Page 3 - TABLE 1: BSI SPECIFICATIONS; II Specifications; FIGURE 1: BSI BOILERS - GENERAL CONFIGURATION
3 TABLE 1: BSI SPECIFICATIONS 2 II Specifications FIGURE 1: BSI BOILERS - GENERAL CONFIGURATION INP UT(M B H) (M BH ) (Sq . ft) (M BH) (% ) " A" "B " "C" "D " (Gal) B SI0 69 S 8 0.0 B SI0 69 E 8 1.9 B SI1 03 S 8 0.0 B SI1 03 E 8 2.0 B SI1 38 S 8 0.3 B SI1 38 E 8 2.0 B...
Page 4 - III Before Installing; National Fuel Gas Code; IV Locating the Boiler; ) The boiler must be installed on a hard level surface.; Warning
4 3 III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordancewith this manual and the requirements of the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must ...
Page 5 - ) The boiler should be located as close to the chimney as possible.; V Air for Combustion and Ventilation
5 4 4) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or used. Do notinstall this boiler in an area where large amounts of airborne dust will be present, such as a workshop. 5) The boiler should be located as close to the chimney as possib...
Page 6 - For Buildings of Other than Unusually Tight Construction; National Fuel; For Buildings of Unusually Tight Construction
6 For Buildings of Other than Unusually Tight Construction 1) Determine whether the boiler is to be installed in a confined space - A confined space is defined by the National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To...
Page 9 - VI Venting
9 8 VI Venting Vent installation must be in accordance with local building codes, or the local authority having jurisdiction, or the National Fuel Gas Code , NFPA 54/ANSI Z 223.1. A typical vent installation is illustrated by Figure 8. The components of vent installation are the vent damper (if used...
Page 10 - screws and support as required.; Removing an Existing Boiler from a Common Chimney; will operate continuously.
10 9 14) Vent damper installation is mandatory on all sizes from the BSI069 to BSI276. The BSI310 through BSI379 may be orderedwith or without vent damper. If supplied, install vent damper (see Figure 9) as follows: a) Open vent damper carton and remove installation instructions. Read the instructio...
Page 12 - FIGURE 10: GAS CONNECTION TO BOILER; VII Gas Piping
12 11 FIGURE 10: GAS CONNECTION TO BOILER * State of Massachusetts Requires ManualShut-off Valve to be “T” Handle Type * VII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at a line pressure between the minimum and maximum valu...
Page 13 - CAUTION; VIII System Piping; General Piping Notes; Installation Guide for Residential Hydronic Heating Systems
13 12 CAUTION • INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTEDFROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERATION AND SERVICE (CIRCULATOR REPLACEMENT, ETC.). • OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGENCAN CAUSE SEV...
Page 14 - PIPE SAFETY VALVE DISCHARGE TO A SAFE LOCATION.
14 Piping Installation 1) Remove parts bag from boiler crate. 2) Install safety valve (spindle must be in vertical position) into tapping on boiler left side (see Figure 1) using the 3/4” NPTnipples and elbow supplied. 3) Pipe the discharge of the safety relief valve to a location where water or ste...
Page 15 - BETWEEN RISERS
15 14 WRONG - HEADER BULLHEADEDINTO TAKE-OFFAND EQUALIZER WRONG - TAKE-OFF BULLHEADED INTOTWO MAINS WRONG - TAKE-OFF BETWEEN RISERS FIGURE 12: COMMON NEAR-BOILER PIPING MISTAKES FIGURE 11: STEAM BOILER PIPING FOR GRAVITY RETURN "A" "B" "C" "D" BSI069 * 2 1 1/2 1 1/4 B...
Page 16 - IX Indirect Water Heater Piping; IMPORTANT; FIGURE 13: INDIRECT WATER HEATER BOILER-SIDE PIPING
16 IX Indirect Water Heater Piping All BSI series boilers are equipped with tappings to permit the connection of a Crown Mega-Stor, or other indirect water heater. In this type of system, hot boiler water is drawn from below the water line and passed through the heat exchanger inthe indirect water h...
Page 17 - X Wiring; BLACK
17 X Wiring 1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt connections are made inside the junction box on the left side of the boiler. Remove the transformer to gain access to thisbox (also see Figures 16 through 19): • Hot (“b...
Page 18 - Do; NOT; Indirect Water Heater Wiring
18 Feeder Wiring for Boilers Equipped with McDonnell & Miller #67 Low Water Cut-offs Figures 14a and 14b show feeder wiring for McDonnell & Miller #101A, McDonnell & Miller WF2-U-24 and Hydrolevel VXT-24 feeders on boilers equipped with #67 low water cutoffs. The following points apply t...
