Crown Boiler PHNTM399 Page 1 Installation And Operating Instructions Manual Download

Page: 1 / 120

105358-04 - 08/15

WARNING:

Improper installation, adjustment, alteration,

service or maintenance can cause property damage, injury,

or loss of life. For assistance or additional information,

consult a qualified installer, service agency or the gas

supplier. This boiler requires a special venting system.

Read these instructions carefully before installing.

Series

High Efficiency Gas-Fired Hot Water

Direct Vent Condensing Boilers

INSTALLATION AND OPERATING INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler and

retained for future reference.

Models:

• PHNTM399

• PHNTM500

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

www.crownboiler.com

9700609

This manual is for use with

boilers having a part number

ending in “B” (example:

PHNTM399HNL17UB.

Summary of Contents for PHNTM399

Page 1: ...these instructions carefully before installing Series High Efficiency Gas Fired Hot Water Direct Vent Condensing Boilers INSTALLATION AND OPERATING INSTRUCTIONS These instructions must be affixed on o...

Page 2: ...icense reg state ma us pubLic pl_products pb_pre_form asp for the latest Approval Code or ask your local Sales Representative The Commonwealth of Massachusetts requires this product to be installed by...

Page 3: ...l be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating...

Page 4: ...l 33 VI Water Piping and Trim 35 VII Gas Piping 47 VIII Electrical 51 IX System Start Up 62 X Operation 70 A Overview 70 B Supply Water Temperature Regulation 71 C Boiler Protection Features 72 D Mult...

Page 5: ...g a part number ending in B example PHNTM399HNL17UB Table 1B Dimensions See Figures 1A and 1B Dimension Boiler Model PHNTM399 PHNTM500 A Inch mm 28 7 8 734 44 7 8 1140 B Inch mm 6 3 16 157 22 1 8 562...

Page 6: ...6 I Product Description Specifications and Dimensional Data continued Figure 1A Phantom Model PHNTM399...

Page 7: ...7 Figure 1B Phantom Model PHNTM500 I Product Description Specifications and Dimensional Data continued...

Page 8: ...ater Ratings based on piping and pickup allowance of 1 15 Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements such as intermittent system opera...

Page 9: ...clearance providing III Pre Installation and Boiler Mounting 1 Access to boiler front is provided through a door or removable front access panel 2 Access is provided to the condensate trap located un...

Page 10: ...left side of boiler 3 Access is provided to thermal link located at the boiler rear 4 Boiler Installation a For basement installation provide a solid level base such as concrete where floor is not le...

Page 11: ...panel lower dimples The remaining lower bracket hole must align with a matching bottom boiler left side panel top positioning dimple Once bracket holes and side panel dimple alignment is verified att...

Page 12: ...ping and Trim Follow instructions in Section VI Water Piping and Trim of the manual for system piping and boiler secondary piping selection sizing based on combined heating capacity and or gross outpu...

Page 13: ...calculations Use vent combustion air equivalent length worksheet provided in Table 6B b Maintain minimum clearance to combustible materials See Figure 2 for details c Enclose vent passing through occ...

Page 14: ...Same as above but separate snorkel type terminals 4 6A 6B 9 12 14 10A 10B Optional Vertical Vertical through roof or chimney chase The system includes separate Flexible Polypropylene vent liner and R...

Page 15: ...d vacuation doivent pr ciser que les sections horizontales doivent tre support es pour Table 6A Vent System and Combustion Air System Components Equivalent Length vs Component Nominal Diameter Vent o...

Page 16: ...lent Length B Nominal Diameter Quantity Pc Equivalent Length per Pc Subtotal Equivalent Length A 4 in 100 mm or 110 mm 4 5 ft 1 4 m 4 in 100 mm or 110 mm 13 ft 4 0 m Straight Pipe Installer Supplied 4...

Page 17: ...al separation depends upon the depth of the soffit See Figure 4 for details l Maintain minimum 12 in 300 mm horizontal spacing between vent terminal and a building corner m Under certain conditions wa...

