Home

Crown Boiler BSI069 User's Manual

1. VENT DAMPER NOTE 2 HONEYWELL VENT DAMPER 882288 POWER SUPPLY WIRING HARNESS SPDT RELAY 120 60 1 1 3 RE HWS YE 24V THERMOSTAT BY OTHERS PRIMARY 1 Jj SECONDARY THERMOSTAT ITEMS SUPPLIED BY INSTALLER GND 40VA TRANSFORMER L2 Dower L1 SUPPLY 120 60 1 SERVICE FUSED DISCONNECT SWITCH SWITCH CODE 7 LESS VENT BLACK DAMPER BLACK WITH WHITE TRACE 2 V8295A GRAY WITH WHITE Ba BSI310 379 ONLY BLUE FLAME BLOCKED 1 i ROLL OUT VENT ae BROWN SWITCH SWITCH i FRS BVS ANGE LADDER DIAGRAM LEGEND 24V WIRING YELLOW 120 WIRING PINK RD YE RED WITH YELLOW TRACE SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYP TEW AWM STRANDED WIRE 105 C LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X OR POWER LIMITED CIRCUIT CABLE 105 C LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE NOTES LINE VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE i 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT 2 VENT DAMPER REQUIRED ON 51069 BSI276 OPTIONAL ON BSI310 BSI379 3 ON BOILERS LESS VENT DAMPER DAMPER HARNESS NOT USED RED AND BLUE LEADS SHOWN ARE JUMPERED TOGETHER USING RED JUMPER WIRE FIGURE 17 WIRING DIAGRAM
2. SEE TEXT FOR OPENING SIZE FIGURE 7 ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM VI Venting Vent installation must be in accordance with local building codes or the local authority having jurisdiction or the National Fuel Gas Code NFPA 54 ANSI Z 223 1 A typical vent installation is illustrated by Figure 8 The components of vent installation are the vent damper if used vent connector and chimney 1 Acceptable Chimneys The following chimneys may be used to vent BSI series boilers Listed Type B or L gas vent Install in accordance with the manufacturer s instructions the terms of its listing and applicable codes Masonry Chimney The masonry chimney must be constructed in accordance with the Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances NFPA 211 and lined with a clay liner or other listed lining system Do not vent a BSI series boiler into an unlined chimney 2 Acceptable Vent Connectors The following may be used for vent connectors Listed type B or L Gas Vent Single Wall Galvanized Pipe Use 0 018 26 gauge or heavier The size and location of the chimney may not permit the use of a single wall connector in some cases See the National Fuel Gas Code Do not use single wall pipe for vent connectors in attics Other Vent Connectors Permitted by the National Fuel Gas Code 3 Chimney and Vent Connector Sizing Size the c
3. HIGH LIMIT SET FACTORY WIRING NOT WIRE CONNECTION 9 98 Xe BLUE BUILER THERMOSTAT CONNECTION FUSED DISCONNECT NEUTRAL BROWN BOILER THERMOSTAT CONNECTION _ lt CIRCULATOR FIGURE 15 WIRING INDIRECT WATER HEATER TO BOILER 18 BSI Control System Sequence of Operation Refer to Figures 16 through 19 for ladder and connection diagrams Sequence of Operation Standing Pilot 1 When the boiler is energized 24 volts is immediately applied to terminals 1 blue and 4 yellow on the vent damper Assuming that there is no call for heat and that the damper switch is in the automatic position the damper will close On boilers equipped with Hydrolevel CG400A probe type low water cut offs voltage is also always applied to terminals 1 blue and 2 yellow on the low water cut off to power the water level sensing circuit On boilers equipped with 67 float type low water cut offs power is always applied to terminal 2 on the 67 LWCO 2 Assuming that water is above the cut off level power will appear at terminal 3 on the CG400 LWCO or terminal 1 on the 67 LWCO 3 Assuming that steam pressure is below the pressure limit setting power will appear on one side of relay contact IRI Gray lead Relay 1R 1s the R8225 mounted under the
4. CG400LW CO J BOXHARNESS 9601405 tea tea tea tea PRESSURELIMIT J BOXHARNESS 601210 tea tea tea fea INTERMITTENT IGNITION HARNESS 9601100 tea tea tea ea RED JUMPER HARNESS LESS DAMPER NN BOILERS ONLY 9601355 tea tea 1 PICTURED 45 Appendix A Knockdown Boiler Assembly Instructions A Before Installing 1 Thoroughly inspect the cast iron heat exchanger for any shipping damage i e cracks in the castings broken lugs or punctures due to mishandling 2 Do not use the heat exchanger if there is any damage to it 3 Inspect the joints between the sections for openings Reseal any openings with high temperature silicone sealant 4 Keep the base in the shipping carton until it is time to perform the assembly This keeps foreign material from contaminating the burners or creating other hazards Do not use the base assembly if there are any signs of visible damage 5 Review all of the installation requirements in this installation manual B Base Assembly Preparation 1 The combination base burner manifold is shipped assembled from the factory The combination gas valve is shipped assembled and can be found in the Base Box 2 Smear a thin layer of silicone in several places across t
5. etse te RR TR 4l Appendix A Knockdown Boiler Assembly 47 I Product Description The BSI series boilers are low pressure cast iron gas fired steam boilers designed for use in closed steam heating systems These boilers are Category I draft diverter equipped appliances which must be vented by natural draft using a lined masonry or listed metal chimney system An adequate supply of air for combustion ventilation and dilution of flue gases must be available in the boiler room These boilers are not designed for use in process or other open steam systems H Specifications 2 SuPPLY DIA Hf PRESSLRE GAUGE TRANSFORMER amp RELAY NORMAL WATER LINE GLASS DRAIN VALVE A e ALTERNATE v 2 RETURN 2 RETURN GAS VALVE LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW FIGURE 1 BSIBOILERS GENERAL CONFIGURATION TABLE 1 BSISPECIFICATIONS BASIC NUMBER HEATING WATER BOILER OF INPUT CAPACITY DIMENSIONS in 1 MODEL SECTIONS MBH MBH B 510695 80 0 511035 80 0 511385 80 3 511725 80 6 512075 80 9 512415 80 0 512765 80 3 513105 BSI310E 513455 BSI345E iin BSI379S 979 30 45 7 16 Combustion efficiency Volume to normal water line NOTE BSI345 and BSI379 not available for use with LP gas Suffix E Intermittent Ignition Suffix S Standing Pilot Add Suffix N for Natural Gas or Suffix L for Propane Gas
6. Short cycling on low water Boiler or system Flooding Hammering Failure to heat one or more radiators Avoid the three common piping mistakes shown in Figure 12 This applies even if the existing boiler has one of the piping mistakes shown in Figure 12 and appears to be working If two or more steam mains must be connected to the boiler connect a separate take off for each main into the header between the riser s and equalizer Also note the following points 1 A size reduction must be made to connect the header to the equalizer This reduction must be made in the equalizer line Do not make this size reduction in the horizontal header 2 One pipe steam systems require air vents on each radiator as well as at the end of each main For the system to work properly these vents must be properly installed sized and be in good condition Inspect and replace any defective vents If there are no vents at the ends of the mains install them 3 Do not attempt to manifold multiple BSIs with gravity returns 4 For installations with condensate or boiler feed pumps follow the pump manufacturer s piping instructions Such systems generally do not require Hartford loops 5 Do not use a check valve in place of or in addition to a Hartford loop on a gravity return system 6 Pipe the fill connection from a clean source of cold water When the water supply is from a well make sure that a strainer is installed in the well system
7. 7 Piping with a Chiller Ifthe boiler is used in conjunction with a chiller pipe the boiler in parallel with chiller Use isolation valves to prevent chilled water from entering the boiler 2 Piping Installation 1 Remove parts bag from boiler crate 2 Install safety valve spindle must be in vertical position into tapping on boiler left side see Figure 1 using the 3 4 NPT nipples and elbow supplied 3 Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens The end of the discharge pipe must terminate in an unthreaded pipe If the safety valve discharge is not piped to a drain it must terminate at least 6 inches above the floor The termination of the safety valve discharge piping must be in an area where it is not likely to become plugged by debris or subjected to freezing DANGER PIPE SAFETY VALVE DISCHARGE TO A SAFE LOCATION DO NOT INSTALL A VALVE IN THE SAFETY VALVE DISCHARGE LINE DO NOT MOVE SAFETY VALVE FROM FACTORY LOCATION DO NOT PLUG SAFETY VALVE DISCHARGE DO NOT INSTALL A SAFETY VALVE WITH A SETTING GREATER THAN 15 PSI 4 Install drain valve into tapping on boiler left side using the 2 x 3 4 bushing provided see Figure 1 5 Connect system supply and return to boiler See Figure 11 The BSI069 BSI172 require only one supply riser Two supply risers are required on the BSI207 and larger sizes 6 Piping wit
8. 2 Turn off all electric power to the appliance if service is to be performed 27 LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000DERHC SERIES GAS VALVES INTERMITTENT PILOT FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition f you cannot reach your gas supplier call device which automatically lights the pilot the fire department Do not try to light the pilot by hand C Use only your hand to push in or turn the gas BEFORE LIGHTING smell all around the control knob Never use tools If the knob will appliance area for gas Be sure to smell next not push in or turn by hand don t try to repair it to the floor because some gas is heavier than call a qualified service technician Force or air and will settle on the floor attempted repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been Do not try to light any appliance under water Immediately call a qualified service Do not touch any electric switch do not technician to inspect the appliance and to use any phone in your building replace any part of the control system and any Immediately call your gas supplier from gas control which has been under water a neighbor s phone Follow the gas supplier s instruc
9. OFF Do not Force 2 Turn off all electric power to the appliance if service is to be performed 25 LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000 SERIES GAS VALVES STANDING PILOT FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance has a pilot which must be If you cannot reach your gas supplier call lighted by hand When lighting the pilot follow the fire department these instructions exactly C Use only your hand to push in or turn the gas BEFORE LIGHTING smell all around the control knob Never use tools If the knob will appliance area for gas Be sure to smell next not push in or turn by hand don t try to repair it to the floor because some gas is heavier than call a qualified service technician Force or air and will settle on the floor attempted repair may result in a fire or explosion wat TO DO IF YOU SMELL GAS Do not use this appliance if any part has been Do not try to light any appliance under water Immediately call a qualified service Do not touch any electric switch do not technician to inspect the appliance and to use any phone in your building replace any part of the control system and any Immediately call your gas supplier from gas control which has been under water a neighbor s phone Follow the gas suppli
