Crown-boiler 32 User Manual

1D E S I G N E D T O L E A DTel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.comManufa

10Table 2: Minimum Room Volumes Based On Sixteen Times Boiler Volume By Model Size8Boiler ModelOver All Length JacketOver All De pth JacketOve

116) The boiler should be located as close to the chimney as possible.7) Do not install this boiler directly on a surface that may get wet. Raise the

12V Knockdown Boiler Assembly Instructions10 A. Prior To Assembly1) Thoroughly inspect the cast iron heat exchanger sections for any shipping damage,

1311Figure 4: Multiple Base Assembly

1412C. Section Assembly1) Clean the boiler sections inside and out to remove dirt due to shipping and handling.2) Clean all nipples and nipple ports w

1513Figure 6: Assembly Of SectionsFigure 5: Use Of Nipple Gauge

161414) Install the tankless coil/s and/or cover plates using the gaskets and 3/8 x 7/8 bolts and washers provided (seeFigure 7).15) Test assembled bl

17156) Hang a rear tie rod channel bracket on the 4" stud installed in the left end section (Figure 12a).7) Facing the rear of the boiler, find t

1816Figure 12b: Rear Attachment Of Draft HoodFigure 11: Front Attachment Of Draft Hood Figure 12a: Mounting Rear Tie Rod ChannelBracket

1917NOTEBefore installing the jacket, make sure to plug any tappings which are not going to be used. Also make sure that notappings are plugged which

2

2018Figure 14: Exploded View Of Jacket Assembly

2119 VI Air For Combustion and VentilationSufficient fresh air must be supplied for combustion, ventilation and flue gas dilution. Provisions for c

2220• If providing openings into adjacent rooms is undesirable, combustion and ventilation air can be brought intothe boiler room from outdoors. See t

2321Figure 16: All Air From Outdoors, Ventilated Crawl Space & AtticFigure 17: All Air From Outdoors, Via Ventilated AtticFigure 18: All Air Fr

2422Figure 19: All Air From Outdoors, Using Horizontal Ducts Into The Boiler Room

2523VII VentingVent installation must be in accordance with local building codes, or the authority having jurisdiction, or theNational Fuel Gas Code,

266) Lateral venting should slope upwards towards the chimney not less than one inch in four feet. No portion of vent pipeshould run downward or have

2725Figure 21: Series 32 Venting (Each Module Individually Vented)Figure 20: Typical Series 32 Venting (Common Module Venting)

28Removing An Existing Boiler From A Common ChimneyIn some cases, when an existing boiler is removed from a common chimney, the common venting system

2927VIII Steam Boiler Piping & Trim Installation1) Figures 27 shows the recommended near boiler piping for most common types of gravity return st

3Table of ContentsI. Product Description 1II. Specifications 2III. Before Installing 7IV. Locating the Boiler 7V. Knockdown Boiler Assembly Instru

3028Hydrolevel CG450 – This is a probe type LWCO and is installed in tapping “G”. On the CSD-1 controlpackage, and other boilers with redundant low w

3129Table 5Figure 22: Steam Boiler Tapping LocationsTapping Uses Chart For Steam Boilers1 Component Description Tapping Tapping Stan

32f. Boiler Drain Valve - Install with a 3” x ¾” bushing into one of the two return tappings “B”. The drain valvemay also be installed in the return

33Figure 25: Common Near-Boiler Piping MistakesTable 6: Steam Boiler Riser & Header Pipe SizesSteam Steam Return Condensate

34Figure 26: Typical Near-Boiler Piping When Using A Boiler Feed Pump32

35Figure 27a: Recommended Steam Boiler Piping: 1 or 2 Supply Connections, Gravity Return33

36Figure 27b: Recommended Steam Boiler Piping: 3 Supply Connections, Gravity Return34

3735Figure 27c: Recommended Steam Boiler Piping: 4, 5 or 6 Supply Connections, Gravity Return

3836B. Indirect Water Heating Piping (Steam Boilers)The steam version of the Series 32 boiler is equipped with tappings to permit the connection of a

3937CAUTION• INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROMWATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERA

4Figure 1: Base Model - General Configuration2II Specifications

4038DANGER• CONFIRM RELIEF VALVE HAS THE CORRECT PRESSURE SETTING AND CAPACITY FOR THEBOILER.• PIPE THE PRESSURE RELIEF VALVE DISCHARGE TO A SAFE LOCA

4139Tapping Uses Chart For Water Boilers1 Component Description Tapping Tapping Standard CSD-1Location Size (in) Equipment PackageSupply Piping A 3 N

