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BWCAAG000120 - BWCAAG000150
BWHAAG000120 - BWHAAG000150
INSTALLATION & OPERATING INSTRUCTIONS FOR CONTRACTORS
9
WARNING: If the information in this manual
is not followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
Do not store or use gasoline or other flammable
vapors and liquids or other combustible materials
in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the
fire department.
Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.
This manual should be maintained in legible
condition and kept adjacent to the boiler or
in a safe place for future reference.
CAC/BDP
7310 West Morris St
Indianapolis - IN 46231
USA
BWC-H-01SI 07/2020
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Table of Contents
Related Manuals for Carrier BWCAAG000120
Summary of Contents for Carrier BWCAAG000120
- Page 1 BWCAAG000120 - BWCAAG000150 BWHAAG000120 - BWHAAG000150 INSTALLATION & OPERATING INSTRUCTIONS FOR CONTRACTORS WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance.
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Page 2: Table Of Contents
CONTENTS (Air-inlet only) and CPVC Plastic Venting ..26 KEY TO SYMBOLS . . . . . . . . . . . . . . . . . . . . . . 3 General Venting Rules and Guidelines . -
Page 3: Key To Symbols
1 KEY TO SYMBOLS WARNING: Chlorine and chloramine concentration in domestic water must be less than 50 ppm. This is the safety−alert symbol. When you see this symbol on WARNING: Automatic filling systems are not recommended with the appliance and in instructions or manuals, be alert to the potential this product as they will continually add fresh water to the system for personal injury. -
Page 4: Safety
and regulations. When replacing an existing boiler, it is important to must separate the system using heat exchangers. Unsuitable heating system water promotes the formation of sludge and corrosion. This may check the condition of the entire hot water distribution system to ensure damage the heat exchanger or affect its operation. -
Page 5: Product Receipt
Spare modulating gas valve gasket The BWH heating only is a direct vent, CAT IV wall mounted boiler Strain relief for secondary high voltage connexion: - BWCAAG000120-150 that is able to operate as follows: - BWHAAG000120-150 - CASE A: heating only with tank thermostat: in this condition, the... -
Page 6: Structure
Structure 5 . 1 BWCAAG000120 - BWCAAG000150 Front view Filling tap Condensate Trap Backflow preventer valve Drain valve Low Water Cutoff Gas valve Injector DHW sensor Water Temperature High Limit 10 Supply sensor 11 Return sensor 12 Exchanger thermostat 13 Primary Heat exchanger... - Page 7 BWHAAG000120 - BWHAAG000150 Front view Condensate Trap Drain valve Low Water Cutoff Gas valve Injector Water Temperature High Limit 10 Supply sensor 11 Return sensor 12 Exchanger thermostat 13 Primary Heat exchanger 14 Flame sensor 15 Manual air vent hose 16 Manual upper air vent valve 17 Flue temperature sensor 18 Positive air pressure tube...
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Page 8: Boiler Front Control
Boiler front control 5 .2 cons Isplay 136°F SOME OF THE ICONS SHOWN ON THE CONTROL DEVICE SCREEN AT THE START- UP PHASE MIGHT NOT BE AVAILABLE DURING FUNCTIONNING. adjustment knob adjustment knob THIS DEPENDS YOUR BOILER CONFIGURATIONS Light signal indicating the operating status of the boiler. Can be as follows STATUS RED LED GREEN LED... -
Page 9: Technical Data
Technical data 5 .3 Description BWCAAG000120 BWHAAG000120 BWCAAG000150 BWHAAG000150 Country destination US/CAN US/CAN US/CAN US/CAN Input - Output Btu/hr 85,000 85,000 119,000 119,000 Maximum CH input rate (0 - 2,000 ft / 0 - 610 m) 24.91 24.91 34.88 34.88... - Page 10 Description BWCAAG000120 BWHAAG000120 BWCAAG000150 BWHAAG000150 111.63 111.63 140.47 140.47 (0 - 2,000 ft / 0 - 610 m) 3.16 3.16 3.97 3.97 94.88 94.88 116.28 116.28 (2,001 - 5,000 ft / 610 - 1,524m) 2.68 2.68 3.29 3.29 DHW max Gas Rate natural gas (A) 84.65...
