D E S I G N E D T L O E A D BSI Series Gas-Fired Natural Draft Steam Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models: • BSI069 • BSI103 • BSI138 • BSI172 • BSI207 • BSI241 • BSI276 • BSI310 • BSI345 • BSI379 WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life.
Table of Contents I. Product Description .................................................. 1 II. Specifications ............................................................. 2 III. Before Installing ......................................................... 3 IV. Locating the Boiler ...................................................... 3 V. Air for Combustion & Ventilation .............................. 4 VI. Venting ....................................................................... 8 VII.
II Specifications FIGURE 1: BSI BOILERS - GENERAL CONFIGURATION TABLE 1: BSI SPECIFICATIONS BASIC BOILER MODEL BSI069S BSI069E BSI103S BSI103E BSI138S BSI138E BSI172S BSI172E BSI207S BSI207E BSI241S BSI241E BSI276S BSI276E BSI310S BSI310E BSI345S BSI345E BSI379S BSI379E NUMBER OF SECTIONS INPUT (MBH) HEATING CAPACITY (MBH) 3 69 57 179 43 4 103 85 267 64 5 138 113 354 85 6 172 142 446 107 7 207 171 533 128 8 241 199 621 149 9 276 227 708 170 10 310 255 800 192 11
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 requirements of the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code, ANSI Z223.1-latest edition.
FIGURE 2: BSI BOILERS - CLEARANCES TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS, WALLS, AND DOORS. 4) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or used. Do not install 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 possible. 6) Do not install this boiler directly on a surface that may get wet.
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 determine whether the boiler room is a confined space: a. Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest 1000 BTU/hr.
FIGURE 3: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC 76
FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 87
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), vent connector and chimney.
14) Vent damper installation is mandatory on all sizes from the BSI069 to BSI276. The BSI310 through BSI379 may be ordered with 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 instructions thoroughly before proceeding. Verify that vent damper is same size as draft diverter outlet. See Figure 1. Unpack vent damper carefully. Do not force closed damper blade.
FIGURE 8: BSI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS RIGHT SIDE VIEW FIGURE 9: VENT DAMPER INSTALLATION DETAILS 11 10
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 Chapter 2 of the National Fuel Gas Code. Figure 10 shows typical gas piping connection to the BSI boiler. A sediment trap must be installed upstream of all gas controls.
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 IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. General Piping Notes Figure 11 shows recommended near boiler piping for most common types of gravity return steam systems.
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” NPT nipples and elbow supplied. 3) Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe.
BOILER MINIMUM PIPE DIA.
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 in the indirect water heater. This section describes boiler-side piping only. Refer to the indirect water heater instruction manual for domestic water piping.
X 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) 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.
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 VXT24 feeders on boilers equipped with #67 low water cutoffs. The following points apply to all feeder wiring to #67 low water cut-offs: • • Use a separate transformer to power the feeder. Do not use the transformer on the boiler. • Do NOT install a jumper between terminals 2 and 3 on the #67 low water cutoff.
CAUTION DO NOT INSTALL JUMPER BETWEEN 2 & 3 ON #67 L.W.C.O. 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.
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 vent damper. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will close.
“BURNER” “BURNER” V8295A (BSI310-379 ONLY) L N FIGURE 16: WIRING DIAGRAM, STANDING PILOT AND HYDROLEVEL CG-400A LOW WATER CUTOFF VENT DAMPER (NOTE 2) NOTE 3 LESS VENT DAMPER V8295A (BSI310-379 ONLY) L N 2. VENT DAMPER REQUIRED ON BSI069 - BSI276, OPTIONAL ON BSI310 - BSI379 3. ON BOILERS LESS VENT DAMPER, DAMPER HARNESS NOT USED.
Safety Control Operation - Standing Pilot and Intermittent Ignition Hydrolevel CG400A Low Water Cut-off - Interrupts burner operation if the water in the boiler drops below a safe level. As the water drops past the cut-off point, the amber lamp on the CG400 will glow. The CG400 will interrupt power to the burners 15 seconds after the water level drops past the cut-off point. This feature prevents short cycling of the burners due to a bouncing water line.
Blocked Vent (“Spill”) Switch - Automatically interrupts burner operation in the event that flue gas spills from the draft diverter opening. This switch is equipped with a reset button which must be pressed to restore normal burner operation. An open blocked vent switch is indicative of a problem with the vent system. If the blocked vent switch opens, the cause of the venting problem must be found and corrected by a qualified gas service technician before the blocked vent switch is reset.
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. 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 sections that are filled with air.
16) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER-FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD. 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.
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8200 AND VR8300 SERIES GAS VALVES (STANDING PILOT) FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. If you cannot reach your gas supplier, call the fire department. A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. C.
