Carrier BW4, BW5, BW4AAH000120AAAA, BW4AAH000181AAAA, BW4AAH000239AAAA Installation, Start-up, And Operating Instructions Manual

Installation, Start-Up, and Operating Instructions

Oil-Fired
Cast Iron Hot Water Boilers

BW4
BW5

Sizes 74,000 through 239,000
Series A

ama

ASME

NOTE: Read the entire instruction manual before starting the installation. These instructions must be affixed on or adjacent to the boiler.
This symbol → indicates a change since the last issue.

MODEL BW4/BW5

®

Form: IM-BW4A-03 Cancels: IM-BW4A-02 Printed in U.S.A. 5-98 Catalog No. 63BW-4A0

A88177

INDEX

Page

SAFETY CONSIDERATIONS.....................................................................................................................................................................................3

INTRODUCTION..........................................................................................................................................................................................................3

BOILER RATINGS AND CAPACITIES.....................................................................................................................................................................4

Explanation of Model Numbers and Rating Plate...................................................................................................................................................4

General Information..................................................................................................................................................................................................4

LOCATING THE BOILER...........................................................................................................................................................................................5

INSTALLATION REQUIREMENTS...........................................................................................................................................................................6

FRESH AIR FOR COMBUSTION ...........................................................................................................................................................................6-7

Boiler Located in Unconfined Space.......................................................................................................................................................................6

Boiler Located in Confined Space........................................................................................................................................................................6-7

BOILERS WITH TANKLESS HEATER COIL..........................................................................................................................................................8

Mounting Aquastat Control......................................................................................................................................................................................8

Tankless Coil Piping.................................................................................................................................................................................................8

INSTALLATION—SYSTEM PIPING......................................................................................................................................................................8-9

CHIMNEY AND CHIMNEY CONNECTION.....................................................................................................................................................10-11

Checking Chimney..................................................................................................................................................................................................10

Chimney Connector and Draft Regulator..............................................................................................................................................................10

Minimum Vent Pipe Clearance..............................................................................................................................................................................10

Optional Power Venting.........................................................................................................................................................................................10

ELECTRICAL WIRING........................................................................................................................................................................................12-14

Installing Thermostat (Not Provided) ....................................................................................................................................................................12

Grounding................................................................................................................................................................................................................12

Electric Power Supply............................................................................................................................................................................................12

Connecting 115-v Electric Wiring to Boiler..........................................................................................................................................................12

Thermostat Connections .........................................................................................................................................................................................12

Thermostat Heat Anticipator Adjustment..............................................................................................................................................................12

Wiring Diagrams ...............................................................................................................................................................................................13-14

EQUIPMENT AND OPTIONAL ACCESSORIES....................................................................................................................................................15

Relief Valve (Provided)..........................................................................................................................................................................................15

Expansion Tank (Not Provided).............................................................................................................................................................................15

Diaphragm-Type Expansion Tank (Not Provided)................................................................................................................................................15

Air Eliminating Fitting (Air Purger) (Not Provided)............................................................................................................................................15

Main Air Vent for Downflow Systems or Diaphragm-Type Expansion Tank (Not Provided) ..........................................................................15

Aquastat Relay Control (Provided)........................................................................................................................................................................15

Automatic Fill Valve (Not Provided) ....................................................................................................................................................................15

Drain Valve (Provided) ..........................................................................................................................................................................................15

Circulating Pump (Provided)..................................................................................................................................................................................15

FILLING BOILER..................................................................................................................................................................................................15-16

How a Hot-Water System Operates.......................................................................................................................................................................15

Filling System with Water................................................................................................................................................................................15-16

OPERATING BOILER ..........................................................................................................................................................................................16-18

To Start....................................................................................................................................................................................................................16

Fuel Units and Oil Lines........................................................................................................................................................................................16

Air Supply for Combustion....................................................................................................................................................................................16

Draft Regulators (Provided) ...................................................................................................................................................................................16

Nozzles (Provided)..................................................................................................................................................................................................16

Final Burner Adjustments.......................................................................................................................................................................................16

Oil Burner Maintenance....................................................................................................................................................................................16-18

CHECKING AND ADJUSTING CONTROLS..........................................................................................................................................................18

Adjusting Operating Controls.................................................................................................................................................................................18

Checking Thermostat Operation.............................................................................................................................................................................18

MAINTENANCE....................................................................................................................................................................................................18-19

Relief Valve............................................................................................................................................................................................................18

Expansion Tank ......................................................................................................................................................................................................19

Water System..........................................................................................................................................................................................................19

Tankless Coil (or Cover Plate) Gasket..................................................................................................................................................................19

OIL BOILER/BURNER CLEANING INSTRUCTIONS.....................................................................................................................................19-20

SEQUENCE OF OPERATION—BOILER WITH COIL.....................................................................................................................................20-21

High Limit Controller.............................................................................................................................................................................................20

Low Limit and Circulator Controller.....................................................................................................................................................................20

SERVICE HINTS ........................................................................................................................................................................................................21

REPAIR PARTS.....................................................................................................................................................................................................22-24

—2—

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, and CAUTION. These words are used with 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 would 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.

