Crown Boiler 24-03 Page 2 Installation Instructions Manual Download

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Summary of Contents for 24-03

Page 1: ...njury 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 ca...

Page 2: ...2...

Page 3: ...n a t S l a n o i t a N n a c i r e m A f o n o i t i d E t n e r r u C s t n e m e r i u q e r g n i t n e V r o F s e c n a i l p p A g n i n r u B l e u F d i l o S d n a s t n e V s e c a l p e r...

Page 4: ...flooring Do not install boiler on carpeting Do not operate on floors where heat affected material is below Do not tamper with or alter the boiler or controls Retain your contractor or a competent serv...

Page 5: ...n a n o s a e s g n i t a e h e h t f o t r a t s e r a s m e t s y s e k a t n i r i a d n a g n i t n e v d e t c u r t s b o n u d n a n a e l C s n o i t c u r t s b o y n a r o f n o s a e s d n...

Page 6: ...g Domestic Hot Water DHW Applications 33 Tankless Heater Piping 41 Electric Wiring 43 Return Temperature Control RTC and Components 43 SECTION IV OPERATING INSTRUCTIONS Filling System 47 Adjusting Con...

Page 7: ...ith without priority using Indirect Water Heater and Outdoor reset A4 3 way RTC in Primary Secondary Indirect Water Heater as load on primary loop without Outdoor reset A5 3 way Multiple Boiler RTC in...

Page 8: ...8 Section I General Information FIGURE 1 Dimensional Information...

Page 9: ...5 0 5 1 8 8 7 4 9 4 1 1 9 0 3 1 0 0 3 1 7 6 8 1 1 5 3 1 8 7 5 1 2 4 1 0 4 0 4 0 1 0 9 2 1 8 4 0 4 7 5 2 4 0 1 1 1 4 2 5 0 5 0 9 6 1 9 2 4 5 3 0 3 1 0 7 4 1 0 6 4 1 3 9 0 2 5 9 4 1 0 5 7 1 7 5 1 5 4 5...

Page 10: ...25 12 Dia 43 28 NOTICE Recommended clearance for service may be reduced to minimum clearance to combustible material However increased service and maintenance difficulty will result WARNING Boiler is...

Page 11: ...spaces crawl or attic that communicate with the outdoors a Where communicating by means of vertical ducts each opening shall have a free area of not less than 1 sq inch per 4 000 Btuh 35 sq inch per g...

Page 12: ...aft typically three 3 feet above the roof line see Figure 3a The damper shall be adjusted to maintain a positive pressure of 0 1 W C in the vent connector box during burner high re operation see breec...

Page 13: ...ng the edge of the section with the wire brush d Open the Boiler Assembly Carton s and remove the bottle of adhesive Using the dauber supplied in the bottle apply the adhesive to the groove Be sure to...

Page 14: ...ive was applied it may be necessary to reapply Continue to af x the rope to the groove in this fashion around the perimeter of the section Make sure that the rope does not droop or hang outside of the...

Page 15: ...lugs with dual holes are cast in the four 4 corners of each casting Starting with the upper holes install four 4 5 8 x 9 long draw up rods along with washers and nuts see Figure 9 NOTICE The sections...

Page 16: ...s between adjoining sections should be spaced 1 4 to 3 8 apart Spacing of more than 3 8 will limit number of sections that can be drawn up in one unit and could indicate cocked nipples On long boiler...

Page 17: ...ons make contact at the ground joints g After all sections have been drawn up but before removing the hydraulic rams and draw up rods the 9 long tie rods must be installed The large draw up rod lugs w...

Page 18: ...r through concealed breakage caused in shipping and handling This precaution is for your protection and will simplify handling of necessary replacements and adjustment claims 5 After making certain th...

Page 19: ...tlet cover that mounts against the canopy and back section Gasket must be centered over all attachment holes Do not overlap corners cut butt joints 10 Attach either the rear ue outlet damper assembly...

Page 20: ...20 Figure 16 Bare Boiler Assembly...

Page 21: ...eeved loose tting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from ot...

Page 22: ...ver cleanout openings on left side of boiler as shown in Figure 19 See Important Product Safety Information on Page 21 of this manual regarding refractory ceramic ber product warning 1 Locate the cove...

Page 23: ...piping in a similar manner c Attach jacket top panel to the front panel rear panel and upper tie bar panels with sheet metal screws 7 Install Jacket side Panels a Snap black thumb hole bushings into a...

Page 24: ...24 Figure 22 Series 24 Jacket Assembly Boiler Models 24 03 thru 24 12...

Page 25: ...ed burner will be provided by Crown 2 Open Adaptor Plate carton and remove contents CAUTION Failure to properly fill all gaps between the insulation and burner blast tube may result in damage to the...

