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CANADIAN GAS ASSOCIATION
Installation, Start-Up, and Operating Instructions
Gas-Fired
BW3
Induced-Draft Hot Water Boilers
Series B
Sizes 42,500 through 225,000
ama
®
APPROVED
R
®
ASME
NOTE: Read the entire instruction manual before starting the installation. These instructions must be affixed on or adjacent to the boiler.
This symbol → indicates a change since the last issue.
MODEL BW3
A95465
Index Page
SAFETY CONSIDERATIONS....................................................................
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CHIMNEY AND VENT PIPE CONNECTION .......................................................................................................................................................7-9 Checking Chimney....................................................................................................................................................................................................8 Minimum Vent Pipe Clearance.......................................................................
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INTRODUCTION This boiler cannot be used with all types of chimneys. Read these instructions carefully before installing. These Gas-Fired Hot Water Boilers are low-pressure, sectional cast iron boilers design certified by the American Gas Association (A.G.A.) and Canadian Gas Association (C.G.A.) for use with natural and propane gases. They are constructed and hydrostatically tested for a maximum working pressure of 50 psi in accordance with the American Society of Mechanical Engineers (A.S.M.E.)
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1 1 ⁄ ″ SUPPLY 4 1 23 ⁄ ″ A 4 COMBINATION
RELIEF
VENT
LIMIT & RELAY
TEMP
VALVE CONNECTOR CONTROL PRESSURE
GAGE 1 1 ⁄ ″ RETURN 4 BLOWER 29″ 1 25 ⁄ ″ 4 23″ PRESSURE
SWITCH 5 5 5 ⁄ ″ 5 ⁄ ″ 8 8 CIRCULATOR BURNER 3 1 ⁄ ″ 4 GAS
INT. PILOT
7″ VALVE CONTROL LEFT SIDE FRONT RIGHT SIDE A85084 Gas-Fired Hot Water Boilers NATURAL AND PROPANE GAS† DIMENSIONS (IN.) Net Width Vent Diameter NO. OF A.G.A. Heating BOILER MODEL NUMBER* I=B=R SECTIONS Input Capacity To Chimney Rating A MBH MBH (Category
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→ Table 1—Room Large In Comparison With Boiler MINIMUM ROOM VOLUME REQUIRED BOILER SIZE BOILER VOLUME TO BE LARGE (SECTIONS) (CU FT) ROOM (CU FT)* 2 4.3 68.7 3 5.6 89.0 4 6.8 109.3 5 8.1 129.5 6 9.4 149.8 7 10.6 170.1 * For room with single boiler only. Table 2—Minimum Clearances From Combustible Materials and For Servicing ALCOVE OR ROOM ROOM LARGE NOT LARGE PART OF BOILER IN COMPARISON IN COMPARISON WITH BOILER (IN.) WITH BOILER (IN.) Top 66 Rear 66 Control Side 86 Opposite Control Side 66 Fro
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Equipment located in buildings of unusually tight construction shall be provided with air for combustion, ventilation, and dilution of flue gases using the methods described in example 2B or shall be specially engineered. The authority having jurisdiction must approve specially engineered installations. PROCEDURE 2—BOILER LOCATED IN CONFINED SPACE EXAMPLE 2A: ALL AIR FROM INSIDE THE BUILDING The confined space shall be provided with two permanent openings communicating directly with an additiona
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INSTALLATION—SYSTEM PIPING 1. Place boiler in selected location (as close to chimney as possible). Boiler is shipped assembled. Only the relief valve with a drain line to carry any water to a drain and a drain valve need to be installed. 2. Install relief valve on 3/4-in. pipe nipple in tapped opening in left end section. Connect a drain line of same pipe size (3/4 in.) to carry any water away to a drain. No shutoff of any description shall be placed between safety relief valve and boiler, or on
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TO SYSTEM A B C D WATER
CHILLER VALVES C & D
VALVES A & B
CLOSE FOR HEATING;
OPEN FOR HEATING;
OPEN FOR COOLING CLOSE FOR COOLING A96141 Fig. 4—Piping Arrangements for Boiler Used in Connection with Refrigeration System 2. The boiler’s induced draft blower has a 3-in. outlet. A 3-in. X 4-in. increaser fitting is included in the parts bag. Locate increaser fitting on outlet of induced draft blower and secure gastight with a bead of the factory-supplied silicone sealant. The increaser fitting
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THE VENT PIPE MUST BE AT
LINER LEAST 2 FT HIGHER THAN
ANY PART OF THE ROOF
WITHIN A 10 FT RADIUS
CHIMNEY OF THE VENT. 2' MIN THIMBLE 10' 3' MIN VENT SYSTEM CLEANOUT SHEET METAL
FIRESTOP A95196 Fig. 5—Type-B Gas Vent Table 4—Boiler and Power Venter BOILER SIZE (SEC- FIELD CONTROLS TIONS) POWER VENTER KIT 2, 3, 4, 5 SWG-4D 6, 7 SWG-5D For boilers with connections to gas vents or chimneys, vent installations shall be in accordance with Part 7 NFGC, Venting of Equipment, in the Unit
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3. Boiler installation site experiences gusting or high winds. A power venter can help prevent the boiler from short cycling due to gusting or high winds by providing vent exhaust pressures greater than the boiler’s induced draft blower alone. 4. When installer or homeowner prefers a negative pressure vent system instead of a positive pressure vent system. 5. May be more cost effective than stainless steel venting, particularly at longer vent lengths. The Fields Controls power vent kit includes
