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OIL FIRED CAST IRON
HOT WATER BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Models
BW4BAH000112
BW4RAH000112
BW5BAH000112
BW5RAH000112
BW4BAH000175
BW4RAH000175
BW5BAH000175
BW5RAH000175
(Series D)
BW4BAH000140
BW4RAH000140
BW5BAH000140
BW5RAH000140
BW4BAH000217
BW4RAH000217
BW5BAH000217
BW5RAH000217
CAC/BDP
7310 WEST MORRIS ST.
INDIANAPOLIS, IN 46231
IM-BW4-5-02
[240013014 Rev. B [12/31/2020]
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Summary of Contents for CAC / BDP BW4BAH000112
- Page 1 OIL FIRED CAST IRON HOT WATER BOILER INSTALLATION, OPERATION & MAINTENANCE MANUAL Models (Series D) BW4BAH000112 BW4BAH000140 BW4RAH000112 BW4RAH000140 BW5BAH000112 BW5BAH000140 BW5RAH000112 BW5RAH000140 BW4BAH000175 BW4BAH000217 BW4RAH000175 BW4RAH000217 BW5BAH000175 BW5BAH000217 BW5RAH000175 BW5RAH000217 CAC/BDP 7310 WEST MORRIS ST. INDIANAPOLIS, IN 46231 IM-BW4-5-02...
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Page 2: Table Of Contents
TABLE OF CONTENTS Introduction Contents This boiler is a natural draft oil fired hot water boiler Boiler Ratings And Capacities ........3 comprised of cast iron sections. Boiler is available with 3, 4, Safety Notices .............4 or 5 cast iron sections. These sections are held together by cast iron push nipples. -
Page 3: Boiler Ratings And Capacities
BOILER RATINGS AND CAPACITIES Figure 1 - Dimensions 17 1/2” RIELLO 20 1/2” BECKETT 36” BOILER RATINGS AND CAPACITIES DIMENSIONS ‡NET INPUT Boiler BOILER MODEL NO. **HEATING AHRI (inches) A.F.U.E. Water CAPACITY RATING SEC. Capacity *Mbh WATER +gph *Mbh (US Gal.) *Mbh BW(4,5)(B,R)AH000112ADAA 0.80... -
Page 4: Safety Notices
SAFETY NOTICES Become familiar with symbols identifying potential hazards. FOR YOUR SAFETY READ BEFORE OPERATING This is the safety alert symbol. Symbol alerts you DANGER to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death. -
Page 5: Safe Installation And Operation
SAFE INSTALLATION AND OPERATION WARNING Be certain oil burner nozzle is the size required. Over- firing will result in early failure of the boiler sections. Combustion chamber insulation in this product This will cause dangerous operation. contains ceramic fiber material. Ceramic fibers can Never vent this boiler into enclosed space. -
Page 6: Locating The Boiler
LOCATING THE BOILER Complete Prior To Installing Boiler. Place boiler in location centralized with the piping system and as close to chimney as possible. A. Verify you have selected the right size boiler with Boiler must be level. If necessary use metal shims proper capacity. - Page 7 LOCATING THE BOILER Figure 3 - Boiler With Piping System IM-BW4-5-02 [240013014 Rev. B [12/15/2020]...
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Page 8: Fresh Air For Combustion
FRESH AIR FOR COMBUSTION EXAMPLE 2: Boiler Located in Confined Space WARNING Asphyxiation, fire hazard. Do not obstruct air All Air from Inside the Building: Confined openings to combustion area. Follow instructions space shall be provided with two permanent openings below, to maintain adequate combustion air. - Page 9 FRESH AIR FOR COMBUSTION All Air from Outdoors: Confined space shall 3. When communicating with outdoors through be provided with two permanent openings, one horizontal ducts, each opening shall have commencing within 12 inches of top and commencing minimum free area of one square inch per 2,000 within 12 inches of bottom of enclosure.
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Page 10: System Piping
SYSTEM PIPING Installation of boiler for new heating system, Figure 6a - Safety Relief Valve Installation Install all of radiation units (panels, radiators, baseboard, or tubing) and supply and return mains first. After all heating system piping and components have been installed, make final connection of system piping to boiler. - Page 11 SYSTEM PIPING Low Design Water Temperature Systems (Below 140° F) And Large Water Content Systems • Significant condensation may form in this boiler and/ or venting system if boiler is operated with return temperatures of less than 120°F. • Condensation is corrosive and can eventually cause damage to boiler and venting system.
- Page 12 SYSTEM PIPING Figure 7 - Bypass Piping Arrangement Diagram > 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 SECTION ON “FILLING THE SYSTEM WITH WATER”...
- Page 13 SYSTEM PIPING Figure 8 - System Piping Arrangement Zoning With Zone Valves > 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”...
- Page 14 SYSTEM PIPING Figure 9 - System Piping Arrangement Zoning With Circulators > 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 IM-BW4-5-02 [240013014 Rev.
- Page 15 SYSTEM PIPING Figure 10 - System Piping Arrangement Alternate Near Boiler Piping > PER THIS MANUAL, USE OPTION #2 IN “FILLING THE SYSTEM WITH WATER” > DIAPHRAGM EXPANSION TANK MOUNTED OFF THE BOILER > THIS PIPING ARRANGEMENT CAN BE USED WITH ZONE VALVES OR ZONE >...
