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D E S I G N E D T O L E A D
BSI Series
Gas-Fired Natural Draft Steam Boilers
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Models:
WARNING: Improper installation,
adjustment, alteration, service or
• BSI069 • BSI207
maintenance can cause property
• BSI103 • BSI241
damage, injury, or loss of life. For
assistance or additional informa-
• BSI138 • BSI276
tion, consult a qualified installer,
• BSI172 • BSI310
service agency or the gas
supplier. Read
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Table of Contents I. Product Description .................................................. 1 II. Specifications ............................................................. 2 III. Before Installing ......................................................... 3 IV. Locating the Boiler ...................................................... 3 V . Air for Combustion & Ventilation .............................. 4 VI. Venting ....................................................................
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II Specifications FIGURE 1: BSI BOILERS - GENERAL CONFIGURATION TABLE 1: BSI SPECIFICATIONS BASIC NUMBER HEATING I=B=R NET RATING, WATER BOILER OF INPUT CAPACITY STEAM AFUE DIMENSIONS (in.) VOL. ** MODEL SECTIONS (MBH) (MBH) (Sq. ft) (MBH) (%) "A" "B" "C" "D" (Gal) BSI069S 80.0 3 69 57 179 43 12 3/4 28 40 7/16 4 5.1 BSI069E 81.9 BSI103S 80.0 4 103 85 267 64 16 28 40 7/16 5 6.5 BSI103E 82.0 BSI138S 80.3 5 138 113 354 85 19 1/4 28 40 7/16 6 7.9 BSI138E 82.0 BSI172S 80.6 6 172 142 446 107 22 1/2
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III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code, ANSI Z223.1-latest edition. • Where required by the authority having jurisdiction, this installation must conform to the Standard for Co
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FIGURE 2: BSI BOILERS - CLEARANCES TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS, WALLS, AND DOORS. 4) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or used. Do not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop. 5) The boiler should be located as close to the chimney as possible. 6) Do not install this boiler directly on a surface that may get wet. Rais
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For Buildings of Other than Unusually Tight Construction 1) Determine whether the boiler is to be installed in a confined space - A confined space is defined by the National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To determine whether the boiler room is a confined space: a. Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest 1000 BTU/hr. b. Find the vo
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FIGURE 3: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC 7 6
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FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 8 7
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VI Venting Vent installation must be in accordance with local building codes, or the local authority having jurisdiction, or the National Fuel Gas Code, NFPA 54/ANSI Z 223.1. A typical vent installation is illustrated by Figure 8. The components of vent installation are the vent damper (if used), vent connector and chimney. 1) Acceptable Chimneys - The following chimneys may be used to vent BSI series boilers: • Listed Type B or L gas vent - Install in accordance with the manufacturer’s instruc
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14) Vent damper installation is mandatory on all sizes from the BSI069 to BSI276. The BSI310 through BSI379 may be ordered with or without vent damper. If supplied, install vent damper (see Figure 9) as follows: a) Open vent damper carton and remove installation instructions. Read the instructions thoroughly before proceeding. Verify that vent damper is same size as draft diverter outlet. See Figure 1. Unpack vent damper carefully. Do not force closed damper blade. Forcing vent damper closed may
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FIGURE 8: BSI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS RIGHT SIDE VIEW FIGURE 9: VENT DAMPER INSTALLATION DETAILS 11 10
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VII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at a line pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or Chapter 2 of the National Fuel Gas Code. Figure 10 shows typical gas piping connection to the BSI boiler. A sediment trap must be installed upstream of all gas controls. Install a manual shut-off valve outside the jacket an
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VIII System Piping CAUTION • INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERATION AND SERVICE (CIRCULATOR REPLACEMENT, ETC.). • OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. General Piping Notes Figure 11 shows recommended near boiler piping for most common types of gravity return
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Piping Installation 1) Remove parts bag from boiler crate. 2) Install safety valve (spindle must be in vertical position) into tapping on boiler left side (see Figure 1) using the 3/4” NPT nipples and elbow supplied. 3) Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the safety valve discharge is not piped to a drain it must
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BOILER MINIMUM PIPE DIA. (IN NPT) MODEL "A" "B" "C" "D" BSI069 * 2 1 1/2 1 1/4 BSI103 * 2 1 1/2 1 1/4 BSI138 * 2 1 1/2 1 1/4 BSI172 * 2 1 1/2 1 1/4 BSI207 2 3 1 1/2 1 1/4 BSI241 2 3 2 1 1/2 BSI276 2 3 2 1 1/2 BSI310 2 3 2 1 1/2 BSI345 2 3 2 1 1/2 BSI379 2 3 2 1 1/2 * SECOND 2" SUPPLY RISER OPTIONAL BO I L ER FR O N T FIGURE 11: STEAM BOILER PIPING FOR GRAVITY RETURN WRONG - TAKE-OFF BETWEEN RISERS WRONG - HEADER BULLHEADED INTO TAKE-OFF AND EQUALIZER WRONG - TAKE-OFF BULLHEADED INTO TWO MAINS
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IX Indirect Water Heater Piping All BSI series boilers are equipped with tappings to permit the connection of a Crown Mega-Stor, or other indirect water heater. In this type of system, hot boiler water is drawn from below the water line and passed through the heat exchanger in the indirect water heater. This section describes boiler-side piping only. Refer to the indirect water heater instruction manual for domestic water piping. The components in this system and their functions are as follo
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X Wiring WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70) 1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt connections are made inside the junction box on the left side of the boiler. Remove the transformer to gain access to this box (also see Figures 16 through 19): • Hot (“black”) -
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Feeder Wiring for Boilers Equipped with McDonnell & Miller #67 Low Water Cut-offs Figures 14a and 14b show feeder wiring for McDonnell & Miller #101A, McDonnell & Miller WF2-U-24 and Hydrolevel VXT- 24 feeders on boilers equipped with #67 low water cutoffs. The following points apply to all feeder wiring to #67 low water cut-offs: • Use a separate transformer to power the feeder. Do not use the transformer on the boiler. • It is not necessary to touch any of the 24 volt factory boiler wiring wh
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CAUTION DO NOT INSTALL JUMPER BETWEEN 2 & 3 ON #67 L.W.C.O. FIGURE 14b: WIRING MCDONNELL & MILLER WF2-U-24 FEEDER OR THREE-WIRE HYDROLEVEL VXT-24 FEEDER TO BOILER EQUIPPED WITH #67 L.W.C.O. FIGURE 15: WIRING INDIRECT W A TER HEA TER TO BOILER 19 18
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BSI Control System – Sequence of Operation (Refer to Figures 16 through 19 for ladder and connection diagrams) Sequence of Operation, Standing Pilot 1) When the boiler is energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damper. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will close. On boilers equipped with Hydrolevel CG400A probe type low water cut-offs, voltage is also always ap
