Bryant BW4, BW5 Installation Instructions Manual

BW4
BW5

Installation Instructions

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 S tart 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.......................................

Oil---Fired Cast Iron

Hot W ater Boilers

Sizes 140,000 through 280,000

ama

ASME

®

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.

BW4 / BW5

A02217

Fig. 1 -- Model BW4/BW5

7. Be sure there is adequate air supply for complete
combustion.

8. Follow a regular service and maintenance schedule for
efficient and safe operation.

9. Keep boiler area clean and free from combustible
materials, gasoline, and other flammable vapors and
liquids.

10. Oil Burners are not do--it yourself items. This boiler must
be installed and serviced by qualified professionals using
combustion test instruments.

11. Be aware when piping the relief valve that if the system
pressure exceeds the safe limit of 30 pounds per square
inch, the relief valve will automatically lift open. Lifting of
the relief valve can discharge large quantities of steam and
hot water, which may damage the surroundings. Before
installing the relief valve read the manufacturer’s
instructions and maintenance section of the manual on
relief valves.

12. Installation and sizing of the expansion tank must consider
the heating systems total water volume, temperature, boiler
initial fill pressure, and system arrangement. An
improperly installed and sized expansion tank may result
in frequent lifting of the relief valve or other heating
system problems. For proper installation, sizing, and
maintenance of the expansion tank follow the guidelines
established 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 heating system of air and gases when first
putting the boiler into service is critical for proper

circulation and quiet performance. Once the air and gases
are purged, for boiler installations using float type vents,
the air vents should be closed for normal operation. If air
is heard or noticed by loss of heat, purge the system and
open the vents for a short period of time.

!

WARNING

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal
injury, death and or property damage.

Use only number 1 or number 2 fuel oil having commercial
standard grade CS 12-- 48. Do not use gasoline, kerosene,
crankcase oil, or any oil containing gasoline.

!

WARNING

OPERATION AND WARRANTY HAZARD

Failure to follow this warning could result in personal
injury, death and or property damage.

This boiler has been designed for residential installations. If
used for commercial applications, all jurisdictional
requirements must be met. This may require wiring and/or
piping modifications. The manufacturer is not responsible
for any changes to original design.

2

1

1

GAUGE

36″

1

20

/2″

FRONT SIDE REAR

/4 IN. SUPPLY

AQUASTAT
CONTROL
(WITHOUT COIL)

AQUASTAT
CONTROL
(WITH COIL)

1

/4 IN.

1
RETURN

9″

C B

TANKLESS
HEATER

1

/2 IN. N.P.T.

A

3

/4 IN.
ASME
RELIEF
VALVE

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

A06591

BW4 / BW5

!

WARNING

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.

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

!

WARNING

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.

Explanation of Model Numbers and Rating Plate

Each model number except for the BW4(5)RAH280ABAA h as 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

3

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

For BW4RAH models equipped with Riello burners:

There are two different Riello burners used on the BW4RAH
boilers, the F5 and F10 burner. The BW4RAH000280AAAA is
shipped with one additional nozzles to fire the F10 burner at the
next alternate lower input listed on the rating plate. The
BW4RAH000210AAAA and BW4RAH000140AAAA are
equipped with F5 burners and shipped with two additional
nozzles to fire the boilers at the next lowest inputs listed on the
rating plate.

The BW5B and BW5R models are the same as the BW4B and
BW5B models, except the tankless water heater is factory
installed.

Refer to Tables 1 and 7 (Beckett) or Table 8 (Riello) for
additional oil burner information. Refer to the boiler product data
sheet for the correct accessory low--fire kit.

General Information

Boilers with the same number of sections are identical to each
other except for their firing rate and/or type of burner. The firing
rate is determined by the nozzle size used in the oil burner and the

BW4 / BW5

oil pressure at the nozzle. For example, models BW4RAH091,
BW4RAH105, and BW4RAH140 are the same boiler, without a
tankless coil. They all have a Riello oil burner fired at a different
input rate. Models BW5RAH245 and BW4RAH280 are the same
boiler, with a tankless coil. They both have a Riello oil burner
fired at a different input rate.

1. Check to be sure you have selected the right size boiler
with the proper capacity. The I=B=R rating of the boiler
selected should be greater than or equal to the calculated
peak heating load (heat loss) for the building or area(s)
served by the boiler and associated hot water heating
systems. (See Table 1.) Any heat loss calculations used
should be based on approved methods.

2. Boiler must be supplied with the proper oil supply and oil
piping, sufficient fresh combustion air, and a suitable
electrical supply.

3. Boiler must be connected to a suitable venting system and
a piping system adequate to distribute the heating load.

4. A thermostat must be properly located and installed for
control of the heating system.

If there are any doubts as to the various requirements, check 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 boiler is to be part of an
existing system, it is usually best to put it where the old one was.

If location is to be changed, additional materials as well as an
adequate base will be required. The following rules apply:

1. The boiler must be level.

2. Use a raised base if floor can become wet or damp.

3. These boilers must have a non -- combustible base if
installed on a combustible floor. Two inch concrete patio
blocks or a 2--in. Cladlite--pad may be used.

4. The vent pipe connection should be as short as possible.

5. Maintain clearances for fire safety as well as servicing.
Refer to Fig. 3 for minimum clearances. An 18--in.
clearance must be maintained at a side where passage is
required to access another side for cleaning, servicing,
inspection, or replacement of any parts that normally may
require such attention. Boilers must be installed at least
6--in. from combustible materials on all sides and above.
Allow at least 24--in. front clearance for servicing. Allow
at least 18 --in. right--side clearance for servicing boilers
equipped with a tankless coil.

6. Fresh air for combustion must be available at front of
boiler. Fresh air for ventilation must be available to front
AND rear of boiler. Air passages must be free of
obstructions at all times. V entilating and combustion air
must enter boiler room without restrictions.

7. Be sure installation is in accordance with the requirements
of local authorities having jurisdiction. Compliance with
these regulations is required. In the absence of local codes,
follow NFPA 31--Installation of Oil Burning Equipment.

INSTALLATION

Installation Requirements

Refer to Fig. 4 for the basic requirements of a typical installation.
NOTE: Always keep manual fuel supply valve shut off if burner

is shut down for an extended period of time.

Fresh Air for Combustion

6″ MIN

24″ MIN

BOILER

FRONT

6″ MIN

18″ WITH COIL

Fig. 3 -- Minimum Clearance Dimensions

6″

A95592

4

CIRCULATING PUMP
IN SUPPLY LINES

2 IN. FILL PIPE

VENT PIPE

MINIMUM 2 IN. ID

SHUTOFF

VALVE

OIL

FILTER

ENTRANCE

OIL

TANK

SERVICE LINE

SWITCH

ELECTRIC LINE

AUTOMATIC
FILL VALVE
AND SHUTOFF

DIAPHRAGM
EXPANSION TANK

OVERCURRENT
PROTECTED
SAFETY SWITCH

LINES TO OTHER
APPLIANCES

TO OUTSIDE

VENT PIPE

DRAFT

REGULATOR

RELIEF VALVE

TO RADIATION

FROM RADIATION

OIL BURNER

FOUNDATIONS

OIL LINES

Fig. 4 -- General Principal Requirements for a Typical Installation

Table 1 – Boiler Ratings and Capacities

C
H

I
M
N
E
Y

BW4 / BW5

A02230

WITHOUT

TANKL ESS

COIL

BW4BAH140

BW4RAH140

BW4BAH210

BW4RAH210

BW4BAH280

BW4RAH280

Shaded areas are as shipped. Alternate inputs require a field--- installed alternate oil nozzle supplied with base model.
* MBH = 1,000 BTU per hour/BTU=British Thermal Unit
** Heating Capacity is based on a 13 percent CO2 with a --- 0.02 in. wc draft over fire and a #1 smoke or less. Testing was done in accordance with the D.O.E.
(Department
of Energy) test procedure.
+ GPH = Gallons per hour of oil at 140,000 BTU per gallon
++ A.F.U.E. = Annual Fuel Utilization Efficiency based upon D.O.E. test procedure
# As an Energy Star Partner, the manufacturer has determined that this product meets Energy Star guidelines for Energy Efficiency
} The 168,000 Btuh input is only available with a Beckett burner.

NO.

