Crown Boiler BWC070 User manual

BWC Series



 

INSTALLATION INSTRUCTIONS





BWC070

BWC090

BWC120

BWC151

: Improper installation, adjustment, alteration,

service or maintenance can cause property damage, injury,

or loss of life. For assistance or additional information, con-

sult a qualied installer, service agency or the gas supplier.

This boiler requires a special venting system. Read these

instructions carefully before installing.

DESIGNED TO LEAD

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

www.crownboiler.com





Table of Contents

I. Product Description 2

 II.  Specications      2

III. Before Installing 3

IV. Locating The Boiler 3

V. Mounting The Boiler 6

VI. Air For Ventilation 9

VII. Venting 11

A. Vent System Design 11

B. Removing An Existing Boiler From Common Chimney 21

C. Assembly of Crown 60/100mm Concentric Venting 22

D. Assembly of Crown 80/125mm Concentric Venting 26

E. Assembly of Stainless Steel Venting 35

F. Condensate Trap and Drain 40

VIII. Gas Piping 42

IX. System Piping 43

General System Piping Precaution 43

System Design 43

Standard Piping Installation Requirements 50

Piping For Special Situations 51

X. Wiring 53

XI. Start-up and Checkout 57

XII. Operation 63

XIII. Service and Maintenance 68

XIV. Troubleshooting 70

XV. Parts 73

Appendix A: OptionalMethodforRetrottingBWCBoilers85

into Existing Circulator Zone Systems

Appendix B: Special Requirements For Side-Wall 87

Vented Appliances In The Commonwealth

of Massachusetts

I Product Description

TheBWC070,BWC090,BWC120andBWC151arealuminumgasredcondensingboilersdesignedforusein

forced hot water heating systems requiring supply water temperatures of 180°F or less. These boilers are designed

forinstallationonawall,howevertheymaybeoormountedusinganoptionalpedestalkitavailablefromCrown.

This boiler may be vented vertically or horizontally with combustion air supplied from outdoors. This boiler is not

designedforuseingravityhotwatersystemsorsystemscontainingsignicantamountsofdissolvedoxygen.

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” AL29-4C Horizontal Stainless Vent System and Optional Stainless Steel Vent Kit..........100 ft

See Vent Section for additional venting options and requirements.

Figure2.1:GeneralConguration

IISpecications

Table2.2:Specications

MODEL* NO. OF

SECTIONS

MAXIMUM

INPUT

(BTU/hr)

MINIMUM

INPUT

(BTU/hr)

D.O.E.

HEATING

CAPACITY

(BTU/hr)

AHRI NET

RATING

(BTU/hr)

WATER

VOLUME

(Gal.)

SUPPLY &

RETURN

CONNECTION

SIZE (NPT)

GAS

CONNECTION

SIZE (NPT)

APPROX.

NET

WEIGHT

(lb)

BWC070 mono block 70,000 30,000 63,000 55,000 0.41 1” 1/2” 102

BWC090 mono block 90,000 30,000 80,000 70,000 0.41 1” 1/2” 102

BWC120 mono block 120,000 40,000 107,000 93,000 0.62 1” 1/2” 110

BWC151 mono block 150,000 50,000 135,000 119,000 1.13 1” 1/2” 133

*Addsufx“EN”fornaturalgasand“EL”forpropane.Ratingsarethesameforbothfuels.

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

 • Whererequiredbytheauthorityhavingjurisdiction,thisinstallationmustconformtotheStandardfor

Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1).

2) BWC boilers utilize aluminum heat exchangers constructed, tested, and stamped in accordance with ASME

Boiler and Pressure Vessel Code Case 2382. Some jurisdictions which require ASME boiler construction do

not recognize this Code Case and may not approve the installation of an aluminum boiler. Consult the author-

ity having jurisdiction before installing this boiler.

3) Read Section VII to verify that the maximum combustion air and exhaust pipe lengths will not be exceeded in

the planned installation. Also verify that the vent terminal can be located in accordance with Section VII.

4) Make sure that the boiler is correctly sized:

• Forheatingsystemsemployingconvectionradiation(baseboardorradiators),useanindustryaccepted

sizing method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the

Hydronics Institute in Berkely Heights, NJ.

• Fornewradiantheatingsystems,refertotheradianttubingmanufacturer’sboilersizingguidelines.

• ForsystemsincludingaCrownMega-Storindirectwaterheater,sizetheboilertohaveeithertheDOE

Heating Capacity required for the Mega-Stor or the net rating required for the heating system, whichever

results in the larger boiler.

• Forsystemsthatincorporateotherindirectwaterheaters,refertotheindirectwaterheatermanufacturer’s

instructions for boiler output requirements.

5) Makesurethattheboilerreceivedisconguredforthecorrectgas(naturalorLP).

