Carrier BW9 Series Installation Instructions Manual
Gas-fired, direct vent, condensing hot water boiler sizes 125,000 through 200,00 series a
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Also See for BW9 Series:
- User's information manual (8 pages) ,
- User manual (8 pages) ,
- Operation and maintenance manual (8 pages)
Table of Contents
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BW9
NOTE: Read the entire instruction manual before starting the
installation.
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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. When working on
heating equipment, observe precautions in literature, on tags, and
on labels attached to or shipped with unit and other safety
precautions that may apply.
Recognize safety information. This is the safety- -alert symbol
. When you see this symbol on the unit and in instruction
manuals, be alert to the potential for personal injury.
Understand
the
signal
words
CAUTION, and NOTE. These words are used with the
safety- -alert symbol. DANGER identifies the most serious
hazards which will result in severe personal injury or death.
Installation Instructions
PAGE
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DANGER,
WARNING,
Gas---Fired, Direct Vent, Condensing
Sizes 125,000 Through 200,00
WARNING signifies hazards which could result in personal
injury or death. CAUTION is used to identify unsafe practices
which may result in minor personal injury or product and
property damage. NOTE is used to highlight suggestions which
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will result in enhanced installation, reliability, or operation.
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3
3
3
5
5
6
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ASME
14
15
Read and obey the following rules to ensure safe installation and
operation:
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1. Read the entire installation manual before beginning the
installation.
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installation and operation and these instructions could
cause a malfunction of the boiler and result in death,
serious bodily injury, and/or property damage.
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2. Check all applicable state and local building codes and
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utility company requirements before installation. The
installation must conform with these requirements in their
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entirety. In the absence of these codes, use NFPA
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Installation Codes and good industry practices.
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3. Before servicing the boiler, allow boiler to cool. Always
shut off any electricity and gas supply connected to the
35
boiler prior to servicing.
4. Inspect gas line for leaks.
5. Be certain gas input rate is correct. Overfiring may result
in early failure of boiler sections. This may cause
dangerous operation. Underfiring may result in too much
air for the pre- -mix burner causing poor combustion or
loss of combustion.
6. Never vent the products of combustion from this boiler to
an enclosed space. Always vent to the outdoors. Never
vent to another room or to inside a building.
7. Be sure there is adequate air supply to boiler for complete
combustion.
8. Follow a regular service and maintenance schedule for
efficient and safe operation.
9. Keep boiler area clean and free from combustible and
flammable materials.
Hot Water Boiler
Series A
ama
CERTIFIED
®
Failure to follow these rules of safe
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Table of Contents
Troubleshooting
Related Manuals for Carrier BW9 Series
Summary of Contents for Carrier BW9 Series
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Page 1: Table Of Contents
Gas---Fired, Direct Vent, Condensing Hot Water Boiler Sizes 125,000 Through 200,00 Series A Installation Instructions NOTE: Read the entire instruction manual before starting the WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices installation. -
Page 2: Introduction
OPENING FOR AIR VENT OPENING FOR RELIEF VALVE AND EXPANSION TANK DISCHARGE PIPE CONNECTION STANDARD SUPPLY & RETURN OPENINGS 1 1/4 NPT CONNECTIONS PROVIDED INSIDE BOILER VENT CONNECTION (2 CPVC) CABINET. JUNCTION BOX FOR 120V. POWER & 24 V THERMOSTAT LEADS COMBUSTION AIR INTAKE FITTING 20 1/8 32 5/16... -
Page 3: Installation
Table 1—Sea Level Ratings- -Natural and Propane Gases {HEATING NET I=B=R SHIPPING MODEL INPUT* (MBH) CAPACITY* FLUE DIAM. }AFUE RATING* (MBH) WEIGHT (LBS) (MBH) 2” CPVC and 3” 112.5 2” CPVC and 3” 2” CPVC and 3” 157.5 2” CPVC and 3” *1 MBH = 1,000 Btuh Btuh = British Thermal Units per Hour { AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity is based on the D.O.E. - Page 4 Table 2—Boiler Clearances (In.) COMBUSTIBLE ACCESSIBILITY/ UNIT SERVICING CONSTRUCTION CLEANING Left Side Right Side Base Front Back Intake/Vent Piping Near Boiler Hot Water Piping LOCATING THE BOILER WARNING All distances measured from the cabinet of the boiler. (See Table FIRE AND EXPLOSION HAZARD 1.
