Crown Boiler BWC Series Installation Instructions Manual
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Crown Boiler BWC Series Installation Instructions Manual

Bwc series high effi ciency gas-fired hot water direct vent condensing boilers
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D
E S I G N E D
BWC Series
High Effi ciency Gas-Fired Hot Water
Direct Vent Condensing Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affi xed on or adjacent to the boiler.
Models:
BWC150
•
BWC225
•
Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com
Manufacturer of Hydronic Heating Products
D
E S I G N E D
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
L
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 qualifi ed installer, service agency or the gas supplier.
This boiler requires a special venting system. Read these
instructions carefully before installing.
L
T O
E A D
E A D

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  • Page 1: Installation Instructions

    E S I G N E D BWC Series High Effi ciency Gas-Fired Hot Water Direct Vent Condensing Boilers INSTALLATION INSTRUCTIONS These instructions must be affi xed on or adjacent to the boiler. Models: BWC150 • BWC225 • Manufacturer of Hydronic Heating Products Tel: (215) 535-8900 •...

  • Page 3: Table Of Contents

    Specifications III. Before Installing Locating The Boiler Air For Ventilation Venting Vent System Design Removing An Existing Boiler From Common Chimney 14 Vent/Intake System Assembly VII. Gas Piping VIII. System Piping General System Piping Precautions System Design Standard Piping Installation Requirements...

  • Page 4: Ii. Specifications

    180°F or less. This boiler may be vented vertically or horizontally with combus- tion air supplied from outdoors. This boiler is not designed for use in gravity hot water systems or systems contain- ing significant amounts of dissolved oxygen.

  • Page 5: Iv. Locating The Boiler

    5) Make sure that the boiler received is configured for the correct gas (natural or LP). 6) Make sure that the boiler is configured for use at the altitude at which it is to be installed. This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts.
  • Page 6 Figure 4.1: Clearances To Combustible Or Non-combustible Material Table 4.2: Clearances From Vent Piping To Combustible Construction TYPE OF VENT PIPE PIPE DIRECTION HEAT FAB SAF-T VENT PROTECH FASNSEAL VERTICAL OR Z-FLEX Z-VENT III HORIZONTAL FLEX-L STAR-34 HEAT FAB SAF-T VENT PROTECH FASNSEAL HORIZONTAL OR VERTICAL Z-FLEX Z-VENT III...

  • Page 7: V. Air For Ventilation

    3) Divide the volume of the boiler room by the input in thousands of BTU/hr. If the result is less than 50, the boiler room is a confined space.
  • Page 8 • If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per 1000 BTU/hr of total appliance input, install a pair of identical openings into a third room. Connect addi- tional rooms with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input.

  • Page 9: Vi. Venting

    * Do not attempt to vent this boiler with galvanized, PVC, or any other vent system not listed in Table 4. * Do not attempt to mix components from different approved vent systems.
  • Page 10 The Vent Option #1 column in Table 6.2a describes a horizontal direct vent system using 3” vent pipe. From this column, we see that a BWC150 may have a vent length of up to 55ft. The first 90 elbow and the termination elbow are not considered.
  • Page 11 • Maintain the correct clearance and orientation between the vent and air intake terminals. The vent and air intake terminals must be at the same height and their center lines must be between 12 and 36 inches apart. Both terminals must be located on the same wall.
  • Page 12 FIGURE 6.3a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 6.3b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS FIGURE 6.3c: POSITIONING VENT TERMINAL UNDER OVERHANGS...
  • Page 13 • 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 the terminal is subjected to winds in excess of 40 mph. • Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools.
  • Page 14 TABLE 6.2b: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # CLASSIFICATION USED IN THIS MANUAL ILLUSTRATED IN FIGURE VENT PIPE STRUCTURE PENETRATION AIR INTAKE PIPE STRUCTURE PENETRATION VENT PIPE SIZE AIR INTAKE PIPE SIZE BWC150 BWC225 BWC150 BWC225 EXHAUST TERMINAL AIR INTAKE TERMINAL VENT MATERIAL AIR INTAKE MATERIAL...
  • Page 15 TABLE 6.5: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS MANUFACTURER VENT SYSTEM SAF-T VENT HEAT FAB EZ SEAL PROTECH SYSTEMS FASNSEAL INC. Z-FLEX SERIES III (“Z-VENT III”) FLEX-L INTL. STAR-34 NOTE: See vent system manufacturer’s literature for other part numbers that are required such as straight pipe, elbows, firestops and vent supports.

  • Page 16: Vent/Intake System Assembly

    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. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
  • Page 17 Bend the three hose clamp tabs on this collar outward slightly. c) Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler. Use a cleaner such as Methyl Ethyl Keytone (MEK) or naptha.
  • Page 18 Bend the three hose clamp tabs on this collar outward slightly. c) Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler. Remove dirt, grease, and moisture from the surfaces to be sealed. Dry surfaces or allow to dry thoroughly.
  • Page 19 1” into the collar. Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler with an alcohol pad. On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately ½...
  • Page 20 ¼” wide bead of high temperature silicone approximately 1/4 inch from the male end of the pipe. Insert the male end of the pipe into the boiler vent collar until it bottoms out. Apply an additional bead of silicone over the outside of the joint and the seams on the vent collar and smooth out (Fig 6.10).
  • Page 21 flue gases in the boiler. A length of drain hose is supplied with the boiler and is connected to the trap as shown in Figure 6.11. This hose may be routed through the back of the boiler or to either side through the knockouts provided.

