Crown Boiler BSI207 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. S treet Philadelphia, P A 19134 BSI Series Gas-Fired Natural Draf t S team Boilers INST ALLA TION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler WARNING [...]

2 T able of Contents I . Product Description .................................................. 1 II. Specifications ............................................................. 2 III. Before Installing ......................................................... 3 IV . Locating the Boiler ...................................................... 3 V . [...]

3 T ABLE 1: BSI SPECIFICA TIONS 2 II Specifications FIGURE 1: BSI BOILERS - GENERAL CONFIGURA TION INP UT (M B H ) (M B H ) (Sq . ft) (M B H ) (% ) " A " "B " "C " "D " (G al) BS I06 9S 80 .0 BS I06 9E 81 .9 BS I10 3S 80 .0 BS I10 3E 82 .0 BS I13 8S 80 .3 BS I13 8E 82 .0 BS I17 2S 80 .6 BS I17 2E 82 .1 BS I20[...]

4 3 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 Nati[...]

5 4 4 ) Do not install this boiler in a location where gasoline or other flammable vapors or 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 [...]

6 For Buildings of Other than Unusually Tight Construction 1) Determine whether the boiler is to be installed in a confined space - A confined space is defined by the National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To determine whether the boiler room is a confined s[...]

7 6 FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC FIGURE 3: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE[...]

8 FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 7[...]

9 8 VI V enting 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 Chi[...]

10 9 1 4 ) Vent damper installation is mandatory on all sizes from the BSI069 to BSI276. The BSI310 through BSI379 may be ordered with 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 v[...]

11 10 FIGURE 8: BSI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS FIGURE 9: VENT DAMPER INSTALLATION DETAILS RIGHT SIDE VIEW[...]

12 11 FIGURE 10: GAS CONNECTION TO BOILER * State of Massachusetts Requires Manual Shut-off V alve to be “T” Handle T ype * VII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at a line pressure between the minimum and maximum values shown on the rating plate. For more info[...]

13 12 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 IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. VIII Sy[...]

14 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 d[...]

15 14 WRONG - HEADER BULLHEADED INT O T AKE-OFF AND EQUALIZER WRONG - T AKE-OFF BULLHEADED INTO TWO MAINS WRONG - T AKE-OFF BETWEEN RISERS FIGURE 12: COMMON NEAR-BOILER PIPING MIST AKES FIGURE 11: STEAM BOILER PIPING FOR GRAVITY RETURN "A" "B" "C" "D" BSI 069 * 2 1 1/ 2 1 1/ 4 BSI 103 * 2 1 1/ 2 1 1/ 4 BSI 13[...]

16 IX Indirect W ater 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 describes boiler-side piping[...]

17 X Wiring 1) 120 V olt W iring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 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”) - W ire nut to black transformer [...]

18 Feeder Wiring for Boilers Equipped with McDonnell & Miller #67 Low W ater Cut-offs Figures 14a and 14b show feeder wiring for McDonnell & Miller #101A, McDonnell & 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: [...]

19 18 FIGURE 14b: WIRING MCDONNELL & MILLER WF2-U-24 FEEDER OR THREE-WIRE HYDROLEVEL VXT -24 FEEDER T O BOILER EQUIPPED WITH #67 L.W .C.O. CAUTION D O NOT INST ALL JUMPER BETWEEN 2 & 3 ON #67 L.W .C.O. FIGURE 15: WIRING INDIRECT W A TER HEA TER TO BOILER[...]

20 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 ener gized, 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[...]

21 20 FIGURE 16: WIRING DIAGRAM, STANDING PILOT AND HYDROLEVEL CG-400A LOW WATER CUTOFF “BURNER” “BURNER” L N V8295A (BSI310-379 ONL Y) FIGURE 17: WIRING DIAGRAM, STANDING PILOT AND McDONNELL & MILLER MODEL 67 LOW WATER CUTOFF L N V8295A (BSI310-379 ONL Y) VENT DAMPER (NOTE 2) NOTE 3 LESS VENT DAMPER 2. VENT DAMPER REQUIRED ON BSI069 - [...]

