Crown Boiler MWC Series Installation Instructions Manual

Mwc series mid efficiency gas-fired hot water direct vent condensing boilers

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E S I G N E D

MWC Series

Mid

Efficiency Gas-Fired Hot Water

Direct Vent Condensing Boilers

InStallatIon InStruCtIonS

these instructions must be affixed on or adjacent to the boiler.

Models:

MWC116ENT

•

MWC116ELT

•

MWC116ENL

•

MWC116ELL

•

Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com

Manufacturer of Hydronic Heating Products

E S I G N E D

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

T O

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.

T O

E A D

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Page 1: Installation Instructions
E S I G N E D MWC Series Efficiency Gas-Fired Hot Water Direct Vent Condensing Boilers InStallatIon InStruCtIonS these instructions must be affixed on or adjacent to the boiler. Models: MWC116ENT • MWC116ELT • MWC116ENL • MWC116ELL • Manufacturer of Hydronic Heating Products Tel: (215) 535-8900 •...
Page 3: Table Of Contents
Air For Ventilation VII. Venting A. Vent System Design B. Removing An Existing Boiler From Common Chimney C. Assembly of Crown 60/100 Concentric Venting D. Assembly of Crown 80/125 Concentric Venting E. Condensate Trap and Drain Line VIII. Gas Piping...
Page 4: Product Description
The MWC Series are gas ﬁ red condensing boilers designed for use in forced hot water heating systems requiring supply water temperatures of 176F or less and return water temperatures greater than 86F. The primary heat exchanger is a copper water tube design. Additional heat is extracted from the ﬂ ue gas in a stainless steel secondary heat exchanger located down stream of the inducer.
Page 5 Figure 1.1: MWC Boiler Principle Components...
Page 6: Speciﬁ Cations
* Insert sufﬁ x “N” for natural gas and “L” for propane. Ratings are the same for both fuels (Example: MWC116ENT denotes Natural Gas, Combi). Using 60/100mm Concentric Vent System Supplied with the Boiler ...25 in. Using Optional 60/100mm Concentric Vent Components ...8ft -10in Using Optional 80/125mm Concentric Vent Components ...27 ft...
Page 7: Before Installing
Make sure that the boiler received is conﬁ gured for the correct gas (natural or LP). Make sure that the boiler is conﬁ gured for use at the altitude at which it is to be installed. This product must be installed by a licensed plumber or gas ﬁ tter when installed within the Commonwealth of Massachusetts.
Page 8 Clearance From Hot Water Pipes To Combustibles = 1” Figure 4.1: Clearances To Combustible Or Non-combustible Material...
Page 9: Mounting The Boiler
A hot water boiler installed above radiation level or as the Authority having jurisdiction, must be provided with a low water cutoff device either as a part of the boiler or at the time of installation. V Mounting The Boiler...
Page 10 Figure 5.1 Wall Mounting Hole Locations...
Page 11 Figure 5.2 Boiler Mounting...
Page 12: Air For Ventilation
To ensure an adequate ventilation air supply, perform the following steps: Step 1: Determine whether the boiler is to be installed in a conﬁ ned space - A conﬁ ned space is deﬁ ned by National Fuel Gas Code ,ANSI Z223.1.
Page 13 Where screens are used, they must be no ﬁ ner than ¼” (4 x 4) mesh. Step 2b: If the boiler is to be placed in an unconﬁ ned space the natural inﬁ ltration into the boiler room will provide adequate air for ventilation without additional openings into boiler room.
Page 14: Venting
See Table 7.1 or 7.6 for the maximum vent length. In horizontal vent systems, the lengths shown in Table 7.1 are in addition to the Elbow Adaptor on top of the boiler. If more elbows are desired, the maximum allowable vent length must be reduced by the amount shown in Table 7.5 for each additional elbow used.
Page 15 • If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if these terminals are subjected to winds in excess of 40 mph. •...
Page 16 THROUGH STRUCTURE 60/100 mm VENT PIPE SIZE CONCENTRIC INLET AIR ORIFICE SIZE MAX. VENT LENGTH MIN. VENT LENGTH VENT TERMINAL (INCLUDED WITH BOILER) VENT MATERIAL Figure 7.2: Horizontal Concentric Venting (Vent Options 1-3) HORIZONTAL HORIZONTAL CONCENTRIC CONCENTRIC WALL WALL 60/100 mm...
Page 17 2) Sloped roof ﬂ ashing suitable for roof angles between 25 and 45 degrees. 3) Used at base of vertical run inside unused masonry chimney. USED ON SIZE VENT OPTION # 60/100mm INCLUDED WITH STANDARD BOILER 60/100mm 60/100mm INCLUDED WITH STANDARD BOILER 60/100mm INCLUDED WITH STANDARD BOILER 60/100mm...
Page 18 Figure 7.4a: Location Of Vent Terminal Relative To Windows, Doors, Grade Figure 7.4b: Location Of Vent Terminal Relative To Meters And Forced Air Inlets Figure 7.4c: Positioning Vent Terminal Under Overhangs...
Page 19 Pitch of Horizontal Piping - Pitch all horizontal piping so that any condensate which forms in the piping will run towards the boiler. Pitch Crown horizontal concentric venting 5/8” per foot Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported. Support Crown concentric venting near the female end of each straight section of pipe.
Page 20 Figure 7.7: Vertical Concentric Vent System (Vent Option 5)
Page 21: Removing An Existing Boiler From Common Chimney
B. Removing an Existing Boiler From a Common Chimney Read this only if the MWC boiler is replacing an existing boiler that is being removed from a common chimney. This section does not apply to the installation of a MWC boiler.
Page 22: Assembly Of Crown 60/100 Concentric Venting
Start by attaching the elbow adaptor (or straight adaptor, if used instead) to the top of the boiler using the gasket and four 4.2mm sheet metal screws provided in the vent kit as shown in Figure 7.20. For V 82mm air inlet oriﬁ...
Page 23 FIGURE 7.20: INSTALLATION OF 60/100 ADAPTORS ON BOILER FIGURE 7.21: DIMENSION “L”...
Page 24 If additional pieces of pipe are used, install them starting at the boiler elbow. Support each section of straight pipe at its female end. Use locking bands provided to join adjacent sections of non-cuttable pipe as well as ﬁ ttings. The male end of the terminal section and other cuttable sections must be held to the female end of the adjoining pipe with at least three #10 x 1/2”...
Page 25 Figure 7.24: Preparing 60/100mm Terminal Section For Installation In The Wall Figure 7.25: Attaching 60/100mm Terminal Section...
Page 26: Assembly Of Crown 80/125 Concentric Venting
80/125mm vent systems. The components listed in Table 7.3b are required for 80/125mm installations and are not supplied with the boiler. Before starting assembly of an 80/125mm vent system, make sure that the planned installation is in accordance with the “Vent System Design” section of this manual and that all required 80/125mm vent components are on hand.
Page 27 Installation of the MWC116 with 80/125mm venting requires the use of the 80/125mm appliance adaptor (Crown PN 340523). This adaptor is installed on top of the boiler as shown in Figure 7.30. For vent options 3 and 5, sandwich the 82mm air inlet oriﬁ ce between the boiler and the adaptor as shown.
Page 28 Push the male end of the ﬁ rst ﬁ tting into the boiler collar until it bottoms out. The male end of cuttable sections should go 1” into the collar until the insertion mark (made in Step 3d above) is covered. On other ﬁ...
Page 29 Figure 7.33a: Joining Cuttable Pipe Figure 7.33b: Joining Non-Cuttable Pipe...
Page 30 80/125mm Horizontal Terminal Installation Cut a 5-1/2” diameter hole through the exterior wall at the planned location of the horizontal terminal. Measure distance “L” from the outside surface of the exterior wall to the end of the last ﬁ tting as shown in Figure 7.34a.
Page 31 Figure 7.34c: Cutting Inner Pipe Of 80/125mm Horizontal Terminal Figure 7.34d: Completing 80/125mm Horizontal Terminal Installation...
Page 32 If the roof is sloped, cut a hole large enough for the terminal to pass through the roof while remaining plumb. Caution: If the boiler is installed directly under the hole, cover it while cutting the hole to prevent saw dust and other debris from falling into the boiler.
Page 33 Figure 7.35b: Cutting Vertical Terminal Figure 7.35c: Completing Vertical Terminal Installation...
Page 34 • Do not attempt to construct a vertical vent system inside a chimney that is used to vent a ﬁ replace or other appliances. • Do not attempt to construct a vertical vent system inside a chimney ﬂ ue adjacent to another ﬂ...
Page 35: Condensate Trap And Drain Line
All condensate which forms in the boiler or vent system leaves the boiler through the condensate trap. This trap allows condensate to drain while retaining ﬂ ue gases in the boiler. This boiler is supplied with a length of drain hose already attached. Route this hose to a drain or other suitable location to dispose of the condensate.
Page 36: Gas Piping
Gas piping to the boiler must be sized to deliver adequate gas for the boiler to ﬁ re at the nameplate input at an inlet pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or the National Fuel Gas Code Natural Gas and Propane Installation Code.
Page 37 Figure 8.2: Gas Connection To Boiler...
Page 38: System Piping
Relief valve (Included & Required) in Figure 9.3. The relief valve shipped with the boiler is set to open at 30 psi. This valve may be replaced with one having a setting at or below the Maximum Allowable Working Pressure (MAWP) shown on the ASME plate attached to the heat exchanger.
Page 39 As shipped, the expansion tank is suitable for installations where the vertical distance between the relief valve and the highest point in the system is 23ft or less. Consult the factory if it is desired to install this boiler on a system having a greater height.
Page 40 ﬁ tting bag along with gaskets. Sweat the ﬁ rst copper ﬁ ttings to these tail pieces and then connect the tail pieces to the boiler using the gaskets provided. If required, install the ﬂ ow restrictor in the supply as shown in Figure 9.4.
Page 41 ﬂ ow rate must be greater than 5.5 GPM. In these cases, the piping shown in Figure 9.5 is used so that the ﬂ ow through the system is completely independent of the ﬂ ow through the boiler. This ensures reliable operation of the boiler’s ﬂ...
Page 42 Figure 9.5: Primary-Secondary Piping Figure 9.6: Chiller Piping...
Page 43 Figure 9.7: MWC116E*T (Combi) Internal Boiler-Side Piping Schematic...
Page 44 Figure 9.8: MWC116E*L (Heat-Only) Internal Piping Schematic...
Page 45: Domestic Water Piping
Figure 10.1. Connections to the boiler are made with 1/2” copper tail pieces as shown in Figure 10.2. Solder the ﬁ rst ﬁ tting to these tail pieces before mounting them on the boiler. The components in this...
Page 46 Figure 10.1: DHW Piping Figure 10.2: DHW Tailpiece Installation...
Page 47 Figure 10.3: MWC116E*T (Combi) Internal DHW-Side Piping Schematic...
Page 48: Wiring
This Whip is designed to provide proper strain relief at the boiler and also permits the control box to be easily slid in and out of the boiler with all wiring connections intact. A 7/8 hole is located in the metal rail behind the control box as shown in Figure 11.3.
Page 49 Figure 11.1: Accessing Electrical Connections Field Supplied J-Box End Boiler End Figure 11.2: “Whip”...
Page 50 Figure 11.3: Location of Terminal Blocks and 7/8 Hole for Whip Figure 11.4: Electrical Connections Inside Control Box.
Page 51 Figure 11.5: Field Wiring - 120VAC Thermostat Figure 11.6: Field Wiring - 24V Thermostat Using Installer-Supplied Fan Center...
Page 52 - green gnye - green / yellow gy - grey or - orange rd - red wh - white vt - violet ye - yellow Figure 11.7: Internal Boiler Wiring Safety Air pressure Ignition thermostat switch electrodes gnye gnye...
Page 53: Start-Up And Checkout
Replace the shaft cover screw. At the end of the purging process, make sure that the pressure gauge on the boiler reads between 5 and 19 psi.
Page 54 Rotate the Heating System Knob clockwise from “0” to the maximum supply water temperature setting (at approximately 5:00) . Lamp should light after approximately 15 - 30 seconds. Once the boiler has lit, Lamps 1 and 3 will ﬂ ash continuously.
Page 55 Other possibilities include inadequate inlet gas pressure or a boiler that is conﬁ gured for the wrong fuel. If the boiler does not light on the ﬁ rst try, it will go into a lockout condition.
Page 56 Check the low ﬁ re manifold pressure. To do this, turn off the boiler and remove one of the modulation leads (Figure 12.6). Turn the boiler back on. Read the low ﬁ re manifold pressure. It should be set at: The gas valve manifold pressures are factory set and should rarely need to be adjusted.
Page 57 Figure 12.5: Inner Cover Removal Figure 12.6: Gas Pressure Taps Figure 12.7: Gas Pressure Adjustments (Pry Off Transparent Cover to Access)
Page 58 MWC Series Lighting and Operating Instructions...
Page 59 Check the entire gas train for leaks. Fix any leaks found immediately. Run the gas valve safety shut-down test. With the boiler ﬁ ring, close the gas cock upstream of the boiler. The gas valve should close as soon as loss of ﬂ ame is detected (within a few seconds of closing the gas cock).
Page 60: Operation
• - Boiler will not respond to a call for heat or domestic hot water (DHW). The boiler will ﬁ re, if necessary, to protect itself from freezing. In addition, it will operate the circulator and the 3-way valve for a few seconds every 24 hours to prevent these devices from sticking.
Page 61 Figure 13.2: Heating System Knob Since a room thermostat will almost always be used to initiate a call for heat (either directly or through zone controls), it is generally recommended that the Heating System Knob be left at the appropriate Target Supply Temperature year round. Figure 13.3: Domestic Hot Water (DHW) Thermostat The domestic water thermostat on the Maui is not intended to serve as a scald protection device.
Page 62: Sequence Of Operation
The ignition module generates an ignition spark and opens the valve. The presence of ﬂ ame is detected through a separate ﬂ ame rod. If no ﬂ ame is detected after 10 seconds, the boiler will go into lockout. If the ﬂ ame is proven and this proof is subsequently lost at any point during the burner cycle, the boiler will attempt to re-light once, then go into lockout.
Page 63 (See Part XV for Error Codes) Lamp Number (Short pulse every 4 seconds): Heating System Knob in “Off” position. Boiler will not respond to call for heat or DHW. Frost protection and pump/valve exercise function still active (1 second pulse every 2 seconds): Heating System Knob set to target supply temperature.
Page 64: Service And Maintenance
: In addition to the inspections listed above the following should be performed by a qualiﬁ ed service technician once every year: Follow the procedure for turning the boiler off found in the MWC Series Lighting and Operating Instructions. Inspect the wiring to verify the conductors are in good condition and attached securely.
Page 65 CO in ﬂ ue gas (see Start-up section). A CO “sniffer” designed for testing CO levels in ambient air cannot be used to check boiler combustion. A normal CO reading for an MWC series boiler is less than 50ppm (0.005%). A higher reading is indicative of a combustion problem.
Page 66: Service Notes
ﬁ re, when the switch signal exceeds the “make setting” shown below. Once the switch is made, the boiler will ﬁ re as long as the pressure at the switch is above the “break setting” shown below.
Page 67 Figure 14.3: Condensate Trap Removal Figure 14.4: Location of Pressure Switch Taps and Limit Reset Buttons...
Page 68: Troubleshooting
Turn off power to boiler before replacing fuses or working on wiring. Table 15.1: No Error Code Displayed CONDITION Boiler does not run, no lights are on or ﬂ ashing Lamp 1 ﬂ ashes every two seconds, but boiler does not respond to a call for heat.
Page 69 Lamp OFF Lamp ON Table 15.3: Error Codes Corrective Action Reset the boiler by turning the Heating System Knob to “0” for a few seconds, then returning it to its original position. Then: • Verify that that boiler and system are purged of air •...
Page 70 Supply Temp Limit was open and will probably open again. Look for: * A problem with the supply sensor Reset Boiler * Water-side blockage in one of the boiler heat exchangers or internal boiler piping Is 120VAC present across Inducer?
Page 71: Parts
The following parts may be obtained from any Crown distributor. To ﬁ nd 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 C.h. return group and d.h.w. heat exchanger (Model combi)
Page 72 C.h. flow group and three way diverter valve (Model combi) 23 (lower part) * Includes items 23, 28, 29, 30, 31, 32, 20, 36 23 (upper part) 30 31 32...
Page 73 C.h. flow and return groups (Model c.h. only) 147* * Includes items 20, 28, 29, 30, 31, 32, 36 30 31 32...
Page 74 Pump and main circuit assembly (Model combi)
Page 75 Pump and main circuit assembly (Model c.h. only)
Page 76 Gas assembly...
Page 77 Connection pipes * Not for model c.h. only...
Page 78 Control panel and ignition device (Model combi)
Page 79 Control panel and ignition device (Model c.h. only)
Page 80 Wiring (Model combi)
Page 81 Wiring (Model c.h. only)
Page 82 Fan, combustion chamber and case panels...
Page 83 Key no. Description O-ring gasket 1,78x15,6 Drainage valve O-ring gasket 17,04x4,00 mm Screw M5x25 mm - Hexagon socket cap Return group kit (Model combi) Domestic water restrictor Flat gasket 3/4" Toothed lock washer external 6,4 mm Screw M6x8 mm - BZP RPH Flat gasket 1/2"...
Page 84 Key no. Description Main exchanger connection clip Condensing heat exchanger inlet pipe Automatic air purger valve Pump connection fork Fork Fork Fork Screw 5X16 Pump (complete) Pump gasket Main exchanger outlet pipe (Model combi) Probe holder O-ring gasket 2,62X9,92 mm Expansion vessel connection pipe Flat gasket 3/8"...
Page 85 Key no. Description Screw 3,5x16 mm self tap RPH Electronic control - ignition p.c.b. Fuse 2AF Service panel cover Control panel cover Screw 3,5X9,5 mm self tap RPH Flame detection electrode cable Detection to trap wiring Full nut M5 Hexagon Toothed lock washer external 5,3x10 mm stainless Machine Screw M5x10 mm Recessed Pan Head Trap to earth wiring...
Page 86: Appendix A Special Requirements For Side-Wall
Key no. Description Flue thermostat Twin ﬂ ue cover plate Gasket - Air intake twin kit Air restrictor d. 45 mm Return group (Model c.h. only) By-pass pipe (Model c.h. only) Flow group kit (Model c.h. only) Safety valve connection pipe (Model c.h. only) Main exchanger outlet pipe (Model c.h.
Page 87 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certiﬁ ed. 3. SIGNAGE. A metal or plastic identiﬁ cation plate shall be permanently mounted to the exterior of the building at a mini- mum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
Page 88 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com...

This manual is also suitable for:

Mwc116ell Mwc116elt Mwc116enl Mwc116ent

Crown Boiler MWC Series Installation Instructions Manual

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