THERMOSTAT NEUTRAL BOILER WIRING 120 VOLT IN J-BOX 60 HZ 1 0 GROUND POWER SUPPLY SERVICE SWITCH FIELD WIRING CONNECTIONS SERVICE SWITCH JUNCTION BOX A99168...
  • Page 21 —21—...
  • Page 22 120 VOLT POWER SUPPLY ON/OFF SWITCH * RECEPTACLE P7-2 P7-1 P7-3 P4-1 P4-3 CIRCULATOR MOTOR P10-1 P5-3 P5-1 DRAFT P10-2 INDUCER HOT SURFACE IGNITER P6-1 P12-1 P12-2 P6-2 120 VAC P1-3 P1-1 TRANSFORMER 24 VAC P2-2 P2-1 CASTING TEMPERATURE SAFETY SWITCH (MANUAL RESET) GAS VALVE VR8205A...

  • Page 23: Draft Inducer Temperature Safety Switch

    (in. w.c.). The factory settings on these switches are 1.00-in.w.c. for BW9-100, 1.35-in. w.c. for BW9-75 and 1.55-in. w.c. for BW9-50. The contacts are normally open, and close when the draft inducer is running and causing the differential pressure at the switch to exceed the setting.

  • Page 24: Start-Up Procedures

    START-UP PROCEDURES PROCEDURE 1—WATER TREATMENT AND FREEZE PROTECTION 1. When filling the boiler and heating system, water treatment is generally not required or desired. For localities where the water is unusually hard (above 7 grains hardness) or for low pH water conditions (below 7.0), consult a local water treatment specialist. a.

  • Page 25: Check Out Procedure And Adjustments

    FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped •...

  • Page 26: Test High Limit Control And Adjust

    DIAGNOSTIC INDICATOR LAMPS POWER PURGE IGNITER VALVE FLAME CONTROL PANEL AIR PRESSURE SWITCH TRANSFORMER A99170 Fig. 21—Indicator Lamps Remove the 1/8-in. plug from the outlet pressure tap. Install the appropriate barbed fitting into the outlet pressure tap and connect the pressure side of the guage or manometer to the barbed fitting.
  • Page 27 Table 9—Diagnostic Sequence DIAGNOSTIC INDICATOR LAMPS SEQUENCE OF OPERATION DIAGNOSTIC A (Green) B (Green) C (Green) D (Green) E (Red) Power ON, boiler standing by. Lamp A is illuminated indi- cating 24 volt power is being supplied to the integrated boiler control.

  • Page 28: Set Thermostat To Desired Room Temperature

    PRESSURE GAS VALVE VENT VINYL CAP REGULATOR ADJUSTMENT (under cover screw) ROTOR CLAMP OUTLET PRESSURE TAP (1/8” PLUG) 4 - WAY CONNECTOR TO PRESSURE SWITCH PRESSURE WHITE TRANSPARENT VINYL TUBING REFERENCE PRESSURE DIFFERENTIAL PRESSURE U-TUBE GUAGE MANOMETER A00313 Fig. 22—Manifold Pressure Measurement Detail J.

  • Page 29: Daily During Heating Season

    PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW) OUTLET OUTLET PRESSURE PRESSURE INLET INLET GAS CONTROL KNOB SHOWN IN "ON" POSITION A95154 A00312 Fig. 23—Gas Valve j. Restore electrical power and gas supply to unit. 2. Check that boiler area is free from combustible materials, gasoline, and other flammable vapors and liquids. WARNING: Keep boiler area clean of debris and free of flammable and combustible materials, vapors, and liquids.

  • Page 30: Periodically During Heating Season

    PROCEDURE 4—PERIODICALLY DURING HEATING SEASON Where low water cut-offs are used, a periodic inspection of the low water cut-off is necessary, including flushing of float type devices. Refer to low water cut-off manufacturer’s specific instructions. PROCEDURE 5—END OF EACH HEATING SEASON — ANNUAL SHUT DOWN PROCEDURE 1.

