BWF Series Gas-Fired Fan Assisted Hot Water Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models: • BWF061 • BWF095 • BWF128 • BWF162 • BWF195 • BWF229 WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas supplier. This boiler requires a special venting system.
Table of Contents I Product Description………………………...2 II Specifications………………………………..2 III Before Installing……………………………..3 3 IV Locating the Boiler………………………….. V Air for Combustion and Ventilation………… 5 VI Venting……………………………………….9 Horizontal Vent System Design……….. 9 Vertical Vent System Design…………... 14 Vent System Assembly………………….18 VII Gas Piping………………………………… 25 VIII System Piping………………………………. 26 IX Wiring………………………………………..31 X Start-up and Checkout……………………… 36 XI Service and Maintenance…………………..
I Product Description The BWF series boiler is a cast iron gas fired boiler designed for use in forced hot water heating systems. The BWF is intended for installations where a usable chimney is not available. The BWF is normally vented using an approved vertical or horizontal AL29-4C stainless steel venting system, which is not included with the boiler. If a suitable chimney is available, the BWF series can be vented into it using an optional BWF Category I Vent Kit available from Crown.
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 this manual and the National Fuel Gas Code, ANSI Z223.1 In Canada, installation must be in accordance with CSA B149 (Installation Code for Gas Burning Appliances and Equipment).
3) Do not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop. Do not install in a location where sources of hydrocarbons will be stored or used. Some common sources of hydrocarbons include bleaches, fabric softeners, paints, cleaners, refrigerants, and cat boxes. Traces of these chemicals can be drawn into the boiler, causing severe corrosion damage to the boiler and/or objectionable odors.
V Air for Combustion and Ventilation Sufficient fresh air must be supplied for both combustion and ventilation. Provisions for combustion, ventilation, and dilution air for gas utilization equipment must be made in accordance with local building codes, or in the absence of such codes, in accordance with Sections 5.3.3 and 5.3.4 (“Air for Combustion and Ventilation”) of the National Fuel Gas Code, NFPA 54/ANSI Z223.1.
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 have a free area of 1 square inch per 1000 BTU/hr input of all gas burning appliances in the boiler room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per opening.
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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 Category I Vent Kit available from Crown.
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.
5) Minimum Vent Pipe Length: 2 ft + (1) 90 degree elbow + terminal 6) Permitted Terminals: • Choice of Tjernlund VH1 series terminal, a 90-degree elbow with rodent screen, or a termination tee with a rodent screen. The Tjurnlund VH1 terminals may not be used on BWF195s and BWF 229s when they are vented with 3” pipe.
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 the normal snow line. In no case should it be less than 12” above grade level (Fig 10). The bottom of the terminal must be at least 7 feet above a public walkway.
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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.
4) Maximum Vent Pipe Length: • • • • BWF061 to BWF162 – 39.5 ft + (2) 90 degree elbows + cap BWF195, BWF229 (using 4” vent pipe): 37 ft + (2) 90 degree elbows + cap BWF195, BWF229 (using 3” vent pipe): 24.5 ft + (2) 90 degree elbows + cap Reduce the above maximum straight pipe runs by the equivalent length from Table 4 for each additional elbow beyond the first two.
11) Piping supports – Vertical and horizontal sections of piping must be properly supported. See the “Vent System Assembly” section of this manual for more information. 12) Location of vent cap– The lowest discharge opening on the cap must be at least 2 feet above any object located within 10 feet (Fig.
TABLE 7: FIRESTOPS FOR VERTICAL VENT SYSTEMS VENT SYSTEM FLEX-L-INTL STAR-34 Z-FLEX SVE SERIES III (SUPPORT) Z-FLEX SVE SERIES III (SPACER) HEAT FAB SAF-T VENT PROTECH SYSTEMS FASNSEAL VENT MANUFACTURER'S PART # 3 INCH 4 INCH SRFS03 SRFS04 2SVSFSSF03 2SVSFSSF04 2SVSFSF03 2SVSFSF04 7373GC 7473GC FSFS3 FSFS4 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.
