Home

Crown Boiler DTR220 User's Manual

1. m COI un H pem Ce 2 Ed 77 TEICHE ker LE m el _ H 3 Two asi types mes codes are on the display Sof Lockout Codos When a lockout occus the bie wil shutdown and the display wil alier ute between the number 9 kuer followed by digit service code list of these odes nd their meanings is shown m Table 133 The bode will automatica rest anoe ths condi that caused the loch come Hard Lockout Codes When a hand lockout cur the boiler will shut down and the display wil a the letter followed by a to digit service code A ha of these codes and their meanings it sown in Table 134 Once the tht caused d kaku is corrected the boiler will noed to he manually reset sing the RESET bata se the display L Bumer on Heid in iow fre Table 11 3 Boiler Status 4 Ian outdoor senor is installa the tor will automatically adjust the heating zone set point temperature based oa the outdoor peset curve in Figure 11 4 The maximum set pois defined by parameter 4 factory et 10 180 when te outdoor temperature is F or below The minimum sct pont temperature shown is 130 F when the outdoor temperature is la F or boe As he outdoor temperature falls the sappy water
2. Check seas comede Gi INTENTIONALLY LEFT BLANK XIV Parts The following parts may be obtained from any Crown distributor find the closest Crown distributor consult he ares Crown representative or the factory at Crown Boiler Co Customer Service Boy 14818 Philadephia PA 19134 5 REPLACEMENT PARTS UST secus secus eme T E RIZE a em gt s E L x 1 gt wm 2 ss 127 127 som 3 gt sr 1 Pe z meer gt gt ELLES se 2 gt mo emo ene oar se os xm Not used with Dunga 56 REPLACEMENT PARTS UST acus m Jaume SRM Tau LEN KT TET omm CEN EII s Je EN ELT 1 7 CEN ETT xom sme REET gt s m T ss ra terme ra epar L CE TTT je CE oe se rir m m erroe Tee xo DT m TL LENT gt
3. to manage all boiler functions including fame supervision and modulation Two lt pa target her supply temperatures are sored in the memory one for space und one for domeste water production If an outdoor tempera senor is connected her the eating spy se poit will automatically adjust downwards the outdoor temperature increases For ere formatio feature see discussion bor water reset belo The MCBA modulates the boiler input by varying the fan speed As the fan speed so does the mount of gas drawn nto the blower As result fay constant Fuel ratos maintained cross all pul The MCBA determines the input needed by looking at current and reven between the supply temperature and the set pont temperature As the supply temperature approaches the set porn temperature he fan wl slow down and the input Depending en model oder dhe minimum spt n between and VS of vimm input The MURBA also monitors return and temperature in all her safety controls including the low water und aft limit connected mao the MCHA The wes input from ll onto ether hut down th hier when an uale odian exists or in some cases to rec he problem 2 be display panel has Ihre primary modes of operation These are Standby Mode Displays eier current tun This is the default operating mode Parameter Mode Used to change con
4. 2 Minimum air inlet em 20 Vent Options 12 vent terminalis either a ee or an elbow supplied by the system manufacturer and equipped wth a rodem screen Vent system manufacturer s put fo thene are down in Table 6 3 In some be elbows and shown in Table 6 require separate rodent serens When this is the case vent manufacturer part number for ses additional paris re shown in Table 6 along with the termination feing The air intake fiting on a horizontal vent systems is always a 90 degree eo with rodent sereen This elbow is made out of the sarne materialas the rest of the air miet system cer galvanized or PVC and is installed as shown in Figure 6 5 Horizontal Vent and Air Intake Terminal Location Observe flowing limitations vent terminal ation also see Figure 63 Vent terminals must be at est 1 foot fom any dor window gravity inlet into building Matam corset clearance and enem between vent and nr make terminals The vent and anr intake terminas most te at same height and beir center lines mast between 2 and 36 inches Both terminals me be located oo the wall The bottom of the ent nd nir take terminal mast be at east 12 they be less than 12 above grade evel above the normal soow line In no case should The of be vent terminal ust be st est 7 feet shove a puli walkway Do aos insta
5. Loes T LEN ana Tune NO xam same LET x gt EK LEN es nme Gi 1 sm CE 3 LEN se m Eo cM 5 E Gas Train Assembly Honeywell Valve Gas Train Assembly Dungs Valve 8 Cage rae at np Le Comer III ETE r TET Brno Le ary Sen LETTER NH 12 EI TS 7 18 wasp p eme 151 MOTERA s IAE Jason Sort Jam ej IT AS REN EET ITI LEE Ew UI LE A CI E Ez een Tan a EI REI 65 xog am weds oud samog
6. Sest SAFT Vent General Nes These instructions cover he installation of Saf T Vent EZ Seal Sa T Vem EZ Seal piping has integral sets installed ia te female cdo or pipe which sea the joints In Vent pipe sections may not be Exceptions to this are he Vent connector and connect to the boier ves cla la these case use a Sharp pair of aviation ripe an abrasive ora plasma cuter Soothe Ven fo formata cutting the ip come Orient Vent component so that the arrows oo the piping labels ane in the direction of ue pas flow Support horizontal piping sections at intervals 006 feet or le Vertical venting systems must be supported by at kaq one Fab support An additional vertical support is required afler any fs 1 Connection to Boiler Start of the vent system at the boiler Remove the hose clamp shipped on the BWC vent collar Bend ie bee hose champ tabs on lis colla outward slightly Cut the male o of he fira piece of pipe Fig 6 9 If necerayerimp the cu end of pipe so an erat I ito Chen er f be ne sp of pipe ana ls imide of the collar on the boler With an Pad the mak end of the pipe apply Beh petas eos ments chim b maed f s pe A y a end of lione along he frt 2 of the longitudinal wekl Insert male end of e pie nt he boiler collar until it bottoms out Apply an addito bead of silicone ove
7. auri 108008 oranseA JO ES Jano LX i isi li Inner Vestibule Blower Control Harness i i I 1 mi H ira Appendix A Special Requirements For Side Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4 0 and 5 0 for installation of sidewall vemod pas appliances as flows For diroct vent appliances mechanical ven eating appliances or domest bo water equipment where be bottom of the vent termina and he ir intake ista blow four fect above grade the following requirements mus he satisfied sot already one present ech oor kevel where are a carbon monoxide detector and alarm shall e placed nthe vig area outside the bedroom s The carbon monoxide detector shall comply with 720 2005 Edson P A carbon monoxide detecto shall be located in the room that houses the appliance or equipment and shal Be powered by the same electrical circuit as the appliance or equipement such hat only service wich services both the appliance andthe carbon monoxide detector Have tery back up power Meet ANSUUL 2034 Sundar and comply with NFPA 720 2005 Edition and Have been approved and listed by Nationally Recognize Text
8. god condition and tached securely CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING 49 Remove the ignition electrode ad inspect for oxides Clean unides ol the with Tues male gli ana Remove any accumulated deri m the sz indet screen T Remove aan hos md a ie The ya cale ed tu ol the hae in place Remove the combustion valve assembly ad inspect he fan and fan Blade for int and dust Vacuums required Remove the burner hood to acces the temer and the chamber Remove the burner vacuam any dst burner Wip the side of the burner With clean soft clodh Do sot wipe the mesh side of dhe kumar Ihe burner shows sigas of or comic replace specie burner pasket a place noces Wath the burner remove consta chamber and clean zs neca Inspect the heat echunger and vacuam xay deis ound pi ad oor surfacen Clan be casting pias by using with clean water Aft ay laa bush may used accen rn Drain and Nush the nido of dw heat exchanger and condensate collector as require Do not use any cleaning agents or solvents he condensate tp to verify is open nd five fromm debi Clean if Reinstall e bare burner hood combustion fan gas valve
