Crown Boiler BWC Series manual

BWC Series High Effi ciency Gas-Fired Hot W ater Direct V ent Condensing Boilers INST ALLA TION INSTRUCTIONS These instructions must be affi xed on or adjacent to the boiler . Models: • BWC150 • BWC225 W ARNING : Improper installation, adjustment, alteration, serv ice or mai nten ance can cause prope rty damage , inj ury , or loss of life. Fo[...]

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T able of Contents I. Product Description 2 II. Specifications 2 III. Before Installing 3 IV . Locating The Boiler 3 V . Air For V entilation 5 VI. V enting 7 V ent System Design 7 Removing An Existing Boiler From Common Chimney 14 V ent/Intake System Assembly 14 VII. Gas Piping 20 VIII. System Piping 21 General System Piping Precautions 21 System[...]

2 I Pr oduct Description The BWC is an aluminum gas fired condensing boiler designed for use in forced hot water heating systems requir- ing supply water temperatures of 180°F or less. This boiler may be vented vertically or horizontally with combus- tion air supplied from outdoors. This boiler is not designed for use in gravity hot water systems[...]

III Befor e Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code , ANS[...]

4 Figure 4.1: Clearances T o Combustible Or Non-combustible Material T able 4.2: Clearances From V ent Piping T o Combustible Construction TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MINIMUM CLEARANCE TO COMBUSTIBLE MA TERIAL HEA T F AB SAF-T VENT PROTECH F ASNSEAL Z-FLEX Z-VENT III FLEX-L ST AR-34 VER TICAL OR HORIZONT AL A T LEAST ONE SIDE OPEN, C[...]

V Air for V entilation Air for combustion must always be obtained directly from outdoors, however sufficient air for ventilation must still be provided in the boiler room. Air for ventilation is required to keep various boiler components from over- heating and is always obtained from indoors. T o ensure an adequate ventilation air supply , perform[...]

6 Figure 5.1: Boiler Installed In A Confined Space, V entilation Air From Inside • 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 addi- tional rooms with openings until the t[...]

7 VI V enting W ARNING Failure to vent this boiler in accordance with these instructions could r esult in unreliable boiler operation, severe damage to the boiler or property , or unsafe operation: * Do not attempt to vent this boiler with galvanized, PVC, or any other vent system not listed in T able 4. * Do not attempt to mix components from diff[...]

8 3) Minimum V ent and Air Intake Lengths - Minimum vent length is 2ft. Minimum air inlet length is 2ft. 4) Permitted T erminals for Horizontal V enting (V ent Options 1,2) - The vent terminal is either a tee or an elbow supplied by the vent system manufacturer and equipped with a rodent screen. V ent system manufacturer ’ s part numbers for thes[...]

9 T ABLE 6.2a: SUMMAR Y OF HORIZONT AL VENTING OPTIONS VENT OPTION # 1 2 3 4 5 CLASSIFICA TION USED IN THIS MANUAL HORIZONT AL DIRECT VENT HORIZONT AL DIRECT VENT (RESER VED FOR FUTURE USE) (RESER VED FOR FUTURE USE) (RESER VED FOR FUTURE USE) ILLUSTRA TED IN FIGURE 6.1 6.1 VENT PIPE STRUCTURE PENETRA TION W ALL W ALL AIR INT AKE PIPE STRUCTURE PEN[...]

10 FIGURE 6.3a: LOCA TION OF VENT TERMINAL RELA TIVE TO WINDOWS, DOORS, GRADE FIGURE 6.3b: LOCA TION OF VENT TERMINAL RELA TIVE TO METERS AND FORCED AIR INLETS FIGURE 6.3c: POSITIONING VENT TERMINAL UNDER OVERHANGS[...]

1 1 • If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if the terminal is subjected to winds in excess of 40 mph. • Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools. See[...]

12 T ABLE 6.2b: SUMMAR Y OF VER TICAL VENTING OPTIONS VENT OPTION # 6 7 CLASSIFICA TION USED IN THIS MANUAL VER TICAL DIRECT VENT VER TICAL DIRECT VENT ILLUSTRA TED IN FIGURE 6.4 6.4 VENT PIPE STRUCTURE PENETRA TION ROOF ROOF AIR INT AKE PIPE STRUCTURE PENETRA TION ROOF ROOF VENT PIPE SIZE 3” 4” AIR INT AKE PIPE SIZE 4” 4” MAXIMUM VENT PIPE[...]

