Crown Boiler PHNTM399 Installation And Operating Instructions Manual
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Crown Boiler PHNTM399 Installation And Operating Instructions Manual

Phantom-x series
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High Efficiency Gas-Fired Hot Water
Direct Vent Condensing Boilers

INSTALLATION AND OPERATING INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler and
retained for future reference.
Models:
• PHNTM399
• PHNTM500
This manual is for use with
boilers having a part number
ending in "B" (example:
PHNTM399HNL17UB.
105358-04 - 08/15
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
Series
WARNING:
Improper installation, 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. This boiler requires a special venting system.
Read these instructions carefully before installing.
9700609

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Summary of Contents for Crown Boiler PHNTM399

  • Page 1: Installation And Operating Instructions

    INSTALLATION AND OPERATING INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler and retained for future reference. Models: 9700609 • PHNTM399 WARNING: Improper installation, adjustment, alteration, • PHNTM500 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.
  • Page 2 IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.
  • Page 3 Special Installation Requirements for Massachusetts A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: 1.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Product Description, Specifications and Dimensional Data...... Unpacking Boiler..................III. Pre-Installation and Boiler Mounting............Venting...................... A. General Guidelines................13 B. CPVC/PVC Venting................18 C. Polypropylene Venting................. 24 D. Stainless Steel Venting................ 27 E. Removing the Existing Boiler............... 30 F.

  • Page 5: Product Description, Specifications And Dimensional Data

    This manual is for use with boilers having a part number ending in “B” (example: PHNTM399HNL17UB). Table 1A: Specifications Boiler Model Specification PHNTM399 PHNTM500 Altitude (ft. above sea level) - USA 0-7000 0-7000 Altitude (ft. above sea level) - Canada...

  • Page 8: Unpacking Boiler

    Number (MBH) (MBH) Efficiency (%) Efficiency (%) Min. Max. PHNTM399 94.1 94.5 PHNTM500 95.0 95.0 Ratings shown are for installations at sea level and elevations up to 2000 ft. For elevations above 2000 ft., the boiler will naturally derate by 2.5% for each 1000 ft. above sea level.

  • Page 9: Pre-Installation And Boiler Mounting

    CAN/CSA-B149.1, Venting Systems and Air Supply for cycling and accelerated component failure. Appliances. Crown Boiler Company DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler to the system. WARNING Multiple boiler installations greatly reduce the likelihood of boiler oversizing.
  • Page 10 III. Pre-Installation and Boiler Mounting G. General (continued) 4. Boiler Installation: * Note: a. For basement installation provide a solid level When boiler is vented vertically, the minimum base such as concrete where floor is not level or clearance from the rear of the jacket is increased where water may be encountered on the floor to 18 in.
  • Page 11 PHNTM399 PHNTM399 g. Repeat above procedure to install the fourth PHNTM500 PHNTM399 or PHNTM500 stacking boiler attachment bracket to secure 2. To field assemble individual Phantom boilers into a stacked boiler right side panels at the rear right stackable configuration, use the steps below: corner.
  • Page 12 III. Pre-Installation and Boiler Mounting G. General (continued) VII “Gas Piping” of the manual for sizing heating capacity and/or gross output of the selected stackable boiler combination. Follow and installation of an individual boiler. When instructions of Section VI “Water Piping common gas piping is sized, insure it will have adequate capacity for combined input and Trim”...

  • Page 13: Venting

    IV. Venting WARNING Asphyxiation Hazard. Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage, personal injury or death. Do not use a barometric damper, draft hood or vent damper with this boiler. Do not locate vent termination under a deck.