- Page 11 Description BWCAAG000120 BWHAAG000120 BWCAAG000150 BWHAAG000150 (0 - 2,000 ft / 0 - 610 m) 9,150 9,150 9,350 9,350 (2,001 - 5,000 ft / 610 - 1,524m) 9,800 9,800 9,400 9,400 Number of fan rotations max DHW (E) (5,001 - 7,500 ft / 1,524- 2,286 m)
- Page 12 Description BWCAAG000120 BWHAAG000120 BWCAAG000150 BWHAAG000150 max air free ≤ 120 ≤ 120 ≤ 90 ≤ 90 CO natural gas (A) min air free ≤ 20 ≤ 20 ≤ 15 ≤ 15 max air free ≤ 170 ≤ 170 ≤ 150 ≤...
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Page 13: Hydraulic Circuit
Hydraulic circuit 5 .4 BWCAAG000120 - BWCAAG000150 manual main heat air vent exchanger supply temperature return sensor temperature sensor expansion tank water temperature high limit Low water domestic hot water temperature sensor heat Cutoff exchanger check valve pump automatic filling... - Page 14 BWCAAG000120 - BWCAAG000150 BWHAAG000120 - BWHAAG000150 9/16” 3/4” 9/16” 9/16” 3/4” 9/16” 3/4" NPT 1/2" NPT 3/4" NPT 1/2" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT condensate condensate check valve check valve Indirect water tank...
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Page 15: Dimensions And Connections
Dimensions and connections 5 .5 Front and side view 3/4” 7/8” 1/2” Top view 1/2” 3/4” 1/4” 1/16” 1/16” 15/16” 15/16” Recommended Minimum service clearances 3/4" 1” 6” * 25 mm 150 mm 7/8" 18 in. 5/16" 15/16" * Service clearances on the right side of the boiler can be decreased up to 1” (25 mm) if the provided Warning Label and Lighting Instructions are applied to the front of the boiler casing... -
Page 16: Before Installation
6 BEFORE INSTALLATION Alcove Installations Alcove installations have the same minimum clearances as closet The manufacturer strongly recommends that this manual be installations, except the front must be completely open to the room reviewed thoroughly before installing your boiler. at a distance no greater than 18 in. [457 mm] from the front of Please review “3 Safety”... -
Page 17: Prevent Combustion Air Contamination
The shipping weights of the boiler are approximately: appliances remaining connected to the common venting system are not in operation. BWCAAG000120 - combi = 89 lb (40.5 kg) BWHAAG000120 - only heating = 87 lb (39.5 kg) Seal any unused openings in the common venting system. -
Page 18: Boiler Template
Boiler template 7 .2 BWHAAG000120 - BWHAAG000150 (heating only) BWCAAG000120 - BWCAAG000150 (combi) 1 5 1 / 4 " - ( 3 8 7 m m ) 5 / 8 " - ( 1 6 . 6 m m ) 5 / 8 "... -
Page 19: Asme Pressure Relief Valve
removed and inspected. Do not attempt to conduct this inspection - Install the gas valve main supply. - Install the exhaust flue and intake air piping. on your own. Contact your plumbing contractor for a reinspection to assure continuing safety. - Carry out the electrical connection according to local code rules. -
Page 20: Loose Flow Regulators
CAUTION: BWHAAG000120 and BWHAAG000150 must not to provide both high limit protection and modulating temperature be operated as a potable Hot Water Boiler. BWCAAG000120 control. The PCB also provides low water protection using a and BWCAAG000150 must not be operated in an open water pressure sensor (minimum 6.5 psi (0.45 bar)). -
Page 21: Making The Gas Connection
Do not proceed with start-up if there is any BWCAAG000120 - BWHAAG000120 indication of a gas leak. Repair any leak at once. WARNING: for LPG boilers only — Your propane supplier mixes an odorant with the gas to make its presence detectable. -
Page 22: External Wiring Limitations