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000ERHC SERIES GAS VALVES (STANDING PILOT) FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. If you cannot reach your gas supplier, call the fire department. A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. C.
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8204 AND VR8304 SERIES GAS VALVES (INTERMITTENT PILOT) FOR YOUR SAFETY READ BEFORE LIGHTING 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 is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. If you cannot reach your gas supplier, call the fire department. C.
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000DERHC SERIES GAS VALVES (INTERMITTENT PILOT) FOR YOUR SAFETY READ BEFORE LIGHTING 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 is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. If you cannot reach your gas supplier, call the fire department. C.
FIGURE 22b: MAIN BURNER FLAME - 40mm (“HIGH ALTITUDE”) BURNERS FIGURE 22a: MAIN BURNER FLAME - 1” BURNERS 17) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. For standing pilot boiler models, pilot burner should remain lit but the main burners should stop firing. For intermittent ignition boiler models both pilot burner and main burners should stop firing. Raise the thermostat back to the highest setting.
FIGURE 23a: GAS VALVE DETAIL - HONEYWELL VR8200 OR VR8300 (STANDING PILOT) FIGURE 23b: GAS VALVE DETAIL - ROBERTSHAW 7000ERHC AND HONEYWELL V8295 (STANDING PILOT) FIGURE 24a: GAS VALVE DETAIL - HONEYWELL VR8204 AND VR8304 (INTERMITTENT IGNITION) FIGURE 24b: GAS VALVE DETAIL - ROBERTSHAW 7000DERHC (INTERMITTENT IGNITION) 31 30
e) Turn off gas supply to boiler per the appropriate Lighting and Operating instructions on pages 25 - 28. Drain hot water from boiler through boiler drain valve to a location where hot water can be safely discharged. Refill the boiler to normal water line level. If water in the gauge glass does not look clear, repeat above boil-out procedure again until water is clears. f) Reinstall safety valve and related piping. g) Conduct pH and Alkalinity test of water in the system.
replace cable. 8) Reinstall burners, being careful to put the pilot main burner in its original location. 9) Inspect all boiler wiring for loose connections or deterioration. 10) Inspect the vent system: • • • • Make sure that the vent system is free of obstructions. Make sure that all vent system supports are intact. Inspect joints for signs of condensate or flue gas leakage. Inspect venting components for corrosion or other deterioration. Replace any defective vent components.
disturbed during the inspection process for leaks. Heat Exchanger Cleaning Procedure 1) 2) 3) 4) 5) 6) 7) 8) 9) Turn off electrical power and gas supply to the boiler Disconnect the damper and vent connector from the boiler. Remove the upper front and top jacket panels. If possible, remove the rear and left side jacket panels Remove the burners. Remove the blocked vent (“spill”) switch Remove the ¼-20 nuts and washers holding the flue collector onto the heat exchanger.
XIII Troubleshooting The following 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 chart on page 35 or 37 and follow the appropriate path though the chart until a box with a list of possible causes is reached. If the problem is known to be within the ignition system, go directly to the appropriate troubleshooting guide for the boiler (standing pilot on page 39 or intermittent ignition on page 40).
Troubleshooting Chart for BSI Boilers Equipped with Hydrolevel CG400A Low Water Cut-offs and Vent Dampers Caution: Read page 34 before attempting to use this chart START Vent damper open? Is there an audible click as R8225 relay pulls in w hen the thermostat calls for heat? Thermostat calls for heat Y N Is yellow LED lit on LWCO? 24 volts across blue and yellow w ires inside junction box? N N Y N 24 volts betw een P2 and 2 on CG400 LWCO? N 120 volts across black and w hite transformer leads? Y
Main burners light? Do burners shut down when pressure exceeds limit setting? Y Do burners shut down when water level drops below cut-off point? Y Y END N N 24 volts across red damper lead and yellow transformer lead? N * Defective damper * Defective or loose damper harness * Obstruction in path of damper blade N * Defective pressure limit control * Blockage in siphon tube Y 24 volts across standing pilot gas valve terminals or terminals 5&6 on S8600 module? Y *Grounded probe or probe lead *
Troubleshooting Chart for BSI Boilers Equipped with McDonnell & Miller #67 Low Water Cut-offs and Vent Dampers Caution: Read page 34 before attempting to use this chart START Vent damper open? Is there an audible click as R8225 relay pulls in w hen the thermostat calls f or heat? Thermostat calls f or heat Y Y N 24 volts across blue and yellow w ires inside junction box? N N 24 volts betw een terminal # 1 on 67 LWCO and yellow tranf ormer connection? N 120 volts across black and w hite transf orm
Main burners light? Do burners shut down when pressure exceeds limit setting? Y Do burners shut down when water level drops below cut-off point? Y Y END N N 24 volts across red damper lead and yellow transformer lead? N * Defective damper * Defective or loose damper harness * Obstruction in path of damper blade N * Defective pressure limit control * Blockage in siphon tube Y 24 volts across standing pilot gas valve terminals or terminals 5&6 on S8600 module? Y *LWCO float bowl filled with mu
Standing Pilot Ignition System Troubleshooting Chart START (24 VOLTS PRESENT ACROSS TH AND TR ON GAS VALVE, BUT MAIN BURNERS DO NOT LIGHT) Y Pilot lit? Ensure knob on gas valve is set to ON Caution: Read page 34 before attempting to use this chart Main burners light? Y Does pilot stay lit? N N Turn control on gas valve to PILOT. Depress red button and light pilot. Hold button for at least one minute. Turn control on gas valve to ON.
