Crown Boiler 32 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 32 Gas-Fired Natural Draf t Steam or W ater Boilers INST ALLA TION AND OPERA TING INSTRUCTIONS These instructions must be affixed on or adjacent [...]

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3 T able of Contents I. Product Description 1 II. Specifications 2 III. Before Installing 7 IV . Locating the Boiler 7 V . Knockdown Boiler Assembly Instructions 10 VI. Air for Combustion & V entilation 19 VII. V enting 23 VIII. S team Boiler Piping & T rim Installation 27 A. Heating System Piping 27 B. Indir ect W ater Heater Piping 36 IX.[...]

4 Figure 1: Base Model - General Configuration 2 II Specifications[...]

5 3 T able 1A: Dimensional Data Jacket Overall Len g t h 'A' 'B' Dia. 'C' Dia. 'D' Dia. 'E' Dia. 'F' Dia. 'G' Dia. 'H' 'J' 'K' 'L' 'M' 'N' 'P' 'R' 'S' 'T' 'U' 10" 12[...]

6 T able 1B: Specifications 4 Wa t e r (MB H) (MB H) (S q . ft ) (MB H) (M B H ) (G al ) (G al ) 32-475W(S )N 6 475 380 1188 285 330 80-1/ 2 28.58 39.80 11.4 32-570W(S )N 7 570 456 1425 342 397 80-1/ 2 32.65 45.47 13.6 32-665W(S )N 8 665 532 1663 399 463 80-1/ 2 36.72 51.14 15.9 32-760W(S )N 9 760 608 1900 456 529 80-1/ 2 40.79 56.81 18.2 32-855W(S[...]

7 5 Figure 2a: Series 32 S team Boilers - Arrangement Of S team Riser Connections, Draft Hoods And Base Assemblies[...]

8 6 Figure 2b: Series 32 W ater Boilers - Arrangement Of W ater Supply Connections, Draft Hoods And Base Assemblies[...]

9 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 [...]

10 T able 2: Minimum Room V olumes Based On Sixteen T imes Boiler V olume By Model Size 8 B o ile r Mo d el Ove r A ll Le ngth Jack e t O ve r A ll De p t h Jack e t Ove r A ll H e ight F loor To Top O f Jack e t Bo i l e r Vo l um e (F t3) M i n i mu m Ro o m Vol um e (F t3 ) 32- 475 36 3/4 32 1/4 46 5/8 32.0 511. 7 32- 570 42 1/4 32 1/4 46 5/8 36[...]

11 6) The boiler should be located as close to the chimney as possible. 7) Do not install this boiler directly on a surface that may get wet. Raise the boiler on a pad. C lear anc es R equir ed F or R em ov al O f T ank l es s H eater T- 1 T - 2 T- 3 Lef t Side 24" 18" ( C ontr ols ) 27" 32" 42" R ight Side 24" 18"[...]

12 V Knockdown Boiler Assembly Instructions 10 A. Prior T o Assembly 1) Thoroughly inspect the cast iron heat exchanger sections 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 section. Replace it with an undamaged heat exchanger section. 3) Keep the base in t[...]

13 11 Figure 4: Multiple Base Assembly[...]

14 12 C. Section Assembly 1) Clean the boiler sections inside and out to remove dirt due to shipping and handling. 2) Clean all nipples and nipple ports with kerosene immediately prior to section assembly . 3) Set the left end section on the base so that the locating lugs on the bottom of the section go inside the front and rear base panels. Left e[...]

15 13 Figure 6: Assembly Of Sections Figure 5: Use Of Nipple Gauge[...]

16 14 14) Install the tankless coil/s and/or cover plates using the gaskets and 3/8 x 7/8 bolts and washers provided (see Figure 7). 15) T est assembled block for leaks. Unless local codes have other requirements, use the following procedure: a) Run a hose from the water service to one of the lower tappings. Install a ball or gate valve in one of t[...]

17 15 6) Hang a rear tie rod channel bracket on the 4" stud installed in the left end section (Figure 12a). 7) Facing the rear of the boiler , find the square mounting holes underneath the draft hood. Drop a 5/16 x 5" carriage bolt through this hole and through the hole in the rear tie rod channel bracket. Loosely secure with a wing nut a[...]

18 16 Figure 12b: Rear Attachment Of Draft Hood Figure 1 1: Front Attachment Of Draft Hood Figure 12a: Mounting Rear T ie Rod Channel Bracket[...]