INPUT

SEC

*MBH

3 91 80 70 0.65 #86.3 8” X8” X15’ 14 1/2 6 8 460 N/A
3 105 92 80 0.75 #85.2 8” X8” X15’ 14 1/2 6 8 460 N/A
3 140 119 103 1.00 83.4 8” X8” X15’ 14 1/2 6 8 460 N/A
4 126 111 97 0.90 #86.0 8” X8” X15’ 17 3/4 6 95/8 533 N/A
4 175 150 130 1.25 83.9 8” X8” X15’ 17 3/4 6 95/8 533 N/A
4 210 178 155 1.50 82.4 8” X8” X15’ 17 3/4 6 95/8 533 N/A
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

**HEATING

CAPACITY

*MBH

NET

I=B=R

RATING

*MBH

FIRING

RATE

GPH

A.F.U.E.

MIN.

CHIMNEY

SIZE/HEIGHT

DIMENSIONS --- IN

A B C

SHIPPING

WEIGHT

TANKL ESS

HEATER

G.P.M.

5

Table 1 -- Boiler Ratings and Capacities (Cont.)

NO.

WITH TANK-

LESS COIL

BW5BAH140

BW5RAH140

BW5BAH210

BW5RAH210

BW5BAH280

BW5RAH280

Shaded areas are as shipped. Alternate inputs require a field--- installed alternate oil nozzle supplied with base model.
* MBH = 1,000 BTU per hour/BTU=British Thermal Unit
** Heating Capacity is based on a 13 percent CO2 with a --- 0.02 in. wc draft over fire and a #1 smoke or less. Testing was done in accordance with the D.O.E.
(Department
of Energy) test procedure.
+ GPH = Gallons per hour of oil at 140,000 BTU per gallon
++ A.F.U.E. = Annual Fuel Utilization Efficiency based upon D.O.E. test procedure
# As an Energy Star Partner, the manufacturer has determined that this product meets Energy Star guidelines for Energy Efficiency
# # Gallons of water per minute, heated from 40˚F to 140˚F, with 200˚F boiler water temperature, intermittent draw.
} The 168,000 Btuh input is only available with a Beckett burner.

SEC

INPUT

*MBH

3 91 80 70 0.65 #86.3 8” X8” X15’ 14 1/2 6 8 470 2.90
3 105 92 80 0.75 #85.2 8” X8” X15’ 14 1/2 6 8 470 3.00
3 140 119 103 1.00 83.4 8” X8” X15’ 14 1/2 6 8 470 3.25
4 126 111 97 0.90 #86.0 8” X8” X15’ 17 3/4 6 95/8 545 3.15
4 175 150 130 1.25 83.9 8” X8” X15’ 17 3/4 6 95/8 545 3.50
4 210 178 155 1.50 82.4 8” X8” X15’ 17 3/4 6 95/8 545 3.75
5 }168 147 128 1.20 #86.5 8” X8” X 15’ 21 6 11 1/2 620 N/A
5 245 209 182 1.75 83.6 8” X8” X15’ 21 6 11 1/2 630 4.00
5 280 236 205 2.00 82.0 8” X8” X20’ 21 6 11 1/2 630 4.25

**HEATING

CAPACITY

*MBH

NET

I=B=R

RATING

*MBH

FIRING

RATE

GPH

A.F.U.E

MIN.

CHIMNEY

SIZE/HEIGHT

DIMENSIONS--- IN

SHIPPING

WEIGHT

TANK LES S

HEATER

##G.P.M.H W D

BW4 / BW5

FRESH AIR DUCT SIZE (IN.) 1/4–IN. MESH SCREEN (BTUH) WOOD LOUVERS (BTUH) METAL LOUVERS

3 ---1/2 X 12 144,000 36,000 108,000

8X8 256,000 64,000 192,000

8X12 384,000 96,000 288,000

8X16 512,000 128,000 384,000

!

WARNING

Table 2 – Fresh Air Duct for Tightly Sealed House

FIRE AND CARBON MONOXIDE POISONING
HAZARD

Failure to follow this warning can cause personal injury or
death.

Be sure to provide enough fresh air for combustion.
Enough air ensures proper combustion and ASSURES
THAT NO HAZARD WILL DEVELOP DUE TO LACK
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.

Enough fresh air must be provided to assure proper combustion.
The fire in the boiler uses oxygen. It must have a continuous
supply. The air in a house contains only enough oxygen to supply
the burner for a short time. Outside air must enter the house to
replace that used by the burner. The exact fresh air requirements
depend on whether the boiler is located in an unconfined or
confined space.

(BTUH)

!

WARNING

CARBON MONOXIDE POISONING AND UNIT
OPERATION HAZARD

Failure to follow this warning could result in personal
injury, death and or property damage.

If a fireplace or a kitchen or bathroom exhaust fan is used,
an outside air intake should be installed. These devices rob
the boiler and water heater of combustion air.

A. Boiler Located in Unconfined Space

An unconfined space is defined as a space with volume not less
than 50 cu ft.. per 1000 Btuh of total input rating of all appliances
installed in that space.

If boiler is in an open area (unpartitioned basement) in a
conventional house, air that leaks through cracks around doors
and windows will usually be adequate to provide air for
combustion. The doors should not fit tightly. Cracks around
windows should not be caulked.

B. Boiler Located in Confined Space

ALL AIR FROM INSIDE BUILDING

The confined space shall be provided with 2 permanent openings
communicating directly with an additional room(s) of sufficient
volume so that the combined volume of all spaces meets the
criteria for an unconfined space. The total input of all combustion
equipment installed in the combined space shall be considered in
making this determination. Each opening shall have a minimum
free area of 1 sq.. in. per 1000 Btuh of total input rating for all
combustion equipment in the confined space, but not less than
100 sq. in. One opening shall be within 12 in. of the top and 1
within 12 in. of the bottom of the enclosure. (See Fig. 5.)

6

VENTILATING

GRILLE

Fig. 5 -- Air Openings for Closet or Utility

COMBUSTION
AIR GRILLE

Room Installations

FRESH AIR
DUCT

A95594

3. When communicating with the outdoors through
horizontal ducts, each opening shall have 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
use of this coil eliminates the need for a hot water storage tank.
Instantaneous heating of water in the coil provides a flow of hot
water for domestic use if proper burner and water supply line
controls are used. Tankless coils are meant to provide domestic
hot water for intermittent draws, not

IMPORTANT: Do not use a tankless coil if water is
excessively hard with lime or other deposits which will
accumulate inside coil.

C. Mounting Aquastat Control

The control configuration on this boiler has been set up so that
the Honeywell L8124C Combination Hi/Low Limit Aquastat
Relay mounts on the tankless coil. This maximizes tankless coil
performance by making the burner respond more quickly to a call
for domestic hot water. The boiler is completely wired according
to schematic wiring diagram. (See Fig. 14.) The installer must
mount the L8124C Aquastat on control well in 3/4-- in. tapping
on tankless coil. (See Fig. 7.)

D. Tankless Coil Piping

continuous flows.

BW4 / BW5

BOILER

A95595

Fig. 6 -- Fresh Air Duct for Tightly Sealed House

Example: The boiler is rated at 100,000 Btuh. The water heater is
rated at 30,000 Btuh. The total is 130,000 Btuh. Two grilles are
needed, each with 130 sq. in. of FREE opening. Metal grilles
have about 60 percent FREE area. To find the louvered area
needed, multiply the FREE area required by 1.7 (130 X 1.7 =

221.0 sq. in. louvered area). In this example, 2 grilles each having
an 8 in. X 30 in. (240 sq. in.) louvered area would be used. Fig. 5
shows grille locations.
ALL AIR FROM OUTDOORS
The confined space shall be provided with 2 permanent openings,
1 commencing within 12--in. of the top and 1 commencing within
12--in. of the bottom of the enclosure. The openings shall
communicate directly, or by ducts, with the outdoors or spaces
(crawl or attic) that freely communicate with the outdoors. See
Table 2 and Fig. 5 or 6.

1. When directly communicating with the outdoors, each
opening shall have a minimum free area of 1 sq. in. per
4000 Btuh of total input rating of all equipment in the
enclosure.

2. When communicating with the outdoors through vertical
ducts, each opening shall have a minimum free area of 1
sq. in. per 4000 Btuh of total input rating of all equipment
in the enclosure.

IN

⁄2 IN. NPT

3



⁄4 IN. NPT



CONTROL WELL

A95596

1

Fig. 7 -- Tankless Heater Coil

Piping is as shown in Fig. 8. A tempering valve (mixing valve) is
recommended. A flow restrictor may be required on tankless coil
inlet piping so that flow rates are matched to boiler heat input.
See Table 3.