Page 18: ...als B CPVC PVC Venting WARNING Asphyxiation Hazard Failure to follow these instructions could cause products of combustion to enter the building resulting in severe property damage personal injury or...

Page 19: ...r optional vertical roof terminals shown in Figure 7 2 Field Installation of CPVC PVC Two Pipe Vent System Connector Refer to Figure 9 and following steps Vent Components Quantity PHNTM399 PHNTM500 Ho...

Page 20: ...stalled Flue Temperature Sensor and Sensor Cap 3 Near Boiler Vent Combustion Air Piping Refer to Figure 10 and the following Steps a Apply supplied dielectric grease grease pouch attached to two pipe...

Page 21: ...IPS Corporation 790 Multi Purpose Solvent Cement Always use primer on both the pipe and fitting before applying the cement Assemble the pipe in accordance with the instructions on the cans of primer...

Page 22: ...g such taht a minimal clearance is obtained and to allow easy insertion of vent pipe Apply sealant between vent pipe and wall opening to provide weather tight seal Sealant should not restrain the expa...

Page 23: ...vent pipe See Figure 6B At top of air pipe length install another PVC 90 elbow so that elbow leg is opposite the building s exterior surface Install rodent screen and combustion air terminal supplied...

Page 24: ...anufacturers M G DuraVent or Centrotherm whichever applicable Failure to do so could cause products of combustion to enter the building resulting in severe property damage personal injury or death Whe...

Page 25: ...nting See Figures 9 and 14 b Apply provided dielectric grease grease pouch taped to the vent system connector all around to the vent or air connection inner red silicon gasket c Push and twist PVC to...

Page 26: ...nt systems made by M G DuraVent and Centrotherm Eco Systems rely on gaskets for proper sealing When these vent systems are used take the following precautions Make sure that gasket is in position and...

Page 27: ...em manufacturer s literature for other part numbers that are required such as straight pipe elbows firestops and vent supports Table 11 Acceptable Stainless Steel Vent Systems and Vent Components WARN...

Page 28: ...air piping sections with PVC cement c Do not drill holes in vent pipe 2 Field Installation of CPVC PVC Two Pipe Vent System Connector and PVC to Stainless Steel Adapter a Install CPVC PVC two pipe ven...

Page 29: ...ld protrude the same distance from the wall as the exhaust terminal as shown in Figure 5 Install a rodent screen not supplied in the inlet terminal Use a screen having 1 2 in x 1 2 in 13 mm x 13 mm me...

Page 30: ...de ANSI Z223 1 NFPA 54 and or the Natural Gas and Propane Installation Code CAN CSA B149 1 Au moment du retrait d une chaudi re existante les mesures suivantes doivent tre prises pour chaque appareil...

Page 31: ...subsequent frost damage To avoid minimize frost damage extend the distance from building surfaces to vent termination end and increase the horizontal distance between adjacent vent terminations e Ind...

Page 32: ...32 Figure 17 Multiple Boiler Direct Vent Termination IV Venting F Multiple Boiler Installation Venting continued...

Page 33: ...r to Figures 1A 1B 1C 1D and 18 5 Condensate trap must be filled up with water prior to boiler start up and before connecting any condensate line to the boiler to insure combustion products cannot esc...

Page 34: ...one and acidic condensate and lose neutralizing effectiveness over time Therefore periodic condensate neutralizer maintenance and limestone chip replacement must be performed A pH test or acid test ki...

Page 35: ...s 1 Locate and remove in NPT x close black nipple in NPT x 10 in black nipple in NPT black tee in FPT x in FPT safety relief valve and in NPT drain valve VI Water Piping and Trim Figure 19 Factory Sup...

Page 36: ...D because a The flow rate through system must be the same as through boiler and fall within limits specified in Table 13 VI Water Piping and Trim A Factory Supplied Piping Trim B Piping System to be E...

