Crown Boiler BWF061, Installation Instructions Manual

Page 1: ...ns must be affixed on or adjacent to the boiler WARNING Improper installa tion adjustment alteration service or maintenance can cause property damage injury or loss of life For assistance or additional information consult a qualified installer service agency or the gas supplier This boiler requires a special venting system Read these instructions carefully before installing Models BWF061 BWF095 BW...

Page 2: ...or Combustion and Ventilation 5 VI Venting 9 Horizontal Vent System Design 9 Vertical Vent System Design 14 Vent System Assembly 18 VII Gas Piping 25 VIII System Piping 26 IX Wiring 31 X Start up and Checkout 36 XI Service and Maintenance 40 XII Troubleshooting Charts 43 XIII Parts 47 Table of Contents ...

Page 3: ... for use in gravity or open heating systems Where an adequate source of clean indoor combustion air cannot be guaranteed use a direct vent boiler such as the Crown CSC series II Specifications BWF061EN 3 61 000 51 000 44 000 83 3 14 1 4 3 2 BWF095EN 4 95 000 78 000 68 000 83 1 17 1 2 4 0 BWF128EN 5 128 000 106 000 92 000 82 8 20 3 4 4 7 BWF162EN 6 162 000 134 000 117 000 82 5 24 5 5 BWF195EN 7 195...

Page 4: ...e the boiler to have either the DOE Heating Capacity required for the Mega Stor or the net rating required for the heating system whichever results in the larger boiler For systems that incorporate other indirect water heaters refer to the indirect water heater manufacturer s instructions for boiler output requirements 4 Make sure that the boiler received is configured for the correct gas natural ...

Page 5: ...bric softeners paints cleaners refrigerants and cat boxes Traces of these chemicals can be drawn into the boiler causing severe corrosion damage to the boiler and or objectionable odors 4 The boiler should be located so as to minimize the length of the vent system while still meeting the requirements in Section VI 5 Do not install this boiler over carpeting 6 Do not install this boiler directly on...

Page 6: ...ruction 1 Determine whether the boiler is to be installed in a confined space A confined space is defined by the National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU hr input of all appliances installed in that space To determine whether the boiler room is a confined space a Total the input of all appliances in the boiler room in thousands of BTU hr Round the result to th...

Page 7: ... outdoors See the instructions under For Buildings of Unusually Tight Construction For Buildings of Unusually Tight Construction a Openings must be installed between the boiler room and the outdoors or a ventilated space such as an attic or crawl space which communicates directly with the outdoors b Two openings are required The top edge of the upper opening must be within 12 inches of the ceiling...

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Page 10: ...N TABLE III STRUCTURE PENETRATION WALL ROOF ROOF MAXIMUM LENGTH BWF061 BWF162 45 FT 1 EL 39 5 FT 2 ELS BWF195 BWF229 using 4 Pipe 45 FT 1 EL 37 FT 2 ELS BWF195 BWF229 using 3 Pipe 30 FT 1 EL 24 5 FT 2 ELS MINIMUM LENGTH BWF061 BWF162 2 FT 1 EL 6 FT 2 ELS BWF195 BWF229 2 FT 1 EL 6 FT 2 ELS NOMINAL DIA BWF061 BWF162 3 3 BWF195 BWF229 3 or 4 3 or 4 BWF061 BWF162 BWF195 BWF229 using 4 Pipe BWF195 BWF2...

Page 11: ...ivalent length from Table 4 for each additional elbow Example A vent system is planned for a BWF162 which has the following components 2 ft vertical pipe 1 90 elbow 5 ft horizontal pipe 1 90 elbow 3 ft horizontal pipe 1 45 elbow 4 ft horizontal pipe 1 termination elbow Since the boiler is a BWF162 all piping must be done in 3 pipe The first 90 degree elbow and the termination elbow are not conside...

Page 12: ...s Wall thimbles are required where the vent pipe passes through combustible walls with less than a 5 clearance Use the appropriate wall thimble shown in Table 5 8 Pitch of horizontal piping A per foot pitch towards the outside is preferred Alternatively the horizontal piping may be pitched per foot towards the boiler however a condensate trap is required See 9 9 Condensate traps In some horizontal...

