Crown Boiler BSI172 Installation Instructions Manual
  1. Manuals
  2. Brands
  3. Crown Boiler Manuals
  4. Boiler
  5. BERMUDA BSI172
  6. Installation instructions manual

Crown Boiler BSI172 Installation Instructions Manual

Bsi series, gas-fired natural draft steam boilers
Hide thumbs Also See for BSI172:
Table of Contents

Advertisement

Quick Links

BSI Series
Gas-Fired Natural Draft Steam Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler
D
E S I G N E D
Models:
BSI069
•
BSI103
•
BSI138
•
BSI172
•
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
L
T O
E A D
BSI207
•
BSI241
•
BSI276
•
BSI310
•
BSI345
•
BSI379
•
1
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause property
damage, injury, or loss of life. For
assistance or additional informa-
tion, consult a qualified installer,
service agency or the gas
supplier. Read these instructions
carefully before installing.

Advertisement

Table of Contents
loading

Related Manuals for Crown Boiler BSI172

Summary of Contents for Crown Boiler BSI172

  • Page 1: Installation Instructions

    • damage, injury, or loss of life. For BSI138 BSI276 assistance or additional informa- • • tion, consult a qualified installer, BSI310 BSI172 • • service agency or the gas BSI345 supplier. Read these instructions • carefully before installing. BSI379 •...

  • Page 2: Table Of Contents

    Table of Contents Product Description ..........1 II. Specifications ............. 2 III. Before Installing ............3 IV. Locating the Boiler ............3 Air for Combustion & Ventilation ......4 VI. Venting ............... 8 VII. Gas Piping ..............11 VIII. System Piping ............12 IX.

  • Page 3: Specifications

    II Specifications FIGURE 1: BSI BOILERS - GENERAL CONFIGURATION TABLE 1: BSI SPECIFICATIONS *Combustion efficiency ** Volume to normal water line NOTE: BSI345 and BSI379 not available for use with LP gas. Suffix E = Intermittent Ignition, Suffix S = Standing Pilot. Add Suffix N for Natural Gas or Suffix L for Propane Gas to basic BSI model number (example: BSI207SN, BSI207SL)

  • Page 4: Before Installing

    III Before Installing 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 National Fuel Gas Code, ANSI Z223.1-latest edition.

  • Page 5: Air For Combustion & Ventilation

    FIGURE 2: BSI BOILERS - CLEARANCES TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS, WALLS, AND DOORS. 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.
  • Page 6 For Buildings of Other than Unusually Tight Construction 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 space: Total the input of all appliances in the boiler room in thousands of BTU/hr.
  • Page 7 FIGURE 3: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC...
  • Page 8 FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM...

  • Page 9: Venting

    VI Venting 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.
  • Page 10 14) 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: Open vent damper carton and remove installation instructions. Read the instructions thoroughly before proceeding. Verify that vent damper is same size as draft diverter outlet.
  • Page 11 FIGURE 8: BSI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS RIGHT SIDE VIEW FIGURE 9: VENT DAMPER INSTALLATION DETAILS...

  • Page 12: Gas Piping

    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 information on gas line sizing, consult the utility or Chapter 2 of the National Fuel Gas Code.

  • Page 13: System Piping

    VIII System Piping 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.

  • Page 14: Piping Installation

    4) Install drain valve into tapping on boiler left side using the 2 x 3/4 bushing provided (see Figure 1). 5) Connect system supply and return to boiler. See Figure 11. The BSI069 - BSI172 require only one supply riser. Two supply risers are required on the BSI207 and larger sizes.

  • Page 15: Steam Boiler Piping For Gravity Return

    "A" "B" "C" "D" BSI069 1 1/2 1 1/4 BSI103 1 1/2 1 1/4 BSI138 1 1/2 1 1/4 BSI172 1 1/2 1 1/4 BSI207 1 1/2 1 1/4 BSI241 1 1/2 BSI276 1 1/2 BSI310 1 1/2 BSI345 1 1/2...

  • Page 16: Indirect Water Heater Piping

    IX Indirect Water 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.