Page 37: ...o be replaced the replacement valve must have a relief capacity equal or exceeding the minimum relief valve capacity shown on the heat exchanger ASME plate Also when replacing the safety relief valve...

Page 38: ...60 37 7 16 9 2400 70 PHNTM500 1 2 27 1 7 4 0013 31 7 9 6 2400 60 38 0 13 1 2400 65 47 5 19 1 2400 70 Boiler Model Supply Return Connection in Near Boiler Pipe Size in T 35 F T 30 F T 25 F T 20 F Flow...

Page 39: ...ust above the boiler with no intervening valves Set the manual reset high limit to 210 F Follow Section VIII Electrical to wire the high limit 8 Y strainer Recommended A Y strainer or equivalent strai...

Page 40: ...en after ini tial fill and eliminate any water leakage as early as possible Maintain the water pressure in the boiler at a minimum of 14 5 psi 100 kPa The boiler water pH must be within 7 5 pH 9 5 If...

Page 41: ...41 Figure 20 Near Boiler Piping Heating Only VI Water Piping and Trim C Standard Installation Requirements continued...

Page 42: ...42 Figure 21 Near Boiler Piping Heating Plus Indirect Water Heater VI Water Piping and Trim C Standard Installation Requirements continued...

Page 43: ...ments All components on the oxygenated side of the heat exchanger such as the pump and expansion tank must be designed for use in oxygenated water Table 16 Multiple Boiler Water Manifold Sizing Boiler...

Page 44: ...Refer to this Section of this manual for a Installation of factory supplied piping and trim components for an individual module boiler b Regarding an individual module boiler piping system specific d...

Page 45: ...stic Hot Water Heater Page 1 of 2 VI Water Piping and Trim E Multiple Boiler Installation Water Piping continued NOTICE Installing a low water cutoff in the system piping of multiple boilers is strong...

Page 46: ...w Domestic Hot Water Heater Page 2 of 2 VI Water Piping and Trim E Multiple Boiler Installation continued NOTICE Installing a low water cutoff in the system piping of multiple boilers is strongly reco...

Page 47: ...118 95 81 72 65 60 56 52 50 0 824 360 247 199 170 151 137 126 117 110 104 1 1 049 678 466 374 320 284 257 237 220 207 195 1 1 380 1392 957 768 657 583 528 486 452 424 400 1 1 610 2085 1433 1151 985 87...

Page 48: ...858 1492 1277 1131 1025 943 877 823 778 2 2 469 4308 2961 2377 2035 1803 1634 1503 1399 1312 1239 3 3 068 7615 5234 4203 3597 3188 2889 2658 2472 2320 2191 1 CFH of LP Gas is approximately equal to 2...

Page 49: ...PT x 12 in long black nipple and left side panel grommet factory installed disregard the supplied in NPT x 6 in long black nipple in the miscellaneous parts carton c Mount the in NPT external gas shut...

Page 50: ...al gas supplier for instructions and equipment ratings Figure 25 Gas Inlet Pressure Tap and Pressure Switch Location 2 The low gas pressure switch must be reset after the boiler is piped to the gas su...

Page 51: ...age 24 VAC Connections see Figure 27 DANGER Electrical Shock Hazard Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or con...

Page 52: ...rements Nominal boiler current draw is provided in Table 21 These values are for planning purposes only and represent only the boiler s power consumption To obtain total system power consumption add a...

Page 53: ...53 VIII Electrical continued Figure 26 Ladder Diagram...

Page 54: ...54 VIII Electrical continued...

Page 55: ...55 Figure 27 Wiring Connections Diagram VIII Electrical continued...

Page 56: ...re 28A Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating with Central Heating Circulators Plus Alternately Piped Indirect Water Heater VIII Electrical con...

Page 57: ...re 28B Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating with Central Heating Zone Valves Plus Alternately Piped Indirect Water Heater VIII Electrical con...

