Crown Boiler BIMINI BUDDY BWC090 Installation Instructions Manual Download Page 83

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PARTS LIST

Part #

QTY

Part #

QTY

Part #

QTY

Part #

QTY

105 Zinc Plated Brass Spacer

960054

106 8-32 x 3/4 Round Head Machine Screw

900725

107 8-32 x 1/2" PH Machine Screw

90-052

108 8-32 Hex Nut

90-053

109 Resistor Clamp

960090

110 Condensate Pump Receptacle

960023

111 Escutcheon Plate

230380

230385

112 #8 Self Drilling Screw

900055

114 Rear Panel

230303

115 #10 x 1/2 Truss Hd Screws

900120

116 1/8" Aluminum Pop Rivet

90-068

117 Draw Latch

230202

119 Top Panel

230323

230325

120 Vent Stub

230502

121 Wall Hook

230410

122 5/16" Flat Washer

900102

123 5/16" x 2" Lag Screw

900726

124 1/4-20 x 1/2 Phillips Pan Hd with Ext Washer

900720

125 Boiler Hanging Bracket

230435

126 1/4-20 Nylon Insert Lock Nut

900721

127 LH Side Panel

230301

2303015

128 RH Side Panel

230300

2303005

129 8" Long Bead Chain Lanyard

230210

130 6-32 x 1/2 HWH type F Self Tapping Screw

900713

131 6-32 Wing Nut

900724

132 Rubber Bumper

230905

133 Pinhole Grommet

10-026

134 Draw Keeper

230204

135 Bottom Panel

230343

230345

136 Bottom Pan Support Bracket

230395

137 AM Door Gasket

230400

138 Upper Front Jacket Panel

230353

139 Crown Aluminum Nameplate

98-004

140 10-32 x 1/2 Machine Screw

90-058

141 10-32 Screw Retainer

900727

142 Nylon Spacer, #10 x 0.125

230212

143 3/16 x 1/2 Slic Pin

230200

144 Lower Front Jacket Panel

230363

145 Heyco 2" Window

900723

146 Latch CM Cam

230206

147 Straight Cam

230208

150 AM X3/X4 Harness

9602306

151 AM X2 Harness

9602307

152 Line Voltage Blower Harness

9602309

153 AM MCBA X1 Harness

9602310

154 Violet Jumper Wire

9602412

155 120VAC Pigtail Harness

9602407

156 AM Display Harness

9602308

157 AM Limit Harness

9602301

9602350

158 AM Sensor Harness

9602302

159 AM Blower Power Harness (Inner)

9602303

160 AM Tacho Harness

9602304

161 Dungs Gas Valve Harness

9602305

162 Igniton Cable

9602311

163 Float Switch

240060

164 Heat Exchanger Support Bracket

230420

165 M6 x 12 Machine Screw

900015

166 1/4-20 x 3/4 Cap Screw

90-213

167 1/4-20 Nut

90-202

BWC151

BWC090

BWC120

* NOT SHOWN

Key

DESCRIPTION

BWC070

Summary of Contents for BIMINI BUDDY BWC090

Page 1: ...n 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 w...

Page 2: ......

Page 3: ...mbly 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 Retrofitt...

Page 4: ...90 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 S...

Page 5: ...or 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 ...

Page 6: ...he 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 fluorocarbons paint removers cleaning solvents and detergents ...

Page 7: ...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 WI...

Page 8: ...ll 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 figure 5 2 9 If not already done in...

Page 9: ...7 Figure 5 1 Wall Mounting Hole Locations ...

Page 10: ...Figure 5 2 Boiler Mounting Hardware 8 ...

Page 11: ... BTU hr If the result is less than 50 the boiler room is a confined space Example A BWC120 and a water heater are to be installed in a room measuring 6ft 3 in x 7ft with an 8 ft ceiling The water heater has an input of 30000 BTU hr Total input in thousands of BTU hr 120000 BTU hr 30000 BTU hr 1000 150 MBTU hr Volume of room 6 25 ft x 7 ft x 8 ft 350 ft3 350 150 2 33 Since 2 33 is less than 50 the ...

