Crown BWF162 - Manual

6 If the boiler is in a confined space – Provide two openings into the boiler room, one near the floor and one near the ceiling. The top edge of the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the floor (Fig 3). • Each opening must h...

9 VI Venting There are three basic ways to vent the BWF boiler: • Horizontal (“side wall”) venting using an approved AL29-4C stainless steel vent system. • Vertical venting using an approved AL29-4C stainless steel vent system. • Chimney venting using a masonry or “B” vent chimney and a special Cate...

10 Horizontal Vent System Design 1) See Figure 8 for the general horizontal exhaust configuration. For the purposes of this manual, a “horizontal exhaust system” is one that exits the structure through a wall. 2) Approved Systems – Use one of these four approved vent systems: • Flex-L-International ...

12 12) Location of Horizontal Vent Terminal – Observe the following limitations on the terminal location: • Terminal must be at least 4 feet below or 4 feet horizontally from any window, door, or gravity air inlet into the building (Fig. 10). • The bottom of the terminal must be at least 12” above t...

14 Vertical Vent System Design 1) See Figure 13 for the general vertical stainless steel venting configuration. For the purposes of this manual, a “vertical exhaust system” is a Category III vent system that exits the structure through a roof. 2) Approved Systems – Use one of these four approved ven...

17 Removing an Existing Boiler From a Common Chimney In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large for the remaining appliances. At the time of removal of an existing boiler, the following steps shall be followed with each applian...

18 Vent System Assembly 1) General Assembly Notes: a) Where the use of “silicone” is called for in the following instructions, use only the following sealants: • Flex-L-International Star-34 – GE RTV106 or GE IS806 • Z-FLEX SVE Series III (“Z-Vent III”) – Silicone not required for joints between pip...

25 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 values shown on the rating plate. For more information on gas line sizing, consult the utility or Part 2 of the National F...

26 VIII System Piping CAUTION • INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM WATER (DRIPPING, SPRAYING, RAIN, ETC) DURING APPLIANCE OPERATION AND SERVICE (CIRCULATOR REPLACEMENT, ETC). • OPERATION OF THIS BOILER WITH CONTINUOUS RETURN TEMPERATURES BELOW 120F CAN CAUSE...

27 7) Manual Reset High Limit (Required by some codes) – This control is required by ASME CSD-1 and some other codes. Install the high limit in the boiler supply piping just beyond the boiler with no intervening valves. Set manual reset high limit as far above the operating limit setting as possible...

31 IX Wiring WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70). Single Zone Wiring 1) Line Voltage (120 VAC) Connections (Fig 32) – The line voltage connections ...

32 Wiring Variations 1) Multiple Circulator Zones – Figure 33 shows wiring for two or more circulator zones using Honeywell R845As. One fewer R845A is used than the total number of circulator zones. A DPST Honeywell RA832A may be substituted in place of the R845A using the “X” and “X” terminals in p...

34 BWF Control System – Sequence of Operation (Refer to Figures 35 and 36 for BWF ladder and connection diagrams) 1) A call for heat from the thermostat energizes relay coil 1K (the relay on the R8285), causing contacts 1K1 and 1K2 to make. Contact 1K1 starts the circulator. Contact 1K2 sends power ...

36 IX Start-up and Checkout NOTE SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS MANIFOLD AND CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS SPECIFIED IN Z21.13 Use the following procedure for initial start-up of the boiler: 1) Make sure that the boile...

40 X Service and Maintenance The following routine maintenance should be performed on an annual basis: 1) Turn off power to the boiler. 2) Inspect the flue passages for signs of blockage. If there is any carbon in the combustion chamber or the flue passages, clean the heat exchanger before proceedin...

41 11) Clean the bottom surfaces of the heat exchanger. 12) Put a light in the combustion chamber and look through the flue passages from the top to verify that they have been thoroughly cleaned. 13) Apply a heavy (1/4”) bead of RTV-732 silicone sealant with a 500F intermittent duty temperature rati...

43 XII Troubleshooting The following three pages contain troubleshooting charts for use in diagnosing control problems. To use these charts, go to the box marked “Start” at the top of the next page and follow the appropriate path though the chart until a box with a list of possible causes is reached...

44 120 volts across black and white transformer primary leads on back of R8285 ? Thermostat calls for heat Circulator start? * Power off * Blown fuse or tripped breaker * Miswired or loose electricalconnection in120 volt line 120 volts across circulator connections? * Loose connection in t'stat or z...

46 Does spark stop when pilot lights? 24 volts across terminals 2 & 3 at S8670? Spark across ignitor/sensor gap? Y Can you hear sparking? * Defective S8670 module * Break in spark cable insulation * Break in pilot porcelain * Incorrect pilot spark gap * Loose connection in spark cable * Loose gr...

47 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 (215)-535-8900 www.crownboiler.com Main burner orifice and vacuum...

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