Page 58: ...58 Figure 28C DHW Priority Circulators with Crown PN 3501505 Zone Panel Piped Off System Header Wiring Schematic for Heating Zone Circulators CROWN PN 3501505...

Page 59: ...59 Figure 29 Multiple Boiler Wiring Diagram Internal R7910 Multiple Boiler Control Sequencer Three Boilers Shown Typical Connections for up to Eight Boilers VIII Electrical continued...

Page 60: ...ster Sequencer enabled R7910 Controller The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master Refer to piping diagram Figure 23...

Page 61: ...m 1 through 8 WARNING When two boiler s addresses are the same undesirable simultaneous operation occurs 5 Enable 1 Boiler Master Enable only one R7910 Control s Sequencer Master WARNING When more tha...

Page 62: ...tem Start up E Confirm that the boiler and system have no water leaks F Prepare to check operation 1 Obtain gas heating value in Btu per cubic foot from gas supplier 2 Phantom gas valves have inlet an...

Page 63: ...63 IX System Start up continued Phantom Series Operating Instructions Figure 32 Operating Instructions...

Page 64: ...tle and or offset specified herein and subsequent combustion data O2 CO2 CO ppm collection must be performed using a calibrated combustion analyzer Failure to use combustion analyzer could result in p...

Page 65: ...ify O2 or CO2 and CO are within limits specified in Table 22 natural gas or Table 23 LP gas at both high and low fire as described in the following steps a Lock boiler in high fire and allow boiler to...

Page 66: ...ermostats Adjust the heating and indirect water heater thermostats to their final set points Q Field Conversion From Natural Gas to LP Gas Phantom models PHNTM399 and PHNTM500 are factory shipped as n...

Page 67: ...jacent to the outer boiler jacket Fill in the date of the conversion and the name and address of the company making the conversion with a permanent marker R Correcting Throttle Screw Mis Adjustment if...

Page 68: ...ss of life Under these conditions most combustion analyzers used in the field will show 0 O2 and a very high well over 1000 ppm CO Combustion readings will also appear to be unresponsive to throttle a...

Page 69: ...r heating system Refer to Paragraph G Adjusting Parameters Pump Setup Menu for additional information Boiler Pump Domestic Pump 5 Contractor Setup Contractor Name Enter your contact information name a...

Page 70: ...llations 5 Built in Safety Control TheControlincludessafetycontrolsdesignedtoensuresafe and reliable operation In addition to flame safety controls the Control includes supply water temperature differ...

Page 71: ...Outdoor Reset is enabled the Central Heat setpoint will automatically adjust downwards as the outdoor temperature increases When the water temperature is properly matched to heating needs there is mi...

Page 72: ...temperature for longer than a limit time delay the Control shuts down the boiler and delays restart If the inverted temperature is detected more than five times the boiler manual reset Hard Lockout is...

Page 73: ...der of the year 6 Multiple Demands The Sequence Master responds to Central Heat DHW and frost protection demands similar to the stand alone boiler For example when selected and DHW priority is active...

Page 74: ...conducted Pre ignition Spark is energized and it is confirmed that no flame is present Direct Ignition Spark and Main fuel valve are energized Supply 132 F 140 F Rate 100 Status Setpoint Boiler 1 Prio...

Page 75: ...e Fault and Rate Limit symbols provide a link to the cause of a boiler fault or firing rate limit The first boiler status screen provides an overview of boiler operation including fault status Rate Fi...

Page 76: ...protec tion logic the 6 symbol blinks and becomes a screen link Rate The rate value is equal to the actual kbtu hr input divided by the boiler rated input Priority The selected Priority is shown Avai...

Page 77: ...s can be an indication of gas supply issues Additionally supply and return tempera ture dual pen trends brings a focused look at heat exchanger and pump performance For example studying a differential...

Page 78: ...re Press the zone control button to view individual zone Zone Panel 1 typical for 2 through 4 Zone panel screens show individual zone status cycle counts and individual zone heat loss size in kbtu hr...

