Crown Boiler BWC151 Installation Instructions Manual
  1. Manuals
  2. Brands
  3. Crown Boiler Manuals
  4. Boiler
  5. BIMINI BUDDY BWC151
  6. Installation instructions manual

Crown Boiler BWC151 Installation Instructions Manual

Bwc series high efficiency gas-fired hot water direct vent condensing boilers
Hide thumbs Also See for BWC151:
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Related Manuals for Crown Boiler BWC151

Summary of Contents for Crown Boiler BWC151

  • Page 3: Table Of Contents

    Table of Contents Product Description Specifications III. Before Installing Locating The Boiler Mounting The Boiler Air For Ventilation VII. Venting A. Vent System Design B. Removing An Existing Boiler From Common Chimney C. Assembly of Crown 60/100mm Concentric Venting D. Assembly of Crown 80/125mm Concentric Venting E.

  • Page 5: Before Installing

    III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code, ANSI Z223.1.
  • Page 7 Table 4.2: Clearances From Vent Piping To Combustible Construction MINIMUM CLEARANCE TO COMBUSTIBLE TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MATERIAL 80/125 and 60/100mm VERTICAL OR ENCLOSED ON ALL FOUR SIDES 0” CONCENTRIC VENTING HORIZONTAL HEAT FAB SAF-T VENT AT LEAST ONE SIDE OPEN, PROTECH FASNSEAL VERTICAL OR 1”...

  • Page 11: Air For Ventilation

    VI Air for Ventilation WARNING OUTDOOR COMBUSTION AIR MUST BE PIPED TO THE AIR INTAKE. NEVER PIPE COMBUSTION AIR FROM AREAS CONTAINING CONTAMINATES SUCH AS SWIMMING POOLS AND LAUNDRY ROOM EXHAUST VENTS. CONTAMINATED COMBUSTION AIR WILL DAMAGE THE BOILER AND MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. Air for combustion must always be obtained directly from outdoors, however sufficient air for ventilation must still be provided in the boiler room.

  • Page 13: Venting

    VII Venting WARNING FAILURE TO VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS COULD CAUSE FLUE GAS TO ENTER THE BUILDING RESULTING IN SEVERE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH: * Use only vent systems and materials explicitly permitted by Crown for use with this boiler. * Do not attempt to mix components from different approved vent systems.
  • Page 14 2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected and the boiler size. See Table 7.1 or 7.9 for the maximum vent length. In horizontal vent systems, the lengths shown in Table 7.1 are in addition to the first standard elbow on top of the boiler.
  • Page 15 Horizontal Terminal Clearance Requirements (continued): • Vent terminal must be at least 6 feet from an inside corner. • Under certain conditions, water in the flue gas may condense, and possibly freeze, on objects around the vent terminal including on the structure itself. If these objects are subject to damage by flue gas condensate, they should be moved or protected.
  • Page 17 TABLE 7.4a: CROWN CONCENTRIC 60/100 VENT COMPONENTS (VENT OPTION 1) USED ON CROWN PN DESCRIPTION SIZE VENT COMMENTS OPTION # 80/125 x 60/100mm REDUCING 80/125 x INCLUDED WITH STANDARD 230521 ELBOW 60/100mm BWC070/090/120 INCLUDED WITH STANDARD 230520 TERMINAL SECTION 60/100mm BWC070/090/120 INCLUDED WITH STANDARD 230522...
  • Page 18 6) Permitted Terminals for Vertical Venting - • Vent Option 5 - A straight termination is installed in the end of the vent pipe. Vent manufacturer part numbers for these screens are shown in Table 7.5. The air inlet terminal consists of a 180 degree elbow (or two 90 degree elbows) with a rodent screen as shown in Figure 7.10.
  • Page 20 9) 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 • Pitch Stainless steel venting 1/4” per foot. 10) Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported: •...
  • Page 21 TABLE 7.8: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH VENT FITTING EQUIVALENT LENGTH (ft) 60/100mm 90° CONCENTRIC ELBOW 60/100mm 45° CONCENTRIC ELBOW 80/125mm 90° CONCENTRIC ELBOW 80/125mm 90° SWEEP CONCENTRIC ELBOW 80/125mm 45° CONCENTRIC ELBOW 80/125mm 90° CONCENTRIC SUPPORT ELBOW 3” SINGLE WALL 90° ELBOW 3”...
  • Page 22 FIGURE 7.10: VERTICAL TWIN PIPE VENT SYSTEM (VENT OPTION 5) FIGURE 7.11: VERTICAL CONCENTRIC VENT SYSTEM (VENT OPTION 6)

  • Page 23: Removing An Existing Boiler From Common Chimney

    B. Removing an Existing Boiler From a Common Chimney Read this only if the BWC boiler is replacing an existing boiler that is being removed from a common chimney. This section does not apply to the installation of a BWC boiler. 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 24: Assembly Of Crown 60/100Mm Concentric Venting

    C. Assembly of Crown 60/100mm Concentric Venting (IMPORTANT - Skip to Section D for 80/125mm Concentric Vent Assembly) WARNING Failure to follow the instructions could result in flue gas leakage into the combustion air or indoor air, resulting in unsafe or unreliable operation. •...

  • Page 28: Assembly Of Crown 80/125Mm Concentric Venting

    D. Assembly of Crown 80/125mm Concentric Venting (IMPORTANT - See Section C for 60/100mm Concentric Vent Assembly) WARNING Failure to follow the instructions could result in flue gas leakage into the combustion air or indoor air, resulting in unsafe or unreliable operation. •...
  • Page 38 3) Assembly of Metal-Fab Corr/Guard Vent System: a) Corr/Guard General Notes: • Do not cut Corr/Guard vent components. • Refer to Corr/Guard installation instructions for proper methods of support. • Orient Corr/Guard components so that the males ends of all fittings point in the direction of the boiler. b) Start assembly of the vent system at the boiler.
  • Page 39 4) Assembly of Z-Flex Z-Vent III: a) General Notes: • Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw. File or sand the cut end smooth before assembling. Expanded ends may be cut to adapt the SVE series III to the vent collar.
  • Page 40 5) Assembly of Heat Fab Saf-T Vent EZ Seal: a) Saf-T Vent General Notes: • These instructions cover the installation of Saf-T Vent EZ Seal. Saf-T Vent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. •...

  • Page 42: Condensate Trap And Drain

    8) Installation of Vertical Exhaust Terminal - Use the terminal supplied by the vent system manufacturer shown in Table 7.5. Attach to the vent system, following the assembly instructions in this manual for the stainless vent system being used. 9) Assembly of the Air Intake System and Air Intake Terminals: a) Assemble the air intake system using either galvanized or PVC pipe.

  • Page 45: System Piping

    IX System Piping A. General System Piping Precautions WARNING INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM WATER (DRIPPING, SPRAYING, RAIN, ETC) DURING APPLIANCE OPERATION AND SERVICE (CIRCULATOR REPLACEMENT, ETC). CAUTION THE HEAT EXCHANGER USED IN THE BWC IS MADE FROM A SPECIAL ALUMINUM ALLOY. FAILURE TO TAKE THE FOLLOWING PRECAUTIONS COULD RESULT IN SEVERE BOILER DAMAGE.
  • Page 50 TABLE 9.6: PIPE AND CIRCULATOR SIZING FOR INDIRECT WATER HEATER LOOP MAX. I.W.H. I.W.H. LOOP MAX BOILER PIPE CROWN INDI- FLOW PRESSURE EQUIVALENT CIRCULATOR MODEL SIZE RECT WATER DROP LENGTH MODEL HEATERS (in NPT) (GPM) (ft) (ft HEAD) MS-26 (*) MS-40 (*) BWC070 Taco 008...

  • Page 52: Standard Piping Installation Requirements

    19.00 18.00 17.00 16.00 BWC120 15.00 BWC070, BWC090 14.00 13.00 BWC151 12.00 11.00 10.00 9.00 8.00 7.00 6.00 5.00 4.00 3.00 2.00 1.00 0.00 FLOW (GPM) Figure 9.9: Boiler Head Loss C: 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 2.1.

  • Page 53: Piping For Special Situations

    2) Circulator (Required) - Usually at least two circulators will be required to properly install a BWC Series boiler. See the previous section for information on sizing the circulators. 3) Expansion Tank (Required) - If this boiler is replacing an existing boiler with no other changes in the system, the old expansion tank can generally be reused.

  • Page 55: Wiring

    X Wiring WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70). 1) Line Voltage (120 VAC) Connections (Fig 10.1) – The line voltage connections are located in the junction box on the right side of the vestibule: •...

  • Page 59: Start-Up And Checkout

    XI Start-up and Checkout NOTE SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS TRAIN ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TEST 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.

  • Page 61: Operating Instructions

    BWC Series Lighting and Operating Instructions FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. • This appliance does not have a pilot. It is If you cannot reach your gas supplier, call the equipped with an ignition device which fire department.
  • Page 64 WARNING EACH BWC SERIES BOILER IS TESTED AT THE FACTORY AND ADJUSTMENTS TO THE AIR-FUEL MIXTURE ARE NORMALLY NOT NECESSARY. CONSULT A CROWN REPRESENTATIVE BEFORE ATTEMPTING TO MAKE ANY SUCH ADJUSTMENTS. IM- PROPER GAS VALVE OR MIXTURE ADJUSTMENTS COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE.
  • Page 66 In standby mode, it is possible to view both the heating supply set point temperature and the “domestic hot water reference set point”. The “domestic hot water reference set point” plus 45°F equals the boiler supply set point when it is responding to a call from the indirect water zone. It is not the actual domestic hot water set point. The BWC is designed for use with a storage type indirect water heater such as the Crown Mega-Stor.
  • Page 69 Figure 12.4: Outdoor Reset Curve 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 70: Service And Maintenance

    XIII. Service and Maintenance IMPORTANT WARRANTY DOES NOT COVER BOILER DAMAGE OR MALFUNCTION IF THE FOL- LOWING STEPS ARE NOT PERFORMED AT THE INTERVALS SPECIFIED. 1) Continuously: Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids.
  • Page 71 Remove the ignition electrode and inspect it for oxides. Clean the oxides off the electrode with sandpaper. Inspect the ceramic insulator for cracks and replace the ignitor assembly if necessary. Remove the fan/gas valve assembly from the burner hood. Inspect for lint and dust. If significant lint and dust are found, disassemble the fan/gas valve assembly to expose the swirlplate and fan inlet (see the exploded diagram in the parts list at the back of this manual).

  • Page 73: Troubleshooting

    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. Table 14.3: Soft Lockout Codes Displayed CODE CONDITION...

  • Page 75: Parts

    XV 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...

This manual is also suitable for:

Bwc070Bwc090Bwc120

Table of Contents