Crown Boiler BSI069 Installation Instruction
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Crown Boiler BSI069 Installation Instruction

Bsi series gas-fired natural draft steam boilers
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BSI Series
Gas-Fired Natural Draft Steam Boilers

INStallatIoN INStructIoNS

These instructions must be affixed on or adjacent to the boiler
Models:
BSI207
BSI069
•
•
BSI241
BSI103
•
•
BSI276
BSI138
•
•
BSI311
BSI172
•
•
BSI346
•
BSI380
•
D
E S I G N E D
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
L
T O
E A D
WarNING: Improper instal-
lation, adjustment, alteration,
service or maintenance can
cause property damage, injury,
or loss of life. For assistance or
additional information, consult a
qualified installer, service agency
or the gas supplier. Read these
instructions carefully before
installing.

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  • Page 1: Installation Instructions

    Gas-Fired Natural Draft Steam Boilers INStallatIoN INStructIoNS These instructions must be affixed on or adjacent to the boiler Models: WarNING: Improper instal- lation, adjustment, alteration, BSI207 BSI069 • • service or maintenance can BSI241 BSI103 • cause property damage, injury, •...
  • Page 3 WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings unless alarms or other safeguards are in place to printed in this manual and posted on the boiler. prevent such damage INSPECT THE BOILER ANNUALLY. To keep your DO NOT BLOCK AIR FLOW into or around the boiler safe and efficient, have a service technician boiler.

  • Page 4: Table Of Contents

    Table of Contents Product Description ............ 2 II. Specifications ............. 3 III. Before Installing ............4 IV. Locating the Boiler ............. 4 V. Air for Combustion & Ventilation ......5 VI. Venting ............... 9 VII. Gas Piping ..............12 VIII. System Piping............13 IX. Indirect Water Heater Piping ........16 X. Wiring ..............17 XI. Start-Up & Checkout ..........23 XII. Service & Maintenance ...........

  • Page 5: Specifications

    AFUE % DIMENSIONS (in.) VOL. ** MODEL SECTIONS (MBH) (MBH) (Sq. ft) (MBH) "A" "B" "C" "D" (Gal) BSI069 81.9 12 3/4 40 7/16 BSI103 82.0 40 7/16 BSI138 82.0 19 1/4 40 7/16 BSI172 82.1 22 1/2 40 7/16 BSI207 82.1...

  • Page 6: 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 requirements of 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-latest edition. • Where required by the authority having jurisdiction, this installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1)-latest edition. Warning This Product Must be Installed By A Licensed Plumber Or Gas Fitter when Installed Within The Commonwealth Of Massachusetts 2) Make sure that a properly sized chimney is available which is in good condition. Consult the authority having jurisdiction, Part VI of this manual, and the National Fuel Gas Code for additional information on venting requirements.

  • Page 7: Air For Combustion & Ventilation

    FIGURE 2: BSI BOILERS - CLEARANCES TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS, WALLS, AND DOORS. 4) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or used. Do not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop. 5) The boiler should be located as close to the chimney as possible. 6) Do not install this boiler directly on a surface that may get wet. Raise the boiler on a pad. V Air for Combustion and Ventilation Sufficient fresh air must be supplied for combustion, ventilation and flue gas dilution. Provisions for combustion, ventilation and flue gas dilution air for gas utilization equipment vented by natural draft must be made in accordance with local building codes or, in absence of such codes, in accordance with sections 5.3.3 and 5.3.4 (“Air for Combustion and Ventilation”) of the National Fuel Gas Code, NFPA 54/ANSI Z223.1. To ensure an adequate supply of combustion, ventilation and flue gas dilution air supply, start by determining whether the boiler is to be installed in a building of unusually tight construction. A good definition of a building of unusually tight construction is one which has all of the following features: • Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed • Weather stripping has been added on openable windows and doors • Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other openings.

  • Page 8: Bsi172

    For Buildings of Other than Unusually Tight Construction 1) Determine whether the boiler is to be installed in a confined space - A confined space is defined by the National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To determine whether the boiler room is a confined space: a. Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest 1000 BTU/hr. b. Find the volume of the room in cubic feet. The volume of the room in cubic feet is: Length (ft) x width (ft) x ceiling height (ft) In calculating the volume of the boiler room, consider the volume of adjoining spaces only if no doors are installed between them. If doors are installed between the boiler room and an adjoining space, do not consider the volume of the adjoining space, even if the door is normally left open. c. 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. Example: A BSI172EN and a water heater are to be installed in a room measuring 6 ft - 3 in x 7 ft with an 8 ft ceiling. The water heater has an input of 30000 BTU/hr: Total input in thousands of BTU/hr = (172000 BTU/hr + 30000 BTU/hr)/1000 = 202 Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft 350/202 = 1.73. Since 1.73 is less than 50, the boiler room is a confined space. 2) Unconfined Space - Natural infiltration into the boiler room will normally provide adequate air for combustion and ventilation without additional louvers or openings into boiler room. 3) Confined Space - Provide two openings into the boiler room, one near the floor and one near the ceiling. The top edge of the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the floor (Figure 3). • Each opening must have a free area of 1 square inch per 1000 BTU/hr input of all gas burning appliances in the boiler room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per opening.
  • Page 9 FIGURE 3: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC...
  • Page 10 FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM...