  • Page 14: Combustion Air

    Equivalent Equivalent Pipe Equivalent Equivalent Diameter Length Length Diameter Length Length PHNTM399 4 in. 2.5 ft. 100 ft. 4 in. 2.5 ft. 100 ft. (100 mm or 110 mm) (760 mm) (30.5 m) (100 mm or 110 mm) (760 mm) (30.5 m)
  • Page 15 IV. Venting A. General Guidelines (continued) Figure 4: Location of Vent Terminal Relative to Windows, Doors, Grades, Overhangs, Meters and Forced Air Inlets - Two-Pipe System Vent Terminal (Shown), Two-Pipe System Air Intake Terminal (Not Shown) d. Slope horizontal vent pipe minimum 1/4 in/ft prévenir le fléchissement.
  • Page 16 IV. Venting A. General Guidelines (continued) Table 6B: Vent/Combustion Air Equivalent Length Calculation Work Sheet Combustion Air Vent 90° Elbow(s) (Installer Supplied) 90° Elbow(s) (CPVC Supplied with Boiler) Subtotal, Subtotal, Quantity Equivalent Quantity Equivalent Length, Nominal Diameter Equivalent Nominal Diameter Equivalent (Pc) Length, per Pc...
  • Page 17 IV. Venting A. General Guidelines (continued) Figure 7: Direct Vent - Vertical Terminations e. Do not install vent terminal directly above windows or doors. Figure 6A: Direct Vent - Optional Vent Sidewall f. Locate bottom of vent terminal at least 3 ft. (900 Snorkel Termination mm)above any forced air inlet located within 10 ft.

  • Page 18: Cpvc/Pvc Venting

    IV. Venting A. General Guidelines - B. CPVC/PVC Venting (continued) Figure 8: Direct Vent - Vertical Terminations with Sloped Roof Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of 12 in. (300 mm) [18 in. (460 mm) Canada] from roof surface. Allow additional vertical (‘X’) distance for expected snow accumulation.
  • Page 19 Vent System Connector Refer to Figure 9 and following steps: Table 7A: CPVC/PVC Vent & Air Intake Components Included With Boiler Part Number (Quantity) Models PHNTM399 & PHNTM500 Vent & Air Intake Components Standard 4 In. Termination Vent Kit (P/N 102189-03) includes Schedule 40 PVC Tee 230804 (Qty.
  • Page 20 Table 7C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical (Roof) Termination Quantity Vent Components PHNTM399 & PHNTM500 Vertical (Roof) Termination, 4 in. Schedule 40 PVC Coupler Schedule 40 PVC 90° Elbow Schedule 40 CPVC Pipe x 6 in. (150 mm) min. horizontal run Schedule 40 CPVC Pipe x 9 in.
  • Page 21 IV. Venting B. CPVC/PVC Venting (continued) Figure 10: Near-Boiler Vent/Combustion Air Piping 4. System Assembly b. Install provided Schedule 40 x 30 in. (760 mm) long CPVC pipe into the vent section of the connector with a slight twisting motion and WARNING secure by tightening the worm band clamp screw.
  • Page 22 IV. Venting B. CPVC/PVC Venting (continued) Table 8: Expansion Loop Lengths Length of Loop Length Nominal Straight Run “L” Pipe Dia. (In.) 1520 1880 2159 2413 2642 • Do not enclose PVC venting. Use higher temperature rated CPVC pipe in enclosed Figure 11: CPVC/PVC Expansion Loop and Offset spaces or to penetrate combustible or non-combustible walls.
  • Page 23 IV. Venting B. CPVC/PVC Venting (continued) NOTICE Methods of securing and sealing terminals to the outside wall must not restrain the thermal expansion of the vent pipe. Figure 13: Rodent Screen Installation ii. Combustion Air Piping air terminal (supplied with boiler). See •...