Page 12: ...room Connect addi tional rooms with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU hr of input The free area of an opening takes into account the blocking effect of mesh grills and louvers Where screens are used they must be no finer than 4 x 4 mesh Step 2b If the boiler is to be placed in an unconfined space the natural infiltration into the boiler room will p...

Page 13: ...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 ...

Page 14: ... 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 Concentri...

Page 15: ...e 1 APPROVED STAINLESS STEEL VENT SYSTEM SHOWN IN TABLE 7 5 CROWN 80 125mm VENT COMPONENTS SHOWN IN TABLE 7 4b AIR INTAKE MATERIAL GALVANIZED OR PVC Note 1 In Vent Option 1 the 80 125mm concentric straight section PN 230515 shown in Table 7 4a may be used between the boiler and the first 80 125 x 60 100 reducing elbow If this is done the overall maximum vent length is still restricted to that show...

Page 16: ...14 FIGURE 7 2 HORIZONTAL CONCENTRIC VENTING VENT OPTION 1 3 FIGURE 7 3 HORIZONTAL TWIN PIPE VENTING VENT OPTION 2 ...

Page 17: ...IONS 3 6 CROWN PN DESCRIPTION SIZE USED ON VENT OPTION COMMENTS 230527 90 DEGREE EL STANDARD 80 125mm 3 6 230528 90 DEGREE EL SWEEP 80 125mm 3 6 230526 45 DEGREE EL 80 125mm 3 6 230517 19 1 2 STRAIGHT 80 125mm 3 6 CAN BE CUT 230515 39 STRAIGHT 80 125mm 3 6 CAN BE CUT 230518 39 STRAIGHT 80 125mm 3 6 MAY NOT BE CUT 230519 78 STRAIGHT 80 125mm 3 6 MAY NOT BE CUT 230525 TELESCOPING STRAIGHT 80 125mm 3...

Page 18: ...han 24 horizontally from the exhaust pipe 8 Wall thimbles Wall thimbles are required where single wall vent pipe passes through combustible walls with less than the required clearance shown in Table 4 2 or as required by local codes Stainless vent manufacturer s wall thimble part numbers are shown in Table 7 5 Note that concentric vent has a zero clearance to combustibles and therefore does not re...

Page 19: ...GURE 7 6a LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS DOORS GRADE FIGURE 7 6b LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS 17 FIGURE 7 6c POSITIONING VENT TERMINAL UNDER OVERHANGS ...

Page 20: ...Supporting Pipe Vertical and horizontal sections of pipe must be properly supported Support Crown concentric venting near the female end of each straight section of pipe Exception Vertical runs of concentric pipe in an unused chinmey Figure 7 36 need only be supported at the terminal and at the base of the run Support stainless steel venting as called for by the vent manufacturer s instructions FI...

Page 21: ...t 2ft BWC120 2ft 2ft BWC151 2ft 2ft INLET BWC070 2ft 2ft BWC090 2ft 2ft BWC120 2ft 2ft BWC151 2ft 2ft VENT TERMINAL STRAIGHT TERMINAL BY VENT SYSTEM MFR TABLE 7 5 CROWN 230532 CONCENTRIC TERMINAL TABLE 7 4b AIR INTAKE TERMINAL 3 180 ELBOW FIGURE 7 10 VENT MATERIAL APPROVED STAINLESS STEEL VENT SYSTEM CROWN 80 125 mm VENT COMPONENTS SHOWN IN TABLE 7 4b AIR INTAKE MATERIAL GALVANIZED OR PVC TABLE 7 ...

Page 22: ...20 FIGURE 7 10 VERTICAL TWIN PIPE VENT SYSTEM VENT OPTION 5 FIGURE 7 11 VERTICAL CONCENTRIC VENT SYSTEM VENT OPTION 6 ...