  • Page 17: Wiring

    X 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) 1) 120 Volt Wiring - 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.
  • Page 18 Feeder Wiring for Boilers Equipped with McDonnell & Miller #67 Low Water 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: •...
  • Page 19 CAUTION DO NOT INSTALL JUMPER BETWEEN 2 & 3 ON #67 L.W.C.O. FIGURE 14b: WIRING MCDONNELL & MILLER WF2-U-24 FEEDER OR THREE-WIRE HYDROLEVEL VXT-24 FEEDER TO BOILER EQUIPPED WITH #67 L.W.C.O. FIGURE 15: WIRING INDIRECT WATER HEATER TO BOILER...
  • Page 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 energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damper.
  • Page 21 “BURNER” “BURNER” V8295A (BSI310-379 ONLY) FIGURE 16: WIRING DIAGRAM, STANDING PILOT AND HYDROLEVEL CG-400A LOW WATER CUTOFF VENT DAMPER (NOTE 2) NOTE 3 LESS VENT DAMPER V8295A (BSI310-379 ONLY) 2. VENT DAMPER REQUIRED ON BSI069 - BSI276, OPTIONAL ON BSI310 - BSI379 3.
  • Page 22 Safety Control Operation - Standing Pilot and Intermittent Ignition Hydrolevel CG400A Low Water Cut-off - 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 level drops past the cut-off point.
  • Page 23 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 operation. An open blocked vent switch is indicative of a problem with the vent system.

  • Page 24: Start-Up & Checkout

    NOTE SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS MANIFOLD AND CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS SPECIFIED IN Z21.13. XI Start-up and Checkout Use the following procedure for initial start-up of the boiler: 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) Check all new gas piping for leaks and purge piping sections that are filled with air.
  • Page 25 16) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER-FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD. 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.

  • Page 26: For Your Safety Read Before Operating

    LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8200 AND VR8300 SERIES GAS VALVES (STANDING PILOT) FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 27 LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000ERHC SERIES GAS VALVES (STANDING PILOT) FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.

  • Page 28: Operating Instructions

    LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8204 AND VR8304 SERIES GAS VALVES (INTERMITTENT PILOT) FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 29 LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000DERHC SERIES GAS VALVES (INTERMITTENT PILOT) FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 30 FIGURE 22b: MAIN BURNER FLAME - 40mm FIGURE 22a: MAIN BURNER FLAME - 1” BURNERS (“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 ignition boiler models both pilot burner and main burners should stop firing.
  • Page 31 FIGURE 23a: GAS VALVE DETAIL - HONEYWELL VR8200 OR VR8300 (STANDING PILOT) FIGURE 23b: GAS VALVE DETAIL - ROBERTSHAW 7000ERHC AND HONEYWELL V8295 (STANDING PILOT) FIGURE 24a: GAS VALVE DETAIL - HONEYWELL VR8204 AND VR8304 (INTERMITTENT IGNITION) FIGURE 24b: GAS VALVE DETAIL - ROBERTSHAW 7000DERHC (INTERMITTENT IGNITION)

  • Page 32: Service & Maintenance

    Turn off gas supply to boiler per the appropriate Lighting and Operating instructions on pages 25 - 28. Drain hot water from boiler through boiler drain valve to a location where hot water can be safely discharged. Refill the boiler to normal water line level.
  • Page 33 replace cable. Reinstall burners, being careful to put the pilot main burner in its original location. Inspect all boiler wiring for loose connections or deterioration. 10) Inspect the vent system: • Make sure that the vent system is free of obstructions. •...
  • Page 34 14) 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 Procedure Turn off electrical power and gas supply to the boiler Disconnect the damper and vent connector from the boiler.

