Page 3 - Table of Contents; and
1 Table of Contents I. Product Description 2 II. Specifi cations 4 III. Before Installing 5 IV. Locating The Boiler 5 V. Mounting The Boiler 7 VI. Air For Ventilation 10 VII. Venting 12 A. Vent System Design 12 B. Removing An Existing Boiler From Common Chimney 19 C. Assembly of Crown 60/100 Concent...
Page 4 - I Product Description; Key
2 I Product Description The MWC Series are gas fi red condensing boilers designed for use in forced hot water heating systems requiring supply water temperatures of 176F or less and return water temperatures greater than 86F. The primary heat exchanger is a copper water tube design. Additional heat ...
Page 5 - Figure 1.1: MWC Boiler Principle Components
Page 6 - II Specifi cations
4 Table 2.2: Ratings MODEL* APPLICATION MAX. INPUT (BTU/hr) MINIMUM INPUT (BTU/ hr) D.O.E. HEATING CAPY. (BTU/hr) IBR NET RATING (BTU/hr) AFUE (%) DHW Output (GPM) HEATING DHW 77F Rise 90F Rise MWC116E*T Combi 116,000 75,000 49,500 102,000 89,000 85.0 2.67 2.25 MWC116E*L Heat Only 116,000 75,000 N/A...
Page 7 - III Before Installing; Standard for; IV Locating the Boiler; NOTICE
5 III Before Installing Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in 1) 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 8 - Figure 4.1: Clearances To Combustible Or Non-combustible Material
6 Figure 4.1: Clearances To Combustible Or Non-combustible Material Clearance From Hot Water Pipes ToCombustibles = 1”
Page 9 - V Mounting The Boiler; CAUTION; This boiler weighs approximately 110 pounds:
7 V Mounting The Boiler CAUTION This boiler weighs approximately 110 pounds: Two people are required to safely lift this boiler onto the wall mounting hook. • Make sure that wall mounting hook is anchored to a structure capable of supporting the • weight of the boiler and attached piping when fi lled...
Page 10 - Figure 5.1 Wall Mounting Hole Locations
Page 11 - Figure 5.2 Boiler Mounting
Page 12 - VI Air for Ventilation; WARNING
10 VI Air for Ventilation WARNING Outdoor combustion air must be piped to the air intake. Never pipe combustion air from areas containing contaminates such as areas where swimming pool chemicals are stored. Contaminated combustion air will damage the boiler and may cause property damage, personal in...
Page 14 - VII Venting; Do not install a barometric damper or drafthood on this boiler.; A. Vent System Design; Horizontal (“Side Wall”) Concentric Venting
12 VII Venting WARNING Failure to vent this boiler in accordance with these instructions could cause fl ue gas to enter the building resulting in severe property damage, personal injury, or death: Do not attempt to vent this boiler with galvanized, PVC, or any other vent components not • listed in T...
Page 15 - Vent Option 3
13 2 (contd.) Example: A 60/100mm concentric vent system is planned for a horizontally vented MWC116 which has the following components: 60/100mm Elbow Adaptor (supplied with the boiler) • 1 ft Straight Pipe • 90 elbow • Uncut Terminal Section (supplied with the boiler) • The Vent Option #2 column i...
Page 16 - Table 7.1: Summary Of Horizontal Venting Options
14 Table 7.1: Summary Of Horizontal Venting Options VENT OPTION # 1 2 3 4 CLASSIFICATION USED IN THIS MANUAL HORIZONTAL CONCENTRIC HORIZONTAL CONCENTRIC HORIZONTAL CONCENTRIC RESERVED FOR FUTURE USE ILLUSTRATED IN FIGURE 7.2 7.2 7.2 VENT PIPE PENETRATION THROUGH STRUCTURE WALL WALL WALL VENT PIPE SI...
