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Summary of Contents for CAC / BDP BWBBAN000045
- Page 1 Cast Iron Gas Boiler For Forced Hot Water INSTALLATION, OPERATION & MAINTENANCE MANUAL Models BWBBAN000045 BWBBAN000070 BWBBAN000096 BWBBAN000120 BWBBAN000145 BWBBAN000170 BWBBAN000195 BWBBAN000245 BWBBAN000295 P/N IM-BWBB-01 [240011111 REV C, 3/31/2017]...
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Page 2: Ratings & Data - Natural Gas & Propane Gas
Net AHRI Recommended Water Input AFUE Elect. Altitude No. Of Capacity Rating Water Air Cushion Tank Content Model No. Ign. Input Burners (Gals.) BWBBAN000045 82.0% BWBBAN000070 82.0% BWBBAN000096 82.0% BWBBAN000120 82.0% BWBBAN000145 82.0% BWBBAN000170 82.0% BWBBAN000195 82.0% BWBBAN000245 82.0% BWBBAN000295 82.0%... -
Page 3: Dimensions
2 - DIMENSIONS Dimensions ** Minimum Height for Low Water Cutoff Installation Table 2 - Dimensions Dimensions (Inches) Natural Gas Pump Size Supply & Model No. Inlet* Return Tappings BWBBAN000045 ½" 11¼ 5⅝ 27⅛ 20 1¼" BWBBAN000070 ½" 15⅛ 28⅛ 20 1¼"... -
Page 4: Table Of Contents
TABLE OF CONTENTS CONTENTS 1 - Ratings & Data - Natural Gas & Propane Gas ............2 2 - Dimensions ......................3 3 - Installation Procedure ..................6 4 - Ventilation & Combustion Air ................7 5 - Connecting Supply & Return Piping ............... 8 6 - Vent Installation .................... - Page 5 SAFETY MESSAGES KEEP THIS MANUAL NEAR BOILER IMPORTANT: Read the following instructions RETAIN FOR FUTURE REFERENCE COMPLETELY before installing!! WARNING Safety Symbols & Warnings The following defined symbols are used throughout this Fire, explosion, asphyxiation and electrical shock manual to notify the reader of potential hazards of varying hazard.
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Page 6: Installation Procedure
3 - INSTALLATION PROCEDURE WARNING WARNING Improper installation, adjustment, alteration, service Fire hazard. Do not install boiler on combustible or maintenance could result in death or serious flooring or carpeting. Failure to follow these injury instructions could result in death or serious injury. FOR INSTALLATION ON NON-COMBUSTIBLE Installation must conform to the requirements of the FLOORS ONLY - For installation on combustible... -
Page 7: Ventilation & Combustion Air
4 - VENTILATION & COMBUSTION AIR Provide combustion air and ventilation air in accordance • All Outdoor Air. Provide permanent opening(s) with the section “Air for Combustion and Ventilation,” of the communicating directly or by ducts with outdoors. National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections о... -
Page 8: Connecting Supply & Return Piping
5 - CONNECTING SUPPLY & RETURN PIPING WARNING Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation. Discharge line shall: •... - Page 9 5 - CONNECTING SUPPLY & RETURN PIPING Hydronic Piping - General • Do not install shutoff valve between boiler and safety relief valve. • Install piping in accordance with authority having jurisdiction. • Systems with automatic fill valves require back flow prevention device.
- Page 10 5 - CONNECTING SUPPLY AND RETURN PIPING NOTICE Circulators in following illustrations are mounted on system supply side, mounting on system return side is also acceptable practice. Figure 2 - Circulators Mounted on Supply System, Boiler Used In Configuration to Chiller System. See Special Conditions, Page 9 PRESSURE REDUCING...
- Page 11 5 - CONNECTING SUPPLY AND RETURN PIPING Figure 3 - Bypass Piping -Automatic Mixing Valve, See Bypass Piping Options, Page 9 FROM SYSTEM TO SYSTEM WATER INLET EXPANSION Note: Bypass TANK connection not showing primary/secondary BOILER piping ALTERNATE CIRCULATOR LOCATION PRESSURE BALL VALVE AIR SEPARATOR...
