Page 4 - I Product Description; ing significant amounts of dissolved oxygen.; II Specifications
2 I Product Description The BWC is an aluminum gas fired condensing boiler designed for use in forced hot water heating systems requir- ing supply water temperatures of 180°F or less. This boiler may be vented vertically or horizontally with combus- tion air supplied from outdoors. This boiler is not...
Page 5 - III Before Installing; National Fuel Gas Code; IV Locating the Boiler; NOTICE
III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with t...
Page 6 - Figure 4.1: Clearances To Combustible Or Non-combustible Material
4 Figure 4.1: Clearances To Combustible Or Non-combustible Material Table 4.2: Clearances From Vent Piping To Combustible Construction TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MINIMUM CLEARANCE TO COMBUSTIBLE MATERIAL HEAT FAB SAF-T VENT PROTECH FASNSEAL Z-FLEX Z-VENT III FLEX-L STAR-34 VERTICAL O...
Page 7 - V Air for Ventilation; WARNING; AND MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
V Air for Ventilation Air for combustion must always be obtained directly from outdoors, however sufficient air for ventilation must still be provided in the boiler room. Air for ventilation is required to keep various boiler components from over- heating and is always obtained from indoors. To ensur...
Page 9 - VI Venting; * Do not obtain combustion air from within the building.; A. Vent System Design; Vertical Venting; ft vertical pipe
7 VI Venting WARNING Failure to vent this boiler in accordance with these instructions could result in unreliable boiler operation, severe damage to the boiler or property, or unsafe operation: * Do not attempt to vent this boiler with galvanized, PVC, or any other vent system not listed in Table 4....
Page 10 - in Table 6.5 along with the termination fitting.
8 3) Minimum Vent and Air Intake Lengths - Minimum vent length is 2ft. Minimum air inlet length is 2ft. 4) Permitted Terminals for Horizontal Venting (Vent Options 1,2) - The vent terminal is either a tee or an elbow supplied by the vent system manufacturer and equipped with a rodent screen. Vent sy...
Page 11 - TABLE 6.2a: SUMMARY OF HORIZONTAL VENTING OPTIONS; must be located on the same wall.
9 TABLE 6.2a: SUMMARY OF HORIZONTAL VENTING OPTIONS VENT OPTION # 1 2 3 4 5 CLASSIFICATION USED IN THIS MANUAL HORIZONTAL DIRECT VENT HORIZONTAL DIRECT VENT (RESERVED FOR FUTURE USE) (RESERVED FOR FUTURE USE) (RESERVED FOR FUTURE USE) ILLUSTRATED IN FIGURE 6.1 6.1 VENT PIPE STRUCTURE PENETRATION WAL...
Page 12 - FIGURE 6.3c: POSITIONING VENT TERMINAL UNDER OVERHANGS
10 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 14 - TABLE 6.2b: SUMMARY OF VERTICAL VENTING OPTIONS
12 TABLE 6.2b: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # 6 7 CLASSIFICATION USED IN THIS MANUAL VERTICAL DIRECT VENT VERTICAL DIRECT VENT ILLUSTRATED IN FIGURE 6.4 6.4 VENT PIPE STRUCTURE PENETRATION ROOF ROOF AIR INTAKE PIPE STRUCTURE PENETRATION ROOF ROOF VENT PIPE SIZE 3” 4” AIR INTAKE PI...
Page 16 - NEVER COMMON VENT A BWC BOILER WITH OTHER APPLIANCES; CAUTION; systems are used, take the following precautions:
14 B. Removing an Existing Boiler From a Common Chimney Read this only if the BWC boiler is replacing an existing boiler that is being removed from a common chimney. This section does not apply to the installation of a BWC boiler. In some cases, when an existing boiler is removed from a common chimn...
Page 20 - FIGURE 6.10: FASNSEAL CONNECTION TO VENT COLLAR
18 5) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of flue gas flow. • Support horizontal piping s...
Page 22 - VII Gas Piping; gas line sizing, consult the utility or the
20 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 an inlet pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or the National Fuel Gas C...
Page 23 - VIII System Piping; A. General System Piping Precautions; TABLE 8.1: FLOW REQUIREMENTS THROUGH BOILER
21 VIII System Piping A. General System Piping Precautions CAUTION THE HEAT EXCHANGER USED IN THE BWC IS MADE FROM A SPECIAL ALUMINUM ALLOY. FAILURE TO TAKE THE FOLLOWING PRECAUTIONS COULD RESULT IN SEVERE BOILER DAMAGE. • INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM ...
Page 24 - Method 1: Primary/Secondary Piping - Boiler in Secondary Loop
22 Method 1: Primary/Secondary Piping - Boiler in Secondary Loop This method can be used in heat-only applications as shown in Figure 8.2 or with an indirect water heater as shown in Figure 8.3. This method relies on primary/secondary pumping to ensure that the required flow is always maintained thro...
Page 27 - TABLE 8.5: PIPE AND CIRCULATOR SIZING FOR BOILER LOOP
25 TABLE 8.5: PIPE AND CIRCULATOR SIZING FOR BOILER LOOP BOILER MODEL (a) (b) (c) (d) PIPE SIZE FLOW CIRCULATOR MODEL BOILER LOOP MAX EQUIVALENT LENGTH (in NPT) (GPM) (ft) BWC150 1 1/4 8.0 Taco 007 148 BWC150 1 1/4 8.0 Taco 0010 224 BWC225 1 1/4 12.0 Taco007 138 BWC225 1 1/4 12.0 Taco 0010 208 NOTE:...