10. Use the following procedure for initial start up of the boiler 1 2 3 4 5 6 8 9 10 12 13 14 15 Make sure that boiler is filled with water to the normal water line 28 3 4 inches above the floor pad which the boiler is installed Check all new gas piping for leaks and purge piping sections that are filled with air See Part 4 of the National Fuel Gas Code for additional information on testing and purging gas lines WARNING NEVER USE A FLAME TO 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 DAMPER MUST BE IN OPEN POSITION WHEN APPLIANCE MAIN BURNER IS OPERATING Verify that vent system is complete and free of obstructions before attempting to fire boiler Inspect all wiring for loose or uninsulated connections Make sure the main burners are seated properly in the rear of burner tray and on orifices Adjust steam pressure limit control for a cut in pressure of 0 5 psi and a differential pressure of psi Adjust thermostat to the highest setting Start the boiler using the appropriate lighting instructions for the gas valve on the boiler on pages 25 28 Upon initial start up the gas train will be filled with air Even if the gas line has been completely purged of air it may take several tries for ignition before a flame is established Once a flame has been established
11. CLEARANCES TO ALL TYPESOFCOMBUSTIBLECONSTRUCTION AND NONCOMBUSTIBLE CEILINGS WALLS AND DOORS 4 Donot install this boiler in a location where gasoline or other flammable vapors liquids will be stored or used Do not install this boiler in an area where large amounts of airborne dust will be present such as a workshop 5 The boiler should be located as close to the chimney as possible 6 Do not install this boiler directly on a surface that may get wet Raise the boiler on a pad V Air for Combustion and Ventilation Sufficient fresh air must be supplied for combustion ventilation and flue gas dilution Provisions for combustion ventilation and flue gas dilution air for gas utilization equipment vented by natural draft must be made in accordance with local building codes or in absence of such codes in accordance with sections 5 3 3 and 5 3 4 Air for Combustion and Ventilation of the National Fuel Gas Code NFPA 54 ANSI Z223 1 To ensure an adequate supply of combustion ventilation and flue gas dilution air supply start by determining whether the boiler is to be installed in a building of unusually tight construction A good definition of a building of unusually tight construction is one which has all of the following features e Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm less with openings gasketed and sealed Weather stripping has been added on
12. MOUNTING BRACKET a 6 L 7 L 8 L 4 5 1 17 4 2 2 24 900121 90 048 90 212 900102 900103 900101 1 900145 90 201 90 215 900125 1 1 1 1 1 1 1 2 4ea 4ea 4ea 2 ea 2ea 2 ea 4ea 4ea 4 ea 3ft 4ea 4ea 4ea 4 4 4ea 4ea 1 1 1 1 1 41 1 1 2 ea 4 4 4 4 4 1 1 2 4 4ea 1ea 1 2 ea ea 1 1 2 4 4 4 4 4 4 4 4 4 4 4 1 1 2 4 4 1 DESCRIPTION EU OR QUANTITY PER BOILER OR CROWN WN 2 18 41 1 BURNER WITH PILOT BRACKET 180502 Q350 PILOT 1 BURNER WITH PILOT BRACKET QT WAT PLOTS sm 1111 1 BURNER WITH PILOT Qr LP PLOT UO I ee ee 2 2 42 t BURNERLESSPILOT BRACKET 150501 2 4 8 11 13ea 15ea 17 20 22 44 GAS ORIFICE 1 25mm DRILL SIZE 950336 EXCEPT 40mm BURNERS VR82
13. STANDING PILOT AND McDONNELL amp MILLER MODEL 67 LOW WATER CUTOFF Safety Control Operation Standing Pilot and Intermittent Ignition Hydrolevel CG400A Low Water Cut off Interrupts burner operation if the water in the boiler drops below a safe level As the water drops past the cut off point the amber lamp on the CG400 will glow The CG400 will interrupt power to the burners 15 seconds after the water level drops past the cut off point This feature prevents short cycling of the burners due to a bouncing water line The burners will then remain off until 30 seconds after the water level has been raised above the cut off point The CG400 is also equipped with a feature which will shut down the burners after they have been firing for 10 minutes regardless of the water level status The CG400 then keeps the burners off for 90 seconds allowing the water level and any foam which is present to settle During this 90 second interval the green LED on the CG400 will glow If the water level is still above the cut off line at the end of this 90 second interval the CG400 will restart the burners The vent damper will close when the low water cut off interrupts burner operation McDonnell amp Miller 267 Low Water Cut off Interrupts burner operation if the water in the boiler drops below a safe level Burner operation is restored when the water level in the boiler is raised above the cut off point The vent damper will close when the low water cut
14. TSHAW 7000ERHC OUTLET PRESSURE THERMOCOUPLE TAP SIDE CONNECTION PILOT ADJUSTMENT LNDER CAP SCREW 218185 He GAS INLET ES PILOT HONEYWELL CONNECTION 295 INLET PRESSURE PRESSURE REGULATOR TAP SIDE UNDER SCREW gt GAS CONTROL KNOB FIGURE 23b GAS VALVE DETAIL ROBERTSHAW 7000 AND HONEYWELL V8295 STANDING PILOT GAS CONTROL KNOB PILOT ADJUSTMENT __ UNDER CAP SCREW PILOT OUTLET UTLE ET OUTLET PRESSURE WIRING TERMINAL PRESSURE REGULATOR UNDER CAP SCREW VIEW FIGURE 24a GAS VALVE DETAIL HONEY WELL VR8204 AND VR8304 INTERMITTENT IGNITION OUTLET PRESSURE PILOT ADJUSTMENT TAP CON SIDE UNDER SCREW PILOT CONNECTION OUTLET GAS INLET PRESSURE REGULATOR UNDER SCREW GAS CONTROL KNDH FIGURE 24b GAS VALVE DETAIL ROBERTSHAW 7000DERHC INTERMITTENT IGNITION 30 Turn off gas supply to boiler per the appropriate Lighting and Operating instructions on pages 25 28 Drain hot water from boiler through boiler drain valve to a location where hot water can be safely discharged Refill the boiler to normal water line level If water in the gauge glass does not look clear repeat above boil out procedure again until water 18 clears f Reinstall safety valve and related piping g Conduct pH and Al
15. approximately 94 diameter hole in the vent damper blade which must be left open for boilers equipped with standing pilot and should be plugged on boilers with an intermittent pilot system using the plug supplied with the damper Mount the vent damper on the flue collar without modification to either and secure with sheet metal screws Make sure screws do not interfere with damper blade operation Vent damper blade position indicator must be visible to users c The damper wire harness is shipped wired into the boiler junction box Plug the loose end of this harness into the damper and secure the flexible conduit to the damper using a connector nut provided d Install vent connector pipe and vent fittings from vent damper outlet to chimney or gas vent Secure with sheet metal screws and support as required Removing an Existing Boiler from a Common Chimney In some cases when an existing boiler is removed from a common chimney the common venting system may be too large for ther emaining appliances At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a b c d e 8 Seal any unused opening in the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine
16. controls have not shut off the boiler Upon test completion refill the boiler to the normal water level 19 Check pressure limit control operation When steam pressure is registered on pressure gauge lower pressure limit setting below gauge reading For standing pilot boiler models pilot burner should remain lit when the main burners stop firing For intermittent ignition boiler models both pilot burner and main burners should stop firing Raise pressure limit setting above gauge reading The main burners for standing pilot boiler models or pilot burner and main burners for intermittent ignition boiler models should relight 20 After the boiler has operated for approximately 30 minutes check the boiler and heating system piping for leaks Repair any leaks found at once 21 Inspect the vent system for flue gas leaks Repair any leaks found before leaving the boiler in operation 22 Replacement of a steam boiler tends to break loose accumulated scale from the system During the first week of operation blow down the 67 low water cut off at least three times following the blow down instructions on the yellow sticker adjacent to the low water cut off 23 After new boiler has been installed and put into continuous operation for several days clean the boiler of oil grease sludge and other contaminants that may have been present in existing piping This will prevent unsteady water line and water carry over into supply main The boiler boil
17. for the first time subsequent calls for burner operation should result in a flame on the first try Observe pilot burner flame See Figure 20 for standing pilot Pilot burner should produce single steady medium blue flame covering around 3 8 to gt of thermocouple tip See Figure 21 for intermittent ignition Pilot burner produces three flames The center one should be a steady medium blue flame covering around 3 8 to gt of spark electrode flame rod Make sure vent damper is in open position when main burners are firing Inspect the main burner flames visible through the observation port in burner access panel The flame should be stable and mostly blue see Figure 22 No yellow tipping should be present however intermittent flecks of yellow and orange in the flame are normal Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is firing Fix any leaks found immediately Run gas valve safety shutdown test For standing pilot boiler models disconnect the thermocouple from gas valve Both pilot burner and main burners should stop firing For intermittent ignition boiler models with main burners firing disconnect ignition cable from ignition module Both pilot burner and main burners should stop firing 23 16 Check the manifold pressure and adjust if necessary To do this use the following procedure WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDUR
18. junction box 4 Acall for heat from the thermostat energizes relay coil causing contacts 1 1 to make Current then flows through contacts 181 to pin terminal 2 orange at the vent damper and the damper opens 5 Once the vent damper 18 fully open an end switch inside the damper will make energizing pin 3 red at the damper 6 Current passes from terminal 3 on the vent damper though the flame rollout and blocked vent spill switches Under normal conditions both of these switches are made and voltage will therefore immediately appear across the combi nation gas control gas valve terminals and TR 7 When the boiler is first placed into operation the pilot must be lit The pilot heats a thermocouple which generates a small amount of electricity sufficient to hold open the safety shut off valve in the combination gas control The circuit connecting the thermocouple and the safety shut off valve is self contained and completely independent of all other wiring on the boiler This safety shut off valve 18 upstream of the 24 volt valves in the gas control which open in response to a call for heat If the pilot is not lit the safety shut off valve will remain closed and gas will not reach the 24 volt valves 8 Assuming that the pilot is established and proven by the thermocouple the application of 24 volts across the combina tion gas valve terminals energizes the redundant 24 volt solenoid valves in
19. of 48 volts across the relay coil In older buildings this transformer may be hidden in a location far from the boiler If this second transformer exists it must be found and removed before the R8225 is replaced When checking voltage across damper harness pins be careful not to insert the meter probes into the pins Doing so may damage the pin resulting in a loose connection when the harness is reconnected Troubleshooting Chart for BSI Boilers Equipped with Hydrolevel CG400A Low Water Cut offs and Vent Dampers Caution Read page 34 before attempting to use this chart Is there an audible Thermostat click as R8225 relay calls for heat pulls in w hen the thermostat calls for heat 5 yellow LED lit on LWCO 24 volts betw een P2 and 2 on CG400 LWCO 120 volts across black and w hite transformer leads Jumper missing 24 volts across betw een 1 and P1 on blue and yellow CG400 wires inside Poor connection junction box betw een transformer and terminals 1 amp 2 CG400 24 volts present betw een each Boiler off on low water Pow er off press wan Loose probe connection Poor ground path from PON SSO 24 volts yellow transformer heat g h to CG400 tripped present across connection eat exchanger to breaker brown and case Misw ired or yellow leads on loose 120 volt R8225 re