  • Page 24: Polypropylene Venting

    IV. Venting B. CPVC/PVC Venting - C. Polypropylene Venting (continued) C. Polypropylene Venting terminal may be installed closer to roof than vent. Alternatively, boiler may be installed with vertical roof vent terminal and sidewall combustion air terminal. WARNING • Size roof opening to allow easy insertion Asphyxiation Hazard.
  • Page 25 Pipe Joint Side Wall Chimney Kit for Model PVC to PP Nominal Dia. Nominal Dia. Locking Band Termination Tee Venting Only PHNTM399 4 in. 4 in. 4PPS-04PVCM-4PPF 43PPS-LB 43PPS-TB 4PPS-FK (100 mm) (100 mm) PHNTM500 Table 10B: Listed Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco...
  • Page 26 IV. Venting C. Polypropylene Venting (continued) NOTICE WARNING The venting system must be free to expand Asphyxiation Hazard. Vent systems made by and contract and supported in accordance M&G/DuraVent and Centrotherm Eco Systems with installation instructions included by the rely on gaskets for proper sealing. When these original polypropylene venting component vent systems are used, take the following manufacturers, M&G/DuraVent or Centrotherm,...

  • Page 27: Stainless Steel Venting

    48 ft. (14.6 m). f. When flexible polypropylene pipe (liner) is used a. Models PHNTM399 and PHNTM500 are listed for combustion air supply to a boiler, the pipe for vertical venting by installing flexible vent...

  • Page 28: D. Stainless Steel Venting

    IV. Venting D. Stainless Steel Venting D. Stainless Steel Venting WARNING Asphyxiation Hazard. Follow these instructions and the installation instructions included by the original stainless steel venting component manufacturers, Heat Fab, M&G/DuraVent or Z-Flex, whichever applicable. Failure to do so could cause products of combustion to enter the building, resulting in severe property Figure 16: Field Installation of Two-Pipe Vent damage, personal injury or death.
  • Page 29 IV. Venting D. Stainless Steel Venting (continued) in Figure 5. NOTICE • Install a rodent screen (not supplied) in the inlet terminal. Use a screen having The venting system must be free to expand 1/2 in. x 1/2 in. (13 mm x 13 mm) mesh. and contract and supported in accordance b.

  • Page 30: Removing The Existing Boiler

    IV. Venting E. Removing the Existing Boiler (continued) Natural Gas and Propane Installation Code, CAN/ having 1/2 in. x 1/2 in. (13 mm x 13 mm) CSA B149.1. or larger mesh. Au moment du retrait d’une chaudière existante, les E. Removing the Existing Boiler mesures suivantes doivent être prises pour chaque When an existing boiler is removed from a common appareil toujours raccordé...

  • Page 31: Multiple Boiler Installation Venting

    IV. Venting F. Multiple Boiler Installation Venting (continued) F. Multiple Boiler Installation Venting 2. Combustion Air Piping a. Multiple boiler combustion air terminations are 1. Vent Piping and Terminations shown in Figure 17. a. Multiple boiler vent terminations are shown in b.

  • Page 33: Condensate Disposal

    *Maximum Condensate Flow, line in areas subject to freezing temperatures. Model c. If the point of condensate disposal is above the PHNTM399 trap, a condensate pump is required to move the condensate to the drain. Select a condensate PHNTM500 pump approved for use with condensing *Assumes 100% of water in fuel condenses.
  • Page 34 V. Condensate Disposal (continued) Figure 18: Condensate Trap and Drain Line 2. Limestone chips in neutralizers will get coated limestone chip replacement must be performed. A by salts (product of chemical reaction between pH test or acid test kits are available from HVAC/ limestone and acidic condensate) and lose plumbing distributors and should be used to measure neutralizing effectiveness over time.