  • Page 11: Venting

    VI Venting Vent installation must be in accordance with local building codes, or the local authority having jurisdiction, or the National Fuel Gas Code, NFPA 54/ANSI Z 223.1. A typical vent installation is illustrated by Figure 8. The components of vent installation are the vent damper (if used), vent connector and chimney. 1) Acceptable Chimneys - The following chimneys may be used to vent BSI series boilers: • Listed Type B or L gas vent - Install in accordance with the manufacturer’s instructions, the terms of its listing, and applicable codes. • Masonry Chimney - The masonry chimney must be constructed in accordance with the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances (NFPA 211) and lined with a clay liner or other listed lining system. Do not vent a BSI series boiler into an unlined chimney. 2) Acceptable Vent Connectors - The following may be used for vent connectors: • Listed type B or L Gas Vent • Single Wall Galvanized Pipe - Use 0.018” (26 gauge or heavier). The size and location of the chimney may not permit the use of a single wall connector in some cases. See the National Fuel Gas Code. Do not use single wall pipe for vent connectors in attics. • Other Vent Connectors Permitted by the National Fuel Gas Code. 3) Chimney and Vent Connector Sizing - Size the chimney and vent connector in accordance with the National Fuel Gas Code.
  • Page 12 14) Vent damper installation is mandatory on all sizes from the BSI069 to BSI276. The BSI311 through BSI380 may be ordered with or without vent damper. If supplied, install vent damper (see Figure 9) as follows: a) Open vent damper carton and remove installation instructions. Read the instructions thoroughly before proceeding. Verify that vent damper is same size as draft diverter outlet. See Figure 1. Unpack vent damper carefully. Do not force closed damper blade. Forcing vent damper closed may result in damaged gear train and void warranty. b) Vent damper is factory shipped having approximately ¾” diameter hole in the vent damper blade, which must be left open for boilers equipped with standing pilot, and should be plugged on boilers with an intermittent pilot system, using the plug supplied with the damper. Mount the vent damper on the flue collar without modification to either and secure with sheet metal screws. Make sure screws do not interfere with damper blade operation. Vent damper blade position indicator must be visible to users. c) The damper wire harness is shipped wired into the boiler junction box. Plug the loose end of this harness into the damper and secure the flexible conduit to the damper using a connector nut provided. d) Install vent connector pipe and vent fittings from vent damper outlet to chimney or gas vent. Secure with sheet metal screws and support as required. Removing an Existing Boiler 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. 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. a) Seal any unused opening in the common venting system.
  • Page 13 FIGURE 8: BSI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS RIGHT SIDE VIEW FIGURE 9: VENT DAMPER INSTALLATION DETAILS 11 11...

  • Page 14: 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 a line pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or Chapter 2 of the National Fuel Gas Code. Figure 10 shows typical gas piping connection to the BSI boiler. A sediment trap must be installed upstream of all gas controls. Install a manual shut-off valve outside the jacket and ground joint union as shown. The boiler and its gas connection must be leak tested before placing the boiler in operation. When doing this, the boiler and its individual shut-off must be disconnected from the rest of the system during any pressure testing of that system at pressures in excess of 1/2 psi. When pressure testing the gas system at pressures of 1/2 psi or less, isolate the boiler from the gas supply system by closing its individual manual shut-off valve. * State of Massachusetts Requires Manual Shut-off Valve to be “T” Handle Type FIGURE 10: GAS CONNECTION TO BOILER 12 12...

  • Page 15: System Piping

    VIII System Piping CAUTION • 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.). • OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. General Piping Notes Figure 11 shows recommended near boiler piping for most common types of gravity return steam systems. Additional information on steam system design may be found in Installation Guide for Residential Hydronic Heating Systems (Pub. #200) published by the Hydronics Institute in Berkeley Heights NJ. One of the primary purposes of this near boiler piping is to separate tiny water droplets from the steam exiting the boiler so that “dry” steam is sent to the system. If the near boiler piping is not correct, wet steam will enter the system and the following problems may occur: • Short cycling on low water • Boiler or system Flooding • Hammering • Failure to heat one or more radiators Avoid the three common piping mistakes shown in Figure 12. This applies even if the existing boiler has one of the piping mistakes shown in Figure 12 and appears to be working. If two or more steam mains must be connected to the boiler, connect a separate take-off for each main into the header between the riser(s) and equalizer. Also note the following points: 1) A size reduction must be made to connect the header to the equalizer. This reduction must be made in the equalizer line. Do not make this size reduction in the horizontal header. 2) One pipe steam systems require air vents on each radiator, as well as at the end of each main. For the system to work properly, these vents must be properly installed, sized, and be in good condition. Inspect and replace any defective vents. If there are no vents at the ends of the mains, install them.