  • Page 31: Differential Air Pressure Switch Check

    Table 10—Differential Air Pressure Switch Setting BOILER STATUS DIFFERENTIAL PRESSURE (W.C.) PRESSURE SWITCH CONNECTS Not Running 0-in. Normally Open Setpoint 1.0–in. for BW9–100 1.35–in. for BW9–75 1.55–in. for BW9–50 Running without Blockage Greater Than Setpoints Closed Running with Blockage Less Than or Equal to Setpoints...

  • Page 32: Normal Sequence Of Operation

    NORMAL SEQUENCE OF OPERATION POWER ON STANDBY THERMOSTAT IF MAIN BURNER DOES NOT PROVE FLAME CALLS FOR HEAT IN 3 TRIALS, CONTROL LOCKOUT. VALVE/ FLAME LIGHT BLINKS. RESET IS REQUIRED. THIS PROBLEM IS A RESULT OF NOT ESTABLISHING FLAME SIGNAL. CIRCULATOR ENERGIZES THRU 2K1 CONTACTS...
  • Page 33 SAFETY SEQUENCES DURING OPERATION DRAFT INDUCER TEMPERATURE SAFETY SWITCH CASTING TEMPERATURE SAFETY SWITCH IF DRAFT INDUCER TEMPERATURE REACHES IF BURNER OPERATES WHEN BOILER HAS NO TEMPERATURE SAFETY SWITCH SETPOINT, WATER, ALUMINUM BOILER SECTIONS HEAT SAFETY SWITCH CONTACTS OPEN IMMEDIATELY UP RAPIDLY. CLOSING GAS VALVE.
  • Page 34 END OF NORMAL SEQUENCE OF OPERATION THERMOSTAT ENDS CALL FOR HEAT. GAS VALVE AND CIRCULATOR PUMP ARE DE-ENERGIZED. VALVE LIGHT GOES OUT. DRAFT INDUCER RUNS FOR 30 SECOND POSTPURGE. PURGE LIGHT ON. DRAFT INDUCER IS DE-ENERGIZED AFTER 30 SECONDS. PURGE LIGHT SHUTS OFF. BOILER STANDS BY FOR NEXT CALL FOR HEAT DETAILED SEQUENCE OF OPERATION A00316...

  • Page 35: Trouble Shooting

    ! ! WARNING ! ! FIRE, EXPLOSION OR SHOCK HAZARD MAY CAUSE PROPERTY DAMAGE, SEVER INJURY OR DEATH. DO NOT ATTEMPT TO MODIFY THE PHYSICAL OR ELECTRICAL CHARACTERISTICS OF THIS BROILER IN ANY WAY. IMPORTANT IN A RESET FROM LOOKOUT CONDITION, ALL ELECTRICAL METER READINGS ARE THE GAS CONTROL VALVE (24 VAC) MUST BE TAKEN WITHIN THE TRIAL FOR IGNITION PERIOD.