Low voltage connections CAUTION: To ensure the tightness of the boiler, use a self- Carry out the low voltage connections as follows: locking wire connector and tighten it on the wire. 4 poles connector for BUS 485 (- A B +) signal (reserved for ƒ... -
Page 23: Ot And Room Thermostat Connection To The Boiler
board as follows: ƒ remove the casing ƒ gently lift and turn the control panel to free it from the side hooks. ƒ remove the electrical parts cover as shown in the figure below RiCLOUD ZONE VALVE END SWITCH The central heating set point selected on the boiler display is used when a heating request is made at the room thermostat connection (W-R). -
Page 24: Check/Control Water Chemistry
24V terminal strip, other than those approved/supplied by the NOTICE: If the side panels have been removed, reassemble them manufacturer. in the original position by referring to the adhesive labels on the side walls. 7 .13 Check/control water chemistry NOTICE: If the front panel is missing, it must be replaced. WARNING: Do not use petroleum-based cleaning or sealing NOTICE: The noise absorbing panels inside the front and side compounds in heating system. -
Page 25: Refill Of The System
NOTICE: see Section “11.4 Bleeding and Releasing of Circulator Before draining the system, switch off or disconnect the external power supply to the boiler. Shaft”. − Close the heating system’s valves. − Begin venting all manual air vents in the hydronic piping system, −... -
Page 26: General Venting
8 GENERAL VENTING Fixer, hydrochloric acid Photo labs, chemical / plastics (muriatic acid), bromide, iodine processing plants DANGER: Ensure the exhaust and intake vent piping comply Cement powder, crack fill dust, Concrete plant or construction with these instructions regarding the vent system. Inspect cellulose, fiber based insulation site finished combustion air intake and exhaust piping thoroughly... - Page 27 - Horizontal between air-inlet and exhaust vent: The horizontal WARNING: Failure to properly support the air-inlet and vent distance between the inlet and exhaust must be a minimum of may result in substantial property damage, severe personal 4” [102 mm] center to center. injury or death.
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Page 28: Combustion Air And Ventilation Openings
Existing Chimney Chase Way Exhaust Vent Exhaust Vent Min. Chimney 18 in. above air-inlet Min. 12 in. above Air-Inlet Air-Inlet roof and snow level Existing Chimney (used as a chase way) It is permissible to use an existing chimney as a chase way to run the Vent/Air-inlet piping as long as: 1. - Page 29 Crawl Space and Attic combustion air CRAWL SPACE For vent and combustion air pipe length refer to the approved configu- Ventilated combustion ration of horizontal and vertical vent air intake pipe installation - Section 8.8, fig. 7 for 2” and fig. 20 for 3” WARNING: When using a ventilated crawl space Pipe hangar...
- Page 30 (*) above maximum snow level or at least 24” (610 mm) whichever is greater VENT/AIR-INLET TERMINATION CLEARANCES The quick reference table below is to be read in conjunction with the numbered notes as indicated in figures of the previous page, and the Venting Rules and Guidelines in Section 8.4.
- Page 31 Clearance to service regulator vent outlet 3 ft. (0.9m) 3 ft. (0.9m) Clearance to non-mechanical air supply inlet 12" (305mm) 3 ft. (0.9m) 3 ft. (0.9m) above if within Clearance to mechanical air supply inlet 10 ft. (3m) horizontally Clearance above paved sidewalk or paved driveway located on public 7 ft.
