Crown Boiler BWF061 manual

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 BWF Series Gas-Fired Fan Assisted Hot W ater Boilers INST ALLA TION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler WARNING : Improper installa- tion, ad[...]

1 I Product Description………………………... 2 II Specifications……………………………….. 2 III Before Installing…………………………….. 3 IV Locating the Boiler………………………….. 3 V Air for Combustion and Ventilation………… 5 VI Venting………………………………………. 9 Horizontal[...]

2 I Product Description The BWF series boiler is a cast iron gas fired boiler designed for use in forced hot water heating systems. The BWF is intended f or installations w here a usable chim ney is not available. The BWF is normal ly vented using an a pproved verti cal or horizontal AL29-4C stainless steel ven ting system, which is not included wi[...]

3 III Before Installing 1) Safe, reliable operation of this boiler depe nds upon installation by a professi onal heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an autho rity having jurisdiction, installation must be in acco rdance with this manual and the National Fuel Gas Cod e[...]

4 3) Do not install this boiler in an area wh ere large amounts of airborne dust will be present, such as a workshop. Do not install in a location where sources of hydrocarbons will be st ored o r used. Some common sources of hydroc arbons include bleaches, fabric softeners, pai nts, cleane rs, refrigerants, a nd cat boxes. Traces of these c hemica[...]

5 V Air for Combustion and Ventilation Sufficient fresh air must be supplied for both co mbustion and ventilation. Provisions for combustion , ventilation, and dilution air for gas utilization equ ipment must be made in accordance with local building codes, or in the absen ce of such codes, in accordance with Section s 5.3.3 and 5.3.4 (“Air for C[...]

6 If the boiler is in a confined space – Provide two ope nings into the boile r room, one near t he floor and one near t he 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 fl oor (Fig 3). • Each opening m ust have a free area of 1 square inch per[...]

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9 VI Venting There are three basic ways to vent the BWF boiler: • Horizontal (“si de wall”) venting usi ng an approved AL 29-4C stainless steel vent system. • Vertical venti ng using an appr oved AL29-4C st ainless steel vent system . • Chimney vent ing using a masonry or “B” vent chim ney and a special Cat egory I Vent Ki t available[...]

10 Horizontal Vent System Design 1) See Figure 8 f or the general hori zontal exhaust c onfiguration. For t he purposes of thi s manual, a “horiz ontal exhaust system” is one that exits the st ructure through a wall. 2) Approve d Systems – Use one of these four a pproved vent system s: • Flex-L-Inter national Star-3 4 • Z-FLEX SVE Series [...]

11 5) Minim um Vent Pipe Length: 2 ft + (1) 90 degree el bow + terminal 6) Permitted Terminals: • Choice of Tjernlund VH1 series terminal , a 90-degree elbow with rodent screen , or a termination tee with a rodent screen. The Tjur nlund VH1 term inals may not be used on BWF195s and B WF 229s when they a re vented with 3” pipe . If the Tjurnlund[...]

12 12) Locatio n of Horizontal Ve nt Terminal – Obse rve th e following limitations on the terminal location: • Terminal must be at least 4 feet belo w or 4 feet horizontally from any window, door, or gravity air inlet into the building (Fig. 10). • The bottom of the terminal must be at least 12” above the normal snow line. In no case shou [...]

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14 Vertical Vent System Design 1) See Figure 13 for the ge neral vertical stai nless steel venting configuration . For the purposes of this manual, a “vertical exhaust system ” is a Category III ve nt syst em that exits the stru cture through a roof. 2) Approve d Systems – Use one of these four a pproved vent s ystems: • Flex-L-Inter nation[...]

15 4) Maxim um Vent Pipe Length: • BWF061 to B WF162 – 39.5 ft + ( 2) 90 degree elbows + cap • BWF195, B WF229 (using 4” ve nt pipe): 37 ft + ( 2) 90 degree elbows + cap • BWF195, B WF229 (using 3” ve nt pipe): 24.5 ft + (2) 90 degree elb ows + cap • Reduce the above maximum straight pi pe runs by the equivalent length from Table 4 fo[...]

16 11) Pipin g supports – Vert ical and horizontal se ctions of pipin g must be properly supported. See the “Ve nt System Assembly ” section of this manual for more information. 12) Location of vent cap– The lowest discharge opening on the cap m ust be at least 2 feet above any object located within 10 feet (Fig. 14):[...]

17 Removing an Existing Boil er From a Common Chimney In some cases, when an exist ing boiler is re moved from a comm on chimney, the com mon venting syst em may be too large for the remaining appliances. At the time of removal of an ex isting boiler, the following steps shall b e followed with each appliance remaining connected to the c ommon vent[...]

18 Vent System Assembly 1) General Assembly Notes: a) Where the use of “silicone” is called for in the following instru ctions, use only the following sealants: • Flex-L-Inter national Star-3 4 – GE RTV106 or GE IS806 • Z-FLEX SVE Series II I (“Z-Ven t III”) – Silicone not required for joints between pipe sections. • Heat Fab Saf [...]

