Crown Boiler PHNTM080 Installation Instructions Manual
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Crown Boiler PHNTM080 Installation Instructions Manual

Phantom series
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High Efficiency Gas-Fired Hot Water
Direct Vent Condensing Boilers
Multiple Boiler Installation Instructions
These instructions must be affixed on or adjacent to the boiler and
retained for future reference.
Models:
PHNTM080
•
PHNTM100
•
PHNTM120
•
PHNTM150
•
PHNTM180
•
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
Series
WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information, con-
sult a qualified installer, service agency or the gas supplier.
This boiler requires a special venting system. Read these
instructions carefully before installing.

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Summary of Contents for Crown Boiler PHNTM080

  • Page 1 These instructions must be affixed on or adjacent to the boiler and retained for future reference. Models: WARNING: Improper installation, adjustment, alteration, PHNTM080 • service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, con- PHNTM100 •...
  • Page 3 IMPORTANT INFORMATION - READ CAREFULLY The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. DANGER CAUTION Indicates an imminently hazardous situation Indicates a potentially hazardous situation which, if not avoided, will result in death, serious which, if not avoided, may result in moderate or injury or substantial property damage.
  • Page 4 DANGER Explosion Hazard. DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in the building.

  • Page 5: Table Of Contents

    Table of Contents Preface Venting Multiple Boilers A. Terminal Spacing B. Condensate Drain Line III. Gas Piping Multiple Boilers System Piping Multiple Boilers A. General System Piping Precautions Wiring A. Multiple Boiler Wiring Start-up and Checkout VII. Operation A. General Information B. Configuring The Control 18 C.

  • Page 6: Preface

    I Preface These instructions are meant to provide information specific to multiple boiler (“Lead-Lag”) installations of the following models: • PHNTM080 • PHNTM100 • PHNTM120 • PHNTM150 • PHNTM180 For larger Phantom models, refer to the instructions provided with that boiler for information on multiple installations. Boilers covered by these instructions apply to the above models where the complete model number ends in “C” (example: PHTM180HNT1SUC). Consult the factory before attempting multiple boiler installations where the above models have a different last letter. These instructions cover only multiple boilers installations consisting solely of the above models. It is also generally recommended that all boilers on the installation be of the same size.

  • Page 7: Condensate Drain Line

    Refer to the installation manual supplied with the boiler for other important terminal clearances, such as distance above normal snow line. B. Condensate Drain Line Condensate drain lines from multiple boilers may be manifolded together. Size the condensate disposal system to carry the condensate rate per boiler shown in Table 2.7 multiplied by the number of boilers in the system.
  • Page 8 FIGURE 2.1: MULTIPLE BOILER HORIZONTAL CPVC/PVC DIRECT VENT FIGURE 2.2: MULTIPLE BOILER HORIZONTAL CPVC/PVC DIRECT VENT ALTERNATE...
  • Page 9 FIGURE 2.3: MULTIPLE BOILER HORIZONTAL VENTING WITH LOW PROFILE TERMINALS FIGURE 2.4: MULTIPLE BOILER HORIZONTAL VENTING WITH CONCENTRIC VENT TERMINALS...
  • Page 10 FIGURE 2.5: MULTIPLE BOILER VERTICAL CPVC/PVC DIRECT VENT FIGURE 2.6: MULTIPLE BOILER VERTICAL VENTING WITH CONCENTRIC VENT TERMINALS...
  • Page 11 TABLE 2.7: MAXIMUM CONDENSATE FLOW Boiler *Maximum Condensate Flow, Model PHNTM080 PHNTM100 PHNTM120 PHNTM150 PHNTM180 *Assumes 100% of water in fuel condenses...

  • Page 12: Gas Piping Multiple Boilers

    III Gas Piping Multiple Boilers It is recommended that the gas piping of each individual boiler be installed as shown in Figure 3.1. When common gas piping is sized, insure it will have adequate capacity for the combined input of the multiple boilers being installed. Additional gas pressure regulators may need to be installed to properly regulate inlet gas pressure at the smallest individual boiler. Follow the instructions in Section VIII of the Phantom 080-180 Installation and Operating Instructions Manual for more detail on gas piping installation and hazards. CAUTION If gas pressure in the building is above 1/2 psig (3.4 kPa), an additional gas pressure regulator is required.

  • Page 13: System Piping Multiple Boilers

    See Table 4.1 and Figures 4.2 for piping recom- mendations. Table 4.1: Multiple Boiler Water Manifold Sizing Number of Boilers Boiler Model Recommended Minimum Common Water Manifold Size (NPT) PHNTM080 1¼” 1½” 1½” 2” 2” 2”...
  • Page 15 FIGURE 4.3: RECOMMENDED “IMMERSION” TYPE HEADER SENSOR INSTALLATION DETAIL...

  • Page 16: Wiring

    V. WIRING DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction ...
  • Page 17 4) Header sensor P/N 103104-01 must be used in Phantom Multiple boiler applications. Install it in the system piping as shown in Figure 4.2 (also see Fig 4.3 for installation detail). Wire it to the Master boiler as shown in Figure 5.1. Observe the precautions against electrical noise that are described for sensor wiring in Part X of the boiler installation manual. 5) Outdoor Sensor – If used, wire to the Master as shown in Figure 5.1. 6) LWCO and/or external limits – In general, if low water cut-offs and/or external limits are required, separate ones must be provided for each boiler. Consult the authority having jurisdiction. 7) MODBUS Communication Wiring – The Master communicates with the Slaves using the MODBUS connections on the low voltage PCB. The simplest way to make these connections is using Ethernet (PC network) cables. Use the standard “straight through” cables for this and plug them into the Modbus receptacles as shown in Figure 5.1. Alternatively, Modbus connections can also be made using the “A, “B”, and “-V” screws terminals located directly above the Ethernet receptacles. To do this, connect all “A”, “B”, and “-V” terminals together as shown in Figure 5.2.

  • Page 20: Start-Up And Checkout

    VI Start-up and Checkout Refer to Section XI (Start-up and Checkout) in the Phantom 80-180 installation manual. Boilers are started, adjusted, and inspected as individual boilers. They are then configured to operate as a multiple boiler system in Section VII of this manual (Operation). Because the slaves have no thermostats connected to them, it will be necessary to temporarily jump the DHW Thermostat terminals on each slave in order to fire it so that it can be checked out. VII Operation Information in this section supersedes that in Part XII (“Operation”) of the Phantom 80-180 Installation manual. A. General Information This boiler uses the microprocessor based Honeywell R7910B “boiler control” to manage all boiler functions including flame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the control’s memory; one for space heating (CH) and one for domestic hot water (DHW) production. If an outdoor temperature sensor is connected to the boiler, and enabled, the space heating supply set point will automatically shift downward as the outdoor temperature increases. For more information on this feature see the discussion on boiler water reset below. The control modulates the boiler input by varying the fan speed. As the fan speed increases, so does the amount of gas drawn into the blower. As a result, a fairly constant air-fuel ratio is maintained across all inputs. The control determines the input needed by looking at both current and recent differences between the supply temperature and the set point temperature. As the supply temperature approaches the set point temperature, the fan will slow down and the input will drop. The minimum input is approximately 1/5 of maximum input. This boiler control also monitors boiler return and flue temperatures. In addition, all other safety controls are connected into the R7910B. The R7910B uses inputs from all of these controls to either shut down the boiler when an unsafe condition exists or, in some cases, to correct the problem. Up to 8 Phantoms may be piped and wired together as described earlier in this manual to create a multiple boiler (“Lead-lag”) system. When this is done, one boiler acts as the “Master”. The Master receives demands from loads shared by the boilers and determines firing order and rate for all boilers in the system. The exact manner in which this is done is described in Part F of this section. Finally, the basic boiler control manages up to three pumps: •...
  • Page 21 IMPORTANT This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE: •...
  • Page 22 DHW, No DHW priority  Outdoor Reset  pumping. Options:    Enabled*  Disabled (see Note  Advanced  on Page 73) Configuration:  See Figure 7.2.    WWSD Options:  Off* Boiler Model Options:   PHNTM080 (S.L. – 2000ft) ODR Boost Options:  PHNTM100 (S.L. – 2000ft)  Disabled*  PHNTM120 (S.L. – 2000ft)  Enabled  PHNTM150 (S.L. – 2000ft)  PHNTM180 (S.L. – 2000ft) * Default  HOW TO CHANGE OPTIONS For Buttons with Three or More  For Buttons with Two Options  Options Like This: Like These: ...
  • Page 23 d) Press ADVANCED, then LEAD-LAG to enter the lead lag configuration menu e) Verify that all boilers are powered and all Modbus cables are connected. Also make sure that the header sensor is connected to the Master. Press NEXT. f) Press the button marked ENABLE LEAD-LAG in order to enable lead-lag. g) Press NEXT. h) On the Master (see Figure 5.1) boiler only – Press the button marked ENABLE MASTER in order to enable the Master. If the Master is successfully enabled, the screen will look like that in Figure 7.2. If there is no header sensor connected to this boiler, or if there is a problem with the header sensor, an error message will appear on this screen. i) Press NEXT j) Use the +1 key to assign the boiler an address between 1 and 8. Each boiler must have a unique address. Order in which the boilers are addressed is not important. Press SET to save the address. CAUTION Enabling more than one master or assigning the same address to more than one boiler will cause erratic operation.
  • Page 24 From Main Menu (Figure 7.0) See Appendix A in Phantom 80‐180  Installation manual for details on altitude  configuration Lead‐Lag Configuration Screens  (Default Shown) Lead‐Lag Configuration Screens  (Shown Configured as Master) Lead‐Lag Configuration Screens  (Shown Configured as Slave) FIGURE 7.2: ADVANCED CONFIGURATION MENU...
  • Page 25 4) If the system is installed with an indirect water heater which sends a DHW demand directly to the Master boiler, press the DHW button on the Configuration menu to configure the pump and DHW priority operation. If this is a heat only installation, or if the indirect water heater is controlled by an external zoning panel, skip to Step 5. There are three possible DHW configurations. Each of these options is described below and also summarized in Table 7.7. In all three cases, this boiler is intended to accept a DHW demand generated by a thermostat mounted in the indirect water heater, such as a Honeywell L4006A or L4080B, with this device set to the desired potable water temperature. The “DHW target temperature” is therefore the boiler supply temperature required during a call for DHW. WARNING Burn Hazard. Water temperatures over 125°F can cause personal injury or death due to scalding. Children Disabled, and Elderly are at most risk of being scalded.
  • Page 26 DHW Priority – This multiple boiler system is capable of regulating only one target boiler water temperature at any given time. This means that priority must be given to either the CH or DHW target temperature. For this reason, the system gives priority to the DHW demand for the first 60 minutes during which both calls for CH and DHW continuously exist. If there are still simultaneous calls for DHW and CH at the end of this time, the system will attempt to maintain the target CH temperature and operate the pump/s needed to satisfy the call for heat. The system will once again give priority to the DHW temperature when either of the following events occur: • The call for CH ends. • The call for DHW is removed and then restored. Regardless of the DHW option selected, the target water temperature will always change from that for DHW to CH if the simultaneous demand exceeds 60 min.
  • Page 27 5) Pressing the ADVANCED button on the configuration menu takes the user to the Advanced Configuration menu. This menu allows the user to access rarely needed configuration options. These include: FACTORY SET - This button allows the user to restore all factory configuration and setting options. This function can be used to restore all factory settings if a large number of settings are suspect or if the original control is replaced by one that is programed for use on another size Phantom. Pressing this button brings up the screen shown in Figure 7.8. Press the model number button until the desired model number is reached. When the selection is changed, this button will flash. When the desired model is reached, press SET to select it. When this change is accepted by the control, the button will stop flashing. Press EXIT to Return to the Advanced Configuration Menu. If factory settings are restored, the set-up process described in this section must be repeated. ALTITUDE – Allows the boiler to be configured for Altitudes above 2000ft. See Appendix A of the Phantom 80-180 installation manual for additional details. Each boiler in a lead lag system installed above 2000ft must be must be individually configured for the installed altitude. LEAD-LAG – This Menu allows the user to enable or disable the ability of the boiler to operate as part of a multiple boiler (Lead-Lag”) System. See Steps 1 and 2 of this Section for details on the use of this Menu. The Lead Lag menu is not visible if the standard “005” password was entered when the configuration menu was entered.
  • Page 28 CH (Heating) Zone Indirect  Water  Heater CH (Heating)   Pump Pump – Control supplied by installer SystemPump‐  Boiler Boiler Runs on Call for CH or DHW Exp.  Tank Boiler Boiler Pump Pump FIGURE 7.6: DHW PIPING OPTION #3 Table 7.7: Summary of Target Temp and Pump Behavior Demands Description Status of: CH+DHW CH+DHW Option # None CH Only DHW Only (<60 min) (>60 min) Boiler Pump*...

  • Page 29: Changing Settings

    C. Changing Settings Use the Settings Menu to change temperature set points and to temporarily lock the boiler in high or low fire. On a new installation configure all boilers first, then go to the Settings Menu. Most settings adjustments are made on the Master only. A map of the Settings Menu structure is shown in Figure 7.8. To change settings: 1) From the Home Screen (shown in Figure 12.0) , press “MENU” to enter the Main Menu: a) Press “SETTINGS” b) When prompted for a password, use the “+1” key to raise the password to “005” or “014”. Press SUBMIT, then NEXT (if you accidently scroll past 014, press EXIT to return to the main menu and start over). c) Review the Warning and press ACCEPT to continue to the Settings Menu. Note: If you go from the Configurations Menu to the Settings Menu without returning to the Home Screen, you will not have to reenter a password. 2) CH Settings – CH adjustments are made on the Master only (this menu is not even visible on slaves). Press CH to change the target supply water temperature setting. a) If outdoor reset is disabled, only one CH set point exists. The multiple boiler system will always attempt to maintain this temperature at the header sensor during a call for CH. To change the setting, touch the button containing the current setting. Adjust the temperature using the “+” and “-” arrows shown and press SET to save the change (also see “How to Change Settings” in Figure 7.8).
  • Page 30 FIGURE 7.8a: MASTER SETTINGS MENU...