Page 18 - Figure 7.4c: Positioning Vent Terminal Under Overhangs
16 Figure 7.4a: Location Of Vent Terminal Relative To Windows, Doors, Grade Figure 7.4b: Location Of Vent Terminal Relative To Meters And Forced Air Inlets Figure 7.4c: Positioning Vent Terminal Under Overhangs
Page 19 - table 7.6: Summary of Vertical Venting options
17 Permitted Terminals for Vertical Venting 6) - Use Crown PN 230532 with the appropriate flashing (Table 7.3b) Vertical Vent Terminal Locations (Vent Option 5) 7) - Observe the following limitations on the location of all vertical vent terminals (see Figure 7.7): The top of the vent pipe must be at...
Page 21 - Never common vent a MWC boiler with other appliances.
19 B. Removing an Existing Boiler From a Common Chimney Read this only if the MWC boiler is replacing an existing boiler that is being removed from a common chimney. This section does not apply to the installation of a MWC boiler. In some cases, when an existing boiler is removed from a common chimn...
Page 22 - all cuts are square and allow for proper insertion.; Vent gasket and screws for attachment of vent system to boiler.; outer pipe only
20 C. Assembly of Crown 60/100mm Concentric Venting (IMPORTANT - Skip to Section D for 80/125mm Concentric Vent Assembly) WARNING Failure to follow the instructions could result in fl ue gas leakage into the combustion air or indoor air, resulting in unsafe or unreliable operation. • Do not lubricat...
Page 27 - Figure 7.31b: Non Cuttable Straight Section; Cutting Straight Pipe
25 Figure 7.31a: Cuttable Straight Section Figure 7.31b: Non Cuttable Straight Section Installation of the MWC116 with 80/125mm venting requires the use of the 80/125mm appliance adaptor 2) (Crown PN 340523). This adaptor is installed on top of the boiler as shown in Figure 7.30. For vent options 3 ...
Page 28 - OUTER PIPE ONLY; Joining Pipe; Use a drill stop or other means to ensure that
26 3) (contd.) To cut the straight sections listed above refer to Figure 7.32 and the following instructions: Determine the required length of the a) outer pipe. When doing this allow an additional 1” of length for insertion into the female end of the adjoining pipe. Mark the cut line on the outer p...
Page 30 - Figure 7.34b: Cutting Outer Pipe Of 80/125mm Horizontal Terminal; 0/125mm Horizontal Terminal Installation
28 Figure 7.34a: Dimension “L”, 80/125mm Horizontal Terminal Figure 7.34b: Cutting Outer Pipe Of 80/125mm Horizontal Terminal 80/125mm Horizontal Terminal Installation 5) - Cut a 5-1/2” diameter hole through the exterior wall at the planned location of the horizontal terminal. a) Measure distance “L...
Page 31 - Figure 7.34c: Cutting Inner Pipe Of 80/125mm Horizontal Terminal
29 Figure 7.34c: Cutting Inner Pipe Of 80/125mm Horizontal Terminal Figure 7.34d: Completing 80/125mm Horizontal Terminal Installation
Page 32 - roof using the fl at roof fl ashing.
30 Vertical Terminal Installation 6) - In addition to the vertical terminal, either a Flat Roof Flashing (PN 230533) or Sloped Roof Flashing (PN 230535) is required for this installation. Determine the center line of the terminal location on the roof. If the roof is fl at, cut a 5-1/2” diameter hole...
Page 33 - Figure 7.35c: Completing Vertical Terminal Installation
31 Figure 7.35b: Cutting Vertical Terminal Figure 7.35c: Completing Vertical Terminal Installation
Page 34 - fl ue used by a fi replace or other appliances.
32 Figure 7.36: Chimney Chase Installation WARNING Do not attempt to construct a vertical vent system inside a chimney that is used to vent a • fi replace or other appliances. Do not attempt to construct a vertical vent system inside a chimney fl ue adjacent to another • fl ue used by a fi replace o...
Page 35 - E. Condensate Trap and Drain Line; another trap for the one provided with the boiler.