  • Page 16: Bsi207

    Piping Installation 1) Remove parts bag from boiler crate. 2) Install safety valve (spindle must be in vertical position) into tapping on boiler left side (see Figure 1) using the 3/4” NPT nipples and elbow supplied. 3) Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the safety valve discharge is not piped to a drain it must terminate at least 6 inches above the floor. The termination of the safety valve discharge piping must be in an area where it is not likely to become plugged by debris or subjected to freezing. DANGER • PIPE SAFETY VALVE DISCHARGE TO A SAFE LOCATION. • DO NOT INSTALL A VALVE IN THE SAFETY VALVE DISCHARGE LINE. • DO NOT MOVE SAFETY VALVE FROM FACTORY LOCATION. • DO NOT PLUG SAFETY VALVE DISCHARGE. • DO NOT INSTALL A SAFETY VALVE WITH A SETTING GREATER THAN 15 PSI. 4) Install drain valve into tapping on boiler left side using the 2 x 3/4 bushing provided (see Figure 1). 5) Connect system supply and return to boiler. See Figure 11. The BSI069 - BSI172 require only one supply riser. Two supply risers are required on the BSI207 and larger sizes. 6) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler in parallel with chiller. Use isolation valves to prevent chilled water from entering the boiler. 14 14...

  • Page 17: Bsi138

    BOILER MINIMUM PIPE DIA. (IN NPT) MODEL "A" "B" "C" "D" BSI069 1 1/2 1 1/4 BSI103 1 1/2 1 1/4 BSI138 1 1/2 1 1/4 BSI172 1 1/2 1 1/4 BSI207 1 1/2 1 1/4 BSI241 1 1/2 BSI276...

  • Page 18: Indirect Water Heater Piping

    IX Indirect Water Heater Piping All BSI series boilers are equipped with tappings to permit the connection of a Crown Mega-Stor, or other indirect water heater. In this type of system, hot boiler water is drawn from below the water line and passed through the heat exchanger in the indirect water heater. This section describes boiler-side piping only. Refer to the indirect water heater instruction manual for domestic water piping. The components in this system and their functions are as follows: 1) Circulator - Mount the circulator as shown in Figure 13. The circulator should be located as low and as close to the boiler as practical. Do not install valves, or other devices having a significant pressure drop, between the boiler and the circulator inlet. All piping between the boiler and the circulator inlet should be 1”, regardless of the size of the piping required in the rest of the system. See Figure 15 in Part X for wiring information. 2) “Y” Strainer - Install a “Y” strainer to prevent sediment from accumulating inside the indirect water heater. 3) Check Valve - Prevents gravity circulation through the indirect water heater when the boiler is responding to a call for heat. 4) Boiler Limit Control - Use a SPST break-on-rise temperature limit control such as the Honeywell L4006A. Do not set the limit above 180F as doing so may cause the boiler to steam when there is no call for heat. See Figure 15 for wiring information. 5) Valves and Unions - Install shut-off valves, drain valves, and unions in locations that will facilitate maintenance of the system. Do not install any valves between the boiler and circulator inlet. IMPORTANT • Some indirect water heaters may not be suitable for use with a steam boiler. Consult the water heater manufacturer’s guidelines before installing it in this type of system. • Boiler water temperatures and flow rates in this type of system may be considerably lower than those upon which the water heater manufacturer’s ratings are based. This may result in substantially longer water heater recovery times. FIGURE 13: INDIRECT WATER HEATER BOILER-SIDE PIPING 16 16...

