Crown Boiler BWC225 Installation Instructions Manual
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Crown Boiler BWC225 Installation Instructions Manual

High efficiency gas-fired hot water direct vent condensing boilers
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D
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:
BWC150
•
BWC225
•
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 BWC225

  • Page 1: Installation Instructions

    • service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, con- BWC225 • sult a qualified installer, service agency or the gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

  • Page 3: Table Of Contents

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

  • Page 4: Product Description

    EXHAUST (BTU/hr) BWC150 150,000 50,000 133,000 117,000 BWC225 225,000 75,000 202,000 176,000 * MODELS SHOWN ARE FOR NATURAL GAS. ADD “LP” SUFFIX TO MODEL NUMBER SHOWN FOR PROPANE MODEL NUMBER (ie BWC225LP). PERFORMANCE RATINGS ARE THE SAME FOR BOTH FUELS.

  • Page 5: Before Installing

    III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code, ANSI Z223.1.
  • Page 6 Figure 4.1: Clearances To Combustible Or Non-combustible Material Table 4.2: Clearances From Vent Piping To Combustible Construction MINIMUM CLEARANCE TO COMBUSTIBLE TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MATERIAL HEAT FAB SAF-T VENT AT LEAST ONE SIDE OPEN, PROTECH FASNSEAL VERTICAL OR 1”...

  • Page 7: Air For Ventilation

    Example: A BWC225 and a water heater are to be installed in a room measuring 6ft – 3 in x 7ft with an 8 ft ceiling. The water heater has an input of 30000 BTU/hr: Total input in thousands of BTU/hr = (225000 BTU/hr + 30000 BTU/hr) / 1000 = 255 MBTU/hr Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3...
  • Page 8 Figure 5.1: 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 9: Venting

    VI Venting WARNING Failure to vent this boiler in accordance with these instructions could result in unreliable boiler operation, severe damage to the boiler or property, or unsafe operation: * 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 10 The Vent Option #1 column in Table 6.2a describes a horizontal direct vent system using 3” vent pipe. From this column, we see that a BWC150 may have a vent length of up to 55ft. The first 90 elbow and the termination elbow are not considered.
  • Page 11 WALL WALL PENETRATION VENT PIPE SIZE 3” 4” AIR INTAKE PIPE SIZE 4” 4” BWC150 55 FT N.R. BWC225 N.R. 55 FT BWC150 60 FT N.R. BWC225 N.R. 60 FT 3” 90 ELBOW 4” 90 ELBOW EXHAUST TERMINAL OR TEE...
  • Page 12 FIGURE 6.3a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 6.3b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS FIGURE 6.3c: POSITIONING VENT TERMINAL UNDER OVERHANGS...
  • Page 13 6) Permitted Terminals for Vertical Venting (Vent Options 6, 7) - A rodent screen is installed in the end of the vent pipe. Vent manufacturer part numbers for these screens are shown in Table 4. The air inlet terminal consists of a 180 degree elbow (or two 90 degree elbows) with a rodent screen as shown in Figure 6.4.
  • Page 14 ROOF ROOF PENETRATION VENT PIPE SIZE 3” 4” AIR INTAKE PIPE SIZE 4” 4” BWC150 49.5 FT N.R. BWC225 N.R. 47 FT BWC150 52 FT N.R. BWC225 N.R. 52 FT RODENT SCREEN BY VENT SYSTEM EXHAUST TERMINAL MANUFACTURER. SAME DIAMETER AS VENT SYSTEM.
  • Page 15 TABLE 6.5: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS WALL HORIZONTAL VERTICAL MANUFACTURER VENT SYSTEM SIZE THIMBLES TERMINATION TERMINATION 7393GC ELBOW: 7314TERM 7393GCS TEE: 7390TEE 9392 SAF-T VENT 5391CI HEAT FAB EZ SEAL 7493GC ELBOW: 7414TERM 7493GCS 9492 TEE: 7490TEE 5491CI ELBOW: FSELB9003 + FSBS3 FSWT3...