20. openable windows and doors e Caulking and sealants are applied to areas such as joints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines and at other openings 1 2 3 1 For Buildings of Other than Unusually Tight Construction 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 18 a confined space Total the input of all appliances in the boiler room in thousands of BTU hr Round the result to the next highest 1000 BTU hr Find the volume of the room in cubic feet The volume of the room in cubic feet is Length ft x width ft x ceiling height ft In calculating the volume of the boiler room consider the volume of adjoining spaces only if no doors are installed between them If doors are installed between the boiler room and an adjoining space do not consider the volume of the adjoining space even if the door is normally left open Divide the volume of the boiler room by the input in thousands of BTU hr If the result is less than 50 the boiler room is a confined space Example A BSI172EN a water heater are to be installed in a room measuring 6 ft 3 in x 7 ft with an 8
21. out should be done as follows a Turn off gas supply to boiler per the appropriate Lighting and Operating instructions on page 25 28 b Drain water from boiler until about one inch of water is visible in gauge glass c Runahose or temporary piping from the boiler drain valve to a location where hot water can be safely discharged Drain approximately five gallons of water from the boiler and mix in an appropriate amount of an approved boil out compound Remove safety valve and refill the boiler with prepared solution through funnel inserted into elbow under the safety valve Run hose or temporary piping from safety valve tapping to a location where hot water be safely discharged DO NOT INSTALLANY VALVES IN THIS LINE d Light offthe boiler per the appropriate instructions on page 25 28 Run boiler for several hours boiling the water without generating steam pressure Open the water feed valve sufficiently to allow a slight overflow of water through the safety valve tapping drain line Continue boiling until water coming out is clear 29 GAS CONTROL KNOB PILOT ADJUSTMENT RED RESET BUTTON UNDER CAP SCREW __ THERMOCOUPLE PILOT OUTLET CONNECTION INLET PRESSURE TAP urLET E Ti Lai OUTLET PRESSURE PRESSURE REGULATOR WIRING TERMINAL ADJUSTMENT UNDER CAP SCREW Ew FIGURE 23a GAS VALVEDETAIL HONEYWELL VR8200OR VR8300 STANDINGPILOT LIBER
22. 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 These troubleshooting charts assume that the vent damper is closed at the beginning of the troubleshooting process With the 120 volts applied to the boiler and no call for heat the damper should go to the closed position If it does not do the following Confirm that 120 volts is applied to the boiler and that there is no call for heat Make sure that the switch on the damper is in the automatic position Unplug the harness from the damper and check for 24 volts across pin 1 blue and pin 4 yellow If voltage is present the damper is defective or there is an obstruction in the path of the damper blade fno voltage is present there is either a loose connection in the damper harness or the transformer is defective If the charts indicate that the transformer is defective it is possible that this transformer has been destroyed by a short circuit in the boiler wiring Before replacing the transformer carefully inspect all low voltage wiring on the boiler for places where it is touching the frame of the boiler or wiring on the other side of the transformer If the charts indicate that the R8225 relay is defective there is a good chance that a second transformer is present in the thermostat circuit resulting in the application
23. there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Insofar as practical close all building doors and windows and all doors between the space in which all the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so the appliance will operate continuously Test for spillage at the draft hood relief opening after five 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliances to their previous condition of use Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined usin
24. this manual to complete boiler installation 51 LEFT SIDE VIEW RIGHT SIDE VIEV FIGURE A3 TAPPING LOCATIONS SEE TEXT FOR TAPPING USES 52 CROWN Boiler Co Manufacturer of Hydronic Heating Products P O Box 14818 36331 Street Philadelphia PA 19134 Tel 215 535 8900 Fax 215 535 9736 www crownboiler com
25. 00C6008 i 40mm BURNERS ONLY VR8200C6032 i VR8204C6000 GAS VALVE STND PILOT NAT GAS 3507110 EXCEPT 40mm BURNERS VR8300C4134 GAS VALVE STND PILOT NAT GAS 3507355 40mm BURNERS ONLY VR8300C4183 GAS VALVE E I NAT GAS 3507120 VR8304P4298 GAS VALVE STND PILOT NAT GAS 3507300 V8295A1024 3507305 Qoi 2 lt gt 45 gt lt gt Q gt lt gt GAS VALVE STND PILOT GAS ROBERTSHAW 7000ERHC S7C GAS VALVE E l NAT GAS ROBERTSHAW 7000DERHC 3507810 GAS VALVE STND PILOT LP GAS 3507210 VR8200C6040 GAS VALVE PILOT LP GAS 3507220 VR8204C6018 GAS VALVE STND PILOT LP GAS 3507230 VR8300C4548 GAS VALVE 1 LP GAS 3507240 VR8304P4280 46 PILOT ASSY STND PILOT NAT GAS 3504050 Q350A1644 46 PILOT ASSY STND PILOT NAT GAS 3504005 Q327A1949 46a ASSY E l NAT GAS 35 4700 Q348A1275 46 PILOT ASSY STND PILOT LP GAS 35 4020 gt w Q327A1915 46a ASSY LP GAS 35 4600 Q348A1259 THERMOCOUPLE 1 ea IGNITION CABLE GAS VALVE 392449 PILOT ASSEMBLY 392449 4 NAT GAS INCLUDED WITH PILOT GAS INCLUDED WITH PILOT ASSY i i GAS INCLUDED WITH PILOT ASSY K14 PILOT ORIFICE Q327 PILOT LP GAS INCLUDED WITH PILOT ASSY GAS INCLUDED WITH PILOT ASSY 40mm BURNER WITH PILOT BRACKET 40mm BURNER WITH PILOT BRACK
26. 1 Secure with the 1 4 20 carriage bolt nuts and washers provided 7 Carefully inspect the joint between the flue collector and the heat exchanger to verify that the gasket is properly positioned 8 Install the blocked vent switch using the 8 sheet metal screw provided as shown in Figure 1 D Jacket Installation NOTE Before installing the jacket make sure to plug any tappings which are not going to be used Also make sure that no tappings are plugged which will be needed See Figure of this appendix as well as Parts XIII and IX ofthe installation manual 1 Attach the diverter Panel to the vestibule panel using two 10 sheet metal screws Install these screws in the outside holes 2 Slip this diverter vestibule panel assembly behind the draft diverter opening in the draft diverter assembly Figure A2 Attach to the diverter assembly using 10 sheet metal screws 3 Attach the right side panel to the base and vestibule panel using four 10 sheet metal screws 4 Orient the rear jacket panel so that the two notches are up Slip the rear panel under the flange on the rear ofthe side panel installed in the previous step and secure with three 10 sheet metal screws 47 FIUE COLLECTOR 1 4 WING NUT pr 1 4 WASHER BIOCKED VENT SWITCH 0 X 172 SHEET METAL SCREW HEAT EXCHANGER 5 16 LOCK NUT 3 16 WASHER 8 1 4 20 CARRIAGE ob 18 SELF TAPPING SCREW FIGURE
27. 600 Defective S8600 module 24 volts between MV amp on gas valve Loose connection in ignition cable or ground wire harness Pilot electrode porcelain cracked Pilot flame not covering gap between electrode and grounding strap Defective gas valve Low gas pressure at gas valve inlet Defective S8600 module XIV 5 The following parts may be obtained from any Crown distributor To find the closest Crown distributor consult the area Crown representative or the factory at Crown Boiler Co Customer Service Box 14818 Philadelphia PA 19134 www crownboiler com For boilers installed at elevations above 2000 ft consult the local Crown representative or the factory for the correct main burner orifice QTY OR QUANTITY PER BOILER OR CROWN DESCRIPTION BSI HEAT EXCHANGER ASSY BSI CWI LEFT END SECTION BSI RIGHT END SECTION CROWN 69 850013 1 1 103 138 172 850014 1 ea 850016 1 207 850017 1 1 241 850018 8 276 850019 1 310 345 379 850020 1 850021 1 ea 850022 1 t 1ea BSI CWI INTERMEDIATE SECTION UPPER PUSHNIPPLE 1 1 1 3 ea 4ea 5 1 2 7 ea 8 1 1 8 9 ea 9 ea 10 11 LOWER PUSHNIPPLE BASE TRAY BASE WRAPPER BURNER TR
28. 70 tea tea tea tea 92 SAFETY VALVE 15 psi 95070 tea tea tea 93 90DEGREEPIGTAIL 950608 PRESSUREUMTIPARIRTS smo Tee ren Tee 95 3 4 BOILER DRAIN 9504 tea tea fea rem tea tea tea Yea Ten Tem tea Tee TRANSFORMER MOUNTING PLATE 9615 tea tea tea 98 24 14001012 950200 99 8 32 X 1 2 SELF TAPPING SCREW 90223 4 4 4 4ea 4 4 4ea 100 SPSTRELAY R8225B1049 3505040 tea tea tea tea tea DAMPER WIRE HARNESS 90300 tea tea tea BLOCKED VENT SWITCH HARNESS 9601270 tea tea tea j BOX RO SWITCHHARNESS 9601280 tea JH67LW CO BOXHARNESS 9601367
29. A1 BASE HEAT EXCHANGER FLUE COLLECTOR ASSEMBLY 8 9 10 11 12 1 2 3 2 3 4 Install the left side panel in the same manner as the right side Attach the front corners of the diverter panel to the side jacket panels using 10 sheet metal screws Install the horizontal angle jacket clips in the front edge of the side jacket panels Slide this clip through the rectangular slot that is about halfway up the front edge of the side jacket panels and secure with the 8 32 self tapping screws provided Slip the Vertical Jacket Clip through the rectangular slot that is near the bottom of the front edge of the side jacket panels Secure with the 8 32 sheet metal screws provided Install the top jacket panel Use 10 sheet metal screws to attach it to the rear jacket panel and the top front corners of the side panels Install the upper front jacket panel Insert the flange on the top of this panel under the top panel Run two 10 sheet metal screws into the horizontal jacket clips through the holes in the bottom of this panel Attach the door knobs to the Lower Front Panel using 8 32 x 1 2 machine screws The labels have been applied at the factory Verify the location of the labels according to the list below a Clearance Label Located on the top jacket panel b Lighting Instructions Located on the lower left corner of the right side panel next to the gas manifold c Lowest Permissible Water Level P
30. ARENT BLUE OUTER CONE DARKER TRANSPARENT BLUE INNER CONE SHARPLY OUTLINED INNER CONE BRIGHT LIGHT BLUE SHARPLY OUTLINED WITH BRIGHT LIGHT BLUE FLAME RETENTION INNER CONE PARTIALLY LIFTED FROM BURNER 1 re SN PARTIALLY LIFTED FROM BURNER END VIEW END VIEW FIGURE 22b MAIN BURNER FLAME 40mm HIGH ALTITUDE BURNERS FIGURE 22a MAIN BURNER FLAME 1 BURNERS 17 Test thermostat operation while the boiler is running Turn the thermostat to the lowest setting For standing pilot boiler models pilot burner should remain lit but the main burners should stop firing For intermittent ignition boiler models both pilot burner and main burners should stop firing Raise the thermostat back to the highest setting The main burners for standing pilot boiler models or pilot burner and main burners for intermittent ignition boiler models should relight 18 Verify low water cutoff operation while the boiler is running Slowly open drain valve and drain boiler until the water level drops below low water cutoff line Water still should be visible in the gauge glass when the low water cutoff shuts down the main burners For standing pilot boiler models pilot burner should remain lit when the main burners stop firing For intermittent ignition boiler models both pilot burner and main burners should stop firing Make sure pressure limit thermostat or other