19 17 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 later for piping the boiler . See Sections VIII and IX for piping and trim installation. D. Jacket Assembly Instructions 1) On the left and right side base panels attach the jacket [...]

20 18 Figure 14: Exploded V iew Of Jacket Assembly[...]

21 19 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 [...]

22 20 • 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[...]

23 21 Figure 16: All Air Fr om Outdoors, V entilated Crawl Space & Attic Figure 17: All Air Fr om Outdoors, V ia V entilated Attic Figure 18: All Air Fr om Outdoors, Using Openings Into Boiler Room[...]

24 22 Figure 19: All Air Fr om Outdoors, Using Horizontal Ducts Into The Boiler Room[...]

25 23 VII V enting V ent installation must be in accordance with local building codes, or the authority having jurisdiction, or the National Fuel Gas Code, NFP A 54/ANSI Z223.1 . T ypical vent installations are shown in Figures 20 and 21. The vent system shown in Figure 20 uses a common vent for all boiler modules. In Figure 21, each boiler module [...]

26 6) Lateral venting should slope upwards towards the chimney 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. 7) The connector rise coming off the boiler should be as tall as possible, while still maintaining the proper clearance from the horizontal vent connector[...]

27 25 Figure 21: Series 32 V enting (Each Module Individually V ented) Figure 20: T ypical Series 32 V enting (Common Module V enting)[...]

28 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[...]

29 27 VIII S team Boiler Piping & T rim Installation 1) Figures 27 shows the recommended near boiler piping for most common types of gravity return steam systems. Use Table 6 to determine the riser, header and equalizer piping sizes for the appropriate boiler model. 2) One of the primary purposes of the near boiler piping is to separate tiny wa[...]

30 28 Hydrolevel CG450 – This is a probe type L WCO and is installed in tapping “G”. On the CSD-1 control package, and other boilers with redundant low water cut-offs, the CG450 is the operating low water cut-of f and should be used to control a feeder (if used). The CG450 supplied with the Series 32 uses a special probe which does not have a[...]

31 29 T able 5 Figure 22: S team Boiler T apping Locations Tapp ing U ses C h art For Steam B oil ers 1 C om pone nt De s c r iption Ta pping Ta pping St a nda r d C SD-1 L o cati o n S i ze ( i n ) E q u i p men t P acka g e S upply Pipin g A 3 N N Ret ur n P ipin g B 3 N N Sa fe ty R e l i e f V a l v e s ( W it h I nlet O pening Up T o & I n[...]

32 f. Boiler Drain Valve - Install with a 3” x ¾” bushing into one of the two return tappings “B”. The drain valve may also be installed in the return piping, but it must be installed in the leg of a tee so that it is directly opposite and as close as possible to the return tapping. The leg of the tee must be at least 1½” pipe size. A b[...]

33 Figure 25: Common Near -Boiler Piping Mistakes T able 6: S team Boiler Riser & Header Pipe Sizes Steam Steam R eturn C ondens ate E qual i z er Boi l er H eader R i s er P ipe H eader R etur n P i pe P ipe M odel Si z e ( in) Quant ity Si z e ( i n) Si z e ( in) Q uanti ty Si z e ( in) Q uanti ty Si z e ( i n) 32- 380 3 1 3 1 1/2 1 1 1/2 1 2[...]

34 Figure 26: T ypical Near -Boiler Piping When Using A Boiler Feed Pump 32[...]

35 Figure 27a: Recommended S team Boiler Piping: 1 or 2 Supply Connections, Gravity Return 33[...]

36 Figure 27b: Recommended S team Boiler Piping: 3 Supply Connections, Gravity Return 34[...]

37 35 Figure 27c: Recommended S team Boiler Piping: 4, 5 or 6 Supply Connections, Gravity Return[...]

38 36 B. Indirect W ater Heating Piping (S team Boilers) The steam version of the Series 32 boiler is 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. Th[...]

39 37 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 WITH CONTINUOUS RETURN TEMPERATURES BELOW 120°F CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. • OPERATION OF [...]

40 38 DANGER • CONFIRM RELIEF V AL VE HAS THE CORRECT PRESSURE SETTING AND CAP ACITY FOR THE BOILER. • PIPE THE PRESSURE RELIEF VALVE DISCHARGE TO A SAFE LOCATION. • DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE. • DO NOT PLUG RELIEF VALVE DISCHARGE. 3) In addition to the boiler trim, the following system components are required[...]