  • Page 36: Troubleshooting

    SYSTEM STATUS THE INDICATOR LIGHTS TRACK THE OPERATING SEQUENCE. IF THE SYSTEM LOCKS OUT, THE LIGHTS INDICATE THE POINT IN THE SEQUENCE OF OPERATION WHERE LOCKOUT OCCURS. IF THIS TABLE DOES NOT READILY PROVIDE THE REASON FOR BOILER MALFUNCTION OR NON-OPERATION, REFER TO THE FOLLOWING PAGES FOR MORE DETAILED TROUBLESHOOTING PROCEDURES.
  • Page 37 A00318 Fig. 29—Troubleshooting Chart No. 1 —37—...
  • Page 38 TROUBLESHOOTING CHART 2 CHECK THAT CIRCUIT BREAKERS IS ON OR FUSES ARE OK AT THE ELECTRICAL PANEL CHART 1 CHECK THAT SERVICE SWITCH IS ON CHECK CASTING TEMPERATURE SAFETY CHECK WATER LEVEL IN BOILER. CHECK OPEN SWITCH. PUSH RESET BUTTON ON SWITCH. FOR AIR TRAPPED IN TOP OF BOILER.
  • Page 39 A00319 Fig. 31—Troubleshooting Chart No. 3 —39—...
  • Page 40 A00320 Fig. 32—Troubleshooting Chart No. 4 —40—...
  • Page 41 A00321 Fig. 33—Troubleshooting Chart No. 5 —41—...
  • Page 42 A00322 Fig. 34—Troubleshooting Chart No. 6 —42—...
  • Page 43 DIFFERENTIAL AIR PRESSURE SWITCH WHITE TRANSPARENT VINYL TUBING TO SIGHT GLASS SILICONE TUBING SUCTION PORT WHITE TRANSPARENT VINYL TUBING TO GAS VALVE VENT RED TRANSPARENT 4-WAY CONNECTOR VINYL TUBING TO AIR INLET SUCTION PORT WHITE TRANSPARENT VINYL TUBING VINYL CAP (TYP.2) TESTING LINES INCLINED MANOMETER...

  • Page 44: Repair Parts

    PROCEDURE 9—REPAIR PARTS TYP OF 4 A99174 Fig. 36—Jacket and Base Assembly → KEY NO. ITEM NUMBER DESCRIPTION QUANTITY 750701020 Q90 Front Panel — Blue 750701021 Q90 Right Panel — Blue 750701022 Q90 Left Panel — Blue 750701023 Q90 Back Panel — Blue 750701024 Q90 Top Panel —...
  • Page 45 CONNECT TO THE DRAIN PORT AT THE BOTTOM OF BOILER CONNECT TO THE DRAIN PORT AT THE EXHAUSTER A99175 Fig. 37—Condensate Drain Trap Assembly → KEY NO. ITEM NUMBER DESCRIPTION QUANTITY 14631035 59019 1/2–in. ID X 1/8–in. thick Vinyl Tubing 14631114 57134 3/4–in.
  • Page 46 A99176 Fig. 38—Boiler Block and Piping Assembly —46—...
  • Page 47 → KEY NO. ITEM NUMBER DESCRIPTION QUANTITY 14631156 Hoffman Vent #77 14693001 3/4-in. X 1/8-in. Bushing 14693076 3/4-in. Black Tee 14693040 3/4-in. X 90 Street Elbow 14607002 3/4-in. X 6-1/2-in. Nipple 14622011 3/4-in. ASME Relief Valve 14607201 3/4-in. X 2 Nipple 14695810 1/4-in.
  • Page 48 TO SIGHT GLASS ADAPTER A99177 Fig. 39—Mixer and Air Pressure Switch Assembly —48—...
  • Page 49 1/4-in. ID X 3/8-in. OD Vinyl Tubing (Red) AS REQUIRED 14629003 1/4-in. ID Silicone Tubing AS REQUIRED 14631312 PPS10111-2680 Air Pressure Switch (BW9-100) 14631010 PPS10111-2681 Air Pressure Switch (BW9-75) 14631044 PPS10111-2682 Air Pressure Switch (BW9-50) 14631103 62043 1/2-in. NPT X 1/2-in. ID Tube Elbow 14631310 Gas Orifice —...
  • Page 50 A99178 Fig. 40—Flue Adapter and Exhauster Assembly KEY NO. ITEM NUMBER DESCRIPTION QUANTITY 43331109 Exhaust Tee Assembly — 1-A, B, C, D, E, & F 14631101 62017 1/2-in. NPT X 1/2-in. ID Tube Straight 14631103 PVC 1-1/2-in. Male Slip X 1/2-in. Female NPT 14631014 PVC Sch 40 2-in.
  • Page 51 —51—...
  • Page 52 imbw9a03 —52— © 2003 CAC/BDP 7310 W. Morris St., Indianapolis, IN 46231 Catalog No. 63BW-9A4...

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