9. if cy Verify net pressure is between the upper and over limits showen on the rating plate with all gas appliances and ol WARNING THE CORRECT OUTLET PRESSURE FOR THE GAS VALVE HAS BEEN FACTORY SE AND REQUIRES NO FIELD ADJUSTMENT THIS SETTING IS SATISPACTORY FOR BOTH NATURAL GAS AND PROPANE ATTEMPTING TO ADJUST THE OUTLET PRES SURE MAY RESULT IN DAMAGE TO THE GAS VALVE AND CAUSE PROPERTY DAM AGE PERSONAL INJURY OR LOSS OF LIFE a Gas Inlet oe Inlet Pressure Honeywell Gas Valve Figure 10 22 Honeywell Gas Valve Detail y 00 NOT Figure 10 2b Dungs Gas Valve Detail 11 Performa combustion test On horizontally vented units he sample probe may inserted into the terminal hiss not possible and if no sample preset in the vent system remove the fle temperature sensor and insert the ual ze probe in the sensor opening On BWC 150 and BWWC22S the temperature probe is located behind the lower vestibule door For be boiler to operate this sensor will need to be temporarily Connected outside ofthe hole itis removed be sue to reum the gas temperature sensor original poston ale combustion testing complete Check CO2 or 02 and CO at both high and low fire The boiler may be temporarily into high or low Fire or 15 minutes as follows a To lock the boiler in high fire smultaneoush press and hold the butto
10. nd op the eon op comi of ended pq n Fi PE dot eal eee ne ken eg satel wt E eii ts of al tings secondary kup Total ee ale len quad tol ref ar mah pp omar The rout ie a quan abe nd Pe ie being ial and als bier soy itr be a tamu egal Eng ntum nen sb ol ues eng cated ey o Water Hester Loop Ping net Water Henter is Ud Al piping mos the ize in Table solu tient ate eter conecto ae an he p so called Tor solar toc the pe we th most vale eme rancia Tor the ecto 1 Coumi al iting tm the planned Inde Water Hester Loop be indie water henter lop consists of the st png in Pagare A In dg wie cating som ping amd tings ihm eomm lo inhaling se com ar ap pg anl ich were comal Nep Do teu e oy tl nn vt es quiin ts and add them to the total length of pipe in the indirect water heater loop ee pair bat de AAA AA en Example Asume that is to be in a benting sem along with a Crown MS 40 ips hemer Ao 15 wright i be ail enc Her an e mary ta dU tg pre lb tin eee apd indere water bester Filings are as shown in Figure requires a Dow of X GPM and bes ow o 30 f Total fittings in Secondary boiler loop 790 low 2 Rane of Toes 1 Swing Check 2 Valves Note nons Secondary Connection Tee
11. 5 F and wget Der supply temperature when responding oa from he diet water heatet enero TRO F 135 F The detal heating supply et pit parameter 4 is standby mode it i al possible to tm or o ea Beating domestic water one There s normally no um ol ia of thet aes and dog s not recommended CAUTION PUSHING AND HOLDING THE 7 WHILE IN STANDBY MODE WILL PREVENT THE BOILER FROM RESPONDING TO A CALL FOR HEAT PUSHING AND HOLDING THE 77 WHILE IN STANDBY MODE WILL PREVENT THE BOILER FROM RESPONDING TO A CALL FOR DOMES TIC WATER IF THIS HAPPENS OF or WILL APPEAR ON THE DISPLAY TO TURN BACK ON THE HEATING FUNCTION PRESS AND HOLD UNTIL e AND THE SET POINT andy mode Mode and ether 4 or are simultaneously pushed and held for cas 2 seconds the bumer can be forced ino ether high o ow ie This feature is used for running combustion tests After 13 minutes be burner will automatically revert to modulation It ded to revert to modulation before 15 minutes has med simultaneously pushing und will restore modulation Parameter mode both set points can be changed and both zones mad on or ol nation boh ones can be configured for continuous pump operation te eating zone w set for continuous pump operation parameter 3 sel 19 3 the henting pump will still shutdown when there for domestic hot water either the henting supply set poin
12. Do not combeston air from within he building Da not install a barometric damper or drafthood this beiler Da net attempt to une he vent system fr this aller with any her appliance Moisture and ce may form he surfaces around the vent termination To present deterioration surfaces should bel god repair scaled painted t A Vent System Design Thor are two basic ways to vent the BWC boiler Horizontal slde wall Venting Vent ste exits the ling hough hana through a separate pipe ftom outside Vertical Venting gt Vent systern exits the building though a rof Combustion air is obtained though a separate pipo from vate outside wall Combustion A description of each a these venting options is listed ia Tables 6 2a ad 62 For clarity these vent options numbered fom to 7 One ofthe vent option columns ln Table 62 must match the planned vent and alr intake exact In an observe a allowing under sen Use oniy one of he approved ven ystems shown in Table 4 These systems are made of a Spera unless steel alloy AL29 1C for protection again Aue pas condense They designed 6 provide a pan tight seal at joints und as o that gas docs not ctr the ling Each approved vent stem has unique method or installation do oot attempt to mix components rom different vent stem 2 Maximum Vent anl Air Ink Lengths The maximum length of he vent air intak
13. E LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS TRAIN ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TEST SPECIFIED IN 221 13 sehe following procedure for iil start up of the der 1 not already don sh the system to remove sediment and aces of oj additives hia sold be she wih boiler slate fim he ale 2 Fille boler and y don y tr wid water meeting the following requirements pl between 65 and XS Total Solid lea than 2500 PPM Harden low tun 120 PPM 2 Grain Pressure systern to at least 12 pa u the boiler WARNING NEVER ATTEMPT TO FILL A HOT EMPTY DOLLER 3 Check all new piping for es and purge piping nections hat are filled with air Sec the National Fuel Gas Cale infomation on testing ad purging pas Ines WARNING NEVER USE A FLAME CHECK FOR GAS LEAKS MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS 4 Vent system mua be complete und free of obstructions before tempting fre boiler Make sre thst the lione creme called for in the vent assembly instructions has passed before firing boiler Inspect all line voltage wiring for loce or connections Remove the from the condensate trap Fig 6 11 Add water to the trap water runs out the con casate drain Reinstall he dost 38 WATER QUALITY A
14. H THAT ANY CONDENSATE LEAKAGE WILL NOT CAUSE PROPERTY DAMAGE SOME JURISDICTIONS MAY REQUIRE THAT CONDENSATE BE NEUTRALIZED PRIOR TO DISPOSAL 19 INTENTIONALLY LEFT BLANK INTENTIONALLY LEFT BLANK INTENTIONALLY LEFT BLANK VII Gas Piping Gas piping oder must e sized io deliver gas for the Boiler to fire at the nameplate input a an inlet pere between the minis mati alas shown em th rating plate For more information on ps line sizing consult he ity or ise Nation Fue Gas Code Figure 7 1 bows typical as piping connection to the BWC boiler A sediment trap mas o installed upstream gas nale factory provide manual shutoff valve outside the jacket with ground joint union The boiler and its gas connection must be kuk tested before placing the boiler in operation When doing this the oie and is divido hu omas fom the of sytem dng any pressure esting of at system pressures in evens of 1 2 When testing the gas system at premure of 172 or less olathe boiler Irom he gas supply system by losing 1 individu mamas hut valve VIII System Piping A General System Piping Precautions WARNING INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM WATER DRIPPING SPRAYING RAIN ETC DURING APPLIANCE OPERATION AND SERVICE CIRCULATOR REPLACEMENT ETC CAUTION THE HEA