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Page 5: Placing The Boiler
NOTE: Condensate trap is to be built in the field per Fig. 7. 9. After it has been determined that each appliance remaining connected to the common venting system properly vents Wood frame or blocks may be used to raise the boiler when tested as outlined above, return doors, windows, to maintain drain pitch or to be above external condensate exhaust fans and any other gas- -burning appliances to their... -
Page 6: Combustion Air And Vent Pipe
A hot water boiler installed above radiation level must be The 1/2” diameter schedule 40 PVC or CPVC condensate drain equipped with a low water cut off device. A periodic inspection is piping and pipe fittings must conform to ANSI standards and necessary, as is flushing of float type devices, per low water cut ASTM D1785 or D2846. - Page 7 ZONE SERVICE PRESSURE VALVE RELIEF DEVICE FLOW CHECK VALVE SUPPLY TO ZONES ZONE SERVICE VALVE CIRCULATORS FLOW CHECK PRESSURE VALVE REDUCING VALVE GATE VALVE CAN VENT REDUCED PRESSURE FEED BACKFLOW PREVENTER WATER RETURN FROM ZONES EXPANSION TANK ZONE SERVICE VALVE ZONE SERVICE VALVE NOTE: When zoning with circulators, the furnished circulator pump should...
- Page 8 EXPANSION TANK SERVICE VALVE (GATE VALVE OR FULL PORT BALL VALVE) AUTOMATIC AIR VENT* 3/4" x 1/8" BUSHING* COMBINATION QUICK FILL VALVE, STRAINER, CHECK VALVE AND PRESSURE REDUCING VALVE - FURNISHED IN PARTS BAG COLD WATER FILL PRESSURE REDUCING VALVE REDUCED PRESSURE BACKFLOW PREVENTER GATE VALVE...
- Page 9 Table 3—Gas Piping Sizes NATURAL GAS Pipe Capacity --- BTU per hour Input Includes Fittings Length of Pipe (ft.) 1/2” 3/4” 1” 1--- 1/4” 92,000 190,000 350,000 625,000 63,000 130,000 245,000 445,000 50,000 105,000 195,000 365,000 PROPANE GAS Pipe Capacity --- BTU per hour Input Includes Fittings Copper Tubing* Iron Pipe Length of Pipe (ft.)
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Page 10: Gas Supply Piping
STEP 6 —Gas Supply Piping CHECKING THE GAS PIPING CHECK GAS SUPPLY After all connections have been made, check immediately for leaks. Open the manual shutoff valve. Test for leaks by applying The gas pipe to your boiler must be the correct size for the length soap suds (or a liquid detergent) to each joint. - Page 11 OVERHANG 12” MINIMUM 12” SEPARATION BETWEEN BOTTOM OF 90° COMBUSTION AIR INTAKE AND BOTTOM OF VENT VENT MAINTAIN 12” MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE 3” MAXIMUM SEPARATION 15” MAXIMUM 18” MAXIMUM LESS THAN 12” CLEARANCE OVERHANG 12”...
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Page 12: Gas Connection
INSTALL YOUR THERMOSTAT MAINTAIN 12 IN. VENT (18 IN FOR CANADA) The thermostat location has an important effect on the operation MINIMUM CLEARANCE ABOVE HIGHEST of your boiler system. BE SURE TO FOLLOW THE ANTICIPATED SNOW LEVEL. MAXIMUM OF INSTRUCTIONS INCLUDED WITH YOUR THERMOSTAT. 24 IN. - Page 13 A06088 Fig. 15 --- Field Wiring Connections If any of the original wire as supplied wiht this appliance must be replaced, it must be replaced with type 150_C Thermoplastic wire or its equivalent A06089 Fig. 16 --- Schematic Wiring Connections...
