Granby BKC User manual

GRANBY CAST IRON SERIES
OIL-FIRED HOT WATER BOILER
BKC
Installation, Operation and
Maintenance Manual
INSTALLATIONS MUST MEET ALL LOCAL AND FEDERAL
CODES THAT MAY DIFFER FROM THIS MANUAL
Please read this complete manual before beginning installation. These instructions must be kept with
the boiler for future reference.
GRANBY FURNACES INC
PO Box 637
12118 Hwy 209
Parrsboro Nova Scotia Canada
B0M 1S0
www.GranbyIndustries.com

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TABLE OF CONTENTS
General Instructions 1
Receiving Shipment 2
Clearances for Service & Combustible Materials 2
Combustion Air and Ventilation 3
Air for Combustion 3
Air for Ventilation 3
Combustion Air Supply with No Barometric Damper 3
Boiler Location & Leveling Of Unit 3
Burner Tube Insertion 3
Jacket Assembly 4
Piping 6
General Requirements for Piping Circuits 6
Circulation Pump 7
Controls/General 7
Piping Install Diagrams 7
Wiring 9
General Instructions 10
Typical Wiring Diagrams 10
Venting Requirements 10
Natural Draft Applications 11
Condensation 11
Fuel System 11
Boiler Series Specifications 12
Burner Specifications 13
Start Up Procedure 13
Maintenance and Testing-Serviceman 14
Testing Safety and Control Devices 14
Cleaning Boiler Sections 14
Cleaning Fuel System and Burner 14
Perform Combustion Tests 14
Parts List and Boiler Diagram 15
THE INSTALLATION OF THE EQUIPMENT SHALL BE IN ACCORDANCE WITH THE REGULATION
OF AUTHORITIES HAVING JURISDICTION AND CSA STANDARD B139
THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE AUTHORITIES
HAVING JURISDICTION.
READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE.
NOTICE: All installations must conform to federal, state and local code.

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CAUTION
DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED,
WHEN THE UNIT IS FULL OF VAPOUR OR WHEN THE COMBUSTION CHAMBER IS
VERY HOT. NEVER BURN GARBAGE OR PAPER IN THE UNIT AND NEVER LEAVE
COMBUSTIBLE MATERIAL AROUND IT.
STEPS PRIOR TO INSTALLATION
Before beginning the installation process it is highly recommended that you read this manual
carefully. Your boiler must be installed by a qualified and where required licensed contractor in
accordance with all local codes. When local codes are not in effect the boiler must be installed
in accordance with NFPA 31 and NFPA 211, Standard for installation of Oil Burning Equipment
in the U.S. and CSA B139 in Canada. Failure to have the appliance installed by a qualified
technician in accordance with code may void your warranty.
Before installing the boiler inspect all items supplied by Granby for physical damage. Any
physical damage should be reported to your boiler wholesaler, not Granby. Your package will
include the boiler block, jacket assembly, burner and trim kit assembly including control.
To avoid injury and potential property damage, Granby has identified, in its opinion,
certain potential hazards to health and equipment, which are noted in Bold Face Large
Print announcements labeled CAUTION, WARNING, NOTICE or DANGER. You must pay
particular attention to these announcements.
This manual is presented in a sequence that allows for an orderly trouble free installation. We
suggest that you follow the instructions in order eliminate potential hazards.
Prior to system installation there should be an inspection of the chimney or proposed vent
system to determine that the condition is acceptable. Repair or replace any defects in the
chimney liner. The vent system and installation must be in compliance with all applicable
heating and building codes. Improperly sized vent systems can cause poor burner operation,
sooting, odour or condensation that might create chimney damage. Installation of Barometric
draft controls will insure adequate draft. A minimum draft required at the vent collar is -.01”
W.C.
CLEARANCES
Proper clearances must be maintained not only from combustible materials but also to provide
adequate access for servicing. All installations must comply with local codes and NFPA-31
and NFPA-211 and CSA B139. Consult local fire codes for required clearances. Connections
to chimney must be made with the proper gauge thickness and diameter of fluepipe as
required by NFPA-211 and CSA B139.
CLEARANCE FOR SERVICING Front 24”
Back 24”
Left Side 24”
Right Side 2”
Top 10”