15. ND BOILER WATER ADDITIVES IMPORTANT NOTE This boiler equipped with lamina het exchanger hat can be seriously damaged by failure o Bote ony gulae installation flushing the sem wil hush tea befor he ea sedan toe ie and acero adver Even B nen da mot am hi new m tem wi conn solder ux and even 2 The sgh Important Tap wer cons heen epee cose inane mt eprom oo hs od AE rem un deg ds a Te q da sm Co A ee EIU Fe To minimise ations of make up water ee tm rg before pc in re ten clades ping or oer papang ia huch leak might po undated sti ating De delis ft an Aa cir a water meter te ie o rowed of a water KX Ti K Eo ithe ie an be the Or Te aang tod with an xy on umor miro of oxygen o e water he der to be tld cot om als tlg wha n ur he ltd rom e oder wi ra down uae 310 Do mou ua ne res sy soy fc amat ie d cn permit d Feros Alit T Fermor CHP m USP Grade vgn peop leme gcn available from Crown Ga Amman Sale M Ad either ofthe above autores ar used est tbe bir water an basis to ensure that he arcae nemaina Tha a done with Fermo tea Kit TR avila iom Crown 9 Do ad akar us dey ar F a SE Sys
16. O TO TURN OFF GAS TO THE APPLIANCE tr you cannot reach your gas supple call the Arc department Use your hand to tum the gas control knob Never use tools Ifthe knob wil not push in or tum by hand don try to repair P call a qualifed service technician Force or attempted repair may resin a fre or explosion D Do not use mis appliance If any part has been under water Immediately call a qualited service technician o inspect me applance and to replace any part of the control system and any ges control which ha been Under water Tum the extemal boier manual gas valve T handle counterclockwise to open gas supply 7 Smell tor gas in the enclosure If you smell gas STOP Follow B in the safety Information above If You don smell gas go to the next step Tum on all electi power to the appliance 9 Set the thermostat to desired setting 10 digit ot the control display panel wit how a series of numbers that indicate the boller sequence The number or 4 means the burners ring The number 0 means there is no heat the thermostat or the domestic water heater 1 tthe appliance not operate follow the instructions To Turn Of To Appliance below and call your service technician or gas supple 12 Replace the upper bor access pane and the font door panel 3 Tum he extemal boler manual gas valve T handle c
17. S THROUGH BOILER MIN REQUIRED FLOW ALLOWARLE FLOW GPM 3s BOILER MODEL Method 1 Primary Secondary Piping Boiler in Secondary Loop This method can be ul heat as shown in Figure amp 2 or with an idet water hester as shown in Figure R3 This method res en primary secondary pampay t ensure tat he required Row 5 raised through hole In is system rough ie bar independent of be ov through heating y tem Us following ensure tat the wll ave e required How shown in Table 81 ofthe m the beating system 7 Primary Lop Piping See the crio piping o design ow rte ugh being tem a would on ay ober beating sem All tenween Ihe tank and send tes must be at cat as lare ht shown Table eo rates in i imr endende Ip mienne dr pow a damens of se etm le and of non te tance Denen he andthe it tec ay diras rc 2 Secondary Loop Ber Loop Piping Al piping ehe size shown for boiler in Table column S Tos de act 5 Select one ofthe boiler vae rats down in column t fr the oder being ali When iin sre le f Ap rp dd iar op rec blo Fence pp ner mutig Gee i mali el yr rm lee eig gt Came ings n
18. T EXCHANGER USED INTHE BWC IS MADE FROM A SPECIAL ALUMINUM ALLOY FAILURE TO TAKE THE FOLLOWING PRECAUTIONS COULD RESULT IN SEVERE BOILER DAMAGE BEFORE CONNECTING BOILER MAKE SURE THAT THE SYSTEM IS FREE OF SEDIMENT FLUX AND ANY RESIDUAL BOILER WATER ADDITIVES FLUSH THE SYSTEM IF NECESSARY TOENSURE THAT THESE CONTAMINATES ARE REMOVED DO NOT CONNECT THIS BOILER TO A SYSTEM THAT IS SUBJECT TO REGULAR ADDITIONS OF MAKEUP WATER OR ONE WHICH EMPLOYS RADIANT TUBING WITHOUT AN OXYGEN BARRIER DO NOT ADD ANTIFREEZE OR OTHER BOILER WATER TREATMENT CHEMICALS EXCEPT THOSE LISTED IN PART X OF THIS MANUAL MAINTAIN THE PRESSURE IN THE BOILER AT A MINIMUM OF 12 PSL DESIGN SYSTEM TO ENSURE THAT THE FLOW FALLS WITHIN THE LIMITS CALLED FOR IN TABLE System Design Proper operation of the BWC boiler ries hat the water Bow boe remain within the inia shown in Table amp 1 bummer is firing Fade to martin fow within these ants could esl operation or premature boiler There ue two Basic methods that can be wd pipe the BWC boiler Method 1 is almost always prefered The instructions ll following pages describe these methan fo pang BWC bes and explain how to size the tnd piping Additional information on by dini sy stem design may be fund im Installation of Residential Hydronic Systems Pub 200 published by the Hydronics Insti Berkey Heights NI TABLE FLOW REQUIREMENT
19. TROL MCBA ONE EXAMPLE OF AN EXTERNAL POWER SOURCE THAT COULD BE INADVERTENTLY CON NECTED TO THE LOW VOLTAGE CONNECTIONS IS A TRANSFORMER IN OLD THERMOSTAT WIRING 4 outdoor sensor s connect to terminals 5 and bor will just the tanpet space heating set point supply water temperature downwards outdoor temperature Huse th sensor sould le local en the outside of e structure in am ura where will sen average temperatur around e house placing di sensor in aneas whee it may Pe covered with or ano In general locations were the sensor wil pick up dc aan froen de sun hold also te avoided Avoid placing De sensor potential sources o electrical oie such as uansformers power lines and fluorescent lighting Wire the sensor to the boder using 22 gauge rper wie As with be sent he sensor wiring sould be routed away sous of electrical mise Whew iis imposible to tok sch noe suce Wie he sensor using UL CM AWM Style 2092 C sick cale Connect one end of Be shielding oa dis cable to ground Figure 9 2 Ladder Diagram Figure 9 3 Wiring of Isolation Relay for Control of Two Heating Circulators X Start up and Checkout SAF
20. ately and dhe tenor hose Reconnect any wiring which has disconnected Qualified service personnel shell thoroughly the eating systers correct any deficiencies pror to restarting the boiler Follow Section X Startup and Checkout instructions tere leaving installation Perform combustion et outlined i Seton X Very thatthe em PH I between 63 KS XIIL Troubleshooting WARNING TURN OFF POWER TO BOILER BEFORE REPLACING FUSES OR WORKING ON WIRING problems whare no ode ia dane No Error Code Displayed Table 13 CONDITION POSSIBLE CAUSES T E DES ee a r Po ee mente are Figure 13 2 MBCA Fuse Location B Troubleshooting problems where a lochs codes plays When of lockout occurs the boiler will down andthe display will aerate between tb number and the keer b followed by a too diit Service code boder will automatically restart oec the condition tha caused the cut s comete EI Troubleshooting problems where a hanl lockout code is displayad When a hard lockout occus the bier vl shutdown sd the wil fash he leer E followed by a two digit service code Once he condition that caused the lockout is cocta the boiler will seed be manually rest using he RESET burion on the Table 13 4 Hard Lockout Codes Displayed laser delete vas
21. b 4 Desicneo BWC Series High Efficiency Gas Fired Hot Water Direct Vent Condensing Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models BWC150 BWC225 CROW Bonen N Manufacturer of Hydronic Heating Products Box 14818 3633 1 Street Philadelphia PA 19134 Tel 215 535 8900 Fax 215 535 9736 www erownboileccom Table of Contents I Product Description Il Specifications Ill Before Installing IV Locating The Boiler V Air For Ventilation Venting Vent System Design Removing An Existing Boiler From Common Chimney Vent Intake System Assembly Vil Gas Piping VIII System Piping General System Piping Precautions System Design Standard Piping Installation Requirements Piping For Special Situations IX Wiring X Startup and Checkout Operation Service and Maintenance Troubleshooting XIV Parts Appendix A Special Requirements For Side Wall Vented Appliances In The Commonwealth of Massachusetts Product Description Tho BWC is an aluminum gas fired condensing boiler designed for use in forced hot water heating systems ing supply water of 180 ores This boiler may be Vented vertically or horizontally with conbus Sonar supplied fom outdoors This bode ot designed for sein gr hot waler or sy coma ing amo