  • Page 16: Removing An Existing Boiler From 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 17 3) Assembly of Metal-Fab Corr/Guard Vent System: a) Corr/Guard General Notes: • Do not cut Corr/Guard vent components. • Refer to Corr/Guard installation instructions for proper methods of support. • Orient Corr/Guard components so that the males ends of all fittings point in the direction of the boiler. b) Start assembly of the vent system at the boiler.
  • Page 18 3) 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 or Crown coaxial terminal.
  • Page 19 4) Assembly of Heat Fab Saf-T Vent EZ Seal: a) Saf-T Vent General Notes: These instructions cover the installation of Saf-T Vent EZ Seal. Saf-T Vent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. •...
  • Page 20 5) 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.
  • Page 21 4” galvanized smoke pipe will fit inside the inlet collar on the BWC boiler. Depending upon the exact OD of the pipe used, it may be necessary to crimp this pipe. Secure with a single #10 sheet metal screw through the hole in the inlet collar and seal the outside of the joint with silicone. If PVC is used for the intake system, use a short piece of 4”...
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  • Page 25: Gas Piping

    VII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at an inlet pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or the National Fuel Gas Code.

  • Page 26: 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 8.1: FLOW REQUIREMENTS THROUGH BOILER MIN. REQUIRED FLOW MAX. ALLOWABLE BOILER MODEL (GPM) FLOW (GPM) BWC150 BWC225...
  • Page 27 Method 1: Primary/Secondary Piping - Boiler in Secondary Loop This method can be used in heat-only applications as shown in Figure 8.2 or with an indirect water heater as shown in Figure 8.3. This method relies on primary/secondary pumping to ensure that the required flow is always maintained through the boiler.
  • Page 28 Calculate total equivalent length from Table 8.7: 20 Straight Pipe + 6 Elbows x 3.75 + 2 Turns in Tees x 8 + 1 Swing Check x 10 + 2 valves x 0.8 = 70.1 Equivalent Feet Straight Pipe. From Table 8.6, we see that smallest circulator which will pump at 8 GPM through a BWC150 with 70.1 equivalent feet and an indirect water heater pressure drop of 3 ft is a Taco 0010.
  • Page 29 Figure 8.3: Piping Method #1 - Heat + Indirect Water Heater...
  • Page 30 Figure 8.4a: Piping Method #1 - Secondary Loop Piping (Shaded) Figure 8.4b: Piping Method #1 - Indirect Water Heater Loop Piping (Shaded)
  • Page 31 (GPM) (ft) BWC150 1 1/4 Taco 007 BWC150 1 1/4 Taco 0010 BWC150 1 1/4 12.0 Taco 0010 BWC225 1 1/4 12.0 Taco 007 BWC225 1 1/4 12.0 Taco 0010 BWC225 1 1/4 18.0 Taco 0014 TABLE 8.6: PIPE AND CIRCULATOR SIZING FOR INDIRECT WATER HEATER LOOP MAX.
  • Page 32 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 8.8). 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 8.1.

  • Page 33: Standard Piping Installation Requirements

    6.00 5.00 4.00 3.00 BWC150 2.00 BWC225 1.00 0.00 Flow (GPM) Figure 8.9: Boiler Head Loss C: Standard Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping: 1) The relief valve is packaged loose with the boiler and must be installed in the location shown in Figure 2.1. The relief valve is set to open at 30 psi.

  • Page 34: Piping For Special Situations

    3) The return piping may be connected into the boiler through the back or sides of the boiler by rotating the drain elbow and routing the return piping through the appropriate knockout. 4) Circulator (Required) - Usually at least two circulators will be required to properly install a BWC Series boiler. See previous section (System Design) for information on sizing the circulators.
  • Page 35 Figure 8.10: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger Figure 8.11: Chiller Piping...

  • Page 36: Wiring

    IX 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 9.1) – The line voltage connections are located in the junction box on the right side of the vestibule: •...
  • Page 38 Figure 9.2: Ladder Diagram...
  • Page 39 Figure 9.3: Wiring of Isolation Relay for Control of Two Heating Circulators...

  • Page 40: Start-Up And Checkout

    X Start-up and Checkout NOTE SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS TRAIN ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TEST SPECIFIED IN Z21.13. Use the following procedure for initial start-up of the boiler: 1) If not already done, flush the system to remove sediment, flux, and traces of boiler additives.
  • Page 41 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 42: 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 43 7) Start the boiler using the lighting instructions on page 39. 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 44 If this is not possible, and if no sample tap is present in the vent system, remove the flue temperature sensor and insert the analyzer probe in the sensor opening. On the BWC150 and BWC225 the flue temperature probe is located behind the lower vestibule door. For the boiler to operate, this sensor will need to be temporarily connected outside of the boiler.
  • Page 45 Make sure that the appropriate circulators also start and stop in response to the thermostats. Table 10.3: Typical Sea Level CO2/O2 Combustion Model Fuel %Co2 BWC150 (Honeywell Valve) Natural Gas BWC150 (Dungs Valve) Natural Gas BWC225 (Honeywell Valve) Natural Gas BWC150 (Honeywell Valve) Propane BWC150 (Dungs Valve) Propane 10.1 BWC225 (Honeywell Valve) Propane 10.2...