  • Page 19: 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) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt con- nections are made inside the junction box on the left side of the boiler. Remove the transformer to gain access to this box (also see Figures 16 through 17): • Hot (“black”) - Wire nut to black transformer lead • Neutral (“white”) - Wire nut to white transformer lead • Ground (“green” or bare) - Ground screw inside junction box. 2) Thermostat Wiring - Follow thermostat manufacturer instructions. To insure proper thermostat operation, avoid installa- tion in areas of poor air circulation, hot spots (near any heat source or in direct sunlight), cold spots (outside walls, walls adjacent to unheated areas, locations subject to drafts). Provide Class II circuit between thermostat and boiler. Connect thermostat wire leads to the blue transformer lead and brown relay lead inside the junction box. Set the heat anticipator to 0.2A. Feeder Wiring for Boilers Equipped with Hydrolevel CG400A Low Water Cut-offs CAUTION Do not attempt to connect a McDonnell & Miller model #101A feeder, or other feeder without a delay, to a BSI boiler equipped with a Hydrolevel CG400 low water cutoff. Doing so could destroy the boiler transformer and/or flood the sys- tem. 1) Using Hydrolevel VXT-24 TWO-WIRE feeder - Do not alter factory boiler wiring. Connect VXT-24 to CG400A as fol- lows: • Connect the BLACK lead on the feeder to terminal A on the LWCO •...
  • Page 20 Feeder Wiring for Boilers Equipped with McDonnell & Miller #67 Low Water Cut-offs Figures 14a and 14b show feeder wiring for McDonnell & Miller #101A, McDonnell & Miller WF2-U-24 and Hydrolevel VXT-24 feeders on boilers equipped with #67 low water cutoffs. The following points apply to all feeder wiring to #67 low water cut-offs: • Use a separate transformer to power the feeder. Do not use the transformer on the boiler. • It is not necessary to touch any of the 24 volt factory boiler wiring when connecting a feeder to a #67 equipped boiler. • Do NOT install a jumper between terminals 2 and 3 on the #67 low water cutoff. Indirect Water Heater Wiring Figure 15 shows field wiring for an indirect water heater. A Honeywell R845A or equivalent DPST relay and transformer is required. The high limit described in Part IX must also be supplied by the installer. A call for heat from the indirect water heater thermostat will energize the relay making both sets of contacts. One set of these contacts then energizes the circulator. The other set of contacts will make the “T” and “T” contacts on the burner primary control, firing the burner. If the boiler water temperature exceeds the high limit setting of 180F, the high limit will open the “T” - “T” circuit and the burner will shut down. If there is a call for space heat, the heating thermostat will make the “T”-”T” circuit and the boiler will fire without regard to the status of the indirect water heater. The low water cut-off and pressure limit control will interrupt 120 volt power to the burner in the event of a low water or excessive pressure condition. CAUTION DO NOT INSTALL JUMPER BETWEEN 2 & 3 ON #67 L.W.C.O.
  • Page 21 CAUTION DO NOT INSTALL JUMPER BETWEEN 2 & 3 ON #67 L.W.C.O. FIGURE 14b: WIRING MCDONNELL & MILLER WF2-U-24 FEEDER OR THREE-WIRE HYDROLEVEL VXT-24 FEEDER TO BOILER EQUIPPED WITH #67 L.W.C.O. FIGURE 15: WIRING INDIRECT WATER HEATER TO BOILER 19 19...
  • Page 22 BSI Control System – Sequence of Operation (Refer to Figures 16 & 17 for ladder and connection diagrams) Sequence of Operation, Intermittent Ignition 1) When the boiler is energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damp- er. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will close. On boilers equipped with Hydrolevel CG400A probe type low water cut-offs, voltage is also always applied to terminals “1” (blue) and “2” (yellow) on the low water cut-off to power the water level sensing circuit. On boilers equipped with #67 float type low water cut-offs, power is always applied to terminal “2” on the #67 LWCO. 2) Assuming that water is above the cut-off level, power will appear at terminal “3” on the CG400 LWCO or terminal “1” on the #67 LWCO. 3) Assuming that steam pressure is below the pressure limit setting, power will appear on one side of relay contact 1R1 (Gray lead). Relay 1R is the R8225 mounted under the junction box. 4) A call for heat from the thermostat energizes relay coil 1R causing contacts 1R1 to make. Current then flows through contacts 1R1 to pin terminal “2” (orange) at the vent damper and the damper opens. 5) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin “3” (red) at the damper. 6) Current passes from terminal “3” on the vent damper though the flame rollout and blocked vent (“spill”) switches. Under normal conditions, both of these switches are made and voltage will therefore immediately appear across terminals “24V” and “24V (GND)” on the ignition module. 7) Upon application of voltage across the “24V” and “24V (GND)” terminals, the ignition module will start an ignition spark at the pilot and apply 24 volts across the pilot valve (terminals “PV” and “MV/PV”). 8) Once the pilot is established, the pilot flame will act as a diode, converting the AC current at the electrode to a half wave DC current at the pilot’s ground strap. This DC current flows through the boiler to the “GND (BURNER)” connection on the ignition module. For the ignition module to recognize that a pilot flame is present, the DC current flowing into this terminal must be in excess of approximately 1.0 uA. 9) Once the ignition module detects the presence of a pilot flame, voltage is applied across the main valve (terminals “MV” and “MV/PV”), opening the valve and establishing main flame.
  • Page 23 Blocked Vent (“Spill”) Switch - Automatically interrupts burner operation in the event that flue gas spills from the draft diverter opening. This switch is equipped with a reset button which must be pressed to restore normal burner operation. An open blocked vent switch is indicative of a problem with the vent system. If the blocked vent switch opens, the cause of the venting problem must be found and corrected by a qualified gas service technician before the blocked vent switch is reset. Flame Roll-out Switch - Automatically interrupts burner operation when flames or excessive heat are present in vestibule. The flame roll-out switch is a single use device which must be replaced by an identical switch in order to restore normal operation. An open flame roll-out switch is usually indicative of a plugged heat exchanger. The cause of the flame roll-out must be found and corrected by a qualified gas service technician, and the switch replaced with an identical one, before the boiler is returned to operation. FIGURE 16: WIRING DIAGRAM, INTERMITTENT IGNITION AND HYDROLEVEL CG-400A LOW WATER CUTOFF 21 21...
  • Page 24 FIGURE 17: WIRING DIAGRAM, INTERMITTENT IGNITION AND McDONNELL & MILLER MODEL #67 LOW WATER CUTOFF 22 22...

  • Page 25: Start-Up & Checkout

    NOTE SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS MANIFOLD AND CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS SPECIFIED IN Z21.13. XI Start-up and Checkout Use the following procedure for initial start-up of the boiler: 1) M ake sure that the boiler is filled with water to the normal water line (28 3/4 inches above the floor or pad on which the boiler is installed) 2) Check all new gas piping for leaks and purge piping sections that are filled with air. See Part 4 of the National Fuel Gas Code for additional information on testing and purging gas lines. WARNING • NEVER USE A FLAME TO CHECK FOR GAS LEAKS. • MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND LIQUIDS. • DAMPER MUST BE IN OPEN POSITION WHEN APPLIANCE MAIN BURNER IS OPERATING. 3) Verify that vent system is complete and free of obstructions before attempting to fire boiler. 4) Inspect all wiring for loose or uninsulated connections. 5) Make sure the main burners are seated properly in the rear of burner tray and on orifices. 6) Adjust steam pressure limit control for a cut-in pressure of 0.5 psi and a differential pressure of 1 psi. 7) Adjust thermostat to the highest setting. 8) Start the boiler using the appropriate lighting instructions for the gas valve on the boiler on pages 25 - 26. 9) Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take several tries for ignition before a flame is established. 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 26 WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER- FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD. 16) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a) Connect a manometer to the inlet pressure tap on the gas valve (see Figure 20). b) Check the inlet pressure with all gas appliances on and off. The inlet pressure at the boiler must be within the following limits regardless of what combination of appliances is firing: Inlet Press (inches w.c.) Natural Gas LP Gas Min. 11.0 Max. 14.0 13.0 If the inlet pressure falls outside of these limits, find and correct the cause of the problem before proceeding further. c) Connect a manometer to the manifold (outlet) pressure tap on the gas valve (see Figures 23 and 24). d) Read the manifold pressure. It should be set at: Natural Gas LP Gas Manifold Press. (inches w.c.)

  • Page 27: Operating Instructions

    LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8204 AND VR8304 SERIES GAS VALVES 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. A.
  • Page 28 LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000DERHC SERIES GAS VALVES 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. A.
  • Page 29 FIGURE 19b: MAIN BURNER FLAME - 40mm FIGURE 19a: MAIN BURNER FLAME - 1” BURNERS (“HIGH ALTITUDE”) BURNERS 17) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. Both pilot burner and main burners should stop firing. Raise the thermostat back to the highest setting. The pilot burner and main burners should relight. 18) Verify low water cutoff operation while the boiler is running. Slowly open drain valve and drain boiler until the water level drops below low water cutoff line. Water still should be visible in the gauge glass when the low water cutoff shuts down the main burners. Both pilot burner and main burners should stop firing. Make sure pressure limit, thermostat or other controls have not shut off the boiler. Upon test completion refill the boiler to the normal water level. 19) Check pressure limit control operation. When steam pressure is registered on pressure gauge, lower pressure limit setting below gauge reading. Both pilot burner and main burners should stop firing. Raise pressure limit setting above gauge reading. The pilot burner and main burners should relight. 20) After the boiler has operated for approximately 30 minutes, check the boiler and heating system piping for leaks. Repair any leaks found at once. 21) Inspect the vent system for flue gas leaks. Repair any leaks found before leaving the boiler in operation. 22) Replacement of a steam boiler tends to break loose accumulated scale from the system. During the first week of operation, blow down the #67 low water cut-off at least three times following the blow down instructions on the yellow sticker adjacent to the low water cut-off. 23) After new boiler has been installed and put into continuous operation for several days, clean the boiler of oil, grease, sludge, and other contaminants that may have been present in existing piping. This will prevent unsteady water line and water carry over into supply main. The boiler boil-out should be done as follows: a) Turn off gas supply to boiler per the appropriate Lighting and Operating instructions on page 25 - 26. b) Drain water from boiler until about one inch of water is visible in gauge glass. c) Run a hose or temporary piping from the boiler drain valve to a location where hot water can be safely discharged. Drain approximately five gallons of water from the boiler and mix-in an appropriate amount of an approved boil- out compound. Remove safety valve and refill the boiler with prepared solution through funnel inserted into elbow under the safety valve. Run a hose or temporary piping from safety valve tapping to a location where hot water can be safely discharged. DO NOT INSTALL ANY VALVES IN THIS LINE. d) Light off the boiler per the appropriate instructions on page 25 - 26. Run boiler for several hours, boiling the water, without generating steam pressure. Open the water feed valve sufficiently to allow a slight overflow of water through the safety valve tapping drain line. Continue boiling until water coming out is clear.
  • Page 30 f) Reinstall safety valve and related piping. g) Conduct pH and Alkalinity test of water in the system. The pH reading should be in 7 to 11 range. NOTE When substantial amount of make-up water is used due to lost condensate, or when make-up water is hard or corrosive, water treatment is required. Contact qualified water treatment company for recommended water treatment compounds and procedures. FIGURE 20a: GAS VALVE DETAIL - HONEYWELL VR8204 AND VR8304 FIGURE 20b: GAS VALVE DETAIL - ROBERTSHAW 7000DERHC 28 28...

  • Page 31: Service & Maintenance

    XII Service and Maintenance On a continuous basis: 1) Keep the area around the boiler free and clear from combustible materials, gasoline, and other flammable vapors and liquids. 2) Keep the area around the boiler and boiler room ventilation openings clear of objects which might obstruct the flow of combustion and ventilation air. On at least a weekly basis: For boilers equipped with a #67 low water cut-off, blow down the low water cut-off following the instructions on the yel- low sticker adjacent to the low water cut-off. During this blow down, the low water cutoff should shut down the burners. If it does not the low water cut-off should be replaced immediately. On an annual basis: 1) Turn off electrical power and gas supply to the boiler 2) Inspect the flue passages for signs of blockage. If there is any carbon in the combustion chamber or the flue passages, clean the heat exchanger before proceeding further. See the cleaning procedure below. 3) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation. 4) Remove all burners, noting the location of the pilot main burner. If burners show signs of deterioration, they should be replaced (some discoloration around the burner ports is normal). Clean the burners by first brushing the ports with a soft bristle brush and then vacuuming out any debris through the venturi opening. 5) Inspect the pilot assembly. Clean any deposits found on the electrode and grounding strap. The ideal gap between the electrode and the ground strap is 1/8”. Inspect the porcelain for cracks or other deterioration. Replace pilot assembly if dete- rioration is found.
  • Page 32 • For McDonnell & Miller #67 low water cut-offs - Remove and inspect switch and float mechanism. Inspect float bowl for mud accumulation. Clean as required. Replace the switch and float mechanism every five years or 100,000 cycles. Consult the McDonnell and Miller #67 manual for any additional maintenance information. Test the low water cut-off before placing the boiler back into service. 13) Allow the boiler to cool to room temperature. Remove the drain valve and 2 x 3/4 bushing on the left side of the boiler. Use a flashlight to inspect the bottom row of pushnipples for accumulated scale or mud. If a significant amount is present, use the following procedure to clean the inside of the heat exchanger: a) Temporarily install a 1 1/4 inch or larger full port ball valve in place of the boiler drain. Temporarily pipe the outlet of this valve to a location where hot water and steam can be safely discharged. b) Make sure that this valve is closed and that the water level is at the normal water line. c) If a king valve is present in the steam main takeoff, close it. Alternatively, temporarily replace enough of the vents on the mains and/or radiators with plugs so that 2-5 psi can be developed when the boiler is fired. d) Fire the boiler and allow it to steam until 2-5 psi is registered on the gauge. e) Turn off the burners and immediately fully open the 1-1/4 valve. f) Allow the boiler to blow down until either the water runs clear or the water level reaches the bottom of the gauge glass. g) Allow all parts of the boiler to cool to room temperature. Drain the boiler completely and remove the 1-1/4 valve. h) If significant mud or scale is still present in the bottom of the boiler, repeat steps (b) through (g) until all mud or scale is removed. i) Once all mud or scale is removed, replace the 1-1/4 valve and temporary blow-down piping with the standard drain valve. After all parts of the boiler are at room temperature, refill the boiler to the normal water line. 14) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas pip- ing disturbed during the inspection process for leaks. CAUTION If, during normal operation, it is necessary to add water to this boiler more frequently than once a month, consult a qualified service technician to check your system for leaks. A leaky system will increase the volume of make-up water supplied to the boiler which can significantly shorten the life of the boiler. Entrained in make-up water are dissolved minerals and oxy- gen. When the fresh, cool make-up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas. Both can result in reduced boiler life. The accumulation of sediment can eventually isolate the water from contact- ing the cast iron. When this happens the cast iron in that area gets extremely hot and may eventually crack. The presence of free oxygen in the boiler creates a corrosive atmosphere which, if the concentration becomes high enough, can corrode the cast iron through from the inside. Since neither of these failures types are a result of a casting defect the warranty does not apply. Heat Exchanger Cleaning Procedure 1) Turn off electrical power and gas supply to the boiler 2) Disconnect the damper and vent connector from the boiler.
  • Page 33 12) Replace the flue collector gasket strips. If desired, RTV silicone sealant with a 500F intermittent duty temperature may be substituted for this rope gasket. The flue collector must be thoroughly sealed to the heat exchanger. 13) Replace the ¼-20 nuts and washers that hold down the flue collector 14) Reattach all the jacket components. 15) Reinstall burners, being careful to put the pilot main burner in its original location. 16) Replace the blocked vent switch. 17) Reconnect the damper and vent system. WARNING SOOT DEPOSITS IN THE FLUE PASSAGES ARE A SIGN THAT THE BOILER MAY BE OPERATING AT HIGH CARBON MONOXIDE (CO) LEVELS. AFTER CLEANING THE BOILER OF SOOT DEPOSITS, CHECK THE CO LEVEL IN THE FLUE GAS TO INSURE THAT THE BOILER IS OPERATING PROPERLY. If it is necessary to check CO, use a combustion analyzer, or other instrument which is designed to measure CO in flue gas. A CO “sniffer” designed for testing CO levels in ambient air cannot be used to check boiler combustion. Take a flue gas sample by inserting a sample probe through the draft diverter opening and into the flue collector so that the sample is taken in the area directly over the heat exchanger. Do not take a sample until the boiler has been firing for at least five minutes. A normal CO reading for a BSI series boiler is less than 50ppm (0.005%). A reading of more than 100ppm (0.01%) is indicative of a combustion problem. Some causes of excessive CO include: • Incorrectly sized main burner orifice for the altitude at which boiler is installed • Crooked or out-of-round orifice holes (never attempt to drill orifice for this boiler in the field) • Partially plugged flue passages • Improper manifold pressure • Foreign material in burner venturis or burner ports • Leak in seal between flue collector and heat exchanger • Inadequate supply of combustion air 31 31...
  • Page 34 Notes 32 32...

  • Page 35: Troubleshooting

    XIII Troubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems. To use these charts, go to the box marked “Start” at the top of the chart on page 34 or 36 and follow the appropriate path though the chart until a box with a list of possible causes is reached. If the problem is known to be within the ignition system, go directly to the ignition system troubleshooting guide for the boiler on page 38. In using these charts, the following should be kept in mind: 1) These charts are only meant to be used by a professional heating technician as an aid in diagnosing control problems. 2) Where applicable, follow all precautions outlined in the appropriate lighting instructions on pages 25 - 26. 3) In general, these charts assume that there are no loose or miswired electrical connections. Before using these charts, in- spect all electrical connections on the boiler to make sure that they are tight. Also, check the wiring on the boiler against the appropriate wiring diagram in Figures 16 - 17. 4) The possible causes at the end of each branch in these charts are not listed in order of likelihood. All controls on the BSI are tested at least once in the manufacturing process and a defective control or component is generally the least likely cause. Before replacing a component, try to rule out all other possible causes. 5) These troubleshooting charts assume that the vent damper is closed at the beginning of the troubleshooting process. With the 120 volts applied to the boiler and no call for heat, the damper should go to the closed position. If it does not, do the following: • Confirm that 120 volts is applied to the boiler and that there is no call for heat. • Make sure that the switch on the damper is in the “automatic” position. • Unplug the harness from the damper and check for 24 volts across pin #1 (blue) and pin #4 (yellow). • If voltage is present, the damper is defective or there is an obstruction in the path of the damper blade. • If no voltage is present, there is either a loose connection in the damper harness or the transformer is defective. 6) If the charts indicate that the transformer is defective, it is possible that this transformer has been destroyed by a short circuit in the boiler wiring. Before replacing the transformer, carefully inspect all low voltage wiring on the boiler for places where it is touching the frame of the boiler or wiring on the other side of the transformer. 7) If the charts indicate that the R8225 relay is defective, there is a good chance that a second transformer is present in the thermostat circuit, resulting in the application of 48 volts across the relay coil. In older buildings, this transformer may be hidden in a location far from the boiler. If this second transformer exists, it must be found and removed before the R8225 is replaced.
  • Page 36 troubleshooting chart for BSI Boilers Equipped with Hydrolev- el cG400a low Water cut-offs and Vent Dampers caution: Read page 33 before attempting to use this chart START Vent damper open? Is there an audible Thermostat click as R8225 relay calls for heat pulls in when the thermostat calls for heat?
  • Page 37 Do burners Do burners shut Main shut down when down when water burners pressure level drops below light? exceeds limit cut-off point? setting? 24 volts across red damper lead * Defective damper * Defective and yellow * Defective or loose pressure limit transformer lead? damper harness...
  • Page 38 troubleshooting chart for BSI Boilers Equipped with McDon- nell & Miller #67 low Water cut-offs and Vent Dampers caution: Read page 33 before attempting to use this chart START Vent damper open? Is there an audible Thermostat click as R8225 relay calls for heat pulls in when the thermostat calls for...
  • Page 39 Do burners Do burners shut Main shut down when down when water burners pressure level drops below light? exceeds limit cut-off point? setting? 24 volts across red damper lead * Defective damper * Defective and yellow * Defective or loose pressure limit transformer lead? damper harness...
  • Page 40 Ignition System troubleshooting chart caution: Read page 33 before attempting to use this chart START (24 volts is present across 24V and 24V (GND) on ignition module but main burners do not light) Spark Does Main across Pilot spark stop burner when pilot ignitor/sensor...
  • Page 41 Notes 39 39...

  • Page 42: Parts

    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 For boilers installed at elevations above 2000 ft, consult the local Crown representative or the factory for the correct main burner orifice. QUANTITY PER BOILER OR CROWN P.N. QTY. OR KEY # DESCRIPTION CROWN P.N. BSI HEAT EXCHANGER ASSY. 1 ea. 850013 850014 850015 850016 850017 850018 850019 850020 850021 850022 BSI/CWI LEFT END SECTION 750001...
  • Page 43 41 41...
  • Page 44 QUANTITY PER BOILER OR CROWN P.N. QTY. OR KEY # DESCRIPTION CROWN P.N. 1" BURNER WITH PILOT BRACKET 150500 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. (Q348 PILOTS) 1"...
  • Page 45 43 43...
  • Page 46 QUANTITY PER BOILER OR CROWN P.N. QTY. OR KEY # DESCRIPTION CROWN P.N. LEFT SIDE JACKET PANEL 1 ea. 850301 850301 850301 850301 8503012 8503012 8503012 8503015 8503015 8503015 RIGHT SIDE JACKET PANEL 1 ea. 850300 850300 850300 850300 8503002 8503002 8503002 8503005...
  • Page 47 45 45...

  • Page 48: Appendix A: Knockdown Boiler Assembly

    Appendix A: Knockdown Boiler Assembly Instructions A. Before Installing 1) Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs or punctures due to mishandling. 2) Do not use the heat exchanger if there is any damage to it. 3) Inspect the joints between the sections for openings. Reseal any openings with high temperature silicone sealant.. 4) Keep the base in the shipping carton until it is time to perform the assembly. This keeps foreign material from contaminating the burners or creating other hazards. Do not use the base assembly if there are any signs of visible damage. 5) Review all of the installation requirements in this installation manual. B. Base Assembly Preparation 1) The combination base-burner-manifold is shipped assembled from the factory. (The combination gas valve is shipped assembled and can be found in the “Base Box”.) 2) Smear a thin layer of silicone in several places across the top of the base to adhere the fiber gasket strip. 3) Install the fiber gasket strip, which was shipped in the “Base Box” (Figure A1). 4) Place the base assembly in the location where the boiler is to be installed. Refer to Section III and IV in the instal- lation manual for additional information on placement. C. Heat Exchanger and Flue Collector Installation 1) Position the heat exchanger above the base with the return connection located toward the front of the boiler and the lugs, located on each end of the boiler, centered over the studs, which are on each end of the base (Figure A1). Lower the heat exchanger over the studs, taking care not to disturb the studs which may push out if the heat exchanger comes in contact with them. Also, take care not to disturb the ceramic fiber gasket. 2) Once the heat exchanger has been placed on the base, inspect the gasket for proper seal. Repair or replace gasket if necessary. 3) Secure the heat exchanger with 5/16” lock nuts with nylon inserts and washers from the hardware bag.
  • Page 49 FIGURE A1: BASE, HEAT EXCHANGER, FLUE COLLECTOR ASSEMBLY 47 47...
  • Page 50 5) Install the left side panel in the same manner as the right side. 6) Attach the front corners of the diverter panel to the side jacket panels using #10 sheet metal screws. 7) Install the horizontal (angle) jacket clips in the front edge of the side jacket panels. Slide this clip through the rect- angular slot that is about halfway up the front edge of the side jacket panels and secure with the 8-32 self tapping screws provided. 8) Slip the Vertical Jacket Clip through the rectangular slot that is near the bottom of the front edge of the side jacket panels. Secure with the 8-32 sheet metal screws provided. 9) Install the top jacket panel. Use #10 sheet metal screws to attach it to the rear jacket panel and the top-front corners of the side panels. 10) Install the upper-front jacket panel. Insert the flange on the top of this panel under the top panel. Run two #10 sheet metal screws into the horizontal jacket clips through the holes in the bottom of this panel. 11) Attach the door knobs to the Lower-Front Panel using 8-32 x 1/2 machine screws. 12) The labels have been applied at the factory. Verify the location of the labels according to the list below: a) Clearance Label - Located on the top jacket panel. b) Lighting Instructions - Located on the lower left corner of the right side panel next to the gas manifold c) Lowest Permissible Water Level Plate - Located next to the bottom water gauge tapping. d) Blow Down Card - Located just above the “Lowest Permissible” Water Level Plate e) Wiring Diagram - Located on the inside of the removable door f) “CROWN” Nameplate - Located on the top center of the outside of the removable door g) Rating Plate - Located on the upper left of the right side panel D. Gas Valve Installation 1) The gas valve assembly has been pre-piped with one half of a piping union and is to be connected to the other half of the union located on the gas manifold.
  • Page 51 FIGURE A2: JACKET INSTALLATION 49 49...
  • Page 52 F. Electrical Wiring Connections (Also refer to wiring diagrams in Part X of the installation manual) 1) A pre-wired junction box assembly specific to the control package ordered with the boiler has been provided by the fac- tory. 2) Orient the junction box so the black relay, which is mounted to the outside of the junction box, is facing down. 3) Mount the junction box assembly to the right side jacket using the holes provided (See Figure 1 in the installation manual).
  • Page 53 FIGURE A3: TAPPING LOCATIONS (SEE TEXT FOR TAPPING USES) 51 51...
  • Page 54 Notes 52 52...
  • Page 55 Notes 53 53...
  • Page 56 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com P/N 980433 8/12 Rev. 1...

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