22. dificult a the clearance over ma be alal on un pe rc The relief valve most be m the factory specified han The besler sould be ost so mime length of the vent tem The combustion peng must ermine whee str saab for combustion nd away frorn arene that wl combustion a Avond areas hera containing chine chloride had salts chlorotiuorocarbons paint removers cleaning solvents and detergents 3 NIS NG ns A S SS Figure 4 1 Clearances To Combustible Or Non combustible Material Table 4 2 Clearances From Vent Piping To Combustible Construc WARNING OUTDOOR COMBUSTION AIR MUST BE PIPED TO THE AIR INTAKE NEVER PIPE COMBUSTION AIR FROM AREAS CONTAINING CONTAMINATES SUCH AS SWIMMING POOLS AND LAUNDRY ROOM EXHAUST VENTS CONTAMINATED COMBUSTION AIR WILL DAMAGE THE BOILER AND MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE V Air for Ventilation Air for combustion must always be obtained disc fom outdoor however suficient fr ventilation must sill he provide in the boiler room for venation n reqared o various boiler components fom over heating and is alas from indoors ensue an venison ar supply perform the following Sep termine hehe bier sabe in a space is defined by the Natonal Fuel Gas Cade m having a volume les than 50 cub fet
23. e piping depends upon the vent option selected and the Pier size See Table 62 or he maximum vent length ci to he maximum length of piping shown m Table 6 2 the following tings may also he wed Horizontal Vent Systems One 90 deg elbow Horizontal Air Intake Systems One 0 deg Neral Vent Systems Two 90 deg elbows Air Intake Systems Two 9 deg ebene I additional elbows are desires the maximum allowable vert length mast e reduced by the amount shown in Table 166 foreach additional elbow used Termination fing are not counted when counting aditional eov Example A 37 vent system planed fora horsonal vented HIT S0 which has following component 2 vertical pipe 190 elbow SA horisontal pipe 3 f horizontal pipe TAS elbow pipe Termination eov The Vent Option colens m Table 62a describes horizontal direc ent system wein 3 vent pipe From thir we see hat 150 vent lth of up o SS The fri elbow and termination cow are not considered From Table 6 equivalent length of the 3 45 elbow is 4f ad the equivale of the 790 degree elbow i The maxims allowable rm of trig pipe om this sytem s therefore IMAN Since the planed instalation has only 14 A of aight pipe the pla vent length is acceptable cat 4 suse rr E sc ono FIGURE HORIZONTAL DIRECT VENTING VENT OPTIONS 1 2 Mini vent
24. ealed with any general purpose icone salant meh ax GERTVIUZ PVC air nlt ppg sectors are connected wis PVC cement M Longitdnal welded should not he placed the honom of horizontal sections of exhaust pipe Do not drill holes in vent pipe Do not attempt to mix vent components of different vet system manufacturers In some een there are between the em system instructions m mana hose nthe vet manual Where mc differences exis his manual takes provedene ver the vent manufacturer mama CAUTION Vent systems made by Heat Fab Protech and Z Flex rely on gaskets for proper sealing When these vent systems are used ake he following precautions Make sure that plat in position and undamaged in the female end of the pipe Make sur that both the mole amd female pipes are froe of damage prior to assembly 1 Only vent pipe as permitted by the vent manufacturer ln accordance with thle Instructions When pipe icut cuf end mas be square and carefully deburred prior to asembly 3 Assembly of Metal Fab Cor Gras Vent System General Notes Do not eut Cor uar vent Retro Cora ln cis pooper eno Tren Con nd compren de maie miro fats Ps e direcion ofthe ble b Start assembly of the vent system at the oder Remove the hos clamp shipped en BWC vent collar Bend he roe hose lamp ubs on thus colla outward Clea exter of the male end of die piece o
25. f ipe and de inside of the vent olla o boiler Remove dirt grease and mouture fom the surfaces o be sealed On the male nd of the pipe apply a wid bead of hightemperature silicone approximately 14 inch from the nale end of the pipe Insert the male end of the pipe ints e boiler vert ollar nti bots out Apply an bad o abcone over the outs o ad e seams the Vent collar and eod ou Fig amp 10 Replace and tighten the clamp on the vent colla 1 All other joints in Fasa venting system rey on a gasket the of pipe for a proper seul 0 Align the longitu seam of otb pies Insert the male end of the second pipe into the female end af the Tirst pipe the bead on the male ed comics e are on female end Tighten the looking band with a mut driver T Repeat ani e for the remaining components Allow the silicone ocur per the before operating the boiler pu FIGURE 6 10 FASNSEAL CONNECTION TO VENT COLLAR 6 Assembly of the air intake 2 Assemble the air intake system using eher galvanized or PVC pie by IPVC piping i cement to meme the PVC intake stem components I galvanized piping owed we at kas two metal per ji Seal he outside of all joints is connected Ue tmp as shown ta Figure 6 1 Tis hose he routed through the back of the boiler or o thr wk toug
26. f pipe and the inside of the vent cellar the boiler Remove li grense and mitre surfaces o be scale Dry surfaces allow to dy male end of he pipe apply 2 Wie rado icone prima TY e sert he male end of the into the boiler vent olla a bottoms ou T Apply bead al icone ener the cui of le joint ad oul enlace n nahen campo de D Assemble remaining Com uad component accordance with the instructs Allow the scone to cure per he stone manufacturer s before operating the hole one dada e pipe Fig FIGURE 67 CONNECTION TO VENT COLLAR 15 3 Assembly af Z Flex Zens M 5 h n General Notes Norcespandad end of SVE Series ping sections muy be cut using aviation anis or a 24 thread inch hack File or the cut mood before assembling Expanded ende may beca lo Map the SVE series he vent colla or Crown coaxial terminal the following instructions Support horizontal piping sections at intervals of 48 or less Verl venting systema mast be supported by at least ae Z Flex fire siop An additional vertical supporti after any oaet nd as repre by th Z Vent instalas instruction assembly of the vent system at he Remove the hose clamp the BWC vent callar Bend the hoe hone clamp taba ca tha collar
27. h the Knockout povided Route hose to drain stable Note the following when disposing of the condena 4 1 be condensat drin ne mus e extended construct the extension fim PVC or CPVC pie Inser the ose provided withthe boiler into the end ofthe extension as shown in Figure 6 11 Condensate is slighty acidic Do not use metal pipe o figs inte condensate drain line Do not roule the dis line hh areas that coude damaged y Somejunsdicions may rue that the te neutrale before ein disposed of Dispose of in acordarse with heal eder 4 Do not roule or termite the condensate drain line in areas subjected to temperatures the point of condensate disposal is above the it wili be tous a condena pump to move he I da such cass pup that s approved for une wilh condensing fumaces If overflow fom his pump property damage selecta pump witha overflow switch and us ths switch to shut down te boiler heat necessity the overflow switch o mager an alarm T Do not attempt to move tap rom Location shown in Figure 6 11 Do not attempt to substituie for the one provided lr ID The vent shown in Figure II mut be kf open for rap to work properly WARNING BOILER CONDENSATE IS CORROSIVE ROUTE CONDENSATE DRAIN LINE IN MANNER SUC