7

BW4BAH091
BW4RAH091

BW4BAH105
BW4RAH105

BW4BAH140
BW4RAH140

BW4BAH126
BW4RAH126

BW4BAH175
BW4RAH175

BW4RAH210
BW4BAH210

Table 3 – Boiler Rating Information

BOILER MODEL BURNER FIRING RATE INPUT (MBH) TANKLESS RATING (GPM)

BW5BAH091
BW5RAH091

BW5BAH105
BW5RAH105

BW5BAH140
BW5RAH140

BW5BAH126
BW5RAH126

BW5BAH175
BW5RAH175

BW5RAH210
BW5BAH210

0.65 91 2.90

0.75 105 3.00

1.00 140 3.25

0.90 126 3.15

1.25 175 3.50

1.50 210 3.75

BW4BAH168 BW5BAH168

BW4BAH245
BW4RAH245

BW4BAH280
BW4RAH280

* Gallon of water per minute h eated from 40_ F to 140_ F with 200_ F boiler water, intermittent draw. Tankless heater is factory installed on BW5 models, field

BW4 / BW5

install ed accessory on BW4 models.

(TO AUTOMATIC

DISHWASHER, ETC.)

BW5BAH245
BW5RAH245

BW5BAH280
BW5RAH280

UNTEMPERED

HOT WATER

TEMPERED

HOT WATER

1.20 168 3.45

1.75 245 4.00

2.00 280 4.25

responsible for any water damage. Connect a drain line of
the same pipe size (3/4--in.) to carry any water away to a
drain.

3. Connect the 1 1/4--in. NPT supply and return lines to
boiler. Both supply and return lines should be piped to the

TANKLESS COIL

OUT

CENTER LINE
OF COLD TAP

IN

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, first install all radiation
units (panels, radiators, or cabinets) and supply and return mains,
then make connections to boiler.

In connecting cold water supply to reducing valve, make sure that
a clean water supply is available. When water supply is from a
well or pump, a sand stainer should be installed at pump.

When boiler is used in connection with refrigeration systems, it

LIMIT

CONTROL

8 IN. TO

12 IN.

TEMPERING
VALVE

COLD WATER

INLET

shall be installed so that chilled medium is piped in parallel with

SHUTOFF

VALVE

the heating boiler with appropriate valves to prevent chilled
medium from entering the heating boiler.

The minimum boiler supply water temperature setting on the

A98269

Fig. 8 -- Recommended Piping with Tankless Heater Coil

Installation System Piping

1. Place boiler in selected location as close to flue as
possible. (See Fig. 4.) Boiler is shipped assembled. Only
the factory--supplied relief valve needs be installed.

2. Install relief valve in rear section on 3/4 --in. nipple and
street ell. Do not connect directly to a drain, but leave an
air gap. No shutoff of any description shall be placed
between safety relief valve and boiler, or on discharge
pipes between such safety valves and the atmosphere.
Installation of safety relief valve shall conform to
requirements of the ANSI/ASME Boiler and Pressure
Vessel Code, Section IV. The manufacturer is not

aquastat is 140_F. If the boiler is used in a heating system where
supply water temperatures below 140_F are desired, a suitable
method, such as, the use of bypass piping shown in the figure 10,
a 3 way or 4 way mixing valve, or some other means needs to be
used to ensure return water temperatures to the boiler are no less
than 120_F. When the boiler is operated with return water
temperatures less than 120_F, condensation may form in the
boiler and venting. This condensation is corrosive and can
eventually cause severe damage to the boiler and venting system.
Antifreeze added to boilers must be non--toxic and must be of a
type specifically intended for use in closed hydronic heating
systems. Under no circumstances should automotive antifreeze be
used. Antifreeze used in any boiler may reduce capacity by 10
percent or more and increase fuel consumption. Tankless coil
performance will fall as concentration of antifreeze is increased.
Refer to boiler and piping water volumes tables on next page.

8

RETURN FROM SYSTEM

M

R

SHUTOFF VALVE
BOILER SERVICE

BOILER
DRAIN
VALV E

SHUTOFF VALVE
BOILER SERVICE

DRAIN VALVE
FOR POWER
PURGING

AQ U AS TAT

R

MAIN SHUTOFF
VALV E

S

AUTOMATIC
FILL VALVE

FILTROL WITH
AIR PURGER

Fig. 9 -- Circulator on Supply Pumping Away

RETURN FROM SYSTEM

THROTTLING VALVE

DRAIN VALVE
FOR POWER
PURGING

S

AQ U AS TAT

MAIN SHUTOFF
VALV E

AUTOMATIC
FILL VALVE

CIRCULATOR
PUMP

FILTROL WITH
AIR PURGER

SUPPLY TO
SYSTEM

FILL LINE WITH SHUT OFF VALVE

ADJUST THE TWO THROTTLINE VALVES TO
MAINTAIN AT LEAST 120
BOILER RETURN. THE THROTTLING VALVES
ARE USED FOR BYPASS PIPING, IF REQUIRED.

O

F IN THE

THROTTLING VALVE

SUPPLY TO
SYSTEM

ISOLATION VALVES

FILL LINE WITH SHUT OFF VALVE

A01032

BW4 / BW5

ISOLATION
VALVES

SHUTOFF VALVE
BOILER SERVICE

BOILER
DRAIN
VALV E

BOILER
DRAIN
VALV E

Fig. 10 -- Bypass Piping Circulator on Supply

RETURN FROM SYSTEM

Fig. 11 -- Piping Circulator on Supply Side

R

SHUTOFF VALVE
BOILER SERVICE

CIRCULATOR
PUMP

AQ U AS TAT

A01034

SUPPLY TO
SYSTEM

*

AUTOMATIC
FILL VALVE

FILTROL WITH
AIR PURGER

FILL LINE WITH
SHUT OFF VALVE

LOCATE CIRCULATOR PUMP HERE WHEN SYSTE

*

PIPING USES ZONE VALVES. IF SYSTEM PIPING
USES ZONE CIRCULATORS, USE THIS CIRCULATO
AS A ZONE CIRCULATOR

A01035

9

Table 4 – Recommended Minimum Chimney Sizes

FIRING RATE

(GPH)

0.60 to 1.30 15 8X8 6 6 --- 3 / 4 X 6 --- 3 / 4

1.31 to 1.80 15 8X8 7 6 --- 3 / 4 X 6 --- 3 / 4

1.81 to 2.00 20 8X8 8 6 --- 3 / 4 X 6 --- 3 / 4

---For elevations above 2000 ft. above sea level, add 3 ft. to chimney heights. (See figure 12.)

CHIMNEY HEIGHT

(FT . )

Chimney and Chimney Connection

Follow local codes. In the absence of local codes, follow
ANSI/NFPA 31 Installation of Oil Burning Equipment, latest
revision.

A. Checking Chimney

The chimney is a very important part of the heating system. No
boiler, however efficient its design, can perform satisfactorily if
the chimney serving it is inadequate. Check chimney to make
certain it is the right size, properly constructed, and in sound
condition.

B. Chimney Connector and Draft Regulator

Boiler requires 6-- in. diameter chimney connector pipe. The draft
regulator shipped with boiler must also be used. When properly
installed, the regulator controls the draft automatically. It is best to

BW4 / BW5

install it in a horizontal section of the pipe, but it may be in an
angled or vertical section. Make certain that the “top” is at top and
that the short pipe section which holds vane is horizontal. Install
it as close as practicable to boiler. (See Fig. 12.)
Install chimney connector as follows:

1. Start at boiler with a vertical pipe, at least 1 foot tall, and
then an elbow.

2. Install draft regulator making it horizontal.

3. When regulator is in place, start at chimney and work back
to regulator.

4. Join the 2 sections with a drawband. The horizontal pipe
must slope up toward chimney at least 1/4--in. per ft.. It
must not leak and must be firmly supported.

5. Join sections with at least 3 sheet metal screws. Space
evenly around the pipe.

6. Support every 5 feet with metal straps or stove pipe wire.

C. Minimum Vent Pipe Clearance

Wood and other combustible materials must not be closer than
18--in. from any surface of vent pipe.

Electrical Wiring

See Fig. 14 for wiring diagrams for the various models.

A. Installing Thermostat (Not Provided)

The 24--v thermostat location has an important effect on
operation of boiler system. BE SURE TO FOLLOW
INSTRUCTIONS INCLUDED WITH THERMOSTAT.

B. Grounding

Permanently ground boiler according to local codes and the
current edition of The National Electrical Code. Run a 14 gage or
heavier copper wire from boiler to a grounded connection in
service panel or a properly driven and electrically grounded
ground rod.

C. Electrical Power Supply

NORMAL CHIMNEY AREA (IN.) ROUND LINER INSIDE

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

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 a competent electrician do this job.

Boiler controls are all wired at the factory. All that is required is
to connect a 115--v electric supply and thermostat wires to
aquastat relay.