31. AY 1 BURNERS BURNER TRAY 40mm BURNERS BASE FRONT PANEL ASSY INCLUDES INSULATION 2 ea 3 4 5ea 700643 700647 700663 700667 700683 700687 751683 751684 751686 751687 4 4 8 8 8 700648 700668 700688 751688 700608 8 ea 700649 700669 700689 751689 751690 700609 9 700650 700670 700690 700610 10 700651 700671 700691 700611 11 700652 700672 700692 700612 700628 2 700629 2 N 2ea 7 2 2 2 BASE REAR INSULATION 720603 720604 720606 720607 720608 720609 720610 720611 720612 BASE LEG ASSY 70011 4ea 10 1 4 20 X 1 2 SELF TAPPING SCREW 900100 20 21ea 21ea 21ea 21ea 25ea 25 11 1 2 x 2 SEALING STRIP 900146 3 7 ft 4 2 ft 5 3 ft 5 9 ft 6 4 ft 70 7 5 ft 8 0 ft 8 5 ft 12 ROLLOUT SWITCH G4AM0600240C 960122 1 1 1 1 1 1 1 1 1 1 664 700603 700604 700606 700607 BURNER ACCESS PANEL 700623 700624 700626 700627 700630 700631 700632 BASE INSULATION 2 ROLLOUT SWITCH BRACKET 14 8 3 4 SELF TAPPING SCREW 15 10 1 2 SHEET METAL SCREW 16 516 USS FLAT WASHER 17 5 16 18 LOCK NUT 18 5 16 18 x 1 1 4 SELF TAPPING SCREW DRAFT DIVERTER ASSEMBLY 21 1 2 x 1 SEALING STRIP 22 1 4 20x 1 1 4 CARRIAGE BOLT 23 1 4 USS FLAT WASHER 24 1 4 20 WING NUT BLOCKED VENT SWITCH ASSY INCLUDES
32. CROWN BSI Series Gas Fired Natural Draft Steam Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models WARNING Improper installation BSI069 51207 adjustment alteration service maintenance can cause property 51103 51241 damage injury loss of life For BSI138 51276 assistance or additional informa tion consult a qualified installer 51172 51310 service agency or the gas 51345 supplier Read these instructions 1379 carefully before installing CROWN Boiler Co Manufacturer of Hydronic Heating Products Box 14818 3633 I Street Philadelphia PA 19134 Tel 215 535 8900 Fax 215 535 9736 www crownboiler com Table of Contents L Product Description 22 u s 1 Specifications u uu 2 III Before 3 Locating the Boiler 3 Air for Combustion amp Ventilation 4 aan ina act dedi 8 PIPINE u ite hassan a 11 VIII System PIPING eie cete ed 12 IX Indirect Water Heater Piping 15 X Wiring 55i RE Edere si 16 XL Start Up amp Checkout 23 XII Service amp Maintenance 2 2 3l XIII Troubleshooting 34 XIV
33. E EXACTLY COULD RESULT IN OVER FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD a Connect a manometer to the inlet pressure tap on the gas valve see Figures 23 and 24 b Check the inlet pressure with all gas appliances on and off The inlet pressure at the boiler must be within the following limits regardless of what combination of appliances is firing Inlet Press inches w c Natural Gas LPGas Min 5 0 11 0 Max 14 0 13 0 If the inlet pressure falls outside of these limits find and correct the cause of the problem before proceeding further c Connect a manometer to the manifold outlet pressure tap on the gas valve see Figures 23 and 24 d Read the manifold pressure It should be set at Natural Gas LP Gas Manifold Press inches w c 3 5 10 0 e Ifamanifold pressure adjustment is needed make the adjustment by turning the pressure regulator see Figures 23 and 24 screw clockwise to raise the pressure and counter clockwise to reduce the pressure If a manifold pressure adjustment is made recheck the line pressure to be certain that it is still within acceptable limits Replace the cover screw on the regulator COMBINATION IGNITION CENTER CENTER ELECTRODE SENSING GROUND STRAP e FIGURE 20 STANDING PILOT FIGURE 21 INTERMITTENT IGNITION BURNER FLAME PILOT BURNER FLAME 24 LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8200 AND VR8300 SERIES GAS VALVES STANDING PILOT FOR YOUR SAF
34. ET 40mm BURNER LESS PILOT BRACKET 150541 2ea 4 5ea 8ea 62 MANIFOLD 40mm BURNERS 701253 701254 701255 701256 701257 701258 701259 701260 MAIN BURNER ORIFICE CONSULT CROWN REPRESENTATIVE FOR CORRECT SIZE These Valves Piped in Series to Provide Redundant Shut off 1 4 Pilot Tubing Used with Robertshaw Valves o gt 3 2 2 43 410 43 QUANTITY PER BOILER OR CROWN P N CROWN P N 69 103 138 172 8503012 8503015 716 RIGHT SIDE JACKET PANEL rea 650500 rr 1 es 78 TOP JACKET PANEL fea 850323 79 LOWER FRONT PANEL 850363 80 UPPER FRONT PANEL 850353 850362 81 DIVERTERPANEL 850373 2 V 10 X 1 2 SHEET METAL SCREW 90 212 86 DOOR KNOB 90 210 8 32 X 1 4 H W H SCREW NATURAL GAS ONLY 8600F 1000 NATURAL OR LP GAS 8600M1013 ERO e E E eT ORE BEC RE HE CHR OH e tea tea tea tea 10a tea iem tea 90 FLOAT TYPE LW C O 67 CR 2 4006 tea tea a eao tea f tea f tea tea Ten Ten tea f tea 91 PRESSURE GUAGE 950
35. ETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance has a pilot which must be If you cannot reach your gas supplier call lighted by hand When lighting the pilot follow the fire department these instructions exactly C Use only your hand to push in or turn the gas BEFORE LIGHTING smell all around the control knob Never use tools If the knob will appliance area for gas Be sure to smell next not push in or turn by hand don t try to repair it to the floor because some gas is heavier than call a qualified service technician Force or air and will settle on the floor attempted repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been Do not try to light any appliance under water Immediately call a qualified service Do not touch any electric switch do not technician to inspect the appliance and to use any phone in your building replace any part of the control system and any Immediately call your gas supplier from gas control which has been under water a neighbor s phone Follow the gas supplier s instructions LIGHTING INSTRUCTIONS STOP Read the safety information above on 8 Turn Knob on gas control counterclockwise y this label to PILOT Set the thermostat to lowest setting Push down and hold the red reset
36. IMNEY SEE VENTING SECTIOND x SEE FOR OPENING SIZE FIGURE3 BOILERINSTALLEDINCONFINEDSPACE ALL AIR FROMINSIDE VENTILATED ATTIC gt UPPER OPENING DOUBLE WALL VENT OR LINED MASONRY CHIMNEY SEE VENTING SECTION LOWER OPENING VENTILATED CRAWL SPACE x SEE TEXT DPENING SIZE FIGURE4 ALLAIRFROMOUTDOORS VENTILATED CRAWL SPACE AND ATTIC VENTILATED ATTIC gt 4 UPPER OPENING TYPE DOUBLE WALL VENT OR LINED MASONRY DUCT v D FRDM ATTIC 10 SEE TEXT FOR FIGURE5 ALL AIRFROM OUTDOORS VIA VENTILATED ATTIC TYPE DOUBLE WALL LAC VENT OR LINED MASONRY CHIMNEY SEE VENTING SECTION x UPENING LOWER x Z OPENING SEE TEXT FOR OPENING SIZE FIGURE 6 ALL AIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM TYPE DOUBLE WALL VENT OR LINED MASONRY CHIMNEY VENTING SECTION x HORIZONTAL DUCT LOWER D HORIZONTAL DUCT
37. button while you light pilot burner with a match After about one minute release reset button 4 Remove front access panel Pilot should remain lit If it goes out turn gas control knob clockwise to OFF To relight 5 Rotate the gas control knob clockwise 4 to OFF repeat steps 5 9 f button does not pop up when released stop and immediately call your service technician or gas supplier f the pilot will not stay lit after several tries cis turn the gas control knob to OFF and call GAS OUTLET your service technician or gas supplier Turn off all electric power to the appliance RESET BUTTON After pilot remains lit when red reset button is GAS CONTROEKNOB released turn gas control knob counterclockwise SHOWN IN POSITION to GAS VALVE VIEW 6 Wait five 5 minutes to clear out any gas Then Replace front access panel smell for gas including near the floor If you then smell gas STOP Follow B in the safety inform ation above on this label If you don t smell gas go to the next step Turn on all electric power to the appliance Set thermostat to desired setting 7 Find pilot follow metal pilot tube from gas control to A pilot PILOT THERMO BURNER COUPLE TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 3 Push gas control knob slightly and turn clockwise to
38. can cause severe heat exchanger damage If mud or scale accumulations are found Make sure that all vents are in working order Vents should not permit any passage of steam or water Check all steam and return piping for leaks Be aware that buried return piping can leak and go undetected during normal operation 32 disturbed during the inspection process for leaks Heat Exchanger Cleaning Procedure 1 Turn off electrical power and gas supply to the boiler 2 Disconnect the damper and vent connector from the boiler 3 Remove the upper front and top jacket panels If possible remove the rear and left side jacket panels 4 Remove the burners 5 Remove the blocked vent spill switch 6 Remove the 4 20 nuts and washers holding the flue collector onto the heat exchanger 7 Carefully remove the flue collector gasket strips and set them aside 8 Remove the flue collector from the heat exchanger 9 Clean the flue passageways using a stiff bristle brush Be certain that all foreign material is removed from the gaps between the pins 10 Clean the bottom surfaces of the heat exchanger 11 Puta light in the combustion chamber and look through the flue passages from the top to verify that they have been thoroughly cleaned 12 Replace the flue collector gasket strips If desired RTV silicone sealant with a 500F intermittent duty temperature may be substituted for this rope gasket The flue collector must be thoroughly sealed t
39. d vent switch is indicative of a problem with the vent system If the blocked vent switch opens the cause of the venting problem must be found and corrected by a qualified gas service technician before the blocked vent switch is reset Flame Roll out Switch Automatically interrupts burner operation when flames or excessive heat are present in vestibule The flame roll out switch is a single use device which must be replaced by an identical switch in order to restore normal operation An open flame roll out switch is usually indicative of a plugged heat exchanger The cause of the flame roll out must be found and corrected by a qualified gas service technician and the switch replaced with an identical one before the boiler is returned to operation Pu VENT DAMPER NOTE 2 LESS VENT DAMPER HONEYWELL VR8204 VR8304 SERIES GAS VALVES 51069 345 ROBERTSHAW 7000DERHC GAS VALVE BSI379 2 VENT DAMPER REQUIRED ON 51069 BSI276 OPTIONAL ON BSI310 BSI379 3 ON BOILERS LESS VENT DAMPER DAMPER HARNESS IS NOT USED RED AND BLUE LEADS SHOWN ARE JUMPED TOGETHER USING RED JUMPER WIRE FIGURE 19 WIRINGDIAGRAM INTERMITTENTIGNITION AND McDONNELL amp MILLER MODEL 67 LOW WATER CUTOFF NOTE SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS MANIFOLD AND CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS SPECIFIED IN Z21 13 XI Start up and Checkout
40. ding the safety valve and drain valve provided by the factory 49 9004 10044 49 1 H R H 4 8 25 019 49905 8004 J AJ AI 340 21414594 P 11 jauog apis 1413 8004 19044 Jaddp Buiddo 0113 4aypor 03144 H 0 1 ce 9904 49 8112 Joquoz Jo FIGURE A2 JACKET INSTALLATION 1 2 3 4 8 9 10 F Electrical Wiring Connections Also refer to wiring diagrams in Part X of the installation manual A pre wired junction box assembly specific to the control package ordered with the boiler has been provided by the factory Orient the junction box so the black relay which is mounted to the outside of the junction box is facing down Mount the junction box assembly to the right side jacket using the holes provided See Figure 1 in the installation manual To do this temporarily remove the transformer and attach the box with two 10 sheet metal screws through the holes on the back side of the box Pressure Limit Switch Route the grey wire pair through the bushing on the pressure limit control and connect one of the leads numbered 0 to one of the two terminals on the switch and the other lead numbered 0 to the other terminal on the switch Blocked Vent Switch Locate the two wires marked 8 one of these wires is black the other is black with a white trace Connect these wires to the terminals on the blocked vent swi