- Page 32 APPROVED FOR Standard Pipe diameter Material Item Standard [USA] [Canada] per boiler Flue gas or ANSI/ASTM 2” (60mm) CPVC schedule 40 combustion air F441 3” (80mm) only Combustion air 2” (60mm) PVC schedule 40 ANSI/D1785 only 3” (80mm) WARNING: all vent and air inlet materials PP approved vendor(s)/ material - M&G Flue gas or...
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Page 33: Nearboiler Vent/Air-Inlet Piping
NearBoiler Vent/Air-inlet Piping 8 .5 . 1 WARNING: ABS/PVC venting is not approved for use as The boiler employs universal Exhaust-vent and Air-inlet appliance an exhaust vent material. Failure to comply could result in personal injury, death or property damage and could void the adapters that accept 2 in. - Page 34 Fig. 1 Horizontal flue terminal 2/4 in. (ø 60-100 mm) PP flue Fig. 3 Vertical flue terminal 2/4 in. (Ø 60-100 mm) PP flue gases/air gases/air for flat roof BWCAAG000120 BWCAAG000150 BWCAAG000120 BWCAAG000150 BWHAAG000120 BWHAAG000150 BWHAAG000120 BWHAAG000150 Max length (L) 30 ft (9.14 m)
- Page 35 Fig. 5 Vertical flue terminal 3/5 in. (Ø 80-125 mm) PP flue Fig. 7 Twin flue system 2 in. PP (Ø 60 mm) gases/air for pitched roof BWCAAG000120 BWCAAG000150 BWCAAG000120 BWCAAG000150 BWHAAG000120 BWHAAG000150 BWHAAG000120 BWHAAG000150 Max length (L) 30.5+30.5 ft (9.30+9.30 m) 28+28 ft (8.53+8.53 m)
- Page 36 Fig. 11 Twin flue system 2 in. (Ø 50,8 mm) with horizontal Fig. 9 Twin flue system 3 in. (Ø 80 mm) with horizontal terminal 3 in. (Ø 72,6 mm) CPVC terminal 3/5 in. (Ø 80-125 mm) PP flue gases/air BWCAAG000120 BWCAAG000150 BWCAAG000120 BWCAAG000150...
- Page 37 Fig. 15 Horizontal twin flue system 3 in. (Ø 76,2 mm) with Fig. 13 Vertical twin flue system 2 in. (Ø 50,8 mm) with terminal bend CPVC terminal bend CPVC for pitched roof BWCAAG000120 BWCAAG000150 BWCAAG000120 BWCAAG000150 BWHAAG000120 BWHAAG000150 BWHAAG000120 BWHAAG000150 Max length (L) 76+76 ft (23.16+23.16m) 76+76 ft (23.16+23.16 m)
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Page 38: Multi Family Boiler Installation
Fig. 17 Twin flue system 3 in. (Ø 76,2 mm) with vertical Fig. 19 Vertical twin flue system 3 in. (Ø 76,2 mm) with terminal bend CPVC for flat roof (L) terminal 3 in. (Ø 76,2 mm) CPVC (L) BWCAAG000120 BWCAAG000150 BWCAAG000120 BWCAAG000150... -
Page 39: Wiring Diagram
9 WIRING DIAGRAM Electrical diagram 9 . 1 BWCAAG000120/BWCAAG000150 - Combi Model AKM11 Main PCB SC07 Control Interface BE20 Board Led: green led (operating or temporary stop) red led (boiler in lockout) BE21 24VAC Thermostat X1-X25 Connectors CN1-CN2-CN3A Connectors S.W.1 function button F.S.(1) - Page 40 BWHAAG000120/BWHAAG000150 - Heating Only Model AKM11 Main PCB SC07 Control Interface BE20 Board Led: green led (operating or In C CASE configuration “boiler + external indirect tank with temporary stop) sensor” add a jumper on the TBOL input of the M4a red led (boiler in lockout) BE21 24VAC Thermostat...