  • Page 35: Troubleshooting

    XIII Troubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems. To 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.
  • Page 36 Troubleshooting Chart for BSI Boilers Equipped with Hydrolevel CG400A Low Water Cut-offs and Vent Dampers Caution: Read page 34 before attempting to use this chart START Vent damper open? Is there an audible Thermostat click as R8225 relay calls for heat pulls in w hen the thermostat calls for heat?
  • Page 37 Do burners Do burners shut Main shut down when down when water burners pressure level drops below light? exceeds limit cut-off point? setting? 24 volts across red damper lead * Defective damper * Defective and yellow * Defective or loose pressure limit transformer damper harness...
  • Page 38 Troubleshooting Chart for BSI Boilers Equipped with McDonnell & Miller #67 Low Water Cut-offs and Vent Dampers Caution: Read page 34 before attempting to use this chart START Vent damper open? Is there an audible Thermostat click as R8225 relay calls for heat pulls in w hen the thermostat calls for...
  • Page 39 Do burners Do burners shut Main shut down when down when water burners pressure level drops below light? exceeds limit cut-off point? setting? 24 volts across red damper lead * Defective damper * Defective and yellow * Defective or loose pressure limit transformer damper harness...
  • Page 40 Standing Pilot Ignition System Troubleshooting Chart START Caution: Read page 34 before (24 VOLTS PRESENT ACROSS TH AND TR attempting to use this chart ON GAS VALVE, BUT MAIN BURNERS DO NOT LIGHT) Ensure knob Main Does pilot Pilot lit? on gas valve is burners stay lit?
  • Page 41 Intermittent Ignition System Troubleshooting Chart START Caution: Read page 34 before (24 volts is present across 5 and 6 on S8600 attempting to use this chart module, but main burners do not light) Spark Does Main across Pilot spark stop burner ignitor/sensor lights?

  • Page 42: Parts

    XIV PARTS The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area Crown representative or the factory at: Crown Boiler Co. Customer Service P.O. Box 14818 Philadelphia PA. 19134 www.crownboiler.com For boilers installed at elevations above 2000 ft, consult the local Crown representative or the factory for the correct main burner...
  • Page 44 QTY. OR QUANTITY PER BOILER OR CROWN P.N. KEY # DESCRIPTION CROWN P.N. 1" BURNER WITH PILOT BRACKET 150502 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. (Q350 PILOT) 1" BURNER WITH PILOT BRACKET 150500 1 ea. 1 ea. 1 ea.
  • Page 46 QTY. OR QUANTITY PER BOILER OR CROWN P.N. KEY # DESCRIPTION CROWN P.N. LEFT SIDE JACKET PANEL 1 ea. 850301 850301 850301 850301 8503012 8503012 8503012 8503015 8503015 8503015 RIGHT SIDE JACKET PANEL 1 ea. 850300 850300 850300 850300 8503002 8503002 8503002 8503005 8503005 8503005 REAR JACKET PANEL 1 ea.

  • Page 48: Appendix A: Knockdown Boiler Assembly

    Appendix A: Knockdown Boiler Assembly Instructions A. Before Installing Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs or punctures due to mishandling. Do not use the heat exchanger if there is any damage to it. Inspect the joints between the sections for openings.
  • Page 49 FIGURE A1: BASE, HEAT EXCHANGER, FLUE COLLECTOR ASSEMBLY...
  • Page 50 Install the left side panel in the same manner as the right side. Attach the front corners of the diverter panel to the side jacket panels using #10 sheet metal screws. 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 front edge of the side jacket panels and secure with the 8-32 self tapping screws provided.
  • Page 51 FIGURE A2: JACKET INSTALLATION...
  • Page 52 F. Electrical Wiring Connections (Also refer to wiring diagrams in Part X of the installation manual) A pre-wired junction box assembly specific to the control package ordered with the boiler has been provided by the factory. Orient the junction box so the black relay, which is mounted to the outside of the junction box, is facing down. Mount the junction box assembly to the right side jacket using the holes provided (See Figure 1 in the installation manual).
  • Page 53 FIGURE A3: TAPPING LOCATIONS (SEE TEXT FOR TAPPING USES)
  • Page 54 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 P/N 980423 10/10 Rev. 3...

This manual is also suitable for:

Bsi138Bsi103Bsi310Bsi276Bsi241Bsi379 ... Show all

Table of Contents