41 39 Tappi ng Uses Char t For W at er Boi l er s 1 C ompone nt D escr i p t io n T ap p i n g T ap p i n g S t an d ar d C S D - 1 L o cat i o n S ize ( i n ) E q u i p m en t P ackag e S uppl y P i pi ng A 3 N N R etur n P i pi ng B 3 N N P r e ssu r e R e lie f V a lv e s C 2 1-1/2 Y Y C ombi nat i on P r es s ur e / T emper atur e / A l t i tud[...]

42 40 Figure 30: T ypical W ater Boiler System Piping[...]

43 41 T able 8: W ater Boiler Supply & Return Pipe Sizes Figure 31: Recommended Boiler Piping For Combination Heating & Cooling Systems Suppl y Suppl y Water R etur n R etur n Water Boi ler H eader R is er C onnec tions H eader C onnec ti ons M odel S i z e ( in) Q uanti ty S iz e ( in) Si z e ( in) Q uanti ty Si z e ( in ) 32- 475 2 1 2 2 [...]

44 42 B. TANKLESS HEATER PIPING If the Series 32 water boiler is installed with an optional tankless heater, pipe the heater as shown in Figure 32. The components in this system and their functions are as follows: 1) Mixing Valve (Required) - During the heating season, the water exiting the tankless heater may be 180 degrees or more. The mixing val[...]

45 43 8) Multiple Tankless Heaters - If two tankless heaters are installed in the boiler, it is recommended that each heater be installed in parallel with its own mixing valve, relief valve, flow restrictor, etc.. This will permit either heater to be removed from service for maintenance while still providing some domestic water to the building. T a[...]

46 44 X 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) Fi[...]

47 45 XI Control System 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). W ARNING OPERA TING CONTROL CONT ACTS MUST BE “DR Y” (ELECTRICALL Y ISOLA TED FROM ALL OTHER CIRCUITS IN THE OPERA TING CONTR[...]

48 46 6) Once the ignition module detects the presence of a pilot flame, voltage is applied across the main valve, opening the valve and establishing main flame. 7) 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[...]

49 47 Figure 35: Series 32 S tandard Boiler Wiring[...]

50 48 Figure 36: Series 32 - CSD-1 Boiler Wiring[...]

51 Safety Control Operation T emperature Limit Control (W ater Boilers) – The temperature limit control interrupts burner operation when the supply water temperature exceeds the set point. Maximum allowable water temperature in a water boiler is 250F . The L4006A will reset itself when the water temperature drops below the set point less the diff[...]

52 50 XII 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 [...]

53 51 WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER-FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD. 13) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a. Connect a manometer to the inlet pressure tap on the gas valve (see Figures 39 - 41). b. Check the inlet pressure[...]

54 52 16) (Steam Boilers) - 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. The pilot burner and main burners should stop firing. Mak[...]

55 Figure 40: Gas Valve Detail - Robertshaw 7000DERHC Figure 39: Gas Valve Detail - Honeywell VR8304 53 Figure 41: CSD-1 Gas T rain[...]

56 A. This appl ian c e is equi pp ed w i th an ign ition device w hich automat ic ally lights th e pilot. Do t ry to lig ht the p ilot by han d. B. BE FO RE LIG HTING s mell a ll aro und t he applia n ce ar ea for ga s. Be sure to smel l next to t he floor becaus e so me ga s is h eavier than air an d will settle on the floo r . WHA T TO DO I F YO[...]

57 A. This appl ian c e is equi pp ed w i th an ign ition device w hich automat ically lights th e pilot. Do try to l ig ht the p ilot by han d. B. BE FO RE LIG HTING s mell a ll aro und t he applia n ce ar ea for ga s. Be sure to smel l next to t he floor becaus e so me ga s is h eavier than air an d will settle on the floo r . WHA T TO DO I F YOU[...]

58 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 56 XIII 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 [...]

59 12) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas piping disturbed during the inspection process for leaks. Heat Exchanger Cleaning Pr ocedure 1) T urn of f electrical power and gas supply to the boiler 2) Disconnect the vent connectors from the boiler . 3) Remove the fr[...]

60 XIV 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 the[...]

61 59 285 380 475 285 380 475 A B C D E PART # (STANDARD) 310000 310001 310002 310002 310003 311004 311005 311006 310404 310405 310406 311020 311021 311022 311023 311024 311010 310400 3 11025 311030 PART # (CSD-1) 310000 310001 310002 310002 310003 3110045 3110055 3110065 310404 310405 310406 311020 311021 311022 311023 311024 311010 310400 3110255[...]