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CLEARANCE TO COMBUSTIBLES Front 24”
Back 24”
Left 24”
Right 2”
Chimney Connector 9”
Top 10”
CAUTION: Adequate air supply for both combustion and ventilation must be available.
COMBUSTION AND VENTILATION AIR
Installations taking place in traditional unconfined settings such as basements generally have
an adequate supply of both combustion and ventilation air.
In situations where the boiler is to be located in a confined space with all combustion and
ventilation air coming from within the building two openings must be made with an adjoining
room with one being near the floor and the other being near the ceiling of the boiler room.
These openings must be clear and free of obstacles and measure at least 140 sq. in. per
gallon of oil burned per hour.
In instances where the air supply for both combustion and ventilation is to come from outside
the building two air openings, one near the floor and one near the ceiling, measuring at least
35 sq. in. for each gallon of oil burned per hour.
If there is no accessible source of air for combustion and ventilation available within the
building, combustion air ducts may be installed to convey the air. Those ducts used to convey
air must have areas of at least 35 sq. in per gallon of oil burned per hour for vertical ducts and
70 sq. in per gallon of oil burned per hour for horizontal ducts. The area of the ducts and
corresponding openings of connected free areas must be equal. The duct must have direct
outside access and be installed with a rain hood and insect screen installed at the outside wall.
This dedicated supply of ducted air should be installed within 5 feet of the boiler.
ALL VENTILLATION REQUIREMENTS SHOULD CONFORM TO LOCAL CODE AND OR
NFPA-31 AND CSA B139.
*NFPA or OEM burner specifications take precedence where required.
PLACEMENT & LEVELING OF THE UNIT
The boiler should be located on a firm foundation in an easily accessible area that meets the
previously discussed clearances and air requirements. In situations where the floor may be
uneven the GC may be leveled by using the leg levelers provided on the boiler or through the
insertion of shims under the legs.
BURNER TUBE INSERTION AND BURNER ATTACHMENT
The insertion of the burner air tube must be back 3” for the Riello burner and 2 ¾” for the
Beckett burner. Attach the burner in accordance with the burner manufacturer’s instructions
provided. Make sure that the burner is level and that all nuts are fully tightened.

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JACKET ASSEMBLY AND CONTROL INSTALLATION
The boiler jacket has been designed for ease of assembly and removal. The following step by
step process will ease installation. A screw driver, 17 mm socket and ratchet or a 17 mm
wrench or adjustable wrench are needed.
STEP 1 VERIFY CONTENTS OF JACKET ASSEMBLY PACKAGE.
Your jacket assembly will contain two (2) manifolds with gaskets, a
fastening package which includes all necessary bolts, screws, nuts
and washers for assembly along with burner studs, nuts and
washers, block insulation, rear of block insulation, aluminum faced
tape, leveling frame rails, two (2) side panels, a rear panel top
panel and re-insulated top and bottom front panels.
STEP 2 FRAME RAIL CONNECTION
Attach 10 mm bolts to the underside of the frame rails. These will be used to level the boiler.
Screw the 4 mm jacket affixing screw to the frame rail from the top down. Both the bolt and
affixing screw will be located on the same end of the frame rail. The frame rail will then be
bolted to the legs of the boiler with the frame rail and containing the affixing screw facing in the
direction of the front end of the boiler.
STEP 3 MANIFOLD INSTALLATION
Using the gaskets and bolts supplied connect the manifolds directly to the boiler block. The
top supply manifold will have a 3/4” npt tapping for a relief valve and 1/4” npt tapping for a
gauge. The bottom return manifold has 3/4” npt tapping for a drain vlave. Both manifolds
have 1-1/4” male npt threads for system connection.

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STEP 4 INSULATION INSTALLATION
Drape the large piece of block insulation directly over the block taking care to provide
adequate clearance from frame rails. Using the aluminum faced tape attach the preshaped
rear inslulation to the block insulation. The process is simply taping the two pieces together.
The front panels come pre-insulated.
STEP 5 SIDE AND BACK PANEL ATTACHMENT
Affix panel mounting nuts to the rear of the tie rods. Mount the side panels by placing the
panel over the frame rail so that the hole in the bottom lip of the panel fits directly over the
jacket affixing screw on the rail. You can then lock the panel in place by sliding it slightly
forward. The slot on the rear of the panel will now be in position to slide over the tie rod at the
rear of the boiler. Tighten the nuts on the tie rod end to firmly secure the panel. Repeat on the
other side. Screw the back panel to the side panels.
STEP 6 CONTROL SENSOR ATTACHMENT
Prior to jacket top and front panel installation the control sensor must be inserted into the brass
well located at the back of the boiler and secured by a clip. Feed the sensor through the hole
on the front of the right side panel from the outside. Penetrate the block insulation to insert the
sensor. The sensor must be fully inserted to the bottom of the well.