13 T ABLE 6.5: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS MANUF ACTURER VENT SYSTEM SIZE W ALL THIMBLES HORIZONT AL TERMINA TION VER TICAL TERMINA TION HEA T F AB SAF-T VENT EZ SEAL 3 7393GC 7393GCS 5391CI ELBOW : 7314TERM TEE: 7390TEE 9392 4 7493GC 7493GCS 5491CI ELBOW : 7414TERM TEE: 7490TEE 9492 PROTECH SYSTEMS INC. F ASNSEAL 3 FSWT3[...]

14 B. Removing an Existing Boiler Fr om a Common Chimney Read this only if the BWC boiler is replacing an existing boiler that is being removed from a common chimney . This section does not apply to the installation of a BWC boiler . In some cases, when an existing boiler is removed from a common chimney , the common venting system may be too lar g[...]

15 2) Assembly of Flex-L-Intl. Star-34 V ent System: a) Star-34 General Notes: • Do not cut Star-34 vent components. • Support horizontal piping sections at intervals of 48” or less. • V ertical venting systems must be supported by at least one Star-34 Fire stop. An additional vertical support is required after any offset. • Orient Star-3[...]

16 FIGURE 6.8: Z-VENT III CONNECTION T O VENT COLLAR 3) Assembly of Z-Flex Z-V ent III: a) General Notes: • Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw . File or sand the cut end smooth before assembling. Expanded ends may be cut to adapt the SVE series III to the vent collar[...]

17 4) Assembly of Heat Fab Saf-T V ent EZ Seal: a) Saf-T V ent General Notes: These instructions cover the installation of Saf-T V ent EZ Seal. Saf-T V ent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. • In general, Saf-T V ent pipe sections may not be cut. Exceptions to this are the Saf-T V e[...]

18 5) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of flue gas flow . • Support horizontal piping sections at intervals of 6 feet or l[...]

19 d) 4” galvanized smoke pipe will fit inside the inlet collar on the BWC boiler . Depending upon the exact OD of the pipe used, it may be necessary to crimp this pipe. Secure with a single #10 sheet metal screw through the hole in the inlet collar and seal the outside of the joint with silicone. If PVC is used for the intake system, use a shor[...]

20 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 an inlet pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or the National Fuel Gas Code . Figure 7.1 shows typical gas piping connec[...]

21 VIII System Piping A. General System Piping Precautions CAUTION THE HEA T EXCHANGER USED IN THE BWC IS MADE FROM A SPECIAL ALUMINUM ALLOY . F AILURE T O T AKE THE FOLLOWING PRECAUTIONS COULD RESUL T IN SEVERE BOILER DAMAGE. • INST ALL BOILER SO THA T THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM W A TER (DRIPPING, SPRA YING, RAIN, ETC)[...]

22 Method 1: Primary/Secondary Piping - Boiler in Secondary Loop This method can be used in heat-only applications as shown in Figure 8.2 or with an indirect water heater as shown in Figure 8.3. This method relies on primary/secondary pumping to ensure that the required flow is always maintained through the boiler . In this system, the flow rate [...]

Figure 8.2: Piping Method #1 - Heat Only Figure 8.3: Piping Method #1 - Heat + Indir ect W ater Heater 23[...]

24 Figure 8.4b: Piping Method #1 - Indir ect W ater Heater Loop Piping (Shaded) Figure 8.4a: Piping Method #1 - Secondary Loop Piping (Shaded)[...]

25 T ABLE 8.5: PIPE AND CIRCULA TOR SIZING FOR BOILER LOOP BOILER MODEL (a) (b) (c) (d) PIPE SIZE FLOW CIRCULA TOR MODEL BOILER LOOP MAX EQUIV ALENT LENGTH (in NPT) (GPM) (ft) BWC150 1 1/4 8.0 T aco 007 148 BWC150 1 1/4 8.0 T aco 0010 224 BWC225 1 1/4 12.0 T aco007 138 BWC225 1 1/4 12.0 T aco 0010 208 NOTE: For piping method #1, “boiler loop” i[...]

26 T ABLE 8.7: FITTING EQUIV ALENT LENGTHS FITTING PIPE SIZE EQUIV ALENT LENGTH (ft) 90 ELBOW 1 1/4 3.75 TURN IN TEE 1 1/4 8.00 RUN OF TEE 1 1/4 2.50 SWING CHECK 1 1/4 10.00 GA TE V AL VE 1 1/4 0.80[...]

27 Method 2: Primary/Secondary Piping - Boiler in Primary Loop This method can be used in heat-only applications as shown in Figure 8.8 or with an indirect water heater as shown in Figure 8.9. Like Method 1, this method relies on primary/secondary pumping to ensure that the required flow is always maintained through the boiler . In this system, th[...]

