NOTE: Read the entire instruction manual before starting the installation.
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1
TABLE OF CONTENTS
SAFETY CONSIDERATIONS.....................................................................................................................................................................................2
INTRODUCTION..........................................................................................................................................................................................................3
Boiler Ratings and Capacities..................................................................................................................................................................................3
Boilers for use at High Altitude.........................................................................................................................................................................3
INSTALLATION...........................................................................................................................................................................................................5
Before Installing the Boiler......................................................................................................................................................................................5
Codes...................................................................................................................................................................................................................5
Boiler Sizing........................................................................................................................................................................................................6
Considerations for Boiler Locations...................................................................................................................................................................6
Locating the Boiler .............................................................................................................................................................................................6
Combustion Air and Vent Pipe Requirements...................................................................................................................................................7
Condensate Drain Requirements ........................................................................................................................................................................7
Foundation Requirements ...................................................................................................................................................................................7
Removal of Existing Boiler from Common Vent System ................................................................................................................................8
Placing the Boiler.....................................................................................................................................................................................................8
Near Boiler Piping....................................................................................................................................................................................................8
Supply and Return Lines ....................................................................................................................................................................................8
Pressure Relief Valve..........................................................................................................................................................................................8
Expansion Tank and Make-Up Water................................................................................................................................................................8
Condensate Drain Piping ....................................................................................................................................................................................9
Filling Condensate Trap with Water..................................................................................................................................................................9
Chilled Water Piping ..........................................................................................................................................................................................9
Combustion Air and Vent Pipe................................................................................................................................................................................9
Connections and Termination.............................................................................................................................................................................9
Installation.........................................................................................................................................................................................................11
Concentric Vent Installation ..................................................................................................................................................................................12
Concentric Vent/Air Termination Kit ..............................................................................................................................................................13
Gas Supply Piping..................................................................................................................................................................................................15
Connecting the Gas Piping...............................................................................................................................................................................16
Checking the Gas Piping ..................................................................................................................................................................................17
Electrical Wiring ....................................................................................................................................................................................................17
Electrical Power Supply....................................................................................................................................................................................17
Install Your Thermostat....................................................................................................................................................................................19
Connect Circulator Pump Wiring.....................................................................................................................................................................19
Controls and Accessories.......................................................................................................................................................................................19
Intergrated Boiler Control (IBC)......................................................................................................................................................................19
Gas Control Valve ............................................................................................................................................................................................19
Hot Surface Ignitor ...........................................................................................................................................................................................19
CERTIFIED
ama
ASME
®
Installation, Start-up, and Operating Instructions
BW9
Gas-Fired Direct Vent Condensing
Hot Water Boiler
Sizes 50,000 through 100,000
Series A
Form: IM-BW9A-03 Cancels: IM-BW9A-02 Printed in U.S.A. 8-03 Catalog No. 63BW-9A4
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