- Page 12 5 - CONNECTING SUPPLY AND RETURN PIPING Figure 5 - Single Zone System With DHW Priority Figure 6 - Multi-Zone System with Circulators and DHW Priority P/N IM-BWBB-01 [240011111 REV C, 03/31/2017]...
- Page 13 5 - CONNECTING SUPPLY AND RETURN PIPING Figure 7 - Multi-zone System With Zone Valves And DHW Priority (With Circulator) Multi-zone System With Zone Valves And DHW Priority (With Zone Valve) Figure 8 - P/N IM-BWBB-01 [240011111 REV C, 03/31/2017]...
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Page 14: Vent Installation
6 - VENT INSTALLATION Boiler series is classified as a Category I. Vent WARNING installation shall be in accordance with "Venting of Boiler and venting installations shall be performed Equipment," of the National Fuel Gas Code, ANSI by a qualified expert and in accordance with the Z223.1/NFPA 54, or "Venting Systems and Air Supply for Appliances,"... -
Page 15: Vent Damper Installation & Instructions
8 - VENT DAMPER INSTALLATION & INSTRUCTIONS Figure 9 - Damper Installation Figure 10 - Damper Location UN-ACCEPTABLE DAMPER LOCATIONS CHIMNEY REFER TO DAMPER MANUFACTURER'S INSTALLATION INSTRUCTIONS FOR POSITION OF DAMPER CONTROL BOX ACCEPTABLE VENT DAMPER LOCATIONS HOT WATER HEATER BOILER Verify only boiler is serviced by vent damper. -
Page 16: Connecting Gas Service
9 - CONNECTING GAS SERVICE General CAUTION • Use piping materials and joining methods acceptable WHAT TO DO IF YOU SMELL GAS to authority having jurisdiction. In absence of such requirements: • Do not try to light any appliance. • USA - National Fuel gas Code, ANSI Z223.1/NFPA 54 •... -
Page 17: Electrical Section
10 - ELECTRICAL SECTION 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. Electrical Wiring Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. -
Page 18: Wiring Diagram
11 - WIRING DIAGRAM Figure 12 - Integrated High Limit & Electronic Ignition Control WARNING Modification, substitution or elimination of factory equipped, supplied or specified components may result in personal injury or loss of life. P/N IM-BWBB-01 [240011111 REV C, 03/31/2017]... - Page 19 11 - WIRING DIAGRAM Figure 13 - Integrated High Limit & Electronic Ignition Control P/N IM-BWBB-01 [240011111 REV C, 03/31/2017]...
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Page 20: Lighting Instructions
12 - LIGHTING INSTRUCTIONS OPERATING INSTRUCTIONS FOR INTERMITTENT WARNING PILOT SYSTEM If you do not follow these instructions STOP! Read the safety information to the left. exactly, a fire or explosion may result Set the thermostat to lowest setting. causing property damage, personal injury Turn off all electric power to the appliance. -
Page 21: Normal Sequence Of Operation
13 - NORMAL SEQUENCE OF OPERATION Thermostat actuates on call for heat, completing circuit Figure 15 - Blocked Vent Safety Switch, Roll-out to control. Completed circuit to control will first activate Safety Switch circulator. Control will first monitor water temperature with circulator running to determine if thermostat can be satisfed without firing burner;... - Page 22 14 - GENERAL INSTRUCTIONS • Make visual inspection of main burner and pilot flames Figure 16 - Burner Flame at start of heating season and again in mid-season. Main burner flame should have well defined inner blue mantel with lighter blue outer mantel. Check burner throats and burner orifices for lint or dust obstruction.