Page 19 - FIGURE 15: WIRING INDIRECT WATER HEATER TO BOILER
19 18 FIGURE 14b: WIRING MCDONNELL & MILLER WF2-U-24 FEEDER OR THREE-WIRE HYDROLEVEL VXT-24 FEEDER TO BOILER EQUIPPED WITH #67 L.W.C.O. CAUTION DO NOT INSTALLJUMPER BETWEEN 2 & 3ON #67 L.W.C.O. FIGURE 15: WIRING INDIRECT WATER HEATER TO BOILER
Page 20 - BSI Control System – Sequence of Operation; (Refer to Figures 16 through 19 for ladder and connection diagrams); Sequence of Operation, Standing Pilot
20 BSI Control System – Sequence of Operation (Refer to Figures 16 through 19 for ladder and connection diagrams) Sequence of Operation, Standing Pilot 1) When the boiler is energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the ventdamper. Assuming that there is ...
Page 23 - #67 LOW WATER CUTOFF
23 FIGURE 19: WIRING DIAGRAM, INTERMITTENT IGNITION AND McDONNELL & MILLER MODEL #67 LOW WATER CUTOFF Blocked Vent (“Spill”) Switch - Automatically interrupts burner operation in the event that flue gas spills from the draft diverteropening. This switch is equipped with a reset button which must...
Page 24 - XI Start-up and Checkout; Use the following procedure for initial start-up of the boiler:; NOTE; NEVER USE A FLAME TO CHECK FOR GAS LEAKS.
24 XI Start-up and Checkout Use the following procedure for initial start-up of the boiler: 1) Make sure that the boiler is filled with water to the normal water line (28 3/4 inches above the floor or pad on which the boiler is installed) 2) Check all new gas piping for leaks and purge piping sectio...
Page 25 - WARNING
25 24 16) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a) Connect a manometer to the inlet pressure tap on the gas valve (see Figures 23 and 24).b) Check the inlet pressure with all gas appliances on and off. The inlet pressure at the boiler must be w...
Page 26 - LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL
26 25 A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO...
Page 27 - LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW
27 26 A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO...
Page 30 - FIGURE 22a: MAIN BURNER FLAME - 1” BURNERS; DO NOT INSTALL ANY VALVES IN THIS LINE
30 29 FIGURE 22a: MAIN BURNER FLAME - 1” BURNERS FIGURE 22b: MAIN BURNER FLAME - 40mm (“HIGH ALTITUDE”) BURNERS 17) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. For standing pilot boilermodels, pilot burner should remain lit but the main burners s...
Page 32 - XII Service and Maintenance; On a continuous basis:; Reinstall safety valve and related piping.
32 XII Service and Maintenance On a continuous basis: 1) Keep the area around the boiler free and clear from combustible materials, gasoline, and other flammable vapors andliquids.2) Keep the area around the boiler and boiler room ventilation openings clear of objects which might obstruct the flow o...
Page 35 - XIII Troubleshooting
35 XIII Troubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems. To use these charts, go to thebox marked “Start” at the top of the chart on page 35 or 37 and follow the appropriate path though the chart until a box with alist of possible causes is r...
Page 36 - : Read page 34 before attempting to use this chart
36 Troubleshooting Chart for BSI Boilers Equipped withHydrolevel CG400A Low Water Cut-offs and Vent DampersCaution : Read page 34 before attempting to use this chart 35 Is there an audible click as R8225 relay pulls in w hen the thermostat calls f or heat? Does relay pull in now ? V ent damper open?...
Page 40 - Standing Pilot Ignition System Troubleshooting Chart; Caution; : Read page 34 before
40 Standing Pilot Ignition System Troubleshooting Chart Pilot lit? Main burners light? Y Turn control on gas valve to PILOT . Depress red button and light pilot. Hold button for at least one minute. Does pilot light? N * Pilot tubing blocked, kinked or leaking * Pilot orifice blocked * Gas line not ...
Page 41 - Intermittent Ignition System Troubleshooting Chart
41 40 Does spark stop when pilot lights? 24 volts across terminals 2&3 at S8600? Spark across ignitor/sensor gap? Y Can you hear sparking? * Faulty S8600 module * Break in spark cable insulation * Break in pilot porcelain * Incorrect pilot spark gap * Loose connection in spark cable * Loose grou...
Page 42 - XIV PARTS; representative or the factory at:
42 41 XIV PARTS The following 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 ServiceP.O. Box 14818Philadelphia PA. 19134www.crownboiler.com For boilers installed at elevations ...
Page 48 - punctures due to mishandling.; B. Base Assembly Preparation; tion manual for additional information on placement.; C. Heat Exchanger and Flue Collector Installation; Appendix A: Knockdown Boiler Assembly Instructions; D. Jacket Installation
48 A. Before Installing 1) Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs or punctures due to mishandling. 2) Do not use the heat exchanger if there is any damage to it.3) Inspect the joints between the sections for openings. Reseal ...
Page 51 - FIGURE A2: JACKET INSTALLATION
Page 54 - Manufacturer of Hydronic Heating Products; CROWN; Boiler Co
54 Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 CROWN Boiler Co