Run a separate circuit from a separate overcurrent protective
device in electrical service entrance panel. This should be a
15--amp circuit. Locate a shutoff switch at boiler. It must be
turned OFF during any maintenance. Solder and tape or securely
fasten these connections with wire nuts.

D. Connecting 115-- V Electrical Wiring to Boiler

Connect 115--v electric supply wires to terminals L1 and L2 on
aquastat relay. (See Fig. 14.)

E. Thermostat Connections

The 2 wires from thermostat connect to terminals T and T on
L8148A and L8124C aquastat relay (See Fig. 14.)

F. Thermostat Heat Anticipator Adjustment

Set heat anticipator at 0.2 amps. Measure the AMP draw of the
thermostat circuit and adjust the anticipator setting if necessary.

DIAMETER (IN.)

!

WARNING

Equipment and Optional

Accessories

A. Relief Valve (Required, Provided)

Each low--pressure hot water heating boiler is provided with a
relief valve for over--pressure protection of boiler and heating
system. The relief valve opens when pressure in boiler rises to 30
psig. Each relief valve is provided with a lifting device for testing
and should be tested monthly during heating season. Escape
piping should be provided from discharge side of relief valve so
as to prevent scalding or other hazardous situations. The escape
piping must remain full size and end at a safe point of discharge.

B. Expansion Tank (Not Provided)

In a properly assembled system, expanding water flows into an
expansion tank. This tank should be of the correct size.

The tank is filled with air. As the water expands, it compresses the
air in tank to form an air pressure cushion. This “spring-- like”
cushion serves s to maintain correct operating water pressure
regardless of water temperature. This assures a “full measure” of
water even in the highest radiation unit of system. It also prevents
blowing off the relief valve.

The air in tank in the beginning (with system filled with cold
water) is sufficient for proper operation. The tank also serves as a
trap for excess s air in system. This air would cause gurgling in
pipes and inefficient circulation in radiators if left in system.

SQUARE LINER INSIDE

DIMENSIONS (IN.)

10

It is possible for a tank to become “water-- logged” (filled with
water). It can also become overfilled with air. This can happen
after filling system with new water. Fittings are provided on tank
and in line to tank for bleeding off excess water or air.

When installing this tank, the following are important: :

1. Tank should be higher than boiler top.

2. Pipe to tank should continuously rise up to tank (so that
air can “bubble“ up through it).

C. Diaphragm--Type Expansion Tank (Not Provided)

The diaphragm--type expansion tank takes the place of a
conventional expansion tank. Read instructions packed with tank
assembly carefully. The tank comes with a 10-- 12 psi air charge.
This is the same as the pressure produced in system by automatic
fill valve. When system is first filled, ,tank contains little or no
water. .As water is heated, its pressure increases. It expands into
tank compressing the air in tank. This compressed air cushion
permits water in system m to expand as temperature changes. The
diaphragm--type expansion tank can be mounted on the air purger
fitting or at any other convenient place in the supply or return

MUST BE REQUIRED MINIMUM

HEIGHT. MUST BE AT LEAST

3 FT HIGHER THAN HIGHEST

PART OF PASSAGE THROUGH

ROOF. MUST BE AT LEAST 2 FT

HIGHER THAN ANY NEIGHBORING

OBJECT. MUST HAVE AN 

UNOBSTRUCTED TOP OPENING.

line. It is recommended to locate the diaphragm type 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 or air purger is not provided. The air eliminator fitting or
air purger is used to help remove air from the system before it
reaches the radiators. It should be installed in the supply line. Air
left in the system can cause noises in the pipes and inefficient
circulation in the radiators. .

D. Air Eliminating Fitting (Air Purger) (Not Provided)

Table 5 – Boiler Water Volumes

NUMBER OF BOILER SECTIONS TOTAL V OLUME (GALLONS)

3 9.6
4 11.6
5 13.7

BW4 / BW5

MUST BE AT LEAST 

4 IN. THICK AND BE TIGHT.

MUST SLOPE UP AT 

LEAST 1/4 IN. PER FOOT

OF HORIZONTAL RUN.

DRAWBAND LAST

PIECE INSTALLED

DRAFT REGULATOR

TIGHT, SMOOTH,
CORRECTLY SIZED.

SEALED IN
THIMBLE

TIGHT CLEAN-OUT
DOOR

Fig. 12 -- Typical Chimney Requirements

VANE

BALANCED

WEIGHT

CRIMPED

END

ALTERNATE POSITIONS

TOP

TOP

A95601

11

Table 6 – Piping Water Volumes

PIPE SIZE COPPER PIPE FACTOR STEEL PIPE FACTOR

1 / 2 --- I N . 82.5 63.5

3 / 4 --- I N . 40.0 36.0

1 --- I N . 23.3 22.2

1 --- 1 / 4 --- I N . 15.3 12.8

1 --- 1 / 2 --- I N . 10.8 9.5

2 --- I N . 6.2 5.8

---Divide total length of piping in feet by appropriate factor in table to de-

terminevolumeingallons.

An air purger is used to remove air from system. It is installed in
supply line. It eliminates air from water before it reaches radiators
and bleeds off this air.

E. Main Air Vent for Downflow Systems or

Diaphragm-- Type Expansion Tank (Not Provided)

Before a system is filled with water, there is air in pipes and
radiation units. Some of it will be trapped as system fills. It is
possible to eliminate most of this air through air vents on
radiation units. A main air vent speeds and simplifies this process.
It should be installed on highest point in supply main when all
radiation is below top of boiler.

F. Aquastat Relay Control (Provided)

BW4 / BW5

The water temperature limit control in aquastat relay is adjustable
and may be set as necessary. It may be set as low as 140_Foras
high as 240_F. This depends on type and amount of radiation
involved and weather conditions.

G. Automatic Fill Valve (Not Provided)

For safe, efficient operation, a hot water system must be filled
with water. Adding new water when needed can be done
manually (by use of a hand valve in water supply line). This
requires regular attention to system’s needs. An automatic fill
valve accomplishes this without attention. It is installed in supply
line on hot water boilers only. The valve operates through water
pressure differentials. It does not require electrical connection.

H. Drain Valve (Provided)

This manual valve provides a means of draining all water from
boiler and system. It is installed in a tee where return line enters
boiler.

I. Circulating Pump (Provided)

Every forced hot water system requires a circulating pump. A
separate pump or zone valve is required for each zone if there are
2 or more zones. The circulator must have the capacity to provide
the circulation required by the heating system. The circulator
should be connected to the supply main and must be wired into
the boiler’s electrical system. See the prior pages of installation
section for piping configurations with the circulator located on
the supply main piping using zone circulators or zone valves.
When the piping is arranged with zone circulators and no bypass
piping, the circulator provided with the boiler may be used as a
zone circulator. Both piping arrangements allow the circulator to
pump away from the expansion tank and show how the piping
should be arranged to allow the heating system to be easily
purged of air.

J. Oil Solenoid Valve

The Beckett oil burner uses a standard solenoid valve. Upon
burner shutdown, a standard solenoid valve stops the flow of oil
to the nozzle. Without the solenoid valve, the oil pump continues
to pump oil to the burner nozzle until the motor winds down
below the pump cut--off speed. The Riello oil burner has a delay
oil solenoid valve. 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 Water System Operates

The entire heating system (boiler, piping, and radiation units) is
filled with water. As water in boiler is heated, it is pumped from
top of boiler through supply main to radiation units. The cooler
water in them flows back through return main to boiler. This
provides positive and rapid response to thermostat.

B. Filling System With Water

a. Close the main shutoff valve, isolation valves, and

zone valves (if applicable). If bypass piping is
installed, also close the two throttling valves. Leave
the boiler service shutoff valve (if installed) and the
balancing valves to each heating zone fully open.

b. Open the following valves in order: the drain valve for

power purging, isolating valves before and after the
boiler circulator (if applicable), both throttling valves
(if applicable), and then open the fill line shutoff
valve. Water will fill the bypass piping and push air
through the piping and out the power purging drain
valve. When the power purging drain valve runs air
free, close the bypass throttling valve (leaving the
throttling valve to the supply piping fully open)

c. Next, open the isolation valve (or zone valve) to the

first zone. Water will fill the piping and push any air
out the power purging drain valve. When the power
purging drain valve runs air free, close the isolation
valve or zone valve. Repeat this procedure for the
remaining heating zones.

d. Once all of the zones are filled with water and purged

of air, close the power purging drain valve and fill line
shut off valve, open the main shutoff valve, and adjust
the throttling valves and balancing valves as required.

OPTION

If units have automatic vents, this manual venting is unnecessary
but will speed up proper filling of system.

If system is a closed expansion tank system, there should be an
automatic fill valve. It may be left open to refill system
automatically as needed.