Page 23: ...paces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so the appliance will opera...

Page 24: ...o tabs holding the plastic terminal in the terminal section Figure 7 22 Carefully pull out the terminal and the inner pipe d Cut the outer pipe only at the point marked in Step b using aviation shears a hacksaw or an abrasive wheel cutter Be careful to cut the pipe square De burr the cut end with a file or emery cloth e Cut the plastic inner pipe so that it will protrude 3 8 beyond the outer pipe ...

Page 25: ...FIGURE 7 21 DIMENSION L 23 FIGURE 7 20 INSTALLATION OF REDUCING ELBOW ON CONCENTRIC BOILER COLLAR ...

Page 26: ...ng the desired length of the outer pipe remove the plastic inner pipe by pulling it out from the female end b Cut the outer pipe only at the point marked in Step b using aviation shears a hacksaw or an abrasive wheel cutter Be careful to cut the pipe square De burr the cut end with a file or emery cloth c Cut the plastic inner pipe so that it will protrude 3 8 beyond the outer pipe when reinstalle...

Page 27: ...FIGURE 7 25 ATTACHING 60 100mm TERMINAL SECTION 25 FIGURE 7 24 PREPARING 60 100mm TERMINAL SECTION FOR INSTALLATION IN THE WALL ...

Page 28: ...systems 1 When BWC070 BWC090 or BWC120 boilers are vented using 80 125 venting the 60 100 terminal section and reducing elbow supplied with the boiler are not used The components listed in Table 7 4b are required for 80 125mm installations and are not supplied The BWC151 is supplied with the following 80 125 components a 80 125 Standard Radius Elbow b 80 125 Terminal Section Before starting assemb...

Page 29: ...nd of the adjoining pipe Mark the cut line on the outer pipe b Remove the plastic inner pipe by pulling it out from the female end c Cut the OUTER PIPE ONLY at the point marked in Step a using aviation shears a hacksaw or an abrasive wheel cutter Be careful to cut the pipe square De burr the cut end with a file or emery cloth d Make an insertion mark 1 from the male end of the outer pipe e Cut the...

Page 30: ... 32b c The male end of cuttable fittings must be held to the collar with three 10 x 1 2 sheet metal screws Drill a 1 8 hole through both outer pipes to start this screw Use a drill stop or other means to ensure that the drill bit does not penetrate more than 3 8 into the outer pipe Do not use a sheet metal screw longer than 1 2 Figure 7 32a d Use locking bands provided with all fittings to secure ...

Page 31: ...to cut the plastic pipe and be careful to cut the pipe square if necessary the plastic pipe can be removed from the terminal again for cutting De burr the cut edge of the plastic pipe with a file razor blade or fine sandpaper g Make a mark on the terminal section 1 from the cut end of the outer pipe as shown in Figure 7 33c h Slip the terminal section through the wall from the outside Pass the ter...

Page 32: ...FIGURE 7 33c CUTTING INNER PIPE OF 80 125mm HORIZONTAL TERMINAL FIGURE 7 33d COMPLETING 80 125mm HORIZONTAL TERMINAL INSTALLATION 30 ...

Page 33: ... to install the lower wall bracket b Before mounting the lower wall bracket loosen the M10 x 35 screw on this bracket Adjust this bolt forward or backward so that its center is 6 7 16 from the wall Figure 7 34 and tighten c Center the Lower Wall Bracket on the hole in the wall and mark the location of the four mounting screws on the wall 5 16 mounting screws not supplied are recommended for mounti...

Page 34: ... is required for this installation a Determine the center line of the terminal location on the roof If the roof is flat cut a 5 1 2 diameter hole for the terminal If the roof is sloped cut a hole large enough for the terminal to pass through the roof while remaining plumb Caution If the boiler is installed directly under the hole cover it while cutting the hole to prevent saw dust and other debris...