Page 26: ...eam Boiler Tapping Location C 3 Blow Off Valve D 3 Return E 3 Plug J1 1 F 3 Plug G 1 1 2 Safety Valve Surface Skim Tap Plug J2 1 Float L W C O 3 4 Plug M 3 4 Operating Pressure Limit Control N 3 4 Hi...

Page 27: ...1 1 4 X 3 4 BUSHING 24 03 THRU 24 04 1 19 1 UNION CSD 1 EQUIPPED BOILERS PUMPED RETURN 2 38 1 1 4 X 1 BUSHING 24 05 THRU 24 08 1 20 1 X 3 1 2 NIPPLE CSD 1 EQUIPPED BOILERS PUMPED RETURN 2 39 3 4 CLOSE...

Page 28: ...wn in Figures 25a and 40a Safety valve must be installed in vertical position 7 For boilers with tankless heaters install the operating control in an unused tapping through one of the heater plates 8...

Page 29: ...29 This Page Is Intentionally Left Blank...

Page 30: ...ug K 3 4 Probe L W C O C 3 Return M 3 4 Operating Temperature Limit Control D 3 Plug 24 03 thru 24 11 Return 24 12 N 3 4 Hi Temperature Limit Control Manual Reset E 3 Blow Off Drain Valve P 1 2 Plug F...

Page 31: ...L 1 1 1 18 1 1 4 90 ELBOW 24 11 THRU 24 12 1 9 L4006E1109 CSD 1 EQUIPPED BOILERS 1 19 3 4 CLOSE NIPPLE 24 03 THRU 24 07 1 10 550 PROBE LWCO CSD 1 EQUIPPED BOILERS 1 19 1 CLOSE NIPPLE 24 08 THRU 24 10...

Page 32: ...relief valve as shown in Figure 40b Relief valve must be installed in vertical position 5 Plug extra boiler tappings 6 Install required bottom blowoff drain valve supplied by others per minimum pipin...

Page 33: ...ler supply and return If the conditions above cannot be met then parallel piping systems must be converted to a primary secondary arrangement de coupling the system pump from the boiler loop The syste...

Page 34: ...lection f Glycol Antifreeze Solutions Many systems today use ethylene or propylene glycol antifreeze solutions as a measure for freeze protection as well as a pump lubricator and corrosion inhibitor T...

Page 35: ...iler return tapping as shown 4 Drain valve ball valve preferable gate valve acceptable alternative supplied by others Minimum valve size per ASME code is 3 4 NPT L E D O M Y L P P U S G N I P I P N I...

Page 36: ...shown 4 Drain valve ball valve preferable gate valve acceptable alternative supplied by others Minimum valve size per ASME code is 3 4 NPT 5 Proper boiler circulator sizing is listed in Appendix B Pip...

Page 37: ...f pipe from 3 way bypass port to sensor location 11 feet Bypass line shall be the same diameter as return 6 Minimum linear feet of pipe from point of mixing where bypass meets return line to sensor lo...

Page 38: ...o L d r o f t r a H s m e t s y s s m e t s y s n r u t e r d e p m u p L BOILER PIPING DOMESTIC HOT WATER DHW APPLICATION This section of the manual identi es the boiler piping details when domestic...

Page 39: ...24 04 1 NPT 24 05 24 08 1 1 4 NPT 24 09 24 12 Increasing the valve size will improve the blowdown operation In all cases piping connecting blowoff valve to boiler shall be full size to the point of d...

Page 40: ...40 Figure 35 Typical Steam Piping Arrangement for Boilers with Pumped Condensate Return and Boiler Feed Unit...

Page 41: ...mixing valve should be trapped by installing it below the cold water inlet to heater to prevent lime formation in the valve 3 Flushing of Heater All water contains some sediment which settles on the...

Page 42: ...5 7 5 0 4 2 5 7 6 0 4 2 5 7 5 1 7 0 4 2 5 7 5 1 8 0 4 2 5 7 5 1 9 0 4 2 5 7 5 1 5 2 2 0 1 4 2 5 7 5 1 5 2 2 1 1 4 2 5 7 5 1 5 2 2 2 1 4 2 5 7 5 1 5 2 2 0 3 Notes 1 Ratings are given in gallons per min...

Page 43: ...ount and connect the actuator as illustrated in Appendix C The electrical connections depend on valve orientation Use Figures 39a and 39b as a guide 2 Return Sensor A sensor has been included with the...

Page 44: ...o the bracket with 4 8 32 x type F Phillips Pan head screws supplied with the controller The middle 3 rear knockouts should be used before utilizing the 5 knockouts exiting the bottom of the control D...

Page 45: ...45 Figure 41 Typical Boiler Wiring with RTC Front...

Page 46: ...46 Figure 42 Typical Boiler with RTC Return Sensor Rear...