Check temperature--pressure gage. Note position of hand
indicating pressure. This should be between 10 and 15 psi. Any
lowering of this movable hand below 10 psi indicates loss of
water due to leakage. The automatic fill valve should compensate
for this. If it does not, manually open this valve to refill system

#2

1. Close air vents on all radiation units. Open valves to these
units.

2. Make sure boiler and expansion tank drain cocks are
closed. The air bleed screw on tank drain fitting should be
closed.

3. Open valve in line from boiler to expansion tank.

4. Open water inlet to boiler and leave it open.

5. Start with the LOWEST radiation unit. Open the air vent
on this radiation unit. When all air has escaped and water
starts to flow from vent, close air vent.

6. Proceed to next lowest radiation unit and repeat process
outlined in item 5. Repeat until every radiation unit in
system has been covered. End with the highest unit in
system.

12

until hand is again pointing to same pressure reading. Instructions
are packaged with valve.

OPERATING BOILER

!

WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could result in personal
injury, death and or property damage.

Do not tamper with unit or controls.

IMPORTANT: Follow these instructions carefully.

To Start

Fill entire system with water. V ent all air from system. Refer to
instructions included with oil burner.

Fuel Units and Oil Lines

Install oil line(s) to the oil burner. Recommend using heavy wall
copper tubing and flared fittings, not compression fittings. All
connections and joints must be absolutely airtight. Use an
appropriate non -- hardening thread sealing compound on the
threaded connections, not Teflon tape. See fuel unit data sheet
furnished with the burner for sizing, lift, and length of tubing
recommendations.
The original equipment oil burner (when furnished) is equipped
with a single-- stage fuel unit with the by--pass plug removed for
single pipe installation. This is satisfactory where the fuel supply
is on the same level as, or above the burner, permitting gravity
flow of oil. Per NFPA--31 requirements, never exceed 3 psig
pressure to the inlet side of the fuel unit. When it is necessary to
lift the oil to the burner, a two--pipe installation is required. Run
a return line between the fuel unit and the oil supply. When a
two-- pipe installation is used, the by--pass plug (furnished with
the burner) must be installed in the fuel unit. Refer to the fuel
unit instructions furnished with the burner for specific
instructions on installing the by--pass plug. Do not exceed the
fuel unit manufacturer’s recommendations for running vacuum.
(Note: If lift exceeds 14 feet for Beckett or Carlin burners or 11
feet for Riello burners, a two--stage fuel unit is required with a
return line.)
Install an oil filter of adequate size inside the building between
tank shutoff valve and the oil burner. For ease of servicing, locate

the shutoff valve and filter near the oil burner.

Air Supply for Combustion

Do not install in rooms with insufficient air to supply
combustion. Occasionally, it is necessary to install windows or
cut holes in a door to these rooms to obtain sufficient air and to
prevent less than atmospheric air pressure in the room. If there is
a lack of combustion air, the burner flame will be yellow and
formation of soot will occur in heating unit. In buildings of
conventional frame, brick, or stone construction without utility
rooms, basement windows, or stair doors, infiltration is normally
adequate to provide 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 supply and draft are properly adjusted, combustion
chamber draft will be approximately --0.01 to --0.02 in. wc and
stack draft will be -- 0.02 to --0.04 in. wc. The larger the
installation, the greater the draft required at stack to obtain --0.01
to --0.02 in. wc at combustion chamber.

Nozzles (Provided)

Use the proper size, type, and spray pattern nozzle, refer to Table

6. To install nozzle, loosen clamping screw on retention ring
assembly and slide assembly off adapter. Install and tighten
nozzle in adapter. Be careful not to damage electrode insulators or
bend electrodes. Replace retention ring assembly on adapter.
Make sure clamp is tight against shoulder on adapter. Tighten
clamping screw. Check electrode setting. (See Fig. 13--17.)

Final Burner Adjustments

A final adjustment must be made with the use of a
COMBUSTION TEST KIT. Initial settings for burner are shown
on label on top of ignition transformer and Table 7 for Beckett
burners, Table 8 for Riello burners. Set burner accordingly. After
operating 10 minutes to warm unit up, a smoke tester should be
used to take a smoke reading in flue pipe between boiler and draft
regulator. Smoke should be zero (Shell Bacharach Scale). At
times a new boiler requires more time than this to burn clean due
to oil film on a new heat exchanger. Check draft over the fire.
This should be --0.01 to --0.02 in. wc as previously stated. Adjust
draft if necessary. Gradually close air shutter, and if necessary the
air band, to obtain a smoke reading showing a trace of smoke.
Measure CO2 at this point. Increase air sufficiently to reduce CO2
by 0.5 to 1 percent as an insurance margin. Smoke should be
zero. If a clean fire cannot be obtained, it will be necessary to
verify head and electrode alignment. (See Fig. 15-- 17.) If fire is
still smoky, replace nozzle with a correct replacement. Record
nozzle size, oil pressure, combustion readings and air settings
then place a tag or label on boiler or burner with this information.
Units should be cycled several times to assure good operation
with no fluttering or rumbling. Check for oil leaks.

BECKETT AFG BURNER ELECTRODE ADJUSTMENTS VARIABLE (V1) HEADS

BOILER
MODEL

5EW

5/32
GAP

5/16 ABOVE

Fig. 13 -- Beckett Burner Electrode Adjustments

DIMENSION ÒNÓ

(electrode to nozzle)

L1 OR V1 HEAD

1/16ý

DIMENSION ÒHÓ
SEE ABOVE

DIMENSION ÒNÓ
SEE ABOVE

DIMENSION ÒHÓ
(head to nozzle)

7/32ý Ð 9/32ý

ELECTRODE

NOZZLE

A06663

BW4 / BW5

13

BECKETT AFG VARIABLE (V1) HEAD ADJUSTMENTS AND SETTINGS

LOCATION OF HEAD AT ÒDÓ

POSITION ON ADJUSTING PLATE

ÒZÓ

DIMENSION

3-3/4ý

1/32ý

ÒV1Ó ADJUSTABLE HEAD

AIR TUBE COMBINATION

HOLD DOWN

SCREW

WITNESS

MARK

PRIMARY

ADJUSTING

PLATE

SECONDARY

ADJUSTING

PLATE

KNURLED

NUT

ACORN NUT/ LOCK WASHER

A06664

Fig. 14 -- Beckett Burner Setting Variable (V1) Head

BECKETT AFG BURNER ELECTRODE ADJUSTMENTS F-HEADS

BW4 / BW5

BURNER F-HEAD MODEL

F0 THRU F31

DIMENSION ÒNÓ HEAD TO NOZZLE

5/32
GAP

7/16 ABOVE

1/16ý

DIMENSION ÒNÓ

SEE ABOVE

NOZZLE

Fig. 15 -- Beckett Burner Setting Fixed (F) Head -- 140, 210

A06665

Fig. 16 -- Riello 40--F5 Burner Electrode Adjustments

A06506

14

Fig. 17 -- Riello 40--F10 Burner Electrode Adjustments

BW4 / BW5

A06507

Oil Burner Maintenance

The following preventative maintenance items should be
performed annually, preferably prior to the heating season.

A. Oil Burner Motor

Add 2--3 drops of non--detergent electric motor oil to each oil cup
located at front and rear of motor. Excessive oiling will shorten
the life expectancy of motor.

B. Fuel Filter

This should be replaced so as to prevent contaminated fuel from
reaching the nozzle. A partially blocked fuel filter can cause
premature failure of fuel pump unit.

C. Fuel Pump Unit

Replace pump screen and clean pump unit to maintain reliable
fuel delivery to nozzle.

Clean and adjust as per manufacturer’s recommendations so as to
maintain reliable ignition of oil.

E. Nozzle

Replace so as to maintain safe and reliable combustion efficiency.
Always replace with the exact nozzle as required in Table 7.

These must be 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 coupling for wear
and damage.

