CAC / BDP BW4RAH-168 Operations Instructions

Gas Fired Induced Draft Hot Water BoilersINSTALLATION, OPERATION & MAINTENANCE MANUALModels (Series C) BW3AAN00042BW3AAN00075BW3AAN00112BW3AAN0015

10Check Your ChimneyChimney must be clean, right size, properly constructed and in GOOD CONDITION. 1. Installation must conform to requirements of the

CHECK YOUR CHIMNEYFor boilers for connection to gas vents or chimneys, vent installations shall be in accordance with “Venting of Equipment”, of the N

12Removing Existing Boiler From Common Venting SystemWhen an existing boiler is removed from a common venting system, the common venting system is lik

13OPTIONAL HORIZONTAL VENTING INSTRUCTIONHorizontal venting with a power venter is an alternate method of sidewall venting. This boiler is CSA listed

14CAUTIONWHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance.• Do not touch any electrical switch; do not use any phone in your building.•

15GAS SUPPLY PIPING*Outside diameter:Measure length of pipe or tubing from gas meter or propane second stage regulator.Table 6 - NATURAL GASLength ofP

16ELECTRICAL WIRINGElectrical WiringSee wiring diagram Figure 10 page 18 for details. Refer to Ladder Diagram from document envelope received with boi

17Sequence of Operation - Figure 10, Page 18.1. Thermostat calls for heat, control relay contacts.2. Circulator pump is powered through terminals C1 a

18WIRING DIAGRAMSFigure 10 - Control ModuleDamper is not an option.

19CAUTIONBurn, scald, explosion hazard. Failure to follow these instructions could result in minor or moderate injury.!! Filling System With Water• C

2Boiler Ratings & Capacities... 3Dimensions ... 4Installation Procedure ...

20Operating Instructions. 1. STOP! Read Safety Information on previous page.2. Set the thermostat to lowest setting.3. Turn off all electric power to

21Figure 12 - Automatic Gas ValveGas Valve Safety Shutdown TestWARNINGElectrical shock hazard. Follow instructions to turn off electric power. Failu

22CHECKING AND ADJUSTINGMain burner fl ame should form sharp blue inner mantel with no yellow.Figure 14 - Main Burner FlameAdjust Thermostat Heat Anti

23BurnersBeginning of heating season visually check pilot and main burner fl ames. See Figures 13, and 14.Safety Relief ValveTest safety relief valve

24You 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

25SAFETY RELIEF VALVESafety relief valve is required on your boiler. Water expands as it is heated. If there is no place for water to expand into, wat

26EQUIPMENT & OPTIONAL ACCESSORIESPRESSURE SWITCHAir pressure switch works on negative pressure. When blower comes on air pressure switch operates

27APPENDIX A - CONTROL MODULEA.1 Installation Environment Considerations WARNINGIf you do not follow these instructions exactly, a fi re or explosion m

28APPENDIX A - CONTROL MODULEA.5 OperationModule continuously monitors boiler water temperature and fi res or shuts off burner based on this temperatur

29APPENDIX A - CONTROL MODULEA.6 Boiler High Limit Temperature Controller• When water temperature reaches setpoint, controller ends heating cycle. • W

3New York City MEA Number 484-84-E Vol. IV.BOILER RATINGS & CAPACITIESTable 1 - RATINGS NATURAL AND PROPANE GASESModel Input *MbhHeating Capacit

30APPENDIX A - CONTROL MODULETable 2 - Troubleshooting Error CodesError Code NumberDefi nition Consequence2Pressure switch failed to open (stuck closed

31APPENDIX A - CONTROL MODULESTEP 3: Check spark ignition circuit. Disconnect ignition cable at SPARK terminal on module.WARNINGElectrical shock hazar

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

4DIMENSIONSModel Width (A)BW3AAN00042 11” (279mm)BW3AAN00075 14¼” (302mm)BW3AAN00112 17½” (444mm)BW3AAN00150 20¾” (527mm)BW3AAN00187 24” (610mm)BW3AAN

5INSTALLATION PROCEDUREWARNINGImproper installation, adjustment, alteration, service or maintenance could result in death or serious injury.! 1. The

6VENTILATION & COMBUSTION AIRProvide combustion air and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of th

71. Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements.2. Install relief valve on 3/4”

8Figure 3 - Forced Hot Water Typical PipingFigure 4 - Forced Hot Water Typical Piping With Zone Control ValveINSTALLATION SYSTEM PIPING

9• Install radiation units (panels, radiators or cabinets) and supply and return mains fi rst then make connections at boiler. • Verify clean water sup