19 4) Assembly of Flex-L-Intl. Star-3 4 Vent System: a) Star-34 Genera l Notes: • Do not cut Star-34 vent com ponents. • Support hori zontal piping sect ions at interval s of 48” or less. • Vertical venting systems must be supported by at least one Star-34 Firestop. An additional vertical support is r equired after any offset. • Orient St[...]

20 5) Assembly of Z-Flex SVE Se ries III: a) SVE Series III General Notes: • Non-expande d ends of SVE Se ries II piping sections m ay be cut using a viation snips or a 24 thread per inch hacksaw. File or sand t he cut end smooth be fore assembling. Expanded ends m ay be cut to adapt the S VE Series III to the ve nt collar or VH-1 terminal. S ee [...]

21 l) If a termi nation elbow or tee is use d, a locking band or gear clamp must be use d at either side of t he wall penetration to prevent shifting of the v ent system in and out of the wall. m) To join SVE Series III to the VH-1 term inal, cut off the female en d of the pipe that is to be joined to the terminal. When making this cut, make sure t[...]

22 6) Assembly o f Heat Fab Saf-T Vent : a) Saf-T Vent General Notes: • In general, Sa f-T Vent pipe s ections may not be c ut. Exceptions to this a re the Saf-T vent slip connector and connections to the boiler vent collar and the VH-1 terminal . In these cases, use a sharp pa ir of aviation snips, an abrasive cut- off, or a plasma cutter. See t[...]

23 7) Assembly of Protech FasNSeal: a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. The m ale end of 3” FasNSeal may be cut. Cut m ust be square to ensure a proper seal. • Orient FasNSe al vent components so that the arrows on the pi ping labels are in t he direction of flue gas flow. • Support horiz ontal piping sect ions at in[...]

24 m) To join FasNSeal to a 4” VH-1 terminal slip the female end of the FasNSeal pipe over the terminal connection so there is an overlap of at least 1 ¾”. Ti ghten the hose clamp to m ech anically lock the pipe onto the term inal. Apply and sm ooth silicone over the outside of the joint including the hose clamp in the FasNSeal pipe. n) Allow [...]

25 VII Gas Piping Gas pipi ng to the boiler m ust be sized to deliver a dequate gas for the boi ler to fire at the nameplate input at a li ne press ure between the m inimum and maxim um values shown on the rating plat e. For more informati on on gas line sizi ng, consult the utility or Part 2 of the National Fu el Gas Code . Figure 26 s hows typica[...]

26 VIII System Piping CAUTION • INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONE NTS ARE PROTECTED FROM WATER (DRIPPING, S PRAYING, RAIN, ETC) DURI NG APPLIANCE OPERATIO N AND SERVICE (CIRCULAT OR REPLACEMENT, ETC). • OPERATION OF THIS BOILER WITH CONTINUOU S RETURN TEMPERATURES BELOW 120F CAN CAUSE SEVERE HEAT EXCHANGER CORRO SION DAMAGE[...]

27 7) Manual Reset High Limit (Requi red by some codes ) – This contr ol is required by ASME CSD-1 an d some other code s. Install the high limit in the boiler sup ply piping just beyond the boiler with no interv ening valves. Set manual reset high limit as far above the operating limit setting as possible, but not over 240F. Wire th e control to[...]

28 2) Gravity and “Large Water Volume” Systems – The piping s how n in Figure 29 will minimize th e am ount of time that the boiler operates with return temperatures below 120 F on thes e systems. A bypa ss is installe d as shown to divert some supply water directly into the return water. The bypass pi pe should be the sa me size as the suppl[...]

29 6) Air Handl ers – Where the b oiler is connected to ai r handlers thro ugh which refrigerate d air passes, use fl ow control valves in the boiler piping or other auto matic means to prevent gravity circulation during the cooling cycle.[...]

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31 IX Wiring WARNING All wiring and grounding must be done in accordance with the authority h aving jurisdicti on or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70). Single Zone Wiring 1) Line Voltage (120 VAC) Connectio ns (Fig 32) – The line vo ltage connection s are located in the junction box under th e [...]

32 Wiring Variations 1) Multiple Circulator Zones – Figure 33 shows wiring for tw o or more circulator zones using Honeywell R845As. One fewer R845A is use d than the total number of circulator zones. A DPST Honeywell RA832A may be substituted in place of the R845A using the “X” and “X” terminals in place of the “5” and “6 ” termi[...]

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34 BWF Control System – Sequence of Operation (Refer to Figures 35 and 36 for BWF ladder and connection diagrams) 1) A call for heat from the thermo stat energizes relay coil 1K (the relay on t he R8285), causing c ontacts 1K1 and 1K2 t o make. Contact 1K1 starts the circulator. Contact 1K2 se nds power to the high limit. 2) Assuming that the hig[...]