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 pipe sections. Heat Fab Saf-T Vent – GE RTV 106 ProTech Systems FasNSeal - Silicone not required for joints between pipe sections.
4) Assembly of Flex-L-Intl. Star-34 Vent System: a) Star-34 General Notes: • • • • Do not cut Star-34 vent components. Support horizontal piping sections at intervals of 48” or less. Vertical venting systems must be supported by at least one Star-34 Firestop. An additional vertical support is required after any offset. Orient Star-34 components so that the arrows on the piping labels are in the direction of flue gas flow. b) Start assembly of the vent system at the boiler.
5) Assembly of Z-Flex SVE Series III: a) SVE Series III General Notes: • Non-expanded ends of SVE Series II piping sections may be cut using aviation snips or a 24 thread per inch hacksaw. File or sand the cut end smooth before assembling. Expanded ends may be cut to adapt the SVE Series III to the vent collar or VH-1 terminal. See the instructions below. Support horizontal piping sections at intervals of 48” or less.
l) If a termination elbow or tee is used, a locking band or gear clamp must be used at either side of the wall penetration to prevent shifting of the vent system in and out of the wall. m) To join SVE Series III to the VH-1 terminal, cut off the female end of the pipe that is to be joined to the terminal. When making this cut, make sure that it will be possible to insert the cut end of the pipe at least one inch inside the terminal.
6) Assembly of Heat Fab Saf-T Vent: a) Saf-T Vent General Notes: • • • • In general, Saf-T Vent pipe sections may not be cut. Exceptions to this are the Saf-T vent slip connector and connections to the boiler vent collar and the VH-1 terminal. In these cases, use a sharp pair of aviation snips, an abrasive cut-off, or a plasma cutter. See the Saf-T Vent instructions for information on cutting the slip connector.
7) Assembly of Protech FasNSeal: a) FasNSeal General Notes: • • • • Do not cut 4” FasNSeal pipe. The male end of 3” FasNSeal may be cut. Cut must be square to ensure a proper seal. Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of flue gas flow. Support horizontal piping sections at intervals of 6 feet or less. Vertical venting systems must be supported by at least one FasNSeal support. An additional vertical support is required after any offset.
m) To join FasNSeal to a 4” VH-1 terminal slip the female end of the FasNSeal pipe over the terminal connection so there is an overlap of at least 1 ¾”. Tighten the hose clamp to mechanically lock the pipe onto the terminal. Apply and smooth silicone over the outside of the joint including the hose clamp in the FasNSeal pipe. n) Allow the silicone to cure for 24 hours before operating the boiler. 8) Condensate Traps: a) b) c) d) Trap should have the basic configuration shown in Figure 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 Fuel Gas Code. Figure 26 shows typical gas piping connections to the BWF 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 WITH CONTINUOUS RETURN TEMPERATURES BELOW 120F CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.
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, but not over 240F. Wire the control to break the 120 VAC electrical supply to the boiler.
2) Gravity and “Large Water Volume” Systems – The piping shown in Figure 29 will minimize the amount of time that the boiler operates with return temperatures below 120F on these systems. A bypass is installed as shown to divert some supply water directly into the return water. The bypass pipe should be the same size as the supply. The two throttling valves shown are adjusted so that the return temperature rises above 120F during the first few minutes of operation.
6) Air Handlers – Where the boiler is connected to air handlers through which refrigerated air passes, use flow control valves in the boiler piping or other automatic means to prevent gravity circulation during the cooling cycle.
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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 are located in the junction box under the R8285 fan center on the right side of the boiler.
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 place of the “5” and “6” terminals on a R845A.
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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 to the high limit. 2) Assuming that the high limit is made, current will flow through the normally closed contacts on the pressure switch to relay coil “2K” (the R8222 relay coil).
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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 boiler and system are filled with water. • • WARNING IF ANTIFREEZE IS USED IN THE SYSTEM, IT MUST BE A NONTOXIC TYPE SUCH AS PROPYLENE GLYCOL. NEVER ATTEMPT TO FILL A HOT EMPTY BOILER.