- Page 16 SYSTEM PIPING DANGER Burner Tankless Boiler Input Input Rating Scald, Burn Hazard! Temperatures exceeding 120°F Model (MBH) Rate (gph) (gpm)‡ will cause severe burns or death. Use of water BW5(B,R)AH-112 0.80 3.05 tempering device or mixing valve may be required by the Authority having jurisdiction, follow all codes BW5(B,R)AH-140 1.00...
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Page 17: Antifreeze In The System
ANTIFREEZE IN THE SYSTEM Antifreeze added to boilers must be nontoxic, and must be of type specifically 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. -
Page 18: Chimney And Chimney Connections
CHIMNEY AND CHIMNEY CONNECTIONS WARNING For oil fired boilers for connections to vents or chimneys, vent installations shall be in accordance with applicable Fire Hazard. Maintain minimum vent pipe clearance provisions of NFPA-31 Standard for the Installation of of 9” from surface of vent to wood and other Oil-Burning Equipment (latest edition), and applicable combustible materials. -
Page 19: Typical Chimney Connection
TYPICAL CHIMNEY CONNECTION TYPICAL CHIMNEY CONNECTION Figure 12 - Typical Chimney Connection Minimum Height: Must be 3 FT higher than highest part of passage through roof. Must be at least 2 FT higher than any neighboring object within 10 FT. Must have unobstructed top opening MUST BE AT LEAST 4 INCHES THICK -... -
Page 20: Electrical Connections
ELECTRICAL CONNECTIONS 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. Thermostat Install 24 Volt thermostat (not provided) in proper location. Location of thermostat has effect on boiler system operation. Follow instructions included with thermostat. -
Page 21: Electrical Wiring
ELECTRICAL WIRING Figure 13 - Honeywell L7248L Control with Beckett AFG Burner * When low limit is used, set ELL Parameter on L7248 Honeywell control to ON. Boilers factory equipped with tankless coil are factory set to ON. Figure 14 - Honeywell L7248L Control with Riello F5 Burner * When low limit is used, set ELL Parameter on L7248 Honeywell control to ON. -
Page 22: Filling The Boiler
FILLING THE BOILER How A Hot Water System Operates OPTION #2 Entire heating system (boiler, piping, and radiation units) is filled with water. As water in the boiler is heated, it • Close air vents on all radiation units. is circulated from top of boiler through supply main to •... -
Page 23: Operating The Boiler
OPERATING THE BOILER Draft Regulators: Barometric draft regulator is required Start: Fill entire system with water. Vent all air from for controlling draft through boiler. Mount barometric draft system following section for Filling The Boiler. regulator in chimney connector. Refer back to section on “Chimney And Chimney Connections”. -
Page 24: Preliminary Burner Settings
PRELIMINARY BURNER SETTINGS BECKETT AFG INPUT PUMP BURNER INSERTION DELAVAN OIL BURNER HEAD STATIC BOILER MODEL RATE PRESSURE SHUTTER/ PLATE MODEL DEPTH NOZZLE FIRE BAFFLE HEAD SETTING [gph] [psi] BAND BW(4,5)BAH000112 AFG50MBAS 0.80 2-1/4" 0.65-70°W 10/1 3-3/8" BW(4,5)BAH000140 AFG50MDASN 1.00 0.85-60°A 2-3/4"... -
Page 25: Burner Adjusments And Settings
BURNER ADJUSMENTS AND SETTINGS Figure 15 -Burner Adjustments and Settings Beckett AFG Burner Electrode Adjustments (V1 or L1) Heads Beckett AFG Variable (V1) Head Adjustment and Settings Figure 17 - Riello Turbulator Setting Figure 16 - Riello Electrode Setting SHALL THESE THESE DIMENSIONS SHALL BE OBSERVED AND THESE DIMENSIONS SHALL BE OBSERVED AND VERIFIED... -
Page 26: Checking And Adjusting Controls
CHECKING AND ADJUSTING CONTROLS Check Thermostat Operation: NOTICE Follow instructions included with your thermostat. You or your installer must follow these instructions Locate thermostat five feet above the floor on inside wall. carefully. Locate thermostat to sense average room temperature, avoid the following: THERMOSTAT LOCATIONS TO AVOID WARNING... -
Page 27: Maintenance
MAINTENANCE Diaphragm Expansion Tank : Tank may become WARNING water logged. Frequent automatic opening of safety relief Burn, scald hazard. Some maintenance tasks valve indicates water logging. High boiler temperature require draining the boiler. Verify boiler is cool and accompanied by unusually low radiation unit temperature at zero pressure before draining. -
Page 28: Oil Boiler Cleaning Instructions
OIL BOILER CLEANING INSTRUCTIONS Oil Boiler Cleaning: Carefully vacuum soot accumulations from combustion chamber area, take care to not damage any of Shut off all electrical power to boiler / burner and shut refractory or blanket insulation. To gain access to off fuel oil supply. -
Page 29: Oil Burner Cleaning
OIL BURNER CLEANING General instructions for cleaning an oil burner. For specifics, consult burner manufacturer’s instructions. 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. Verify all electrical power to boiler / burner and fuel supply to burner are shut off. -
Page 30: Service Hints
SERVICE HINTS 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 Check flame. -
Page 31: Pump Curve
PUMP CURVE Taco 007 Pump Curve IM-BW4-5-02 [240013014 Rev. B [12/15/2020]... - Page 32 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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