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Page 14: Controls And Accessories
A06090 Fig. 17 --- Ladder Wiring Diagram STEP 8 —Controls and Accessories removing and reestablishing the thermostat’s call for heat, or by turning the service switch off, then back on. This section provides a brief description of the key controls and L4006A HIGH LIMIT AQUASTAT CONTROL accessories found in this boiler. -
Page 15: Start- -Up And Check- -Out Procedures
DIFFERENTIAL PRESSURE AIR PROVING SWITCH (2) blocked boiler section, or a blocked air inducer. After 5 minutes of inadequate differential pressure, the IBC will lock out. The The diaphragm type differential pressure switches are connected “Purge” indicator lamp will blink, indicating a failure to prove by vinyl tubing to the gas valve and the air inlet connection on adequate combustion air flow or flue gas flow. - Page 16 Table 4—Diagnostic Sequence SEQUENCE OF OPERATION DIAGNOSTIC INDICATOR LAMPS Lamp A is illuminated, indicating that the integrated control is receiving 24 volts and is in standby waiting for the thermostat to call for heat. Thermostat calls for heat, energizing the system circulator. Integrated boiler control performs self check of internal cir --- cuitry, lasting approximately two seconds, and energizes the draft inducer.
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Page 17: Filling Boiler With Water And Purging Air For Systems With Diaphragm Type Expansion Tanks
c. Follow the antifreeze manufacturer’s instructions on Make sure air vent is open. Hold relief valve open until determining proper ratio of antifreeze to water for the water runs air free for five seconds to rapidly bleed air expected low temperature conditions, and for from boiler, then let the relief valve snap shut. -
Page 18: Placing Boiler In Operation
STEP 4 —Placing Boiler in Operation Piping,” located in the INSTALLATION section in this manual. READ BEFORE OPERATING APPLIANCE 3. Check for orifice in negative pressure hose at gas valve 1. This appliance does not have a pilot. It is equipped with an and 2”... - Page 19 Table 5—Natural Gas NOMINAL INPUT 200,000 175,000 150,000 125,000 Vent Lengths Vent Lengths Vent Lengths Vent Lengths Altitude 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000 1,000 197,000 196,500 172,400 172,200 147,800 147,400 123,500 123,000 2,000 194,000 193,000 169,800 169,400 145,600 144,800 122,000...
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Page 20: Care And Maintenance
ADJUSTMENTS AND CHECKOUT CARE AND MAINTENANCE NOTE: It is important that this appliance operate between 8.5 Maintenance as outlined below can be performed by the owner unless otherwise noted. and 10% CO . To verify that the appliance is operating in this range, follow the steps below: The acidic nature of flue gases condensing on the aluminum boiler sections will cause the formation of aluminum oxide. -
Page 21: Service Hints And Troubleshooting
4. Visually inspect the PVC condensate drain pipe for proper fasten with two (2) screws. Use care when installing operation. If the drain pipe shows any signs of blockage, the igniter. It is very brittle! Do not touch the igniter leakage, or deterioration contact a qualified service agency element with your fingers or hands as oil or debris will to clean, repair, or replace it immediately. - Page 22 BOILER STATUS DIFFERENTIAL PRESSURE SWITCH CONTACTS Closed at 3.5” Not Running 0” Closed at 0.5” 1.00” For Model- - 125 Closed at 3.5” 1.50” For Model- - 150 Closed at 0.5” Running without Blockage (Approximate) 1.50” For Model- - 175 2.00”...