41. e or switch loose damper harness 38 across rollout Loose electrical connection in spill Defective pressure limit control Blockage in siphon tube LWCO float bowl filled with mud Defective LWCO DO NOT OPERATE BOILER UNTIL THIS PROBLEM IS CORRECTED ill Chimney blockage Chimney system not contructed in accordance with Parts 7 and 10 of National Fuel Gas Code Down draft Inadequate combustion air supply in boiler room Rollout switch open Replace with exact replacement see parts list Check for blocked heat exchanger or rollout wiring or gas valve common Standing Pilot Ignition System Troubleshooting Chart START 24 VOLTS PRESENT ACROSS TH AND TR Caution Read page 34 before ON GAS VALVE BUT MAIN BURNERS DO attempting to use this chart NOT LIGHT Ensure knob Main Y Does pilot Y on gas valve is burners stay lit set toON light N N Turn control on Loose gas valve to thermocouple PILOT Depress Turn control connection at red button and on gas valve Defective gas gas valve light pilot Hold to ON valve button for at Defective least one thermocouple minute Condensation quenching pilot Disconnect 2 2 T Low line gas valve Connect a Does pilot volt meter to the Does pilot stay lit when N thermocouple Light light red button is the pilot and hold released down the red b
42. e pilot main burner If burners show signs of deterioration they should be replaced some discoloration around the burner ports 15 normal Clean the burners by first brushing the ports with a soft bristle brush and then vacuuming out any debris through the venturi opening 5 Inspect the pilot assembly Standing Pilots Check the thermocouple for deterioration some discoloration of the thermocouple is normal If any deterioration 18 present replace the thermocouple Inspect the pilot assembly for deposits and deterioration Clean or replace the pilot assembly as necessary Intermittent Pilots Clean any deposits found on the electrode and grounding strap The ideal gap between the electrode and the ground strap is 1 8 Inspect the porcelain for cracks or other deterioration Replace pilot assembly if deterioration is found 6 Inspect the combustion chamber insulation for deterioration 7 Intermittent Pilot Boilers Inspect the ignition cable insulation for cracks or other deterioration If deterioration 15 found CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING 3l replace cable 8 Reinstall burners being careful to put the pilot main burner in its original location 9 Inspect all boiler wiring for loose connections or deterioration 10 Inspect the vent system Make sure that the vent syste
43. ect chimney for obstructions or other defects and correct as required Clean chimney as necessary 9 Vent pipe should slope upward from draft diverter not less than one inch in four feet No portion of vent pipe should run downward or have sags Vent pipe must be securely supported 10 The vertical section of vent pipe coming off the boiler should be as tall as possible while still maintaining the proper clearance from the horizontal vent connector to combustibles and the proper pitch called for in 9 above 11 Vent pipe should be installed above the bottom of the chimney to prevent blockage 12 Vent pipe must be inserted flush with inside face of the chimney liner and the space between vent pipe and chimney sealed tight 13 Do not install the vent damper in any portion of the vent system which is used by appliances other than the boiler being installed 14 with Vent damper installation is mandatory all sizes from the BSI069 to BSI276 The BSI310 through BSI379 may be ordered or without vent damper If supplied install vent damper see Figure 9 as follows a Open vent damper carton and remove installation instructions Read the instructions thoroughly before proceeding Verify that vent damper is same size as draft diverter outlet See Figure 1 Unpack vent damper carefully Do not force closed damper blade Forcing vent damper closed may result in damaged gear train and void warranty b Vent damper is factory shipped having
44. ect water heater The low water cut off and pressure limit control will interrupt 120 volt power to the burner in the event of a low water or excessive pressure condition RANSFUORMER 24 VOLT FACTORY DU NOT USE BOILER WIRING DD NOT RANSFURMER 467 LALE 120 VAC 11 _ r 2 O 4 3 d O M M 101A CAUTION apina N E H L VXT 24 ON 67 L W C O DER FIGURE 14a WIRING MCDONNELL amp MILLER 101 AOR TWO WIRE HY DROLEVEL VXT 24 FEEDER TO BOILER EQUIPPED WITH 67 L W C O 17 TRANSFURME DU NUT USE BUILER RANSFURMER Z3 OLT FACTORY LM WIRING DO NOT i MODIFY E 4 M M WF2 U 24 DR y H 19 24 CAUTION Lo 4 5 W OR RED AD DO NOT INSTALL N JUMPER BETWEEN 2 amp 3 967 L W C O N OR WHITE LEAD R BLACK LEAD u FIGURE 14b WIRING MCDONNELL amp MILLER WF2 U 24 FEEDER OR THREE WIRE HYDROLEVEL VXT 24 FEEDER TO BOILER EQUIPPED WITH 67 L W C O INDIRECT WATER HEATER THERMOSTAT 77 SPACE HEATING THERMOSTAT N
45. eeder Wiring for Boilers Equipped with McDonnell amp Miller 67 Low Water Cut offs Figures 14a and 14b show feeder wiring for McDonnell amp Miller 2101A McDonnell amp Miller WF2 U 24 and Hydrolevel VXT 24 feeders on boilers equipped with 67 low water cutoffs The following points apply to all feeder wiring to 67 low water cut offs e Use a separate transformer to power the feeder Do not use the transformer on the boiler tis not necessary to touch any of the 24 volt factory boiler wiring when connecting a feeder to 67 equipped boiler Do NOT install a jumper between terminals 2 and 3 on the 67 low water cutoff Indirect Water Heater Wiring Figure 15 shows field wiring for an indirect water heater A Honeywell R845A or equivalent DPST relay and transformer is required The high limit described in Part IX must also be supplied by the installer A call for heat from the indirect water heater thermostat will energize the relay making both sets of contacts One set of these contacts then energizes the circulator The other set of contacts will make the T and T contacts on the burner primary control firing the burner If the boiler water temperature exceeds the high limit setting of 180F the high limit will open the T T circuit and the burner will shut down If there is a call for space heat the heating thermostat will make the T T circuit and the boiler will fire without regard to the status of the indir
46. em at pressures of 1 2 psi or less isolate the boiler from the gas supply system by closing its individual manual shut off valve GAS SUPPLY ANUAL SHUT OFF VALVE GROUN JOINT UNION kl e 3 MIN GAS VALVE FRONT VIEW State of Massachusetts Requires Manual FIGURE 10 GAS CONNECTION TO BOILER ees TEE System Piping CAUTION 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 OPERATION OF THIS BOILER INASYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE General Piping Notes Figure 11 shows recommended near boiler piping for most common types of gravity return steam systems Additional information on steam system design may be found in nstallation Guide for Residential Hydronic Heating Systems Pub 200 published by the Hydronics Institute in Berkeley Heights NJ One of the primary purposes of this near boiler piping is to separate tiny water droplets from the steam exiting the boiler so that dry steam is sent to the system If the near boiler piping is not correct wet steam will enter the system and the following problems may occur
47. er drain Temporarily pipe the outlet of this valve to a location where hot water and steam can be safely discharged b Make sure that this valve is closed and that the water level 1s at the normal water line c If a king valve is present in the steam main takeoff close it Alternatively temporarily replace enough of the vents on the mains and or radiators with plugs so that 2 5 psi can be developed when the boiler is fired d Fire the boiler and allow it to steam until 2 5 psi 15 registered on the gauge Turn offthe burners and immediately fully open the 1 1 4 valve f Allow the boiler to blow down until either the water runs clear or the water level reaches the bottom of the gauge glass g Allow all parts ofthe boiler to cool to room temperature Drain the boiler completely and remove the 1 1 4 valve h If significant mud or scale 18 still present in the bottom of the boiler repeat steps b through g until all mud or scale 1s removed 1 Once all mud or scale is removed replace the 1 1 4 valve and temporary blow down piping with the standard drain valve After all parts ofthe boiler are at room temperature refill the boiler to the normal water line 14 Place the boiler back in operation using the procedure outlined in Start up Check the pilot line and any other gas piping NOTE A large accumulation of mud or scale in the bottom of the heat exchanger is usually a sign of excessive feedwater make up Such accumulations
48. er s instructions LIGHTING INSTRUCTIONS STOP Read the safety information above on 8 Turn Knob gas control counterclockwise this label to PILOT Set the thermostat to lowest setting Push down and hold the Knob while Turn off all electric power to the appliance you light pilot burner with a match After about one minute release reset button Pilot should remain lit If it goes out turn gas Remove front access panel control knob clockwise 4 to OFF To relight Rotate the gas control knob clockwise 4 to OFF POSITION INDICATOR GAS CONTROL KNOB SHOWN IN OFF POSITION Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then smell gas STOP Follow B in the safety inform ation above on this label If you don t smell gas go to the next step Find pilot follow metal pilot tube from gas control to Ter pilot burner PILOT THERMO BURNER repeat steps 5 9 e If button does not pop up when released stop and immediately call your service technician or gas supplier If the pilot will not stay lit after several tries turn the gas control knob to OFF and call your service technician or gas supplier After pilot remains lit when red reset button is released turn gas control knob counterclockwise Kk Replace front access panel Turn on all electric power to the appliance Set thermostat to desired
49. es boiler side piping only Refer to the indirect water heater instruction manual for domestic water piping The components in this system and their functions are as follows 1 Circulator Mount the circulator as shown in Figure 13 The circulator should be located as low and as close to the boiler as practical Do not install valves or other devices having a significant pressure drop between the boiler and the circulator inlet All piping between the boiler and the circulator inlet should be 1 regardless of the size of the piping required in the rest of the system See Figure 15 in Part X for wiring information 2 Y Strainer Install a Y strainer to prevent sediment from accumulating inside the indirect water heater 3 Check Valve Prevents gravity circulation through the indirect water heater when the boiler is responding to a call for heat 4 Boiler Limit Control Use a SPST break on rise temperature limit control such as the Honeywell L4006A Do not set the limit above 180F as doing so may cause the boiler to steam when there is no call for heat See Figure 15 for wiring information 5 Valves and Unions Install shut off valves drain valves and unions in locations that will facilitate maintenance of the system Do not install any valves between the boiler and circulator inlet IMPORTANT Some indirect water heaters may not be suitable for use with a steam boiler Consult the water heater manufacturer s guideli