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36 IX Start-up and Checkout NOTE SAFE LIGHTING A ND OTHER PERFORMANCE CR ITERIA WERE MET WITH T HE GAS MANIFOLD AND CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS SPEC IFIED IN Z21.13 Use the following procedure for initial start-u p of the boiler: 1) Make sure that the boiler and system are filled with water. WARNING ?[...]

37 A. This applian ce is equipp ed with an ignition d evice which automatically lights the pilot. Do t ry to light the pilot by han d. B. BEFORE LIGHTING smell all ar ound the applian ce area for gas. B e sure to smell next to t he floor because some gas is heavier than air an d will settle on the floo r . WHA T T O D O IF YOU SMELL GAS D o not try[...]

38 c) If the line pressure falls outside of these limits, find and co rrect the cause of the problem before proceeding further. d) Connect a manom eter to the manifold pres sure tap on the gas valve (Fi g. 41a). e) Read the m anifold pressure. It should be set at: Natural Gas LP Gas Manifold P ress. (inches w.c.) 3.5 10.0 f) If a manifold pressure [...]

39 FIGURE 38: PILOT BURNER FLAME[...]

40 X Service and Maintenance The followin g routine maintenance should be perf ormed on an annual basis: 1) Turn off power to the boiler. 2) Inspect the flue passages for signs of blocka ge. If there is any carb on in the combustio n chamber or the fl ue passages, clean the heat exchanger be fo re proceeding further. See th e cleaning procedure bel[...]

41 11) Clean the bottom surfaces of the heat exchanger. 12) Put a lig ht in the combust ion chamber and loo k through the flue passages from the t op to verify that th ey have been thoroughly clean ed. 13) Apply a heavy (1/4”) bead of RTV-73 2 silicone sealant with a 500F in termittent duty temperature rating around the perimeter of the heat e xc[...]

42 3) Vacuum Switch – This boiler i s equipped with a vac uum switch that i s designed to pre vent burner operat ion if the combustion fa n does not oper ate properly or there is a bloc kage in the ve nt system. This switch “makes” (permits burner operation) as the va cuum increases. Figure 40 sh ows the correct method of reading the switch v[...]

43 XII Troubleshooting The followin g three pages contain t roubleshooting c harts for use in di agnosing control p roblems. To use these c harts, go to the box marked “Start” at the top of the next page and follow the approp riate path though the chart until a box with a list of possible causes is reached. If the problem is known to be within [...]

44 120 v ol t s ac ros s bl a c k an d whit e tr a n sf o rm e r p r i ma r y le a d s o n back of R 8285 ? T h ermos t at ca l l s f o r h e a t Circ ul at or sta r t? * Po w e r of f * Bl ow n f us e or t ripped bre ak er * Mis wir ed o r l oos e elec t ri c al c onne c t i on in 1 20 v olt line 120 v olt s ac ros s c i rc ul at or c onnec t i o [...]

45 BWF Troubleshooting Chart (contd.) Caution : Read page 43 before attempting to u se this chart. Pilot light? 24 volts between terminals 5 and 6 on S8670? See "Intermittent Ignition System Troubleshooting Chart" on next page 24 volts between NO terminal on vacuum switch and C on R8285D ? Minimum vacuum at switch called for in Table 9 on[...]

46 Doe s sp a r k sto p when pi l ot li g ht s? 24 v olt s ac r os s t erminal s 2 & 3 at S 8670? Sp ar k ac r os s ignit or/ sens or gap? Y Ca n y ou hear s park ing? * De fec t iv e S8 67 0 module * Br e a k in sp a r k ca b le insulation * Br e a k i n pil ot porc el ain * Inc o rre c t p il ot sp a r k g a p * Loos e c onnec t i on in sp a [...]

47 The followin g parts may be obtained from any Crown distributor. To fi nd the closest Crown di stributor, cons ult the area Crown represen tative or the factory at: Crown Boiler Co. Customer Service P.O. Box 14818 Philadelphia Pa. 19134 (215)-535-8 900 www.crownbo iler.com Main burne r orifice and vac uum switch part n umbers shown are for sea l[...]

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49 61 95 128 162 195 229 41 1" BURNER W IT H PILOT BRACKET 150500 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 42 1" BURNER LESS PILOT BRACKET 150501 2 ea. 4 ea. 6 ea. 8 ea. 11 ea. 13 ea. 43 MANIFOLD (1" BURNERS) 1 ea. 650153 650154 650155 650156 650157 650158 44 NAT GAS ORIFICE (#44 DRILL SI ZE) 950300 3 ea. 44 NAT GAS ORIFICE (#45 DRILL SI [...]

50 1” Burner Components 50mm Burner Components[...]

51 CAUTION Vacuum swit ch part numbers shown below for use on boilers installed at altitudes b elow 2000 ft. 61 95 128 162 195 229 75 LEFT SIDE JACKET PANEL 650301 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 76 RIGHT SIDE JACKET PANEL 650300 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 77 REAR JACKET PANEL 1 ea. 650303 650304 650305 650306 650307 650308 78 TOP JACK[...]

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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 Boiler Co[...]