Crown Boiler BERMUDA BSI069 Installation Instructions Manual Download Page 1 | Manualshive

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Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

7HO)D[ZZZFURZQERLOHUFRP

BSI Series

Gas-Fired Natural Draft Steam Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

WARNING

: Improper installation,

adjustment, alteration, service or
maintenance can cause property
damage, injury, or loss of life. For
assistance or additional informa-
tion, consult a qualified installer,
service agency or the gas
supplier. Read these instructions
carefully before installing.

Models:

•

BSI069

•

BSI103

•

BSI138

•

BSI172

•

BSI207

•

BSI241

•

BSI276

•

BSI310

•

BSI345

•

BSI379

D

E S I G N E D T O

L

E A D

1
2
3
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Summary of Contents for BERMUDA BSI069

Page 1: ...ffixed on or adjacent to the boiler WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or loss of life For assistance or additional informa tio...

Page 2: ...AppendixA Knockdown BoilerAssembly 47 I Product Description The BSI series boilers are low pressure cast iron gas fired steam boilers designed for use in closed steam heating systems These boilers are...

Page 3: ...URATION Combustion efficiency Volume to normal water line NOTE BSI345 and BSI379 not available for use with LP gas Suffix E Intermittent Ignition Suffix S Standing Pilot Add Suffix N for Natural Gas o...

Page 4: ...for the correct gas natural or LP The BSI345 and BSI379 may only be used with natural gas 5 Boilers installed at altitudes above 2000 ft require different burners and main burner orifice than those at...

Page 5: ...Air for Combustion and Ventilation of the National Fuel Gas Code NFPA 54 ANSI Z223 1 To ensure an adequate supply of combustion ventilation and flue gas dilution air supply start by determining wheth...

Page 6: ...square inch per 1000 BTU hr input of all gas burning appliances in the boiler room The minimum opening dimension is 3 inches Minimum opening free area is 100 square inches per opening If the total vo...

Page 7: ...7 6 FIGURE4 ALLAIRFROMOUTDOORS VENTILATED CRAWL SPACE AND ATTIC FIGURE5 ALLAIRFROMOUTDOORS VIA VENTILATED ATTIC FIGURE3 BOILERINSTALLEDINCONFINEDSPACE ALL AIR FROM INSIDE...

Page 8: ...8 FIGURE6 ALLAIRFROMOUTDOORS USING OPENINGSINTOBOILERROOM FIGURE7 ALLAIRFROMOUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM 7...

Page 9: ...n exterior chimneys may be used An exterior masonry chimney may be used if it is lined with B vent or a listed chimney lining system 5 This boiler may be vented using a listed power venter The power v...

Page 10: ...d with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any u...

Page 11: ...11 10 FIGURE8 BSI BOILERTYPICALVENTSYSTEM INSTALLATION AND COMPONENTS FIGURE 9 VENTDAMPERINSTALLATIONDETAILS RIGHT SIDE VIEW...

Page 12: ...ows typical gas piping connection to the BSI boiler A sediment trap must be installed upstream of all gas controls Install a manual shut off valve outside the jacket and ground joint union as shown Th...

Page 13: ...n Figure 12 and appears to be working If two or more steam mains must be connected to the boiler connect a separate take off for each main into the header between the riser s and equalizer Also note t...

Page 14: ...area where it is not likely to become plugged by debris or subjected to freezing 4 Install drain valve into tapping on boiler left side using the 2 x 3 4 bushing provided see Figure 1 5 Connect system...

Page 15: ...ERPIPINGMISTAKES FIGURE11 STEAMBOILERPIPINGFORGRAVITYRETURN A B C D BSI069 2 1 1 2 1 1 4 BSI103 2 1 1 2 1 1 4 BSI138 2 1 1 2 1 1 4 BSI172 2 1 1 2 1 1 4 BSI207 2 3 1 1 2 1 1 4 BSI241 2 3 2 1 1 2 BSI276...

Page 16: ...on 2 Y Strainer Install a Y strainer to prevent sediment from accumulating inside the indirect water heater 3 Check Valve Prevents gravity circulation through the indirect water heater when the boiler...

Page 17: ...WIRE feeder Do not alter factory boiler wiring Connect VXT 24 to CG400Aas follows Connect the BLACK lead on the feeder to terminal A on the LWCO Connect the WHITE lead on the feeder to terminal 2 on t...

Page 18: ...igh limit described in Part IX must also be supplied by the installer Acall for heat from the indirect water heater thermostat will energize the relay making both sets of contacts One set of these con...

Page 19: ...GURE14b WIRINGMCDONNELL MILLERWF2 U 24FEEDERORTHREE WIREHYDROLEVEL VXT 24FEEDERTOBOILEREQUIPPEDWITH 67L W C O CAUTION DO NOT INSTALL JUMPER BETWEEN 2 3 ON 67 L W C O FIGURE15 WIRINGINDIRECTWATERHEATER...

Page 20: ...in gas flow through the control and burner operation Sequence of Operation Intermittent Ignition 1 When the boiler is energized 24 volts is immediately applied to terminals 1 blue and 4 yellow on the...

Page 21: ...WIRINGDIAGRAM STANDINGPILOTANDMcDONNELL MILLERMODEL67LOWWATERCUTOFF L N V8295A BSI310 379 ONLY VENT DAMPER NOTE 2 NOTE 3 LESS VENT DAMPER 2 VENT DAMPER REQUIRED ON BSI069 BSI276 OPTIONAL ON BSI310 BSI...

Page 22: ...er cut off interrupts burner operation McDonnell Miller 67 Low Water Cut off Interrupts burner operation if the water in the boiler drops below a safe level Burner operation is restored when the water...

