Carrier B Series Installation, Start-Up, And Operating Instructions Manual
Gas-fired natural draft steam boilers sizes 70,000 through 299,000
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Installation, Start-Up, and Operating Instructions
Gas-Fired
Natural Draft Steam Boilers
Sizes 70,000 through 299,000
NOTE: Read the entire instruction manual before starting the installation. These instructions must be affixed on or adjacent to the boiler.
This symbol → indicates a change since the last issue.
MODEL BS1
Continuous Pilot
Index
SAFETY CONSIDERATIONS.....................................................................................................................................................................................3
INTRODUCTION..........................................................................................................................................................................................................3
BOILER RATINGS AND CAPACITIES ....................................................................................................................................................................4
Form: IM-BS1A-05
ama
A95139
Cancels: IM-BS1A-04
ASME
Electronic Intermittent Ignition
Printed in U.S.A.
8-03
BS1 and BS2
Series B
MODEL BS2
Catalog No. 63BS-1A3
®
A90003
Page
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Table of Contents
Related Manuals for Carrier B Series
Summary of Contents for Carrier B Series
- Page 1 Installation, Start-Up, and Operating Instructions Gas-Fired BS1 and BS2 Natural Draft Steam Boilers Series B Sizes 70,000 through 299,000 ® ASME NOTE: Read the entire instruction manual before starting the installation. These instructions must be affixed on or adjacent to the boiler. This symbol →...
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Page 2: Table Of Contents
LOCATING THE BOILER......................................4 FRESH AIR FOR COMBUSTION ...................................5-6 Boiler Located in Unconfined Space ..................................5 Boiler Located in Confined Space ...................................6 INSTALLATION—SYSTEM PIPING..................................6-8 For Use with Cooling Units .....................................8 CHIMNEY AND VENT PIPE CONNECTION ..............................8-11 Checking Chimney........................................8 Chimney Sizing.........................................8 Connecting Vent Damper and Vent Connector..............................8-10 Minimum Vent Pipe Clearance ....................................10 Removing Existing Boiler from Common Venting System ..........................10-11 VENT DAMPER OPERATION....................................11... - Page 3 SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as maintaining water level. All other operations must be performed by trained service personnel.
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Page 4: Locating The Boiler
BOILER RATINGS AND CAPACITIES VENT PRESSURE DAMPER ″ ⁄ GAGE RELIEF ″ ⁄ VALVE ″ ⁄ TRANSFORMER GLASS PRESSURE GAGE LIMIT CONTROL WATER ″ N.P.T. ⁄ LOW WATER LINE CUT-OFF 29 ″ LOW WATER ″ ″ 24 ″ ⁄ ⁄ CUT-OFF PROBE ″... -
Page 5: Fresh Air For Combustion
Table 1—Room Large In Comparison With Boiler MINIMUM ROOM VOLUME REQUIRED BOILER SIZE BOILER VOLUME TO BE LARGE (SECTIONS) (CU FT) ROOM (CU FT)* 100.4 129.4 158.4 11.7 187.4 13.5 216.4 15.3 245.4 17.2 274.5 * For room with single boiler only. Table 2—Minimum Clearances From Combustible Materials and For Servicing ALCOVE OR ROOM ROOM LARGE... -
Page 6: Boiler Located In Confined Space
PROCEDURE 2—BOILER LOCATED IN CONFINED SPACE EXAMPLE 2A: ALL AIR FROM INSIDE THE BUILDING The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. - Page 7 STEAM 15″ MIN. MAINS PIPE FULL SIZE SAME AS BOILER TAPPING (2 1/2″) POP SAFETY VALVE 6″ TO 10″ MAIN VENT REDUCING ELL POINTING DOWN RETURN MAIN 24″ MIN. FLUE COLLAR ″ MIN. PIPE SIZE 15″ MIN. L I N ″...
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Page 8: For Use With Cooling Units
STEAM PIPE FULL SIZE SAME MAINS AS BOILER TAPPING (2 1/2") 15″ MIN. POP SAFETY VALVE CONNECT RISER TO ″ BOILER WITH 2 6″ TO 10″ MAIN VENT ELBOW AND NIPPLE REDUCING ELL (NOT SHOWN) POINTING DOWN RETURN MAIN 24″ MIN. FLUE COLLAR ″... - Page 9 THIS PIPING CONFIGURATION IS INCORRECT TO SHOW COMMON MISTAKES WRONG WAY DO NOT BULLHEAD, USE 2 TAKE OFFS WRONG WAY TAKE OFFS MUST BE BETWEEN RISER & EQUALIZER WRONG WAY SWING JOINTS ARE MISSING WRONG WAY MISSING TEE FOR SKIMMING L I N A95495 Fig.