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.

WARNING: 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. A failure to adhere to this warning can cause a fire, explosion,
physical injury, or death.

WARNING: 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.

INTRODUCTION

Check to be sure boiler size is correct before starting installation. See rating and capacity table shown in Fig. 1. 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 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: 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.
Failure to follow this warning could result in electrical shock, fire, personal injury, or death.

—3—

36″

GAGE

BOILER RATINGS AND CAPACITIES

1

1

⁄4 IN. SUPPLY

AQUASTAT
CONTROL
(WITHOUT COIL)

AQUASTAT
CONTROL
(WITH COIL)

1

⁄4 IN. 

1
RETURN

C B

TANKLESS
HEATER

1

⁄2 IN. N.P.T.

3

⁄4 IN.
ASME
RELIEF 
VALVE

19 5⁄8″

9″

A

FRONT SIDE REAR

A96152

Oil-Fired Hot Water Boiler Ratings

NET

MBH

MAXIMUM

FIRING

RATE

GPH

BOILER MODEL NUMBER

Without

Tankless Coil

BW4AAH000120AAAA BW5AAH000120AAAA

BW4AAH000181AAAA BW5AAH000181AAAA

BW4AAH000239AAAA BW5AAH000239AAAA

* Heating Capacity is based on a 13 percent CO2with a -0.02 in. wc draft over fire and a #1 smoke or less. The testing on boilers was done in accordance with the

Department of Energy (DOE) test procedure.
MBH—1000 Btuh (British Thermal Unit Per Hr)
GPH—Gallons per hour oil at 140,000 BTU per gallon

PROCEDURE 1—EXPLANATION OF MODEL NUMBERS AND RATING PLATE

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

Each model number has 3 possible firing rates depending on which nozzle is installed. The model number represents the largest possible output
for the unit. For example, a BW4AAH120AAAA has a maximum output of 120,000 Btuh. The rating plate for each model shows the three possible
firing rates. Boilers come shipped with the largest nozzle installed. By changing nozzles, the BW4AAH120AAAA firing rate can be changed to
92,000 or 74,000 Btuh output.

PROCEDURE 2—GENERAL INFORMATION

Selection of boiler size should be based upon "Net I=B=R Rating MBH" being equal to or greater than calculated heat loss of building.
The Net I=B=R Ratings shown are based on an allowance of 1.15 in accordance with factors in the I=B=R Standard as published by The Hydronics

Institute.
These boilers are low-pressure, sectional cast iron boilers constructed and hydrostatically tested for a maximum working pressure of 50 psi in

accordance with the American Society of Mechanical Engineers (A.S.M.E.) Section IV Standards for cast iron heating boilers. They are capacity
rated in accordance with the code of the Hydronics Institute.

Shaded areas are as shipped.

With

Tankless Coil

Fig. 1—Dimensional Drawing and Boiler Ratings and Capacities

NO. OF

SECTIONS

3 84 74 64 0.60 8 X 8 15 17-3/4 6 9-3/4
3 105 92 80 0.75 8 X 8 15 17-3/4 6 9-3/4

3 140 120 104 1.00 8X8 15 17-3/4 6 9-3/4
4 126 111 97 0.90 8 X 8 15 21 6 11-3/8
4 175 153 133 1.25 8 X 8 15 21 6 11-3/8

4 210 181 157 1.50 8X8 15 21 6 11-3/8
5 168 147 128 1.20 8 X 8 15 24-1/4 6 13
5 245 210 183 1.75 8 X 8 15 24-1/4 6 13

5 280 239 209 2.00 8X8 20 24-1/4 6 13

INPUT

MBH

HEATING

CAPACITY

MBH*

I=B=R

RATING

TYPICAL

CHIMNEY

Area

Height

(In.)

(Ft)

DIMENSIONS

(IN.)

ABC

—4—

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-in. 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. 2 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″ MIN

24″ MIN

BOILER

FRONT

6″ MIN

18″ WITH COIL

6″

A95592

Fig. 2—Minimum Clearance Dimensions

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. Ventilating 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.

—5—

INSTALLATION REQUIREMENTS

Refer to Fig. 3 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.