Page 35: ...FIGURE 7 35b CUTTING VERTICAL TERMINAL FIGURE 7 35c COMPLETING VERTICAL TERMINAL INSTALLATION 33 ...

Page 36: ...in the support bracket Determine the desired vertical location of the support elbow in the chimney and mark the location of the pin on the back of the support bracket on the back wall of the chimney Drill a 7 16 dia x 2 1 2 deep hole at this location to support the back of the bracket The front of the elbow mounting bracket is supported by the bottom of the opening into the WARNING Do not attempt ...

Page 37: ...be placed at the bottom of horizontal sections of exhaust pipe c Do not drill holes in vent pipe d Do not attempt to mix vent components of different vent system manufacturers 2 Mounting Stainless steel vent collar The use of stainless steel venting requires the stainless steel vent collar Crown PN 230510 which replaces the 80 125mm concentric collar supplied with the boiler To install the stainle...

Page 38: ... the inside of the vent collar on the boiler Remove dirt grease and moisture from the surfaces to be sealed Dry surfaces or allow to dry thoroughly d On the male end of the pipe apply a wide bead of silicone approximately 1 2 from the end of the pipe Fig 7 47 e Insert the male end of the pipe into the boiler vent collar until it bottoms out f Apply an additional bead of silicone over the outside o...

Page 39: ... a wide bead of high temperature silicone approximately inch from the male end of the pipe Apply beads of silicone along both sides of the longitudinal seam Fig 7 48 e Insert the male end of the pipe into the boiler vent collar until it bottoms out f Apply an additional bead of silicone over the outside of the joint and smooth out g Replace and tighten the clamp on the vent collar h The female end...

Page 40: ... pipe so that it can be inserted at least 1 into the collar Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler with an alcohol pad On the male end of the pipe apply a wide bead of high temperature silicone approximately inch from the male end of the pipe Also apply a bead of silicone along the first 2 of the longitudinal weld Insert the ma...

Page 41: ...asNSeal venting system rely on a gasket in the female end of the pipe for a proper seal d Align the longitudinal seam of both pipes Insert the male end of the second pipe into the female end of the first pipe until the bead on the male end contacts the flare on the female end e Tighten the locking band with a nut driver f Repeat d and e for the remaining FasNSeal components g Allow the silicone to...

Page 42: ...oiler The trap is supplied loose and must be installed as shown in Figure 7 51 A length of drain hose is supplied with the boiler and is connected to the trap as shown in Figure 7 51 Note the following when disposing of the condensate a If the condensate drain line must be extended construct the extension from PVC or CPVC pipe Insert the hose provided with the boiler into the end of the extension ...

Page 43: ...FIGURE 7 51 CONDENSATE PIPING ARRANGEMENT 41 ...

Page 44: ...pstream of all gas controls Install the factory provided manual shut off valve outside the jacket with a ground joint union as shown The boiler and its gas connection must be leak tested before placing the boiler in operation When doing this the boiler and its individual shut off must be disconnected from the rest of the system during any pressure testing of that system at pressures in excess of 1...

Page 45: ... Proper operation of the BWC boiler requires that the water flow through the boiler remain within the limits shown in Table 9 1 any time the burner is firing Failure to maintain the flow within these limits could result in erratic operation or premature boiler failure There are two basic methods that can be used to pipe the BWC boiler Method 1 is almost always preferred The instructions on the fol...

Page 46: ... result is the total equivalent length of the secondary loop d Using Table 9 5 find the boiler size being installed and select a boiler secondary circulator that shows a maximum equivalent length column e in excess of the total equivalent length calculated in Step c 3 Indirect Water Heater Loop Piping If Indirect Water Heater is Used All piping must be the size shown in Table 9 6 column a If the i...

Page 47: ...ves Calculate total equivalent length from Table 9 7 20 Straight Pipe 5 Elbows x 2 75 2 Turns in Tees x 5 5 1 Swing Check x 7 2 valves x 0 6 52 95 Equivalent Feet Straight Pipe From Table 9 6 we see that smallest circulator which will pump at 8 GPM through a BWC120 with 52 95 equivalent feet and an indirect water heater pressure drop of 3 ft is a Taco 0014 ...

Page 48: ...Figure 9 3 Piping Method 1 Heat Indirect Water Heater Figure 9 4a Piping Method 1 Secondary Loop Piping Shaded 46 ...

Page 49: ...07 67 BWC070 1 6 0 21 Taco 008 171 BWC090 1 8 0 21 Taco 0014 135 BWC120 1 8 0 29 Taco 0014 166 BWC120 1 9 0 25 Taco 0014 95 BWC120 1 12 0 19 Taco 0013 Note 1 51 BWC151 1 8 0 34 Taco 008 106 BWC151 1 11 0 25 Taco 0014 68 BWC151 1 14 0 19 Taco 0013 Note 1 59 NOTE 1 Use isolation relay between Taco 0013 and BWC see Figure 10 3 Figure 9 4b Piping Method 1 Indirect Water Heater Loop Piping Shaded ...

Page 50: ...26 MS 40 MSH 40H MT040GBR MT050GBR MT065GBR MT080GBR Taco 0014 108 BWC120 1 8 0 5 0 MSH 53H Taco 0014 70 BWC151 1 8 0 3 0 MS 26 MS 40 MSH 40H MT040GBR MT050GBR MT065GBR MT080GBR Taco 008 49 BWC151 1 8 0 5 0 MS 53 MS 53H MSH 79 Taco 0014 150 TABLE 9 6 NOTES 1 Indirect water heaters with an asterisk will not achieve their catalog rating due to inadequate boiler water flow and or inadequate boiler ou...

Page 51: ...ult to accurately calculate the pressure drop through the system In replacement installations it may be impossible to get an accurate measurement of the amount of piping and number of fittings in the system In addition if the system is zoned the system flow may drop well below the minimum required when only one zone is calling for heat The one advantage to this method is its installation simplicit...

Page 52: ...he boiler Pipe the discharge of the relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens The end of the discharge pipe must terminate in an unthreaded pipe If the relief valve discharge is not piped to a drain it must terminate at least 6 inches above the floor Do not run relief valve discharge piping through an area that is prone to ...

Page 53: ...lled on the return tee located in the lower vestibule compartment as shown in Figure 9 2 10 Low Water Cut off Required The low water cut off supplied with this boiler must not be removed D Piping for Special Situations 1 Systems containing oxygen Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to an aluminum boiler such as the BWC Some examples include Radian...

Page 54: ...52 Figure 9 11 Chiller Piping Figure 9 10 Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger ...

Page 55: ... 5 and 6 the boiler will adjust the target space heating set point supply water temperature downwards as the outdoor air temperature increases If used this sensor should be located on the outside of the structure in an area where it will sense the average air temperature around the house Avoid placing this sensor in areas where it may be covered with ice or snow In general locations where the sens...

Page 56: ...54 Figure 10 1 Wiring Connections Diagram ...

Page 57: ...55 Figure 10 2 Ladder Diagram ...

Page 58: ...56 Figure 10 3 Wiring of Isolation Relay for Control of Two Heating Circulators ...

Page 59: ...formation on testing and purging gas lines 4 Vent system must be complete and free of obstructions before attempting to fire boiler Make sure that the silicone cure time called for in the vent assembly instructions has passed before firing boiler 5 Inspect all line voltage wiring for loose or uninsulated connections 6 Remove the dust cap from the condensate trap Fig 7 21 Add water to the trap unti...

Page 60: ...he fill line to record additions of make up water Make sure that the expansion tank is properly sized and in good condition If it is not the relief valve may open frequently resulting in regular additions of make up water 3 Radiant Tubing and Oxygen Barriers Even if the system is tight oxygen can be introduced into the system through some types of non metallic tubing used in radiant or snow melt s...