Page 79: ...d last to stop The lead boiler is automatically rotated after 24 hours of run time Additionally the lead is rotated if there is a lead boiler fault Firing Rate Demanded firing rate is provided The Seq...

Page 80: ...ssword is 86 and press the return arrow to close the keypad Press the Save button Press the Adjust button to enter Adjustment mode F Changing Adjustable Parameters Figure 39 Adjust Mode Screens 2 Adju...

Page 81: ...surement matching the refer ence reading Not Connected Connected Not Connected Zone Control Status Connected When the Zone Control is connected adjustable settings are automatically shown under the Ad...

Page 82: ...e the boiler type setting if you are installing a new or replacement Control The boiler type setting determines minimum and maximum blower speeds Incorrect boiler type can cause hazardous burner condi...

Page 83: ...he expected heat rate value to set a maximum heat rate The maximum heat rate is the highest heat rate that the boiler can fire to at that moment The maximum heat rate is the summation of the expected...

Page 84: ...ted Heat Rate This parameter defines the highest modulation rate the Control will go to during the auxiliary heat call for heat If the rated input of the Auxiliary Heat Zones is less than the maximum...

Page 85: ...l for heat Central Heat off DHW demand Make sure indirect water heater and DHW circulator are sized to maintain flow through boiler within limits shown in Table 13 Pump Runs during central heat and fr...

Page 86: ...tem pump X DHW pump X Boiler Pump X X Sequencer Master Parameter Selections Sequencer Master Enabled Indirect Water Heater Boiler Piped Pump Parameter Selections System Pump Central Heat No Priority N...

Page 87: ...l It is permissible for the domestic and system pumps to run at the same time The boiler pump must run for every call for heat X Operation F Changing Adjustable Parameters continued Example Pump Param...

Page 88: ...thout Saving Clear Entire Field Backspace Save Field and Exit Save Press box to input contractor information Contractor Name i Bill Smith 1 7 6 5 4 3 2 A ES C D C B 8 CL R 7 BS 8 Enter Contractor Info...

Page 89: ...erature drops Diff Below degrees below the setpoint 3 1 to 5 Response Speed This parameter adjusts the Central Heat temperature controller Proportion Integral Derivative PID values Higher values cause...

Page 90: ...alue increases to high fire causing the temperature to exceed the Diff Above setpoint and cycle the boiler unnecessarily Lower values cause a smaller firing rate change for each degree of temperature...

Page 91: ...ange for each degree of temperature change If set too low the firing rate response will be sluggish and temperature will wander away from setpoint 10 seconds 0 to 300 seconds Low Fire Hold Time Low Fi...

Page 92: ...s typically set to the coldest outdoor temperature 70 F 21 1 C 32 F to 100 F 0 C to 37 8 C Central Heat High Outdoor Temperature The High Outdoor Temperature parameter is the outdoor temperature at wh...

Page 93: ...iary Heat Low Outdoor Temperature The Low Outdoor Temperature parameter is also called Outdoor Design Temperature This parameter is the outdoor temperature used in the heat loss calculation It is typi...

Page 94: ...Fan Coil 100 F to 140 F 37 8 C to 60 C In Slab Radiant High Mass Radiant 160 F to 190 F 71 1 C to 87 8 C Convection Baseboard Fin Tube Convective 130 F to 160 F 54 4 C to 71 1 C Staple up Radiant Low...

Page 95: ...ped below the setpoint minus Diff below setpoint Longer time delay will prevent nuisance starts due to short temperature swings 195 F 90 6 C Central Heat Setpoint 195 F 90 6 C Stop All Boilers Setpoin...

Page 96: ...ut Saving Clear Entire Field Backspace Save Field and Exit NOTE Zone Control Description Setup shown for 2 panels typical for up to 4 Factory Setting Range Choices Parameter and Description Central He...

Page 97: ...loose fitting 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 other...