Page 13: ...fits or overhangs Overhang may not exceed 3 feet Fig 12 Do not use the Tee terminal under an overhang deeper than 6 Terminal must be at least 3 feet from an inside corner Under certain conditions water in the flue gas may condense on the structure in areas around the terminal If these areas are made of materials subject to damage by flue gas condensate they should be protected If possible install ...

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Page 15: ... Systems Use one of these four approved vent systems Flex L International Star 34 Z FLEX SVE SeriesIII Z Vent III Heat Fab Saf T Vent ProTech Systems FasNSeal 3 Vent Pipe Size BWF061 to BWF162 3 BWF195 BWF229 4 TABLE 6 CAPS FOR VERTICAL VENT SYSTEMS VENT MANUFACTURER S PART VENT SYSTEM 3 INCH 4 INCH FLEX L INTL STAR 34 SRRC 03 SRRC 04 Z FLEX SVE SERIES III 2SVSRCF03 2SVSRCF04 HEAT FAB SAF T VENT 5...

Page 16: ...as 13 5 ft of straight pipe the planned vent length is within the maximum limit 5 Minimum Vent Pipe Length 6 ft 2 90 degree elbows cap 6 Permitted Terminals A cap must be used which is compatible with the rest of the vent system See Table 6 for the appropriate cap 7 Condensate traps A condensate trap is required on all vertical venting systems Install this trap as shown in Figure 13 If there are a...

Page 17: ...tions of piping must be properly supported See the Vent System Assembly section of this manual for more information 12 Location of vent cap The lowest discharge opening on the cap must be at least 2 feet above any object located within 10 feet Fig 14 ...

Page 18: ...m speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so the appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has bee...

Page 19: ...ms should not be placed at the bottom of horizontal sections of vent pipe c Do not drill holes in vent pipe d Do not attempt to mix vent components of different vent system manufacturers 2 Vent Collar Installation The vent collar is shipped loose in the accessory bag along with two collar gaskets the outlet orifice and four 10 32 mounting screws Verify that the model number marked on the outlet ex...

Page 20: ...e second pipe into the female end of the first pipe k Insert a StaR joiner band into the inlet of the beaded channel Feed the joiner band in so that it makes its way around the channel and overlaps by approximately Fig 18 l Cut the excess joiner band so that it lays flat in the beaded channel Fig 18 m Fill the inlet of the beaded channel with silicone Smooth the silicone over the channel inlet as ...

Page 21: ...de bead of high temperature silicone approximately inch from the male end of the pipe Apply beads of silicone along both sides of the longitudinal seam Fig 19 e Insert the male end of the pipe into the boiler vent collar until it bottoms out f Apply an additional bead of silicone over the outside of the joint and smooth out Also apply silicone over the seams in the collar Fig 19 g Replace and tigh...

Page 22: ...e end of the terminal On the male end of the pipe apply a wide bead of high temperature silicone approximately inch from the male end of the pipe Apply beads of silicone along both sides of the longitudinal seam Fig 19 Insert this end of the pipe into the terminal connection with at least a 1 overlap It may be necessary to crimp the end of the vent pipe before it can be inserted into the terminal ...

Page 23: ...Apply an additional bead of silicone over the outside of the joint and smooth out Fig 21 Also apply silicone over the seams in the vent collar h Replace and tighten the clamp on the vent collar i Clean the male end of the next piece of pipe Also clean the female end of the first piece of pipe j Apply a bead of silicone around the male end of the second piece of pipe between and 3 8 from the end of...

Page 24: ...d smooth out Fig 23 g Replace and tighten the clamp on the vent collar h All other joints in the FasNSeal venting system rely on a gasket in the female end of the pipe for a proper seal CAUTION MAKE SURE THAT GASKET IS IN POSITION AND UNDAMAGED IN THE FEMALE END OF THE PIPE MAKE SURE THAT BOTH THE MALE AND FEMALE PIPES ARE FREE OF DAMAGE PRIOR TO ASSEMBLY IF 3 PIPE IS CUT CUT END MUST BE SQUARE AN...

Page 25: ...sNSeal pipe n Allow the silicone to cure for 24 hours before operating the boiler 8 Condensate Traps a Trap should have the basic configuration shown in Figure 25 All tubing is 3 8 I D b All drain tubing must be acid resistant c At least the first 6 inches of tubing must be silicone with a 400F temperature rating d Pipe condensate to a drain or other suitable location Make sure that condensate dis...