50. ft ceiling The water heater has an input of 30000 BTU hr Total input in thousands of BTU hr 172000 BTU hr 30000 BTU hr 1000 202 Volume ofroom 6 25 ft x 7 ftx 8 ft 350 fe 350 202 1 73 Since 1 73 is less than 50 the boiler room is a confined space Unconfined Space Natural infiltration into the boiler room will normally provide adequate air for combustion and ventilation without additional louvers or openings into boiler room Confined Space Provide two openings into the boiler room one near the floor and one near the ceiling The top edge of the upper opening must be within 12 of the ceiling and the bottom edge of the lower opening must be within 12 of the floor Figure 3 Each opening must have a free area of 1 square inch per 1000 BTU hr input of all gas burning appliances in the boiler room The minimum opening dimension is 3 inches Minimum opening free area is 100 square inches per opening If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per 1000 BTU hr of total appliance input install a pair of identical openings into a third room Connect additional rooms with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU hr of input The free area of an opening takes into account the blocking effect of mesh grills and louvers Where screens are used they must be no finer than 4 4 x 4 mesh If providing openin
51. g the appropriate tables in the National Fuel Gas Code ANSI Z223 1 HORIZONTAL VENT CONNECTOR SLOPE SECTIONS UPWARD NOT LESS THAN ONE INCH IN FOUR FEET VENT DAMPER CLEANDUT 7 DRAFT DIVERTER FIGURE8 BSI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS C m VENT DAMPER POSITION b DAMPER INDICATOR ZED CONNECTOR J BOX WITH TRANSFORMER RELAY RIGHT SIDE VIEW FIGURE 9 VENT DAMPER INSTALLATION DETAILS Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at line pressure between the minimum and maximum values shown on the rating plate For more information on gas line sizing consult the utility or Chapter 2 of the National Fuel Gas Code Figure 10 shows typical gas piping connection to the BSI boiler A sediment trap must be installed upstream of all gas controls Install a manual shut off 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 1 2 psi When pressure testing the gas syst
52. gauge glass low water cutoff assembly to the other side of the brass union d Ifnot already present on the jacket attach the blow down card to the left side jacket panel just above the Lowest Permissible Water Level plate e Provide blow down discharge piping Steam Boiler with Probe Low Water Cutoff a Install low water cutoff probe into tapping Handle probe with care b Attach low water cutoff control to probe per the instructions packed with the control Install the gauge glass fittings and extensions into tappings The lower fitting has a small drain cock d Install gauge glass and protective rods in fittings Install safety valve spindle must be in vertical position into tapping on the boiler left side See Figure 1 in the installation manual using the NPT nipples and elbow supplied Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens The end of the discharge pipe must terminate in an unthreaded pipe The safety valve discharge piping must be in an area where it is not likely to become plugged by debris or subjected to freezing Install drain valve into tapping J on the boiler left side using 2 x 34 bushing provided See Figure 1 in the installation manual See Section VIII System Piping in the installation manual for instructions on completing the piping of this boiler inclu
53. gs into adjacent rooms is undesirable combustion and ventilation air can be brought into the boiler room from outdoors See the instructions under For Buildings of Unusually Tight Construction For Buildings of Unusually Tight Construction 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 2 Two openings are required The top edge of the upper opening must be within 12 inches of the ceiling The bottom edge of the lower opening must be within 12 inches of the floor 3 Size openings and ducts as follows Vertical ducts or openings directly outdoors Figure 4 Figure 5 and Figure 6 Each opening must have a free cross sectional area of 1 square inch per 4000 BTU hr of the total input of all gas fired appliances in the boiler room but not less than 100 square inches Minimum opening size is 3 inches Openings to outdoors via horizontal ducts Figure 7 Each opening must have a free cross sectional area of 1 square inch per 2000 BTU hr of the total input of all gas fired appliances in the boiler room but not less than 100 square inches Minimum opening size is 3 inches The free area of an opening takes into account the blocking effect of mesh grills and louvers Where screens are used they must be no finer than 8 4 x 4 mesh TYPE DOUBLE WALL VENT OR LINED MASONRY CH
54. h a Chiller Ifthe boiler is used in conjunction with a chiller pipe the boiler in parallel with chiller Use isolation valves to prevent chilled water from entering the boiler 13 BOILER MINIMUM PIPE DIA IN NPT c BIG POINT ABOVE BOILER AND DRIP O BSI069 2 112 114 ENDS MAINS INTO WET RETURN LOW POINT OF SUPPLY MAIN NOT TO BE LESS THAN 28 ABOVE WATER LINE SUPPLY MAIN TO BE TAKEN OFF TOP OF HEADER VERTICALLY OR AT 45 ANGLE zY FITTING C CLUSE DR SHOULDER NIPPLE C BOILER ALTERNATE HARTFORD FILL T RETURN CONNECTION SECOND 2 SUPPLY RISER OPTIONAL d SHUT OFF VALVE SHUT OFF __ VALVE PREFERRED HARTFORD 02 77 RETURN CONNECTION N VALVE STEAM WET RETURN PITCH DOWN BOILER PROVIDE DRAIN VALVES FOR FLUSHING BOILER AND SYSTEM PLUGGED TEE FIGURE 11 STEAM BOILER PIPING FOR GRAVITY RETURN WRONG TAKE OFF BETWEEN RISERS WRONG HEADER BULLHEADED INTO TAKE OFF AND EQUALIZER WRONG TAKE OFF BULLHEADED INTO TWO MAINS FIGURE 12 COMMON NEAR BOILER PIPING MISTAKES 14 IX Indirect Water Heater Piping All BSI series boilers are equipped with tappings to permit the connection of a Crown Mega Stor or other indirect water heater In this type of system hot boiler water is drawn from below the water line and passed through the heat exchanger in the indirect water heater This section describ
55. he Robertshaw 7000ERHC are also equipped with a Honeywell Model V8295 gas valve to provide redundancy This valve should be factory pre wired to the 7000 with one black lead connected to the terminal and the other black lead connected to the TR terminal on the 7000 gas valve Honeywell Intermittent Ignition System a Mount the 58600 series ignition control to the left side of the jacket just above the gas manifold using the standoff bracket supplied and 10 sheet metal screws b Locate the intermittent ignition harness plugged into the gas valve assembly This harness has red blue and yellow wires and has molex plugs on both ends Plug the loose end of the harness into the 58600 module c Plug the green burner ground wire numbered 4 to terminal 4 on the 58600 Check that the ground wire has been routed under the burners and that the other end is attached to the pilot assembly under the lower mounting screw d Plug the red wire with the yellow trace numbered 5 to terminal 5 on the 58600 module e Plug the black wire with the white trace numbered 6 to terminal 6 on the 58600 module f Plug the orange Pilot Ignition Cable numbered 9 to terminal 9 on the 58600 module Verify that this cable has been routed under the burners and that the other end is plugged onto the pilot assembly electrode G Complete Installation Follow the instructions that start on page of
56. he top of the base to adhere the fiber gasket strip 3 Install the fiber gasket strip which was shipped in the Base Box Figure A1 4 Place the base assembly in the location where the boiler is to be installed Refer to Section III and IV in the installa tion manual for additional information on placement C Heat Exchanger and Flue Collector Installation 1 Position the heat exchanger above the base with the return connection located toward the front of the boiler and the lugs located on each end of the boiler centered over the studs which are on each end of the base Figure A1 Lower the heat exchanger over the studs taking care not to disturb the studs which may push out if the heat exchanger comes in contact with them Also take care not to disturb the ceramic fiber gasket 2 Once the heat exchanger has been placed on the base inspect the gasket for proper seal Repair or replace gasket if necessary 3 Secure the heat exchanger with 5 16 lock nuts with nylon inserts and washers from the hardware bag 4 Loosen nuts on tie rods until they are finger tight 5 Fiber gasket strips are used to seal the flue collector to the heat exchanger this 18 the same material used between the heat exchanger and base Install this gasketing on the top of the heat exchanger Figure A1 A few dabs of silicone may be used to keep this gasketing from shifting when the flue collector is installed 6 Install the flue collector as shown in Figure A
57. himney and vent connector in accordance with the National Fuel Gas Code 4 Exterior Chimneys An exterior chimney has one or more sides exposed to the outdoors below the roof line There are two conditions under which an exterior chimney may be used Insome very restrictive cases BSI series boilers may be vented into an exterior ceramic lined masonry chimney See the National Fuel Gas Code for information on when exterior chimneys may be used Anexterior masonry chimney be used if it is lined with B vent or a listed chimney lining system 5 This boiler may be vented using a listed power venter The power venter must be sized and installed in accordance with the power venter manufacturer s instructions the terms of the power venter listing and applicable codes The boiler must be electrically interlocked with the power venter to prevent boiler operation if the power venter fails to operate Before deciding to use a power venter make certain that the flue gas exiting the power venter will not damage adjacent construction or other structures Also make certain that the power venter terminal will not be subjected to winds which could effect power venter operation 6 Do not connect the vent of this appliance into any portion of a mechanical vent system operating under positive pressure 7 Do not connect the boiler into a chimney flue serving an open fireplace or other solid fuel appliance 8 Prior to boiler installation insp
58. is or burner ports Leak in seal between flue collector and heat exchanger Inadequate supply of combustion air 16 Replace the blocked vent switch 17 Reconnect the damper and vent system 33 XIII Troubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems To use these charts go to the box marked Start at the top of the chart on page 35 or 37 and follow the appropriate path though the chart until a box with a list of possible causes is reached If the problem 18 known to be within the ignition system go directly to the appropriate troubleshooting guide for the boiler standing pilot on page 39 or intermittent ignition on page 40 In using these charts the following should be kept in mind 1 2 3 4 5 8 These charts only meant to be used professional heating technician aid in diagnosing control problems Where applicable follow all precautions outlined in the appropriate lighting instructions on pages 25 28 In general these charts assume that there are no loose or miswired electrical connections Before using these charts inspect all electrical connections on the boiler to make sure that they are tight Also check the wiring on the boiler against the appropriate wiring diagram in Figures 16 19 The possible causes at the end of each branch in these charts are not listed in order of likelihood All controls on the BSI are