  • Page 46: Operation

    XI 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.
  • Page 47 In standby mode, it is possible to view both the heating supply set point temperature and the “domestic hot water reference set point”. The “domestic hot water reference set point” plus 45°F equals the boiler supply set point when it is responding to a call from the indirect water zone. It is not the actual domestic hot water set point. The BWC is designed for use with a storage type indirect water heater such as the Crown Mega-Stor.
  • Page 49 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 13.3.
  • Page 50 Figure 11.4: Outdoor Reset Curve 7) The sequence of operation for a BWC series boiler on a call for heat from a thermostat is as described below: a) When power is first turned on, 120V is provided to the MCBA, the combustion fan and the LWCO trans- former.

  • Page 51: Service And Maintenance

    XII. Service and Maintenance IMPORTANT WARRANTY DOES NOT COVER BOILER DAMAGE OR MALUFUNCTION 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 52 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 as necessary. Remove any accumulated debris from the air inlet screen. Remove the attenuator hose and clean as necessary. (Note: The nylon cable tie used to hold the attenuator hose in place is releasable.) Remove the combustion fan/gas valve assembly and inspect the fan and fan blade for lint and dust.

  • Page 53: Troubleshooting

    XIII. Troubleshooting WARNING TURN OFF POWER TO BOILER BEFORE REPLACING FUSES OR WORKING ON WIRING. A. Troubleshooting problems where no error code is displayed: Table 13.1: No Error Code Displayed CONDITION POSSIBLE CAUSES • No 120VAC Power at boiler. Check breaker and wiring Display Blank, Fan off, LWCO lights off between breaker panel and boiler •...
  • Page 54 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 13.3: Soft Lockout Codes Displayed CODE CONDITION...

  • Page 55: Hard Lockout Codes Displayed

    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.
  • Page 56 PAGE INTENTIONALLY LEFT BLANK...

  • Page 57: 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...
  • Page 58 BWC REPLACEMENT PARTS LIST BWC150 BWC225 DESCRIPTION CROWN CROWN QUANTITY QUANTITY PART # PART # Crown Aluminum Nameplate 98-004 98-004 Aluminum Door Knob 90-210 90-210 #8-32 x 1/4” H.W.H. Screw 90-211 90-211 Front Door Panel 240313 240310 #6-32 Hex Nylon Insert LockNut...
  • Page 59 BWC REPLACEMENT PARTS LIST BWC150 BWC225 DESCRIPTION CROWN CROWN QUANTITY QUANTITY PART # PART # Nylon Glide Foot 1”Dia x 3/4” Long 700111 700111 Combination Base / Rear Panel 240303 240304 Vesibule Top Panel Assembly 240423 240420 Vent Seal Gasket...
  • Page 63 Gas Train Assembly (Honeywell Valve)
  • Page 64 Gas Train Assembly (Dungs Valve)
  • Page 65 BWC REPLACEMENT PARTS LIST BWC150 BWC225 DESCRIPTION CROWN CROWN QUANTITY QUANTITY PART # PART # #6-32 x 13mm Hex x 92mm, Long Standoff 900711 900711 M6 x 1.0 x 75mm, Hex Head Screw 240960 240960 Manifold Seal Ring, EPDM 240200 240200 M6 x 1.0 x 30mm, SS Hex Socket Set Screw...
  • Page 67 BWC REPLACEMENT PARTS LIST BWC150 BWC225 DESCRIPTION CROWN CROWN QUANTITY QUANTITY PART # PART # 3 x 63mm O-Ring 230003 Fan Inlet Block 230150 Dungs Air Inlet Adapter (Male) 3507345 42.5 Short Fan Adaptor Plate 3507346 12mm (Gray) Swirlplate 3507336...

  • Page 71: Appendix A Special Requirements For Side-Wall

    Appendix A: 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: For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: If there is not already one present, on each floor level where there are bedroom(s), a carbon...
  • Page 73 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com PN: 980040 Rev. 6 BWC - 12/12...

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