Page 98: ...installed on the heating system to prevent damage if the boiler is inoperative Burn Hazard This boiler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disco...

Page 99: ...every year 1 Test the flow switch by disabling the boiler primary loop circulator The boiler must not start when there is not water flow 2 Follow the procedure for turning the boiler off per Figure 3...

Page 100: ...nditioning a The following heating system water treatment products are recommended for an initial existing heating system sludge removal initial boiler cleaning from copper dust flux residue and any b...

Page 101: ...ard Use only inhibited propylene glycol solutions specifically formulated for hydronic systems Do not use ethylene glycol which is toxic and can attack gaskets and seals used in hydronic systems Use o...

Page 102: ...ils from boiler wiring c Disconnect pressure switch hose from condensate trap d Disconnectoutsidecondensatecompressionfitting from condensate trap e Using pliers release spring clip securing the overf...

Page 103: ...uttons to be directed to the Fault cause B Display Faults Figure 45 Help Menu Boiler Energy Save On Max Efficiency On Standby i Status Help Adjust Detail Lockout History Service Contract Boiler Size S...

Page 104: ...45 peer to peer network disconnected Sequencer Master was Enabled and then Disabled Master s Boiler has been powered down To clear fault restore communication or cycle power Boiler Size Setup Boiler...

Page 105: ...firing rate is limited or reduced to help avoid a lockout or save energy Refer to Hard Lockout section for corrective actions High Stack Temperature Limit High Supply Temperature Limit High Different...

Page 106: ...ut 4 Loose wiring to limit device External Limit defective or jumper not installed If yellow light on LWCO is on system is low on water If neither yellow or green light is on check LWCO harness 7 Retu...

Page 107: ...miswired blower speed harness Defective blower 19 Purge rate proving failed Blower is not running at Purge rate when it should or blower speed signal not being detected by R7910 Loose connection in 12...

Page 108: ...g parts 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 Philadel...

Page 109: ...er Components Key No Description Part Number PHNTM399 PHNTM500 1K Replacement Burner Kit includes burner burner head seal and hardware 104988 01 104989 01 1L Replacement Burner Door Kit includes door...

Page 110: ...y swirl plate blower adapter plate and mounting hardware 101704 04 101704 05 2D Blower Inlet Replacement Kit includes swirl plate blower adapter plate and mounting hardware 104620 04 104620 05 2E Repl...

Page 111: ...Kit includes float switch and clamp 105005 01 3C Spring Hose Clamp 15 16 in OD hose 101632 01 3D Rubber Grommet Condensate Trap 101595 01 3E Condensate Neutralizer Kit not shown includes limestone ch...

Page 112: ...ion Part Number PHNTM399 PHNTM500 4A Replacement R7910 Control Kit 0 7000ft Altitude 106193 01 106193 04 4B Replacement Display programmed includes mounting hardware 106217 01 4C Transformer 3502430 4...

Page 113: ...113 THIS PAGE LEFT BLANK INTENTIONALLY...

Page 114: ...114 XIII Repair Parts continued PHNTM399 and PHNTM500...

Page 115: ...includes gasket 105010 01 5H Replacement Access Panel Kit 5 in x 16 in includes gasket N A 105011 01 5J Access Panel Gasket 5 in x 8 in 102877 01 5K Access Panel Gasket 5 in x 16 in N A 102613 01 5L...

Page 116: ...703 01 6E Gas Pressure Switch Wire Harness N A 102704 01 6F Flow Switch Kit not shown includes switch and paddles 104927 01 6G Flow Switch Repair Paddle Kit not shown includes paddles and hardware 104...

Page 117: ...es 10A 10B 10C 10D 102701 03 10A Main Low Voltage Harness 103009 03 10B High Voltage Harness 103010 02 10C Blower Power Harness 103012 01 10D Communication Harness 103011 01 10E Igniter Harness 105752...

Page 118: ...118...

Page 119: ...119...

Page 120: ...120 Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com CBC PN 980133 Rev C 08 15...

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