Crown Boiler BIMINI BWC225 Installation Instructions Manual Download Page 51

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XII. Service and Maintenance

IMPORTANT

WARRANTY DOES NOT COVER BOILER DAMAGE OR MALUFUNCTION IF THE FOL

LOWING STEPS ARE NOT PERFORMED AT THE INTERVALS SPECIFIED

Continuously

a. Keep the area around the boiler free from combustible materials, gasoline and other

flammable vapors and liquids.

b. Keep the area around the combustion air inlet terminal free from contaminates .

c. Keep the boiler room ventilation openings open and unobstructed.

Monthly Inspections:

a. Inspect the vent piping and outside air intake piping to verify they are open, unobstructed and free

from leakage or deterioration. Call the service technician to make repairs if needed.

b. Inspect the condensate drain system to verify it is leak tight, open and unobstructed. Call the service

technician if the condensate drain system requires maintenance.

c. Inspect the water and gas lines to verify they are free from leaks. Call the service technician to make

repairs if required.

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 button on the display to restore normal

operation. If the yellow light does not come on, determine why the low water cutoff is not working

properly.

b. Follow the procedure for turning the boiler off found in the BWC Series Lighting and Operating

Instructions.

c. Inspect the wiring to verify the conductors are in good condition and attached securely.

CAUTION

WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR

OTHER SYSTEM COMPONENTS. IMMEDIATELY REPAIR ANY LEAKS FOUND.

CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS.

WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY

PROPER OPERATION AFTER SERVICING.

Summary of Contents for BIMINI BWC225

Page 1: ...t 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...

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Page 3: ...Intake System Assembly 14 VII Gas Piping 23 VIII System Piping 24 General System Piping Precautions 24 System Design 24 Standard Piping Installation Requirements 31 Piping For Special Situations 32 IX Wiring 34 X Start up and Checkout 38 XI Operation 44 XII Service and Maintenance 49 XIII Troubleshooting 51 XIV Parts 55 Appendix A Special Requirements For Side Wall 69 Vented Appliances In The Comm...

Page 4: ...tems or systems contain ing significant amounts of dissolved oxygen II Specifications Figure 2 1 General Configuration 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 VENT COLLAR DIAMETERS IN INLET EXHAUST BWC150 3 150 000 50 000 133 000 117 000 4 3 BWC225 4 225 000 75 000 202 000 176 000 4 4 MODELS SHOWN ...

Page 5: ...n 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 co...

Page 6: ...ENT 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 OFFSE...

Page 7: ...BTU hr If the result is less than 50 the boiler room is a confined space Example A BWC225 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 225000 BTU hr 30000 BTU hr 1000 255 MBTU hr Volume of room 6 25 ft x 7 ft x 8 ft 350 ft3 350 255 1 37 Since 1 37 is less than 50 the b...

Page 8: ...d 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...

Page 9: ... 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 Table 4 These systems are made of a special stainless steel alloy AL29 4C for protection against corrosive flue gas condensate They are also designed to provide a gas tight seal at all joints and seams so that flue gas does not enter the buildi...

Page 10: ...ocation also see Figure 6 3 Vent terminals must be at least 1 foot from any door window or gravity inlet into the building 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 the...

Page 11: ...eet USA Only 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 In Canada refer to B149 1 Installation Code for clearance to meters regulators and relief equipment Do not locate the vent terminal under decks or similar structures Top of vent terminal...

Page 12: ... FIGURE 6 3a LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS DOORS GRADE FIGURE 6 3b LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS FIGURE 6 3c POSITIONING VENT TERMINAL UNDER OVERHANGS ...

Page 13: ...d on the roof The air intake terminal must be located on the roof and must be no further than 24 horizontally from the exhaust pipe 8 Wall thimbles Wall thimbles are required where the vent pipe passes through combustible walls with less than the required clearance shown in Table 4 2 or as required by local codes Vent manufacturer s wall thimble part numbers are shown in Table 6 5 9 Pitch of Horiz...

Page 14: ... ROOF ROOF VENT PIPE SIZE 3 4 AIR INTAKE PIPE SIZE 4 4 MAXIMUM VENT PIPE LENGTH BWC150 49 5 FT N R BWC225 N R 47 FT MAXIMUM INTAKE PIPE LENGTH BWC150 52 FT N R BWC225 N R 52 FT EXHAUST TERMINAL RODENT SCREEN BY VENT SYSTEM MANUFACTURER SAME DIAMETER AS VENT SYSTEM SEE TABLE 6 5 AIR INTAKE TERMINAL 4 180 ELBOW 4 180 ELBOW VENT MATERIAL APPROVED VENT SYSTEM SHOWN IN TABLE 6 5 AIR INTAKE MATERIAL GAL...

Page 15: ...FSBS4 TEE FSTT4 FSBS4 Z FLEX SVE SERIES III Z VENT III 3 2SVSWTEF03 ELBOW 2SVSTEX0390 TEE 2SVSTTF03 24SVSTPF03 4 2SVSWTEF04 ELBOW 2SVEEWCF0490 2SVSTPF04 TEE 2SVSTTF04 24SVSTPF04 METAL FAB CORR GUARD 3 CGSWWPK 3 ELBOW CGSW90LTM 3 TEE CGSWTTM 3 CGSWTTM 3 4 CGSWWPK 4 ELBOW GSW90LTM 4 TEE CGSWTTM 4 CGSWTTM 4 NOTE See vent system manufacturer s literature for other part numbers that are required such a...

Page 16: ...mmon venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliances to their previous condition of use g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 When re sizing any portion of the common venting system the comm...

Page 17: ... 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 18: ...he pipe apply 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 6 8 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 Th...

Page 19: ...e 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 m...

Page 20: ... male end of the pipe into the boiler vent collar until it bottoms out Apply an additional bead of silicone over the outside of the joint and the seams on the vent collar and smooth out Fig 6 10 Replace and tighten the clamp on the vent collar c All other joints in the FasNSeal venting system rely on a gasket in the female end of the pipe for a proper seal d Align the longitudinal seam of both pip...

Page 21: ... must be extended construct the extension from PVC or CPVC pipe Insert the hose provided with the boiler into the end of the extension as shown in Figure 6 11 b Condensate is slightly acidic Do not use metallic pipe or fittings in the condensate drain line Do not route the drain line through areas that could be damaged by leaking condensate c Some jurisdictions may require that the condensate be n...

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Page 25: ...e of the boiler A sediment trap must be installed upstream 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...

Page 26: ...URE IN THE BOILER AT A MINIMUM OF 12 PSI DESIGN SYSTEM TO ENSURE THAT THE FLOW FALLS WITHIN THE LIMITS CALLED FOR IN TABLE 8 1 B System Design Proper operation of the BWC boiler requires that the water flow through the boiler remain within the limits shown in Table 8 1 any time the burner is firing Failure to maintain the flow within these limits could result in erratic operation or premature boil...

Page 27: ...al equivalent length of the secondary loop d Using Table 8 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 8 6 column a If the indirect water heat...

Page 28: ...ht Pipe 6 Elbows x 3 75 2 Turns in Tees x 8 1 Swing Check x 10 2 valves x 0 8 70 1 Equivalent Feet Straight Pipe From Table 8 6 we see that smallest circulator which will pump at 8 GPM through a BWC150 with 70 1 equivalent feet and an indirect water heater pressure drop of 3 ft is a Taco 0010 26 ...

Page 29: ...Figure 8 3 Piping Method 1 Heat Indirect Water Heater 27 ...

Page 30: ...Figure 8 4b Piping Method 1 Indirect Water Heater Loop Piping Shaded Figure 8 4a Piping Method 1 Secondary Loop Piping Shaded 28 ...

Page 31: ... MSH 40H MT040GBR MT080GBR Taco 0010 150 BWC150 1 1 4 8 0 5 0 MS 53 MS 79 MSH 53H Taco 0010 81 BWC225 1 1 4 9 0 3 0 MT040GBR MT080GBR Taco 007 91 BWC225 1 1 4 9 0 5 0 MS 26 MS 40 MS 53 MSH 40H MSH 53H MS 119 Taco 0010 91 BWC225 1 1 4 10 6 3 0 MT120GBC Taco 0010 73 Catalog rating of indirect water heater will not be achieved due to inadequate boiler output TABLE 8 5 PIPE AND CIRCULATOR SIZING FOR B...

Page 32: ... This method is generally not recommended because it is often very difficult 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 callin...

Page 33: ...aded 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 freezing The termination of the relief valve discharge piping must be in an area where it is not likely to become plugged by debris 2 The fitting in which the gauge relief valve and LWCO are to be mounted must ...

Page 34: ...ulator zone systems through zones that are not calling for heat 10 Isolation Valves Recommended Isolation valves are useful when the boiler must be drained as they will eliminate having to drain and refill the entire system 11 Drain Valve Required The drain valve is installed on the return tee located in the lower vestibule compartment as shown in Figure 8 2 12 Low Water Cut off Required The low w...

Page 35: ...33 Figure 8 11 Chiller Piping Figure 8 10 Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger ...

Page 36: ...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 senso...

Page 37: ...Figure 9 1 Wiring Connections Diagram 35 ...

Page 38: ...Figure 9 2 Ladder Diagram 36 ...

Page 39: ...Figure 9 3 Wiring of Isolation Relay for Control of Two Heating Circulators 37 ...

Page 40: ... 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 6 11 Add water to the trap until water runs out the con...

Page 41: ...system with a heat exchanger Alternatively consider installing a water meter in the 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 th...

Page 42: ...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 43: ...ion are needed 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 10 1 No yellow tipping should be present however intermittent flecks of yell...

Page 44: ...or will need to be temporarily connected outside of the boiler If it is removed be sure to return the flue gas temperature sensor to its original position after combustion testing is complete Check CO2 or O2 and CO at both high and low fire The boiler may be temporarily locked into high or low fire for 15 minutes as follows a To lock the boiler in high fire simultaneously press and hold the Mode b...

Page 45: ... taking combustion readings At both high and low fire CO readings should be less than 75 PPM Typical CO2 readings are shown in Table 10 3 Normal modulation should return 15 minutes after the boiler is locked in high or low fire 12 Test any external limits or other controls in accordance with the manufacturer s instructions 13 Verify that the boiler starts and stops in response to calls for heat fr...

Page 46: ...y 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 Mode...

Page 47: ...ues the boiler 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 temper...

Page 48: ...3 22 Long Turn 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 i...

Page 49: ...the 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 contr...

Page 50: ... 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 51: ...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 52: ...pect the burner gasket and replace if necessary j With the burner removed inspect the combustion chamber and clean as necessary k 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 requ...

Page 53: ...ided 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 54: ...ed 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 Suppl...

Page 55: ...24VAC across AT140 transformer 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 excess of 200 F for an extended period o...

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Page 57: ...arts 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 58: ... Wsh Hd Screw 90 212 25 90 212 26 21 10 Flat Washer 90 057 4 90 057 4 22 Inspection Port Window 980035 1 980035 1 23 Upper Vestibule Door 240453 1 240450 1 24 Partition 240403 1 240404 1 25 10 x 1 2 Truss Hd Screw 900120 21 900120 21 26 Shutter Bushing for 875 Hole 96 050 2 96 050 2 27 Flat Wire Clip Ribbon Cable 900012 2 900012 2 28 Right Side Panel Assembly 240300 1 240300 1 29 5 16 ID Cable Cla...

Page 59: ...e F Screw 900470 8 900470 8 67 10 32 x 3 16 Ground Screw 146 95 301 1 146 95 301 1 68 Control Chassis 240330 1 240330 1 69 4 X 4 J Box 96 055 1 96 055 1 70 4 X 4 J Box Cover Plate 96 054 1 96 054 1 71 Resistor Clamp 312 Dia 960090 1 960090 1 72 Terminal Block 375 c c 9 Pole 960095 1 960095 1 73 Pressure Switch 230009 1 240050 1 74 40VA Transformer LWCO Power Supply 35 2000 1 35 2000 1 75 Boiler Co...

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Page 63: ...61 Gas Train Assembly Honeywell Valve ...

Page 64: ...Gas Train Assembly Dungs Valve 62 ...

Page 65: ...ight Glass Gasket 5mm 240952 2 240952 2 109 Ignition Electrode 240010 1 240007 1 110 Ignition Electrode Gasket 5mm 240011 1 240011 1 111 Exhaust Pipe Lip Ring Seal 240039 1 240049 1 112 Burner Hood 240030 1 240040 1 113 Burner 240036 1 240045 1 114 Burner Hood Seal 240032 1 240042 1 115 Burner Air Distributor Plate 240038 1 240048 1 116 Nipple Pressure Measuring G1 8 240910 1 240910 1 117 Hi Tempe...

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Page 67: ...5 1 155B 1 2 x 13 Yellow Coated CSST 230707 1 156 Bulkhead Bracket 230721 1 230721 1 157A 3 4 Bulkhead CSST Adapter 230724 2 157B 5 8 Bulkhead CSST Adaptor 230720 1 158 Combustion Air Blower Dungs Valve 230002 1 NA 1 159 1 2 Close Nipple 95 021 1 Not Shown 3 4 Bulkhead CSST Adaptor NA 230724 2 Not Shown 3 4 x 20 Yellow Coated CSST NA 230725 1 Not Shown 11 1 2 Releasable Nylon Cable Wire Tie 960025...

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Page 71: ...a product approved air intake must be used Installation shall be in strict compliance with the manufacturer s instructions A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation d A metal or plastic identification plate shall be mounted at the exterior of the building four feet directly above the location of the vent terminal The ...

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Page 73: ...PN 980040 Rev 6 BWC 12 12 Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com ...

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