  • Page 22: Vii. 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 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.

  • Page 23: Viii. System Piping

    Table 8.1 any time the burner is firing. Failure to maintain the flow within these limits could result in erratic operation or premature boiler failure. There are three basic methods that can be used to pipe the BWC boiler. The instructions on the following pages describe three alternative methods for piping BWC boilers and explain how to size the circulator and piping for each one.
  • Page 24 first secondary tee and 4 diameters downstream of the second secondary tee. Keep the distance between the expansion tank and the first secondary tee as short as practical. 2) Secondary Loop (“Boiler Loop”) Piping – All piping must be the size shown for the boiler in Table 8.5, column a. To size the circulator: a) Count all fittings in the planned secondary loop (the secondary loop consists of the shaded piping in Figure...
  • Page 25 Figure 8.2: Piping Method #1 - Heat Only Figure 8.3: Piping Method #1 - Heat + Indirect Water Heater...
  • Page 26 Figure 8.4a: Piping Method #1 - Secondary Loop Piping (Shaded) Figure 8.4b: Piping Method #1 - Indirect Water Heater Loop Piping (Shaded)
  • Page 27 BWC150 BWC225 BWC225 NOTE: For piping method #1, “boiler loop” is heating system secondary loop For piping method #2, “boiler loop” is heating system primary loop TABLE 8.6: PIPE AND CIRCULATOR SIZING FOR INDIRECT WATER HEATER LOOP BOILER PIPE SIZE...
  • Page 28 TABLE 8.7: FITTING EQUIVALENT LENGTHS PIPE SIZE FITTING 90 ELBOW 1 1/4 TURN IN TEE 1 1/4 RUN OF TEE 1 1/4 SWING CHECK 1 1/4 GATE VALVE 1 1/4 EQUIVALENT LENGTH (ft) 3.75 8.00 2.50 10.00 0.80...
  • Page 29 Pressure drop curves for the BWC Series boilers are shown in Figure 8.12. Calculation of the system pressure drop, and selection of the circulator, must be performed by someone having familiarity with pressure drop calculations, such as an HVAC...
  • Page 30 Figure 8.8: Piping Method #2 - Heat Only Figure 8.9: Piping Method #2 - Heat + Indirect Water Heater...
  • Page 31 Figure 8.10a: Piping Method #2 - Secondary Loop Piping (Bolded) Figure 8.10b: Piping Method #2 - Primary Loop Piping (Bolded)
  • Page 32 Figure 8.10c: Piping Method #2 - Indirect Water Heater Loop Piping (Bolded) Figure 8.11: Piping Method #3 - Direct Connection of Boiler to Heating System...

  • Page 33: Standard Piping Installation Requirements

    Observe the following guidelines when making the actual installation of the boiler piping: 1) The relief valve is packaged loose with the boiler and must be installed in the location shown in Figure 1. The relief valve is set to open at 30 psi. If the valve is replaced, the replacement must have a relief capacity in excess of the DOE heating capacity for the boiler.

  • Page 34: Piping For Special Situations

    4) Circulator (Required) - Usually at least two circulators will be required to properly install a BWC Series boiler. See previous section (System Design) for information on sizing the circulators.
  • Page 35 Figure 8.13: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger Figure 8.14: Chiller Piping...

  • Page 36: Ix. Wiring

    OLD THERMOSTAT WIRING. 4) If the outdoor sensor is connected to terminals 5 and 6, the boiler will adjust the target space heating set point supply water temperature downwards as the outdoor air temperature increases. If used, this sensor should be located on the outside of the structure in an area where it will sense the average air temperature around the house.
  • Page 38 Figure 9.2: Ladder Diagram...
  • Page 39 Figure 9.3: Wiring of Isolation Relay for Control of Two Heating Circulators...

  • Page 40: X. Start-Up And Checkout

    SPECIFIED IN Z21.13. Use the following procedure for initial start-up of the boiler: 1) If not already done, flush the system to remove sediment, flux, and traces of boiler additives. This should be done with the boiler isolated from the system.

  • Page 41: Operating Instructions

    Turn the external boiler manual gas valve T- handle counterclockwise to open gas supply. Smell for gas in the boiler enclosure. If you smell gas, STOP! Follow "B" in the safety information above. If you don't smell gas, go to the next step.
  • Page 42 flame is established. If more than 5 tries for ignition are needed, it will be necessary to press the reset button to restart the boiler. Once a flame has been established for the first time, subsequent calls for burner operation should result in a flame on the first try.
  • Page 43 If it is removed, be sure to return the flue gas temperature sensor to its original position after combustion testing is complete. Check CO2 (or O2) and CO at both high and low fire. The boiler may be temporarily locked into high or low fire for 15 minutes as follows: a) To lock the boiler in high fire, simultaneously press and hold the “Mode”...
  • Page 44 12) Test any external limits or other controls in accordance with the manufacturer’s instructions. 13) Verify that the boiler starts and stops in response to calls for heat from the heating thermostat and indirect wa- ter heater thermostat. Make sure that the appropriate circulators also start and stop in response to the thermostats.
  • Page 45 Under normal conditions, the boiler is in standby mode and the display looks like that shown in Figure 11.1. The three digits to the right of the decimal point are the boiler’s supply temperature. The digit to the left of the decimal point is the boiler’s status code.
  • Page 46 (either heat or DHW). If an outdoor sensor is connected to the boiler, and the boiler is responding to a call for heat, this value will be the current point on the reset curve. When no call for heat or DHW is present, Step 6 shows the heating supply set point.
  • Page 47 Used Used Used Steps Between made been change that indicating released STORE when Flash will Setting Decreases Setting Increases Parameters Between Toggle Display MCBA. setting Saves Toggle...
  • Page 48 3 and 4 when adding an external limit control to the system. If the external limit opens, the boiler will shut down and error code “b 26” will be displayed. If the limit installed is a manual reset type, it will need to be reset before the boiler will operate.
  • Page 49 7) The sequence of operation for a BWC series boiler on a call for heat from a thermostat is as described below: a) When power is first turned on, 120V is provided to the MCBA, the combustion fan and the LWCO trans- former.

  • Page 50: Xii. Service And Maintenance

    If the yellow light does not come on, determine why the low water cutoff is not working properly. Follow the procedure for turning the boiler off found in the BWC Series Lighting and Operating Instructions. Inspect the wiring to verify the conductors are in good condition and attached securely.
  • Page 51 Reconnect any wiring which has been disconnected. Qualified service personnel should thoroughly inspect the heating system and correct any deficiencies prior to restarting the boiler. Follow Section X Start-up and Checkout instructions before leaving installation. Perform the combustion test outlined in Section X.

  • Page 52: Xiii. Troubleshooting

    TURN OFF POWER TO BOILER BEFORE REPLACING FUSES OR WORKING ON WIRING. A. Troubleshooting problems where no error code is displayed: Table 13.1: No Error Code Displayed CONDITION Display Blank, Fan off, LWCO lights off Display Panel Blank, Fan running Display reads “U.125”...
  • Page 53 B. Trouble shooting problems where a soft lockout code is displayed. When a soft lockout occurs, the boiler will shut down and the display will alternate between the number “9” and the letter “b” followed by a two digit service code. The boiler will automatically restart once the condition that caused the lockout is corrected.

  • Page 54: Hard Lockout Codes Displayed

    flash the letter “E” followed by a two digit service code. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset using the RESET button on the display.

  • Page 55: 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 XIV Parts...
  • Page 56 Right Side Panel Assembly 5/16 ID Cable Clamp Left Side Panel Assembly 3/4” Boiler Drain Valve 1-1/4” x 3/4” x 1-1/4” Bk Reducing Tee Vinyl Grommet - .1.625” ID (For 2.625” Hole) M6 x 1.0 x 12 Hex Hd Cap Screw...
  • Page 57 Terminal Block .375” c/c, 9-Pole Pressure Switch 40VA Transformer (LWCO Power Supply) Boiler Control Module (Natural Gas - Sea Level) Boiler Control Module (LP Gas - Sea Level) 50VA Transformer (Boiler Control Module) M5 x 0.8 x 25mm, Set Screw 77b1 M5 x 0.8 x 30mm, Set Screw...
  • Page 62 DESCRIPTION #6-32 x 13mm Hex x 92mm, Long Standoff M6 x 1.0 x 75mm, Hex Head Screw Manifold Seal Ring, EPDM M6 x 1.0 x 30mm, SS Hex Socket Set Screw M6 x 1.0, Lock Washer M4 x 0.7 x 12mm, Phillips Pan Head Mach. Screw M4 x 0.7 x 20mm, SS Hex Socket Set Screw M4 x 0.7, Hex Nut, NP M6 x 1.0 x 35mm, SS Hex Socket Set Screw...
  • Page 64 DESCRIPTION Not Shown 11-1/2” Releasable Nylon Cable Wire Tie Not Shown 6” Nylon Wire Tie Not Shown 1-5/8” Hole Plug Not Shown 5mm x 20mm Fast Acting, Ceramic Tube, 5 Amp Fuse Not Shown 5mm x 20mm Time Delay, Glass Tube, 4 Amp Fuse Not Shown 1/2”...

  • Page 68: Appendix A Special Requirements For Side-Wall

    Appendix A: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts 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: 1. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: If there is not already one present, on each floor level where there are bedroom(s), a carbon...
  • Page 70 Manufacturer of Hydronic Heating Products E S I G N E D E A D P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com PN: 980040 BWC - 08/05...

This manual is also suitable for:

Bwc150Bwc225

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