Crown Boiler 16-325 500506 manual

1 D E S I G N E D T O L E A D T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 Series 16 Gas-Fired Natural Draf t W ater Boilers INST ALLA TION AND OPERA TING INSTRUCTIONS These instructions must be af fixed on or adjacent to the b[...]

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3 T able of Contents I. Product Description . . . . . . . . . . . . . . . . . . . 1 II. Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2 III. Before Installing . . . . . . . . . . . . . . . . . . . . . . 3 IV . Locating the Boiler . . . . . . . . . . . . . . . . . . . . 3 V . Knockdown Boiler Assembly Instructions 6 A. Prior T o Ass[...]

4 2 II Specifications[...]

5 III 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. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the latest [...]

6 Figure 2: Minimum Clearances to Combustibles 4 All Models - The following service clearances are recommended from the top and front of the boilers: 16-325, 16-390 – 24 inches 16-455, 16-520, 16-585 – 48 inches These clearances may be reduced to those shown in T able 2, however servicing the boiler will become increas- ingly difficult as these[...]

7 5 T able 3: Minimum Room V olumes Based On Sixteen Times Boiler V olume By Model Size Bo ile r M ode l O v e r A ll Le ngt h Jack e t O v e r A ll D e pt h Jack e t O v e r A ll H e i ght F l oor To Top O f Jack e t Bo ile r Vo l u m e (F t 3) M i n i mu m Ro o m Vo l u m e (F t3) 16-32 5 23 3/ 4 32 7/ 16 32 1/ 2 14. 5 231. 8 16-39 0 27 1/ 2 32 7[...]

8 V Knockdown Boiler Assembly Instructions 6 A. Prior T o Assembly 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 a damaged heat exchanger . 3) All joints between sections have been factory sealed. Inspect the joints between the sect[...]

9 7 8) Slide or walk the assembly into its permanent position. DO NOT DROP . 9) The assembly must be level in both directions and supported around the entire base bottom. Shim and grout under base if necessary. 10) The flame roll-out switch has been mounted to the burner access panel at the factory. On boilers with two access panels the panel with [...]

10 8 C. Jacket Assembly 1) Align the left jacket side panel with the screw holes located on the upper flange of the left base end panel and loosely attach the left jacket side panel with two #10 x 1/2” sheet metal screws as shown in Figure 6. 2) Repeat Step 1 for the right side panel. 3) Insert the left and right sides of the jacket rear panel be[...]

11 5) Lay the jacket top panel on top of the jacket side and rear panels. Locate the top of the rear jacket panel to the inside of the jacket top panel. Align the sides of the jacket top panel to be flush with the outside of the jacket side panels. Loosely attach the rear flange of the jacket top panel to the jacket rear panel using three #10 x 1/2[...]

12 10 Figure 6: Jacket Assembly[...]

13 11 Figure 7: Gas Train - Standard Build Figure 8: Gas Train - CSD-1 Build, 16-455, 16-520,& 16-585[...]

14 F . Control & T rim Installation 1 ) Table 4 shows the use of all tappings on Series 16 boilers. The tapping letter designations referenced are shown in Figure 4. Control and trim components are as follows: a. 4 x 4 Junction Box - Install the supplied junction box on the inside of right jacket side panel with two 8-32 x 1/2” machine screws[...]

15 13 VI Air For Combustion and V entilation 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 [...]

16 14 • If providing openings 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 ”. B. For Buildings Of Unusually Tight Construction 1) Provide outdoor air through two permanent openings which communicat[...]

17 15 Figure 1 1: All Air Fr om Outdoors, V entilated Crawl Space & Attic Figure 12: All Air From Outdoors, V ia V entilated Attic Figure 13: All Air Fr om Outdoors, Using Openings Into Boiler Room[...]

18 16 Figure 14: All Air Fr om Outdoors, Using Horizontal Ducts Into The Boiler Room[...]

19 17 VII V enting V ent installation must be in accordance with local building codes, or the authority having jurisdiction, or Chapters 7 and 10 of the National Fuel Gas Code, NFP A 54/ANSI Z223.1. A typical vent installation is shown in Figure 15. The components of a vent installation are the draft hood, vent damper (optional), vent connector and[...]

20 9) Series 16 boilers are supplied with an external draft hood which must be installed as shown in Figure 15 without alteration. Before installing the draft hood, verify that the model number marked on the draft hood matches that of the boiler being installed. Prior to securing the draft hood verify that the distance from the top of the jacket to[...]

21 b) Vent damper is factory shipped having approximately ¾” 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, using the plug supplied with the damper. Mount the vent damper on the flue collar without modification to either and se[...]

22 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 the remaining 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 syste[...]

23 VIII System Piping A. Standard Heating System Piping 1) Figure 18 shows typical boiler system connections on a single zone system. Additional information on hydronic system design may be found in Installation of Residential Hydronic Systems (Pub. #200) published by the Hydronics Institute in Berkeley Heights, NJ. The components in this system an[...]

24 this low water cutoff have a manual reset function. The low water cutoff may be a float type or probe type, but must be designed for use in a hot-water system. The low water cutoff should be piped into the boiler supply just above the boiler with no intervening valves between it and the boiler. Use a low water cutoff that breaks the 120 VAC supp[...]

25 23 Figure 18: S tandard Boiler Piping[...]

26 Figure 19: Recommended Piping for Combination Heating & Cooling (Refrigeration) System 24[...]

27 25 IX Gas Piping 1) Gas piping to the boiler must be sized to deliver an adequate supply of gas for the boiler to fire at the nameplate input with the inlet pressure at the gas valves between the minimum and maximum valves shown on the rating plate. For more information on gas line sizing, consult the Utility or the National Fuel Gas Code . 2) F[...]