  • Page 35: Water Piping And Trim

    Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Crown Boiler Company’ s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
  • Page 36 12. Select the paddle stamped “1” for the d. This piping arrangement can be used either for space heating-only applications or space heating PHNTM399 and PHNTM500. with indirect water heater(s) applications. 13. Attach paddle to flow switch stem using Space heating only - refer to Tables 14A and supplied machine screw.
  • Page 37 50 psi (340 kPa) at total calculated pressure drop. on PHNTM399 and PHNTM500. Optional 80 psi (550 kPa) and 100 psi (689 kPa) safety relief valve c. It is often very difficult to accurately calculate kits are available.
  • Page 39 VI. Water Piping and Trim C. Standard Installation Requirements (continued) 5. Fill Valve (Required) – Either manual (recommended) or automatic fill valve may be used. CAUTION However, if automatic refill is employed, a water meter must be added to evaluate the makeup water Burn Hazard.
  • Page 40 VI. Water Piping and Trim C. Standard Installation Requirements (continued) 10. Isolation Valves (Strongly Recommended) 11. Drain Valve (Required) – – Drain valve is Isolation valves are useful when the boiler must be packaged loose with boiler and must be installed in drained, as they will eliminate having to drain and the location shown in Figure 19 “Factory Supplied refill the entire system.
  • Page 43 • Systems with routine additions of fresh water Boiler Model Recommended Minimum Common • Systems open to atmosphere Water Manifold Size (NPT) If the boiler is used in such a system, it must be PHNTM399 2½” 3” 3” 4” 5”...
  • Page 44 VI. Water Piping and Trim E. Multiple Boiler Installation Water Piping (continued) Figure 22B: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger (IWH Piped Off System Header) E. Multiple Boiler Installation Water Piping - See 2. For installations where indirect domestic hot water heater is combined with space heating, Table 16 and Figures 22B 23A and 23B.

  • Page 47: Gas Piping

    VII. Gas Piping 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system WARNING pressure is ½ psig (3.4 kPa). Actual point of delivery pressure may be less; contact gas supplier for Explosion Hazard. Failure to properly pipe gas additional information.
  • Page 48 VII. Gas Piping (continued) B. Connect boiler gas valve to gas supply For materials or conditions other than those listed above, refer to National Fuel Gas Code, ANSI Z223.1/ system. NFPA 54 or Natural Gas and Propane Installation Code, CAN/CSA B149.1, or size system using standard engineering methods acceptable to authority having jurisdiction.
  • Page 49 Inlet to Gas Valve Valve resistant to action of liquefied petroleum gas. (in. w.c.) (in. w.c.) (in. w.c.) 3. Phantom boilers have factory supplied PHNTM399 13.5 miscellaneous parts cartons, which include gas- 11.0 PHNTM500 13.5 piping components to connect boiler gas valve(s) to gas supply system.
  • Page 50 VII. Gas Piping (continued) 3. An additional gas pressure regulator(s) may need 2. The low gas pressure switch must be reset after to be installed to properly regulate inlet gas pressure the boiler is piped to the gas supply and before it is at the smallest individual module (boiler).

  • Page 51: Electrical

    VIII. Electrical DANGER Electrical Shock Hazard. Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Electrical Shock Hazard.
  • Page 52 • 2 – “Heating Thermostat” Nominal Current Model Number • 3 – “DHW Temperature Switch” (amps) • 4 – “DHW Temperature Switch” PHNTM399 < 7 • 5 – “Outdoor Sensor” PHNTM500 < 6 • 6 – “Outdoor Sensor” • 7 – “Header Sensor”...
  • Page 53 VIII. Electrical (continued) Figure 26: Ladder Diagram...
  • Page 56 VIII. Electrical (continued) Figure 28A: Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header - Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater...
  • Page 58 CROWN PN 3501505 Figure 28C: DHW Priority/Circulators (with Crown PN 3501505 Zone Panel) Piped Off System Header Wiring Schematic for Heating Zone Circulators...
  • Page 60 VIII. Electrical (continued) G. External Multiple Boiler Control System b. Ethernet Cables Ethernet cables are used to connect the boiler This boiler is equipped with a Honeywell R7910 Control network together. These are standard “straight which has a built-in sequencer for multiple boiler through”...
  • Page 61 VIII. Electrical (continued) G. Multiple Boiler Operating Information (continued) Figure 31: RJ45 Splitter Installation Detail 1. Required Equipment and Setup (continued) d. Multiple Boiler Setup Step Description Comments Wire the header sensor to low voltage terminal strip terminals “Header sensor”. Install and wire the Header NOTE Sensor...