Intermittent Ignition System Troubleshooting Chart START (24 volts is present across 5 and 6 on S8600 module, but main burners do not light) Spark across ignitor/sensor gap? Y Pilot lights? Does spark stop when pilot lights? Y N N Y N 24 volts across PV & MV/PV at gas valve? N Y *Defective S8600 module 24 volts between MV & MV/PV on gas valve? N N Y *Break in spark cable insulation END N *Defective S8600 module Y Y 24VAC across terminals 1&2 on S8600? N *Faulty S8600 module Main bur
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 For boilers installed at elevations above 2000 ft, consult the local Crown representative or the factory for the correct main burner orifice. KEY # DESCRIPTION 1 * * * * * 2 3 4 4 BSI HEAT EXCHANGER ASSY.
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KEY # 41 41 41 42 43 44 44 44 44 44 44 44 45 45 45 45 DESCRIPTION 1" BURNER WITH PILOT BRACKET (Q350 PILOT) 1" BURNER WITH PILOT BRACKET (Q327 NAT, Q348 PILOTS) 1" BURNER WITH PILOT BRACKET (Q327 LP PILOT) 1" BURNER LESS PILOT BRACKET MANIFOLD (1" BURNERS) NAT GAS ORIFICE (#42 DRILL SIZE) NAT GAS ORIFICE (#44 DRILL SIZE) NAT GAS ORIFICE (#47 DRILL SIZE) NAT GAS ORIFICE (#48 DRILL SIZE) LP GAS ORIFICE (#54 DRILL SIZE) LP GAS ORIFICE (#55 DRILL SIZE) LP GAS ORIFICE (#1.25mm DRILL SIZE) GAS VALVE (STND.
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KEY # DESCRIPTION 75 76 77 78 79 80 81 82 83 84 85 86 87 LEFT SIDE JACKET PANEL RIGHT SIDE JACKET PANEL REAR JACKET PANEL TOP JACKET PANEL LOWER FRONT PANEL UPPER FRONT PANEL DIVERTER PANEL VESTIBULE PANEL HORIZONTAL JACKET CLIP VERTICAL JACKET CLIP #10 X 1/2" SHEET METAL SCREW DOOR KNOB 8-32 X 1/4" H.W.H. SCREW IGNITION MODULE (E.I. BOILERS) (NATURAL GAS ONLY) IGNITION MODULE (E.I. BOILERS) (NATURAL OR LP GAS) MODULE BRACKET (E.I. BOILERS) VENT DAMPER GLASS SET FLOAT TYPE L.W.C.O.
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Appendix A: Knockdown Boiler Assembly Instructions A. Before Installing 1) 2) 3) 4) 5) Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs or punctures due to mishandling. Do not use the heat exchanger if there is any damage to it. Inspect the joints between the sections for openings. Reseal any openings with high temperature silicone sealant.. Keep the base in the shipping carton until it is time to perform the assembly.
FIGURE A1: BASE, HEAT EXCHANGER, FLUE COLLECTOR ASSEMBLY 49 48
5) 6) 7) Install the left side panel in the same manner as the right side. Attach the front corners of the diverter panel to the side jacket panels using #10 sheet metal screws. Install the horizontal (angle) jacket clips in the front edge of the side jacket panels. Slide this clip through the rectangular slot that is about halfway up the front edge of the side jacket panels and secure with the 8-32 self tapping screws provided.
FIGURE A2: JACKET INSTALLATION 51 50
F. Electrical Wiring Connections (Also refer to wiring diagrams in Part X of the installation manual) 1) 2) 3) A pre-wired junction box assembly specific to the control package ordered with the boiler has been provided by the factory. Orient the junction box so the black relay, which is mounted to the outside of the junction box, is facing down. Mount the junction box assembly to the right side jacket using the holes provided (See Figure 1 in the installation manual).
FIGURE A3: TAPPING LOCATIONS (SEE TEXT FOR TAPPING USES) 53 52
CROWN Boiler Co 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.