28. he boiler room these openings mus cach have a minimum aes of 100 quare mehes IE other gav are im the biker mom the openings ia accordance withthe appliance manufacturer s or the National Fel Gar Cade opening re aren s 100 square inches even if opening requirements for other appliances are Jess Figure 5 1 Boiler Installed In A Confined Space Ventilation Air From Inside totul volume of oh he hole room nd the room to which the openings connect es than 30 fet per 1000 ISTU of tol appliance iut insala of identical openings ito thd rom Connect addi room with openings until the total volume o all rooms is t kaw 50 cube fet per 1000 BTU of input The free of an opening takes account the blocking of mesh grills and louvers Where cens wed hey must be finer 4 4 me Step Z Ifthe boiler to be placed in an umso space the natural nitration ito the baller mom will provide aust a fr enolate without ona oping mo ee tm VI Venting WARNING Failure to vent this boiler in accordance with these instructions could result in unreliable beiler operation sevene damage t he boiler or property or unsafe operation Uve omy vent systems and materials explicitly permitted by Crown for use with this boiler Da mot attempt to mis components from different approved vent systeme
29. iler is correctly size Forhening systems employing convection radiation schwa or str use a duty accepted sizing method suh as he Heo Last Candi Guide Pub 21 or 802 published by he Iii Heights N For new radiant heating stem refer othe radiant manufacturer s boiler siring guidelines For systems including Crown Mega Stor indict water bester size the boiler 10 have either the DOE Heating Capacity required for the Mega Stor or the net rating required forthe beating system whichever result in the laper hor Tot sy tema that incorpore ober rect water hers refer othe indie henter manufacturer instructions for boiler output requirements Make sune boiler receive is configure for correct gas natural or LP Make sure that toris configured foc use at the alinde at which be installed NOTICE Jis prodit e talle by ce or pas fiter wn installed within the Commonweal of Masachuseti Ses Append A for tum pta informal dot hs rode win e f Mensch IV Locating the Boiler Observ the minimum clearances shown in Figure 4 These clearances apply to ud combust and non combustible material Observe the minima clearances to combustibles for vent shown im Table 2 Not the recommended serve clearances in Figure 4 1 The recommended sevice clearances may he re lc the mananam coms clearances with the understanding th src he will sony
30. ing Laboratory as recognized 327 CMR vent terminal must used and if applicable product approved intake mast be used Installation shall ein rc compliance withthe manufacturer instructions A copy he installation instructions shall remain With the appliance or equipment a the completion ol he lA metal or plastic identification plate shall be mounted at the exterior of the building four fet directly above the location of the vent terminal The plate shall be of sufficient size o read from a distance of eight fect away and rend Gas Vent Direc Below For diroct vent appliances mechanical ven heating appliances or domestic hot water equipment where be bottom of the vent terminal nd heat na alla above four fet atve grade the falling requirements must he satisfied fiber is pot alrendy one present each lor level where there are hodroomts a carbon monoxide detector and alarm shall be placed n tbe living area cute the Pedros The carbon monoid detestar shall comply with NFPA 720 2005 Edition bo A carton monoxide detector shall i Be located n the room that houses the appliance or equipment 4 Be either hard wired or buttery powered or both and ili Comply with NFPA 720 2005 Edition e A produst approved vent terminal must be used and if applicabile a product approved air intake must be used Installation shall be i strict compliance withthe manufacturer s
31. instructions A copy of the installation instructions shall ren wit appliance or equipment he completion of the installation Manufacturer of Hydronic Heating Products Box 14818 3633 1 Street Philadelphia 19134 Tel 215 535 8900 215 535 9736 www erownboilercom Pu stot Rex 3 Pr
32. ions Fig 9 1 voltage connections are located i the junction box on the ight sd of the vestibule Black Line voltage or White Neutral for boiler aerators Red Henting circulate hor Blus Water Hester circulator hot Geven Ground connection 2 Maximum continuous sument kaw is 2A When Piping Method 1 is it may be desirable to s the boiler to disc coto the primary circulator in addition to the secondary f his is done cool both heating circulators using a relay with a 20VAC coil such as Honeywell R4222 as shown in Figure 9 3 Selecta relay with a contact rating excess of be combined dran of the two circulators 3 Low Voltage Connections Fig 9 1 These connections ane screw terminals located on be terminal strip next Jo he junction on the left Terminals 1 and 2 Henting thermostat connections Terminal und 4 Limit Control connections Terminal 5 and 6 Outdoor Reset connections Terminal 7 and 8 Domestic Water Henter thermostat connection Terminal 9 Flame Signal Reading Hent anticipo setting for e thermostat connecta s 0 1 when bermosat conecte directly 19 terminal Land 2 CAUTION WHEN MAKING LOW VOLTAGE CONNECTIONS MAKE SURE THAT NO EXTERNAL POWER SOURCE I PRESENT IN THE THERMOSTAT OR LIMIT CIRCUITS IF SUCH A POWER SOURCE IS PRESENT IT COULD DESTROY THE BOILER S MICROPROCESSOR CON
33. l he vest ema discs ovet windows ar doors Pto of the vent terminal be at least 3 foet above forced air ile located wii 10 fc TUSA Alas tft nny mu e mi tawa te neal any Do pot termal over equipament In nada tr BTA aid Code fr mea regulators ad el oque Do leat the vent terminal under deck ot similar secures Top of ven terminal must be st least 5 fet below eves sofas or overhangs Maximum dep af overhang is 3 ent terminal mua hea enit fet Bom an jsi corner Under certain conditions wate in the fue gas conne and pay freeze on objects around the terminal einigen sn Im gu md oy seni posible install be vent and tk terials wall ay ro prevailing wind Reliable operation of this cannot be 1f the subjected to winds in excea of 40 mph intake ternal mus mot emit in areas that might contain combustion air contaminates such as near Swimming See Section IV for rore formation on posible contains TABLE 624 SUMMARY OF HORIZONTAL VENTING OPTIONS VENT STRUCTURE romanon LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS DOORS GRADE FIGURE 63b LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS ll Js FIGURE 65 POSITIONING VENT TERMINAL UNDER OVERHANGS 10 9 Te
34. lockwise to close the gas supply 4 Replace the upper boiler access panel and the front door pane 40 7 Sanh boiler using the lighting instructions oq page 39 Afer boder is powered up it shoul go through the following sequence Sequence Display Messing 1 Blank Checking intemal software power up oniy 2 050 Ballerinaanity SWT Supply Water Temp No call for best After call for hent from beating thermostat H on Strap 4 ssur Blower and on Checking for adequate ir ow 5 isur Prepare 6 asur Trial for ignition asur Flame establish Boiler responding to a for heat Upon initial start up be gas ai will be fled with siz Even if the gas line has ben completely purged of ai 1 may several tres f r ignition before lame s established If more than 5 Ines for needed twi be necessary to the reset buon to restar the boiler Once flame has been established for first time subsequent calls for burner operation should ret in on the fis 9 Inspect the ame visible through the window high fire he flame soul te sable and mostly Fig 0 1 No yellow tipping should be present however of yellow and orange in the fame re normal INNER CONE OUTER CONE ae lame e Tranaparant Blue BURNER SURFACE Orange Glowing Fibers Figure 10 1 BWC Burner 10 Chick the inlet pressure and adjust