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Page 10: Minimum Vent Pipe Clearance
TO SYSTEM WATER CHILLER VALVES C & D VALVES A & B CLOSE FOR HEATING; OPEN FOR HEATING; OPEN FOR COOLING CLOSE FOR COOLING A95143 Fig. 6—Chilled Water Piping IMPORTANT: The damper blade on factory-supplied vent damper has a 1/2-sq in. hole (approximately 3/4-in. diameter). On boilers equipped with standing pilot, the hole MUST be left open. -
Page 11: Vent Damper Operation
2-FT MIN 3-FT MIN ROOF RIDGE 3 /4 HT MAXIMUM MUST SLOPE UP AT LEAST 1 /4 IN. PER FT OF HORIZONTAL RUN A95144 Fig. 7—Typical Masonry Chimney Requirements At the time of removal of an existing boiler, the following items shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. -
Page 12: Automatic Operation Of Vent Damper
HORIZONTAL INSTALLATION FLOW TO FURNACE VENT TO CHIMNEY CAUTION: Do not install OR BOILER DAMPER the vent damper INSTALL VENT DAMPER WITH within 6 in. (152 mm) of ACTUATOR TO SIDES OF combustible material. VENT ONLY. DO NOT MOUNT ABOVE OR BELOW VENT. HERE VERTICAL INSTALLATION INSTALL... -
Page 13: Connecting Gas Piping
Table 4—Gas Pipe Sizes NATURAL GAS Pipe Capacity—Btuh Input Length Includes Fittings of Pipe MANUAL (Ft) 1/2 in. 3/4 in. 1 in. 1-1/4 in. SHUTOFF VALVE 92,000 190,000 350,000 625,000 63,000 130,000 245,000 445,000 GROUND JOINT 50,000 105,000 195,000 365,000 UNION LP GAS Length... -
Page 14: Wiring Diagrams
VENT DAMPER MOLEX PLUG 115V/60HZ/1Ø BK BR POWER SUPPLY NEUT THERMOSTAT t´ PRESSURE LIMIT OVERCURRENT PROTECTED DISCONNECT LOW WATER CUT OFF OPTIONAL WF-2U-24 WATER BLOCKED VENT FEEDER SAFETY SHUT OFF NOTE: FLAME ROLLOUT LWCO PROBE TERMINAL NO. 3 APPEARS ONLY SAFETY SHUT OFF ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON. - Page 15 VENT DAMPER MOLEX PLUG 115V/60HZ/1Ø POWER SUPPLY NEUT THERMOSTAT t´ PRESSURE OVERCURRENT PROTECTED LIMIT DISCONNECT LOW WATER CUT OFF OPTIONAL WF-2U-24 WATER FEEDER NOTE: LWCO PROBE TERMINAL NO. 3 APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON. - WIRE NUT GAS VALVE COLOR CODE...
- Page 16 VENT DAMPER MOLEX PLUG 24 VOLT TRANSFORMER 115V/60HZ/1Ø POWER SUPPLY - WIRE NUT THERMOSTAT t´ OVERCURRENT PROTECTED COLOR CODE DISCONNECT - BLACK - BROWN PRESSURE LIMIT NEUT - ORANGE - YELLOW - RED - BLACK WITH TRACER - WHITE - GREEN LOW WATER UT 1003-620 SERIES OPTIONAL WF-2U-24...
- Page 17 VENT DAMPER MOLEX PLUG 24 VOLT TRANSFORMER 115V/60HZ/1Ø POWER SUPPLY - WIRE NUT THERMOSTAT t´ OVERCURRENT PROTECTED COLOR CODE DISCONNECT - BLACK - BROWN PRESSURE LIMIT NEUT - ORANGE - YELLOW - RED - BLACK WITH TRACER - WHITE - GREEN LOW WATER OPTIONAL WF-2U-24 CUT OFF...
