BW4
BW5
Installation Instructions
Oil---Fired Cast Iron
Hot Water Boilers
Sizes 140,000 through 280,000
NOTE
: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS
1
. . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Explanation of Model Numbers and Rating Plate
3
. . . . . . . . .
General Information
4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locating the Boiler
4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION
4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Requirements
4
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fresh Air for combustion
4
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boilers with Tankless Heater Coil
7
. . . . . . . . . . . . . . . . . . . . .
Installation System Piping
8
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chimney and Chimney Connection
10
. . . . . . . . . . . . . . . . . . .
Electrical Wiring
10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment and Optional Accessories
10
. . . . . . . . . . . . . . . . . .
Filling Boiler
12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING BOILER
13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Start
13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Units and Oil Lines
13
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Supply for Combustion
13
. . . . . . . . . . . . . . . . . . . . . . . . .
Draft Regulators
13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzles
13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Burner Adjustments
13
. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Burner Maintenance
15
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting Controls
16
. . . . . . . . . . . . . . . . . . . .
MAINTENANCE
16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief Valve
16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conventional Expansion Tank
16
. . . . . . . . . . . . . . . . . . . . . . .
Diaphragm Expansion Tank
16
. . . . . . . . . . . . . . . . . . . . . . . . .
Water System
16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tankless Coil (or Cover Plate Gasket)
16
. . . . . . . . . . . . . . . . .
Oil Boiler/Burner Cleaning Instructions
17
. . . . . . . . . . . . . . . .
Sequence of Operation
17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Hints
22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List
22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASME
ama
®
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due
to oil 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 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
will
result in severe personal injury or death.
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
will
result in enhanced installation, reliability, or operation. Read
and obey the following rules to ensure safe installation and
operation:
1. Read the Owner’s Manual carefully for safe operation.
Failure to follow the rules of safe operation and the
instructions can cause a
malfunction of the boiler and result in death, serious
bodily injury, and/or property damage.
2. Check local codes and utility requirements before
installation. The installation must be in accordance with
their directives, or follow NFPA 31–Installation of Oil
Burning Equipment, latest revision.
3. Before servicing, allow boiler to cool. Always shut off any
electricity and oil to boiler when working on it. This
prevents any electrical shocks or burns.
4. Inspect oil line and connections for leaks.
5. Be certain oil burner nozzle is size required. Overfiring
will result in early failure of boiler sections. This causes
dangerous operation.
6. Never vent this boiler into an enclosed space. Always vent
to the outside. Never vent to another room or inside a
building.