35. matic Ait Ven Required At east automatic sir vent is required Manual vents will usually be ruil in other paris of the system to remove air during initiat IL Manual Reset High Limit Required by some codes control is required by ASME and sone other ode Intl he high linit in he boiler supply piping just shove the boiler with no intervening valves Set the est high to 200 Wine dhe fmt er Figures 9 1 amp 92 in the Wiring section 9 Eloy Valus Required The flow conto valve prevents through the system unless he crestor is operating Flow contral valves are used to prevent gravity or ghost flows in circulator zone tems through zones that are not calling for heat 10 lation Ya Recommended Isolation valves are weil when the boiler sunt be drained as they will having to drain and refil the entre atm 11 Dun Vly Required The dain valve installo on return ee located in the lower vestibule compartment as shown in Figure 2 12 Low Water Cuff The low water cto supplied with is oder mua not be removed D Piping for Special Situations 1 Systems containing osy en Many hydronic systems contain enough dissolved oxygen to severe corrosion damage to an aluminum boiler such athe BWC Some examples include Radiant systema that employ tubing without an oxygen barrier Systems with routine additions of fresh water Systems which a
36. n and baton the display flashes H indicating that the boiler has ben driven to high fre Ale this happens allow the boler to operate for approximately 5 minutes before taking combustion readings 2 D To lock the boiler in low fire pres and bok he Modo button and button until be display flashes 17 indicating that he has been driven to low fre Afer this happens allow the halle 1o operate for approximately 5 minute before taking combustion readings At both high and low fire CO readings shoul be les than 75 PPM Typical CO readings shown in Table 103 Normal modulation should reum 13 mines after lockat in high or ow re 12 Test any extemal ints other controls with the manufacturer s instructions 13 Verify that the boiler starts and stops in espeso to calla fr est fren the basting tt and indirect water eser thermostat Make su at the appropriate circulators alo tart and stop ta response to e thermostat Table 10 3 Typical Sea Level CO2 02 Combustion WARNING EACH BWC SERIES BOILER IS TESTED AT THE FACTORY AND ADJUSTMENTS TO THE AIR FUEL MIXTURE ARE NORMALLY NOT NECESSARY CONSULT CROWN REPRESENTATIVE BEFORE ATTEMPTING TO MAKE ANY SUCH ADJUSTMENTS IMPROPER GAS VALVE OR MIXTURE ADJUSTMENTS COULD RESULT IN PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE s XI Operation 1 The BWC boiler uses a micropmeessr fused control known asa
37. om The Hw rte rang be musi therefore al s teman lass ben m Tati casa the pressure drop le che sytem most he nan did he reu dp and a clar selected which will roads te ow the total calculated pros through sytem miis ma he ule et acc he tol nein mr irai ea ated Os en Bow may dp Sell below te minum eared whe on one one s alg Torbe hong adage hist mai sh os u ha ned hen be tem vida mew zoe mtem how are drop carves lor lore we shown pr of e om opm eo ie mus performed by opens having amar easton a an HVAC Figure 8 3 Piping Method 2 Direct Connection of Boiler to Heating System 6 00 35 00 3 g 400 2 p 200 100 0 00 0 5 10 15 20 25 Flow GPM Figure 8 9 Boiler Head Loss Standard Piping Installation Requirements Observe the following guidelines when making the seta installation of the piping 1 The relief valve package Lose wid boder and must e installed ia location shown in Figure 2 1 The lief valve is set open 30 If die valve is replaced replacement mu have ai capacity in ences of the DOE heating capacity for the boiler Pipe the discharge ofthe relief valve 1o a location where water or eum will not hazan or property damage if
38. outward gb Clean the exteio ofthe male end of the pace of ipe the inside of he vent colla oa the boiler Remove di grease and om he surfaces sealed Dry or sllow o dry thoroughly On the male and of the pipe apply a wide bead high ico approvimatl inch hom the malo end of be pipe Apply of lione alo both sides of the longitudinal aam Fig 6 Tert he mak end of the pipe the oder vent collar tls out Apply an additional ead of icone over ouside of the joint and mood Replace and tighten the clamp on he vent collar The female nd ofeach Vet Il component has a silicone sealing gasket Examine all vent component 16 insure that be gasket integrity has remained during spring Caskets must heim the proper positon or Toe as could leak resulting m carton monoxide pomor Aig the second piece of pe with e rt and Pu he together as far as hey will go but not oss Tighten clamp to minimum torque of 40 and a maximum Steps h forte reining Z Vet componente In horizontal vent systems a locking had or pr champ must be used at cir ide of the wall penetration 16 prevent shifting of be vent m and out of the wall This apples to odi combustible and non walls Allo the to cure per te silicone manufacturers instructions before operating the bier 4 Assembly of Hest Fab SOFT Vent EZ
39. per 1000 input of all instal in determine whether the room 1 a confined space I Total the input of all appliances in boiler room in thousands of BTU Round the ret next highest 1000 BU 3 Find he volume ofthe room in fet The volume of be oom in cubic feet i Length x wid iting eight i In calculating the volume of the ber room conse the vom o ning spaces enl i no doors are installed between If doors are stalled between the boler room and an dining d no consider the volume ofthe adjoining apace even if the doo normaly If open 3 Divide volume of the boiler room by the inp in thousands of BTU If Ue reisen than 0 the boiler room sa confined space ample A BWC22S water henter are o be installed room 3 im x with om cil The war heater h mn of 0000 BTL Total np in of BTU hr 228000 or 0000 BTU hr 1000 285 MBTU hr Volume 625 ft T 380 3 80288 137 Since 1 37 is less lm S0 the boiler i a confined space 2 the tiers to be placed in provide two openings the boiler room one near the doc and one new the eng The top of be upper opening mus be within 12 of be ceiling and the bottom edge of he lower opening ust be within 127 of te foor Fig 5 1 The minimum opening dimension is 3 inches Mihe BWC boiler is the only hing opinor in t
40. r outside of the joint amd out Fig 6 9 Replace and tighten he clamp on vent collar 9 Assembly of Saf Vent Vent Components Clea the male end of be pex piece of pipe with an eobol pud ai make that its free of ur Check female ed of the first pece of pipe o make Hare pasket iin pce and Uang alight isting motion he malo nd f the second iting ito the female end of ie tig taking care no w dislodge or the factory gasket n extremely ard conditions may he caer to assemble these tings i Ue gasket i with water prior to assembly Bend the locking tabs over the lock ing onthe adjacent of pipe Repeat lese sep for he Sal ent component FIGURE 69 SAF T VENT EZSEAL CONNECTION TO VENT COLLAR 5 Assembly of Protech Sea 3 FasNSeal General Noe Do mot ct 47 FasNSenl pipe Cons FasN Seal instructions for method of cutng other 3 pie Orient vet components ao that dhe arrows on the piping labels are in the direction of fue Sapport horizontal piping sections at intervals of 6 foet or le venting systema muat be supporta by at kaq oac FashSeal support An ational vertical support is any M Remove the how clamp shipped on the BWC vent collat Bend the ee clamp tabs on this collar outward slighty Clean the exer of the male end of the piece o
41. r spaces of be bung Turon lobes dryers and am appliance not to the common ven ng system Tum any exhaust fana such as runge hoods ad exse they will operate at maximum sped Do ol operate a summer exhaust fan Close fireplace dampers 4 Place in operation the being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continously 10 for spillage at the dr od relief opening afler mainte of main buer operation Use the ame of math or candle or smoke hom or pie ifi Aller has teen determined that each appliance connected to the common venting system properly vens when tested as outlines above return doors windows exhaust fam place damper and ny ber gas burung appliances o previos condition of we Any improper operation o De common venting sould corrected conforms wth the National Fuel Gas Code ANSI 2223 1 When re tzing any portion of the common venting em the common he e te to approach he uuu se determined sig the appropriate tables in Part 11 of the National Fuel Gas Code ANSI 2223 1 WARNING NEVER COMMON VENT A BWC BOILER WITH OTHER APPLIANCES C Vent take System Assembly 1 General Assembly Notes 10 Were use of silicone is called for in the following instructions use OE 106 for he vent coll inlet ip sections are s