2 IN. FILL PIPE

VENT PIPE

MINIMUM 2 IN. ID

SHUTOFF

VALVE

OIL

FILTER

ENTRANCE

OIL

TANK

SERVICE LINE

SWITCH

FOUNDATIONS

OIL LINES

ELECTRIC LINE

OVERCURRENT
PROTECTED
SAFETY SWITCH

LINES TO OTHER
APPLIANCES

TO OUTSIDE

OIL BURNER

AUTOMATIC
FILL VALVE
AND SHUTOFF

DIAPHRAGM
EXPANSION TANK

DRAFT

REGULATOR

VENT PIPE

RELIEF VALVE

TO RADIATION

FROM RADIATION

CIRCULATING
PUMP IN
RETURN LINE

→ Fig. 3—General Principal Requirements for a Typical Installation

FRESH AIR FOR COMBUSTION

C
H

I
M
N
E
Y

A98268

WARNING: 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. Failure to follow this warning can cause a fire,
personal injury, or death.

CAUTION: 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.
Excessive exposure to contaminated combustion air will result in safety and performance related problems.

CAUTION: 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.

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.

PROCEDURE 1—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.

PROCEDURE 2—BOILER LOCATED IN CONFINED SPACE
A. 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. 4.)

—6—

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. 4 shows grille locations.

VENTILATING

GRILLE

COMBUSTION
AIR GRILLE

A95594

Fig. 4—Air Openings for Closet or Utility Room Installations

B. 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.

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.

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.

Table 1—Fresh Air Duct Capacities for Ducts Supplying

Fresh Air to Boiler in Tightly Constructed Houses (Btuh)*

FRESH AIR

DUCT SIZE (IN.)

3X12 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

* Based on opening covered by 1/4-in. mesh screen, wood louvers, or metal
louvers.

1/4-IN. MESH

SCREEN

WOOD

LOUVERS

FRESH AIR
DUCT

METAL

LOUVERS

BOILER

A95595

Fig. 5—Fresh Air Duct for Tightly Sealed House

—7—

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 coil provides a flow of hot water for domestic

use if proper burner and water supply line controls are used.

IMPORTANT: Do not use a tankless coil if water is excessively hard with lime or other deposits which will accumulate inside coil.
PROCEDURE 1—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 burner respond more quickly to a call for domestic hot water.

The boiler is completely wired according to schematic wiring diagram. (See Fig. 13.) The installer must mount the L8124C Aquastat on control
well in 3/4-in. tapping on tankless coil. (See Fig. 6.)

PROCEDURE 2—TANKLESS COIL PIPING

Piping is as shown in Fig. 7. A tempering valve (mixing valve) is recommended.

UNTEMPERED

HOT WATER

(TO AUTOMATIC

DISHWASHER, ETC.)

TANKLESS COIL

OUT

CENTER LINE
OF COLD TAP

IN

TEMPERED

HOT WATER

8 IN. TO

IN

⁄2 IN. NPT

3



⁄4 IN. NPT



CONTROL WELL

1

Fig. 6—Tankless Heater Coil

LIMIT

CONTROL

A95596

→ Fig. 7—Recommended Piping with Tankless Heater Coil

12 IN.

TEMPERING
VALVE

COLD WATER

INLET

SHUTOFF

VALVE

A98269

INSTALLATION—SYSTEM PIPING

1. Place boiler in selected location as close to flue as possible. (See Fig. 3.) Boiler is shipped assembled. Only the factory-supplied relief valve
need 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 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 supply and return lines to boiler. Both supply and return lines should be piped to the 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. 8, 9, and 10.)

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 shall be installed so that chilled medium is piped in parallel with the heating boiler
with appropriate valves to prevent chilled medium from entering the heating boiler. (See Fig. 10.)

—8—

TO ZONE 2

SUPPLY MAIN

ELL

MAIN AIR VENT

AIR PURGER

SUPPLY MAIN

Fig. 8—Forced Hot Water Typical Piping

FRONT

TO RADIATION

COLD WATER
INLET AND
AUTOMATIC
FILL VALVE

DIAPHRAGM-TYPE
EXPANSION TANK

A95598

TO ZONE 1

SUPPLY

MAIN

TEE

FRONT

A95599

Fig. 9—Forced Hot Water Typical Piping with Zone

Control Valves

TO SYSTEM

A

B

C

D

WATER
CHILLER

VALVES C & D
CLOSE FOR HEATING;
OPEN FOR COOLING

VALVES A & B
OPEN FOR HEATING;
CLOSE FOR COOLING

Fig. 10—Piping Arrangements for Boiler When Used in Connection with Refrigeration System

A96153

—9—

CHIMNEY AND CHIMNEY CONNECTION

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

PROCEDURE 1—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.

It is cheaper to rebuild a poor chimney that to pay excessive fuel bills. If chimney is an old masonry chimney, a new steel liner or a new
prefabricated chimney may be the best solution.

Table 2 shows recommended minimum chimney sizes based on Table 3 and Fig. 6 of the I=B=R Testing and Rating Standard for Heating Boilers,
Sixth Edition, June 1989.