Figure 8.8: Piping Method #2 - Heat Only Figure 8.9: Piping Method #2 - Heat + Indir ect W ater Heater 28[...]

Figure 8.10a: Piping Method #2 - Secondary Loop Piping (Bolded) Figure 8.10b: Piping Method #2 - Primary Loop Piping (Bolded) 29[...]

F i g u r e 8 . 1 0 c : P i p i n g M e t h o d # 2 - I n d i r e c t W a t e r H e a t e r L o o p P i p i n g ( B ol de d ) 30 Figure 8.1 1: Piping Method #3 - Dir ect Connection of Boiler to Heating System[...]

31 C: Standard Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping: 1) The relief valve is packaged loose with the boiler and must be installed in the location shown in Figure 1. The relief valve is set to open at 30 psi. If the valve is replaced, the replacement must have a rel[...]

32 3) The return piping may be connected into the boiler through the back or sides of the boiler by rotating the drain elbow and routing the return piping through the appropriate knockout. 4) Circulator (Required) - Usually at least two circulators will be required to properly install a BWC Series boiler . See previous section (System Design) for i[...]

33 Figure 8.14: Chiller Piping Figure 8.13: Isolation of the Boiler Fr om Oxygenated W ater with A Plate Heat Exchanger[...]

34 IX Wiring 1) Line V oltage (120 V AC) Connections (Fig 9.1) – The line voltage connections are located in the junction box on the right side of the vestibule: • Black – Line voltage “hot” • White – “Neutral” for boiler and circulators • Red – “Heating” circulator “hot” • Blue – “Indirect W ater Heater “ circ[...]

Figure 9.1: W iring Connections Diagram 35[...]

Figure 9.2: Ladder Diagram 36[...]

Figure 9.3: W iring of Isolation Relay for Contr ol of T wo Heating Circulators 37[...]

X Start-up and Checkout Use the following procedure for initial start-up of the boiler: 1) If not already done, flush the system to remove sediment, flux, and traces of boiler additives. This should be done with the boiler isolated from the system. 2) Fill the boiler and hydronic system with water meeting the following requirements: pH between 6.[...]

A. • C. B. D. • • • 1. 6. 2. 7. 3. 4. 8. 9. 5. 10. 11. 12. 1. 3. 2. 4. FOR YOUR SAFETY READ BEFORE LIGHTING This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. Do not touch any electric switch; do not use any phone in your building. If yo[...]

40 7) Start the boiler using the lighting instructions on page 39. After the boiler is powered up, it should go through the following sequence. Sequence Display Meaning 1 U.125 or Blank Checking internal software (power-up only) 2 0.SWT Boiler in standby . SWT = Supply W ater T emp. No call for heat. (After call for heat from heating thermostat) 3 [...]

41 Figure 10.2: Gas V alve Detail 1 1) Perform a combustion test. On horizontally vented units, the sample probe may be inserted into the terminal. If this is not possible, and if no sample tap is present in the vent system, remove the flue temperature sensor and insert the analyzer probe in the sensor opening. On the BWC150 and BWC225 the flue t[...]

42 12) T est any external limits or other controls in accordance with the manufacturer ’ s instructions. 13) V erify that the boiler starts and stops in response to calls for heat from the heating thermostat and indirect wa - ter heater thermostat. Make sure that the appropriate circulators also start and stop in response to the thermostats. 14) [...]

XI Operation 1) The BWC boiler uses a microprocessor based control, known as a “MCBA”, to manage all boiler functions including flame supervision and modulation. T wo set point or “target” boiler supply temperatures are stored in the MCBA ’ s memory; one for space heating and one for domestic water production. If an outdoor tempera- ture[...]

44 In standby mode, it is possible to view both the heating supply set point temperature and the “domestic hot water reference set point”. The “domestic hot water reference set point” plus 45°F equals the boiler supply set point when it is responding to a call from the indirect water zone. It is not the actual domestic hot water set point.[...]

STEP + - STORE STEP + - STORE + Short Shows supply set point when responding to call for heat (Note 1) c 190 1 DHW reference set point (Note 2) 68°F - 144°F (Default Setting 135°F) 1 Supply water temperature 1.170 + Long Turn heating on/off c OFF 0 = Off 2 Return water temperature 2.135 - Short Shows domestic hot water reference set point (Note [...]