Page 26: ...d upstream of all gas controls Install a manual shutoff valve outside the jacket and ground joint union as shown The boiler and its gas connection must be leak tested before placing the boiler in operation When doing this the boiler and its individual shut off must be disconnected from the rest of the system during any pressure testing of that system at pressures in excess of psi When pressure tes...

Page 27: ...through an area that could be subjected to freezing temperatures The termination of the relief valve discharge piping must be in an area where it is not likely to become plugged by debris DANGER PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE DO NOT INSTALL RELIEF VALVE IN ANY OTHER LOCATION THAN THAT SHOWN IN FIGURE 1 DO NOT PLUG RELIEF VAL...

Page 28: ...in circulator zone systems through zones that are not calling for heat 9 Isolation Valves Optional Isolation valves are useful if the boiler must be drained as they will eliminate having to drain and refill the entire system 10 Drain Valve The drain valve is shipped in the boiler parts bag Install it in the opening in the tee on the boiler return Figure 1 Piping for Special Situations Certain type...

Page 29: ...t be properly sized and the correct flow rates are required on either side of the heat exchanger Consult the heat exchanger manufacturer for sizing information The water in the boiler is completely isolated from the water in the system This means that separate fill and expansion tanks are required for the heating system loop There are several other ways to connect low temperature systems to the no...

Page 30: ...lers Where the boiler is connected to air handlers through which refrigerated air passes use flow control valves in the boiler piping or other automatic means to prevent gravity circulation during the cooling cycle ...

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Page 32: ... 32 The line voltage connections are located in the junction box under the R8285 fan center on the right side of the boiler Black Line voltage hot White Neutral for boiler and circulators Green Ground connection 2 The circulator is factory wired If a different circulator is wired to the boiler its full load current draw must not exceed 12A 3 Connect the 24 volt thermostat to terminals R and G on t...

Page 33: ... sequence will be initiated If this happens when there is no call from the zone 1 thermostat the relay on the R8285A will not be energized and the zone 1 circulator will remain off 2 Multiple Zones using Zone Valves Figure 34 shows wiring for multiple zones using Honeywell V8043F zone valves This wiring diagram may be used for other 24 volt zone valves as long as they are equipped with end switche...

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Page 35: ...n on the ignition module For the ignition module to recognize that a pilot flame is present the DC current flowing into this terminal must be in excess of approximately 1 0 uA 6 Once the ignition module detects the presence of a pilot flame voltage is applied across the main valve terminals MV and MV PV opening the valve and establishing main flame 7 If the ignition module does not detect the pres...

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Page 37: ... line voltage wiring for loose or uninsulated connections 5 Start the boiler using the lighting instructions on page 36 6 Inspect the pilot and main flames These flames should be stable and mostly blue Fig 37 38 No yellow tipping should be present however intermittent flecks of yellow and orange in the flames are normal 7 Check the manifold pressure and adjust if necessary To do this use the follo...

Page 38: ...tion above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the pilot Do try to light the pilot by hand not 5 Remove front access panel 6 Rotate the gas control knob clockwise to OFF 7 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor...

Page 39: ... of the flame supervision system While the boiler is firing disconnect the red ignition cable from the Spark terminal on the ignition module Both the main and pilot flames should extinguish immediately 9 Allow the boiler temperature to increase to the high limit setting Confirm that the high limit shuts down the burners and the combustion fan 10 Pinch or disconnect the vacuum switch tube that is c...

Page 40: ...39 FIGURE 38 PILOT BURNER FLAME ...

Page 41: ...found in this tube 11 Disconnect the vent system from the boiler using the four 10 32 screws in the vent collar Inspect the blower wheel and fan housing for corrosion damage If damage is found replace the fan assembly 12 Inspect the vent system a Make sure that the vent terminal is free of obstructions b Make sure that all vent system supports are intact c Inspect joints for signs of condensate or...