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Page 23: Normal Sequence Of Operation
NORMAL SEQUENCE OF OPERATION PO WER ON STANDBY IF MAIN BURNER DOES NOT PROVE FLAME IN 3 THERMOSTAT TRIALS, CONTROL LOCKOUT. VALVE/FLAME CALLS FOR HEAT LIGHT BLINKS. RESET IS REQUIRED. THIS PROBLEM IS A RESULT OF NOT ESTABLISHING FLAME SIGNAL. CIRCULATOR ENERGIZES THRU 2K1 CONT ACTS... - Page 24 LOSS OF FLAME SIGNAL CASTING TEMPERATURE SAFETY SWITCH IF AN ESTABLISHED FLAME SIGNAL IS LOST IF BURNER OPERATES WHEN BOILER HAS NO WHILE CONTROL EXPECTS THAT THE BURNER WATER, ALUMINUM BOILER SECTIONS IS OPERATING, CONTROL WILL IMMEDIATELY HEAT UP RAPIDLY. DE-ENERGIZE GAS VALVE.
- Page 25 GAS VALVE AND CIRCULATOR PUMP ARE DE-ENERGIZED. VALVE LIGHT GOES OUT. BLOWER RUNS FOR 30 SECOND POST PURGE. PURGE LIGHT ON. BLOWER IS DE-ENERGIZED AFTER 30 SECONDS. PURGE LIGHT SHUTS OFF. A04066 Fig. 23 --- End of Normal Sequence of Operation...
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Page 26: Detailed Sequence Of Operation
WARNING FIRE, EXPLOSION OR SHOCK HAZARD Failure to follow this warning could result in personal injury, death or property damage. Do not attempt to modify the physical or electrical characteristics of this boiler in any way. IMPORTANT 1. IN A RESET FROM LOCKOUT CONDITION, ALL ELECTRICAL METER READINGS AT THE GAS CONTROL VALVE (24 VAC) MUST BE TAKEN WITHIN THE TRIAL FOR IGNITION PERIOD. -
Page 27: Troubleshooting
SYSTEM STATUS THE INDICATOR LIGHTS TRACK THE OPERATING SEQUENCE. IF THE SYSTEM LOCKS OUT, THE LIGHTS INDICATE THE POINT IN THE SEQUENCE OF OPERATION WHERE LOCKOUT OCCURS. IF THIS TABLE DOES NOT READILY PROVIDE THE REASON FOR BOILER MALFUNCTION OR NON-OPERATION, REFER TO THE FOLLOWING PAGES FOR MORE DETAILED TROUBLESHOOTING PROCEDURES. - Page 28 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. The following procedures may expose you to dangerous line voltage. Use caution to avoid touching live electrical contacts. Service must be performed by a trained, experienced service technician.
- Page 29 A04070 Fig. 27 --- Troubleshooting Chart No. 1...
- Page 30 TROUBLESHOOTING CHART 2 CHECK THAT CIRCUIT BREAKERS IS ON OR FUSES ARE OK AT THE ELECTRICAL PANEL CHART 1 CHECK THAT SERVICE SWITCH IS ON CHECK CASTING TEMPERATURE SAFETY CHECK WATER LEVEL IN BOILER. CHECK OPEN SWITCH. PUSH RESET BUTTON ON SWITCH. FOR AIR TRAPPED IN TOP OF BOILER.
- Page 31 TROUBLE SHOOTING CHART 3 CHART 1 OPEN CHECK FOR 120 VAC BETWEEN TERMINALS 1 BLOWER STARTS REPLACE IBC AND 3 AT CONNECTOR CN4 ON IBC CHECK FOR 120 VAC AT REPAIR/REPLACE BLOWER LEADS WIRING FROM IBC ON WIRING HARNESS TO DRAFT INDUCER REPAIR/REPLACE BLOWER IBC WAITS UP TO 5...
- Page 32 TROUBLESHOOTING CHART 4 CHART 3 CHECK FOR 120 VAC IGNITER/SENSOR WARMS BETWEEN TERMINALS 1 UP AND GLOWS YELLOW/ REPLACE IBC AND 2 AT CONNECTOR ORANGE DURING 20 CN1 ON IBC (DURING SECOND WARM UP IGNITER WARM UP) CHECK FOR 120 VAC AT REPAIR/REPLACE WIRING IGNITER/SENSOR LEADS FROM IBC TO IGNITER/...
- Page 33 A04073 Fig. 31 --- Troubleshooting Chart No. 5...
