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Related Manuals for CAC / BDP C Series
Summary of Contents for CAC / BDP C Series
- Page 1 Gas Fired Induced Draft Hot Water Boilers INSTALLATION, OPERATION & MAINTENANCE MANUAL Models (Series C) BW3AAN00042 BW3AAN00075 BW3AAN00112 BW3AAN00150 BW3AAN00187 BW3AAN00225 CAC/BDP 7310 West Morris St. Indianapolis, IN. 46231 P/N# IM-BW3A-07 [240009364, Rev. C [06/2017]...
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Page 2: Table Of Contents
TABLE OF CONTENTS Boiler Ratings & Capacities...... 3 Safety Symbols & Warnings The following defined symbols are used throughout Dimensions ..........4 this manual to notify the reader of potential hazards Installation Procedure ......5 of varying risk levels. Ventilation & Combustion Air ....6 DANGER Installation System Piping ...... -
Page 3: Boiler Ratings & Capacities
BOILER RATINGS & CAPACITIES Table 1 - RATINGS NATURAL AND PROPANE GASES High Heating Net AHRI Input Altitude Flue Collar Model Capacity Rating Water AFUE *Mbh Input (Inches) *Mbh *Mbh *Mbh BW3AAN00042 84.4 BW3AAN00075 83.4 BW3AAN00112 83.0 BW3AAN00150 82.7 BW3AAN00187 82.3 BW3AAN00225 82.0... -
Page 4: Dimensions
DIMENSIONS Model Width (A) BW3AAN00042 11” (279mm) BW3AAN00075 14¼” (302mm) BW3AAN00112 17½” (444mm) BW3AAN00150 20¾” (527mm) BW3AAN00187 24” (610mm) BW3AAN00225 27¼” (692mm) -
Page 5: Installation Procedure
INSTALLATION PROCEDURE WARNING NOTICE Follow local regulations with respect to installation Improper installation, adjustment, alteration, service of CO detectors. or maintenance could result in death or serious injury FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY - For installation on combustible The installation must conform to the requirements of the authority having jurisdiction or, in the absence flooring special base must be used. -
Page 6: Ventilation & Combustion Air
VENTILATION & COMBUSTION AIR • All Outdoor Air. Provide permanent opening(s) Provide combustion air and ventilation air in accordance communicating directly or by ducts with outdoors. with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections о... -
Page 7: Installation System Piping
INSTALLATION SYSTEM PIPING WARNING Figure 2 - Safety Relief Valve Discharge Piping Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. RELIEF VALVE Refer to local codes and appropriate ASME Boiler DISCHARGE and Pressure Vessel Code for additional installation PIPING... - Page 8 INSTALLATION SYSTEM PIPING Figure 4 - Forced Hot Water Typical Piping Figure 3 - Forced Hot Water Typical Piping With Zone Control Valve MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE LIMIT SENSOR MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE LIMIT SENSOR...
- Page 9 INSTALLATION SYSTEM PIPING • Install radiation units (panels, radiators or cabinets) and Low Design Water Temperature Systems (Below supply and return mains first then make connections at 140°F (60°C)) And Large Water Content Systems boiler. • Verify clean water supply is available when connecting Condensation is corrosive and can eventually cause severe cold water supply to water valve.
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Page 10: Vent Installation
VENT INSTALLATION Fasten sections of vent pipe with sheet metal screws to Check Your Chimney make piping rigid. Use stovepipe wires to support pipe Chimney must be clean, right size, properly constructed from above. and in GOOD CONDITION. Do not connect to fireplace flue. Installation must conform to requirements of the authority having jurisdiction or, in absence of such Do not install damper on this boiler. - Page 11 VENT INSTALLATION Figure 7 - Type B Gas Vent Vent pipe must be: At lease 2 ft. (610mm) higher Liner than any part of the roof, but not less than 3 ft. (915mm) tall, and within a 10 ft. within a 10 ft. Chimney (3m) radius of the apex.
- Page 12 VENT INSTALLATION Removing Existing Boiler From Common Venting Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use flame of a match System or candle, or smoke from a cigarette, cigar, or pipe. When an existing boiler is removed from a common After it has been determined that each appliance venting system, the common venting system is likely to be...