6) Makesurethattheboilerisconguredforuseatthealtitudeatwhichitistobeinstalled.

IV Locating the Boiler

1) Observe the minimum clearances shown in Figure 4.1. These clearances apply to both combustible and non-

combustible materials. Observe the minimum clearances to combustibles for vent pipe shown in Table 4.2.

2) Note the recommended service clearances in Figure 4.1. These service clearances are recommended, but may

be reduced to the combustible clearances provided:

a. Access to the front of the boiler is provided through a door.

b. Access is provided to the condensate trap and transformer located underneath the boiler.

3) Whentheboilerisinstalledontheoorusingtheoptionalpedestalkit,theboilermaybeinstalledonanon-

carpeted combustible surface.

4) Thereliefvalvemustbeinstalledinthefactoryspeciedlocation.

NOTICE

Thisproductmustbeinstalledbyalicensedplumberorgastterwheninstalledwithinthe

Commonwealth of Massachusetts. See Appendix A for additional important information about

installing this product within the Commonwealth of Massachusetts.

Figure 4.1: Clearances To Combustible Or Non-combustible Material

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/uorocarbons,paintremovers,cleaningsolventsanddetergents.

Table 4.2: Clearances From Vent Piping To Combustible Construction

TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE

MINIMUM CLEARANCE

TO COMBUSTIBLE

MATERIAL

80/125 and 60/100mm

CONCENTRIC VENTING

VERTICAL OR

HORIZONTAL ENCLOSED ON ALL FOUR SIDES 0”

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

Z-FLEX Z-VENT III

METAL-FAB CORR/GUARD

VERTICAL OR

HORIZONTAL

AT LEAST ONE SIDE OPEN,

COMBUSTIBLE MATERIAL ON A

MAXIMUM OF THREE SIDES

1”

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

Z-FLEX Z-VENT III

METAL-FAB CORR/GUARD

HORIZONTAL OR VERTICAL

WITH OFFSETS ENCLOSED ON ALL FOUR SIDES 2-1/2”

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

Z-FLEX Z-VENT III

METAL-FAB CORR/GUARD

VERTICAL WITH NO OFFSETS ENCLOSED ON ALL FOUR SIDES 2-1/2”

V Mounting The Boiler

A. Wall Mounting

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” centers for installation between two studs at the standard spacing. In

cases where the boiler cannot be centered between the studs, or where the studs are spaced closer than 16”

apart, the boiler may be anchored to ¾” plywood or horizontal 2 x 4s anchored to the studs.

2) 5/16” x 2” lag screws and washers are provided for mounting this boiler. These lag screws are intended

for mounting the boiler directly onto studs covered with ½” sheet rock. When the boiler is attached to

other types of construction, such as masonry, use fasteners capable of supporting the weight of the boiler

and attached piping in accordance with good construction practice and applicable local codes.

3) Make sure that the surface to which the boiler is mounted is plumb.

4) Before mounting the boiler, make sure that wall selected does not have any framing or other construction

that will interfere with the vent pipe penetration.

5) Onceasuitablelocationhasbeenselectedfortheboiler,andanyneededmodicationshavebeenmade

tothewall,useFigure5.1tolocateholes“A”and“B”.Makesurethatthehorizontalcenterlineofthese

holesislevel.Holes“C”and“D”mayalsobedrilledatthistimeoraftertheboilerishungonthewall.If

the 5/16” x 2” lag screws are used, drill 3/16” pilot holes.

6) Cut the opening/s in the wall for the vent system. The recommended hole diameter is 4-3/8” for

60/100mm coaxial pipe and 5-3/8” for 80/125mm pipe.

7) Attach the wall hanging hook using the 5/16” x 2” lag screws and washers, or other suitable anchors as

appropriate (Figure 5.2). Make sure the hook is level.

8) Hangtheboileronthewallhookasshowningure5.2.

9) IfnotalreadydoneinStep(4)locateanddrillholes“C”and“D”usingtheob-roundslotsinthebottom

mountingange.Securethebottomangetothewallusingthe5/16”x2”lagscrews,orotherfastenersas

appropriate(gure5.2).

10)Verifythatthefrontoftheboilerisplumb.Ifitisnot,installwashersatholes“C”and“D”betweenthe

bottommountingangeandthewalltoadjust.

10) See Section VII (Venting) for instructions on attaching the vent system to the boiler.

B. Floor Mounting

ThisboilermaybemountedontheoorusinganoptionalpedestalkitavailablefromCrown.Followthe

instructions provided with this kit to assemble the pedestal, and attach it to the boiler. When this pedestal is used,

theboilermaybeinstalleddirectlyonanon-carpetedcombustibleoor.

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lled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.

Figure 5.1 Wall Mounting Hole Locations

Figure 5.2 Boiler Mounting/Hardware

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