Crown Boiler BWC070 Installation Instructions Manual
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Crown Boiler BWC070 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
MCBa 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 BWC070

  • Page 1: Installation Instructions

    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 • WarninG: Improper installation, adjustment, alteration, BWC120 service or maintenance can cause property damage, injury, •...

  • 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: Product Description

    * Add suffix “EN” for natural gas and “EL” for propane. Ratings are the same for both fuels. 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: 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” CONCENTRIC VENTING HORIZONTAL HEAT FAB SAF-T VENT AT LEAST ONE SIDE OPEN, PROTECH FASNSEAL VERTICAL OR 1”...

  • Page 8: 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: 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: 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 THROUGH STRUCTURE AIR INTAKE PIPE PENETRATION 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...
  • Page 16 FIGURE 7.2: HORIZONTAL CONCENTRIC VENTING (VENT OPTION 1,3) FIGURE 7.3: HORIZONTAL TWIN PIPE VENTING (VENT OPTION 2)
  • Page 17 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 WALL GROMMET 60/100mm BWC070/090/120 230505 39” STRAIGHT...
  • 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 • Pitch Stainless steel venting 1/4” per foot. 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 VENT PIPE PENETRATION ROOF 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...
  • 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

    • Do not attempt to try to mix this concentric pipe with other venting systems. 1) Concentric vent components supplied with the boiler are packed inside the BWC070/090/120 carton and include the following: a) 80/125 x 60/100mm reducing elbow (Crown PN 230521).
  • 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: 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 hole through both outer pipes to start this screw.
  • 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 plate to the inside wall. 5) Snorkel Terminal Installation - The Snorkel Kit (PN 230540) consists of the following (Also see Figure 7.34): Key # Part # Description 230541 Support Elbow IMPORTANT 230542 Lower Wall Bracket The Terminal Elbow and Wall 230543 Air Intake Section Penetration Section included in the...
  • Page 34 and mount the bracket. 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 (Figure 7.35c). 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: 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: 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: 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: 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 BOILER PIPE TEMP FLOW 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...
  • Page 50 CIRCULATOR MODEL SIZE RECT WATER DROP LENGTH MODEL HEATERS (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...
  • 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: 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: 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: 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 57 Figure 10.2: Ladder Diagram...
  • Page 58 Figure 10.3: Wiring of Isolation Relay for Control of Two Heating Circulators...

  • 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. This should be done with the boiler isolated from the system.
  • Page 60 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 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 62 7) Start the boiler using the lighting instructions on page 48. After the boiler is powered up, it should go through the following sequence. Sequence Display Meaning U.125 or Blank Checking internal software (power-up only) 0.SWT Boiler in standby. = Supply Water Temp. No call for heat. (After call for heat from heating thermostat) A.SWT Self-Check on Start-up...
  • Page 63 Normal modulation of the boiler should return 15 minutes after the boiler is locked in high or low fire. At both high and low fire, CO readings should be less than 75 PPM. Typical CO and O readings are shown in Table 11.3. Model Fuel BWC070 Natural Gas BWC070 Propane 10.4 BWC090 Natural Gas BWC090 Propane 10.5...
  • 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 65: Operation

    XII Operation 1) The BWC boiler uses a microprocessor based control, known as a “MCBA”, to manage all boiler functions including flame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the MCBA’s memory; one for space heating and one for domestic water production. If an outdoor tempera- ture sensor is connected to the boiler, the space heating supply set point will automatically adjust downwards as the outdoor temperature increases. For more information on this feature see the discussion on boiler water reset below.
  • 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. The domestic water set point is controlled by the thermostat on the indirect water heater. The “default domestic water reference set point”...
  • Page 68 3) Two basic types of errors codes are shown on the display: • Soft Lockout Codes – When a soft lockout occurs, the boiler will shut down and the display will alter- nate between the number “9” and the letter “b” followed by a two digit service code. A list of these codes, and their meanings, is shown in Table 14.3. The boiler will automatically restart once the condi- tion that caused the lockout is corrected. • Hard Lockout Codes – When a hard lockout occurs, the boiler will shut down and the display will flash the letter “E” followed by a two digit service code. A list of these codes, and their meanings, is shown in Table 14.4.
  • 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. A separate 50VA transformer, connected directly to the MCBA, powers all other low voltage circuits. b) For the first few seconds after power-up the control module goes through a self check.

  • 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. 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 72: Troubleshooting

    XIV. Troubleshooting WARNING TURN OFF POWER TO BOILER BEFORE REPLACING FUSES OR WORKING ON WIRING. A. Troubleshooting problems where no error code is displayed: Table 14.1: No Error Code Displayed CONDITION POSSIBLE CAUSES • No 120VAC Power at boiler. Check breaker and wiring Display Blank, Fan off, LWCO lights off between breaker panel and boiler.
  • Page 73 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 POSSIBLE CAUSES...
  • Page 74 C. Trouble shooting problems where a hard lockout code is displayed. When a hard lockout occurs, the boiler will shut down and the display will flash the letter “E” followed by a two digit service code. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset using the RESET button on the display. Table 14.4: Hard 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...
  • Page 77 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 78 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 83 PARTS LIST BWC070 BWC090 BWC120 BWC151 DESCRIPTION Part # Part # Part # Part # Zinc Plated Brass Spacer 960054 960054 960054 960054 8-32 x 3/4 Round Head Machine Screw 900725 900725 900725 900725 8-32 x 1/2" PH Machine Screw...

  • Page 87: Appendix A: Optional Method For Retrofitting Bwc Boilers

    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 88 Figure A.2: Field Wiring - All Zones Require Same Supply Temperature Figure A.3: Field Wiring With Priority For DHW...

  • Page 89: Appendix B: Special Requirements For Side-Wall

    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 90 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 91 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com PN: 980056 Rev 6 BWC - 12/12...
  • Page 92 MODEL* INPUT INPUT CAPACITY RATING VOLUME CONNECTION SECTIONS CONNECTION WEIGHT (BTU/hr) (BTU/hr) (BTU/hr) (BTU/hr) (Gal.) SIZE (NPT) SIZE (NPT) (lb) BWC070 mono block 70,000 30,000 63,000 55,000 0.41 1” 1/2” BWC090 mono block 90,000 30,000 80,000 70,000 0.41 1” 1/2”...

This manual is also suitable for:

Bwc090Bwc120Bwc151

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