Table 2—Recommended Minimum Chimney Sizes

FIRING RATE

(GPH)

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

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

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

For elevations above 2000 ft above sea level, add 3 ft to chimney heights. (See Fig. 11.)

For additional chimney design and sizing information, consult the ASHRAE 1996 HVAC System and Applications Handbook, Chapter 30,

→

CHIMNEY HEIGHT

(FT)

NOMINAL CHIMNEY

AREA

(IN.)

ROUND LINER-

INSIDE DIAMETER

(IN.)

SQUARE LINER-

INSIDE DIMENSIONS

(IN.)

Chimney, Gas Vent and Fireplace Systems; or the National Standard for Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances,
ANSI/NFPA 211.

PROCEDURE 2—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 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. 11.)

Install chimney connector as follows:

1. Start at boiler with a vertical pipe 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 2 sheet metal screws.

6. Support every second section with a stovepipe wire.

PROCEDURE 3—MINIMUM VENT PIPE CLEARANCE

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

PROCEDURE 4—OPTIONAL POWER VENTING

These boilers are ETL listed for sidewall venting with Field Controls Company Model SWG-6 Power Venter and Model CK-62 Control Kit,
eliminating the need for a chimney. Confirm that this option is allowed by local codes before installing. Follow Field’s instructions included with
power venter and control kit. Electrical wiring diagrams for power venting are shown in Fig. 14 and 15.

When sidewall venting, flue gases must be vented to a point in relation to the prevailing wind so that they may freely disperse without being blown

→

back at the building causing discoloration, or into the building through nearby doors or windows causing odors. Also, under certain conditions,
flue gases condense, forming moisture. In such cases, steps should be taken to prevent building materials at vent terminal from being damaged
by exhausted flue gas.

—10—

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.

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. 11—Typical Chimney Requirements

VANE

BALANCED

WEIGHT

CRIMPED

END

ALTERNATE POSITIONS

TOP

TOP

A95601

—11—

ELECTRICAL WIRING

See Fig. 13-15 for wiring diagrams for the various models.

PROCEDURE 1—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.

PROCEDURE 2—GROUNDING

Permanently ground boiler according to local codes and 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.

PROCEDURE 3—ELECTRIC POWER SUPPLY

WARNING: Turn off electric power at fuse box before making any line voltage connections. Follow local electric

codes. Failure to follow this warning could result in electrical shock, personal injury, or death.

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.

PROCEDURE 4—CONNECTING 115-V ELECTRIC WIRING TO BOILER

Connect 115-v electric supply wires to terminals L1 and L2 on aquastat relay. (See Fig. 12.)

115V 60 CYCLE

NH

SUPPLY

24 VOLT
THERMOSTAT

TO

115V

SUPPLY

AQUASTAT

RELAY

L2 T T

L1

Fig. 12—Wiring Connections to Aquastat Relay

PROCEDURE 5—THERMOSTAT CONNECTIONS
A. Boilers Without Tankless Coil

The 2 wires from thermostat connect to terminals T and T on L8148A aquastat relay.

B. Boilers With Tankless Coil

The 2 wires from thermostat connect to terminals T and T on L8124C aquastat relay.

PROCEDURE 6—THERMOSTAT HEAT ANTICIPATOR ADJUSTMENT

Set heat anticipator at 0.2 amps.

TO
24V
THERM

A95602

—12—

120V
POWER
SUPPLY

FIELD WIRING

NEUT

HOT

OVERCURRENT

PROTECTED

DISCONNECT

COLOR CODE

BK-BLACK
O-ORANGE
Y-YELLOW
R-RED
W-WHITE

BK W

L1

B2 C2

CIRCULATOR
PUMP

24 VOLT THERMOSTAT

L2 T T

C1 ZC

R

ZR B1

W

BK

R

BK

IGNITION
TRANSFORMER

T T

1K

L8124C

INTERNAL

WIRING

1K2

L8124C

AQUASTAT

BK

W

BK

LOW LIMIT/

CIRCULATOR

B

R

A

BK

R4184

W

RELAY

O

OIL BURNER
MOTOR

BRW

1K1
ZR
ZC

HIGH LIMIT

C1
C2

BOILER WITHOUT TANKLESS HEATER COILBOILER WITH TANKLESS HEATER COIL

COLOR CODE

120/60/1 OVERCURRENT PROTECTED DISCONNECT

LINE

NEUTRAL

24 V THERMOSTAT

FIELD WIRING

TTL2L1

L8148A

CAD CELL

Y

F
F

Y

G

AQUASTAT

3

B
R

B2B1C2C1

B

G

GND

L1

L1
(HOT)