D. Ignition Electrods

Table 7 – Beckett Oil Burner Specifications

BASE

MODEL

BOILER IN -

PUT (BTUH)

140 91,000* 0.50–80 B 0.65 F 0 1 --- 1 / 8 YES 10 0 3 --- 5 / 8 175 PSIG

105,000 0.65–70 B 0.75 F 3 1 --- 1 / 8 YES 10 0 3 --- 1 / 2 140 PSIG

140,000 0.85–70 B 1 F 3 1 --- 1 / 8 NO 10 2 3 --- 1 / 2 140 PSIG

210 126,000* 0.75–80 A 0.9 F 3 1 --- 1 / 8 NO 8 0 3 --- 1 / 2 140 PSIG

175,000 1.00–80 A 1.25 F 6 1 --- 1 / 8 NO 10 0 3 --- 3 / 8 140 PSIG

210,000 1.25–80 A 1.5 F 6 1 --- 1 / 8 NO 10 2 3 --- 3 / 8 140 PSIG

280 168,000 1.00–60 B 1.2 V 1 --- 0 NO 10 1.5 2 --- 3 / 4 140 PSIG

245,000 1.50–45 B 1.75 V1 --- 2 NO 10 4 2 --- 3 / 4 140 PSIG

280,000 1.65–60 B 2 V 1 --- 4 NO 10 5 2 --- 3 / 4 140 PSIG

DELEVAN OIL

NOZZLE

FIRING

RATE

(GPM)

HEAD--- ADJUSTMENT

OR SET TING

LOW FIRE

BAFFLE

AIR SHUTTER

AIR

BAND

STATIC

PLATE (IN.)

PUMP PRESSURE

15

BASE MODEL

Note: All Riello 40 F--- 5 and F ---10 oil burners are factory preset at 145
psig.

BOILER

INPUT (BTUH)

91,000 0.50--- 70ºW 0.65 0.5 / 2.0 155 F --- 5

105,000 0.65--- 70ºW 0.75 2.0 / 2.2 150 F --- 5

140,000 0.85--- 70ºW 1.00 2.0 / 3.2 170 F --- 5

126,000 0.75--- 70ºW 0.9 1.5 / 2.6 160 F --- 5

175,000 1.00--- 70ºW 1.25 2.5 / 3.8 170 F --- 5

210,000 1.25--- 70ºW 1.5 4.0 / 7.0 175 F --- 5

245,000 1.50--- 70ºW 1.75 2.0 / 3.8 155 F --- 1 0

280,000 1.75--- 70ºW 2.00 2.5 / 4.1 155 F --- 1 0

DELEVAN

OIL NOZZLE

Checking and Adjusting Controls

BW4 / BW5

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal
injury or death.

Do not attempt to start the burner when excess oil has
accumulated, when unit if full of vapor, or when the
combustion chamber is very hot.

IMPORTANT: These instructions must be followed carefully.

A. Adjusting Operating Controls

Instructions for each control are included. Refer to Table 8 for
recommended settings for the first adjustment:

These settings can be changed after gaining familiarity with how
system responds. If system does not give quite enough heat in
very cold weather, ,the high limit setting can be raised to 220_F.
If more domestic hot water is required, the low limit setting can
also be raised

B. Checking Thermostat Opeation

When set above temperature indicated on thermometer, boiler
burner should start. Make certain thermostat shuts boiler down
when room temperature reaches selected setting and starts boiler
operating when room temperature falls a few degrees.

NOTE: Do not start burner unless all cleanout doors are secured
in place.

!

WARNING

MAINTENANCE

To assure trouble--free operation, we recommend that flue
passages, burner, combustion chamber area (target wall and fire
door insulation), burner adjustment, operation of controls, and
boiler seals (door gasket or silicone seal, cast iron seals and flue
collector) be checked ONCE EACH YEAR by a competent
service technician.

BEFORE THE START OF EACH SEASON (or whenever
system has been shut down 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.

Table 8 – Riello Oil Burner Specifications

FIRING

RATE (GPM)

TURBULATOR/ AIR

SHUTTER SETTING

!

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.

Relief Valve

This valve should open automatically when system pressure
exceeds the safe limit (30 psi). Should it ever fail to open under
this condition, shut system down. Drain it until pressure is
reduced below safe limit, then have valve replaced immediately.
The relief valve should be tested monthly during heating season.
Prior to testing, make certain a discharge pipe is properly
connected to the valve outlet and arranged so as to contain and
safely dispose of boiler discharge. Hold the trip lever fully open
for at least five seconds in order to flush free any sediment that
may lodge on the valve seat. Then permit the valve to snap shut.

Conventional Expansion Tank

As previously noted, this tank may become waterlogged or may
receive an excess of air. Frequent automatic opening of relief
valve indicates waterlogging. A high boiler temperature
accompanied by unusually low radiation unit temperature (and
“knocking”) indicates excess air in tank. To correct either
condition, close valve between boiler and tank. Drain tank until it
is empty. Check all tank plugs and fittings. Tighten as necessary.
Open valve between boiler and tank. Water will rise to normal
height in tank if automatic fill valve is installed, otherwise,
manually refill system.

Diaphragm Expansion Tank

As previously noted, this tank may become waterlogged or may
receive an excess of air. Frequent automatic opening of relief
valve indicates waterlogging. A high boiler temperature
accompanied by unusually low radiation unit temperature (and
“knocking”) indicates excess air in tank. To correct this condition,
replace the diaphragm expansion tank.

Water System

If system is to remain out of service during freezing weather,
always DRAIN IT completely. Water left in to freeze will crack
pipes and/or boiler.

Tankless Coil (or Cover Plate Gasket)

The tankless coil gasket should be checked at least twice a year
for leakage and replaced if necessary.

OIL PUMP PRESSURE

(PSIG)

WARNING

OIL

BURNER

16

Oil Boiler/Burner Cleaning Instructions

OIL BOILER CLEANING

1. Shut off all electrical power to the boiler/burner and shut
off fuel oil supply.

2. Remove the vent pipe from the top of the boiler. Inspect
the pipe and chimney for signs of corrosion and
deterioration. Clean out the base of the chimney. If the
vent pipe shows any signs of corrosion or deterioration,
replace it immediately. If chimney damage or deterioration
is discovered, contact a competent professional.

3. Remove the top jacket panel screws (5), the brass wing
nuts (2) holding the flue collector top, and then the flue
collector top. Inspect the gasket on the underside of the
flue collector and replace as necessary.

4. Before beginning to clean the flue passageways, ensure
that the combustion chamber blanket is covered. If the
blanket is not covered prior to cleaning, replace the
blanket once cleaning is complete.

5. Now with access to the flue passageways, remove the soot
from the fireside surfaces by brushing diagonally through
the flue passages (See Fig. 18). Brushing can be made
easier by cutting the end of the flue brush off and inserting
it into a drill. When brushing, care should be taken so as
not to damage the target wall with the flue brush.

6. Carefully vacuum the soot accumulations from the
combustion chamber area, being particularly careful to not
damage any of the refractory or blanket insulation. To gain
access to the combustion chamber first double check that
the shut off valve on the fuel line is closed and then
disconnect the fuel oil line. Then open the swing door by
simply removing the whiz lock nut holding the door shut.

7. Now inspect the target wall, fire door refractory, and
combustion chamber blanket (when included) for cracking
and deterioration. If there is any signs of cracking or
deterioration, replace the refractory or blanket before
reassembling the burner/front plate.

8. Inspect the door’s braided gasket for wear and damage.
Replace when necessary with braided gasket of the same
material and size. See repairs parts section of this manual.

9. Now inspect and clean the oil burner.

Fig. 18 -- Removing Soot

A95609

OIL BOILER CLEANING

NOTE: These are general instructions for cleaning an oil burner.

For specifics, consult the burner manufacturer’s instructions

1. Make sure all electrical power to the boiler/burner and the
fuel supply to the burner are shut off.

2. With the swing door open, clean any soot accumulations
from the end of the burner 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 the burner being used
has a damaged head, replace the head with the exact same
head recommended for use on this boiler.

6. Inspect and clean the oil burner blower wheel.

7. Remove the oil pump cover and clean/replace the pump
screen. Carefully reassemble ensuring the pump cover
makes a good seal.

8. Securely fasten the swing door shut.

9. Replace the fuel filter (if applicable).

10. Reconnect the electrical and fuel supplies.

11. Fire the burner, checking for proper combustion using
combustion test equipment and making adjustments as
necessary.

12. Ensure that all safety controls and operating controls are
functionally properly.

IMPORTANT: KEEP BOILER AND AREA AROUND IT
CLEAN. NEVER BURN REFUSE OR ANY MATERIAL
OTHER T HAN THE SPECIFIED FUEL IN BOILER. HAVE
BOILER CHECKED EACH YEAR BY A QUALIFIED
TECHNICIAN.

Sequence of Operation

Refer to Fig. 19 and the wiring diagram shown in Fig. 14 while
reviewing sequence of operation.

A. Boiler with Tankless Coil

HIGH LIMIT CONTROLLER

The high limit contacts open and turn burner off when boiler
water temperature reaches high limit set point. The high limit
automatically resets after boiler water temperature drops past set
point and through fixed 10_ differential.