42. re open to the atmosphere boiler is to be used in such systern it mast separated from the oxygenated water being heated with u beat exchanger as shown in Figure 10 Consult the hest exchanger manufacturer for proper best exchanger sizing well as flow temperature requirements components on the oxygenated side of bc heut exchanger such the pump and expansion tank must be designed for use in oxygenated water 2 Piping witha Chiller IF the boiler is used in conjunction with a chiller pipe the boiler nd chiller in parle as shown in Figure Use isolation valves to prevent chilled water fom entering he boiler 3 Ait Handles Where the boiler is connected to air handler through which refigrsod passes use flow control boiler piping or other automatic means o prevent gravy circulation during the cooling cycle 32 Figure 8 10 Isolation of the Boiler Prom Oxygenated Water with A Plate Heat Exchanger MEATING Wa CUSHIUN vini SUPPLY MAIN TO CDMBINED HEATING amp COOLING SYSTEM Figure 8 11 Chiller Piping RETURN MAIN FROM COMBINED HEATING amp COOLING SYSTEM IX Wiring WARNING All wiring and grounding must done in accordance with the authority having jurisdiction or in the absence of sash requirements withthe National Electrical Cade ANSUNFPA 70 1 Line Voltage 120 VAC Connect
43. ret tempera increases For example if the outdoor temperature is 30 F the set point temperature for the supply water is 55 F 5 An indie water heater thermostat can be connected between terminals 7 and on the terminal sirip When this thermostat closes the central heating cireulator will be armed off andthe DEW ciroulator will be mel O An external mit control can be installo between terminals 3 and 4 on the terminal sirip sure to remove the jumper benwoen terminals 3 and 4 when adding an external mit controlo de system Ifthe external limit opens boiler will shut down and errar oode B 267 will be displayed 1f fc limit installed is manual ype it wil neod to be reser before the boiler will operate a Supply Water Target Temp 2 roo Outdoor Ak Temp F Figure 11 4 Outdoor Reset Curve 7 The sequence of operation for s BWC series boiler oma call or best ftom thermostat is as deserihsd below 4 When powers first turned on 120V i provided othe MCBA the combustion fan nd the LWCO wans former A separate SOVA transformer connected direetly to the MCBA powers all other low voltage circuit P For the is few seconds ater power the control module poes rough self check When there ino call for est the control nesh check to make ur the air pressure open iti combustion fan wil be energized and will rump up to speed When he pressure seh clones 10 end prepuge is acti
44. rminals fo Vertical Venting Ven Options 6 7 rodent s installed in the end ofthe vent Vent manufacturer part numbers fr tese screens are shown m Ta 4 The ar inet terminal consists of a degree elbow or tua 90 dere cns wah a rodent as shown Figure 64 Observe following limitations oa the location of all Vertical vent terminals see Figure 64 The top of he vent ipe us bt east 2 feet tore ay object located within 10 feet The vertical distance between tap of e vent and air termi opening must boat as 12 Te boom of e ile terminal mast be at kas 12 above be normal mw accumulation that cun be expected e mot The terminal ust be Located on the rof and mast no futher than 24 horizontally fios the exhaust Pie Will Wall are where the vert pipe passes tough combos walla with estan bo clearance shown Table 4 2 es rogue y al cades Vent manufacturers wall dim ar numbers shown in Tabl 6 5 Pich a Horizontal piping horizontal vent piping mes be Y per foot o thst any condensate which un thus pupung wi towards bed 10 Vertical and horizontal eins of piping must be properly supported See vent system manufacturer s instrustions Tor more formation 11 Bite Stops Use ire stops where required by code or by the vent system manufacturer Consult ven manufacturers teritur or information on ata
45. round boiler fre from combustible materials gasoline and ther vapors and qdo P Keep the are around the air inlet terminal re from contaminates Keep the room ventilation openings open and 2 Month Inspections Inspect vent piping end outside ir itae piping o er they are open unchameted and ive leakage or deterioration Call the service technician make ram i needed spt the condensate dain system o verify is leak tight open and Call the service lechoscun if he drum sy em manera water and gas lines to verily they are fe from kaba Call the service technician to make rem if required CAUTION WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPONENTS IMMEDIATELY REPAIR ANY LEAKS FOUND 4 Annual mecano Service tn ution to the inspections Listed above the following should be per formed by a service technician once every year Test the low wate cutoff by pressing the Tes button located its end The yellow light should come on and E LZ sould fash oa the display Push the reset button on the display o restore normal operation I the yellow light does mot comme on determine why the low water eof i not working property 1 Follows the procedure for turning the oie off found in the BWC Series Lighting und Operating instructions pest he wiring to verify the conductors are m
46. s and factory supplied fitings are ignored total equivalent length frorn Tabte 87 156 Straight Pipe 7 Elbows x 175 2 Runs of Tees x 25 1 Swing Check x 1042 valves x 08 575 Five Foot Sigh Pye From Tabie S wee Tao 0 al amp PA INCISO wth TAS equivale fet of pape so Taco OO S OR Total fittings in Water Heater Loop 69 Elbows ums in Tees 1 Swng Check 2 ato aves 9 Calculate total equivalent length from Table 87 20 Straight Pipe 6 Elbows x 3 75 2 Tuma ia Tees x 8 1 Swing Chock x 10 2 valves x 0 Eat St ale we aa ae wich wl BWCISO wth 701 equivalent fet al an tico water hee Presse drop of 3 701 Taco 0010 Figure 8 2 Piping Method W1 Heat Only Figure S 4b Piping Method 1 Indirect Water Heater Loop Piping Shaded 2 w w w 0 LOOP MAX pire size row PRESSURE EQUIVALENT DROP LENGTH im wens iw 50 Toon Ts 11 we 30 7 Can ig e TABLE 8 7 FITTING EQUIVALENT LENGTHS Method 2 Direct Connection to Heating System Generally NOT Recommended The BWC can be connected directly o heating tem as n done with conventional boilers Figure I thn gh the teri lt p the ow ough be v
47. t parameter 4 or the DHW reference set point parameter 1 are set above bei factory set vales the boiler supply temperature will exocod 180 and there isa possibility that the safety temperature will open this happens the boiler will shut down and a 267 eror will appear the display The boler will resume normal operation without manual when the safety imi closes behavior common on conventional holes Information mode is used view various temperatures and stings but cannot he used o change parameters or otherwise control the boiler The information available is shown in Figure 11 2 and is largely self explanatory The hito the of the decimal point the Step number and tbe digit te he right are the corresponding temperature information mode the supply water temperature set point Step 6 is the supply temperature set point for the one to which the boiler is currently responding either heat or DHW If an outdoor sensor is connected the Poir and the boiler is responding to eall or heat this val will be current point on the reset curve When no call for hest or DHW is present Step 6 shows the heating supply set point In some cases a 22 will appear in Information Mode for a particular reading This moans the reading not applicable For example 22 will appear for the outdoor temperature Step 4 if no outdoor sensor is connected o the boiler as