Page 61: ...nd will settle on the floor STOP read the safety information above on this label Set the thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand remove the front door panel and the upper boiler access panel replace the upper boiler access panel and t...

Page 62: ...eded it will be necessary to press the reset button to restart the boiler Once a flame has been established for the first time subsequent calls for burner operation should result in a flame on the first try 9 Inspect the flame visible through the window On high fire the flame should be stable and mostly blue Fig 11 1 No yellow tipping should be present however intermittent flecks of yellow and ora...

Page 63: ...hes H indicating that the boiler has been driven to high fire After this happens allow the boiler to operate for approximately 5 minutes before taking combustion readings b To lock the boiler in low fire simultaneously press and hold the Mode button and button until the display flashes L indicating that the boiler has been driven to low fire After this happens allow the boiler to operate for appro...

Page 64: ...13 Verify that the boiler starts and stops in response to calls for heat from the heating thermostat and indirect wa ter heater thermostat Make sure that the appropriate circulators also start and stop in response to the thermostats 14 As shipped the heating and indirect water heater set point supply temperatures are both set to 180 F If neces sary adjust these to the appropriate settings for the ...

Page 65: ...ty controls including the low water cut off and safety limit are connected into the MCBA The MCBA uses input from all of these controls to either shut down the boiler when an unsafe condition exists or in some cases to correct the problem 2 The display panel has three primary modes of operation These are Standby Mode Displays boiler s current status This is the default operating mode Parameter Mod...

Page 66: ...oiler supply temperature will exceed 180 F and there is a possibility that the safety temperature limit will open If this happens the boiler will shut down and a b26 error will appear on the display The boiler will resume normal operation without manual intervention when the safety limit closes this behavior is common on conventional boilers Information mode is used to view various temperatures an...

Page 67: ... domestic hot water on off d OFF 2 Off continuous pump 4 Outdoor sensor temp if used Note 5 4 22 MoDE and Long Hold burner in high fire Note 3 H 180 3 On continuous pump 5 Flue gas temperature 5 165 MoDE and Long Hold burner in low fire Note 3 L 180 3 Heat Zone 0 Off 6 Supply water set point temperature 6 180 and Long Deactivate forced high or low firing O 180 1 On 7 Rate of change in supply water...

Page 68: ... supply water target temperature increases For example if the outdoor air temperature is 30 F the set point temperature for the supply water is 155 F 5 An indirect water heater thermostat can be connected between terminals 7 and 8 on the terminal strip When this thermostat closes the central heating circulator will be turned off and the DHW circulator will be turned on 6 An external limit control ...

Page 69: ... fan ignition speed setting If the flame fails to prove the control module will attempt to light the burner 4 more times If a flame is still not established the control will lockout e Once the flame stabilization period has ended the MCBA allows the burner to modulate The actual firing rate is dependent upon the measured current and recent differences between the set point temperature and the supp...

Page 70: ...to verify they are free from leaks Call the service technician to make repairs if required 4 Annual Inspections and Service In addition to the inspections listed above the following should be per formed by a service technician once every year a Test the low water cutoff by pressing the Test button located at its end The yellow light should come on and E12 should flash on the display Push the reset...

Page 71: ... replace it immediately Inspect the burner gasket and replace if necessary h Inspect the heat exchanger and vacuum any debris found on the pins and other surfaces Clean the casting pins by flushing with clean water A soft nylon brush may be used in accessible areas Drain and flush the inside of the heat exchanger and condensate collector as required Do not use any cleaning agents or solvents i Ins...

Page 72: ...ded Display reads U 125 continuously Fan running Defective AT250 transformer Blown F3 fuse in MCBA see Figure 13 2 for location Replace with 4A slow blow fuse provided Boiler not responding to call for heat Status code on display 0 see Figure 11 1 Boiler is not seeing call for heat Check thermostat or zone wiring for loose connection miswiring or defective thermostat zone control Boiler fires but ...

Page 73: ...rsed b 24 MCBA is reading a return sensor temperature higher than the supply sensor temperature Condition must be present for at least 75s for this error code to appear Flow through boiler reversed Verify correct piping and pump orientation No boiler water flow Verify that system is purged of air and that appropriate valves are open Sensor wiring reversed Supply or return sensor defective b 25 Sup...

Page 74: ...oss AT140 transformer Check condensate trap for blockage BWC151 only E 13 E 14 E 15 E 16 E 17 Internal control failure Reset the control If problem reoccurs replace the MCBA E 18 MCBA supply sensor detected temperatures in excess of 200 F for an extended period of time See possible causes for b18 error Also check safety limit for proper operation E 19 MCBA return sensor detected temperatures in ex...

Page 75: ...rts 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 76: ...74 ...

Page 77: ...0124 1 960124 1 18 Burner 230035 1 230035 1 230045 1 230046 1 19 Burner Hood Gasket 230032 1 230032 1 230032 1 230032 1 20 5 x 8 Grooved Pin 230945 2 230945 2 230945 2 230945 2 21 Burner hood AM 230030 1 230030 1 230030 1 230030 1 22 Burner Hood Cover Plate Gasket 230050 1 230050 1 230050 1 230050 1 23 Burner Hood Cover Plate 230051 1 230051 1 230051 1 230051 1 24 M4 X 8 Machine Screw 230923 3 230...

Page 78: ...507337 1 3507337 1 75 9mm Swirlplate Red 3507347 1 75 12mm Swirlplate Gray 3507336 1 76 Dungs Air Inlet Adaptor Part 1 female 3507344 1 3507344 1 3507344 1 3507344 1 77 M4 x 10mm FH Machine Screw 900006 4 900006 4 900006 4 900006 4 78 Injector Plate 3507348 1 3507348 1 3507348 1 3507348 1 79 M4 x 25mm Positdrive Hd Screws 900734 3 900734 3 900734 3 900734 3 80 1 5 x 17mm O Ring 3507349 1 3507349 1...

Page 79: ...77 ...

Page 80: ...78 ...

Page 81: ...79 ...

Page 82: ...80 ...

Page 83: ...26 2 134 Draw Keeper 230204 2 230204 2 230204 2 230204 2 135 Bottom Panel 230343 1 230343 1 230343 1 230345 1 136 Bottom Pan Support Bracket 230395 1 230395 1 230395 1 230395 1 137 AM Door Gasket 230400 1 230400 1 230400 1 230400 1 138 Upper Front Jacket Panel 230353 1 230353 1 230353 1 230353 1 139 Crown Aluminum Nameplate 98 004 1 98 004 1 98 004 1 98 004 1 140 10 32 x 1 2 Machine Screw 90 058 2...

Page 84: ...82 150 151 152 153 154 155 ...

Page 85: ...83 156 157 158 159 160 161 ...

Page 86: ...162 84 ...

Page 87: ...manifolds into the two closely spaced tees shown in Figure A 1 These two tees must be no more than 12 apart At least 8 diameters of straight pipe must be installed upstream of the upper supply tee and at least 4 diameters downstream of the lower return tee If the original zone manifold piping is larger than the boiler loop piping best results will be achieved by making all boiler loop piping betwe...

Page 88: ...86 Figure A 3 Field Wiring With Priority For DHW Figure A 2 Field Wiring All Zones Require Same Supply Temperature ...

Page 89: ...s subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above pro...

Page 90: ...rements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for al...

Page 91: ...PN 980056 Rev 6 BWC 12 12 Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com ...

Page 92: ...TER 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 50 000 135 000 117 000 1 13 1 1 2 133 Add suffix EN for natural gas and EL for propane Ratings ...

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