background image

3

19 

5/8

GAGE

36

1

 

1/4

 

IN. 

RETURN

1

 

1/4

 

IN. 

 

SUPPLY

AQUASTAT

CONTROL

(WITHOUT COIL)

AQUASTAT

CONTROL

(WITH COIL)

TANKLESS

HEATER

1/2

 

IN.

 

N.P.T.

9

3/4

 

IN.

ASME

RELIEF 

VALVE

FRONT

SIDE

REAR

A96152

Fig. 2 -- Dimensional Drawing (See Table 1 for additional information)

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury, death and or property damage
DO NOT USE GASOLINE CRANKCASE DRAININGS

OR ANY OIL CONTAINING GASOLINE.

!

WARNING

INTRODUCTION

Check to be sure boiler size is correct before starting installation.

See rating and capacity table shown in Fig. 2 and Table 1a and
1b. Check rating plate on right side of boiler.
The boiler must be supplied with the proper oil, fresh air for
combustion, and a suitable electrical supply. Boiler must also be

connected to a suitable venting system and an adequate piping

system. Finally, a properly located thermostat is needed for
control of heating system. If there are any doubts as to the various

requirements, check with local authorities and obtain professional
help where needed. The Operating Boiler Instructions and Final

Checks and Adjustments sections later in this document are vital

to the proper and safe operation of the heating system. Take time
to be sure they are all done.
The following steps are all necessary for proper installation and
safe operation of boiler:

1. LOCATING THE BOILER
2. OIL SUPPLY AND PIPING
3. FRESH AIR FOR COMBUSTION
4. PIPING CONNECTIONS
5. CHIMNEY AND VENT PIPE CONNECTIONS
6. ELECTRICAL WIRING
7. THERMOSTAT LOCATION
8. CHECKING AND ADJUSTING
9. MAINTENANCE

FIRE,

EXPLOSION,

ELECTRICAL,

CARBON

MONOXIDE POISONING HAZARD

Failure to follow this warning could result in property

damage, personal injury, or death.
Improper installation, adjustment, alteration, service

maintenance, or use can cause carbon monoxide poisoning,

explosion, fire, electrical shock, or other conditions which

may cause personal injury or property damage. Consult a

qualified installer, service agency, fuel oil supplier, or your

distributor or branch for information or assistance. The

qualified

installer

or

agency

must

use

only

factory--authorized and listed kits or accessories when

modifying this product.

!

WARNING

Explanation of Model Numbers and Rating Plate

Each model number except for the BW4(5)RAH280ABAA has 3

possible firing rates depending on which nozzle or burner is
installed. The model number represents the burner installed in the

boiler and the largest possible input for the boiler. The
BW4(5)RAH280ABAA can only be fired at an input of 280,000

Btuh or 245,000 Btuh.
For example, a BW4BAH000140ABAA has a Beckett burner
and a maximum input of 140,000 Btuh. A BW4RAH000140 has

a Riello burner and a maximum input of 140,000 Btuh. The
rating plate for each model shows the possible firing rates. Boilers

come shipped with the largest nozzle installed. By changing

nozzles, the BW4BAH000140ABAA firing rate can be changed
to 91,000 or 105,000 Btuh input.
For BW4BAH models equipped with Beckett burners:
The BW4BAH000280ABAA is shipped with 2 additional

nozzles to fire the Beckett burner at the alternate inputs listed on
the

rating

plate.

The

BW4BAH000210ABAA

and

BW4BAH000140ABAA are shipped with one additional nozzle

each, to fire the Beckett burner at the next lowest inputs listed on
the rating plate. To fire the BW4BAH000210ABAA and

BW4BAH000140ABAA at the lowest inputs listed on the rating
plate, an accessory low--fire kit for each boiler, not included with

the boiler, is required. The low--fire kits include the alternate size

nozzle and the alternate burner end cone to fire the burners on
these models at the lowest inputs for those models.

BW

4

/BW

5

Summary of Contents for BW4

Page 1: ...hed 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 unit or in instructions and manuals be alert to potential for personal injury Understand the signal words DANGER WARNING CAUTION and NOTE These words are used with the safety alert symbol DANGER identifies the most serious hazards which wi...

Page 2: ...by the boiler manufacturer and the expansion tank manufacturer 13 Expansion tank performance and life expectancy can be hindered by overfilling the boiler An initial fill pressure of 10 12 psig is recommended For higher fill pressures the expansion tank s air charge will need to be increased to match the fill pressure Consult the manufacturer s guidelines for sizing and selection 14 Purging the he...

Page 3: ... installation adjustment alteration service maintenance or use can cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified installer service agency fuel oil supplier or your distributor or branch for information or assistance The qualified installer or agency must use only factory authorized and list...