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. Use only your hand to push in or turn the gas control knob. Never use tools.
c) If the line pressure falls outside of these limits, find and correct the cause of the problem before proceeding further. d) Connect a manometer to the manifold pressure tap on the gas valve (Fig. 41a). e) Read the manifold pressure. It should be set at: Manifold Press. (inches w.c.) Natural Gas 3.5 LP Gas 10.0 f) If a manifold pressure adjustment is needed, make the adjustment by turning the regulator screw clockwise to raise the pressure and counter clockwise to reduce the pressure (Fig 39).
FIGURE 38: PILOT BURNER FLAME 39
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 proceeding further. See the cleaning procedure below. 3) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation.
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 rating around the perimeter of the heat exchanger. 14) Set the flue collector onto the block and press down so that the flue collector is set into the silicone applied in the previous step.
3) Vacuum Switch – This boiler is equipped with a vacuum switch that is designed to prevent burner operation if the combustion fan does not operate properly or there is a blockage in the vent system. This switch “makes” (permits burner operation) as the vacuum increases. Figure 40 shows the correct method of reading the switch vacuum. The vacuums in Table 9 are the minimums required for reliable operation. After the boiler fires, the vacuum will drop for several minutes before stabilizing.
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. If the problem is known to be within the ignition system, go directly to the Intermittent Ignition Troubleshooting guide on page 46.
BWF Troubleshooting Chart Caution: Read page 43 before attempting to use this chart START Induced draft fan start? Y Circulator start? Wait 30-50 seconds (prepurge) Y Continued on next page N N Unplug fan and check for 120 volts across black and white connections on female half of plug.
BWF Troubleshooting Chart (contd.) Caution: Read page 43 before attempting to use this chart.
Intermittent Ignition System Troubleshooting Chart START (24 volts is present across 5 and 6 on S8670, 30-50 second prepurge period has passed, but main burners do not light) Spark across ignitor/sensor gap? Y Pilot lights? N N Y Y N 24 volts across PV & MV/PV at gas valve? N N * Defective S8670 module 24 volts between MV & MV/PV on gas valve? N N Y * Break in spark cable insulation END Y * Defective S8670 module Y Y 24VAC across terminals 1&2 on S8670? N * Defective S8670 module Main
XI 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 (215)-535-8900 www.crownboiler.com Main burner orifice and vacuum switch part numbers shown are for sea level configured boilers.
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KEY # 41 42 43 44 44 44 44 44 44 44 45 45 45 45 46 46 47 48 49 50 51 51 QTY. OR QUANTITY PER BOILER OR CROWN P.N. CROWN P.N. 61 95 128 162 195 229 1" BURNER WITH PILOT BRACKET 150500 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1" BURNER LESS PILOT BRACKET 150501 2 ea. 4 ea. 6 ea. 8 ea. 11 ea. 13 ea. MANIFOLD (1" BURNERS) 1 ea. 650153 650154 650155 650156 650157 650158 NAT GAS ORIFICE (#44 DRILL SIZE) 950300 3 ea. NAT GAS ORIFICE (#45 DRILL SIZE) 950301 5 ea. NAT GAS ORIFICE (#46 DRILL SIZE) 950302 7 ea. 9 ea.
1” Burner Components 50mm Burner Components 50
CAUTION Vacuum switch part numbers shown below for use on boilers installed at altitudes below 2000 ft. DESCRIPTION KEY # 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 * * * * * * * LEFT SIDE JACKET PANEL RIGHT SIDE JACKET PANEL REAR JACKET PANEL TOP JACKET PANEL DOOR INNER PANEL FAN COVER PLATE JACKET BAR DOOR BRACKET 8-32 X 1/2" SCREW 8-32 NUT 4 X 4 JUNCTION BOX #10 X 1/2" SHEET METAL SCREW DOOR KNOB 8-32 X 1/4" H.W.H.
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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.