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Page 18: Installing Thermostat
VENT DAMPER VENT DAMPER 4 PIN 4 PIN MOLEX PLUG MOLEX PLUG ISOLATION RELAY 24V ISOLATION RELAY 24V SPST N.O. HONEYWELL SPST N.O. HONEYWELL R8222A OR EQUIVALENT R8222A OR EQUIVALENT 24 VOLT 24 VOLT TRANSFORMER TRANSFORMER PRESSURE PRESSURE LIMIT LIMIT ELECTRONIC TERMINAL B THERMOSTAT... -
Page 19: Controls And Accessories
CONTROLS AND ACCESSORIES PROCEDURE 1—RELIEF VALVE The relief valve should open automatically if boiler steam pressure exceeds pressure rating of valve (15 psig). Should it ever fail to open under this condition, shut down boiler. If valve discharge occurs or valve fails to open as described above, contact an authorized contractor or qualified service technician to replace relief valve and inspect heating system to determine the cause as this may indicate an equipment malfunction. -
Page 20: Gas Valve Operating Instructions
B. BEFORE OPERATING, smell all around appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. •... -
Page 21: Operating Boiler
PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW) WIRING TERMINALS (2) OUTLET CONVENIENCE PRESSURE TERMINALS (2) (OPTIONAL) INLET PRESSURE INLET OUTLET MATCH HOLDER PILOT PILOT PILOT THERMOCOUPLE OUTLET ADJUSTMENT CONNECTION (UNDER CAP RED RESET SCREW) BUTTON GAS CONTROL KNOB SHOWN IN "ON" POSITION A95521 A99181 Fig. -
Page 22: Water Level
4. Allow boiler to fill until water runs out gauge drain valve, then close gauge drain valve. 5. Continue to fill boiler until water reaches indicated water line. This is about halfway up glass tube. PROCEDURE 3—WATER LEVEL The normal water level is shown on right side of boiler and is 24 in. above the floor. The normal water level is determined when boiler is off and cold (when all of the water in system is inside boiler and return piping below water line) and everything above water line is air, no steam. -
Page 23: Checking Controls
The above is an example of a typical 1-pipe system. For larger systems or other types of systems such as 2-pipe systems or systems with convectors or fan coil units, pressuretrol settings need to be determined on a system-by-system basis. The cut-in setpoint is determined by system pressure drop to furthest radiator or terminal unit. -
Page 24: Maintaining Boiler
If cleaning is necessary, repeat skimming and blowdown procedures above. Usually a long skim is sufficient to clean boiler. In more troublesome cases, it may be desirable to flush the system as well. This is accomplished by closing gate valve in the Hartford Loop and opening drain(s) at end of wet return(s). -
Page 25: Foaming, Priming, Or Surging
3. Remove 2 screws attaching intermediate front panel to left and right side jacket panels. 4. Remove draft diverter and intermediate front panel as 1 unit. 5. Carefully remove cerafelt gasket strips. 6. Clean passageways between sections with a flexible handle wire brush. Remove dirt from bottom of boiler and between sections by vacuuming. -
Page 26: Service Hints
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service. FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS 1. Do not try to light any appliance. 2. Do not touch any electric switch; do not use the phone. 3. -
Page 27: Repair Parts
REPAIR PARTS GAS-FIRED STEAM BOILERS —IMPORTANT— READ THESE INSTRUCTIONS BEFORE ORDERING All parts listed in the following Parts List may be ordered through y y y y y y your nearest supplier. When ordering parts, first obtain Model No. from data plate on boiler, then determine Part No. - Page 28 REPAIR PARTS FOR USE WITH NATURAL GAS ONLY A98238 Gas Burners and Manifold Parts This is a Repair Parts List—Not a Packing List PART NO. DESCRIPTION 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section ELECTRONIC INTERMITTENT IGNITION (Shown) 24-v Gas Valve, Elect.
- Page 29 REPAIR PARTS → BOILER CONTROLS AND PIPING A03137 KEY NO. DESCRIPTION PART NO. 3/4-in. Relief Valve 157-00-01 3/4-in. Coupling 115-00-01 3/4-in. X 6-1/2-in. Nipple 146-07-002 Steam Pressure Gauge 146-23-005 1/4-in. Coupling 146-93-054 1/4-in. X 3-in. Nipple 146-07-001 AT-140D Transformer, 24v 146-62-045 PA-404A Pressuretrol 146-62-015...
- Page 30 —30—...
- Page 31 SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials.
- Page 32 imbs1a05 —32— © 2003 CAC/BDP 7310 W. Morris St., Indianapolis, IN 46231 Catalog No. 63BS-1A3...
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