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Page 23: Checking Gas Input Rate To Boiler
15 - CHECKING GAS INPUT RATE TO BOILER Gas input to boiler can be adjusted by removing protective Figure 19 - Boiler Right Side and Front cap on pressure regulator Figure 14, Page 20 and turning screw clockwise to increase input and counterclockwise to decrease input. -
Page 24: Appendix A - Control Module
APPENDIX A - CONTROL MODULE A.1 Installation Environment Considerations A.3 Adjusting Settings To discourage unauthorized changing of settings, procedure WARNING to enter adjustment mode is required. If you do not follow these instructions To enter adjustment mode, press UP, DOWN, and I buttons exactly, a fire or explosion may result simultaneously for three seconds. -
Page 25: Operation
APPENDIX A - CONTROL MODULE A.5 Operation Control determines burner operation is required, module proceeds to start burner (see state codes list) Module continuously monitors boiler water temperature and and heats water in boiler until setpoint temperature is fires or shuts off burner based on this temperature data. achieved or thermostat is satisfied. - Page 26 APPENDIX A - CONTROL MODULE Table 6 conti. - Vent Damper Models Operation State Codes State Code Definition Explanation Order Number 2. Other possible state codes System is purging before ignition trial; includes Pilot Valve circuit diagnostics. On vent Pre-purge damper models, this is so quick it will typically be over before the display can flash this code, and therefore will rarely be visible.
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Page 27: Boiler High Limit Temperature Controller
APPENDIX A - CONTROL MODULE A.7 Troubleshooting A.6 Boiler High Limit Temperature Controller • Following service procedures are provided as general • When water temperature reaches setpoint, controller guide. ends heating cycle. • On lockout and retry models, meter readings between •... - Page 28 APPENDIX A - CONTROL MODULE Table 7 - Troubleshooting Error Codes Error Display clearing ( once error condition has disappeared) Error Clears itself Up/down Cycle Push Code Definition when root key when Power Number Explanation Things to look for problem is status is solved displayed...
- Page 29 APPENDIX A - CONTROL MODULE Table 7 - Troubleshooting Error Codes - conti. Error Display clearing ( once error condition has disappeared) Error Clears itself Up/down Cycle Code Definition Push when root key when Power Number Explanation Things to look for problem is status is solved...
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Page 30: Intermittent Pilot
APPENDIX A - CONTROL MODULE A.9 Intermittent Pilot STEP 2: Verify ignition system grounding. Nuisance shutdowns are Ignition System Checks often caused by poor or erratic grounding. Common ground is required for module and pilot burner/ STEP 1: Check ignition cable. igniter sensor. - Page 31 APPENDIX A - CONTROL MODULE STEP 3: Check spark ignition circuit. • Recheck ignition sequence as follows. Disconnect ignition cable at SPARK terminal on module. — Reconnect main valve wire. WARNING — Adjust thermostat above room temperature. — Verify ignition sequence at burner. Electrical shock hazard.
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Page 32: Vent Damper Harness - Molex Plugs
APPENDIX B - VENT DAMPER B.1 Vent Damper Harness - Molex Plugs • If boiler ignites: Go to section B.2 page 33. "Vent Damper Troubleshooting Guide". WARNING NOTE: Prior to replacing the damper, verify Do Not negate the action of any existing safety orperational controls. -
Page 33: Vent Damper Troubleshooting Guide
APPENDIX B - VENT DAMPER TROUBLESHOOTING B.2 Vent Damper Troubleshooting Guide WARNING Do Not negate the action of any existing safety orperational controls. Avoidance of these in- structions could result in death or serious injury. When servicing controls, all wires must be Note labeled prior to disconnection. - Page 34 APPENDIX B - VENT DAMPER TROUBLESHOOTING For troubleshooting only. Verify damper is in Note open position. Use service switch to keep damper in open position. Place jumper between 2 & 3. If appliance fires, remove jumper and plug receptacle back into damper controller plug.
- Page 35 SERVICE RECORD P/N IM-BWBB-01 [240011111 REV C, 03/31/2017]...
- Page 36 I M P O R T A N T In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.
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