L2

L2

CIRCULATOR

W

BW

W

B

W

O

B

B

R4184D

RELAY

B

B1
B2

L1

JUMPER

3TT

B

1K1

1K 1K2

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

IGN
TRANS

F
F

R

LINE
VOLTAGE

CLASS II
24 VOLTS

OIL BURNER

MOTOR

Y

CAD
CEL

Y

C1

C2 B2 B1L2

Fig. 13—Wiring Diagrams for Boilers With and Without Tankless Heater Coil

A95610

—13—

L1
L2

120 VAC

PPC-4
N/O

BK

MNL1

WBK

BK

W

120/60/1 OVERCURRENT PROTECTED DISCONNECT

RELAY

CK-KIT
JUNCTION
BOX

T3T2T1

BK

W

SWG POWER
VENTER MOTOR

BK

W

M

WMO-1 SECONDARY
SAFETY SWITCH (SPILL SWITCH)

BK

BK BK

WW

IGNITION
TRANSFORMER

OIL BURNER
MOTOR

NEUT

LINE

BK

R4184
RELAY

O

W

W

F
F

CAD CELL

Y

Y

Fig. 14—Boiler With Tankless Heater Coil

(With Optional Field SWG Power Venter and CK-62 Control Kit)

BK W

L1 L2 T T

C1 ZC

B2

C2 ZR B1

W

W

THERMOSTAT

L8124C
AQUASTAT

BK

W

CIRCULATOR
PUMP

BK

A96154

L1
L2

120 VAC

PPC-4
N/O

WBK

BK

120/60/1 OVERCURRENT PROTECTED DISCONNECT

RELAY

CK-KIT
JUNCTION

MNL1

W

BK

W

W

T3T2T1

BK

SWG POWER
VENTER MOTOR

BK

M

BOX

WMO-1 SECONDARY
SAFETY SWITCH (SPILL SWITCH)

BK

BKBK

WW

IGNITION
TRANSFORMER

OIL BURNER
MOTOR

NEUT

LINE

BK

R4184
RELAY

O

W

W

CIRCULATOR
PUMP

CAD CELL

Y

F
F

Y

BK

BK W

G L1 L2

3

C1

C2 B1 B2

W

B
R

T T

BK W

THERMOSTAT

L8148A
AQUASTAT

A96155

Fig. 15—Boiler Without Tankless Heater Coil

(With Optional Field SWG Power Venter and CK-62 Control Kit)

—14—

EQUIPMENT AND OPTIONAL ACCESSORIES

PROCEDURE 1—RELIEF VALVE (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.

PROCEDURE 2—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

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
air in system. This air would cause gurgling in pipes and inefficient circulation in radiators if left in system.

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).

PROCEDURE 3—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

to expand as temperature changes.
The diaphragm-type tank can be mounted on air purger fitting or at any other convenient place in supply or return line.

PROCEDURE 4—AIR-ELIMINATING FITTING (AIR PURGER) (NOT PROVIDED)

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.

PROCEDURE 5—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.

PROCEDURE 6—AQUASTAT RELAY CONTROL (PROVIDED)

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

PROCEDURE 7—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.

PROCEDURE 8—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.

PROCEDURE 9—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.
This pump must have the capacity to provide circulation required by system. The pump is connected into return main just ahead of boiler. It is
also wired to electrical system.

PROCEDURE 1—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.

PROCEDURE 2—FILLING SYSTEM WITH WATER

To fill:

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.

FILLING BOILER

—15—

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.

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

OPERATING BOILER

CAUTION: Do not tamper with the unit or controls.

IMPORTANT: Follow these instructions carefully.
PROCEDURE 1—TO START

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

PROCEDURE 2—FUEL UNITS AND OIL LINES

The oil burner is provided with a single-stage 3450 RPM fuel unit with by-pass plug removed for a single-pipe installation. This is satisfactory
where fuel supply is on same level or above burner, permitting gravity flow of oil. Never exceed 3 psi pressure to suction side of fuel unit. A
pressure over 3 psi may cause damage to shaft seat and allow it to leak oil. When it is necessary to lift oil to burner, a return line should run between
fuel unit and oil supply. If lift exceeds 10 ft, a 2-stage fuel unit must be used with a return line. When a 2-line installation is made, by-pass plug
must be installed. This is supplied with burner attached to fuel unit along with a fuel pump data sheet in a plastic bag. When oil lines are installed,
continuous runs of heavy wall copper tubing is recommended. Be sure that all connections are absolutely airtight. Check all connections and joints.
Flared fittings are recommended. Do not use compression fittings. See pump data sheet for sizing, lift, and length of tubing recommendations. Use
an oil filter of adequate size for all installations. Install inside building between tank shutoff valve and burner. For ease of servicing, locate shutoff
valve and filter near burner.

PROCEDURE 3—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.

PROCEDURE 4—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.

PROCEDURE 5—NOZZLES (PROVIDED)

Use the proper size, type, and spray pattern nozzle. 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. 16-20.)