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Page 41: Ladder Diagram
Ladder diagram 9 .2 BWCAAG000120/BWCAAG000150 - Combi Model 120V / 60 Hz / 1 ph MAINS MAINS CN1-1 CN1-2 CN1-4 CN3A-1 CE8|R CN1-3 CN3A-2 CE8|C wire color code CN3A-3 CE8|W black white CN2-1 X11-5 blue CN2-2 X11-6 brown green MAINS... - Page 42 BWHAAG000120/BWHAAG000150 - Heating Only Model 120V / 60 Hz / 1 ph MAINS MAINS CN1-1 CN1-2 CN1-4 CN3A-1 CE8|R CN1-3 CN3A-2 CE8|C CN3A-3 CE8|W wire color code CN2-1 X11-5 black CN2-2 white X11-6 blue brown MAINS MAINS X1-2 X1-3 green MAINS GND yellow X9-1...
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Page 43: Lighting Instructions
10 LIGHTING INSTRUCTIONS There are several steps involved in starting up the boiler. POUR VOTRE SECURITE LISEZ FOR YOUR SAFETY AVANT DE METTRE EN MARCHE READ BEFORE OPERATING WARNING: AVERTISSEMENT: If you do not follow these instructions exactly, Quiconque ne respecte pas à la lettre les a fire or explosion may result causing property damage, instructions dans la présente notice risque de déclencher un incendie ou personal injury, or loss of life (death). -
Page 44: Commissioning
11 COMMISSIONING remove any installation debris from the boiler. Refill the boiler and heating system (See Section 7.13 for more details). 11 .1 Preliminary checks Once the system is brought to the central heating setpoint, it is recommended that a second flush and fill be commenced to remove When commissioning the boiler, the first ignition is carried out by any other contaminants from the system. -
Page 45: First Commissioning
combustion analysis arancione button SW1 E.R. ***** F2=4A T - Display firmware version: e. g. FW0.1 (no actions are required) AKM0x - After the “Start-up phase”, “WAIT COMM.” will always appear, which means that the SC07 front control is waiting FWX.Y for communication with the boiler. -
Page 46: Adjusting The Heating Water Temperature Without An Outdoor Temperature Sensor Connected
11 .7 Adjusting the heating water temperature without an outdoor temperature sensor connected When there is no outdoor temperature sensor, the boiler operates at a fixed setpoint. If the central heating mode is active, to adjust the 136°F central heating temperature rotate the knob until the “ ”... -
Page 47: Access To The Info Menu
11 .11 Access to the PARAMETER menu NOTICE: Make sure you are in the “Operation mode”, backlight ON (see section 11.6). 114°F Access to the PROGRAMMING menu by pressing the “MENU/ RESET” button for at least 5 seconds, until “000” appears. Pressing the “MENU/RESET”... - Page 48 PARAMETER list PARAMETER VALUE VALUE RANGE ACCESS DISPLAYED DESCRIPTION FACTORY LEVEL MESSAGE 0 = combi and flowswitch 1 = combi and flowmeter Hydraulic BWC = 1 2 = heating only with tank thermostat [0:4] INSTALLER HYDR. CFG configuration BWH = 2 3 = heating only with tank sensor and sliding outlet 4 = heating only with tank sensor and fixed outlet 0 = Natural gas...