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STEP 7 TOP AND FRONT PANEL ATTACHMENT
Affix the top panel by placing the holes located on the underside of the panel over the jacket
affixing pins. Press down on the top panel and it will snap in place. Affix the lower front panel
by placing the openings on the lips of the panel over the jacket affixing screws and pushing
downward on the panel. The panel will lock in place. Repeat the process for the top front
panel.
Upon completion of the jacket assembly the control unit can be mounted on the side of the
boiler. The boiler is now ready for piping and connection to the fuel system, heating and
domestic hot water, thermostat and 110 Volt 60 cycle AC current.
CAUTION: Safety or relief valve discharge should be piped downward to within 6” of the floor
or to a drain. The valve must be mounted in a vertical position.
PIPING
Prior to connecting the BGC to an existing piping system certain procedures must be followed.
The system should be flushed to insure that scale and sludge will not be introduced to the
boiler. This is a must when replacing a gravity open system. The BGC is a low mass boiler
requiring low water content and steps must be taken to insure that the boiler is not flooded
from an existing high volume standing cast iron system. If the conversion is from a high
volume system a bypass loop must be installed. If high pressure testing of the existing system
is necessary make sure the BGC is isolated during the testing. Manual shut off valves must be
installed on both the supply line and on the boiler bypass loop. ASME Boiler Code requires
that feed or make up water be introduced to the piping system and not directly to the boiler.
Pressure reducing valves should be installed and adjusted to 12 psi cold water. The pressure
relief valve must be piped from the boiler and downward to within 6” of the floor or to a height
to meet existing code. An expansion tank, circulating pump and automatic air eliminators must
be part of the system. The relief valve, backflow preventer and drain valve should be piped
according to code to a drain with piping that is the same size as the relief valve.
All piping, including heating, domestic hot water and fuel lines must be done in accordance
with all local codes. It is suggested that you refer to the Water Installation Survey and
Hydronics Institute Residential Hydronic Heating Installation/Design Guide.
All piping must be properly sized, free from defect and be made of copper, steel, brass,
aluminum or PEX.
Test results have shown that the safest operating temperature range for modern boilers
including the BGC is 160°F to 200°F. Allowing the water temperature in the boiler to drop
below 160°F for an extended period of time can cause corrosion and boiler plugging.

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Circulation Pump
A calculation for proper pump selection must be performed for all installations. The pump(s)
should not be operated at maximum working pressures above 30 psi or maximum working
temperatures above 200°F and within limits advised by the manufacturer. The pump must not
be operated unless the system has been bled of all air and completely filled with water.
Recommended locations for the circulator, expansion tank, relief valve and other trim
are shown in Figure 1, Figure 2, Figure 3 and Figure 4.
Controls
The BGC Boiler package includes a aquastat. Based on your personal preference it will either
be a Honeywell L7248, a Hydrolevel Hydrostat Model 3250 or a Beckett Aquasmart model
7600. Wiring diagrams for these controls are similar in the regard that the line Voltage is
applied to L1 and L2 and the burner connection is applied to B1 and B2. Please refer to the
Honeywell wiring diagram included in this manual on Figure 5 as well as diagrams for a priority
indirect application with a Taco SR503 or equivalent. For special control systems such as
outdoor reset, multiple zones, multiple boiler installations, unit heaters, radiant heating etc.
consult the respective manufacturers manual or contact Granby. For controls other than
Honeywell, please refer to the instructions supplied with these controls.
Figure 1
A typical installation with no domestic hot water and no by-pass loop installed.

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Figure 2
A typical installation with no domestic hot water and with a by-pass loop installed. The control
valve should be either a needle or throttling vlave.
Figure 3
A typical installation with domestic hot water supplied by an indirect heater and with a by-pass
loop installed. The control valve should be either a needle or throttling valve.

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Figure 4
A typical installation with domestic hot water supplied by an indirect heater and with no by-
pass loop installed.
WIRING
All external wiring must be performed in compliance with existing electrical codes within the
local jurisdiction. In the United States this is generally the NATIONAL ELECTRICAL CODE,
NFPA70. In Canada the CSA, STANDARD C22-1 and the Canadian Electrical Code.
Connections should be carried out in accordance with this manual and only by qualified
individuals.
•The boiler and burner should only be operated on 120 Vac.
•Field connections should be properly sized and protected with a minimum 15 amp fuse or
circuit breaker.
•A separate fused disconnect must be installed as required by code so that power can be
shut off for servicing.
•The boiler must be ground to the water piping or the main service ground.
•Room thermostats should be installed or relocated away from cold drafts, air currents,
lamps, televisions or sunlight. Set the heat anticipator on the thermostat to match the
operating control. Connect the thermostat leads to the circulation pump operating control
or aquastat as applicable.
The connections must be made in a manner to insure that there is no crossing of the neutral
with the phase, a proper ground is provided and all three wires are connected to the operating
control.