PROCEDURE 6—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. 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 CO
point. Increase air sufficiently to reduce CO

by 0.5 to 1 percent as an insurance margin. Smoke should be zero. If a clean fire cannot be obtained,

2

at this

2

it will be necessary to verify head and electrode alignment. (See Fig. 16-20.) If fire is still smokey, 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.

PROCEDURE 7—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.

—16—

DIMENSION "H"

SEE BELOW

5

⁄32″

ELECTRODE

GAP

5

⁄16″ ABOVE

NOZZLE

L1 OR V1

HEAD

DIMENSION "N"
SEE BELOW

UNIT

SIZE

HEAD

DIMENSIONS (IN.)

N H (Head to Nozzle)

120 L1 1/16 7/32 to 9/32
181
239

V1 1/16 7/32 to 9/32

Fig. 16—Beckett Burner Electrode Adjustments

(For L1 or V1 Heads)

5 11⁄16″

5 1⁄16″

1 3⁄8″

A95603

DIMENSION "Z"

1 3⁄4″ ± 1⁄32″

WITNESS

MARK

LOCATION OF HEAD
AT "0" POSITION
ON ADJUSTING PLATE

PRIMARY
ADJUSTING
PLATE

SECONDARY
ADJUSTING
PLATE

KNURLED

"V1" ADJUSTABLE

NUT

HEAD

"MD" AIR

TUBE COMBINATION

HOLD DOWN

ACORN NUT/
LOCK WASHER

SCREW

Fig. 17—Beckett Burner Setting Variable (V1) Head

5 13⁄16″

5 7⁄32″

1 3⁄4″

A95604

1 5⁄8″

5 15⁄32″

1

6

⁄2″

Fig. 18—Beckett Burner Fixed Head Dimensional

Relationships for 120 Size Unit

Fig. 20—Beckett AFII Burner Electrode Adjustments

A95605

3

⁄32″ ± 1⁄32″

5

⁄32″ ± 1⁄32″

—17—

1 5⁄8″

4 15⁄32″

1

6

⁄2″

A95606

Fig. 19—Beckett Burner Variable Head Dimensional

Relationships for 181 and 239 Size Units

1

⁄8″ ± 1⁄32″

1

⁄4″ ± 1⁄32″

A95607

Table 3—Oil Burner Nozzles

UNIT SIZE UNIT CAPACITY

74,000 0.65-70°-B —

120

181

239

92,000 0.75-70°-A 0.65-70°-B
120,000 1.00-70°-A 0.85-60°-B
111,000 0.90-60°-W 0.75-70°-B
153,000 1.25-70°-B 1.00-70°-B
181,000 1.50-70°-B 1.25-60°-B
147,000 1.20-70°-B —
210,000 1.75-70°-B —
239,000 2.00-70°-B —

DELAVAN NOZZLE TYPE FOR

BECKETT AFG OIL BURNER

OIL PUMP 100 PSI

DELAVAN NOZZLE TYPE FOR

BECKETT AFII OIL BURNER

OIL PUMP 140 PSI

C. Fuel Pump Unit

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

D. Ignition Electrodes

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 3.

F. Fan and Blower Housing

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.

CHECKING AND ADJUSTING CONTROLS

WARNING: Do not attempt to start the burner when excess oil has accumulated, when unit is full of vapor, or when

the combustion chamber is very hot. Failure to follow this warning could result in fire, personal injury, or death.

IMPORTANT: These instructions must be followed carefully.
PROCEDURE 1—ADJUSTING OPERATING CONTROLS

Instructions for each control are included. Refer to Table 4 for recommended settings for the first adjustment:

Table 4—Recommended Operating Control Settings

OPERATING CONTROL CONTROL SETTING
High Limit
Low Limit (When Used) 140°F

Differential (When Used) 10°F

Standing Radiators 180°F

Baseboard and Convectors 200°F

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.

PROCEDURE 2—CHECKING THERMOSTAT OPERATION

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.

Finally, set thermostat for desired temperature. Special conditions in home and location of thermostat will govern this setting.

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

MAINTENANCE

To assure trouble-free operation, we recommend that flue passages, burner, combustion chamber area (target wall and fire door insulation), burner
adjustment, and operation of controls 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.

WARNING: Never burn garbage or paper in the unit, and never leave combustible material around it.

PROCEDURE 1—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. Refer to valve manufacturer’s instructions packaged with relief valve.

—18—

PROCEDURE 2—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.

PROCEDURE 3—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.

PROCEDURE 4—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 BOILER/BURNER CLEANING INSTRUCTIONS

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

2. Remove sheet metal smoke pipe from top of boiler. Inspect pipe and chimney for signs of corrosion and deterioration. Clean base of
chimney.

3. Remove top jacket panel (6 screws). Remove 2 screws holding left side jacket panel to rear jacket panel and separate the 2 panels enough
for side jacket panel to slip off the "Z" bars on collector top.