Page 23: ...terrupts burner operation when flames or excessive heat are present in vestibule The flame roll out switch is a single use device which must be replaced by an identical switch in order to restore norm...

Page 24: ...should produce single steady medium blue flame covering around 3 8 to of thermocouple tip See Figure 21 for intermittent ignition Pilot burner produces three flames The center one should be a steady m...

Page 25: ...manometer to the manifold outlet pressure tap on the gas valve see Figures 23 and 24 d Read the manifold pressure It should be set at NaturalGas LPGas Manifold Press inches w c 3 5 10 0 e If a manifol...

Page 26: ...you light pilot burner with a match After about one minute release reset button Pilot should remain lit If it goes out turn gas control knob clockwise to OFF To relight repeat steps 5 9 If button does...

Page 27: ...old the Knob while you light pilot burner with a match After about one minute release reset button Pilot should remain lit If it goes out turn gas control knob clockwise to OFF To relight repeat steps...

Page 28: ...all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the pilot Do try to light the pilot by hand not 5 Remove front access panel 6 Rotat...

Page 29: ...lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the pilot Do try to light the pilot by hand not 5 Remove f...

Page 30: ...ler models should relight 20 After the boiler has operated for approximately 30 minutes check the boiler and heating system piping for leaks Repair any leaks found at once 21 Inspect the vent system f...

Page 31: ...204ANDVR8304 INTERMITTENT IGNITION FIGURE 23a GASVALVEDETAIL HONEYWELLVR8200ORVR8300 STANDINGPILOT FIGURE 23b GASVALVEDETAIL ROBERTSHAW 7000ERHCANDHONEYWELLV8295 STANDINGPILOT FIGURE 24b GASVALVEDETAI...

Page 32: ...ck the thermocouple for deterioration some discoloration of the thermocouple is normal If any deterioration is present replace the thermocouple Inspect the pilot assembly for deposits and deterioratio...

Page 33: ...s present in the steam main takeoff close it Alternatively temporarily replace enough of the vents on the mains and or radiators with plugs so that 2 5 psi can be developed when the boiler is fired d...

Page 34: ...llector 14 Reattach all the jacket components 15 Reinstall burners being careful to put the pilot main burner in its original location 16 Replace the blocked vent switch 17 Reconnect the damper and ve...

Page 35: ...s assume that the vent damper is closed at the beginning of the troubleshooting process With the 120 volts applied to the boiler and no call for heat the damper should go to the closed position If it...

Page 36: ...hermostat Thermostat misw ired or misapplied N N 24 volts between P2 and 2 on CG400 LWCO Jumper missing betw een 1 and P1 on CG400 Poor connection betw een transformer and terminals 1 2 on CG400 24 vo...

Page 37: ...ational Fuel Gas Code Down draft Inadequate combustion air supply in boiler room Y N Y 24 volts across rollout switch Loose electrical connection in spill switch or rollout switch wiring or gas valve...

Page 38: ...ve transformer See Note 6 on page 34 N Y Bad connection in thermostat w iring Defective thermostat Thermostat misw ired or misapplied N N 24 volts betw een terminal 1 on 67 LWCO and yellow tranformer...

Page 39: ...onal Fuel Gas Code Down draft Inadequate combustion air supply in boiler room Y N Y 24 volts across rollout switch Loose electrical connection in spill switch or rollout switch wiring or gas valve com...

Page 40: ...orifice partially plugged Y N N Y N Turn control on gas valve to ON Y END Defective gas valve Y START 24 VOLTS PRESENT ACROSS TH AND TR ON GAS VALVE BUT MAIN BURNERS DO NOT LIGHT Ensure knob on gas v...

Page 41: ...rcelain cracked Pilot flame not covering gap between electrode and grounding strap Low gas pressure at gas valve inlet Defective S8600 module Main burner lights N Y 24VAC across terminals 1 2 on S8600...

Page 42: ...rown distributor consult the area Crown representative or the factory at Crown Boiler Co Customer Service P O Box14818 Philadelphia PA 19134 www crownboiler com For boilers installed at elevations abo...

Page 43: ...43 42...

Page 44: ...36 3501136 3501136 3501136 48 PILOT TUBING 1 ea 90 042 90 042 90 042 90 043 90 043 90 043 900041 900041 900041 49 35 1600 392449 50 35 1650 392449 4 51 51 51a 51 51a 61 40mm BURNER LESS PILOT BRACKET...

Page 45: ...45 44...

Page 46: ...FLOAT TYPE L W C O 67 CR 2 400676 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 90a PROBE TYPE L W C O CG400 400821 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 91 PRESSURE GUAGE 95 070 1 ea...

Page 47: ...47 46...

Page 48: ...2 Once the heat exchanger has been placed on the base inspect the gasket for proper seal Repair or replace gasket if necessary 3 Secure the heat exchanger with 5 16 lock nuts with nylon inserts and wa...

Page 49: ...49 48 FIGUREA1 BASE HEATEXCHANGER FLUE COLLECTORASSEMBLY...

Page 50: ...g pilot boilers only E ControlandTrimInstallation Refer to Figure A3 for Tapping Locations 1 Install the pressure limit control into tapping H with the siphon A x bushing has been factory installed Do...

Page 51: ...51 50 FIGUREA2 JACKETINSTALLATION...

Page 52: ...8 Hydrolevel CG 400 Probe Low Water Cutoff a Mount the end of the BX cable containing the 3 wire Molex plug and the single red wire to the control box with the BX cable fitting nut supplied b Insert t...

Page 53: ...53 52 FIGUREA3 TAPPING LOCATIONS SEE TEXT FOR TAPPING USES...

Page 54: ...54 Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 7HO D ZZZ FURZQERLOHU FRP P N980423 10 10Rev 3...

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