  • Page 62: System Start-Up

    IX. System Start-up E. Confirm that the boiler and system have no water leaks. WARNING F. Prepare to check operation. Explosion Hazard. Asphyxiation Hazard. 1. Obtain gas heating value Electrical Shock Hazard. Start-up of this boiler (in Btu per cubic foot) should be undertaken only by trained and skilled from gas supplier.
  • Page 63 IX. System Start-up (continued) Phantom Series Operating Instructions Figure 32: Operating Instructions...
  • Page 64 Check the inlet pressure and adjust if necessary. Verify that the inlet pressure is between the upper and lower Less PHNTM399 9.9 - 8.2 3.5 - 6.5 9.3 - 7.9 4.5 - 7.0 limits shown on the rating plate with all gas appliances than 100 on and off.
  • Page 65 Verify CO is less than 100 ppm. % CO % CO d. Lock boiler in low fire and allow boiler to PHNTM399 11.4 - 9.5 3.5 - 6.5 11.4 - 9.1 3.5 - 7.0 Less than operate for approximately 5 minutes before 100 PPM PHNTM500 10.8 - 9.1...
  • Page 66 Failure to properly secure the flue Phantom models PHNTM399 and PHNTM500 are temperature sensor into the port could lead to factory shipped as natural gas builds and can be field property damage, personal injury or loss of life.
  • Page 67 Throttle Screw Turns for LP Conversion lights. Approximate Throttle Boiler Model Gas Valve Screw Turns GB-057 HO WARNING PHNTM399 1¾ (¾” NPT) GB-057 HO Asphyxiation Hazard. The throttle adjustments PHNTM500 (¾” NPT) shown in Table 24 are approximate. The final throttle setting must be found using a cannot be remedied following “Help”...
  • Page 68 IX. System Start-up (continued) WARNING Asphyxiation Hazard. If the throttle is very far out of adjustment on the “rich” (counter-clockwise) side, the boiler burner may be running at 0% excess air or even with air deficiency. Operating the boiler in this condition may cause property damage, personal injury or loss of life.
  • Page 69 IX. System Start-up (continued) S. Controls Startup Check List The Control is factory programmed with default parameters. Before operating the boiler, these parameters must be checked and adjusted as necessary to conform to the site requirements. Follow the steps below, making selections and adjustments as necessary to ensure optimal boiler operation.

  • Page 70: Operation

    X. Operation A. Overview 5. Built-in Safety Control 1. R7910 Controller The Control includes safety controls designed to ensure safe and reliable operation. In addition to flame safety controls The R7910 Controller (Control) contains features and the Control includes supply water temperature, differential capabilities which help improve heating system operation, water temperature, and stack temperature safety limits and and efficiency.

  • Page 71: Supply Water Temperature Regulation

    X. Operation B. Supply Water Temperature Regulation (continued) B. Supply Water Temperature Regulation 5. Outdoor Air Reset 1. Priority Demand If an outdoor temperature sensor is connected to the boiler and Outdoor Reset is enabled, the Central Heat setpoint The Control accepts a call for heat (demand) from will automatically adjust downwards as the outdoor multiple places and responds according to it’s “Priority”.

  • Page 72: Boiler Protection Features

    In the event of an ignition failure: lieu of low water cutoff. ALSO ADHERE TO ALL LOCAL CODE REQUIREMENTS. Contact your local code inspector • Model PHNTM399 - the control retries 5 times and prior to installation. then goes into soft lockout for one hour.

  • Page 73: Multiple Boiler Control Sequencer

    X. Operation D. Multiple Boiler Control Sequencer (continued) 6. Multiple Demands D. Multiple Boiler Control Sequencer The Sequence Master responds to Central Heat, DHW 1. “Plug & Play” Multiple Boiler Control Sequencer and frost protection demands similar to the stand alone When multiple boilers are installed, the Control’s boiler.