Page 47: ...Close ll valve Note If make up water line is equipped with pressure reducing valve system will automatically ll to normal system design operating pressure Leave globe valve open j Open isolation valve...

Page 48: ...be tested on initial start up as well as during any troubleshooting exercise Depressing the test button will activate a test sequence and energize the red test light on the front of the control Each...

Page 49: ...cle until 135 F has been sensed at the return sensor Once the return sensor has sensed a return temperature reading of 135 F after the heat demand cycle has initiated the grace period is terminated Th...

Page 50: ...the operating aquastat cannot be set lower than 135 20 155 F In reality most systems are designed for a 180 F supply water and 160 F return water The accuracy of the operating aquastat is less than th...

Page 51: ...until excess water in boiler ows out through supply main and water lowers by steaming until it reaches normal level in boiler Turn off burner Drain boiler Open all radiator valves Reinstall all suppl...

Page 52: ...added to the system until the boiler pressure gauge registers normal system design operating pressure To insure that the system is full water should come out of all air vents when opened 2 Boiling Ou...

Page 53: ...the inside Since neither of these failure types are the result of a casting defect the warranty does not apply The maintenance of system integrity is the best method to prevent these types of failure...

Page 54: ...runs e Tightness of joints f Remove the smoke pipe Remove all accumulations of soot with wire brush and vacuum Remove all obstructions Replace all deteriorated parts and support properly Seal all joi...

Page 55: ...ount the low water cutoff control from the probe DANGER Assure that the boiler is at zero pressure before removing the LWCO probe Do not rely on the pressure gauge to indicate that the boiler is at ze...

Page 56: ...ubricate F GENERAL MAINTENANCE CONSIDERATIONS 1 Keep radiators and convectors clean 2 If a hot water radiator is hot at the bottom but not at the top it indicates that air has accumulated inside and s...

Page 57: ...G A H P 0 6 X 0 0 4 7 0 4 2 3 8 T T E K C E B 0 0 4 1 F C D K 6 6 F C 4 A N A N 0 3 5 6 0 5 1 5 7 2 O G A H P 5 4 X 0 0 5 8 0 4 2 6 9 T T E K C E B 0 0 4 1 F C E E K 6 6 F C 1 A N A N 5 3 5 8 0 5 1 0...

Page 58: ...The following parts may be obtained from any Crown distributor To nd the closest Crown distributor consult the area Crown representative or the factory at Crown Boiler Co Customer Service P O Box 1481...

Page 59: ...7W 1 1 5 2 1 1 1 1 330127 330207 331005 331105 24 08W 1 1 6 1 1 1 1 1 1 330128 330208 331006 331106 24 09W 1 1 7 2 1 1 1 1 330129 330209 331007 331107 24 10W 1 1 8 3 1 1 1 1 330130 330210 331008 33110...

Page 60: ...60 Figure 43 Series 24 Jacket Assembly Boiler Models 24 03 thru 24 12 SECTION VII REPAIR PARTS Continued...

Page 61: ...TIE BAR ASSY 9 SEC 330349 2 LOWER TIE BAR ASSY 10 SEC 330350 2 LOWER TIE BAR ASSY 11 SEC 330351 2 LOWER TIE BAR ASSY 12 SEC 330352 2 TOP PANEL 3 SEC 330323 1 TOP PANEL 4 SEC 330324 1 TOP PANEL 5 SEC 3...

Page 62: ...62 Figure 44 Bare Boiler Assembly...

Page 63: ...CANOPY CARTON 330127 1 8 SEC CANOPY CARTON 330128 1 9 SEC CANOPY CARTON 330129 1 10 SEC CANOPY CARTON 330130 1 11 SEC CANOPY CARTON 330131 1 12 SEC CANOPY CARTON 330132 1 15 1 2 X 2 CERAFELT GASKET 92...

Page 64: ...SPRING PIN 1 1 OBSERVATION PORT ASSEMBLY INCLUDES OBSERVATION PORT COVER 1 1 OBSERVATION PORT OUTER GASKET 1 1 OBSERVATION PORT GLASS 1 1 OBSERVATION PORT INNER GASKET 1 1 INCLUDES B M P AND ALL ITEMS...

Page 65: ...BUSHING 95 146 1 3 4 RECESSED HEAD PLUG 950265 3 1 NPT RECESSED HEAD PLUG 950270 4 3 SQ HD PLUG 950273 2 3 X 1 1 4 BLK BUSHING 950275 1 1 1 2 X 4 BLK NIPPLE 950124 1 1 1 2 BLK TEE 950180 1 1 1 2 BLK...

Page 66: ...4 330855 330856 1 VALVE WITH OUTDOOR RESET 1 1 1 VALVE W O OUTDOOR RESET 1 1 1 1 4 VALVE WITH OUTDOOR RESET 1 1 1 1 4 VALVE W O OUTDOOR RESET 1 1 1 1 2 VALVE WITH OUTDOOR RESET 1 1 1 1 2 VALVE W O OUT...