22 Safety Control Operation - S tanding Pilot and Intermittent Ignition Hydrolevel CG400A Low W ater Cut-of f - 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 l[...]

23 FIGURE 19: WIRING DIAGRAM, INTERMITTENT IGNITION AND McDONNELL & MILLER MODEL #67 LOW WATER CUTOFF Blocked Vent (“Spill”) Switch - Automatically interrupts burner operation in the event that flue gas spills from the draft diverter opening. This switch is equipped with a reset button which must be pressed to restore normal burner operatio[...]

24 XI S tar t-up and Checkout Use the following procedure for initial start-up of the boiler: 1 ) Make sure that the boiler is filled with water to the normal water line (28 3/4 inches above the floor or pad on which the boiler is installed) 2 ) Check all new gas piping for leaks and purge piping sections that are filled with air. See Part 4 of the[...]

25 24 1 6 ) 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 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 [...]

26 25 A. This a pplian ce has a pilot wh ich m ust b e l ighted by hand . Whe n lighting th e pilot, f oll ow these in s truc tions exactly. B. BEFO RE LIGHTING smell all a round t he applian ce area fo r gas. B e su re to smell next to t he floor beca use s ome gas is he avier than air and w ill settl e on the floo r . WHA T TO DO IF YOU SMEL L GA[...]

27 26 A. This a pplian ce has a pilot which m ust b e l ighted by hand . Whe n lighting th e pilot, f ol low these in s truc tions exactly. B. BEFO RE LIGHTING smell all a round t he applian ce area fo r gas. B e su re to smell next to t he floor beca use s ome gas is he avier than air and w ill settl e on the floo r . WHA T TO DO IF YOU SME LL G A[...]

28 27 A. This applian ce is e quipped w ith an ign ition device whic h automa ti cally lights the pilot. Do try to lig ht the p ilot by han d. B. B E FO RE LIGHTING smell all a round t he applian ce area fo r gas. B e su re to smel l next to t he floor beca use s o me gas is he avier than ai r an d w ill settl e on the fl oor . WHA T TO DO IF YOU S[...]

29 28 A. This applian ce is e quipped w ith an ign ition device whic h automa ti cally lights the pilot. Do try to lig ht the p ilot by han d. B. B E FO RE LIGHTING smell all a round t he applian ce area fo r gas. B e su re to smel l next to t he floor beca use s ome gas is he avier than ai r an d w ill settl e on the fl oor . WHA T TO DO IF YOU SM[...]

30 29 FIGURE 22a: MAIN BURNER FLAME - 1” BURNERS FIGURE 22b: MAIN BURNER FLAME - 40mm (“HIGH ALTITUDE”) 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 ignitio[...]

31 30 FIGURE 24a: GAS VALVE DETAIL - HONEYWELL VR8204 AND VR8304 (INTERMITTENT IGNITION) FIGURE 23a: GAS VALVE DETAIL - HONEYWELL VR8200 OR VR8300 (STANDING PILOT) FIGURE 23b: GAS VALVE DETAIL - ROBERTSHAW 7000ERHC AND HONEYWELL V8295 (STANDING PILOT) FIGURE 24b: GAS VALVE DETAIL - ROBERTSHAW 7000DERHC (INTERMITTENT IGNITION)[...]

32 XII Service and Maintenance On a 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[...]

33 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. 1 0 ) Inspect the vent system: • Make sure that the vent system is free of obstructions. • Make sure that all vent system supports are intact. • Inspect joints for [...]

34 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[...]

35 XIII T roubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems. T o 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 is known to be with[...]

36 T roubleshooting Chart for BSI Boilers Equipped with Hydrolevel CG400A Low W ater Cut-offs and V ent Dampers Caution : Read page 34 before attempting to use this chart 35 I s th er e an aud i b le c li c k as R 8225 rel ay pulls in w hen t h e th er m os tat c al l s f or heat ? Do e s r e l a y pull in now ? Ve n t dam per open ? ST A R T Th e [...]