Page 4: ...ck with local authorities and obtain professional help where needed The Operation Instructions Final Checks and Adjustments and Maintenance sections in this manual are vital to the proper and safe operation of the heating system Take the time to be sure they are all done Locating the Boiler If boiler is part of a planned heating system locate it as close as possible to where it is shown on plan If...

Page 5: ... 6 8 460 N A BW4BAH210 BW4RAH210 4 126 111 97 0 90 86 0 8 X8 X15 17 3 4 6 9 5 8 533 N A 4 175 150 130 1 25 83 9 8 X8 X15 17 3 4 6 9 5 8 533 N A 4 210 178 155 1 50 82 4 8 X8 X15 17 3 4 6 9 5 8 533 N A BW4BAH280 BW4RAH280 5 168 147 128 1 20 86 5 8 X8 X15 21 6 11 1 2 620 N A 5 245 209 182 1 75 83 6 8 X8 X15 21 6 11 1 2 620 N A 5 280 236 205 2 00 82 0 8 X8 X20 21 6 11 1 2 620 N A Shaded areas are as s...

Page 6: ...CK OF OXYGEN WARNING UNIT LIFE REDUCTION HAZARD Failure to follow this warning could result in personal injury death and or property damage Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products WARNING Enoug...

Page 7: ... a minimum free area of 1 sq in per 2000 Btuh of total input rating of all equipment in the enclosure 4 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall not be less than 3 in Boilers With Tankless Heater Coil Boilers may be factory packaged with a tankless heater coil The u...

Page 8: ...th supply and return lines should be piped to the front section or both to the rear section The boiler should NOT be piped return line to the front supply line to the rear or vice versa as this will cause boiler water to short circuit heat exchanger The connections may require certain additional fittings and parts as shown on diagrams See Fig 9 10 and 11 If installing an entire new heating system ...

Page 9: ...LVE THROTTLING VALVE CIRCULATOR PUMP AQUASTAT S R MAIN SHUTOFF VALVE ADJUST THE TWO THROTTLINE VALVES TO MAINTAIN AT LEAST 120 O F IN THE BOILER RETURN THE THROTTLING VALVES ARE USED FOR BYPASS PIPING IF REQUIRED A01034 Fig 10 Bypass Piping Circulator on Supply FILTROL WITH AIR PURGER AUTOMATIC FILL VALVE SUPPLY TO SYSTEM SHUTOFF VALVE BOILER SERVICE FILL LINE WITH SHUT OFF VALVE RETURN FROM SYSTE...

Page 10: ... grounded ground rod C Electrical Power Supply ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Turn off electric power at fuse box before making any line voltage connections Follow local electric codes WARNING All electrical work must conform to local codes as well as the National Electrical Code If not familiar with wiring and codes in general have ...

Page 11: ...ype expansion tank a in the supply line with the circulator located after the expansion tank or b off the e3 4 in tapping provided on the top of the rear casting with the circulator mounted directly off the boiler s supply piping connection This configuration allows the circulator to pump away from the expansion tank for improved air elimination and system performance The air reliminator fitting o...

Page 12: ...e The delay solenoid valve provides the same shut down action of the standard solenoid valve plus on burner start up the delay solenoid valve remains closed for an additional 15 seconds This allows the burner fan motor to pre purge the combustion chamber and the oil pump to bring the supply oil pressure up to its set point helping to provide a clean light off Filling Boiler OPTION 1 A How a Hot Wa...

Page 13: ...vide air for combustion and operation of barometric draft control The room should be isolated from any area served by exhaust fans Do not install exhaust fans in this room See Fresh Air for Combustion section earlier in this document Draft Regulators Provided A draft regulator is required It should preferably be mounted in smoke pipe Use a draft gage to adjust to proper opening When burner air sup...

Page 14: ... PLATE WITNESS MARK BECKETT AFG VARIABLE V1 HEAD ADJUSTMENTS AND SETTINGS A06664 Fig 14 Beckett Burner Setting Variable V1 Head 5 32 GAP 7 16 ABOVE NOZZLE DIMENSION N SEE ABOVE BURNER F HEAD MODEL F0 THRU F31 DIMENSION N HEAD TO NOZZLE 1 16 BECKETT AFG BURNER ELECTRODE ADJUSTMENTS F HEADS A06665 Fig 15 Beckett Burner Setting Fixed F Head 140 210 A06506 Fig 16 Riello 40 F5 Burner Electrode Adjustme...

Page 15: ...kept clean and free of dirt lint and oil so as to maintain proper amount of air the fuel requires to burn NOTE If any component parts must be replaced always use parts recommended by burner manufacturer F Fan and Blower Housing Check burner blower wheel for dirt grease and grime Clean as necessary Check motor is attached to burner housing and wheel is attached tightly to motor shaft Check pump cou...