4. Remove 2 brass wing nuts holding flue collector top. Remove top jacket support bracket and 2 "Z" bars and collector top.

5. Check gasket on underside of flue collector and replace as necessary.

6. Remove lower front jacket panel (4 sheet metal screws and 2 cap nuts).

7. Remove oil burner (3 cap screws).

-OR-

Remove oil burner/fire door assembly (4 hex nuts). This is the recommended method as it allows full access to combustion chamber and
less potential for damage to target wall during cleaning process.

8. Remove burner drawer assembly. Clean any soot accumulations.

9. Replace burner nozzle with exact size and type recommended for use on this boiler.

NOTE: Changing to a different firing rate (other than is recommended) or type of nozzle may change performance of boiler and/or cause a
hazardous condition.

10. Clean electrode assembly and set electrodes as per manufacturer’s recommendations. (See Fig. 16 and 20.)

11. Reinstall drawer assembly and check for proper head location as per manufacturer’s recommendations. (See Fig. 17, 18, and 19.)

12. Inspect target wall and fire door insulation for cracking and deterioration. If there is any sign of cracking or deterioration, replace before
reassembling boiler.

13. Remove soot from fireside surfaces by brushing diagonally through flue passages. (See Fig. 21.) Care should be taken so as not to damage
target wall with flue brush.

A95609

Fig. 21—Removing Soot

—19—

14. Carefully vacuum soot accumulations from combustion chamber area being particularly careful not to damage target wall with vacuum.

15. Reinstall burner/fire door assembly.

16. Reinstall flue collector top, "Z" bars, and top jacket support bracket and secure with 2 brass wing nuts.

17. Hang side jacket panels on "Z" bars and reassemble left side and rear jacket panels. Reinstall top jacket panel. Reconnect flue pipe.

18. Inspect and clean oil burner blower wheel.

19. Oil burner motor. DO NOT OVEROIL.

20. Remove oil pump cover and clean/replace pump screen. Carefully reassemble.

21. Replace fuel filter (if applicable).

22. Reconnect electrical and fuel supplies.

23. Fire burner, checking for proper combustion using combustion test equipment. Make adjustments as necessary. See Final Burner
Adjustments section earlier in this document.

24. Ensure that all safety controls and operating controls are functioning properly.

IMPORTANT OPERATING AND MAINTENANCE REQUIREMENTS KEEP BOILER AND AREA AROUND IT CLEAN

NEVER

BURN REFUSE OR ANY MATERIAL OTHER THAN THE SPECIFIED FUEL IN BOILER HAVE BOILER CHECKED EACH

YEAR BY A

QUALIFIED TECHNICIAN

SEQUENCE OF OPERATION—BOILER WITH COIL

Refer to Fig. 22 and the wiring diagram shown in Fig. 13 while reviewing sequence of operation.

PROCEDURE 1—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.

PROCEDURE 2—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:

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 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 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.

—20—

240 F (116 C)

SWITCH BREAKS ON

HI LIMIT

SETTING

LOW LIMIT

AND

CIRCULATOR

SETTING

10 F (5.6 C)

DIFF

25 F (13.9 C)

DIFF

10 F (5.6 C)

DIFF

110 F (43 C)

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.

Fig. 22—Relationship of Set Points and Differential

SERVICE HINTS

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

A95611

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

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 burner cleaned and readjusted.
Burner may not be firing at proper rate Check nozzle size it there is any doubt. Have burner adjusted.

Short-cycling (too frequent off and on) of burner causes sooting. If boiler and/or burner becomes dirty at

Burner may be short-cycling

No power to boiler 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 be in closed position.
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 dirty 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.

frequent intervals, correct the "dirt condition," then also correct the control setting (or other cause of short­cycling).
Check thermostat heat anticipator and correct setting, if necessary, per instruction sheet packed with thermo­stat.

IF BURNER IS NOISY. . .

IF RADIATORS ARE NOISY. . .

RELIEF VALVE LEAKING. . .

HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.

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.

PARTS LIST

—21—

REPAIR PARTS

→ OIL-FIRED HOT WATER BOILERS

16

8

2

7

6

3

1

4

5

19

8

9

9

Boiler Parts

This is a Repair Parts List—Not a Packing List

KEY

NO.