4240Figure 30: Typical Water Boiler System Piping

4341Table 8: Water Boiler Supply & Return Pipe SizesFigure 31: Recommended Boiler Piping For Combination Heating & Cooling SystemsSupply

4442B. TANKLESS HEATER PIPINGIf the Series 32 water boiler is installed with an optional tankless heater, pipe the heater as shown in Figure 32. Theco

45438) Multiple Tankless Heaters - If two tankless heaters are installed in the boiler, it is recommended that each heater beinstalled in parallel wit

4644X Gas Piping1) Gas piping to the boiler must be sized to deliver an adequate supply of gas for the boiler to fire at the nameplateinput with the i

4745XI Control System WiringWARNINGAll wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of s

48466) Once the ignition module detects the presence of a pilot flame, voltage is applied across the main valve, openingthe valve and establishing mai

4947Figure 35: Series 32 Standard Boiler Wiring

53Table 1A: Dimensional DataJacket Overall Length'A''B' Dia.'C' Dia.'D' Dia.'E' Dia.&ap

5048Figure 36: Series 32 - CSD-1 Boiler Wiring

51Safety Control OperationTemperature Limit Control (Water Boilers) – The temperature limit control interrupts burner operation when the supplywater t

5250XII Start-up and CheckoutUse the following procedure for initial start-up of the boiler:1) Make sure that the boiler is filled with water.2) Chec

5351WARNINGFAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULTIN OVER-FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD.13) Check the manif

545216) (Steam Boilers) - Verify low water cutoff operation while the boiler is running. Slowly open drain valve and drainboiler until the water level

55 Figure 40: Gas Valve Detail - Robertshaw 7000DERHC Figure 39: Gas Valve Detail - Honeywell VR8304 53Figure 41: CSD-1 Gas Train

56A. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.B. BEFOR

57A. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.B. BEFOR

58CAUTIONWATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPO-NENTS. REPAIR ANY LEAKS FOUND IMMEDIATELY56XIII Service an

5912) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any othergas piping disturbed during the

6Table 1B: Specifications4Water(MBH) (MBH) (Sq. ft) (MBH) (MBH) (Gal) (Gal)32-475W(S)N 6 475 380 1188 285 330 80-1/2 28.58 39.8011.432-570W(S)N 7 570

60XIV PARTS The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area Crownrepresentat

6159285 380 475 285 380 475 A B C D EPART # (STANDARD) 310000 310001 310002 310002 310003 311004 311005 311006 310404 310405 310406 311020 311021 311

6260285 380 475285 BASE ASSEMBLY (STD) 310114 1380 BASE ASSEMBLY (STD) 310115 1475 BASE ASSEMBLY (STD) 310116 1285 BASE ASSEMBLY (CSD-1) 3101145 1380

6361"A" "B" "C" "D" "E"7" PUSHNIPPLE 310005 5 6 7 8 93" PUSHNIPPLE 310006 5 6 7 8 95/8 X 9

64285 380 4751 BASE FRONT PANEL (285) 310604 11 BASE FRONT PANEL (380) 310605 11 BASE FRONT PANEL (475) 310606 12a BASE FRONT LEG (RH) 310110 1 1 12b

6563Figure 42: Exploded View - Base Parts

6664285 380 47520 MANIFOLD ASSY, COMPLETE (285) 310154 120 MANIFOLD ASSY, COMPLETE (380) 310155 120 MANIFOLD ASSY, COMPLETE (475) 310156 121 1/4-20 X

6765Figure 43: Exploded View - Gas Manifold / Burners / Pilot Assembly

6866L4006A2015 35-3510 1L4006E1109 MAN. RESET (CSD-1 ONLY) 35-3100 11/2 LONG WELL 35-1006 1HYDROLEVEL 550 LWCO (CSD-1 ONLY) 450550 11-1/2 X 1/2 BLK B

6967BOILER MODEL98-11198088898042598092090036595-04095-08195-13495050095-09695-02795-05795-10595018595011495019095011095-04795-03395-05895-031 32-475W

75Figure 2a: Series 32 Steam Boilers - Arrangement Of Steam Riser Connections, Draft Hoods And Base Assemblies

7068BOILER MODEL98-11198088898042598092090036595051095051595052095052595053095012495018095017595017095-09695018595-047 32-475S 111111 11 11 32-570S 11

71PN 980888 Rev.2 10/08Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.comManufacturer of Hydroni

86Figure 2b: Series 32 Water Boilers - Arrangement Of Water Supply Connections, Draft Hoods And Base Assemblies

9III Before Installing1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strictaccordance w