  • Page 74: Boiler Sequence Of Operation

    X. Operation E. Boiler Sequence Of Operation (continued) E. Boiler Sequence of Operation 1. Normal Operation Table 28: Boiler Sequence of Operation Status Screen Display Description Boiler 1 Priority: 140 F Supply (burner Off, circulator(s) Off) Standby > 140 F <...

  • Page 75: Using The Display

    X. Operation E. Boiler Sequence Of Operation (continued) 2. Using The Display The Control includes a touch screen LCD display. The user monitors and adjusts boiler operation by selecting screen navigation “buttons” and symbols. The “Home Screen” and menu selections are shown below. When no selection is made, while viewing any screen, the display reverts to the “Home Screen”...

  • Page 76: Status Screens

    X. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” though boiler operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the “Status”...
  • Page 77 X. Operation E. Boiler Sequence Of Operation (continued) 3. Status Screens (continued) Bargraph Screen Bargraph Screen The bargraph screen presents measured values for easy comparison. Included on this screen is firing rate and when the Zone Panel is connected the measure Heat Loss. Measured heat loss is the heat rate kbtu/hr sum of all active (call for heat) zones.

  • Page 78: Detail Screens

    X. Operation E. Boiler Sequence Of Operation (continued) Circulator Status Screen Pumping is a major part of any hydronic system. This screen provides the status of the boiler’s demand to connected pumps as well as the status of Frost Protection and pump Exercise functions. Head Demand Screen This screen provides the status of the boilers five (5) possible heat demands.

  • Page 79: Multiple Boiler Sequencer Screens

    X. Operation E. Boiler Sequence Of Operation (continued) 5. Multiple Boiler Sequencer Screens available: When the Sequence Master is enabled the following screens are The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Mas- ter is enabled.

  • Page 80: Changing Adjustable Parameters

    X. Operation F. Changing Adjustable Parameters (continued) F. Changing Adjustable Parameters 1. Entering Adjust Mode The Control is factory programmed to include basic modulating boiler functionality. These settings are password protected to discourage unauthorized or accidental changes to settings. User login is required to view or adjust these settings: - Press the “Adjust”...