28 26 X Contr ol System W iring 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) Provide the boiler with a dedicated branch circuit with a fused disconnect. The minimum rating of this circuit must be 15A. 2[...]

29 27 Sequence of Operation – S tandard Boiler Wiring 1) All low water cut-of fs and auxiliary limit controls are wired in series so that the boiler will not operate if any of these controls are open. Under normal circumstances, only the operating control contacts will be open. 2) Upon a call for heat, the operating control will make and the vent[...]

30 28 Figure 21: Series 16 S tandard Boiler Wiring[...]

31 29 Figure 22: Series 16 - CSD-1 Boiler W iring[...]

32 Safety Control Operation T emperature Limit Control – The temperature limit control interrupts burner operation when the supply water tempera- ture exceeds the set point. Maximum allowable water temperature in a water boiler is 250F . The L4080D will reset itself when the water temperature drops below the set point less the dif ferential (typi[...]

33 31 XI S tart-up and Checkout Use the following procedure for initial start-up of the boiler: 1) Make sure that the boiler is filled with water. 2) Check all new gas piping for leaks and purge piping sections that are filled with air. See the National Fuel Gas Code for additional information on testing and purging gas lines. 3) Verify that vent s[...]

34 32 WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER-FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD. 8) 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 e[...]

35 Figure 25: Gas Valve Detail - Robertshaw 7000DERHC 33 14) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. Both pilot burner and main burners should stop firing and the vent damper (if used) should close. Raise the thermostat back to the highest setting. The vent damper (if used) should open and t[...]

36 A. This appl ianc e is equipp ed with an ign ition device whi ch a utomatic ally lights th e pilot. Do t ry to lig ht the p ilot by han d. B. BE FORE LIGHTIN G smell a ll ar ound t he applia n ce ar ea for gas. Be sure to sm ell ne xt to t he fl oor because some gas is h eavier than air an d will se ttle on the floo r . WHA T TO DO IF YOU SMELL [...]

37 CAUTION W A TER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE T O THE BOILER OR OTHER SYSTEM COMPO- NENTS. REP AIR ANY LEAKS FOUND IMMEDIA TEL Y . 35 XII Service and Maintenance The following routine maintenance should be performed: On a continuous basis: 1) Keep the area around the boiler free and clear from combustible materials, gasoline, and other[...]

38 Heat Exchanger Cleaning Pr ocedure 1) T urn off electrical power and gas supply to the boiler . 2) Disconnect the vent connector from the boiler . 3) Remove the blocked vent switch and the draft hood. 4) Remove the door panel and the top jacket panel. 5) Remove the burner access panels. 6) Remove the burners and inspect them for foreign debris a[...]

39 XIII P AR TS The following parts may be obtained from any Crown distributor . T o find the closest Crown distributor , consult the area Crown representative or the factory at: Crown Boiler Co. Customer Service P .O. Box 14818 Philadelphia P A. 19134 (215) 535-8900 www .crownboiler .com For boilers installed at elevations above 2000 ft, consult t[...]

40 Figure 26: Exploded View - Base Parts & Manifold 38[...]

41 39 16-325 16-390 16-455 16-520 16-585 1 BASE END PANEL 260660 22222 16-325 260646 2 16-390 260647 2 16-455 260648 2 16-520 260649 2 16-585 260650 2 16-325 260666 1 16-390 260667 1 16-455 260668 1 16-520 260669 1 16-585 260670 1 16-325 260606 1 16-390 260607 1 16-455 260608 1 16-520 260609 1 16-585 260610 1 16-325 260626 1 16-390 260627 1 16-455 [...]

42 Figure 27: Exploded V iew - Base / Heat Exchanger / Flue Collector - Assembly 40[...]

43 41 16-325 16-390 16-455 16-520 16-585 16-325 See Figure 26 1 16-390 See Figure 26 1 16-455 See Figure 26 1 16-520 See Figure 26 1 16-585 See Figure 26 1 16-325 260016 1 16-390 260017 1 16-455 260018 1 16-520 260019 1 16-585 260020 1 30a LEFT END SECTION 260001 11111 30b INTERMEDIATE SECTION 260002 45678 30c RIGHT END SECTION 260000 11111 16-325 [...]

44 42 Figure 28: Exploded V iew - Jacket[...]

45 43 16-325 16-390 16-455 16-520 16-585 40 RIGHT SIDE JACKET PANEL 260300 11111 41 LEFT SIDE JACKET PANEL 260301 11111 16-325 260306 1 16-390 260307 1 16-455 260308 1 16-520 260309 1 16-585 260310 1 16-325 260386 1 16-390 260387 1 16-455 260388 1 16-520 260389 1 16-585 260390 1 16-325 260326 1 16-390 260327 1 16-455 260328 1 16-520 260329 1 16-585[...]

46 44 Figure 29: Exploded View - T rim & Control Components[...]

47 45 16-325 16-390 16-455 16-520 16-585 61 IGNITION MODULE MOUNTING BRACKET 905000 11111 62 IGNITION MODULE, S8610M 1011 (STD ONLY) 3505015 11111 63 3505555 1 1 1 1 1 64 GAS VALVE TRAIN ASSEMBLY (NAT GAS) (STD ONLY) - 1 1 1 1 1 64 GAS VALVE TRAIN ASSEMBLY (LP GAS) (STD ONLY) - 1 1 1 1 1 65 OPERATING LIMIT L4080D1218 35-3300 1 1 1 1 1 66 3/4" [...]

48 PN:980416 S16-06/04 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134[...]