62 60 285 380 4 75 285 BA SE A SSE M BLY ( ST D ) 3101 14 1 380 BA SE A SSE M BLY ( ST D ) 3101 15 1 475 BA SE A SSE M BLY ( ST D ) 3101 16 1 285 BA SE A SSE M BLY ( C SD - 1) 310114 5 1 380 BA SE A SSE M BLY ( C SD - 1) 310115 5 1 475 BA SE A SSE M BLY ( C SD - 1) 310116 5 1 RE A R TIE RO D CHA NNE L B RA CK E T 3 1 0 3 1 1 1 1 1 5/8 X 4 S T U D 9[...]

63 61 "A " "B" "C " "D " "E " 7" P U SH N I P P LE 310005 5 6 7 8 9 3" P U SH N I P P LE 310006 5 6 7 8 9 5/8 X 9 3/4 T I E R OD 90031 0 1 5 18 21 24 27 5/8 H E X N U T 90031 1 3 0 36 42 48 54 5/8 F LA T W A SH E R 9003 12 30 36 42 48 54 LO C TI TE # 59 2, 50 m l T U BE 90035 0 2 3 3 LO C [...]

64 285 380 475 1 BA SE F R O N T P A N E L (285) 310 604 1 1 BA SE F R O N T P A N E L (380) 310 605 1 1 BA SE F R O N T P A N E L (475) 310 606 1 2a BA SE F R ON T LE G (R H ) 310110 1 1 1 2b BA SE F R ON T LE G (LH ) 310111 1 1 1 3 INS UL A TION B A S E F RO NT ( 2 8 5 ) 3 1 2 6 1 4 1 3 INS UL A TION B A S E F RO NT ( 3 8 0 ) 3 1 2 6 1 5 1 3 INS [...]

65 63 Figure 42: Exploded V iew - Base Parts[...]

66 64 285 380 475 20 M A N I FO LD A S SY , C OM P LE T E ( 285) 310 15 4 1 20 M A N I FO LD A S SY , C OM P LE T E ( 380) 310 15 5 1 20 M A N I FO LD A S SY , C OM P LE T E ( 475) 310 15 6 1 21 1/4- 20 X 1/2 S E LF T A P P I N G S C R E W 90010 0 4 4 4 22 M A I N BU R N E R L E SS P I L OT BR KT 15 03 21 7 10 13 23 M A I N BU R N E R WI T H P I LO[...]

67 65 Figure 43: Exploded V iew - Gas Manifold / Burners / Pilot Assembly[...]

68 66 L4006A 201 5 35- 3510 1 L4006E 1109 M A N . R E SE T ( C SD - 1 ON LY ) 35- 310 0 1 1/2 LO N G W E LL 35-1006 1 H Y D R OLE V E L 55 0 LWC O (C SD - 1 ON LY ) 45 0550 1 1- 1/ 2 X 1 / 2 BLK BU SH I N G 9 50 02 1 1 TRIDICA TO R G A UGE 9 5 - 0 3 8 1 1/ 2 X 1/ 4 BL K BU SH I N G 95 - 05 3 1 BLA NK C OI L P L A TE 27 00 0 3 2 C OI L G A SKE T 270[...]

69 67 BOILER MODEL 98-111 980888 980425 980 92 0 900365 95-040 95-081 95-134 950500 95-096 95-027 95-057 95-105 950185 950114 950190 950110 95-047 95-033 95-058 95-031 32-475W 111111 1111 32-570W 111111 1111 32-665W 11111 1 1111 32-760W 11111 1 1111 32-855W 11111 1 1111 32-950W 11112 1 1111 32-1045W 11112 1 1111 32-1140W 11112 1 1111 32-1235W 11112[...]

70 68 BOILER MODEL 98-111 980888 980425 980 92 0 900365 950510 950515 950520 950525 950530 950124 950180 950175 950170 95-096 950185 95-047 32-475S 111111 11 11 32-570S 111111 11 11 32-665S 11111 1 11 1 1 32-760S 11111 1 11 1 1 32-855S 11111 1 11 1 1 32-950S 11112 1 11 1 1 32-1045S 11112 1 11 1 1 32-1140S 11112 1 11 1 1 32-1235S 11112 1 11 1 1 32-1[...]

71 PN 980888 Rev .2 10/08 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[...]