Crown Boiler BWC070 Manuals

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 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. D E S I G N E D T O L E A D Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com Equipped with Honeywell MCBA Control Table of Contents I. Product Description 2 II. Specifications 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 Retrofitting BWC Boilers 85 into Existing Circulator Zone Systems Appendix B: Special Requirements For Side-Wall 87 Vented Appliances In The Commonwealth of Massachusetts 1 2 I Product Description The BWC070, BWC090, BWC120 and BWC151 are aluminum gas fired 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 floor 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 significant 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 Configuration II Specifications Table 2.2: Specifications 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 suffix “EN” for natural gas and “EL” for propane. Ratings are the same for both fuels.

BWC070, BWC090, BWC120 Installation Manual Supplement June 12th, 2007 The following pages are copied from the latest edition of the installation manual for the above boilers, which is not yet in print. These pages cover new vent options that have been added for these boilers and which are not shown in the current manual. These options include: 1) 80/125mm concentric venting may be used to achieve longer vent runs. 2) 80/125mm concentric venting may be used for vertical vent applications. 3) An 80/125mm concentric snorkel kit is now offered. 4) Metal-Fab “Corr/Guard” may now be used for stainless steel vent applications. Refer to the installation manual supplied with the boiler for important warnings and other information not covered in this supplement. 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: * Do not attempt to vent this boiler with galvanized, PVC, or any other vent components not listed in Table 7.4. * Do not attempt to mix components from different approved vent systems. * Do not obtain combustion air from within the building. * Do not install a barometric damper or drafthood on this boiler. A. Vent System Design There are four basic ways to vent this boiler: • Horizontal (“Side Wall”) Concentric Venting - Vent system exits the building through an outside wall. Concentric venting consists of a “pipe within a pipe”. Flue gas exits the building through the inner pipe and combustion air is drawn into the boiler through the space between the inner and outer pipe. • Horizontal (“Side Wall”) Twin Pipe Venting - Vent system exits the building through an outside wall. Combustion air and flue gas are routed between the boiler and outdoors using separate pipes. • Vertical Concentric Venting - Vent system exits the building through the roof. Concentric venting consists of a “pipe within a pipe”. Flue gas exits the building through the inner pipe and combustion air is drawn into the boiler through the space between the inner and outer pipe. • Vertical Twin Pipe Venting - Vent system exits the building through a roof. Combustion air and flue gas are routed between the boiler and outdoors using separate pipes. All of these systems are considered “direct vent” because in all of them air for combustion is drawn directly from the outdoors into the boiler. A description of all of these venting options are shown in Tables 7.1 and 7.9. For clarity, these vent options are numbered from 1 to 6. One of the vent option columns in Tables 7.1 or 7.9 must match the planned vent and air intake system exactly. In addition, observe the following guidelines: 1) Approved vent systems - Use only one of the approved vent systems shown in Tables 7.4 or 7.5. These vent systems fall into two basic categories: • Concentric Vent System - The standard boiler is supplied with a concentric vent system having a maximum usable length of 25” (Figure 1.1). For longer runs, additional straight lengths and elbows are available from Crown. In some cases, larger diameter concentric pipe must be used. Each Crown concentric vent component consists of an inner pipe of polypropylene and the outer pipe of steel. Integral gaskets on each concentric fitting provide a gas tight seal. A list of all Crown concentric vent components is shown in Table 7.4. In this manual, concentric pipe sizes are called out in terms of the inner and outer pipe nominal diameters in millimeters. For example, “60/100mm” pipe consists of a 60mm exhaust pipe inside a 100mm diameter outer pipe. • Twin Pipe Vent Systems - Approved vent systems are made of a special stainless steel alloy (AL29-4C) for protection against corrosive flue gas condensate. They are designed to provide a gas tight seal at all joints and seams so that flue gas does not enter the building. Each approved vent system has a unique method for installation - do not attempt to mix components from different vent systems. A list of approved twin pipe vent systems is shown in Table 7.5. Note that a special vent collar (Crown PN 230510) is required if the boiler is to be vented with one of the approved stainless vent systems. 11 CAUTION Moisture and ice may form on the surfaces around the vent termination. To prevent deterioration, surfaces should be in good repair (sealed, painted, etc.). 12 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. If more elbows are desired, the maximum allowable vent length must be reduced by the amount shown in Table 7.8 for each additional elbow used. Termination fittings are never counted, although the length of the concentric terminal section is counted. Example: A 60/100mm concentric vent system is planned for a horizontally vented BWC120 which has the following components: 80/125 x 60/100mm Reducing Elbow (supplied with the boiler) 5ft Straight Pipe 90 elbow 1-1/2ft Straight Pipe 45Elbow Uncut Terminal Section (supplied with the boiler) The Vent Option #1 column in Table 7.1 describes a horizontal direct vent system using 60/100mm concentric vent pipe. From this column, we see that a BWC120 may have a vent length of up to 18ft. The 90 degree reducing elbow is not considered. The length of the terminal section (not including the plastic terminal itself) is approximately 22 1/2” (1.9ft) installed. From Table 7.8, we see that the equivalent length of the 60/100mm elbow is 4.5ft and that the equivalent length of the 45 degree elbow is 4ft. The total equivalent length of the planned venting system is therefore: 5ft (Straight ) + 4.5ft (90 Elbow) + 1.5ft (Straight ) + 4 ft (45 Elbow) + 1.9ft (Uncut Terminal Section) = 16.9ft. Since Table 7.1 shows a maximum allowable vent length of 18ft, the planned vent system length is acceptable. 3) Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in tables 7.1 and 7.9. 4) Permitted Terminals for Horizontal Venting: • Vent Option 1 - The 60/100mm concentric vent terminal is supplied with the boiler as part of the standard vent system. • Vent Option 2 - The exhaust terminal is Crown PN 230511. The air intake fitting is a 90 degree elbow with a rodent screen supplied by the installer. This elbow is made out of the same material as the rest of the air inlet system (either galvanized or PVC) and is installed as shown in Figure 7.3. • Vent Option 3 - Two terminals are permitted: a) 80/125mm Concentric Vent Terminal (Crown PN 230531) b) 80/125mm Snorkel Terminal (Crown PN 230540) . This terminal allows the vent system to exit the building close to grade and go up the exterior wall far enough to provide adequate clearance between the terminal itself and the snow line (Figure 7.7). 5) Horizontal Vent and Air Intake Terminal Location - Observe the following limitations on the vent terminal location (also see Figures 7.6, 7.7). When locating a concentric terminal, observe the limitations outlined below for “vent terminals”. • Vent terminals must be at least 1 foot from any door, window, or gravity inlet into the building. • For twin pipe terminals, maintain the correct clearance and orientation between the vent and air intake terminals. The vent and air intake terminals must be at the same height and their center lines must be between 12 and 36 inches apart. Both terminals must be located on the same wall. • The bottom of all terminals must be at least 12” above the normal snow line. In no case should they be less than 12” above grade level. • The bottom of the vent terminal must be at least 7 feet above a public walkway. • Do not install the vent terminal directly over windows or doors. • The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10 feet. • A clearance of at least 4 feet horizontally must be maintained between the vent terminal and gas meters, electric meters, regulators, and relief equipment. Do not install vent terminal over this equipment. • Do not locate the vent terminal under decks or similar structures. • Top of vent terminal must be at least 5 feet below eves, soffits, or overhangs. Maximum depth of overhang is 3 ft.