Page 67: ...1 TOP FLUE OUTLET CARTON 12 330136 1 BASE RAIL SET 4 5 SEC 330604 1 BASE RAIL SET 6 7 SEC 330606 1 BASE RAIL SET 8 9 SEC 330608 1 BASE RAIL SET 9 10 SEC 330610 1 BASE RAIL SET 11 12 SEC 330612 1 POLYE...

Page 68: ...X 1 1 4 BLK BUSHING CROWN PART 98 111 980417 980418 980920 980150 90 212 130185 13 074 130190 980419 950098 950192 950274 950510 950515 950520 950525 95 096 950185 95 047 24 03SO 1 1 1 1 1 2 1 1 1 1...

Page 69: ...WG 1 1 1 1 1 1 1 1 1 1 24 07WG 1 1 1 1 1 1 1 1 1 1 24 08WG 1 1 1 1 1 1 1 1 1 1 24 09WG 1 1 1 1 1 1 1 1 1 1 24 10WG 1 1 1 1 1 1 1 1 1 1 24 11WG 1 1 1 1 1 1 1 1 1 1 24 12WG 1 1 1 1 0 1 1 1 1 1 WATER BOI...

Page 70: ...t be sized using the sizing charts found in Appendix B 4 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe dia...

Page 71: ...can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 5 The Outdoor Sensor S3 and the Mix Supply S...

Page 72: ...y spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 5 The diverting valve V1 must be no greater than 11 linea...

Page 73: ...for circulators greater than 1 3 HP Use motor starters for 3 phase circulators 6 Connect the Tankless Aquastat A1 if you are not using a storage tank If you are using a storage tank with the tankless...

Page 74: ...the sizing charts found in Appendix B 4 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 5 The diver...

Page 75: ...Heat demand can be any electrical signal consisting of 24 240 VAC 4 The Outdoor Sensor S3 and the Mix Supply Sensor S2 are required if the Outdoor Reset feature is selected 5 Use isolation relays for...

Page 76: ...the system heater s performance 5 Closely spaced tees must connect the branch to the larger header The Tee centerlines must be no greater than 4 times the larger header pipe diameter 6 The diverting...

Page 77: ...the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor start...

Page 78: ...B 4 A domestic hot water priority could be used provided the diversion from the heating system loop does not impact the system heater s performance 5 Closely spaced tees must connect the branch to th...

Page 79: ...120 VAC supplying the RTC should be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3...

Page 80: ...he boiler circulator may be located anywhere within the recirculation loop 4 The balancing valve in the boiler return line V1 may be necessary in low head by pass loop applications 5 Domestic Hot Wate...

Page 81: ...ay not be separate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for...

Page 82: ...stalled at the return of the boiler The boiler circulator may be located anywhere within the recirculation loop 4 The balancing valve in the boiler return line V1 may be necessary in low head by pass...

Page 83: ...ate from the burner boiler circuit 3 Heat demand can be any electrical signal consisting of 24 240 VAC 4 Use isolation relays for circulators greater than 1 3 HP Use motor starters for 3 phase circula...

Page 84: ...l a v y a w 3 2 0 5 5 6 1 F l e d o M r e w o P e s a h P 3 r o f r e t r a t S r o t o M e s U r e w o P e s a h P e l g n i S r o f y a l e R l a n o i t i d d A e s U l a i t n e r e f f i D F 0 4...

Page 85: ...w 3 2 0 5 5 6 1 F l e d o M r e w o P e s a h P 3 r o f r e t r a t S r o t o M e s U r e w o P e s a h P e l g n i S r o f y a l e R l a n o i t i d d A e s U l a i t n e r e f f i D F 0 4 s o f d n...

Page 86: ...o M 0 8 r e S 5 1 0 5 7 1 e v l a v y a w 3 2 0 5 5 6 1 F l e d o M r e w o P e s a h P 3 r o f r e t r a t S r o t o M e s U r e w o P e s a h P e l g n i S r o f y a l e R l a n o i t i d d A e s U...

Page 87: ...0 4 e g n a l F 0 3 6 5 8 0 3 3 6 x 4 x 4 0 8 3 4 1 9 8 4 2 1 0 0 2 1 e v l a v y a w 3 2 0 5 5 6 1 F l e d o M r e w o P e s a h P 3 r o f r e t r a t S r o t o M e s U r e w o P e s a h P e l g n i...

Page 88: ...irection of rotation Determine the direction of rotation and mount the correct label under the plastic front cover of motor Manual Operation Always disconnect power before operating by hand Note posit...

Page 89: ...89 SERVICE RECORD DATE SERVICE PERFORMED...

Page 90: ...90 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 PN 980417 S24 12 05...

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