LOW LIMIT AND CIRCULATOR CONTROLLER

On a boiler water temperature rise, with the adjustable differential
set at the minimum setting of 10_, burner circuit contacts RB
break and circulator circuit contacts RW make at low limit set
point. On a boiler water temperature drop of 10_ below set point,
the RB circuit makes and RW circuit breaks

At any differential setting greater than 10_, the RB make and

RW break temperature remains the same (control setting minus
10_). The RB break and RW make temperature is the set point
temperature plus the difference between differential setting and
10_.

The low limit control fires burner to maintain boiler water
temperature at low limit setting (set point plus adjustable
differential setting minus 10_).

While boiler water temperature is below low limit setting,
circulator is prevented from operating, giving preference to
domestic hot water requirements. Once boiler water temperature
rises to low limit setting, thermostat controls firing of burner and
operation of circulator pump as follows:

BW4 / BW5

17

115V 60 CYCLE

NH

SUPPLY

24 VOLT
THERMOSTAT

shutting off burner. Circulator pump remains running as
long as thermostat calls for heat.

7. If boiler water temperature falls 10_ below high limit

setting, contacts BR close energizing burner.

8. Thermostat is satisfied terminating call for heat. Relay coil

TO

115V

SUPPLY

L1

L2 T T

TO
24V
THERM

1K is de--energized opening 1K1 and 1K2 contacts. Both
burner and circulator pump cease operation.

NOTE: The high limit setting must be set a minimum of 20_
higher than low limit setting.

AQUASTAT

RELAY

B. Boiler Without 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

A95602

Fig. 19 -- Wiring Connections to Aquastat Relay

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 heating, the sequence of operation for the

Table 9 – Recommended Operating Control Settings

burner and circulator is as follows:

1. Thermostat calls for heat, completing the circuit between

BW4 / BW5

OPERATING CONTROL

Standing Radiators 180°F

High Limit

Low Limit (When Used) 140°F

Differential (When Used) 10°F

Baseboard and

Convectors

CONTROL

SETTING

200°F

1. Thermostat calls for heat completing circuit between
terminals T and T on L8124C aquastat controller
energizing the 1K relay coil.

2. With 1K relay coil energized, contacts 1K1 and 1K2 are
closed. Terminal B1 is energized providing power to
R4184 oil burner primary control. This in turn powers
ignition coil and burner motor.

3. With R4184 primary control energized, burner operation
starts and burner remains running as long as cad cell
senses flame. In the event of a flame failure or if flame is
not fully proven within 45 sec of initial start--up, the
R4184 primary control locks out and opens burner circuit.
This requires a manual start--up of burner.

4. As long as flame is proven through cad cell relay, burner
remains on until circuit is interrupted by boiler water
temperature reaching high limit setting (opening high limit
contacts BR), or thermostat is satisfied breaking T --T
circuit.

5. Circulator pump is powered through terminal C1 and runs
when boiler water temperature is above low limit setting.

6. If boiler water temperature reaches high limit setting, high
limit contacts BR open de--energizing terminal B1 and

terminals T and T on the aquastat controller, energizing
the 1K relay coil.

2. With the 1K relay coil energized, contacts 1K1 and 1K2
are closed. Terminals C1 and C2 are energized providing
power to the circulator. Terminal B1 is energized,
providing power to the oil burner primary control. This in
turn powers the ignition coil and burner motor.

3. With the primary control energized, the burner operation
starts and remains running as long as the cad cell senses
flame. In the event of flame failure or the flame is not fully
proven within the trial for ignition period, the primary
control will lockout and open the burner circuit. This will
require a manual startup of the burner.

4. As long as flame is proven through the cad cell relay, the
burner will remain on unit the circuit is interrupted by the
boiler water temperature reaching the aquastat’s high limit
setting (opening high limits contracts BR), or the
thermostat is satisfied breaking the T—T circuit.

5. If the boiler water temperature reaches the aquastat’s high
limit setting, the high limit contact BR is de--energized
turning the burner off. However, the circulator pump will
continue to run, as long as, the thermostat calls for heat.

6. After the high limit contact BR is de--energized, the boiler
water temperature must fall 10_ F below the aquastat’s
high limit setting for the high limit contacts BR to close
and energize the burner.

7. When the thermostat is satisfied, the call for domestic
space heating is ended. Relay coil 1K is de--energized,
opening 1K1 and 1K2 contacts. Both the burner and
circulator pump operation stop.

18

BOILER WITHOUT TANKLESS HEATER COILBOILER WITH TANKLESS HEATER COIL

120V
POWER
SUPPLY

FIELD WIRING

NEUT

HOT

OVERCURRENT

PROTECTED

DISCONNECT

COLOR CODE

BK=BLACK
O=ORANGE
Y=YELLOW
R=RED
W=WHITE

OIL
VALVE

CIRCULATOR
PUMP

24 VOLT THERMOSTAT

BK W

L1

L2 T T

R

B2 C2

W

R

C1 ZC

BK

ZR B1

BK

BK

BK

IGNITION
TRANSFORMER

T T

1K

LOW LIMIT/

CIRCULATOR

1K2

A

L8124C

AQUASTAT

BK

W

W

OIL BURNER
MOTOR

B

HIGH LIMIT

R

120/60/1 OVERCURRENT PROTECTED DISCONNECT

LINE

NEUTRAL

24 V THERMOSTAT

FIELD WIRING

G

AQUASTAT

R4184
RELAY

CAD CELL

Y

O

F
F

Y

3

B

R

TTL2L1

L8148A

B2B1C2C1

B

G

GND

L1

L1
(HOT)

L2

L2

BRW

1K1

ZR

ZC

B1

B2

C1

C2

CIRCULATOR

L1

W

BW

JUMPER

B

B

O

B

R4184D

RELAY

W

W

B

B

IK1

3TT

B=BLACK
W=WHITE
O=ORANGE
Y=YELLOW

IGN
TRANS

F

F

R

LINE
VOLTAGE

CLASS II
24 VOLTS

OIL BURNER

MOTOR

OIL
VALVE

Y

Y

CAD
CEL

BW4 / BW5

IK IK2

COLOR CODE

C1

C2 B2 B1L2

BW4B BW5B

Fig. 20 -- Wiring Diagrams for Boilers With and Without Tankless Heaters and Beckett Burners

A02231

19

BW4 / BW5

Fig. 21 -- Boilers Without Tankless Coil and Honeywell L8148 Aquastat Control

A06504

20

F5 only

Fig. 22 -- Boilers With Tankless Coil and Honeywell L8124C Aquastat Control a nd Riello Burners

BW4 / BW5

A06505

21



HI LIMIT

SETTING

LOW LIMIT

AND

CIRCULATOR

SETTING

240 F (116 C)

10 F (5.6 C)

DIFF

25 F (13.9 C)

DIFF

10 F (5.6 C)

DIFF

SWITCH BREAKS ON
RISE, TURNS BURNER
OFF. CIRCULATOR
OPERATES ON CALL
FOR HEAT.

SWITCH MAKES ON
FALL. BURNER
OPERATES ON
CALL FOR HEAT.

SWITCH MAKES R-W,
BREAKS R-B ON RISE
(25 F [13.9 C]
DIFFERENTIAL).

SWITCH MAKES R-W,
BREAKS R-B ON RISE
(10 F [5.6 C]
DIFFERENTIAL).

SWITCH MAKES R-B
ON FALL, BREAKS
R-W. BURNER ON,
CIRCULATOR OFF.

Service Hints

Avoid inconvenience and service calls by checking these points
before calling for service.

have your service technician check any problem you are
unable to correct.

Parts List

All parts are listed in the following Parts Lists. Parts may be
ordered through nearest supplier When ordering parts, first obtain
the Model No. from the name plate on boiler, then determine the
Part No. (not the Key No.) and the Description of each part from
the following appropriate illustration and list. Parts for which no
Part No. is given are standard items which can be procured
locally. Be sure to give all this information: The Part No., The
Part Description, The Boiler Model No.

BW4 / BW5

110 F (43 C)

A956111

Fig. 23 -- Relationship of Set Points and Differential

Table10–ServiceHints

POSSIBLE CAUSE WHAT TO DO

Thermostat is not set correctly Reset thermostat above room temperature.

Boiler and/or burner may be dirty Clean all flue passages and vent pipe. Have b urner 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 dirty at frequent intervals, correct the .dirt condition,. then also correct the control

No power to b oiler Check overcurrent protection. Check to be sure power supply circuit is on.

Controls out of adjustment Reset according to instructions packed with controls.

Radiators not heating Open radiator vents to vent excess air. Check flow control valve (if used). It may

Circulator pump not running Check relay operation.

Poor electrical contact Check all control terminals and wire joints.

POSSIBLE CAUSE WHAT TO DO

Oil burner fan wheel may be d irty Clean fan wheel with a stiff brush and cleaning solvent. Readjust oil burner.