D E S I G N E D T O L E A D Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com D E S I G N E D T O L E A D BWC Series Service Supplement for BWC Series Boilers Equipped with Type III MCBA WARNING IMPROPER SETTING OF PARAMETERS CAN CAUSE UNRELIABLE OR UNSAFE OPERATION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE: • CHANGING PARAMETERS SHOULD ONLY BE ATTEMPTED BY A PROFESSIONAL HEATING SERVICE TECHNICIAN. • DO NOT CHANGE ANY PARAMETERS NOT DESCRIBED IN THIS MANUAL WITHOUT FIRST CONSULTING THE FACTORY. • AFTER CHANGING ANY PARAMETERS, CAREFULLY CONFIRM PROPER BOILER OPERATION BEFORE LEAVING THE INSTALLATION SITE. • THIS MANUAL IS INTENDED AS A SUPPLEMENT, NOT A REPLACEMENT, FOR THE INSTALLATION MANUAL SUPPLIED WITH THE BOILER. SEE THE INSTALLATION MANUAL FOR IMPORTANT INFORMATION NOT SHOWN IN THIS MANUAL. 2 3 TABLE OF CONTENTS I. Boiler Operating Parameters A. Overview 4 B. Entering The Access Code 4 C. Changing Parameters 5 D. Field Adjustable Parameters 8 E. Communication, Fan Speed and Error Modes 10 II. GCI PC Interface A. System Requirements 11 B. Connecting Hardware 11 C. Installing Gascom 11 D. Changing The MCBA Parameters With Gascom 13 E. Using Gascom To Monitor The MCBA 13 F. Reading the MCBA Error Log 13 III. Component Test Procedures A. Flame Signal Check 14 B. NTC Temperature Sensors 14 Appendix A1 Factory Parameter Settings A1-1