  • Page 81: Adjusting Parameters

    X. Operation F. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) The following pages describe the Control’s adjustable parameters. Parameters are presented in the order they appear on the Control’s Display, from top to bottom and, left to right. From the “Home” screen select the Adjust button to access the adjustment mode screens show below (if required, refer to the previous page to review how to enter Adjustment mode): System “Press”...
  • Page 82 X. Operation F. Changing Adjustable Parameters (continued) WARNING Asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are installing a new or replacement Control. The boiler type setting determines minimum and maximum blower speeds.
  • Page 83 X. Operation F. Changing Adjustable Parameters (continued) Expected Heat Rate Adjustment Screens (HeatMatch Software) The Control is shipped with defaults that will provide improved operation. Adjustment is only required to optimize setup. The expected heat rate adjustment is used to better match boiler output to the home heating needs. After receiving a "call for heat"...
  • Page 84 X. Operation F. Changing Adjustable Parameters (continued) Modulation “Press” button to access the following parameters: Setup Factory Range / Choices Parameter and Description Setting Central Heat Maximum Expected Heat Rate Minimum to This parameter defines the highest modulation rate the Control will go to during a central heat 100% Maximum call for heat.
  • Page 85 X. Operation F. Changing Adjustable Parameters (continued) “Press” Pump Setup button to access the following parameters: Factory Setting Range / Choices Parameter and Description System Pump run pump for: Activates the system pump output according to selected function. Never: Pump is disabled and not shown on status screen. Any Demand: Pump Runs during any call for heat.
  • Page 86 X. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single boiler Indirect Water Heater (IWH)Piped to Primary, Optional Domestic Hot Water Priority. Parameter Selections: System Pump= “Central Heat , Optional Priority” Boiler Pump = “any demand” DHW Pump = “Primary Loop Piped IWH” DHW Priority Enable is optional Explanation: This piping arrangement permits the...
  • Page 87 X. Operation F. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority Sequencer Master Boiler 2 (Boiler 1) Wiring locations: Thermostat DHW call for heat System pump DHW pump Boiler Pump Sequencer Master Parameter Selections: Sequencer Master...
  • Page 88 X. Operation F. Changing Adjustable Parameters (continued) Contractor Setup “Press” button to access the following parameters: Contractor Name For Service Contact: Press box to input contractor information. Bill Smith > < Bill Smith 12 Victory Lane Plainview, New York Save 516 123-4567 Press SAVE button to store revisions.
  • Page 89 X. Operation F. Changing Adjustable Parameters (continued) Central Heat “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting 180°F 60°F to 190°F Central Heat Setpoint (82.2°C) (16°C to 87.8°C) Target temperature for the central heat priority. Value also used by the outdoor air reset function. Central Heat Thermostat “Sleep”...
  • Page 90 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Auxiliary Heat Setpoint 180°F 60°F to 190°F Target temperature for the Auxiliary Heat priority. Value also used by the outdoor air reset (82.2°C) (16°C to 87.8°C) function.
  • Page 91 X. Operation F. Changing Adjustable Parameters (continued) Domestic “Press” button to access the following parameters: Hot Water Factory Range / Choices Parameter and Description Setting Domestic Hot Water Setpoint 60°F (16°C) to The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water 170°F 190°F temperature setpoint that is used when DHW heat demand is “on”.
  • Page 92 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Central Heat Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 42.
  • Page 93 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Auxiliary Heat Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 42.
  • Page 94 X. Operation F. Changing Adjustable Parameters (continued) Figure 42: Outdoor Reset Curve - Typical for Central Heat and Auxiliary Heat Central Heat Central Heat Heating Element Type Heating Element Type Setpoint Setpoint 180°F to 190°F 100°F to 140°F In Slab Radiant High Fan Coil (82.2°C to 87.8°C) (37.8°C to 60°C)
  • Page 95 X. Operation F. Changing Adjustable Parameters (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Master Enable/Disable Enable, Disable The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller. Warning! Disable enable ONLY one Sequence Master.
  • Page 96 X. Operation F. Changing Adjustable Parameters (continued) Sequence “Press” button to access the following parameters: Slave Factory Range / Choices Parameter and Description Setting Boiler Address Each boiler must be given a unique address. When ”Normal” slave selection order is used, the None boiler address is used by the Master Sequencer as the boiler start order.

  • Page 97: Service And Maintenance

    XI. Service and Maintenance Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 98 XI. Service and Maintenance (continued) WARNING Asphyxiation Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service.
  • Page 99 XI. Service and Maintenance (continued) DANGER Explosion Hazard. Electrical Shock Hazard. Burn Hazard. This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service.
  • Page 100 XI. Service and Maintenance (continued) prohibited. Do not use any cleaning agents or solvents. If insulation disc has signs of damage, it must be replaced. CAUTION / ATTENTION Inspect the condensate trap to verify it is open and free from debris. Inspect condensate line integrity between Electrical Shock Hazard.
  • Page 101 6th Avenue, Altoona, PA 16602 Tel: (972) 547-6002, Tel: (972) 547-6002 and/or selected Poison Hazard. Use only inhibited propylene HVAC distributors. Contact Crown Boiler glycol solutions specifically formulated for Company for specific details. hydronic systems. Do not use ethylene glycol, which is toxic and can attack gaskets and seals iii.
  • Page 102 XI. Service and Maintenance (continued) overflow switch threads and the switch is properly 2. Condensate Trap Removal and Reinstallation: oriented relative to the trap body - the arrow molded a. Disconnect power supply to boiler. into the switch hex side end must face down for proper switch operation.