46 3) T wo basic types of errors codes are shown on the display: • Soft Lockout Codes – When a soft lockout occurs, the boiler will shut down and the display will alter - nate between the number “9” and the letter “b” followed by a two digit service code. A list of these codes, and their meanings, is shown in T able 13.3. The boiler wil[...]

Figure 1 1.4: Outdoor Reset Curve 47 7) The sequence of operation for a BWC series boiler on a call for heat from a thermostat is as described below: a) When power is first turned on, 120V is provided to the MCBA, the combustion fan and the L WCO trans- former . A separate 50V A transformer , connected directly to the MCBA, powers all other low vo[...]

XII. Service and Maintenance 1) Continuously : a. Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids. b. Keep the area around the combustion air inlet terminal free from contaminates . c. Keep the boiler room ventilation openings open and unobstructed. 2) Monthly Inspections: a. Inspect[...]

i. Remove the burner and vacuum any dust or lint from the burner . W ipe the inside of the burner with a clean soft cloth. Do not wipe the mesh side of the burner . If the burner shows signs of deterioration or corrosion, replace it immediately . Inspect the burner gasket and replace, if necessary . j. W ith the burner removed, inspect the combusti[...]

50 XIII. T roubleshooting A. T roubleshooting problems where no error code is displayed: CONDITION POSSIBLE CAUSES Display Blank, Fan off, L WCO lights off • No 120V AC Power at boiler . Check breaker and wiring between breaker panel and boiler Display Panel Blank, Fan running • Loose 120V AC connection wiring between boiler J-Box and MCBA • [...]

51 B. T rouble shooting problems where a soft lockout code is displayed. When a soft lockout occurs, the boiler will shut down and the display will alternate between the number “9” and the letter “b” followed by a two digit service code. The boiler will automatically restart once the condition that caused the lockout is corrected. CODE COND[...]

52 C. T rouble shooting problems where a hard lockout code is displayed. When a hard lockout occurs, the boiler will shut down and the display will flash the letter “E” followed by a two digit service code. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset using the RESET button on the display .[...]

53 XIV Parts 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[...]

54 BWC REPLACEMENT P ARTS LIST KEY DESCRIPTION BWC150 BWC225 CROWN P ART # QUANTITY CROWN P ART # QUANTITY 1 Crown Aluminum Nameplate 98-004 1 98-004 1 2 Aluminum Door Knob 90-210 2 90-210 2 3 #8-32 x 1/4” H.W .H. Screw 90-21 1 2 90-21 1 2 4 Front Door Panel 240313 1 240310 1 5 #6-32 Hex Nylon Insert LockNut 900705 4 900705 4 6 Control Chassis As[...]

55 BWC REPLACEMENT P ARTS LIST KEY DESCRIPTION BWC150 BWC225 CROWN P ART # QUANTITY CROWN P ART # QUANTITY 47 Nylon Glide Foot 1”Dia x 3/4” Long 7001 1 1 4 7001 1 1 4 48 Combination Base / Rear Panel 240303 1 240304 1 49 V esibule T op Panel Assembly 240423 1 240420 1 50 V ent Seal Gasket 240503 1 240500 1 51 V ent Adapter Assembly 240504 1 240[...]

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60 BWC REPLACEMENT P ARTS LIST KEY DESCRIPTION BWC150 BWC225 CROWN P ART # QUANTITY CROWN P ART # QUANTITY 89 #6-32 x 13mm Hex x 92mm, Long Standof f 90071 1 2 90071 1 2 90 M6 x 1.0 x 75mm, Hex Head Screw 240960 16 240960 16 91 Manifold Seal Ring, EPDM 240200 8 240200 8 92 M6 x 1.0 x 30mm, SS Hex Socket Set Screw 240961 6 240961 6 93 M6 x 1.0, Lock[...]

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BWC REPLACEMENT P ARTS LIST KEY DESCRIPTION BWC150 BWC225 CROWN P ART # QUANTITY CROWN P ART # QUANTITY Not Shown 1 1-1/2” Releasable Nylon Cable Wire T ie 960025 1 960025 1 Not Shown 6” Nylon Wire Tie 97-090 10 97-090 1 1 Not Shown 1-5/8” Hole Plug 900735 1 900735 1 Not Shown 5mm x 20mm Fast Acting, Ceramic T ube, 5 Amp Fuse 960005 1 960005 [...]

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66 Appendix A: Special Requir ements For Side-W all V ented Appliances In The Commonwealth of Massachusetts IMPOR T ANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: 1. For direct-vent appliances, mechanical-vent heating appliances or domes[...]

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Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com D E S I G N E D T O L E A D PN: 980040 BWC - 08/05[...]