1 403-00-004 403-00-004 403-00-004 Fire Door
2 403-00-005 403-00-005 403-00-005 Observation Door
* 146-95-006 146-95-006 146-95-006 5/16-in. X 3/8-in. Socket Shoulder Bolt 1/4-20 Thread
* 146-95-007 146-95-007 146-95-007 5/16-in. Lock Washer
3 146-14-015 146-14-015 146-14-015 Fire Door Insulation
4 146-19-003 146-19-003 146-19-003 Target Wall

5 146-19-021 146-19-021 146-19-021 Jacket Support Spacers (2 required)
6A 146-95-043 146-95-043 146-95-043 5/16-in.-18 X 2 1/4-in. Stud (4 required)
6B 146-19-014 146-19-014 146-19-014 3/4-in. Spacer (4 required)
6C 146-95-013 146-95-013 146-95-013 5/16-in.-18 Hex Nuts (4 required)

7 403-00-001 403-00-001 403-00-001 Front Section

8 403-00-002 403-00-002 403-00-002 Intermediate Section

9 433-00-976 433-00-976 433-00-976 2-in. Nipples†

10 403-00-003 403-00-003 403-00-003 Rear Section
11 425-00-276 425-00-277 425-00-278 Collector Flue
12 146-93-064 146-93-064 146-93-064 Gasket
13 146-27-020 146-27-020 146-27-020 Tankless Heater Coil
14 146-19-001 146-19-001 146-19-001 Tankless Heater Cover Plate
15 146-95-105 146-95-105 146-95-105 3/8-in.-16 X 3/4-in. Hex Head Cap Screw (10)

15A 146-95-113 146-95-113 146-95-113 3/8-in.-16 X 1 1/2-in. Stainless Steel Studs (10 req’d)

15B 146-95-114 146-95-114 146-95-114 3/8-in. Stainless Steel Flat Washer (10 req’d)

15C 146-95-115 146-95-115 146-95-115 3/8-in.-16 Stainless Steel Top Lock Nut (10 req’d)

* 433-60-408 433-60-408 433-60-408 Replacement Coil Kit (Includes 12, 13, and 15)

16 425-00-226 425-00-226 425-00-226 Jacket Support Bracket
17 137-04-007 137-04-007 137-04-007 No. 8-32 Brass Wing Nuts (2 required)

18 403-00-301 403-00-401 403-00-501
19 146-05-002 146-05-051 146-05-053 1/4-in. Tie Rods (2 required)

* 146-95-042 146-95-042 146-95-042 5/16-in.-18 Acorn Cap Nuts (2 required)

* Not illustrated.
† Four are required for first intermediate replacement section and 2 for each additional section.

3 Section 4 Section 5 Section

PART NO.

17

11

9

10

12

18 BLOCK ASSEMBLY

DESCRIPTION

Block Assembly (Includes 1, 2, 3, 4, 6, 7, 8, 9, and

10)

13

15

14

A96157

—22—

REPAIR PARTS

OIL-FIRED HOT WATER BOILERS

7

2

1

6

3

4

KEY

NO.

1 425-00-271 425-00-271 425-00-271 Back Panel
2 425-00-251 425-00-252 425-00-253 Top Panel
3 425-00-241 425-00-242 425-00-243 Right Side Panel
4 425-00-270 425-00-270 425-00-270 Upper Front Panel
5 425-00-272 425-00-272 425-00-272 Lower Front Panel
6 425-00-261 425-00-262 425-00-263 Left Side Panel
7 425-00-273 425-00-273 425-00-273 Z-Bars
* 146-95-074 146-95-074 146-95-074 No. 10 X 1/2-in. Sheet Metal Screw
* 425-00-286 425-00-287 425-00-288 Complete Jacket

* Not illustrated.

This is a Repair Parts List—Not a Packing List

Flush Jacket Parts

PART NO.

3 Section 4 Section 5 Section

5

A95613

DESCRIPTION

—23—

REPAIR PARTS

OIL-FIRED HOT WATER BOILERS

3

4

2A

2B

1

Controls

KEY

NO.

1 146-19-012 146-19-013 146-19-013 Beckett AFG Oil Burner, Primary Control and Cad Cell
1 146-19-026 146-19-026 — Beckett AF-II Oil Burner, Primary Control and Cad Cell
* 146-95-101 146-95-101 146-95-101 5/16-in. X 1-1/4-in. Stud (3 required)

* 146-95-001 146-95-001 146-95-001 5/16-in.-18 Flange Nut (3 required)
2A 433-00-521 433-00-521 433-00-521 Aquastat Control without Tankless Heater
2B 146-62-022 146-62-022 146-62-022 Aquastat Control with Tankless Heater

3 146-23-003 146-23-003 146-23-003 Gage

4 146-26-047 146-26-047 146-26-047 Circulator

* 146-22-011 146-22-011 146-22-011 Relief Valve

* 146-20-007 146-20-007 146-20-007 Barometric Draft Control

* 146-22-000 146-22-000 146-22-000 Drain Valve

* 146-55-003 146-55-003 146-55-003 Flue Brush

* 433-00-814 433-00-814 433-00-814 SWG-6/CK-62 Power Venter Kit

* Not illustrated.

3 Section 4 Section 5 Section

PART NO.

DESCRIPTION

A96156

© 1998 CAC/BDP P.O. Box 70, Indianapolis, IN 46206 imbw4a03

—24—

Catalog No. 63BW-4A0