48. the valve opens The end of he dischrge must termina tn an pipe IF eif valve discharge is ot drain mus terminate at 6 inches above the floot Do not run relief valve discharge piping rough an area at is prone to freezing The termination of dhe lief valve discharge piping e aan where ti ot keh to become plugged by debi 2 The fining in which he gauge ele v speci location Fire 21 vend LWOO anto te mounted ens net be rom de factory DANGER PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION STALL VALVE IN THE RELIEF VALVE DISCHARGE LINE STALL RELIEF VALVE INA LOCATION OTHER THAN THAT SPECIFIED BY THE FACTORY DO NOT PLUG THE RELIEF VALVE DISCHARGE 3 The return piping may be connected no the oder tough the buc ar sides of the oder by rotating the drain bow and routing return piping he appropiate 4 Required Usually at lens two circulators equi properly install a BWC Series boiler See previa section 5 sem Design fo mientos sa sing de 5 Expuasion Tank Required 1 is boiler is replacing an existing boiler with no other changes n the system the ld expansion nk can generally be esed Ifthe evpunseoo ak gus be replaced conl de expansion nk manufacture rata for proper sing 6 ElL Vals Required Either mnaman c stes salve may e used The ideal locaton for the iste expansion tank 7 Auto
49. tm PH Maintain PH in he system between 6 5 ad 83 39 BWC Series Lighting and Operating Instructions FOR YOUR SAFETY READ BEFORE LIGHTING SSES WARNING If you do not follow these instructions exact a fre or explosion may result causing property damage personal injury or oss of We A This appliance does not have a pilot tis equipped wit an gation device which automaticaly lights the bumer Do patty to light the bumer by hand BEFORE OPERATING smell al around the appllance area for gas Be sure to smell next to the noor because some gas ls heavier than air and wil sete on the WHAT TO DO IF YOU SMELL GAS Do not y to ght any appliance Do not touch any electric watch do not use any phone in yourbuliding Immediately your gas supplier a neighbor s phone Folow gas suppliers instructions 1 STOP Read safety Information above on this label Set the thermostat lowest setting Tum all electric power to appliance 4 This appliance s equipped with an ignition device which automatically te burner Do na to light me burner by hand amp Remove nont door panel and upper boilor access panel Open Sr de L 1 External Boiler Manual Gas Valve 1 Turn off all electric power to the appliance if service s to be performed 2 Set he thermostat to the lowest sting JU OPERATING INSTRUCTIONS wasa M
50. tpe B Removing an Existing Boiler From Common Chimney FIGURE 64 VERTICAL DIRECT VENT SYSTEM VENT OPTIONS 6 on i i 1 i SCREEN Y VENT SYSTEM NASCIACTUMII TAME DONI VAS VET SYSTEMA SEE TAI as nome NA ee n NOTE See vent system manufacturer s literature for otber part numbers tha are required such a straight pipe bow and vent supper TABLE 66 VENT AIR INTAKE FITTING EQUIVALENT LENGTH Read this only if the BWC boiler is replacing an existing boder dai being removed a common chim This section doesnot apply to the inlata of a BWC boiler some cases when an sisting boiler is removed from common chimney the common venting system may eto lage fa the remaining appliances Athe time of removal of an existing boiler following es shall be followed wah cach appliance remaning connected to he comae Venting y em placed in operation While the thur appliances remaining connected i the common venti system ae ot operation 18 Soul any unused openings in the comunn veria system 1 Visually venting system fo proper sue and horizontal puch and determino hene is no blockage or restriction leakage and ober wluch cou cause an condita 6 ss encia loe bug doors and wandows sd doo betwen the quce which all the appliances remaining connected the common venting sy tem are and othe
51. trol setings Information Displays oder operating temperatures Under normal conditions the bier ts m tay mode and display hooks thal shown in Figure 1 1 The three digits the right of the decimal port are the hers supply temperature The digi 1o the kf of the decimal poit is the boe stats A h of satus codes and Det meanings shown m Table 11 3 Figure 12 is a mop of menu for control pane Push be mode ky to move fom one mode to the nex As you change modes Ihe rode yon are entering on the display 2 PAA for Parameter Modo M iF for Information Mode 5 Stay for Standby Mode Upon entering standby mode Sty will briefly appear on the display and ien display will show the oder statas along with the spy temperature Figure 1 1 he contro wil retur to standby mee fom any ber modes po ey n pressed for 20 minutes standby mode tis posible to view the eating aspi se pit temperatus al the domes hot waler reference set point The domestic hut water reference plus 45 F equi the boiler supply set point when itis responding to a om he indirect water zone is pot e actual domestic hot set point The BWC is designed for e witha storage type indirect water Bate such she Crown The domestic waler set controlled by the thermostat a be direc water beste The default domestic water reference point ls 13
52. unts of open II Specifications Figure 2 1 General Configuration p RE m an se 25 ES iunc rum FU INLET EXHAUST E UN RR RR 5 9 9 TII Before Installing Saf reliable operation of bi oder depend pon installation by a professional hosting contractor in strict accordance with this manual and the authority kaving jurisdiction tntheatwence of anaubeci having jurisdiction instalation mus be in accordance with this manual ad the National Fuel Gas Cade ANSI 2223 1 In Canada installation mast bei accordance with he BO Code Whore requie by the authority having jurisdiction this installation must confor 1o the Stand for Controls and Safety Devices for Automatically Fired Balers ANSUASME BWC boilers lie aluminum exchangers construed teste dl qanspod in acconanee with ASME oiler and Press Vessel Code Case 2382 2 Some jurdictons which seguire ASME boiler construction do mot tocognize this Code Case and may not approve the instalas of sn alium boiler Consul the h having jurisdiction before isang tus her Read Section VI to verify that the maximum condesion i and exhaust pipe lengths will ot he exceed n the installation Abo verify thatthe vent emia can be load n accordance wih Section VIL Make sue tat the bo
53. vated After the prepurge the contr module energizes the gas control valve and the for 4 5 seconds Farne is established and proved the control allows he flame sable or 5 seconds at he combustion fan ignition sped sening Ihe Dame foils to prove the control module will attempt o light the burner 4 more times flame ssl ot established the control will lockout Once the flame stabilization period has ended the MCBA allows the burner io modulate The actual fring ae Ix dependent gen he measured current ad recent differences Nennen the lt t ennt temperate are the up Temperatur our semor 1s connected he control medal nd he enler t responding to cal for the set point temperature determined by the outdoor reset curve shown in Figure 114 D Once the set point temperature is reached MCBA will uen the burner of allow the combustion fan to operate in postpurge for 35 seconds before it tms The central easing pump will continu to operate eti om thermostat has Fonsi or domestic bot water DIW is given priority on BWC series boilers Ifa call for DHW is received While the boiler is responding to a for best tbe eating circulator deenergized until call for DHW is sated Service and Maintenance IMPORTANT WARRANTY DOES NOT COVER BOILER DAMAGE OR MALUFUNCTION IF THE FOL LOWING STEPS ARE NOT PERFORMED AT THE INTERVALS SPECIFIED Keep the are a

Crown Boiler DTR220 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents