Crown Boiler PHNTM120 Installation And Operation Instructions Manual
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Crown Boiler PHNTM120 Installation And Operation Instructions Manual

Phantom series
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Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
Series
:$51,1*: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information, con-
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Summary of Contents for Crown Boiler PHNTM120

  • Page 1 7KHVH LQVWUXFWLRQV PXVW EH DI¿[HG RQ RU DGMDFHQW WR WKH ERLOHU DQG UHWDLQHG IRU IXWXUH UHIHUHQFH 0RGHOV PHNTM080 ‡ 9700609 PHNTM100 ‡ PHNTM120 :$51,1*: Improper installation, adjustment, alteration, ‡ service or maintenance can cause property damage, injury, PHNTM150 ‡ or loss of life. For assistance or additional information, con- PHNTM180 VXOW D TXDOL¿HG LQVWDOOHU VHUYLFH DJHQF\ RU WKH JDV VXSSOLHU...
  • Page 3 ,03257$17 ,1)250$7,21  5($' &$5()8//< 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. '$1*(5 &$87,21 ,QGLFDWHV DQ LPPLQHQWO\ KD]DUGRXV VLWXDWLRQ ,QGLFDWHV D SRWHQWLDOO\ KD]DUGRXV VLWXDWLRQ ZKLFK LI QRW DYRLGHG ZLOO UHVXOW LQ GHDWK VHULRXV ZKLFK LI QRW DYRLGHG PD\ UHVXOW LQ PRGHUDWH RU LQMXU\ RU VXEVWDQWLDO SURSHUW\ GDPDJH...
  • Page 4 '$1*(5 ([SORVLRQ +D]DUG '2 127 VWRUH RU XVH JDVROLQH RU RWKHU ÀDPPDEOH YDSRUV RU OLTXLGV LQ WKH YLFLQLW\ RI WKLV RU DQ\ RWKHU DSSOLDQFH ,I \RX VPHOO JDV YDSRUV '2 127 WU\ WR RSHUDWH DQ\ DSSOLDQFH  '2 127 WRXFK DQ\ HOHFWULFDO VZLWFK RU XVH DQ\ SKRQH LQ WKH EXLOGLQJ ,PPHGLDWHO\ FDOO WKH JDV VXSSOLHU IURP D UHPRWHO\ ORFDWHG SKRQH )ROORZ WKH JDV VXSSOLHU¶V LQVWUXFWLRQV RU LI WKH VXSSOLHU LV XQDYDLODEOH FRQWDFW WKH ¿UH GHSDUWPHQW :$51,1*...

  • Page 5: Table Of Contents

    Table of Contents Product Description 6SHFL¿FDWLRQV III. Before Installing Locating The Boiler Mounting The Boiler Air For Ventilation VII. Venting A. Vent System Design B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems C. Design Requirements Unique to Vertical Venting Systems D.

  • Page 6: Product Description

    I Product Description 7KLV ERLOHU LV D VWDLQOHVV VWHHO JDV ¿UHG FRQGHQVLQJ ERLOHU GHVLJQHG IRU XVH LQ IRUFHG KRW ZDWHU KHDWLQJ V\VWHPV UHTXLULQJ supply water temperatures of 180°F or less. It is designed for installation on a wall. This boiler may be vented vertically or horizontally with combustion air supplied from outdoors.

  • Page 7: Before Installing

    (Gal.) SIZE (NPT) (MBH) SIZE (NPT) (lb) PHNTM080 0.36 17” 1” 1/2” PHNTM100 0.44 17” 1” 1/2” PHNTM120 0.53 17” 1” 1/2” PHNTM150 0.79 21” 1” 1/2” PHNTM180 0.79 21” 1” 1/2” * The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15. The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

  • Page 8: Locating The Boiler

     $OO ERLOHUV DUH VKLSSHG IURP WKH IDFWRU\ FRQ¿JXUHG IRU XVH ZLWK QDWXUDO JDV 7KH\ PD\ EH FRQYHUWHG IRU XVH ZLWK /3 JDV (“propane”) using a combustion analyzer in accordance with the instructions in Appendix A. '$1*(5 ‡ 'R QRW DWWHPSW WR RSHUDWH WKLV ERLOHU RQ /3 JDV ZLWKRXW FRQYHUWLQJ LW LQ DFFRUGDQFH ZLWK WKH LQVWUXFWLRQV VKRZQ LQ $SSHQGL[ $ ‡...
  • Page 9 Figure 4.1: Minimum Clearances To Combustible Construction...

  • Page 10: Mounting The Boiler

    V Mounting The Boiler A. Wall Mounting CAUTION This boiler weighs as much as 119 pounds: ‡ 7ZR SHRSOH DUH UHTXLUHG WR VDIHO\ OLIW WKLV ERLOHU RQWR WKH ZDOO PRXQWLQJ KRRN ‡ 0DNH VXUH WKDW ZDOO PRXQWLQJ KRRN LV DQFKRUHG WR D VWUXFWXUH FDSDEOH RI VXSSRUWLQJ WKH ZHLJKW RI WKH ERLOHU DQG DWWDFKHG SLSLQJ ZKHQ ¿OOHG ZLWK ZDWHU -XULVGLFWLRQV LQ DUHDV VXEMHFW WR HDUWKTXDNHV PD\ KDYH VSHFLDO UHTXLUHPHQWV IRU VXSSRUWLQJ WKLV ERLOHU 7KHVH ORFDO UHTXLUHPHQWV WDNH SUHFHGHQFH RYHU WKH...
  • Page 11 Figure 5.1 Wall Layout/Mounting Hole Location...
  • Page 12 Figure 5.2 Boiler Mounting Bracket Installation / Boiler Wall Mounting...

  • Page 13: Air For Ventilation

    VI Air for Ventilation :$51,1* 2XWGRRU FRPEXVWLRQ DLU PXVW EH SLSHG WR WKH DLU LQWDNH 1HYHU SLSH FRPEXVWLRQ DLU IURP DUHDV FRQWDLQLQJ FRQWDPLQDWHV VXFK DV VZLPPLQJ SRROV DQG ODXQGU\ URRP H[KDXVW YHQWV &RQWDPLQDWHG FRPEXVWLRQ DLU ZLOO GDPDJH WKH ERLOHU DQG PD\ FDXVH SURSHUW\ GDPDJH SHUVRQDO LQMXU\ RU ORVV RI OLIH Air for combustion must always be obtained directly from outdoors.

  • Page 14: Venting

    VII Venting :$51,1* ‡ $VSK\[LDWLRQ +D]DUG )DLOXUH WR YHQW WKLV ERLOHU LQ DFFRUGDQFH ZLWK WKHVH LQVWUXFWLRQV FRXOG FDXVH SURGXFWV RI FRPEXVWLRQ WR HQWHU WKH EXLOGLQJ UHVXOWLQJ LQ VHYHUH SURSHUW\ GDPDJH SHUVRQDO LQMXU\ RU GHDWK ‡ 'R QRW LQWHUFKDQJH YHQW V\VWHPV RU PDWHULDOV XQOHVV RWKHUZLVH VSHFL¿HG ‡...
  • Page 15 FIGURE 7.0 BASIC VENT OPTIONS FIGURE 7.0a: HORIZONTAL TWIN PIPE FIGURE 7.0b: VERTICAL TWIN PIPE FIGURE 7.0c: SPLIT VENTING FIGURE 7.0d & e: HORIZONTAL & VERTICAL CONCENTRIC VENTING...
  • Page 16 All of these systems are considered “direct vent” because the air for combustion is drawn directly from the outdoors into the boiler. One of the vent option columns in the tables referenced above must match the planned vent and air intake system exactly. Design details applying to all vent systems are shown in this section.
  • Page 17 127,&( 'R QRW H[FHHG PD[LPXP YHQWFRPEXVWLRQ DLU V\VWHP OHQJWK 5HIHU WR 7DEOHV   DQG  LQ WKLV VHFWLRQ IRU PD[LPXP YHQWFRPEXVWLRQ DLU V\VWHP OHQJWK 8VH RQO\ YHQW DQG FRPEXVWLRQ DLU WHUPLQDOV DQG WHUPLQDO ORFDWLRQV VKRZQ LQ 7DEOHV   DQG  DQG UHODWHG )LJXUHV Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in Tables 7.1, 7.13 and 7.21.
  • Page 18 7. Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported. Maximum support spacing is as follows: ‡ 6XSSRUW &39&39& KRUL]RQWDOO\ DQG YHUWLFDOO\ HYHU\  IHHW ‡ 6XSSRUW 'XUD9HQW 3RO\SUR KRUL]RQWDOO\ QHDU WKH IHPDOH HQG RI HDFK VWUDLJKW VHFWLRQ RI SLSH DQG YHUWLFDOO\ HYHU\  IHHW ‡...
  • Page 19 FIGURE 7.3a FIGURE 7.3b FIGURE 7.3c FIGURE 7.3: EXPANSION LOOPS FOR CPVC/PVC PIPE FIGURE 7.4: WALL PENETRATION CLEARANCES FOR PVC VENT PIPE...

  • Page 20: Design Requirements Unique To Horizontal Twin Pipe Venting Systems

    B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems Table 7.5 summarizes all horizontal twin pipe vent options. Illustrations of horizontal twin pipe vent systems are shown in Figures 7.6 – 7.10. In addition to the requirements in Part VII-A, observe the following design requirements: 1.
  • Page 21 Table 7.5: Summary of Horizontal Twin Pipe Venting Options Vent Option 7.6, 7.7, 7.6, 7.7, Illustrated in Figure 7.9, 7.10 7.9, 7.10 Pipe Vent Wall Wall Wall Wall Wall Wall Wall Wall Penetration through Intake Wall Wall Wall Wall Wall Wall Wall Wall...
  • Page 22 2. Horizontal Vent and Air Intake Terminal Location - Observe the following limitations on the vent terminal location (also see Figure 7.11). When locating a concentric terminal, observe the limitations outlined below for “vent terminals”. ‡ Vent terminal must be at least 1 foot from any door, window, or gravity inlet into the building. ‡...
  • Page 23 FIGURE 7.7: HORIZONTAL CPVC/PVC VENTING WITH LOW PROFILE TERMINAL, (VENT OPTIONS #1 & 2, TERMINAL OPTIONS B & C) FIGURE 7.8: HORIZONTAL CPVC/PVC WITH CONCENTRIC VENT TERMINAL, (VENT OPTIONS #1 & 2, TERMINAL OPTIONS D & E)
  • Page 24 FIGURE 7.9: DURAVENT POLYPRO, SELKIRK POLYFLUE OR CENTROTHERM INNOFLUE HORIZONTAL VENTING, (VENT OPTIONS #3 - 8, TERMINAL OPTION A) FIGURE 7.10: DURAVENT POLYPRO HORIZONTAL VENTING WITH CONCENTRIC TERMINAL, (VENT OPTIONS #3 & 4, TERMINAL OPTION F)
  • Page 25 FIGURE 7.11a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 7.11b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS Max. “X” Min. “Y” (in.) (in.) 9HQWLODWHG 6RI¿W 8QYHQWLODWHG 6RI¿W RU 2WKHU 2YHUKDQJ “X” May never exceed 36” ([DPSOH )RU DQ XQYHQWLODWHG ´...

  • Page 26: Design Requirements Unique To Vertical Venting Systems

    FIGURE 7.12: SNORKEL TERMINAL CONFIGURATION (CPVC/PVC VENT SYSTEMS ONLY) C. Design Requirements Unique to Vertical Venting Systems Table 7.13a summarizes all vertical twin pipe vent options. Table 7.13.b summarizes vent options in which an abandoned B-vent chimney is used both as a chase for the vent pipe and as a conduit for combustion air. In addition to the requirements in Part VII-A, observe the following design requirements: 1.
  • Page 27 Table 7.13a: Summary of Vertical Twin Pipe Venting Options Option Illustrated in Figure 7.15, 717 7.15, 7.17 7.17, 7.18 7.17, 7.18 7.17 7.17 7.17 7.17 Pipe Vent Roof Roof Roof Roof Roof Roof Roof Roof Penetration through Intake Roof Roof Roof Roof Roof...
  • Page 28 Table 7.13b: Summary of Vertical “B-Vent Air Chase” Vent Options (B-Vent Chase MUST Be Sealed) Option Illustrated in Figure 7.19 7.19 7.20 7.20 Vent Roof Roof Roof Roof Pipe Penetration Through Structure Intake Roof Roof Roof Roof DuraVent DuraVent Centrotherm Centrotherm Vent PolyPro...
  • Page 29 Terminal Option J: Diversitech Concentric Terminal (Acceptable for Vent Options 10 & 11) - This terminal is shown in Figure 7.16 and may be used with CPVC/PVC vent systems. See Part VII-E of this manual and the Diversitech instructions provided with the terminal, for installation details. Terminal Option K: DuraVent PolyPro Concentric Terminal (Acceptable for Vent Options 12, 13) - This terminal is shown LQ )LJXUH  DQG PD\ EH XVHG ZLWK 'XUD9HQW ´...
  • Page 30 Table 7.14: Equivalent Length of Flex Pipe Equivalent Length (ft) Flex Vent (1 ft): 2” DuraVent PolyPro Flex 2.0 ft ´ &HQWURWKHUP ,QQRÀXH )OH[ 2.0 ft ´ 6HONLUN 3RO\ÀXH 2.0 ft 3” DuraVent PolyPro Flex 2.0 ft ´ &HQWURWKHUP ,QQRÀXH )OH[ 2.3 ft ´...
  • Page 31 FIGURE 7.15: VERTICAL CPVC/PVC VENTING, (VENT OPTIONS 10 & 11, TERMINAL OPTION H) FIGURE 7.16: VERTICAL CPVC/PVC VENTING WITH IPEX CONCENTRIC VENT TERMINAL, (VENT OPTIONS #10 & 11, TERMINAL OPTIONS I, J)
  • Page 32 FIGURE 7.17: DURAVENT POLYPRO, SELKIRK POLYFLUE OR CENTROTHERM INNOFLUE VERTICAL SINGLE WALL PP VENTING, (VENT OPTIONS #12-17, TERMINAL OPTION A) FIGURE 7.18: DURAVENT POLYPRO VERTICAL VENTING WITH CONCENTRIC TERMINAL, (VENT OPTIONS #12 & 13, TERMINAL OPTION K)
  • Page 33 FIGURE 7.19: DURAVENT POLYPRO B-VENT AIR CHASE SYSTEM (VENT OPTIONS #18 & 19) FIGURE 7.20: CENTROTHERM INOFLUE B-VENT AIR CHASE SYSTEM (VENT OPTIONS #20 & 21)

  • Page 34: Design Requirements Unique To Split Vent Systems

    D. Design Requirements Unique to Split Vent Systems Table 7.21 summarizes all split vent options. Illustrations of split vent systems are shown in Figures 7.22, 7.23, and 7.24. In addition to the requirements in Part VII-A, observe the following design requirements: 1.
  • Page 35 Example: A 100MBH model is to be installed as using Vent Option 34 in a masonry chimney as shown in Figure 7.23. The following components are used: Vent: 3” DuraVent Poly-Pro (Rigid) – 4ft 3” DuraVent Poly-Pro Flex – 30ft Poly-Pro elbows –...
  • Page 36 Table 7.21: Summary of Split Vent System Options Option # Illustrated in Figure 7.22 7.22 7.22 7.22 7.22 7.22 Vent Roof Roof Roof Roof Roof Roof Pipe Penetration Through Structure Intake Wall Wall Wall Wall Wall Wall DuraVent DuraVent CPVC/PVC CPVC/PVC Selkirk Selkirk...
  • Page 37 Table 7.21: Summary of Split Vent System Options (cont.) 7.22 7.22 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 7.23, 7.24 Roof Roof Roof Roof Roof Roof Roof Roof Wall Wall Wall Wall Wall Wall Wall Wall DuraVent DuraVent Centrotherm Centrotherm...
  • Page 38 FIGURE 7.22: SPLIT RIGID VENT SYSTEM (VENT OPTIONS 25-32 - CPVC SYSTEM SHOWN IN ABOVE EXAMPLE) FIGURE 7.23: SPLIT VENT SYSTEM (FLEX IN B-VENT CHASE)(VENT OPTIONS 33-38)
  • Page 39 FIGURE 7.24: SPLIT VENT SYSTEM (FLEX IN ABANDONED MASONRY CHIMNEY)(VENT OPTIONS 33-38)
  • Page 40 Venting of Other Appliances (Or Fireplace) into Chase or Adjacent Flues Prohibited! FIGURE 7.25: MASONRY CHIMNEY CHASE REQUIREMENTS...

  • Page 41: Assembly Of Cpvc/Pvc Vent Systems

    E. Assembly of CPVC/PVC Vent Systems :$51,1* ‡ $VSK\[LDWLRQ +D]DUG )DLOXUH WR IROORZ WKHVH LQVWUXFWLRQV FRXOG FDXVH SURGXFWV RI FRPEXVWLRQ WR HQWHU WKH EXLOGLQJ UHVXOWLQJ LQ VHYHUH SURSHUW\ GDPDJH SHUVRQDO LQMXU\ RU GHDWK ‡ 8VH DOO &39& YHQW FRPSRQHQWV VXSSOLHG ZLWK WKH ERLOHU IRU QHDUERLOHU YHQW SLSLQJ EHIRUH WUDQVLWLRQLQJ WR 6FKHGXOH  39&...
  • Page 42 FIGURE 7.27: VENT CONNECTIONS AND FLUE GAS SAMPLE CAP LOCATION g. Assemble the rest of the vent system, being sure to pitch horizontal sections back towards the boiler 1/4”/ft. Support the vent at intervals not exceeding 4ft. h. Maintain the clearances from the vent pipe outlined in Part VII-A of this manual. If exiting the exterior wall using PVC pipe, use half of an appropriately sized wall thimble (or a sheet metal plate) on the exterior of the building, to provide a weather tight seal while maintaining the proper clearance in the wall penetration.
  • Page 43 FIGURE 7.28: INSTALLATION OF STANDARD HORIZONTAL TERMINALS FIGURE 7.29: INSTALLATION OF STANDARD VERTICAL TERMINALS...
  • Page 44 Installation of Vertical Fitting Terminals (Terminal Option H): See Figure 7.29 for the proper orientation of twin pipe vertical terminals. b. The coupling is used to secure the rodent screen to the end of the vent pipe. A 180° bend (or two 90° elbows) are installed on the top of the air intake pipe. If two 90° elbows are used, the rodent screen provided can be installed between them (Figure 7.29).
  • Page 45 FIGURE 7.30: INSTALLATION OF IPEX LOW PROFILE TERMINAL THROUGH SIDEWALL FIGURE 7.31: INSTALLATION OF DIVERSITECH LOW PROFILE TERMINAL THROUGH SIDEWALL...
  • Page 46 FIGURE 7.32: CUTTING IPEX AND DIVERSITECH CONCENTRIC VENT TERMINALS FIGURE 7.33: INSTALLATION OF IPEX AND DIVERSITECH CONCENTRIC TERMINAL THROUGH SIDEWALL...
  • Page 47 FIGURE 7.34: INSTALLATION OF IPEX AND DIVERSITECH CONCENTRIC TERMINAL THROUGH ROOF Cement the outer pipe to the Wye, being careful, to keep the inner and outer pipes concentric. Slip the partially assembled terminal through the wall or ceiling from the inside and for horizontal installations orient so that the side outlet on the Wye is on or above the horizontal plane.

  • Page 48: Assembly Of Duravent Polypro Vent Systems

    F. Assembly of DuraVent PolyPro Vent Systems 1. This boiler has been approved for use with the DuraVent PolyPro single wall polypropylene vent system to be provided by the installer. :$51,1* ‡ $VSK\[LDWLRQ +D]DUG )ROORZ WKHVH LQVWUXFWLRQV DQG WKH LQVWDOODWLRQ LQVWUXFWLRQV LQFOXGHG E\ WKH RULJLQDO SRO\SURS\OHQH YHQWLQJ FRPSRQHQW PDQXIDFWXUHU 0 *'XUD9HQW )DLOXUH WR GR VR FRXOG FDXVH SURGXFWV RI FRPEXVWLRQ WR HQWHU WKH EXLOGLQJ UHVXOWLQJ LQ VHYHUH SURSHUW\ GDPDJH SHUVRQDO LQMXU\ RU GHDWK :KHUH D FRQÀLFW DULVHV EHWZHHQ 0 *'XUD9HQW LQVWUXFWLRQV DQG WKHVH LQVWUXFWLRQV...
  • Page 49 3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows: 'ULOO D ´ FOHDUDQFH KROH LQWR WKH IURQW VLGH RI WKH DLU LQWDNH DGDSWHU ,QVHUW WKH ¿UVW SLHFH RI 39& DLU LQWDNH SLSH into the air intake connection and drill a 1/8”...
  • Page 50 FIGURE 7.36: INSTALLATION OF DURAVENT POLYPRO UV RESISTANT SINGLE WALL HORIZONTAL TERMINAL FIGURE 7.37: INSTALLATION OF DURAVENT POLYPRO UV RESISTANT SINGLE WALL VERTICAL TERMINAL...
  • Page 51 6. Installation of DuraVent PolyPro Horizontal Concentric Vent Terminal (Terminal Option D) - Install PolyPro Horizontal Concentric Termination Kit #2PPS-HK or #3PPS-HK (Figure 7.39) as follows: At the planned location cut a 4-1/8” round hole for the 2” terminal or a 5-1/8” round hole for the 3” terminal in the exterior wall.
  • Page 52 FIGURE 7.39: INSTALLATION OF DURAVENT POLYPRO CONCENTRIC VENT TERMINAL THROUGH SIDEWALL FIGURE 7.40: INSTALLATION OF DURAVENT POLYPRO CONCENTRIC TERMINAL THROUGH ROOF...

  • Page 53: Vvhpeo\ Ri 6Honlun 3Ro\Àxh 9Hqw 6\Vwhpv

    8. ,QVWDOODWLRQV XVLQJ 3RO\3URÀH[ 9HQW 2SWLRQV  : :$51,1* $VSK\[LDWLRQ +D]DUG :KHQ XVLQJ 3RO\SUR ÀH[ REVHUYH WKH IROORZLQJ SUHFDXWLRQV ‡ 3RO\SUR ÀH[ PD\ EH GDPDJHG E\ KDQGOLQJ DW ORZ WHPSHUDWXUHV 'R QRW EHQG XQFRLO RU DWWHPSW WR LQVWDOO LI LW KDV EHHQ VWRUHG DW D WHPSHUDWXUH EHORZ ) ZLWKRXW DOORZLQJ LW WR ZDUP WR D KLJKHU WHPSHUDWXUH ¿UVW ‡...
  • Page 54 6XSSRUW HDFK SLSH VHFWLRQ DV GHVFULEHG LQ 3RO\ÀXH PDQXDO DW LQWHUYDOV QRW H[FHHGLQJ WKH IROORZLQJ Pipe size Horizontal Vertical 2” 30in 16ft 3” 39in 16ft 127,&( 2QFH D YHQW SLSH LV LQVHUWHG LQWR WKLV DGDSWRU LW LV ,03266,%/( WR UHPRYH LW 0DNH VXUH WKH FRUUHFW W\SH RI SLSH LV VHOHFWHG DQG WKDW LW LV RI WKH FRUUHFW OHQJWK EHIRUH LQVHUWLQJ LW LQWR WKH YHQW DGDSWRU 3.
  • Page 55 6. ,QVWDOODWLRQV XVLQJ ÀH[LEOH 3RO\ÀXH 9HQW 2SWLRQV  : :$51,1* $VSK\[LDWLRQ +D]DUG :KHQ XVLQJ 3RO\ÀXH ÀH[ REVHUYH WKH IROORZLQJ SUHFDXWLRQV ‡ 3RO\ÀXH ÀH[ PD\ EH GDPDJHG E\ KDQGOLQJ DW ORZ WHPSHUDWXUHV 'R QRW EHQG XQFRLO RU DWWHPSW WR LQVWDOO LI LW KDV EHHQ VWRUHG DW D WHPSHUDWXUH EHORZ ) ZLWKRXW DOORZLQJ LW WR ZDUP WR D KLJKHU WHPSHUDWXUH ¿UVW ‡...
  • Page 56 FIGURE 7.42: INSTALLATION OF SELKIRK POLYFLUE UV RESISTANT SINGLE WALL HORIZONTAL TERMINAL FIGURE 7.43: INSTALLATION OF SELKIRK POLYFLUE UV RESISTANT SINGLE WALL VERTICAL TERMINAL...

  • Page 57: Vvhpeo\ Ri &Hqwurwkhup ,Qqràxh 9Hqw 6\Vwhpv

    + $VVHPEO\ RI &HQWURWKHUP ,QQRÀXH 9HQW 6\VWHPV 1. 7KLV ERLOHU KDV EHHQ DSSURYHG IRU XVH ZLWK WKH &HQWURWKHUP ,QQRÀXH VLQJOH ZDOO SRO\SURS\OHQH YHQW V\VWHP WR EH provided by the installer. :$51,1* ‡ $VSK\[LDWLRQ +D]DUG )ROORZ WKHVH LQVWUXFWLRQV DQG WKH LQVWDOODWLRQ LQVWUXFWLRQV LQFOXGHG E\ WKH RULJLQDO SRO\SURS\OHQH YHQWLQJ FRPSRQHQW PDQXIDFWXUHU &HQWURWKHUP )DLOXUH WR GR VR FRXOG FDXVH SURGXFWV RI FRPEXVWLRQ WR HQWHU WKH EXLOGLQJ UHVXOWLQJ LQ VHYHUH SURSHUW\ GDPDJH SHUVRQDO LQMXU\ RU GHDWK :KHUH D FRQÀLFW DULVHV EHWZHHQ &HQWURWKHUP LQVWUXFWLRQV DQG WKHVH LQVWUXFWLRQV WKH...
  • Page 58 3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows: 'ULOO D ´ FOHDUDQFH KROH LQWR WKH IURQW VLGH RI WKH DLU LQWDNH DGDSWHU ,QVHUW WKH ¿UVW SLHFH RI 39& DLU LQWDNH SLSH into the air intake connection and drill a 1/8”...
  • Page 59 FIGURE 7.45: INSTALLATION OF CENTROTHERM INNOFLUE UV STABILIZED SINGLE WALL HORIZONTAL TERMINAL FIGURE 7.46: INSTALLATION OF CENTROTHERM INNOFLUE UV STABILIZED SINGLE WALL VERTICAL TERMINAL...
  • Page 60 6. Installations using InnoFlue Flex (Vent Options 20,21,37,38): :$51,1* $VSK\[LDWLRQ +D]DUG :KHQ XVLQJ ,QQR)OXH )OH[ REVHUYH WKH IROORZLQJ SUHFDXWLRQV ‡ ,QQR)OXH )OH[ PD\ EH GDPDJHG E\ KDQGOLQJ DW ORZ WHPSHUDWXUHV 'R QRW EHQG XQFRLO RU DWWHPSW WR LQVWDOO LI LW KDV EHHQ VWRUHG DW D WHPSHUDWXUH EHORZ ) ZLWKRXW DOORZLQJ LW WR ZDUP WR D KLJKHU WHPSHUDWXUH ¿UVW ‡...

  • Page 61: Condensate Trap And Drain

    I. Condensate Trap and Drain Line All condensate which forms in the boiler or vent system passes through the heat exchanger and out of a bottom drain port which is connected to the condensate trap with a hose. This trap allows condensate to drain from the heat exchanger while UHWDLQLQJ ÀXH JDVHV LQ WKH ERLOHU 7KLV WUDS LV DQ LQWHJUDO SDUW RI WKH ERLOHU EXW PXVW EH FRQQHFWHG WR D GUDLQ SLSH DV VKRZQ LQ Figure 7.47.

  • Page 62: Removing An Existing Boiler From Common Chimney

    J. Removing an Existing Boiler From a Common Chimney This section only applies if this boiler is replacing an existing boiler that is being removed from a common chimney. In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large for the remaining appliances.
  • Page 63 This page is intentionally left blank.

  • Page 64: Gas Piping

    VIII Gas Piping :$51,1* ([SORVLRQ +D]DUG )DLOXUH WR SURSHUO\ SLSH JDV VXSSO\ WR ERLOHU PD\ UHVXOW LQ LPSURSHU RSHUDWLRQ RU OHDNV RI ÀDPPDEOH JDV ‡ *DV VXSSO\ WR ERLOHU DQG V\VWHP PXVW EH DEVROXWHO\ VKXW RII SULRU WR LQVWDOOLQJ RU VHUYLFLQJ ERLOHU JDV SLSLQJ ‡...
  • Page 65 &$87,21 ‡ 6XSSRUW WKH ZHLJKW RI WKH JDV OLQH SLSLQJ LQGHSHQGHQWO\ IURP WKH ERLOHU JDV FRQQHFWLRQ ¿WWLQJ ORFDWHG RQ WKH ERWWRP RI WKH ERLOHU ‡ ,I DQ DGGLWLRQDO UHJXODWRU LV XVHG WR UHGXFH ERLOHU LQOHW SUHVVXUH EHORZ  SVLJ  N3D LW PXVW EH DW OHDVW  WR  IHHW XSVWUHDP RI WKH ERLOHU ‡...

  • Page 66: System Piping

    IX System Piping A. General System Piping Precautions :$51,1* ‡ )DLOXUH WR SURSHUO\ SLSH ERLOHU PD\ UHVXOW LQ LPSURSHU RSHUDWLRQ DQG GDPDJH WR ERLOHU RU VWUXFWXUH ‡ ,QVWDOO ERLOHU VR WKDW WKH JDV LJQLWLRQ V\VWHP FRPSRQHQWV DUH SURWHFWHG IURP ZDWHU GULSSLQJ VSUD\LQJ UDLQ HWF GXULQJ ERLOHU RSHUDWLRQ DQG VHUYLFH FLUFXODWRU UHSODFHPHQW HWF  ‡...

  • Page 67: Near Boiler Piping Design

    B. Near Boiler Piping Design 3URSHU RSHUDWLRQ RI WKLV ERLOHU UHTXLUHV WKDW WKH ZDWHU ÀRZ UDWH WKURXJK LW UHPDLQ ZLWKLQ WKH OLPLWV VKRZQ LQ 7DEOH  DQ\ WLPH WKH ERLOHU LV ¿ULQJ $W ÀRZ UDWHV EHORZ WKH PLQLPXP VKRZQ WKH ERLOHU¶V ÀRZ VZLWFK DQGRU WHPSHUDWXUH ULVH OLPLW IXQFWLRQ PD\ SUHYHQW WKH ERLOHU IURP ¿ULQJ )ORZ UDWHV WKURXJK WKH ERLOHU LQ H[FHVV RI WKH PD[LPXP VKRZQ LQ Table 9.1 can result in excessive noise or erosion damage to piping There are two basic methods that can be used to pipe this boiler into the system.
  • Page 71 Example – A 120MBH model is to be connected to a heating system as shown in Figure 9.6. A total of 20 ft of straight pipe will be installed between the boiler and the system loop. &RXQW DOO ¿WWLQJV LQ WKH ERLOHU ORRS VKDGHG LQ )LJXUH   3 90 Elbows 2 Turn in Tee (under boiler- primary-secondary tees not counted) 2 Isolation Valves...
  • Page 73 Method 2: Direct Connection to Heating System (Generally NOT Recommended) In some relatively rare cases it may be possible to connect this boiler directly to the heating system as is done with FRQYHQWLRQDO ERLOHUV )LJXUH   ,I WKLV LV GRQH WKH ÀRZ UDWH WKURXJK WKH ERLOHU ZLOO HTXDO WKH ÀRZ UDWH WKURXJK WKH V\VWHP 7KH ÀRZ UDWH WKURXJK WKH V\VWHP PXVW WKHUHIRUH DOZD\V UHPDLQ ZLWKLQ WKH OLPLWV VKRZQ LQ 7DEOH  )RU WKLV UHDVRQ WKH pressure drop through the entire system must be known.
  • Page 74 Models with Taco 0013 Flow (GPM) FIGURE 9.8a: TACO NET CIRCULATOR PERFORMANCE CURVE Fig9.8b: Models with Grundfos 26 99 (Speed #3 Do not Use Speeds 1 or 2) Flow (GPM) FIGURE 9.8b: GRUNDFOS NET CIRCULATOR PERFORMANCE CURVE...

  • Page 75: Standard Piping Installation Requirements

    C: Standard Piping Installation Requirements Observe the following requirements when installing the boiler piping: 1) Relief Valve (Required) – The relief valve is shipped loose and must be installed in the location shown in Figure  XVLQJ WKH VLGH RXWOHW 7HH DQG RWKHU ¿WWLQJV SURYLGHG $60( 6HFWLRQ ,9 FXUUHQWO\ UHTXLUHV WKDW WKLV UHOLHI valve be installed above the heat exchanger as shown.
  • Page 76 10) Drain Valve (required) – Install the drain valve supplied as shown in Figure 9.9. 11) Low Water Cut-off (may be required by local jurisdiction) – Protection of this boiler against low water and/or LQDGHTXDWH ÀRZ LV SURYLGHG E\ WKH 8/ FHUWL¿HG ÀRZ VZLWFK EXLOW LQWR WKH ERLOHU 7KLV LV D ZDWHU WXEH ERLOHU DQG WKLV ÀRZ VZLWFK LV WKHUHIRUH WKH RQO\ HIIHFWLYH ZD\ WR SURYLGH VXFK SURWHFWLRQ 6HFWLRQ +* F RI WKH  $60( ERLOHU DQG 3UHVVXUH 9HVVHO &RGH UHFRJQL]HV WKH XVH RI D OLVWHG ÀRZ VZLWFK LQ OLHX RI D ORZ ZDWHU FXWRII RQ water tube boilers.

  • Page 77: Piping For Special Situations

    D. Piping for Special Situations 1) Systems containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a this boiler. Some examples include: ‡5DGLDQW V\VWHPV WKDW HPSOR\ WXELQJ ZLWKRXW DQ R[\JHQ EDUULHU ‡6\VWHPV ZLWK URXWLQH DGGLWLRQV RI IUHVK ZDWHU ‡6\VWHPV ZKLFK DUH RSHQ WR WKH DWPRVSKHUH If the boiler is to be used in such a system, it must be separated from the oxygenated water being heated with a heat exchanger as shown in Figure 9.10.

  • Page 78: Wiring

    X Wiring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
  • Page 79 The use of the pump outputs are as follows: a) System Pump - Pumps water through the radiation. This pump is hydraulically separated from the boiler pump, either by closely spaced tees, or by a hydraulic separator. The system pump is always on when the system is responding to a call IRU &+ 'HSHQGLQJ RQ WKH '+: FRQ¿JXUDWLRQ LW PD\ DOVR EH RQ GXULQJ D FDOO IRU '+: b) DHW Pump (“IWH Circulator”) - Pumps water directly through the indirect water heater.
  • Page 80 FIGURE 10.2: HIGH VOLTAGE PCB TERMINAL CONNECTIONS FIGURE 10.3: LOW VOLTAGE PCB TERMINAL CONNECTIONS...
  • Page 81 ‡ 2XWGRRU 6HQVRU  7DVVHURQ 76$$$ 2XWGRRU 7HPSHUDWXUH 6HQVRU  ‡ 2XWGRRU 6HQVRU  7DVVHURQ 76$$$ 2XWGRRU 7HPSHUDWXUH 6HQVRU  ‡ +HDGHU 6HQVRU  2SWLRQDO +RQH\ZHOO  6HQVRU  ‡ +HDGHU 6HQVRU  2SWLRQDO +RQH\ZHOO  6HQVRU  ‡ 02'%86  $ ‡...
  • Page 82 FIGURE 10.4: PROPER INSTALLATION OF HEADER SENSOR...
  • Page 83 120V Line Boiler Control (R7910B) F1 (6.3A Slow Blow) DHW(N) P3 4 DHW(L) P3 10 J4 2 J4 3 DHW Pump P3 11 J4 4 J4 5 L1 1 L1 2 P3 1 Grounded to Boiler Frame via PCB Standoff/Mounting Screw Boiler Pump SYS(L)
  • Page 84 FIGURE 10.6: INTERNAL WIRING CONNECTIONS DIAGRAM...

  • Page 86: Start-Up And Checkout

    XI Start-up and Checkout :$51,1* &RPSOHWHO\ UHDG XQGHUVWDQG DQG IROORZ DOO LQVWUXFWLRQV LQ WKLV PDQXDO EHIRUH DWWHPSWLQJ VWDUWXS 127,&( 6DIH OLJKWLQJ DQG RWKHU SHUIRUPDQFH FULWHULD ZHUH PHW ZLWK WKH JDV WUDLQ DVVHPEO\ SURYLGHG RQ WKH ERLOHU ZKHQ WKH ERLOHU XQGHUZHQW WKH WHVW VSHFL¿HG LQ = Use the following procedure for initial start-up of the boiler: 1) Verify that the venting, water piping, gas piping and electrical system are installed properly.
  • Page 87 '$1*(5 $VSK\[LDWLRQ +D]DUG )DLOXUH WR SURSHUO\ FRQYHUW WKLV ERLOHU IRU XVH RQ OS JDV FDQ FDXVH XQUHOLDEOH RSHUDWLRQ DW HOHYDWHG FDUERQ PRQR[LGH &2 OHYHOV UHVXOWLQJ LQ SHUVRQDO LQMXU\ RU GHDWK NOTICE To minimize the risk of premature heat exchanger failure, observe the following water chemistry requirements: 1) Minimize the introduction of make-up water, dissolved oxygen, and contaminants into the boiler by following the installation guidelines shown in the Water Quality and Boiler Water Additives Note on Page 64.
  • Page 88 MANUAL AIR VENT ATTACH 1/4" ID CLEAR TUBING TO HOSE BARB AND ROUTE TO SAFE PLACE AWAY FROM CONTROLS BEFORE OPENING VENT. FIGURE 11.1: LOCATION OF MANUAL AIR VENT 10) If the boiler is to be converted to propane (LP gas) or used at altitude above 2000ft, start-up and adjust throttle as described in Appendix A.
  • Page 89 PHNTM080 FIGURE 11.2a: HOME SCREEN AT POWER-UP (No Call for Heat) PHNTM080 FIGURE 11.2b: HOME SCREEN ON HEAT DEMAND PHNTM080 FIGURE 11.2c: HOME SCREEN WITH ACTIVE FAULT FIGURE 11.3: BURNER FLAME...
  • Page 90 :$51,1* $VSK\[LDWLRQ +D]DUG (DFK ERLOHU LV WHVWHG DW WKH IDFWRU\ DQG DGMXVWPHQWV WR WKH DLUIXHO PL[WXUH DUH QRUPDOO\ QRW QHFHVVDU\ ZKHQ RSHUDWLQJ RQ QDWXUDO JDV DW VHD OHYHO &RQVXOW WKH IDFWRU\ EHIRUH DWWHPSWLQJ WR PDNH DQ\ VXFK DGMXVWPHQWV ,PSURSHU JDV YDOYH RU PL[WXUH DGMXVWPHQWV FRXOG UHVXOW LQ SURSHUW\ GDPDJH SHUVRQDO LQMXU\ RU ORVV RI OLIH GXH WR FDUERQ PRQR[LGH &2 SRLVRQLQJ :$51,1* $VSK\[LDWLRQ +D]DUG 7KH RXWOHW SUHVVXUH IRU WKH JDV YDOYH KDV EHHQ IDFWRU\ VHW DQG UHTXLUHV QR ¿HOG...
  • Page 91 16) Perform a combustion test. Boilers are equipped with a screw cap in the vent adapter. Be sure to replace this cap when combustion testing is complete. Check CO (or O DQG &2 DW ERWK KLJK DQG ORZ ¿UH 7KH ERLOHU PD\ EH WHPSRUDULO\ ORFNHG LQWR KLJK RU ORZ ¿UH DV IROORZV a) From the Home Screen, press “MENU”...
  • Page 92 Lighting and Operating Instructions...

  • Page 93: Operation

    XII Operation A. General Information 7KLV ERLOHU XVHV WKH PLFURSURFHVVRU EDVHG +RQH\ZHOO 5% ³ERLOHU FRQWURO´ WR PDQDJH DOO ERLOHU IXQFWLRQV LQFOXGLQJ ÀDPH VXSHUYLVLRQ DQG PRGXODWLRQ 7ZR VHW SRLQW RU ³WDUJHW´ ERLOHU VXSSO\ WHPSHUDWXUHV DUH VWRUHG LQ WKH FRQWURO¶V PHPRU\ RQH IRU space heating (CH) and one for domestic hot water (DHW) production.
  • Page 94 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 95 2) Press the CH Button to access central heating options. These include: a) Setpoint Location  ,GHQWL¿HV WKH VHQVRU WKDW ZLOO EH XVHG WR REWDLQ WKH WDUJHW ZDWHU WHPSHUDWXUH ZKHQ WKH ERLOHU LV responding to a call for heat. Choices include: Supply (Generally Recommended) - Boiler attempts to obtain the target temperature during a call for heat at the ‡...
  • Page 96 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...
  • Page 97 :$51,1* %XUQ +D]DUG :DWHU WHPSHUDWXUHV RYHU ƒ) FDQ FDXVH SHUVRQDO LQMXU\ RU GHDWK GXH WR VFDOGLQJ &KLOGUHQ 'LVDEOHG DQG (OGHUO\ DUH DW PRVW ULVN RI EHLQJ VFDOGHG 7KLV ERLOHU LV QRW GHVLJQHG WR GLUHFWO\ FRQWURO GRPHVWLF ZDWHU WHPSHUDWXUH ‡ 8VH RQO\ WKH WKHUPRVWDW UHFRPPHQGHG E\ WKH LQGLUHFW ZDWHU KHDWHU PDQXIDFWXUH WR FRQWURO WKH '+: WHPSHUDWXUH ‡...
  • Page 98 , , FIGURE 12.2: PIPING FOR DHW OPTIONS #1 & 2 (ALSO SEE FIGURES 9.3A & 9.3B) , , , , FIGURE 12.3: PIPING FOR DHW OPTION #3...
  • Page 99 DHW Priority - Like all boilers, the Phantom 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 Phantom gives SULRULW\ WR WKH '+: GHPDQG IRU WKH ¿UVW  PLQXWHV GXULQJ ZKLFK ERWK FDOOV IRU &+ DQG '+: FRQWLQXRXVO\ H[LVW ,I WKHUH DUH still simultaneous calls for DHW and CH at the end of this time, the boiler will attempt to maintain the target CH temperature and operate the pump/s needed to satisfy the call for heat.
  • Page 100 Table 12.4: 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 System Pump used for DHW Pump CH only (Fig. 12.2). System Pump DHW priority pumping.
  • Page 101 FIGURE 12.5: SETTINGS MENU (SEE PART C FOR ADDITIONAL INFORMATION)
  • Page 102 FIGURE 12.6: OUTDOOR RESET CURVE (DEFAULT SETTINGS SHOWN) 3) DHW Settings - From the Settings Menu, press the DHW button to change the setpoint temperature when the boiler is responding to a call for DHW. The “DHW Setpoint” is the setpoint of the boiler supply temperature during a call for DHW. Control of the potable water temperature is accomplished using the thermostat on the storage type indirect water heater.
  • Page 103 D. Enter Service Contact Information If desired, the technician can enter contact information so that the owner knows who to contact for future service. To do this: 1) From the Main Menu, press the DIAGNOSTICS button. 2) From the Diagnostic Menu, press either the INSTALLER or MORE button (only one will be visible depending on whether you are “logged in”).
  • Page 104 & & FIGURE 12.7: DIAGNOSTIC MENU (SEE PART D AND SECTION XIV FOR ADDITIONAL INFORMATION)
  • Page 105 2) Current Priority Screen: a) Current Demand - The demand to which the boiler is currently responding. If more than one demand is present, it is the RQH KDYLQJ WKH KLJKHVW SULRULW\ 6HH DERYH GHVFULSWLRQV XQGHU ³+RPH 6FUHHQ´ IRU VSHFL¿F W\SHV RI &XUUHQW 'HPDQGV b) Setpoint - The temperature that the boiler is currently trying to achieve.
  • Page 106 FIGURE 12.8: STATUS MENU (SEE PART E FOR ADDITIONAL INFORMATION)
  • Page 107 5) Modulation Status Screen: a) Fan Speed - Current actual fan speed in RPM b) Setpoint - Current target fan speed in RPM c) Speed Control  ,QGLFDWHV WKH IXQFWLRQ FXUUHQWO\ FRQWUROOLQJ IDQ VSHHG DQG WKHUHIRUH ¿ULQJ UDWH  7\SLFDO SRVVLELOLWLHV include: ‡...

  • Page 108: Service And Maintenance

    XIII. Service and Maintenance :$51,1* ‡ $VSK\[LDWLRQ +D]DUG )LUH +D]DUG ([SORVLRQ +D]DUG 7KLV ERLOHU UHTXLUHV UHJXODU PDLQWHQDQFH DQG VHUYLFH WR RSHUDWH VDIHO\ )ROORZ WKH LQVWUXFWLRQV FRQWDLQHG LQ WKLV PDQXDO ‡ ,PSURSHU LQVWDOODWLRQ DGMXVWPHQW DOWHUDWLRQ VHUYLFH RU PDLQWHQDQFH FDQ FDXVH SURSHUW\ GDPDJH SHUVRQDO LQMXU\ RU ORVV RI OLIH 5HDG DQG XQGHUVWDQG WKH HQWLUH PDQXDO EHIRUH DWWHPSWLQJ LQVWDOODWLRQ VWDUWXS RSHUDWLRQ RU VHUYLFH ,QVWDOODWLRQ DQG VHUYLFH PXVW EH SHUIRUPHG RQO\ E\ DQ H[SHULHQFHG VNLOOHG DQG NQRZOHGJHDEOH LQVWDOOHU RU VHUYLFH DJHQF\...
  • Page 109 127,&( :DUUDQW\ GRHV QRW FRYHU ERLOHU GDPDJH RU PDOIXQFWLRQ LI WKH IROORZLQJ VWHSV DUH QRW SHUIRUPHG DW WKH LQWHUYDOV VSHFL¿HG 1) Continuously: Keep the area around the boiler free from combustible materials, gasoline and other ÀDPPDEOH YDSRUV DQG OLTXLGV Keep the area around the combustion air inlet terminal free from contaminates. Keep the boiler room ventilation openings open and unobstructed.
  • Page 110 FLEXIBLE GAS LINE WHEN DISCONNECTING FLEXIBLE GAS LINE CONNECTION PLACE A BACKUP WRENCH ON THIS NUT TO PREVENT DAMAGE TO THE GAS VALVE. FIGURE 13.0: DISCONNECTING FLEXIBLE GAS LINE BURNER DOOR MOUNTING NUT (FOUR PLACES) FLAME ROD IGNITION ELECTRODE FIGURE 13.1: FLAME IONIZATION ELECTRODE AND IGNITION ELECTRODE LOCATION...
  • Page 111 8QSOXJ WKH LJQLWLRQ JURXQG DQG ÀDPH URG ZLUHV IURP WKH LJQLWLRQ HOHFWURGH DQG WKH ÀDPH URG )LJXUH   Use a 10mm wrench to remove the four nuts VHFXULQJ WKH ¿UH GRRU WR WKH KHDW H[FKDQJHU )LJXUH   &DUHIXOO\ remove the door/blower/gas valve assembly from the heat exchanger, being careful not to damage the refractory insulation on the inside of the door (see Refractory Warning on next page) or the electrodes.
  • Page 112 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 113 FIGURE 13.2: IGNITION ELECTRODE GAP FIGURE 13.3: CONDENSATE TRAP EXPLODED PARTS VIEW...
  • Page 114 Refer to Part VII (Venting) to re-assemble any vent system components that are disassembled during this inspection. Also refer to Part VII for details on supporting, pitching, and terminating the vent system. Replace any wiring which has been disconnected. Inspect the hydronic system. Look for leaks and repair any found. If system contains antifreeze, or other additives, test and/or maintain them as directed by the additive manufacturer.

  • Page 115: Troubleshooting

    XIV. Troubleshooting '$1*(5 ‡ ([SORVLRQ +D]DUG (OHFWULFDO 6KRFN +D]DUG %XUQ +D]DUG 7KLV ERLOHU XVHV ÀDPPDEOH JDV KLJK YROWDJH HOHFWULFLW\ PRYLQJ SDUWV DQG YHU\ KRW ZDWHU XQGHU KLJK SUHVVXUH $VVXUH WKDW DOO JDV DQG HOHFWULF SRZHU VXSSOLHV DUH RII DQG WKDW WKH ZDWHU WHPSHUDWXUH LV FRRO EHIRUH DWWHPSWLQJ DQ\ GLVDVVHPEO\ RU VHUYLFH ‡...
  • Page 116 a) Soft Lockout  $ VRIW ORFNRXW SUHYHQWV WKH ERLOHU IURP ¿ULQJ XQWLO WKH SUREOHP KDV EHHQ FRUUHFWHG DQG LQ VRPH FDVHV D VSHFL¿HG DPRXQW RI WLPH XS WR  KRXU GHSHQGLQJ RQ WKH QDWXUH RI WKH IDXOW KDV SDVVHG $Q H[DPSOH RI WKH )DXOW 0HQX structure during a soft lockout is shown in Figure 14.0 b) Hard Lockout  $ KDUG ORFNRXW SUHYHQWV WKH ERLOHU IURP ¿ULQJ XQWLO WKH SUREOHP KDV EHHQ FRUUHFWHG $1' WKH ERLOHU KDV been manually reset.
  • Page 117 PHNTM080 FIGURE 14.0: EXAMPLE OF DIAGNOSTIC MENU DURING SOFT LOCKOUT APS Definitely Closed External Limits Definitely Closed Sump Switch/TF Definitely Open Flow Switch Could be Open or Closed FIGURE 14.1: READING LIMIT STATUS SCREEN...
  • Page 118 PHNTM080 214F Reset Boiler Here or at Sola Control FIGURE 14.2: EXAMPLE OF DIAGNOSTIC MENU DURING HARD LOCKOUT Thermal Fuse – The thermal fuse is designed to prevent boiler operation in the event that the heat exchanger is damaged by H[FHVVLYH ÀXH JDV WHPSHUDWXUHV ,W LV VHW WR RSHQ DW ) DQG LV D RQH VKRW QRQUHSODFHDEOH GHYLFH ,I WKLV IXVH RSHQV WKH KHDW H[FKDQJHU PXVW EH UHSODFHG 7KH WKHUPDO IXVH LV HVVHQWLDOO\ D EDFNXS WR WKH ÀXH JDV VHQVRU ZKLFK LV GHVLJQHG WR SUHYHQW ERLOHU RSHUDWLRQ LI WKH ÀXH JDV WHPSHUDWXUH H[FHHGV ) ...
  • Page 119 START Is display Is “ER**” present in completely upper left corner of dark? screen? Is boiler control’s green power light Is boiler fan Consult factory running at high speed? Loose or defective Loose or defective display harness wiring connection between the Is 120VAC present Mismatched display and boiler control software display and terminal J3 on...
  • Page 120 FLUE TEMPERATURE SENSOR THERMAL FUSE SUMP PRESSURE SWITCH PROVING SWITCH RETURN SENSOR GAS VALVE SUPPLY SENSOR FLOW SWITCH PUMP FUSE 24V FUSE COMBUSTION FAN FIGURE 14.4: CONTROLS LOCATION Air Proving Switch (APS) – This pressure switch is normally open and is connected to the outlet tapping on the gas valve as shown in Figure 14.5.
  • Page 121 FIGURE 14.5: PRESSURE SWITCH TUBING CONNECTIONS ‡ 6HL]HG RU GLVFRQQHFWHG ERLOHU SXPS ‡ %ORZQ 3XPS )XVH Supply Sensor – The boiler control infers the supply temperature based on the resistance measured at the supply sensor. Table D VKRZV WKLV UHVLVWDQFH DV D IXQFWLRQ RI ZDWHU WHPSHUDWXUH %HFDXVH WKH FRQWUROVXSSO\ VHQVRU LV XVHG DV WKH ERLOHU¶V ZDWHU temperature limit control, there are actually two “thermistors”...

  • Page 122: Temperature Sensor

    Table 14.6b: Outdoor Air Temperature Sensor Table 14.6a: Supply, Return and Flue Temperature versus Resistance Temperature Sensor Temperature versus Resistance Outdoor Temperature Ohms of Resistance °F °C Temperature Ohms of Resistance -28.9 106926 °F °C -23.3 80485 32624 -17.8 61246 19897 -12.2 47092...

  • Page 123: Parts

    XV Parts 7KH IROORZLQJ SDUWV PD\ EH REWDLQHG IURP DQ\ &URZQ GLVWULEXWRU 7R ¿QG WKH FORVHVW &URZQ GLVWULEXWRU FRQVXOW WKH DUHD Crown representative or the factory at: Crown Boiler Co. Customer Service P.O. Box 14818 Philadelphia, PA 19134 www.crownboiler.com NOTE ‡...
  • Page 124 QUANTITY PER BOILER OR CROWN QTY. OR PART NUMBER DESCRIPTION CROWN FIXING CLAMP BRACKET 2 EA 430003 430004 430005 430006 430006 HOLDING CLAMP 430002 2 EA 2 EA 2 EA 2 EA 2 EA M4 x 6mm FIXING CLAMP SCREW 900240 4 EA 4 EA...
  • Page 126 QUANTITY PER BOILER OR CROWN QTY. OR PART NUMBER DESCRIPTION CROWN M5 x 20mm SET SCREW 9000021 4 EA 4 EA 4 EA 4 EA 4 EA BLOWER OUTLET GASKET 430030 1 EA 1 EA 1 EA 1 EA 1 EA M5 LOCKNUT 900003 4 EA...
  • Page 127 Blower/Gas Valve Assembly for 80, 100, 120...
  • Page 128 Blower/Gas Valve Assembly for 150, 180...
  • Page 130 QUANTITY PER BOILER OR CROWN QTY. OR PART NUMBER DESCRIPTION CROWN GASKET, CONDENSATE TRAP 430105 1 EA 1 EA 1 EA 1 EA 1 EA CONDENSATE TRAP BRACKET 430106 1 EA 1 EA 1 EA 1 EA 1 EA CONDENSATE TRAP (INCLUDES 53A) 430100 1 EA 1 EA...
  • Page 134 QUANTITY PER BOILER OR CROWN QTY. OR PART NUMBER DESCRIPTION CROWN BASE-REAR PANEL 1 EA 430303 430303 430303 430304 430304 BOTTOM SECURING BRACKET 430420 1 EA 1 EA 1 EA 1 EA 1 EA HANGING BRACKET, BOILER 430435 1 EA 1 EA 1 EA 1 EA...
  • Page 136 QUANTITY PER BOILER OR CROWN QTY. OR PART NUMBER DESCRIPTION CROWN 3” STAINLESS STEEL RODENT SCREEN 230833 2 EA 2 EA 2 EA 2 EA 2 EA 3” X 30” SCHEDULE 40 CPVC PIPE 230823 1 EA 1 EA 1 EA 1 EA 1 EA 3”...

  • Page 138: Appendix A: Lp Gas Conversion Instructions

    Appendix A: Instructions for Conversion of This Boiler for Use with LP Gas and/or Altitudes above 2000ft '$1*(5 7KHVH LQVWUXFWLRQV LQFOXGH D SURFHGXUH IRU DGMXVWLQJ WKH DLUIXHO PL[WXUH RQ WKLV ERLOHU 7KLV SURFHGXUH UHTXLUHV D FRPEXVWLRQ DQDO\]HU WR PHDVXUH WKH &2 DQG &DUERQ 0RQR[LGH &2 OHYHOV LQ ÀXH JDV $GMXVWLQJ WKH DLUIXHO PL[WXUH ZLWKRXW D SURSHU FRPEXVWLRQ DQDO\]HU FRXOG UHVXOW LQ XQUHOLDEOH ERLOHU RSHUDWLRQ SHUVRQDO LQMXU\ RU GHDWK GXH WR FDUERQ PRQR[LGH SRLVRQLQJ :$51,1*...
  • Page 139 $OO 3KDQWRP ERLOHUV DUH IDFWRU\ FRQ¿JXUHG IRU XVH RQ 1DWXUDO JDV DW DOWLWXGHV EHORZ  IHHW 3HUIRUP WKH VWHSV OLVWHG LQ WKHVH instructions if either, or both, of the following are true: ‡ %RLOHU LV WR EH XVHG ZLWK /3 JDV ‡...
  • Page 140 :$51,1* ‡ 7KH WKURWWOH DGMXVWPHQWV VKRZQ LQ 7DEOH $ DUH DSSUR[LPDWH 7KH ¿QDO WKURWWOH VHWWLQJ PXVW EH IRXQG XVLQJ D FRPEXVWLRQ DQDO\]HU /HDYLQJ WKH ERLOHU LQ RSHUDWLRQ ZLWK D &2 OHYHO LQ H[FHVV RI 330 DLUIUHH FRXOG UHVXOW LQ LQMXU\ RU GHDWK IURP FDUERQ PRQR[LGH SRLVRQLQJ /HDYLQJ WKH ERLOHU LQ RSHUDWLRQ ZLWK D &2 OHYHO RXWVLGH RI WKH UDQJH VKRZQ LQ 7DEOH $ FRXOG DOVR UHVXOW LQ LQMXU\ RU GHDWK IURP FDUERQ PRQR[LGH SRLVRQLQJ HYHQ LI WKH ERLOHU LV RSHUDWLQJ DW DQ DLUIUHH &2 OHYHO EHORZ 330 GXULQJ WKLV DGMXVWPHQW SURFHGXUH...
  • Page 141 FIGURE A.1a: GAS VALVE DETAIL (80MBH THRU 120MBH) FIGURE A.1b: GAS VALVE DETAIL (150MBH, 180MBH) TABLE A.2: STARTING NUMBER OF THROTTLE TURNS FOR CONVERSION TO LP GAS MODEL # COUNTERCLOCKWISE TURNS (FROM FULLY CLOSED) 3-3/4 5-3/4 6-1/2...
  • Page 142 Home Screen (Password Access Revoked & When Operator Returns Here) Password Required Home Screen After Setting Altitude: x Pressing large button cycles through altitude ranges. x Press SET to save change x To restore original option before SET is pressed, press CANCEL or EXIT. Altitude ranges above 2000ft appear here in thousands of feet (2000 4500ft shown)
  • Page 143 TABLE A.4: ACCEPTABLE COMBUSTION READINGS 0D[ &2 $OORZDEOH &2 5HDGLQJV 330 $LU)UHH 0RGHO )XHO 6HD /HYHO   IW    IW    IW    IW $OO $OWLWXGHV 1DW *DV 8.7 - 9.3 8.7 - 9.2 8.7 - 9.1 8.7 - 9.1...

  • Page 144: Appendix B: Special Requirements For Side-Wall

    Appendix B: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT 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: (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the VLGH ZDOO H[KDXVW YHQW WHUPLQDWLRQ LV OHVV WKDQ VHYHQ  IHHW DERYH ¿QLVKHG JUDGH LQ WKH DUHD RI WKH YHQWLQJ LQFOXG- LQJ EXW QRW OLPLWHG WR GHFNV DQG SRUFKHV WKH IROORZLQJ UHTXLUHPHQWV VKDOO EH VDWLV¿HG...
  • Page 145 1. Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the SDUWV IRU YHQWLQJ WKH ÀXH JDVHV EXW LGHQWL¿HV ³VSHFLDO YHQWLQJ V\VWHPV´ WKH IROORZLQJ UHTXLUHPHQWV VKDOO EH VDWLV¿HG by the manufacturer:...
  • Page 146 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com PN 980125 Rev D, 12/14...

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