CAC / BDP BW4BAH-210 Operations Instructions

An ISO 9001-2008 Certified CompanyMODELS (SERIES B) BW9AAN000125BW9AAN000150BW9AAN000175BW9AAN000200GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER BOIL

10Condensate Drain RequirementsPitch condensate drain line down to fl oor drain at minimum of ¼” per foot (21mm/m). External condensate pump (not furni

11If concentric vent termination is being used, refer to Figure 10 for proper setup.5 - COMBUSTION AIR/ VENT REQUIREMENTSFigure 8 - Roof Vent / Inta

123” Diameter PVCVent/Exhaust1½”4½” Dia.31⅞”AABBCCDEFGG3” Diameter PVCIntake/Combustion Air46¾”Dimension1³⁄ΟΤ”DEFDimensionVENTVENTAABBCCDDCOMAIRCOMBUS

13Connections And TerminationTo prevent damage to gas burner and ensure proper operation of unit, installer must clean and remove all shavings from in

14Installation1. Recommend all pipes be cut, prepared, and pre-assembled before permanently cementing any joint.2. Rigid supports cause excess noise i

15 Check Gas Supply• Gas pipe to boiler must be correct size for length of run and total Btuh input of all gas utilization equipment connected to it.

16WARNINGElectrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could re

17AVOID THE FOLLOWINGDead Spots CornersAlcovesBehind doorsCold SpotsConcealed pipes or ductsStairwells - draftsUnheated rooms on the other side of the

18NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its eq

19NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its eq

21 - Boiler Ratings & Capacities ...32 - Installation A

20See “Troubleshooting” on page 34 for detailed sequences of operation and troubleshooting procedures. See separately provided “Repair Parts Manual” f

21Differential Pressure Switches• Diaphragm type differential pressure switches are connected by vinyl tubing to gas valve, air inlet connection on ne

22Filling Boiler With Water And Purging Air For Systems With Conventional Closed Type Expansion TanksRefer to diagrams on “Near Boiler Piping” on page

23 WARNINGIf you do not follow these instructions exactly, a fi re or explosion may result causing property damage, personal injury or loss of life.• T

2410 - STARTUPIf Burner Pulsates During Ignition:1. Turn off boiler power. Shut off gas supply to boiler.2. Take burner assembly apart by removing com

25DRAFT INDUCER TEMPERATURE SAFETY SWITCHDraft inducer runs through 30 second post purge and switches OFF.Circulator runs with thermostat on call for

26 End Of Normal Sequence Of OperationThermostat ends call for heat.Gas valve and circulator pump are de-energized, valve and fl ame lights go out.Blow

27 SERVICE HINTSPOWER ON STAND BYTHERMOSTATCALLS FOR HEATCIRCULATORENERGIZES THRU2K1 CONTACTSIBC SELFCHECK OF INTERNAL CIRCUITRY1-2 SECIBC CHECKS N.O.

28 Sequence Of Operation DiagnosticsFollow sequence using the diagnostic indicator lamps on Integrated Boiler Control (IBC). See “Controls And Access

29Inspect Venting & Air Intake System - Operate boiler. Verify all vent/air intake connections are gas-tight and water-tight. Repair any leaks im

31 -BOILER RATINGS & CAPACITIESTable 1 - SEA LEVEL RATINGS (NATURAL AND PROPANE GASES)ModelInput (MBH)(1)Heating Capacity(MBH)(1)(2)Net AHRI R

30Set Thermostat To Desired TemperatureSet thermostat to desired room temperature and observe several complete cycles to verify proper operation.Final

3114 - TROUBLESHOOTING - HIGH LIMIT CONTROL AND LWCO LED Legend and LWCO Test Button1 HI TEMP illuminates when boiler water temperature reaches high l

3215 - TROUBLESHOOTING -HYDROSTAT HIGH LIMIT CONTROL AND LWCO Troubleshooting Flow ChartBurner Will Not Fire See Flow Chart, this page.No or Insuffi ci

33Initial Service Checks1. Before Troubleshooting:A. Verify circuit breaker is on or fuse is OK at electrical panel.B. Verify service switch is ON.C

34 System StatusIndicator lights track operating sequence. If system locks out, lights indicate point in sequence of operation were lockout occurs. Re

35

36 Troubleshooting Chart 2  !"

37 Troubleshooting Chart 3CHECK FOR VAC BETWEEN TERMINALS 1 AND 3 AT CONNECTOR CN4 ON IBCNO NOBLOWER STARTSREPLACE IBCCHART 1OPENIBC PURGE LIGHT ON?NO

38 Troubleshooting Chart 4IGNITER/SENSOR WARMSUP AND GLOWS YELLOW/ORANGEDURING 20 SECOND WARM UPCHART 3YESNOCHECK FOR 120 VAC BETWEEN TERMINALS 1 AND

39POSSIBLY MIXTURE TOO LEAN!CHECK GAS LINES DOWNSTREAM OF GAS VALVE FOR BLOCKAGE.ARE GAS LINES CLEAR?IS GAS/VENTURI VALVE CORRECT SIZE? SEE REPAIR PAR

41 - BOILER RATINGS & CAPACITIESThis is gas-fi red direct vent cast aluminum hot water boiler. Cast aluminum heat exchanger means better heat tran

40 Troubleshooting Chart 6RUNS FOR 25-50 SECONDS, THEN TURNS OFF.CHECK FIRING RATE OF UNIT.IS UNIT FIRING AT THE CORRECT RATE?NODOES THE UNIT USE LP G

41Differential air pressure switch is safety device which prevents boiler from fi ring if there is air intake, boiler heat exchanger or vent blockage.F

42Acidic nature of fl ue gasses condensing on aluminum boiler sections cause formation of aluminum oxide. This oxide formation is normal, is generally

43Annual Shut Down Procedure (End Of Each Heating Season)1. Follow the instructions in “WHAT TO DO IF YOU SMELL GAS” on page 23.2. If heating system i

44 P/N# 240006888, Rev. E [06/2011]Aluminum SeriesHigh Effi ciency Gas-Fired BoilerDIELECTRIC ISOLATION & ANTIFREEZE PROTECTION ADDENDUMAPPENDIX A

45System and Operating PrecautionsApplies to ALL Aluminum High Effi ciency Gas-Fired Water BoilersEliminate System LeaksContinuous addition of make-up

46System and Operating PrecautionsApplies to ALL Aluminum High Effi ciency Gas-Fired Water BoilersGeneral Guidelines When Using Antifreeze• Use only a

47Compatible Aluminum Antifreeze & Inhibitor SuppliersNoburst AL AntifreezeNoble CompanyP. O. Box 350Grand Haven, MI 49417www.noblecompany.comTel:

CAC/BDP7310 West Morris St.Indianapolis, IN. 46231

5Boiler is equipped for residential installations. If used for commercial applications; additional code requirements must be adhered to. This may requ

6Locating The Boiler1. Select level location, central to piping systems served and close to vent and air intake terminals as possible.2. Accessibility

76. After it has been determined each appliance remaining connected to common venting system properly vents when tested as outlined above, return door

81. Do not install copper supply and return piping directly into aluminum boiler section castings due to galvanic corrosion between dissimilar metals.

9Safety Relief Valve / Temperature Pressure GaugeBoiler is furnished with safety relief valve and temperature pressure gauge.• Install safety relief v