59. kalinity test of water in the system The pH reading should be in 7 to 11 range NOTE When substantial amount of make up water is used due to lost condensate or when make up water is hard or corrosive water treatment is required Contact qualified water treatment company for recommended water treatment compounds and procedures XII Service and Maintenance Ona continuous basis 1 Keep the area around the boiler free and clear from combustible materials gasoline and other flammable vapors and liquids 2 Keep the area around the boiler and boiler room ventilation openings clear of objects which might obstruct the flow of combustion and ventilation air On at least a weekly basis For boilers equipped with a 67 low water cut off blow down the low water cut off following the instructions on the yellow sticker adjacent to the low water cut off During this blow down the low water cutoff should shut down the burners If it does not the low water cut off should be replaced immediately On an annual basis 1 Turn off electrical power and gas supply to the boiler 2 Inspect the flue passages for signs of blockage If there is any carbon in the combustion chamber or the flue passages clean the heat exchanger before proceeding further See the cleaning procedure below 3 Remove any debris found in the combustion chamber being careful not to disturb combustion chamber insulation 4 Remove all burners noting the location of th
60. late Located next to the bottom water gauge tapping d Blow Down Card Located just above the Lowest Permissible Water Level Plate Wiring Diagram Located on the inside of the removable door f CROWN Nameplate Located on the top center of the outside of the removable door g Rating Plate Located on the upper left of the right side panel D Gas Valve Installation The gas valve assembly has been pre piped with one half of a piping union and is to be connected to the other half of the union located on the gas manifold Connect the pilot tubing from the pilot burner to the gas valve pilot tapping Connect the thermocouple lead to the gas valve standing pilot boilers only E Control and Trim Installation Refer to Figure A3 for Tapping Locations Install the pressure limit control into tapping H with the siphon 94 x 1 4 bushing has been factory installed Do not twist or otherwise bend the control upon installation Install the pressure gauge into tapping B A 3 2 x bushing has been factory installed Tighten with wrench applied to the square shank on the back of the gauge Do not apply pressure on the gauge case since this may ruin the calibration of the gauge Steam boiler with McDonnell Miller 67 float Low Water Cutoff a Install the low water cutoff per the instructions packed with the control b Screw brass nipples with one side of the brass union into tappings c Attach the
61. lay connection Boiler off on pressure limit Defective pressure limit Disconnect Defective Defective thermostat and R8225 transformer temporarily jump See Note 7 See Note 6 on boiler thermostat on page 34 page 34 connections together 24 volts present across blue lead on R8225 and yellow transformer leads Defective R8225 Bad connection in thermostat w iring Loose Defective thermostat connection Thermostat misw ired or betw een misapplied Does relay transformer pull in now and R8225 coil 35 Do burners shut down when Main burners pressure light exceeds limit setting Do burners shut down when water level drops below cut off point 24 volts across red damper lead Defective damper and yellow Defective or loose transformer damper harness lead Obstruction in path of damper blade 8600 module 24 volts across 1 amp 4 blue amp yellow and 2 amp 4 orange amp yellow on damper end of harness Defective or loose damper harness Defective damper Defective or motor loose damper Obstruction in path harness of damper blade 36 siphon tube 24 volts across Refer to standing pilot standing pilot gas or intermittent ignition valve terminals or troubleshooting chart terminals 5 amp 6 on page 39 or 40 24 volts ac
62. leads on loose 120 volt R8225 relay connection Boiler off on pressure limit Defective pressure limit Disconnect Defective Defective thermostat and R8225 transformer temporarily jump See Note 7 See Note 6 on boiler thermostat on page 34 page 34 connections together 24 volts present across blue lead on R8225 and yellow transformer leads Defective R8225 Bad connection in thermostat w iring Loose Defective thermostat connection Thermostat misw ired or betw een misapplied Does relay transformer pull in now and R8225 coil 37 Do burners shut down when pressure exceeds limit setting Main burners light Do burners shut down when water level drops below cut off point 24 volts across red damper lead and yellow transformer lead Defective damper Defective or loose damper harness Obstruction in path of damper blade 24 volts across standing pilot gas valve terminals or terminals 5 amp 6 on S8600 module Refer to standing pilot or intermittent ignition troubleshooting chart page 39 or 40 24 volts across sp switch 24 volts across 1 amp 4 blue amp yellow and 284 orange amp yellow on damper end of harness 24 volts switch Defective or loose damper harness Defective damper motor Obstruction in path of damper blade switch Defectiv
63. m is free of obstructions Make sure that all vent system supports are intact Inspect joints for signs of condensate or flue gas leakage nspect venting components for corrosion or other deterioration Replace any defective vent components 11 Inspect the boiler and system for leaks 12 Inspect the low water cut off For Hydrolevel CG400A low water cut offs Remove and inspect the probe for scale and sediment buildup Clean any sediment or scale from the probe with a scouring pad or steel wool Consult the Hydrolevel CG400 manual for any additional maintenance information Test the low water cut off before placing the boiler back into service For McDonnell amp Miller 67 low water cut offs Remove and inspect switch and float mechanism Inspect float bowl for mud accumulation Clean as required Replace the switch and float mechanism every five years or 100 000 cycles Consult the McDonnell and Miller 67 manual for any additional maintenance information Test the low water cut off before placing the boiler back into service 13 Allow the boiler to cool to room temperature Remove the drain valve and 2 x 3 4 bushing on the left side ofthe boiler Use a flashlight to inspect the bottom row of pushnipples for accumulated scale or mud If a significant amount is present use the following procedure to clean the inside of the heat exchanger a Temporarily installa 1 1 4 inch or larger full port ball valve in place of the boil
64. nes before installing it in this type of system Boiler water temperatures and flow rates in this type of system may be considerably lower than those upon which the water heater manufacturer s ratings are based This may result in substantially longer water heater recovery times 1 SKIM TAPPING 1 1 4 SUPPLY CONNECTION L 1 4 RETURN CONNECTION LIMIT CONTROL IN 3 4 TAPPING 3 4 RELIEF VALVE TAPPING 2 DRAIN OPTIONAL RETURN TAPPING CIRCULATOR REAR OF BSI 7 9 ay STRAINER X Wiring WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 1 120 Volt Wiring The boiler should be provided with its own 15A branch circuit with fused disconnect 120 volt connections are made inside the junction box on the left side of the boiler Remove the transformer to gain access to this box also see Figures 16 through 19 Hot black Wire nut to black transformer lead e Neutral white Wire nut to white transformer lead Ground green or bare Ground screw inside junction box 2 Thermostat Wiring Follow thermostat manufacturer instructions To insure proper thermostat operation avoid installation in areas of poor air circulation hot spots near any heat source or in direct sunlight cold spots outside walls walls adjacent to unheated areas l
65. o light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS STOP Read the safety information above on 5 Remove front access panel this label 6 Rotate the gas control knob clockwise to OFF Set the thermostat to lowest setting 7 Wait five 5 minutes to clear out any gas Then 3 Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand smell for gas including near the floor If you then smell gas STOP Follow B in the safety inform ation above on this label If you don t smell gas go to the next step Rotate the gas control knob counter clockwise to ON GAS CONTROL KNOB SHOWN IN POSITION front access panel lt Turn on all electric power to the appliance GAS INLET Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier GAS VALVE TOP VIEW TO TURN OFF GAS TO APPLIANCE 3 Push in gas control knob slightly and turn 1 Set the thermostat to lowest setting clockwise to OFF Do not Force
66. o the heat exchanger 13 Replace the 4 20 nuts and washers that hold down the flue collector 14 Reattach all the jacket components 15 Reinstall burners being careful to put the pilot main burner in its original location WARNING SOOT DEPOSITS IN THE FLUE PASSAGES ARE A SIGN THAT THE BOILER MAY BE OPERATING AT HIGH CARBON MONOXIDE CO LEVELS AFTER CLEANING THE BOILER OF SOOT DEPOSITS CHECK THE CO LEVEL IN THE FLUE GAS TO INSURE THAT THE BOILER IS OPERATING PROPERLY If it is necessary to check CO use a combustion analyzer or other instrument which is designed to measure CO in flue gas A sniffer designed for testing CO levels in ambient air cannot be used to check boiler combustion Take a flue gas sample by inserting a sample probe through the draft diverter opening and into the flue collector so that the sample is taken in the area directly over the heat exchanger Do not take a sample until the boiler has been firing for at least five minutes A normal CO reading for a BSI series boiler is less than 50ppm 0 005 A reading of more than 100ppm 0 01 is indica tive of a combustion problem Some causes of excessive CO include Incorrectly sized main burner orifice for the altitude at which boiler is installed Crooked or out of round orifice holes never attempt to drill orifice for this boiler in the field Partially plugged flue passages Improper manifold pressure Foreign material in burner ventur
67. ocations subject to drafts Provide Class II circuit between thermostat and boiler Connect thermostat wire leads to the blue transformer lead and brown relay lead inside the junction box Set the heat anticipator to 0 2A Feeder Wiring for Boilers Equipped with Hydrolevel CG400A Low Water Cut offs CAUTION Do not attempt to connect a McDonnell amp Miller model 41014 feeder or other feeder without a delay to a BSI boiler equipped with a Hydrolevel CG400 low water cutoff Doing so could destroy the boiler transformer and or flood the system 1 Using Hydrolevel 24 TWO WIRE feeder Do not alter factory boiler wiring Connect VXT 24 to CG400A as follows Connect the BLACK lead on the feeder to terminal A on the LWCO Connect the WHITE lead on the feeder to terminal 2 on the LWCO 2 Using Hydrolevel VXT 24 THREE WIRE feeder Do not alter factory boiler wiring Connect VXT 24 to CG400A as follows Connect the BLACK lead on the feeder to terminal 1 on the LWCO Connect WHITE lead on the feeder to terminal 2 on the LWCO Connect the RED lead on the feeder to terminal A on the 3 Using McDonnell amp Miller WF2 U 24 feeder Do not alter factory boiler wiring Connect WF2 U 24 to CG400A as follows Connect terminal W on the feeder to terminal A on the LWCO Connect terminal the feeder to terminal 2 on the LWCO Connect terminal H on the feeder to terminal 1 on the LWCO 16 F