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Page 13: Optional Horizontal Venting Instruction
OPTIONAL HORIZONTAL VENTING INSTRUCTION Horizontal venting with a power venter is an alternate • Confirm installation of a power venter is allowed by local method of sidewall venting. This boiler is CSA listed for codes. sidewall venting with standard single wall galvanized or •... -
Page 14: Gas Supply Piping
GAS SUPPLY PIPING Connecting Gas Piping CAUTION Gas line enters boiler from right side. Flexible gas WHAT TO DO IF YOU SMELL GAS connectors must never breach any boiler openings. • Do not try to light any appliance. • Use piping materials and joining methods acceptable to authority having jurisdiction. - Page 15 GAS SUPPLY PIPING Table 6 - NATURAL GAS Table 7- PROPANE GAS Pipe Capacity - BTU Per Hour Input Pipe Capacity - BTU Per Hour Input Length of Length Includes Fittings Includes Fittings Pipe - Ft. Copper Tubing* Iron Pipe ½"...
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Page 16: Electrical Wiring
ELECTRICAL WIRING LWCO kit 550002998 wiring includes wiring instructions WARNING and diagrams. If using other LWCO, refer to specific Electrical shock hazard. Turn OFF electrical power manufacturer instructions supplied by appropriate supply at service panel before making electrical manufacturer. connections. Failure to do so could result in death Connect 115 volt power supply to terminals L1 (HOT) and or serious injury. -
Page 17: Sequence Of Operation
SEQUENCE OF OPERATION Sequence of Operation - Figure 10, Page 18. Thermostat calls for heat, control relay contacts. Circulator pump is powered through terminals C1 and C2. Control holds off burner and attempts to satisfy thermostat with residual boiler heat. Induced draft blower and transformer primary are powered. -
Page 18: Wiring Diagrams
WIRING DIAGRAMS Figure 10 - Control Module Damper is not an option. -
Page 19: Starting Your Boiler
STARTING YOUR BOILER CAUTION Burn, scald, explosion hazard. Failure to follow these instructions could result in minor or moderate injury. Filling System With Water • Close air vents on all radiation units. Open valves to these units. • Verify boiler and expansion tank drain valves are closed. Air bleed screw on tank drain fitting should be closed. - Page 20 STARTING YOUR BOILER Operating Instructions. WARNING STOP! Read Safety Information on previous page. If you do not follow these instructions Set the thermostat to lowest setting. exactly, a fire or explosion may result Turn off all electric power to the appliance. causing property damage, personal injury This appliance is equipped with an ignition device which or loss of life.
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Page 21: Checking And Adjusting
CHECKING AND ADJUSTING Gas Valve Safety Shutdown Test Figure 12 - Automatic Gas Valve WARNING Electrical shock hazard. Follow instructions to turn off electric power. Failure to do so could result in death or serious injury. Ignition system safety shutoff device must be tested after placing boiler in operation. - Page 22 CHECKING AND ADJUSTING Figure 14 - Main Burner Flame Adjust Thermostat Heat Anticipator Instruction for final adjustment of thermostat are packaged with thermostat. Set Heat anticipator at .2. Check thermostat operation. When set above temperature indicated on thermometer, boiler burners should ignite.
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Page 23: Maintaining Your Boiler
MAINTAINING YOUR BOILER Burners Cleaning Your Boiler And Burners Beginning of heating season visually check pilot and main Flue passages between sections should be examined yearly burner flames. See Figures 13, and 14. and cleaned if necessary. To clean: Safety Relief Valve •... -
Page 24: Service Hints
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service: CAUTION 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. -
Page 25: Equipment & Optional Accessories
EQUIPMENT & OPTIONAL ACCESSORIES AIR ELIMINATING FITTING (AIR PURGER) WARNING Air purger is used to remove excess air from system. It Burn and scald hazard. Safety relief valve could is installed in supply line. It will eliminate air from water discharge steam or hot water during operation. - Page 26 EQUIPMENT & OPTIONAL ACCESSORIES PRESSURE SWITCH Air pressure switch works on negative pressure. When blower comes on air pressure switch operates intermittent pilot and gas valve. Air pressure switch is factory set and will only work when blower operates properly. It will not allow boiler to come on if blower does not generate enough pressure or if venting system is blocked.
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Page 27: 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 (see Figure 1) simultaneously for three seconds. -
Page 28: 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 29: Boiler High Limit Temperature Controller
APPENDIX A - CONTROL MODULE A.6 Boiler High Limit Temperature Controller A.7 Troubleshooting • When water temperature reaches setpoint, controller • Following service procedures are provided as general ends heating cycle. guide. • When water temperature drops below setpoint minus •... -
Page 30: Intermittent Pilot
APPENDIX A - CONTROL MODULE Table 2 - Troubleshooting Error Codes Error Code Definition Consequence Number Pressure switch failed to open (stuck closed). Wait for recovery Flame current too low. Check for flame. Non critical alarm Flame sensed out of normal sequence (before opening or after closing gas valve). Soft lockout Gas valve relays welded. - 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.
- 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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