  • Page 31: Boiler Status

    2) From the Diagnostic Menu, press either the INSTALLER or MORE button (only one will be visible depending on whether you are “logged in”). a) If prompted for a password, use the “+1” key to raise the password to “005” or “014”. Press SUBMIT, then NEXT (if you accidently scroll past 014, press EXIT to return to the main menu and start over). b) Review the Warning and press ACCEPT to continue. 3) Press ENTER CONTACT. 4) Touch the top blank field to enter the first line. When you do this, the keyboard shown in Figure 7.10 will appear. Use the up and down arrows to access addition characters. After entering the first line, press the return key to temporarily save the line. 5) Repeat Step 4 for the remaining two lines. 6) Press SET to permanently save all three lines into the memory of the display. FIGURE 7.8b: SLAVE SETTINGS MENU E. Boiler Status The following screens provide the user with information about the current boiler status: • Home Screen (Figure 7.3) – This is the default screen shown on the boiler. It allows the user to see basic information about the boiler at a glance. • Boiler Status Menu (Figure 7.11a) – Allows the user to see more detailed information about the operation of the boiler itself. • Master Status Menu (Figure 7.11b) – This menu is visible on the Master boiler only. It provides detailed information about the operation of the multiple boiler system.
  • Page 32 FIGURE 7.9: OUTDOOR RESET CURVE (DEFAULT SETTINGS SHOWN) Specific information available on these screens is as follows: 1) Home Screen a) Current Demand –The demand to which the boiler is currently responding. If more than one demand is present, the Current Demands shown will be the one having the highest priority. Typical Current Demands include: • Lead-Lag – Boiler is either responding, or is available to respond, to a call from the Master. Normally, this status will be shown on the Home Screen of all Slave boilers in the system, regardless of whether the boiler is actually being called upon to fire. No Master Demand (Master Home Screen only) - The Master boiler is not receiving a demand of any type. • This status should not be seen on the Home screen of any boiler in a multiple boiler system if it is configured and operating correctly. • Master: Central Heat (Master Home Screen Only) – The Master boiler is receiving a call for space heat. Master: Domestic HW - The Master boiler is receiving a call for domestic hot water. • Frost Protection - The boiler supply, or header, temperature fell below 45°F and the boiler is responding to • prevent freeze damage to itself. • Master: CH Off on WWSD (Master Home Screen only) - The warm weather shut down option has been selected in the Configuration Menu and the outside air temperature has exceeded the setting at which this function causes the multiple boiler system to ignore calls for space heating.
  • Page 33 From Main Menu (Figure 7.0) Password Required        0   s Copy Service Contact Instructions (with  Wiley) from existing IOM FIGURE 7.10: DIAGNOSTICS MENU...
  • Page 34 FIGURE 7.11a: BOILER STATUS MENU c) Supply - Current temperature at the boiler’s supply sensor. d) Lead Lag Status – Either “M” for Master or “S” for slave. Shown in the upper right corner. e) Boiler Address – A number from 1 to 8. Shown in the upper right corner. 2) Boiler Status Menu (Figure 7.11a): a) Current Priority Screen • Current Demand – This is the highest priority demand currently present at the boiler. Normally it reads “Lead- Lag (S)” in the multiple boiler applications covered by this manual (regardless of whether the boiler is the Master or a Slave). This is also true, regardless of whether the boiler is actually receiving a demand to fire. • Header Temperature - (Visible on Master Only) - The water temperature at the header sensor location. b) Boiler Temperatures Screen: Supply - Current water temperature at boiler supply sensor. • • Return - Current water temperature at boiler return sensor. • Stack - Current flue gas temperature near boiler vent connection. • Header - Current header sensor temperature (Master Only). c) Burner Status Screen: • Burner Status - Indicates what the burner system is currently doing. Typical Burner Status include: Standby - Burner is not needed because there is no call for heat or the target temperature has been reached.
  • Page 35 x. Running - Burner is firing. xi. Post-Purge - Blower is running after the burner shuts off to clear the combustion chamber of residual gasses. Post xii. purge time is 30s. xiii. Lockout - Boiler is in a hard lockout (see Diagnostic Section). • Active Fault (visible only when there is a problem) - Reverse flashes to indicate a problem with the boiler or the system. Touching this indicator takes the user to the Diagnostic Menu. See Section XIV for more information. • Hold Delay (Visible only during soft lockout) - Indicates remaining time before next ignition sequence. • Flame Signal - Indicates the strength of the flame signal in DC micro-amps.
  • Page 36 “NEXT” Button Only  Visible if More Than 2  Boilers are Present  ODR Status Screens Only  Visible if Outdoor Reset is  Enabled in Configuration  Menu. FIGURE 7.11b: MASTER STATUS MENU b) Staging Status – Provides general picture of the multiple boilers in the system: Target system rate – This is the firing rate (expressed as target fan speed divided by maximum fan speed) that • is used by any boilers which are firing. • Boilers Found – This shows the Modbus address of all Slave boilers that have been found by the Master. Since the Master itself is also a slave, the address of the Master will also be shown here. Current Lead Boiler – Shows the address of the current Lead boiler (the first boiler to start, and the last boiler • to stop in response to a demand). The lead boiler automatically rotates to the next higher address when either of the following occur: The lead boiler has been so for 24 hours of operation ii. There is a fault with the lead boiler. c) Slave Status – The following information is available for each Slave: •...

  • Page 37: Staging Process

    vi. Recovering – Boiler is attempting to return to the “Available” state (for example, this state is shown when the slave is in post purge or powered down). • Lead – Lead boiler is shown. % - If the boiler is firing in response to a call from the Master, this is the percentage of maximum fan speed at • which the boiler is operating. Normally this value will wither be zero or equal to the Target System Rate. d) Master Demands - Shows the current status of the thermostats connected to the Master. This screen also identifies the source of the set point value currently in use by the Master. e) Outdoor Reset Screens (only visible when outdoor reset has been enabled in Configuration Menu): • Outdoor - Current temperature at outdoor sensor. • Setpoint - Current CH set point obtained from outdoor reset curve (Figure 7.9). • Supply (or Header) Temperature - The actual water temperature at the current set point location (either the boiler supply or header, depending on the demand and what set point location was selected in the Configuration Menu).
  • Page 38 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com PN: 980124 Rev 0, 05/15...

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