CAC / BDP BW5BAH-105 Owner's Manual

OIL FIRED CAST IRONHOT WATER BOILER INSTALLATION, OPERATION & MAINTENANCE MANUALBW4BAH-91 BW4RAH-91BW5BAH-91BW5RAH-91BW4BAH-105BW4RAH-105

10Adjust two throttling valves to maintain at least 120°F in boiler return. Throttling valves are used for bypass piping, if required.> LOW DESIGN

11SYSTEM PIPING> CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANKNOTE: CIRCULATOR CAN ALSO BE INSTALLED ON RETURN PIPING.> PIPING A

12> CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK> PIPING ARRANGED FOR “POWER PURGING” AIR OUT OF SYSTEM PIPING, REFER TO

13> DIAPHRAGM EXPANSION TANK MOUNTED OFF THE BOILER> CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK> PER THIS MANUAL, USE OPTI

14BoilerModelBurnerInputRate (gph)Input(MBH)TanklessRating (gpm)‡BW5(B,R)AH-91 0.65 91 2.90BW5(B,R)AH-105 0.75 105 3.00BW5(B,R)AH-140 1.00 140 3.25BW5

15Antifreeze added to boilers must be nontoxic, and must be of type specifi cally intended for use in closed hydronic heating systems. Under no circums

16Chimney Connector And Draft Regulator• Venting the boiler requires 6” diameter chimney connector pipe and use of manufacturer provided draft regula

17TYPICAL CHIMNEY CONNECTIONFigure 12 -Typical Chimney ConnectionMinimum height:• Must be at least 3ft. (.9m) higher than highest part of passage thro

18ELECTRICAL CONNECTIONSThermostatInstall 24 Volt thermostat (not provided) in proper location. Location of thermostat has effect on boiler system ope

19How A Hot Water System OperatesEntire heating system (boiler, piping, and radiation units) is fi lled with water. As water in the boiler is heated, i

2Safety Notices ...3Boiler Ratings And Capacities ...4Fresh Air For Com

20• Room used for supplying combustion air should be isolated from any area served by exhaust fans. • Refer back to the section on Fresh Air For Combu

21Final Burner Adjustments: Final burner adjustments must be made using combustion test instruments. Refer to “Burner Settings”. Set burner accordingl

22OPERATING THE BOILER Figure 13 -Burner Adjustments and Settings

23Adjust Operating Controls: Use the following settings for fi rst adjustment:High Limit:Baseboard and Convectors 200°F Standing Radiators 180°FLow L

24Annually: Recommend fl ue passages, combustion chamber area (target wall, fi re door insulation, durablanket), burner adjustment, control operation, a

25Oil Boiler Cleaning:1. Shut off all electrical power to boiler / burner and shut off fuel oil supply.2. Remove vent pipe from top of boiler. Inspect

26WARNINGElectrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could re

27You may avoid inconvenience and service calls by checking these points before you call for service:IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUG

28ELECTRICAL WIRINGFigure 16 - Honeywell L7248L Control With Beckett AFG Burner

29Figure 17 - Honeywell L7248L Control With Riello F5/F10 BurnerELECTRICAL WIRING

3BOILER RATINGS AND CAPACITIESBOILER MODEL NO.INPUT**HEATINGCAPACITY*Mbh‡NETAHRIRATING WATER*MbhA.F.U.E.++NO.SEC.Boiler Water Capacity (US Gal.)DIMEN

30MAIN AIR VENT: for down fl ow systems or diaphragm type expansion tanks (not provided)Before system is fi lled with water, there is air in pipes and r

NOTES

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

41. Read the Owner’s Manual for Safe Operation. Failure to follow rules for safe operation and instructions can cause malfunction of boiler and result

5Complete Prior To Installing Boiler.A. Verify you have selected the right size boiler with proper capacity. AHRI rating of boiler selected should be

6OIL TANKCHIMNEY ELECTRIC LINEVENTPIPEDRAFTREGULATORDIAPHRAGMEXPANSION TANKAUTOMATICFILL VALVEAND SHUTOFFRELIEF VALVETO RADIATIONFROM RADIATIONCIRCULA

7Provide enough fresh air to assure proper combustion. Fire in the boiler uses oxygen. It must have continuous supply. Air in the house contains only

8B. All Air from Outdoors: Confi ned space shall be provided with two permanent openings, one commencing within 12 inches of top and commencing with

91. Installation of boiler for new heating system, Install all of radiation units (panels, radiators, baseboard, or tubing) and supply and return main