37 36 24 volts across 1 & 4 (blue&yellow) and 2 & 4 (orange&yellow ) on damper end of harness? N Y Main burners light? 24 volts across red damper lead and yellow transformer lead? * Refer to standing pilot or intermittent ignition troubleshooting chart (page 39 or 40). * Defective damper * Defective or loose damper harness * Obstruc[...]

38 37 T roubleshooting Chart for BSI Boilers Equipped with McDonnell & Miller #67 Low W ater Cut-offs and V ent Dampers Caution : Read page 34 before attempting to use this chart I s th er e an aud ibl e c lic k as R 82 25 r elay pul ls in w h en the ther m os ta t c alls f or heat ? Do e s r e l a y pul l i n now ? V ent dam per open ? ST AR T[...]

39 24 volts across 1 & 4 (blue&yellow) and 2 & 4 (orange&yellow ) on damper end of harness? N Y Main burners light? 24 volts across red damper lead and yellow transformer lead? * Refer to standing pilot or intermittent ignition troubleshooting chart (page 39 or 40). * Defective damper * Defective or loose damper harness * Obstructio[...]

40 S tanding Pilot Ignition System T roubleshooting Chart P ilot li t ? Ma in burners li ght ? Y T urn c o nt rol on gas v al v e t o PIL O T . D e pr ess re d b utt on a nd l i ght pi lot . Hold but t on for at le as t o ne mi nu t e . Does pi l ot light? N * P i l o t t ubi ng bl oc k ed, k ink e d or l eak i ng * P ilo t orif i c e bl oc k ed * [...]

41 40 Doe s s park s t op w he n p ilot li ght s ? 24 v olt s a cr o ss t ermi nal s 2& 3 at S 8600? Sp a rk ac ros s i g n i t or/ s ens or gap? Y Can y ou hear spa r k in g? * Fau l ty S 860 0 modul e * B reak i n s p ark cab l e in su l ation * B reak i n pi lot p o r c ela in * Inco rrec t p il ot sp a r k g a p * Loos e c onnec t i on i n [...]

42 41 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 www .crownboiler .com For boilers installed at elevations above 2000 ft, consult the local Crow[...]

43 42[...]

44 43 ** These V alves Piped in Series to Provide Redundant Shut-off ***1/4 Pilot T ubing Used with Robertshaw V alves 69 103 138 1 72 207 241 2 76 310 345 3 79 42 1" B URNE R LES S P ILO T B RA CKET 1505 01 2 e a. 4 ea . 6 e a. 8 ea. 11 ea. 1 3 e a. 15 ea . 17 e a. 2 0 e a. 22 ea . 43 MANI FO LD ( 1" B URN ERS ) 1 e a. 7 0015 3 70015 4 7[...]

45 44[...]

46 45 69 10 3 138 1 72 207 241 2 76 310 345 3 79 7 5 LEF T SI DE JAC K ET P ANEL 1 e a. 8 50 30 1 85 030 1 85 03 01 8 50 30 1 8 50 3012 85 03 012 8 503 01 2 8 50 30 15 8503 01 5 8 503 01 5 7 6 R IG HT SID E JAC KET PANE L 1 e a. 850 30 0 85 030 0 85 03 00 8 50 30 0 8 50 30 02 8503 002 8503 00 2 8 50 30 05 8503 00 5 8 503 00 5 7 7 R EAR JA C KET PAN[...]

47 46[...]

48 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 se[...]

49 48 FIGURE A1: BASE, HEA T EXCHANGER, FLUE COLLECT OR ASSEMBL Y[...]

50 5 ) Install the left side panel in the same manner as the right side. 6 ) Attach the front corners of the diverter panel to the side jacket panels using #10 sheet metal screws. 7 ) 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 fro[...]

51 50 FIGURE A2: JACKET INST ALLA TION[...]

52 F . Electrical Wiring Connections (Also refer to wiring diagrams in Part X of the installation manual) 1 ) A pre-wired junction box assembly specific to the control package ordered with the boiler has been provided by the factory . 2 ) Orient the junction box so the black relay , which is mounted to the outside of the junction box, is facing dow[...]

53 52 FIGURE A3: T APPING LOCA TIONS (SEE TEXT FOR T APPING USES)[...]

54 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 CROWN Bo iler Co[...]