Draft regulator may be stuck Check to see if vane swings freely. Clean if vane is stuck.

POSSIBLE CAUSE WHAT TO DO

Air in system Open radiator vents to vent air. Check expansion tank.

POSSIBLE CAUSE WHAT TO DO

Dirt on seat Open valve manually. Allow water to run and clear valve seat.

Waterlogged expansion tank Drain tank. See instructions.

IF SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .

Burner may be short --- cycling Short--- cycling (too frequent off and

on) of burner causes sooting. If boiler and/or burner becomes

setting (or other cause of short--- cycling).

Check thermostat heat anticipator and correct setting, if neces ---

sary, per instruction sheet packed with thermostat.

be in closed position.

IF BURNER IS NOISY . .

IF RADIATORS ARE NOISY. . .

RELIEF VALVE LEAKING. . .

22

13

2

12

XXX

3
1

14

2

5

XXX

7

XXX

9

XXX

11

1

1

10

XXX

4

XXX

2

XXX

8
1

1

1
1

15

1

16

1

18
10

19
10

20
10

ITEM DESCRIPTION PAR T NUMBER

1 Section Machined Back 403 --- 00--- 008

2 Section Machined Middle 403- -- 00--- 007

3 Section Machined Front 403--- 00 ---006

4 N i p p l e M a c h i n e d 2 --- i n . --- ( 2 --- in . c a s t i r o n p u s h n i p p l e ) 433--- 00---976

Tie Rod 1/4X10 1/4

5

3section 146--- 05 --- 002

4section 146--- 05 --- 051

5section 146--- 05 --- 053

6 Nu t s h e a d ( H e x ) Z P ( Z i n c P l a t e d ) 1 / 4 --- i n . --- 2 0 HW--- 003.02

7

C u t R o p e 5 / 1 8 --- in . X 7 0 --- 1 / 2 --- i n . ( N O R F A B 4 0 0 S e r r a t e d B r a i d e d

Rope)

433--- 00 --- 955

8 Target Wall (Gemcolite Vacuum Formed Ceramic Fiber 2300’) 146--- 19 --- 003

9

S i z e --- 3 s e c t i o n --- 8 --- i n . X 1 2 --- i n . , 4 s e c t i o n --- 8 --- i n . X 2 0 --- i n . 5

D u r a B l a n k e t 3 --- 8 # 1 / 2 --- i n . t h i c k

146--- 30 --- 031

Collector Base

10

3section 425--- 00 --- 279

4section 425--- 00 --- 280

5section 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 W i n g N u t 8 / 3 2 --- B r a s s 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 Gasket PF --- EV 5040 --- 150A 146--- 03 --- 065

16 Coil 3.7 GPM (Gallons Per Minute) C DB 146 ---27 --- 020

17 Cover Plate (Not Shown) 146--- 19--- 001

18 S t u d 1 8 --- 8 S t . S t . ( S t a i n l e s s S t e e l ) 3 / 8 --- 1 6 X 1 --- 1 / 2 --- i n . 146--- 95 --- 113

19 Washer Flat 18 --- 8 St. St. (Stainless Steel) 3/8 146--- 95 --- 114

20 Nut Top Lock 18--- 8 St. St. (Stainless Steel) 3/8 146 --- 95--- 115

21 P l u g S o l i d B l a c k S q u a r e H e a d 1 --- 1 / 4 --- i n . ( N o t S h o w n ) 1395002

22 400_ Black Silicone Rubber Adhesive Sealant (Not Shown) 146--- 06 --- 020

A01039

BW4 / BW5

23

2

3

1

1

10

11

1

12

1

1

4

8

1

1

4
1

1
1

6
2

7
2

5
1

A01040

ITEM DESCRIPTION PART NUMBER

BW4 / BW5

1 Section Machined Front 403–00–006
2 Stud TFL (Threaded Full Length) 3/8–16--in. X 2–1/2--in. 146–95–125
3 Whizlok Nut ZP (Zinc Plated) 3/8 146–95–126
4 Insulation Swing Door (Gemoclite Vacuum Formed Ceramic Fiber 2300°) 146–14–014
5 Hinge Machined 403–00–010
6 Rivet RD (Round) HD (Head) Separated Flange ZP 3/8 --in. X 1--in. 146–95–121
7 Bolt Hex (head) Separated Flange ZP (Zinc Plated) 1/4--in. X 2 --in. 146–95–124
8 Cut Rope FiberFrax Round Braid 3/8--in. X 48 --in. 433–00–905

9 Fire Door Wing Machined 403–00–009
10 Observation Door Machined 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

Electrodes for V1 Head (5 section only) 146–19–105

Electrodes for F Head (3 and 4 section only) 146–19–104

Burner Motor RP --015.00

Fuel Pump RP04501

Oil Solenoid Valve RP04601

Ignitor or Ignition Transformer RP02001

Oil Primary Control 7184B RY00701

Oil Burner Head, F--0 1050003
Oil Burner Head, F--3 1050002
Oil Burner Head, F--6 1050004
Oil Burner Head, V-- 1 Not Stocked--Order from Beckett

Burner Mounting Gasket 14619106

Cad Cell 14662085
Oil Burner, 3 section 146--19--355
Oil Burner, 4 section 146--19--356
Oil Burner, 5 section 146--19--357

24

Table 12 – Riello Oil Burner Service Parts

RIELLO OIL BURNER REPAIR P ARTS

Oil Burner Repair Parts--- Burner Not Shown Part Number

Burner Motor 30A065101
Fuel Pump * 30A065401

Oil Solenoid Coil * * 30A064901

Oil Primary Control 530SE 30A064801

Electrodes 30A065301

Photo Cell 30A065701
Oil Burner, 3 section 1050006
Oil Burner, 4 section 1050006
Oil Burner, 5 section 14619011

O---Ring Pump Press 30A065601

Electric Air Shutter C7001082

Capacitor 12.5uF 30A065201

Pump Drive Key 30A064701

3

XXX

2
1

1

XXX

4Section

Part Number

5Section

Part Number

Item

Description

5
1

6
4

4

XXX

8
4

7

21

9b
4

3Section

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 Panel Upper Front Empire II 42570267AB 42570267AB 42570267AB
6 Acorn Nut --- 5/16” 146 --- 95 ---042 146 --- 95 - -- 042 146---95 --- 042
7 #14 Jacket Screw 146--- 95--- 074 146 --- 95--- 074 146--- 95--- 074
8 S t a n d --- O f f 146--- 95 --- 103 146 ---95 --- 103 146--- 95 --- 103
9 Panel, Lower Front Empire II 42570268AB 42570268AB 42570268AB

BW4 / BW5

A01042

25

FRONT PANEL

JACKET TOP

BOILER SUPPLY
OPENING

COLLECTOR OPENING

TRIDICATOR OPENING

OPENING FOR OPTIONAL
EXPANSION TANK OR AIR
ELIMINATOR

STAND_OFF

ACORN NUT

JACKET SCREW

LOWER FRONT PANEL
SHOWN HERE FOR CLARITY

LEFT SIDE PANEL

BACK PANEL

BW4 / BW5

RIGHT SIDE PANEL

A01041

Fig. 25 -- Jacket Parts

4

2a

(WITHOUT
TANKLESS
COIL)

WATER

OUTLET

7

3a

5

OPTIONAL
TANKLESS

COIL

WATER

HEATER

WITH 1/2” NPT

CONNECTIONS

5a, 5b

2b

(WITH
TANKLESS
COIL)

1

6

FRONT VIEW

RIGHT SIDE VIEW

A02216

ITEM DESCRIPTION 3 SECTION 4 SECTION 5 SECTION

1 Beckett AFG F-- Head oil Burner 146--19--355 146--19--356 ____
1 Beckett AFG Variable Head Oil Burner ____ ____ 146--19 -- 357

1 Riello Oil Burner 1050006 1050006 146 --19 --011
2a L8148A--1124 Aquastat Control (no 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--1/2” Pipe Nipple 146--07--044 146--07--044 146 --07 --044
5b 1--1/4” x 3/4” x 1--1/4” Reducing Tee 1510001 1510001 1510001

6 3/4” Drain Valve 146--22--000 146--22--000 146 -- 22 --000

7 3/4” Relief Valve 146--22--011 146--22--011 146--22-- 011

Fig. 26 -- Repair Parts

Copyright 2006 CAC / B DP D 7310 W. Morris St. D Indianapolis, IN 46231

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Printed in U.S.A. Edition Date: 11/06

C a t a l o g N o : I M --- B W 4 R --- 0 3

Replaces:IM -- B W 4 R -- 0 2

26