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4. Install a sediment trap upstream of gas controls. 5. Use 2 pipe wrenches when making connection to gas valve to keep it from turning. 6. Install a manual shutoff valve in vertical pipe about 5 ft above floor. 7. Tighten all joints securely. 8. Propane gas connections should only be made be a licensed propane installer. 9. Two-stage regulation should be used by propane installer. 10. Propane gas piping should be checked be propane installer. PROCEDURE 3—CHECKING GAS PIPING Upon completion of p
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—12— HOT NEUT 120/60/1 POWER SUPPLY 120/60/1 POWER SUPPLY
LINE VOLTAGE WIRING
POWER SUPPLY CLASS II, 24 VOLT WIRING
OVERCURRENT
CLASS II, 24 VOLT FIELD WIRING
NEUT 24V
PROTECTED
THERMOSTAT HOT = DISCONNECT B BLACK
= BT BLACK WITH TRACER
OVERCURRENT
= W WHITE
120 V. PRIMARY L1 L2 T T PROTECTED
= L1 L2 L8148A
G GREEN
DISCONNECT = AQUASTAT R RED
= 3 O ORANGE 24 V. SECONDARY 1K B T T R DRAFT INDUCER 24 V. THERMOSTAT C1 C2 B1 B2 3 C1 C2 BW 1K1 1K2 BW AT 140C TRANSFORMER B C
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4. When blower gets up to speed and blower suction pressure reaches pressure switch setpoint, pressure switch contacts close sending 24v to S8600 intermittent pilot control from AT 140C transformer secondary. 5. Pilot gas valve opens, and spark initiates to light pilot burner. 6. When pilot flame is proven, spark drops out. 7. Main gas valve opens and pilot burner ignites main burners. 8. If boiler water temperature reaches high limit setpoint, high limit contacts B-R open, cutting power to blow
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PROCEDURE 9—CIRCULATING PUMP Every forced hot water system requires a circulating pump. A separate pump or zone valve is required for each zone if there are 2 or more zones. This pump must have the capacity to provide circulation required by system. The pump is connected into return main just ahead of boiler and wired to electrical system. PROCEDURE 10—BLOWER (DRAFT INDUCER) The blower provides a means for pulling air through boiler and exhausting flue gases into vent system. The blower shuts of
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BEFORE OPERATING, smell all around appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WARNING: IF YOU SMELL GAS: • Do not attempt to operate any appliance; do not touch any electric switch; do not use any phone in your building. • Leave the building immediately and call your gas supplier. • If your gas supplier cannot be reached, call the fire department. WARNING: When turning gas control knob, use only your hand to turn
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PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW) OUTLET
PRESSURE
WIRING
TAP TERMINALS (3) GROUND
INLET
TERMINALS (2) PRESSURE
TAP GAS
GAS
3 1 ⁄8″ to ⁄2″ INLET OUTLET ON FLAME
OFF ON SENSOR PILOT
PILOT
OUTLET GAS CONTROL
ADJUSTMENT
KNOB SHOWN
(UNDER CAP
IN "ON" POSITION SCREW) A95160 A95520 Fig. 9—Pilot Flame and Sensor Fig. 10—Automatic Gas Valve Table 6—Recommended Boiler Water Temperatures TYPE OF HEATING UNIT LIMIT CONTROL SETTING Standing Radiators 180°F Baseboard and Convect
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MAINTAINING BOILER PROCEDURE 1—BURNERS A visual check of pilot and main burner flames should be made at least once each year, preferably at beginning of heating season. See Checking and Adjusting section and Fig. 9, 11, and 12. Main burner flame should form a sharp blue cone with no yellow. PROCEDURE 2—RELIEF VALVE This valve should open automatically when system pressure exceeds pressure rating (usually 30 psi) of relief valve. Should it ever fail to open under this condition, shut down system.
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12. Be sure to check tightness of pilot connections and condition of burner flames after reassembly. (See Fig. 11.) 13. Be sure vent pipe connections to chimney are secure and no obstructions are present. PROCEDURE 8—BLOWER The blower motor features permanently lubricated ball bearing construction. Lubrication is not required. SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service. FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS 1. Do not try
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REPAIR PARTS IMPORTANT — READ THESE INSTRUCTIONS BEFORE ORDERING All parts listed in the following Parts List may be ordered through your nearest supplier. When ordering parts, first obtain the Model No. from the data plate on boiler, then determine the Part No. (not the Key No.) and the Description of each part from the following illustrations and lists. Be sure to give all this information: The Part No. — The Part Description — The Boiler Model No. → FOR USE WITH NATURAL GAS ONLY 3 6 4 5 6A 2
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REPAIR PARTS → FOR USE WITH PROPANE GAS ONLY 3 6 4 5 6A 2 1 A98238 Propane Gas Burners and Manifold Parts This is a Repair Parts List—Not a Packing List PART NO. KEY DESCRIPTION NO. 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 1 24-v Gas Valve, Propane Gas 146-62-062 146-62-062 146-62-062 146-62-062 146-62-059 146-62-059 2 Pilot Tube 146-15-005 146-15-005 146-15-005 146-15-005 146-15-006 146-15-006 3 10-32 X 3/16-in. Slotted Hex Head Screw 146-95-301 146-95-301 146-95-301 146-95-3