68. off interrupts burner operation Pressure Limit Control Interrupts burner operation when the pressure in the boiler exceeds the Cut in setting plus the differential setting The Cut in setting is shown on the outside of the control and is adjusted using the screw on the top of the control The differential is adjusted using the white thumb wheel on the inside of the control Burner operation is restored when the pressure in the boiler drops to the Cut in pressure The vent damper will close when the pressure limit control interrupts burner operation a DAMPER NOTE 2 A BURNER LESS VENT 1 1 1 1 m 1 1 1 I 1 I 1 I 1 1 1 1 I 1 1 1 r 1 1 1 1 L HONEYWELL 204 8304 SERIES GAS VALVES BSI069 345 ROBERTSHAW 7000DERHC GAS VALVE BSI379 2 VENT DAMPER REQUIRED ON BSI069 BSI276 OPTIONAL ON BSI310 BSI379 3 ON BOILERS LESS VENT DAMPER DAMPER HARNESS NOT USED RED AND BLUE LEADS ARE JUMPED TOGETHER USING RED JUMPER WIRE FIGURE 18 WIRING DIAGRAM INTERMITTENTIGNITION ANDHYDROLEVEL CG 400A LOW WATER CUTOFF 21 Blocked Vent Spill Switch Automatically interrupts burner operation in the event that gas spills from the draft diverter opening This switch is equipped with a reset button which must be pressed to restore normal burner operation An open blocke
69. ough the flame rollout and blocked vent spill switches Under normal conditions both of these switches are made and voltage will therefore immediately appear across terminals 24V and 24V GND on the ignition module 7 Upon application of voltage across the 24V and 24V GND terminals the ignition module will start an ignition spark at the pilot and apply 24 volts across the pilot valve terminals and MV PV 8 Once the pilot is established the pilot flame will act as a diode converting the AC current at the electrode to a half wave DC current at the pilot s ground strap This DC current flows through the boiler to the GND BURNER connection 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 9 Oncethe ignition module detects the presence ofa pilot flame voltage is applied across the main valve terminals and MV P V opening the valve and establishing main flame 10 The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot depends upon the exact ignition module supplied with the boiler For more information on module operation consult the ignition module instructions supplied with the boiler or the local Crown representative 19 L BURNER V8295A BSI310 379 ONLY
70. ross spill switch 24 volts across rollout switch pressure limit control Defective Blockage in Grounded probe or probe lead Defective L W C O DO NOT OPERATE BOILER UNTIL THIS PROBLEM IS CORRECTED Chimney blockage Chimney system not contructed in accordance with Parts 7 and 10 of National Fuel Gas Code Down draft Inadequate combustion air supply in boiler room Rollout switch open Replace with exact replacement see parts list Check for blocked Loose electrical heat exchanger connection in spill switch or rollout switch wiring or gas valve common Troubleshooting Chart for BSI Boilers Equipped with McDonnell amp Miller 67 Low Water Cut offs and Vent Dampers Caution Read page 34 before attempting to use this chart Vent damper open ls there an audible Thermostat click as R8225 relay calls for heat pulls in w hen the thermostat calls for heat 24 volts betw een terminal 1 on 67 LWCO and yellow tranformer connection 120 volts across black and w hite transformer leads 24 volts across blue and yellow wires inside junction box 24 volts present betw een each pressure limit Boiler off on low w ater connection and yellow transformer connection Pow er off Blow n fuse or Is 24 volts tripped present across breaker brow n and Misw ired or yellow
71. setting TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Push in gas control knob slightly and turn clockwise to OFF Do not Force 26 LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8204 AND VR8304 SERIES GAS VALVES INTERMITTENT PILOT FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life f you cannot reach your gas supplier call A This appliance is equipped with an ignition the fire department device which automatically lights the pilot Do not try to light the pilot by hand C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water NHET TO DO IF YOU SMELL GAS Do not try t
72. tch it does not matter which of these wires is connected to which terminal on the blocked vent switch Install the strain relief provided in the hole in the jacket through which these wires pass Flame Roll Out Switch a Route the black wire marked 10 through the bushing located on the left jacket panel and connect it to one side of the flame roll out switch b Route the red wire marked 7 through the bushing located on the left jacket panel and connect it to the other side of the flame roll out switch McDonnell Miller Series 67 Low Water Cutoff a Route the black wire numbered 1 and the black wire with the white trace numbered 2 through the fitting on the end of the low water cutoff b Connect lead numbers 1 and 2 to the low water cutoff terminals marked 1 and 2 respectively Hydrolevel CG 400 Probe Low Water Cutoff a Mount the end of the BX cable containing the 3 wire Molex plug and the single red wire to the control box with the BX cable fitting nut supplied b Insert the Molex plug into the receptacle mounted on the CG400 terminal board c Attach the red wire to the terminal marked BURNER Standing Pilot Gas Valve Honeywell VR8200 VR8300 or Robertshaw Model 7000ERHC S7C Connect wire 6 black with a white trace to the TH terminal on the gas valve Connect wire 55 red with a yellow trace to the TR terminal on the gas valve Note Boilers equipped with t
73. the combination gas control resulting in gas flow through the control and burner operation Sequence of Operation Intermittent Ignition 1 When the boiler is energized 24 volts is immediately applied to terminals 1 blue and 4 yellow on the vent damper Assuming that there 15 no call for heat and that the damper switch is in the automatic position the damper will close On boilers equipped with Hydrolevel CG400A probe type low water cut offs voltage is also always applied to terminals 1 blue and 2 yellow on the low water cut off to power the water level sensing circuit On boilers equipped with 67 float type low water cut offs power is always applied to terminal 2 on the 67 LWCO 2 Assuming that water is above the cut off level power will appear at terminal 3 on the CG400 LWCO or terminal 1 on the 67 LWCO 3 Assuming that steam pressure is below the pressure limit setting power will appear on one side of relay contact IRI Gray lead Relay 1R 1s the R8225 mounted under the junction box 4 Acall for heat from the thermostat energizes relay coil causing contacts 1 1 to make Current then flows through contacts to pin terminal 2 orange at the vent damper and the damper opens 5 Once the vent damper 18 fully open an end switch inside the damper will make energizing pin 3 red at the damper 6 Current passes from terminal 3 on the vent damper th
74. tions OPERATING INSTRUCTIONS STOP Read the safety information above on 5 Remove front access panel this label Set the thermostat to lowest setting 6 Rotate the gas control knob clockwise 4 to OFF 7 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then This appliance is equipped with an ignition smell gas STOP Follow B in the safety inform device which automatically lights the pilot ation above on this label If you don t smell gas Do not try to light the pilot by hand go to the next step Turn off all electric power to the appliance Rotate the gas control knob counter clockwise POSITION x to INDICATOR Replace front access panel Turn on all electric power to the appliance 1 DIS oa Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier GAS CONTROL KNOB y gas SUPP SHOWN IN OFF POSITION TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 3 Push in gas control knob slightly and turn clockwise to OFF Do not Force 2 Turn off all electric power to the appliance if service is to be performed INCANDESCENT OUTER MANTLE BLUE WITH OCCASIONAL INCANDESCENT OUTER MANTLE ORANGE FLASHING BLUE WITH OCCASIONAL ORANGE FLASHING OUTER CONE ER TRANSP
75. to basic BSI model number example BSI207SN BSI207SL 800 192 16 3 17 7 HI Before Installing 1 Safe reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction e In the absence of an authority having jurisdiction installation must be in accordance with this manual and the National Fuel Gas Code ANSI Z223 1 latest edition Where required by the authority having jurisdiction this installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 latest edition Warnin This Product Must be Installed By A Licensed Plumber Or Gas Fitter when Installed Within The Commonwealth Of Massachusetts 2 Make sure that a properly sized chimney is available which is in good condition Consult the authority having jurisdiction Part VI of this manual and the National Fuel Gas Code for additional information on venting requirements 3 Make sure that the boiler is correctly sized Use an industry accepted sizing method such as the B R Installation Guide for Residential Hydronic Heating Systems Pub 200 and I B R Heat Loss Calculation Guide Pub H21 or H22 published by the Hydronics Institute in Berkeley Heights NJ 4 Make sure that the boiler received is configured for the correct gas natural or LP The BSI345 and BSI379 may only be
76. used with natural gas 5 Bollers installed at altitudes above 2000 ft require different burners and main burner orifice than those at sea level Make sure that the boiler is configured for use at the correct altitude 6 Ifthis boiler was received as a knockdown boiler follow the instructions in Appendix A to assemble the boiler IV Locating the Boiler Clearances Observe the minimum clearances shown below These clearances apply to all combustible construction as well as noncombustible walls ceilings and doors Also see Figure 2 Front 18 Right Side 18 Left Side 6 6 17 e A24 service clearance from the jacket is recommended on the left right and front of the boiler These clearances may be reduced to those shown in Figure 2 however servicing the boiler will become increasingly difficult as these service clearances are reduced Ifthe right side 24 service clearance is reduced adequate clearance must be maintained to easily read and access the controls Alternatively access may be provided using a door 2 This boiler may be installed directly over a non carpeted combustible floor 3 boiler must be installed on a hard level surface E 18 TOP VIEW ALCOVE QUTLINE FRONT V RIGHT SIDE VIEW MINIMUM RADIAL CLEARANCE AROUND FLUE FIGURE2 BSI BOILERS
77. utton while reading the voltage across the thermocouple Line pressure within the range N indicated on boiler s rating plate Is voltage at Y least 18mV Consult gas Y supplier Pilot tubing blocked kinked or leaking Loose or defective thermocouple connection at gas valve Defective thermocouple Pilot orifice blocked Pilot improperly adjusted Defective gas valve Gas line not 9 purged of air Pilot tube blocked kinked or leaking Pilot improperly i adiusted Pilot orifice partiall 39 START 24 volts is present across 5 and 6 on S8600 module but main burners do not light Spark across gap ignitor sensor Intermittent Ignition System Troubleshooting Chart Caution Read page 34 before attempting to use this chart Pilot Y lights N 24 volts across terminals 2 amp 3 at 58600 Defective Y S8600 module 24 volts across PV amp MV PV at gas valve Break in spark cable insulation Break in pilot porcelain Incorrect pilot spark gap Loose connection in spark cable Loose ground connection Defective El wiring harness Low line pressure Plugged kinked or leaking pilot tubing Plugged pilot orifice Gas line not purged of air Defective pilot assembly Defective gas valve Does spark stop when pilot lights across terminals 1 amp 2 on S8

Crown Boiler BSI069 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents