Crown Boiler BWC090 Installation Instructions Manual
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Crown Boiler BWC090 Installation Instructions Manual

Bwc series high efficiency gas-fired hot water direct vent condensing boilers
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BWC Series
High Efficiency Gas-Fired Hot Water
Direct Vent Condensing Boilers

InStallatIon InStruCtIonS

These instructions must be affixed on or adjacent to the boiler.
Models:
BWC070
•
BWC090
•
BWC120
•
BWC151
•
Equipped with Honeywell
SOLa Control
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 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.

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Summary of Contents for Crown Boiler BWC090

  • Page 1: Installation Instructions

    Direct Vent Condensing Boilers InStallatIon InStruCtIonS These instructions must be affixed on or adjacent to the boiler. Models: BWC070 • BWC090 • WarninG: Improper installation, adjustment, alteration, BWC120 service or maintenance can cause property damage, injury, • or loss of life. For assistance or additional information, con- BWC151 •...

  • Page 3: Table Of Contents

    Table of Contents Product Description II. Specifications 2 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.

  • Page 4: I. Product Description

    Table 2.3: Maximum Vent Lengths Using Concentric Vent System Supplied with the Boiler...................25 in. Using Optional 60/100mm Concentric Vent Components: BWC070................32 ft BWC090................32 ft BWC120................18 ft Using Optional 80/125 Vertical Concentric Vent System...................95ft Using Optional 80/125 Horizontal Concentric Vent System................100ft Using Approved 3”...

  • Page 5: Iii. 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. In Canada, installation must be in accordance with the B149.1 Installation Code.
  • Page 6 5) The boiler should be located so as to minimize the length of the vent system. 6) The combustion air piping must terminate where outdoor air is available for combustion and away from areas that will contaminate combustion air. Avoid areas near chemical products containing chlorine, chloride based salts, chloro/fluorocarbons, paint removers, cleaning solvents and detergents.
  • 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” (0mm) CONCENTRIC VENTING HORIZONTAL HEAT FAB SAF-T VENT AT LEAST ONE SIDE OPEN, PROTECH FASNSEAL VERTICAL OR...

  • Page 8: V. Mounting The Boiler

    V Mounting The Boiler A. Wall Mounting CAUTION This boiler weighs approximately 133 pounds: • Two people are required to safely lift this boiler onto the wall mounting hook. • Make sure that wall mounting hook is anchored to a structure capable of supporting the weight of the boiler and attached piping when filled with water. Jurisdictions in areas subject to earthquakes may have special requirements for supporting this boiler. These local requirements take precedence over the requirements shown below. 1) If the boiler is installed on a framed wall, minimum acceptable framing is 2 x 4 studs on 16” centers. The boiler mounting holes are on 16”...
  • Page 9 Figure 5.1 Wall Mounting Hole Locations...
  • Page 10 Figure 5.2 Boiler Mounting/Hardware...

  • Page 11: Vi. 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 12 Figure 6.1: Boiler Installed In A Confined Space, Ventilation Air From Inside • 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 13: Vii. 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. For vertical vent systems, the maximum vertical vent lengths shown in Table 7.9 are in addition to two standard radius elbows.
  • Page 15 WALL WALL WALL THROUGH STRUCTURE VENT PIPE SIZE 3” 60/100 mm 80/125 mm CONCENTRIC CONCENTRIC AIR INTAKE PIPE SIZE 3” BWC070 32ft 100ft 100ft BWC090 32ft 100ft 100ft BWC120 18ft 100ft 100ft BWC151 100ft 100ft BWC070 32ft 100ft 100ft BWC090...
  • Page 16 FIGURE 7.2: HORIZONTAL CONCENTRIC VENTING (VENT OPTION 1,3) FIGURE 7.3: HORIZONTAL TWIN PIPE VENTING (VENT OPTION 2)
  • 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 19 FIGURE 7.6a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 7.6b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS FIGURE 7.6c: POSITIONING VENT TERMINAL UNDER OVERHANGS...
  • 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 (53mm/m). • Pitch Stainless steel venting 1/4” per foot (21mm/m). 10) 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 21 ROOF THROUGH STRUCTURE AIR INTAKE PIPE STRUCTURE ROOF ROOF THROUGH STRUCTURE VENT PIPE SIZE 3” 80/125 mm CONCENTRIC AIR INTAKE PIPE SIZE 3” BWC070 98ft 95ft BWC090 98ft 95ft BWC120 98ft 95ft BWC151 98ft 95ft BWC070 98ft 95ft BWC090 98ft...
  • 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 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: C. 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 25 FIGURE 7.20: INSTALLATION OF REDUCING ELBOW ON CONCENTRIC BOILER COLLAR FIGURE 7.21: DIMENSION “L”...
  • Page 26 6) Use locking bands provided to join adjacent sections of non-cuttable pipe as well as fittings. 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” sheet metal screws. Drill a 1/8” hole through both outer pipes to start this screw. Use a drill stop or other means to ensure that the drill bit does not penetrate more than 3/8”...
  • Page 27 FIGURE 7.24: PREPARING 60/100mm TERMINAL SECTION FOR INSTALLATION IN THE WALL FIGURE 7.25: ATTACHING 60/100mm TERMINAL SECTION...

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

    • Do not attempt to try to mix this concentric pipe with other venting systems. 1) When BWC070, BWC090, or BWC120 boilers are vented using 80/125 venting, the 60/100 terminal section and reducing elbow supplied with the boiler are not used. The components listed in Table 7.4b are required for 80/125mm installations and are not supplied.
  • Page 29 2) Cutting Straight Pipe - The following straight pipe sections may be cut: Part # Description 230517 19 1/2” Straight 230515 39” Straight These sections have a plain male end (without beads - see Figure 7.30a). They are always cut from the male end. Sections not shown on the above list may not be cut.
  • Page 30 3) Joining Pipe - a) Start assembly of the vent system at the boiler. Lubricate the brown gasket in the boiler vent collar with a few drops of water. b) Push the male end of the first fitting 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 2d above) is covered. On other fittings, the bead on the male pipe will bottom out on the collar (Figure 7.32b). c) The male end of cuttable fittings must be held to the collar with three #10 x 1/2” sheet metal screws. Drill a 1/8”...
  • Page 31 4) 80/125mm Horizontal Terminal Installation - a) Cut a 5-1/2” diameter hole through the exterior wall at the planned location of the horizontal terminal. b) Measure distance “L” from the outside surface of the exterior wall to the end of the last fitting as shown in Figure 7.33a. c) Add 1-1/4” to distance “L”. Carefully mark this length on the pipe as shown in Figure 7.33b. d) Remove the plastic inner pipe from the terminal by gently pulling on it from the male end. Set aside. e) Cut the outer pipe only at the point marked in Step (c) using aviation shears, a hacksaw, or an abrasive wheel cutter. Be careful to cut the pipe square. De-burr the cut end with a file or emory cloth.
  • Page 32 FIGURE 7.33c: CUTTING INNER PIPE OF 80/125mm HORIZONTAL TERMINAL FIGURE 7.33d: COMPLETING 80/125mm HORIZONTAL TERMINAL INSTALLATION...
  • Page 33 5) Snorkel Terminal Installation - The Snorkel Kit (PN 230540) consists of the following (Also see Figure 7.34): Key # Part # Description 230541 Support Elbow 230542 Lower Wall Bracket IMPORTANT 230543 Air Intake Section The Terminal Elbow and Wall 230544 Wall Bracket Penetration Section included in the...
  • Page 34 d) Complete the vent system inside the structure. The support elbow sits on the M10 x 35 screw as shown in Figure 7.34. Cut the Wall Penetration Section to the length required to connect the interior vent system to the Support Elbow following the instructions on Page 26.
  • Page 35 FIGURE 7.35b: CUTTING VERTICAL TERMINAL FIGURE 7.35c: COMPLETING VERTICAL TERMINAL INSTALLATION...
  • Page 36 7) Chimney Chase Installation - A vertical 80/125mm vent system can be installed in an unused masonry chimney. This installation is similar to other vertical installations with the following exceptions (Also see Figure 7.36): a) The chimney chase elbow kit (PN230530) is used at the base of the chimney. This kit consists of a support elbow and a mounting bracket.

  • Page 37: E. Assembly Of Stainless Steel Venting

    E. Assembly of Stainless Steel Venting CAUTION Vent systems made by Heat Fab, Protech, Z-Flex, and Metal-Fab rely on gaskets for proper sealing. When these vent systems are used, take the following precautions: • Make sure that gasket is in position and undamaged in the female end of the pipe. • Make sure that both the male and female pipes are free of damage prior to assembly. • Only cut vent pipe as permitted by the vent manufacturer in accordance with their instructions. When pipe is cut, cut end must be square and carefully de burred prior to assembly. 1) General Assembly Notes: a) Where the use of “silicone” is called for in the following instructions, use GE RTV 106 for the vent collar. Air inlet piping sections are sealed with any general-purpose silicone sealant such as GE RTV102.
  • 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. Remove the hose clamp shipped on the BWC vent collar. 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.
  • 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. See the following instructions. • Support horizontal piping sections at intervals of 48” or less. • Vertical venting systems must be supported by at least one Z-Flex fire stop. An additional vertical support is required after any offset and as required by the Z-Vent III installation instructions.
  • 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. • In general, Saf-T Vent pipe sections may not be cut. Exceptions to this are the Saf-T Vent slip connector and connections to the boiler vent collar.In these cases, use a sharp pair of aviation snips, an abrasive cut-off, or a plasma cutter.
  • Page 41 6) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of flue gas flow. • Support horizontal piping sections at intervals of 6 feet or less. • Vertical venting systems must be supported by at least one FasNSeal support. An additional vertical support is required after any offset. b) Remove the hose clamp shipped on the BWC vent collar. Bend the three hose clamp tabs on this collar outward slightly. 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. On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately 1/4 inch from the male end of the pipe.

  • Page 42: F. 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 43 FIGURE 7.51: CONDENSATE PIPING ARRANGEMENT...

  • Page 44: Viii. Gas Piping

    VIII 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. Figure 8.1 shows typical gas piping connection to the BWC boiler. A sediment trap must be installed upstream of all gas controls.

  • Page 45: Ix. System Piping

    Additional information on hydronic system design may be found in Installation of Residential Hydronic Systems (Pub. #200) published by the Hydronics Institute in Berkeley Heights, NJ. TABLE 9.1: FLOW REQUIREMENTS THROUGH BOILER MIN. REQUIRED FLOW MAX. ALLOWABLE BOILER MODEL (GPM) FLOW (GPM) BWC070 BWC090 BWC120 12.0 BWC151 15.0...
  • Page 46 Method 1: Primary/Secondary Piping This method can be used in heat-only applications as shown in Figure 9.2 or with an indirect water heater as shown in Figure 9.3. This method relies on primary/secondary pumping to ensure that the required flow is always maintained through the boiler. In this system, the flow rate through the boiler is completely independent of the flow rate through the heating system. Use the following guidelines to ensure that the boiler will have the required flow shown in Table 9.1 regardless of the flow in the heating system. 1) Primary Loop Piping - Size the primary circulator and piping to obtain the design flow rate through the heating system as you would on any other heating system. All piping between the expansion tank and secondary connection tees must be at least as large as that shown in Table 9.5, column (a). In order to keep the flow rates in the primary and secondary loops independent of each other, provide at least 8 diameters of straight pipe upstream of the first secondary tee and 4 diameters downstream of the second secondary tee. Keep the distance between the...
  • Page 47 Example (contd.) Total fittings in Indirect Water Heater Loop: 5 90 Elbows 2 Turns in Tees 1 Swing Check 2 Isolation Valves Calculate total equivalent length from Table 9.7: 20 Straight Pipe + 5 Elbows x 2.75 + 2 Turns in Tees x 5.5 + 1 Swing Check x 7 + 2 valves x 0.6 = 52.95 Equivalent Feet Straight Pipe.
  • Page 48 Figure 9.3: Piping Method #1 - Heat + Indirect Water Heater Figure 9.4a: Piping Method #1 - Secondary Loop Piping (Shaded)
  • Page 49 MAX EQUIVALENT CIRCULATOR MODEL SIZE RISE LENGTH MODEL (in NPT) (GPM) (ft) BWC070 Taco 007 BWC070 Taco 008 BWC090 Taco 0014 BWC120 Taco 0014 BWC120 Taco 0014 BWC120 12.0 Taco 0013 (Note #1) BWC151 Taco 008 BWC151 11.0 Taco 0014 BWC151 14.0...
  • Page 50 HEATERS MODEL (in NPT) (GPM) (ft) (ft HEAD) MS-26 (*) MS-40 (*) BWC070 Taco 008 MSH-40H (*) MT040GBR (*) MS-26 MS-40 (*) BWC090 Taco 0014 MSH-40H MT040GBR (*) MS-26 MS-40 MSH-40H MT040GBR BWC120 Taco 0014 MT050GBR MT065GBR MT080GBR BWC120 MSH-53H...
  • Page 51 Method 2: Direct Connection to Heating System (Generally NOT Recommended) The BWC can be connected directly to the heating system as is done with conventional boilers (Figure 9.8). If this is done, the flow rate through the boiler will equal the flow rate through the system. The flow rate through the system must therefore always remain within the limits shown in Table 9.1. For this reason, the pressure drop through the entire system must be known, added to the boiler pressure drop, and a circulator selected which will provide the required flow at the total calculated pressure drop.

  • Page 52: C. 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 Figure 9.9: Boiler Head Loss FLOW (GPM) 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: D. 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 54 Figure 9.10: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger Figure 9.11: Chiller Piping...
  • Page 55 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 56: X. 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 /NFPA 70). In Canada, all wiring and grounding must be done in accordance with the Canadian Electrical Code, Part 1 (CSA C22.1 - latest edition).
  • Page 57 LOW VOLTAGE TERMINAL STRIPS LINE VOLTAGE TERMINAL STRIP (INSIDE J-BOX) Figure 10.0: Terminal Strip Locations Figure 10.1: Line Voltage Field Connections...
  • Page 58 CAUTION When making low voltage connections, make sure that no external power source is present in the thermostat or limit circuits. If such a power source is present, it could destroy the boiler’s control. One example of an external power source that could be inadvertently connected to the low voltage connections is a transformer in old thermostat wiring.
  • Page 59 CONDENSATE PUMP RECEPTACLE CONDENSATE TRAP TAIL PIECE CAT 5 (BOILER-TO-BOILER COMMUNICATION) VIEW OF CONTROL BOX FROM INSIDE TRAP COMPARTMENT (TRAP, RETURN PIPE & GAS PIPE OMITTED FOR CLARITY) Figure 10.2: Condensate Pump Receptical Figure 10.3: Low Voltage Field Wiring...
  • Page 60 CAUTION Do not attempt to use CAT 5 or EnviraCOM connections for any purpose not explicitly permitted by Crown Boiler Company. Attempting to do so may result in unreliable operation and/or damage to controls. Figure 10.4: Proper Installation of Header Sensor...
  • Page 61 Figure 10.5: Internal Ladder Diagram...
  • Page 62 Figure 10.6: Internal Wiring Connections Diagram...

  • Page 64: Xi. 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. This should be done with the boiler isolated from the system.
  • Page 65 WATER QUALITY AND BOILER WATER ADDITIVES IMPORTANT NOTE This boiler is equipped with an aluminum heat exchanger that can be seriously damaged by failure to follow the following guidelines: 1) Flush the system before connecting the boiler - In a replacement installation, flushing the system will remove sediment, solder flux, and traces of old boiler additives.
  • Page 66 8) The boiler should attempt to fire approximately 30 seconds after a call for heat appears. With the upper front cover removed from the boiler, this try for ignition will appear as an audible spark (lasting approximately 4 seconds) and an audible click from the gas valve. 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. If the boiler does not light after three tries for ignition, it will enter a “soft lockout” and will wait for one hour before attempting another ignition sequence. This soft lockout can be reset by interrupting power to the boiler for a few seconds. 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 67 Figure 11.1: Burner Flame Figure 11.2: Gas Valve Detail 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. Improper gas valve or mixture adjustments could result in property damage, personal injury, or loss of life.
  • Page 68 Table 11.3. Final readings should be taken with all doors and covers in place. Model Fuel BWC070 Natural Gas BWC070 Propane 10.4 BWC090 Natural Gas BWC090 Propane 10.5 BWC120 Natural Gas BWC120 Propane 10.5 BWC151 Natural Gas...

  • Page 69: 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 70: Xii. Operation

    XII Operation A. General Information The BWC boiler uses the microprocessor based Honeywell “Sola” control to manage all boiler functions including flame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the Sola’s memory; one for space heating (CH) and one for domestic hot water (DHW) production. If an outdoor temperature sensor is connected to the boiler, and enabled, the space heating supply set point will automatically shift downward as the outdoor temperature increases.
  • Page 71 IMPORTANT This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE: •...
  • Page 72 2) Press the CH Button to access central heating options. These include: a) Setpoint Location - Identifies the sensor that will be used to obtain the target water temperature when the boiler is responding to a call for heat. Choices include: • Supply (Generally Recommended) - Boiler attempts to obtain the target temperature during a call for heat at the supply sensor built into the boiler.
  • Page 73 Figure 12.1: Configuration Menu (See Part B for additional information)
  • Page 74 Press EXIT to return to the Configuration Menu. 3) If this boiler is installed with an indirect water heater, which sends a DHW demand directly to the boiler, press the DHW button on the Configuration Menu. If this is a heat only installation, or if the indirect water heater sends DHW demands to an external zoning panel, skip to Step 4. There are four possible DHW configurations. Each of these options is described below and also summarized in Table 12.6. Option #1: Indirect Water Heater Type: Storage, Zoning: DHW Circulator Pumps Directly to Boiler - An example of this type of system is shown in Figure 12.2.
  • Page 75 Figure 12.2: DHW Config. Option #1 Piping (IWH Direct to Boiler) "DHW PUMP" OUTPUT CONTROLS THIS VALVE SYSTEM PUMP TO SYSTEM FROM SYSTEM BOILER PUMP Figure 12.3: DHW Config. Option #2 Piping (Biminy Buddy Combi)
  • Page 76 DHW Priority - Like all boilers, the BWC is capable of regulating only one target boiler water temperature at any given time. This means that priority must be given to either the CH or DHW target temperature. In addition, it may be undesirable, or even impossible, to operate the pumps needed for both CH and DHW at the same time.
  • Page 77 SYSTEM PUMP "DHW PUMP" OUTPUT CONTROLS THIS VALVE TO SYSTEM FROM SYSTEM BOILER PUMP Figure 12.4: DHW Config. Option #3 Piping (Biminy Buddy Indirect) Figure 12.5: DHW Config. Option #4 Piping (IWH to Primary Loop) - Example #1...
  • Page 78 Table 12.6: Summary of Boiler and DHW Pump Behavior Demands Option CH Only DHW CH +DHW CH +DHW None Description Status of: Only (< 60 min) (> 60 min) • Indirect Water Heater Boiler Pump • Circ Zoning DHW Pump •...
  • Page 79 Figure 12.8: DHW Config. Option #4 Piping (IWH to Primary Loop) - Example #2 2) CH Settings - Press CH to change the target supply water temperature setting. a) If outdoor reset is disabled, only one CH setpoint exists. The boiler will always attempt to maintain this temperature during a call for CH. To change the setting, touch the button containing the current setting. Adjust the temperature using the “+” and “-” arrows shown and press SET to save the change (also see “How to Change Settings”...
  • Page 80 3) DHW Settings - From the Settings Menu, press the DHW button to change the setpoint temperature when the boiler is responding to a call for DHW: • If the DHW Configuration selected is for a Bimini Buddy Combi (BB100C), the “DHW Setpoint” is the desired temperature of the DHW (potable hot water) itself. • If the DHW Configuration selected is for a storage type indirect water heater (such as a Mega-Stor or Maxi- Therm) the “DHW Setpoint” is the setpoint of the boiler supply temperature during a call for DHW. Control of the potable water temperature is accomplished using the thermostat on the storage type indirect water heater.
  • Page 81 From Main Menu (Figure 12.0) If ODR is Enabled in If ODR is Disabled in If BB100C If Storage IWH is Configuration Menu Configuration Menu (Plate HX) is Selected in DHW Selected in DHW Config Menu Config Menu Accessible If WWSD is Enabled in Configuration Menu Manual input is...
  • Page 82 D. Enter Service Contact Information If desired, the technician can enter contact information so that the owner knows who to contact for future service. To do this: 1) From the Main Menu, press the DIAGNOSTICS button. 2) From the Diagnostic Menu, press either the INSTALLER or MORE button (only one will be visible depending on whether you are “logged in”).
  • Page 83 Figure 12.11: Diagnostic Menu (See Part D and Section XIV for additional information)
  • Page 84 2) Current Priority Screen: a) Current Demand - The demand to which the boiler is currently responding. If more than one demand is present, it is the one having the highest priority. See above descriptions under “Home Screen” for specific types of Current Demands. b) Setpoint - The temperature that the boiler is currently trying to achieve. c) Supply (or Header) Temperature - The actual water temperature at the current setpoint location (either the boiler supply or header, depending on the demand and what setpoint location was selected in the Configuration Menu).
  • Page 85 Figure 12.12: Status Menu (See Part E for additional information)
  • Page 86 5) Modulation Status Screen: a) Fan Speed - Current actual fan speed in RPM b) Setpoint - Current target fan speed in RPM c) Speed Control - Indicates the function currently controlling fan speed (and therefore firing rate). Typical possibilities include: • Off - Blower is off. • Burner system - The blower speed is being determined by that needed for pre-purge, ignition, or post purge.

  • Page 87: Xiii. Service And Maintenance

    XIII. Service and Maintenance IMPORTANT WARRANTY DOES NOT COVER BOILER DAMAGE OR MALFUNCTION IF THE FOLLOWING 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. Keep the area around the combustion air inlet terminal free from contaminates.
  • Page 88 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. e. 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 89: Xiv. Troubleshooting

    XIV. Troubleshooting WARNING Turn off power to boiler before working on wiring. A. Using the Diagnostics Menu The plain text display provided with this boiler provides an easy means of identifying most common problems. In the event that the control system detects a problem, such as an open limit or defective sensor, the Active Fault button shown in Figure 14.0 will appear and flash on both the Home Screen and the Burner Status Screen. Touching either Active Fault button will take the user to the Diagnostics Menu. From here, press the flashing button on each successive screen to reach a list of possible causes.
  • Page 90 Figure 14.0: Example of Diagnostic Menu during Soft Lockout Figure 14.1: Reading Limit Status Screen...
  • Page 91 d) Limit Status - The Limit Status Screen shows the status of all safety limits. Each of these limits is either shown as being ON or OFF. It is important to remember that since all of limits are wired in series, any limit which is in the OFF state will cause all limits “downstream” of it to also appear on this screen as being OFF, regardless of whether or not they actually are.
  • Page 92 Figure 14.3: Troubleshooting Blank or Unreadable Screen...

  • Page 93: Xv. 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...
  • Page 94 PARTS LIST BWC070 BWC090 BWC120 BWC151 DESCRIPTION Part # Part # Part # Part # Taco 008 950165 Taco 0014 950160 950160 950160 Gas Cock 950615 950615 950615 950615 M4 x 30mm Machine Screw (for gas valve harness) 3507342 3507342...
  • Page 96 PARTS LIST BWC070 BWC090 BWC120 BWC151 DESCRIPTION Part # Part # Part # Part # 1/2" Blk Elbow 950049 950049 950049 950049 Flanged Nipple Assy 950700 950700 950700 950701 Flanged Nipple Gasket 230401 230401 230401 230405 Pipe Support Bracket 230470...
  • Page 98 PARTS LIST BWC070 BWC090 BWC120 BWC151 DESCRIPTION Part # Part # Part # Part # Tinnerman Nut 90-217 90-217 90-217 90-217 1/8 x 2-1/2" Cotter Pin 900485 900485 900485 900485 10-16 x 1/2" Thread Forming Screw 900725 900725 900725 900725...
  • Page 106 APPENDIX A Optional Method for Retrofitting BWC Boilers into Existing Circulator Zone Systems The piping/wiring method shown in this Appendix is sometimes useful in retrofit applications where the old boiler was installed with circulator zones. The piping shown in this Appendix may offer the advantage of fewer changes to existing piping. In addition, if one of the original zones was used for an indirect water heater, the piping in this Appendix may allow the original indirect water heater circulator to be reused.
  • Page 107 Appendix B: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, includ- ing but not limited to decks and porches, the following requirements shall be satisfied:...
  • Page 108 1. Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:...
  • Page 109 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 110 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com PN: 980009 Rev 6 BWC - 12/12...

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