33 E. Condensate Trap and Drain Line All condensate which forms in the boiler or vent system leaves the boiler through the condensate trap. This trap allows condensate to drain while retaining fl ue gases in the boiler. This boiler is supplied with a length of drain hose already attached. Route this...
Page 36 - VIII Gas Piping; National Fuel Gas Code
34 VIII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fi re 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...
Page 38 - IX System Piping; Installation of Residential Hydronic Systems; DANGER; Pipe relief valve discharge to a safe location.; Throttling Valve or Flow Restrictor
36 IX 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 86F can cause sever...
Page 40 - B. Boiler Connections
38 B. Boiler Connections Boiler supply and return connections are located on the bottom of the boiler as shown in Figure 9.4. Copper 3/4” tail pieces are provided in the fi tting bag along with gaskets. Sweat the fi rst copper fi ttings to these tail pieces and then connect the tail pieces to the bo...
Page 41 - Primary-Secondary Piping; D. Internal Boiler Piping
39 Figure 9.4: Supply And Return Tailpiece Installation C. Piping for Special Situations Certain types of heating systems have additional requirements. Some examples follow: Primary-Secondary Piping 1) – Primary-secondary piping is required when circulator zoning is used or when the system fl ow rat...
Page 45 - X. Domestic Water Piping; Uniform Plumbing Code; - If domestic hot water is drawn from the MWC at a rate in excess of
43 WARNING Like all domestic water heaters, the MWC is capable of generating water that is hot enough to cause injury or death due to scalding. To minimize the risk of scalding: Set domestic hot water (DHW) thermostat as low as possible (see the Start-up Section of this • manual for the location of ...
Page 48 - XI Wiring; re or electricutuion.
46 XI 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), WARNING Attempting to directly connect a low voltage thermostat and/or low voltage wiring to the ...
Page 49 - Figure 11.1: Accessing Electrical Connections; Boiler End
47 Figure 11.1: Accessing Electrical Connections Figure 11.2: “Whip” Boiler End Field Supplied J-Box End
Page 50 - Figure 11.3: Location of Terminal Blocks and 7/8 Hole for Whip
48 Figure 11.3: Location of Terminal Blocks and 7/8 Hole for Whip Figure 11.4: Electrical Connections Inside Control Box.
Page 53 - XII Start-up and Checkout; Use the following procedure for initial start-up of the boiler:; Figure 12.1: Location of Automatic Air Vent Cap; Never attempt to fi ll a hot empty boiler; NOTE
51 XII Start-up and Checkout Use the following procedure for initial start-up of the boiler: If not already done, fl ush the system to remove sediment and debris. 1) This should be done with the boiler isolated from the system. Fill the boiler and hydronic system with water and purge the system of a...
Page 54 - Never use a; Shaft Screw Cover; calcium deposits. Repair any leaks in the system immediately.
52 Check all new water and gas piping for leaks and purge piping sections that are fi lled with air. Fix any 3) leaks found immediately. See the National Fuel Gas Code for additional information on testing and purging gas lines. Vent system must be complete and free of obstructions before attempting ...
Page 58 - MWC Series Lighting and Operating Instructions; FOR YOUR SAFETY READ BEFORE OPERATING
56 MWC Series Lighting and Operating Instructions WARNING : If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A This appliance does not have a pilot. It is equipped with an ignition device whichautomatically ligh...
Page 59 - Table 12.8: High Fire Combustion Readings
57 Remove the monometer and make sure that the inlet and manifold pressure tap screws are closed 9) Check the entire gas train for leaks. Fix any leaks found immediately. 10) Run the gas valve safety shut-down test. With the boiler fi ring, close the gas cock upstream of the boiler. 11) The gas valv...
Page 60 - XIII Operation; Heating System Knob; Off; will respond to a call for DHW.; Target Supply Temperature Setting; - When the Heating System Knob is rotated clockwise to any position
58 XIII Operation Lamp 2 Lamp 1 Lamp 3 Heating System Knob DHW Thermostat (Combi Only) Flame Lockout Lamp Flame Reset Button Figure 13.1: Control Panel Figure 13.1 shows the control panel for the MWC boiler. The purpose of the adjustments and lamps on this panel are as follows: Lamps 1, 2, 3 - These...