- Page 34 REPLACE GAS CONTROL CHECK GAS ORIFACE SIZE IS GAS ORIFICE SIZE CORRECT. CHECK REPAIR PARTS LIST FOR CORRECT SIZE. IS GAS ORIFICE CLEAR OF BLOCKAGE. DOES THIS UNIT USE LP GAS. THEN TURNS OFF. CHECK FIRING RATE OF UNIT. IS UNIT FIRING AT THE CORRECT RATE? ADJUST RATE AS DESCRIBED IN THE CHECK OUT PROCEDURE AND ADJUSTMENT SECTION OF...
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Page 35: Repair Parts
REPAIR PARTS A04076 Fig. 33 --- Jacket and Base Assembly... - Page 36 JACKET AND BASE ASSEMBLY Item Part No. Description Quantity 2272144 Base Replacement Kit 650001028 Control Panel 146622803 Integrated Boiler Control 550001339 40 VA Transformer Kit 14631316 4” x 4” x 2--- 1/8” J --- Box 14631319 Switch P & S 14631318 J --- Box Plate Cover Jacket Panel Left Side Kit...
- Page 37 29 1/2" LONG 12" LONG 7" LONG 1 3/8" LONG 3 3/4" LONG 3 3/4" LONG 2" LONG A06154 Fig. 34 --- Exhaust Tee and Condensate Assembly EXHAUST TEE AND CONDENSATE ASSEMBLY Item Part Number Description Quantity Vent Pipe 2” CPVC 1400008 SCH--- 40 x 29--- 1/2”...
- Page 38 A06153 Fig. 35 --- Boiler Block and Piping Assembly...
- Page 39 BOILER BLOCK AND PIPING ASSEMBLY Item Part Number Description Quantity 2272160 Replacement Block Kit (Includes Items 2 and 30) 1395002 1--- 1/4” Plug Cast Iron Square Head Plug 14631301 Hose 3” Long x 2--- 3/8 I.D. x 2--- 3/4” O.D. 1400008 Vent Pipe 2”...
- Page 40 A04079 Fig. 36 --- Burner Assembly BURNER ASSEMBLY Item Part Number Description Quantity Burner Replacement Kit 2272149 (Includes Items 2 and 3) 1250009 Burner/Casting Gasket 1250008 Burner/Flue Adapter Gasket 1210122 Flue Adapter 14695810 Hex Nut w/Serrated Washer ¼” x 20 1450011 Threaded Stud ¼”...
- Page 41 2" 4" 3" 5 1/2" 4" 2 @ 2" EA. SIGHT GLASS & ADAPTER 13 1/4" GAS VALVE AIR INLET CONNECTION 6" 16 1/2" A06107 Fig. 37 --- Mixer and Air Pressure Switch Assembly MIXER AND AIR PRESSURE SWITCH ASSEMBLY Item Part Number Item...
- Page 42 BLOWER GASKET A04081 Fig. 38 --- Flue Adapter and Exhauster Assembly FLUE ADAPTER AND EXHAUSTER ASSEMBLY Item Part Number Description Quantity Blower Replacement Kit 2272145 (Includes Item 13) 2272140 Gas Valve Replacement Kit (125 Only) 2272141 Gas Valve Replacement Kit (150 Only) 2272142 Gas Valve Replacement Kit (175 Only) 2272143...
- Page 43 Table 7—Conversion Kits - - Nat to LP for 125- -200MBH MODEL # KIT # INCLUDES: Plastic Bag 3 x 6 x 18 Orifice LP Model 125, 3.9MM Label Propane BW9AAN000125 KBANP1401DNK Literature, Conversion 125/200 Key, Torx T--- 20 Label Propane Only Data Plate Plastic Bag 3 x 6 x 18 Orifice LP Model 150, 4.2MM Label Propane...
- Page 44 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________ Installation instructions have been followed Checkout procedure and adjustment s performed Maintenance and Service issues reviewed with owner/ maintenance person Installation booklet affixed on or adjacent to boiler Inst aller (Company) Address Phone...