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Page 49: Hydraulic Configuration
NOTICE: we do not recommend activating this function for water tanks with a capacity of over 26 US gallons (100 liters) since the water tank filling would be too slow. GAS T 11 .11 .3 Heating timer This parameter is used to manage the following timers: - the REDUCED HEATING MAXIMUM OUTPUT TIMING, during which the speed of the fan is limited to 75% of the maximum heating output that has been set... -
Page 50: Maximum Dhw Setpoint
OUTDOOR TEMPERATURE RESET CURVES (°C) (°F) (°C) 13 - 22 - 31 - 40 - 49 - 58 - 67 - 76 - (°F) OUTSIDE TEMPERATURE (°C) 11 .11 .10 Maximum DHW setpoint and provide greater comfort to the living space. This parameter allows you to specify the maximum domestic hot water setpoint that is possible: range 120°F (49°C) - 140°F (60°C), NOTICE: The DHW temperature is independent from the outdoor... -
Page 51: Checks During And After The First Commissioning
in DHW ONLY mode and by keeping the domestic hot water tap Please note that the number displayed is a comfort level: 77°F open, it will be possible to carry out a combustion check (Refer to means it feels hotter, 59°F means it feels colder. Modifications to “11.15 Combustion analysis”... -
Page 52: Combustion Analysis
referring to the speed value of the fan speeds (rpm). To adjust the value choose one of the two knobs and start to rotate. Wait for two seconds from the last rotation, then the value will be confirmed and the display come back to the main page. -ACO- 2100 THIS GAS BOILER IS CONVERTED FOR USE WITH... - Page 53 Boiler faults list ERROR GREEN RED and DESCRIPTION OF ERROR MESSAGE CODE GREEN TYPE OF ALARM E010 flame lockout/ACF electronic fault definitive flashing 0.2 sec E011 parasitic flame transitional on/0.2 sec off flashing 0.5 sec E020 water high limit/heat exchanger thermostat definitive on/0.5 sec off E030...
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Page 54: Temporary Switch-Off
While the electrical supply and the fuel supply remains active, the boiler is protected by the following: - heating anti-freeze: this function is activated if the temperature measured by the supply sensor drops below 41°F (5°C). A heat E020 request is generated in this mode with the ignition of the burner at minimum output, which is maintained until the outlet water temperature reaches 95°F (35°... -
Page 55: Servicing Instructions
12 SERVICING INSTRUCTIONS 12 .3 Maintenance program 12 . 1 General To ensure the continued safe and efficient operation of the boiler, it is recommended that it is checked and serviced To ensure the continued safe and efficient operation of the boiler, it at regular intervals. -
Page 56: Maintenance Of The Combustion Control System
Check the combustion chamber insulation panel (3)and, if it WARNING: After carrying out the maintenance operations a combustion analysis needs to be carried out to make is worn, replace it. sure the boiler is operating correctly. Check the condition of the burner (7), ensure that it is not loose;... -
Page 57: Gas Valve
12 .4 .3 Burner 5/16” +/-1/32” (8mm +/-1mm) Check the condition of the burner, carefully clean it with a soft brush if necessary. Do not use a brush with metallic bristles as this might damage it. If there is dirt remaining inside the burner, blow it out with flame ignition electrode compressed air. - Page 58 WARNING: DO NOT rinse the insulation panel. NOTICE: In case of serious dirt build-up rinsing can be repeated several times, spray white vinegar and wait about 3 to 5 minutes, clean with a mechanical nylon brush and rinse with mains water. WARNING: DO NOT spray and rinse the insulation panel.
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Page 59: Annual Servicing Check List
12 .5 Annual servicing check list BWCAAG000120 - BWCAAG000150 BWHAAG000120 - BWHAAG000150 Owner Information: Name: Street: Email: Zip / Postal Code: State/Prov: City: Please provide data as noted. Installer Information Installer Name Company Name Company Address Phone Number Email Address... - Page 60 Yearly maintenance program Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10 Maintenance date Disconnect power supply and protect the PC board to ensure it cannot get wet during service Using a digital manometer, check incoming gas pressure at the gas regulator Using a digital manometer, check pressure at bottom of gas valve...
- Page 61 Yearly maintenance program (..continue) Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10 Maintenance date Check the combustion chamber insulation panel (3)and, if it is worn, replace it. Check the condition of the burner (7), ensure that it is not loose;...
- Page 62 CAC/BDP 7310 West Morris St Indianapolis - IN 46231 BWC-H-01SI The Company is constantly working to perfect all of its production processes, therefore the aesthetics and size, technical data, equipment and accessories of the products may be subject to change.