Page 62 - Sequence of Operation; If the fl ue temperature exceeds 248F,
60 Sequence of Operation (Also Refer to Figures 9.7, 9.8, 10.3, 11.7) Upon a call for heat from the room thermostat, the circulator is started. 1) If the differential pressure switch connected between the supply and return sees a pressure in excess of 5.1 ft 2) w.c., it closes, allowing the start se...
Page 63 - Table 13.4: Flash Codes During Normal Operation
61 Lamp Number 1 2 3 Meaning (Short pulse every 4 seconds): Heating System Knob in “Off” position. Boiler will not respond to call for heat or DHW. Frost protection and pump/valve exercise function still active (1 second pulse every 2 seconds): Heating System Knob set to target supply temperature. B...
Page 64 - XIV. Service and Maintenance; IMPORTANT; Keep the boiler room ventilation openings open and unobstructed.
62 XIV. Service and Maintenance IMPORTANT Warranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals specifi ed. Continuously: 1) Keep the area around the boiler free from combustible materials, gasoline and other fl ammable vapors a) and liquids.K...
Page 66 - Do not leave the boiler in service with the Inner Cover removed.; Service Notes
64 Figure 14.2: Inducer Neg. Pressure Tap Venturi WARNING Do not leave the boiler in service with the Inner Cover removed. • Do not attempt to fi re this boiler with the Combustion Chamber Cover (Fig. 14.1) removed • Service Notes Orifi ce Size 1) – Sea level orifi ce sizes are: Natural Gas – 1.30 m...
Page 68 - Line Voltage Connections; CONDITION
66 XV. Troubleshooting WARNING Turn off power to boiler before replacing fuses or working on wiring. Figure 15.2: Fuse Location Line Voltage Connections Fuse Table 15.1: No Error Code Displayed CONDITION POSSIBLE CAUSES Boiler does not run, no lights are on or fl ashing • No 120VAC Power at boiler. ...
Page 71 - XVI Parts
69 XVI Parts The following parts may be obtained from any Crown distributor. To fi nd 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 C.h. return group and d.h.w. heat ...
Page 74 - Pump and main circuit assembly (Model combi)
72 Pump and main circuit assembly (Model combi) 45 47 41 57 48 53 52 55 54 50 62 63 7 61 58 56 49 41 41 60 37 39 39 40 42 40 43 44 59 46 38 3 38 44 51 58 7 65 7 64
Page 76 - Gas assembly
74 Gas assembly 67 68 69 70 71 72 73 76 77 78 66 41 7 7 75 74 7
Page 77 - Connection pipes
75 Connection pipes 79 7 10* 80* 81 7 7 10* 79 80* * Not for model c.h. only
Page 78 - Control panel and ignition device (Model combi)
76 Control panel and ignition device (Model combi) 85 53 84 86 87 89 90 91 92 93 94 95 83 96 97 72 72 72 72 72 77 88 82
Page 82 - Fan, combustion chamber and case panels
80 Fan, combustion chamber and case panels 129 121 124 125 126 128 121 122 137 123 138 143 114 119 136 135 132 134 122 127 77 77 77 72 77 116 77 118 130 144 120 131 139 140 117 142 141 140 77 133 115 77
Page 86 - Appendix A: Special Requirements For Side-Wall Vented Appliances
84 Key no. Description Spare part code 141 Flue thermostat BI1262 104 142 Twin fl ue cover plate BI1366 114 143 Gasket - Air intake twin kit BI1016 101 144 Air restrictor d. 45 mm BI1406 129 145 Return group (Model c.h. only) BI1171 107 146 By-pass pipe (Model c.h. only) BI1171 106 147 Flow group ki...
Page 88 - 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 11/07 2008