Page 42: ...ATION CO AND CO2 READINGS SHOULD BE BELOW THE MAXIMUM LIMITS SHOWN IN TABLE 8 Service Notes 1 Measuring CO and CO2 If it is necessary to check CO or CO2 the best place to take a gas sample will usually be at the vent terminal Table 8 shows typical and maximum readings for CO and CO2 on both natural and LP gas Do not leave the boiler in operation if either the CO or CO2 exceeds the maximum limit in...

Page 43: ...minimums required for reliable operation After the boiler fires the vacuum will drop for several minutes before stabilizing The vacuum shown under Burners On in Table 9 is the minimum reading which should be observed after the vacuum has stabilized The Table 9 readings correspond to sea level vacuum switch settings Consult your Crown representative for possible variations in settings at altitudes ...

Page 44: ...The possible causes at the end of each branch in these charts are not listed in order of likelihood All controls on the BWF are tested at least once in the manufacturing process and a defective control or component is generally the least likely cause Before replacing a component try to rule out all other possible causes 5 If the charts indicate that the transformer in the R8285 is defective it is ...

Page 45: ...ote 6 on page 43 Socket not fully seated on relay Y Y N N Y N Y N START Y N Y 24volts across R and C on R8285 fan center Defective transformer Replace R8285 See note 5 on page 43 24 volts across G and C on R8285 fan center Seized or defective circulator Defective relay on R8285 see note 6 on page 43 Relay not fully seated in socket Loose connection in circulator wiring Unplug fan and check for 120...

Page 46: ... vacuum switch tubing Improperly sealed flue collector Damaged or missing fan gasket Defective fan Wind at horizontal vent terminal in excess of 40 mph Rollout switch open Replace switch with exact replacement Crown Part 960122 Check for blocked heat exchanger Main burners light N Do burner circulator and fan shut down at end of call for heat END Y Does boiler shut down when t stat wire is removed...

Page 47: ... electrode porcelain cracked Pilot flame not covering gap between electrode and grounding strap Low gas pressure at gas valve inlet Defective S8670 module Main burner lights N Y 24VAC across terminals 1 2 on S8670 Y N N Defective S8670 module 24 volts between MV MV PV on gas valve Defective gas valve Defective EI harness END START 24 volts is present across 5 and 6 on S8670 30 50 second prepurge p...

Page 48: ...2 ea 2 ea 8 BASE REAR INSULATION 1 ea 720603 720604 720605 720606 720607 720608 9 BASE LEG ASSY 700110 4 ea 4 ea 4 ea 4 ea 4 ea 4 ea 10 1 4 20 X 1 2 SELF TAPPING SCREW 900100 20 ea 20 ea 20 ea 20 ea 21 ea 21 ea 11 1 2 x 2 SEALING STRIP 900146 3 7 ft 4 ft 4 2 ft 4 5 ft 4 8 ft 5 1ft 12 ROLLOUT SWITCH G4AM0600240C 960122 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 13 ROLLOUT SWITCH BRACKET 900121 1 ea 1 ea 1 ea 1 ...

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Page 50: ...ASSY 51 K16 PILOT ORIFICE LP GAS INCLUDED WITH PILOT ASSY 60 50mm BURNER WITH PILOT BRACKET 150550 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 61 50mm BURNER LESS PILOT BRACKET 150551 1 ea 2 ea 3 ea 4 ea 5 ea 6 ea 62 MANIFOLD 50mm BURNERS 1 ea 651153 651154 651155 651156 651157 651158 63 2 ea 63 3 ea 63 4 ea 5 ea 6 ea 7 ea 63 LP GAS ORIFICE 53 DRILL SIZE 2 ea 3 ea 4 ea 5 ea 6 ea 7 ea 64 ORIFICE HITCH PIN 950370...

Page 51: ...50 1 Burner Components 50mm Burner Components ...

Page 52: ...CUUM SWITCH 1 ea 650009 650009 650010 650010 650011 650011 91 IGNITION MODULE S8670E1007 3505010 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 92 RELAY R8222D1022 3505556 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 93 FAN CENTER R8285D5001 3505555 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 94 3 4 BOILER DRAIN 95 041 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 95 CIRCULATOR TACO 007 95 012 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 96 1 1 4 TACO ISOLATION VALVE SET 9...

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Page 54: ...Tel 215 535 8900 Fax 215 535 9736 www crownboiler com Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 CROWN Boiler Co ...