Page 33 - C: Standard Piping Installation Requirements; DANGER
31 C: Standard Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping: 1) The relief valve is packaged loose with the boiler and must be installed in the location shown in Figure 1. The relief valve is set to open at 30 psi. If the ...
Page 34 - D. Piping for Special Situations
32 3) The return piping may be connected into the boiler through the back or sides of the boiler by rotating the drain elbow and routing the return piping through the appropriate knockout. 4) Circulator (Required) - Usually at least two circulators will be required to properly install a BWC Series b...
Page 36 - IX Wiring; National Electrical Code
34 IX Wiring 1) Line Voltage (120 VAC) Connections (Fig 9.1) – The line voltage connections are located in the junction box on the right side of the vestibule: • Black – Line voltage “hot” • White – “Neutral” for boiler and circulators • Red – “Heating” circulator “hot” • Blue – “Indirect Water Heat...
Page 40 - X Start-up and Checkout; National Fuel Gas; NOTE
X Start-up and Checkout Use the following procedure for initial start-up of the boiler: 1) If not already done, flush the system to remove sediment, flux, and traces of boiler additives. This should be done with the boiler isolated from the system. 2) Fill the boiler and hydronic system with water mee...
Page 41 - BWC Series Lighting and Operating Instructions
A. • C. B. D. • •• 1. 6. 2. 7. 3. 4. 8. 9. 5. 10. 11. 12. 1. 3. 2. 4. FOR YOUR SAFETY READ BEFORE LIGHTING This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. Do not touch any electric switch; do ...
Page 42 - SWT
40 7) Start the boiler using the lighting instructions on page 39. After the boiler is powered up, it should go through the following sequence. Sequence Display Meaning 1 U.125 or Blank Checking internal software (power-up only) 2 0.SWT Boiler in standby. SWT = Supply Water Temp. No call for heat. (...
Page 43 - Model; Propane; EACH BWC SERIES BOILER IS TESTED AT THE FACTORY AND ADJUSTMENTS TO
41 Figure 10.2: Gas Valve Detail 11) Perform a combustion test. On horizontally vented units, the sample probe may be inserted into the terminal. If this is not possible, and if no sample tap is present in the vent system, remove the flue temperature sensor and insert the analyzer probe in the sensor...
Page 44 - tion section of this manual for information on how to do this.
42 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 from the heating thermostat and indirect wa- ter heater thermostat. Make sure that the appropriate circulators also start an...
Page 45 - XI Operation; ) The display panel has three primary modes of operation. These are:; Figure 11.1: Normal Display In Standby Mode
XI Operation 1) The BWC boiler uses a microprocessor based control, known as a “MCBA”, to manage all boiler functions including flame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the MCBA’s memory; one for space heating and one for domestic water prod...
Page 46 - FROM RESPONDING TO A CALL FOR HEAT. PUSHING AND HOLDING THE “-” WHILE IN
44 In standby mode, it is possible to view both the heating supply set point temperature and the “domestic hot water reference set point”. The “domestic hot water reference set point” plus 45°F equals the boiler supply set point when it is responding to a call from the indirect water zone. It is not...
Page 48 - First Digit
46 3) Two basic types of errors codes are shown on the display: • Soft Lockout Codes – When a soft lockout occurs, the boiler will shut down and the display will alter- nate between the number “9” and the letter “b” followed by a two digit service code. A list of these codes, and their meanings, is ...
Page 50 - XII. Service and Maintenance; Continuously
XII. Service and Maintenance 1) 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 ...
Page 52 - XIII. Troubleshooting; A. Troubleshooting problems where no error code is displayed:
50 XIII. Troubleshooting A. Troubleshooting problems where no error code is displayed: CONDITION POSSIBLE CAUSES Display Blank, Fan off, LWCO lights off • No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler Display Panel Blank, Fan running • Loose 120VAC connection w...
Page 53 - Table 13.3: Soft Lockout Codes Displayed
51 B. Trouble shooting problems where a soft lockout code is displayed. When a soft lockout occurs, the boiler will shut down and the display will alternate between the number “9” and the letter “b” followed by a two digit service code. The boiler will automatically restart once the condition that c...
Page 54 - Table 13.4: Hard Lockout Codes Displayed
52 C. Trouble shooting problems where a hard lockout code is displayed. When a hard lockout occurs, the boiler will shut down and the display will flash the letter “E” followed by a two digit service code. Once the condition that caused the lockout is corrected, the boiler will need to be manually re...
Page 55 - XIV Parts; area Crown representative or the factory at:
53 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 Service P.O. Box 14818 Philadelphia, PA 19134 www.crownboiler.com
Page 68 - IMPORTANT; installation of side-wall vented gas appliances as follows:
66 Appendix A: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: 1. For direct-vent appliances...
Page 70 - Manufacturer of Hydronic Heating Products
Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com D E S I G N E D T O L E A D PN: 980040 BWC - 08/05