  • Page 103: Troubleshooting

    XII. Troubleshooting WARNING Electrical Shock Hazard. Turn off power to boiler before working on wiring. A. Troubleshooting problems where no error code is displayed. Condition Possible Cause Boiler not responding to call for heat, “Status” and Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection, “Priority”...
  • Page 104 XII. Troubleshooting (continued) C. Help Screen Faults Indication Condition Possible Cause Zone Panel 1 communication lost, typical for Panel 1 through 4: The zone panel’s communication was established and then lost. Check the following to correct the Zone Panel 1 issue: Setup •...
  • Page 105 XII. Troubleshooting (continued) E. Active Fault Screen Faults Indication Condition Possible Cause The Limit String Status screen shows the faulty safety limit. A contact icon, either Limit String Status “open” or “closed”, graphically represents each safety limit. The “closed” contact icon is steady;...
  • Page 106 XII. Troubleshooting (continued) F. Troubleshooting problems where a Soft Lockout Code is displayed. When a soft lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the soft lockout.
  • Page 107 XII. Troubleshooting (continued) G. Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the Hard Lockout.

  • Page 108: Repair Parts

    XIII. Repair 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 109 XIII. Repair Parts (continued) Heat Exchanger Components Part Number Description PHNTM399 PHNTM500 1A Air Vent Valve 101586-01 1B Supply/Return Water Temperature Sensor (2 per boiler) 101685-01 1C High Limit Water Temperature Sensor 101653-01 Replacement Rear Insulation Disc and Thermal Link Switch Kit...
  • Page 110 XIII. Repair Parts (continued) Blower / Gas Train Components Part Number Description PHNTM399 PHNTM500 Replacement Blower Kit (includes blower, blower outlet gasket and 104999-01 104999-02 hardware) Blower Outlet Gasket 101345-01 102614-01 Blower Inlet Assembly (includes gas orifice, injector flange, inlet...
  • Page 111 XIII. Repair Parts (continued) Condensate Trap and Related Components Part Number Description PHNTM399 PHNTM500 Replacement Condensate Trap Kit 104704-01 (includes trap, float switch, grommet, coupling, and clamps) Replacement Condensate Float Switch Kit 105005-01 (includes float switch and clamp) Spring Hose Clamp, 15/16 in. OD hose...
  • Page 112 XIII. Repair Parts (continued) Control Components Part Number Description PHNTM399 PHNTM500 Replacement R7910 Control Kit (0 - 7000ft Altitude) 106193-01 106193-04 Replacement Display 106217-01 (programmed, includes mounting hardware) Transformer 3502430 Upper Front panel 105351-01 Control Slide Out Tray 103336-01...
  • Page 113 THIS PAGE LEFT BLANK INTENTIONALLY...
  • Page 115 XIII. Repair Parts (continued) Sheet Metal, PHNTM399 and PHNTM500 Part Number Description PHNTM399 PHNTM500 Replacement Left Side Panel Kit 105017-01 105017-02 (includes labels, access panels, grommets and header gaskets) Replacement Right Side Panel Kit 105018-01 105018-02 (includes labels, access panels and gaskets)
  • Page 116 XIII. Repair Parts (continued) Additional Components Part Number Description PHNTM399 PHNTM500 CSD-1 Kit (not shown, includes manual reset high limit, immersion 433700 well, gas pressure switches, and hardware) Gas Pressure Switch Assembly 102670-01 Low Gas Pressure Switch 102702-01 High Gas Pressure Switch...
  • Page 117 XIII. Repair Parts (continued) Wiring Harnesses Part Number Description PHNTM399 PHNTM500 Complete Wiring Harness (includes 10A, 10B, 10C & 10D) 102701-03 10A Main (Low Voltage) Harness 103009-03 10B High Voltage Harness 103010-02 10C Blower Power Harness 103012-01 10D Communication Harness...
  • Page 120 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com CBC PN 980133 Rev C, 08/15...

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