Page 16: ...n for some time recheck the whole system for leaks and recheck boiler and vent pipe for leaks Replace or patch any boiler seals that are faulty FIRE EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death Never burn garbage or paper in the unit and never leave combustible material around it WARNING Relief Valve This valve should open automatically when system press...

Page 17: ...er and if applicable burner head 3 Remove the burner drawer assembly clean the electrodes and then reset the electrode spark gap per the manufacturer s recommendations 4 Replace the oil nozzle with the exact same size and type recommended for use on this boiler 5 Reinstall the burner drawer assembly making sure the head location and size if applicable are per the manufacturer s recommendations If ...

Page 18: ...ithout Tankless Coil AQUASTAT HIGH LIMIT CONTROLLER The aquastat control s high limit contacts open and turn off the burner when the boiler water temperature reaches the control s high limit set point The high limit contracts automatically reset after the boiler water temperature drops past the set point by 10_ F which is a fixed differential When the thermostat controls call for domestic space he...

Page 19: ...RING OIL BURNER MOTOR L8148A AQUASTAT IGN TRANS B W CIRCULATOR B W B W W B O B B R4184D RELAY Y Y CAD CEL IK1 JUMPER IK IK2 B2 C2 C1 ZC F F ZR B1 L2 T T T T G GND L1 HOT L2 L1 L2 B1 B2 C1 B R ZR B R W ZC C2 HIGH LIMIT 1K2 LOW LIMIT CIRCULATOR COLOR CODE BK BLACK O ORANGE Y YELLOW R RED W WHITE 1K1 1K A R LINE VOLTAGE CLASS II 24 VOLTS T T L2 L1 3 F F B 3 T T C1 C2 B2 B1 L2 L1 B R G B2 B1 C2 C1 COL...

Page 20: ...20 A06504 Fig 21 Boilers Without Tankless Coil and Honeywell L8148 Aquastat Control BW4 BW5 ...

Page 21: ...21 F5 only A06505 Fig 22 Boilers With Tankless Coil and Honeywell L8124C Aquastat Control and Riello Burners BW4 BW5 ...

Page 22: ...d or burner may be dirty Clean all flue passages and vent pipe Have burner cleaned and readjusted Burner may not be firing at proper rate Check nozzle size it there is any doubt Have burner adjusted Burner may be short cycling Short cycling too frequent off and on of burner causes sooting If boiler and or burner becomes Burner may be short cycling dirty at frequent intervals correct the dirt condi...

Page 23: ...ction 8 in X 12 in 4 section 8 in X 20 in 5 146 30 031 10 Collector Base 3 section 425 00 279 4 section 425 00 280 5 section 425 00 281 11 Tape Plym Collector insulation 1 in X 1 16 in X 100 Included in Part 425 00 279 80 81 12 Collector Top Included in part 425 00 279 80 81 13 Wing Nut 8 32 Brass 137 04 007 14 Screw 14 X 3 4 in HWH SL S M SC Hex Washer Head Slotted Sheet Metal Screw 146 95 109 15...

Page 24: ...chined 403 00 014 11 Washer Lock Plain 5 16 in 146 95 123 12 Bolt 5 16 in X 3 8 in Socket SH Shoulder BLT Bolt 1 4 in 20 TH Thread 146 95 122 Fig 24 Swing Fire Door Assembly Table 11 Beckett Oil Burner Service Parts OIL BURNER REPAIR PARTS BURNER NOT SHOWN PART NUMBER Burner Motor RP 015 00 Fuel Pump RP04501 Oil Solenoid Valve RP04601 Ignitor or Ignition Transformer RP02001 Oil Primary Control 718...

Page 25: ...4 3 XXX 4 XXX 2 1 5 1 6 4 7 21 9b 4 1 XXX A01042 Item Description 3 Section Part Number 4 Section Part Number 5 Section Part Number Complete Jacket 42670289AB 42670290AB 42670291AB 1 Panel Right Empire II 42570244AB 42570245AB 42570246AB 2 Jacket Panel Back 42570269AB 42570269AB 42570269AB 3 Jacket Panel Top 42570254AB 42570255AB 42570256AB 4 Panel Left Empire II 42570264AB 42570265AB 42570266AB 5...

Page 26: ... tankless coil 433 00 521 433 00 521 433 00 521 2b L8124C 1094 Aquastat Control with tankless coil 146 62 022 146 62 022 146 62 022 3a Taco 007 Circulator CI 001 03 CI 001 03 CI 001 03 3c Taco Circulator Gaskets 146 26 050 146 26 050 146 26 050 ____ 1 1 4 Flange set with gaskets nuts and bolts 146 26 049 146 26 049 146 26 049 4 Temperature Pressure Gauge 2 Stem 1260006 1260006 1260006 5a 1 1 4 x 2...

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