Crown-boiler MWC116ENL User Manual

Models:MWC116ENTMWC116ELTMWC116ENLMWC116ELL    

8Figure 5.1 Wall Mounting Hole Locations

9Figure 5.2 Boiler Mounting

10VI Air for VentilationWARNINGOutdoor combustion air must be piped to the air intake. Never pipe combustion air from areas containing contaminates su

11Figure 6.1: Boiler Installed In A Confi ned Space, Ventilation Air From InsideStep 2a (contd.)If the total volume of both the boiler room and the roo

12VII VentingWARNINGFailure to vent this boiler in accordance with these instructions could cause fl ue gas to enter the building resulting in severe p

132 (contd.)Example: A 60/100mm concentric vent system is planned for a horizontally vented MWC116 which has the following components: 60/100mm Elbow

14Table 7.1: Summary Of Horizontal Venting Options VENT OPTION # 1 2 3 4CLASSIFICATION USED IN THIS MANUALHORIZONTAL CONCENTRIC HORIZONTAL CONCENTRICH

15Table 7.3a: Crown Concentric 60/100 Vent Components (Vent Options 1,2)CROWN PN DESCRIPTION SIZEUSED ON VENT OPTION #COMMENTS340509 60/100mm ELBOW A

16Figure 7.4a: Location Of Vent Terminal Relative To Windows, Doors, GradeFigure 7.4b: Location Of Vent Terminal Relative To Meters And Forced Air Inl

17Permitted Terminals for Vertical Venting6) - Use Crown PN 230532 with the appropriate ashing (Table 7.3b) Vertical Vent Terminal Locations (Vent

18Figure 7.7: Vertical Concentric Vent System (Vent Option 5)

19B. 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

20C. Assembly of Crown 60/100mm Concentric Venting(IMPORTANT - Skip to Section D for 80/125mm Concentric Vent Assembly)WARNINGFailure to follow the in

21FIGURE 7.20: INSTALLATION OF 60/100 ADAPTORS ON BOILERFIGURE 7.21: DIMENSION “L”

22If additional pieces of pipe are used, install them starting at the boiler elbow. Support each section of straight pipe 4) at its female end. Use lo

23Figure 7.25: Attaching 60/100mm Terminal SectionFigure 7.24: Preparing 60/100mm Terminal Section For Installation In The Wall

24D. Assembly of Crown 80/125mm Concentric Venting(IMPORTANT - See Section C for 60/100mm Concentric Vent Assembly)WARNINGFailure to follow the instru

25Figure 7.31a: Cuttable Straight SectionFigure 7.31b: Non Cuttable Straight SectionInstallation of the MWC116 with 80/125mm venting requires the use

263) (contd.) To cut the straight sections listed above refer to Figure 7.32 and the following instructions:Determine the required length of the a) o

27Figure 7.33b: Joining Non-Cuttable PipeFigure 7.33a: Joining Cuttable Pipe

1Table of Contents I. Product Description 2 II. Specifi cations 4 III. Before Installing 5 IV. Locating The Boiler 5 V. Moun

28Figure 7.34a: Dimension “L”, 80/125mm Horizontal TerminalFigure 7.34b: Cutting Outer Pipe Of 80/125mm Horizontal Terminal80/125mm Horizontal Termina

29Figure 7.34c: Cutting Inner Pipe Of 80/125mm Horizontal TerminalFigure 7.34d: Completing 80/125mm Horizontal Terminal Installation

30 Vertical Terminal Installation6) - In addition to the vertical terminal, either a Flat Roof Flashing (PN 230533) or Sloped Roof Flashing (PN 2305

31Figure 7.35b: Cutting Vertical TerminalFigure 7.35c: Completing Vertical Terminal Installation

32Figure 7.36: Chimney Chase InstallationWARNINGDo not attempt to construct a vertical vent system inside a chimney that is used to vent a • fi replace

33E. Condensate Trap and Drain Line All condensate which forms in the boiler or vent system leaves the boiler through the condensate trap. This trap

34VIII Gas PipingGas 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 bet

35Figure 8.2: Gas Connection To Boiler

36IX System PipingCAUTIONInstall boiler so that the gas ignition system components are protected from water (dripping, • spraying, rain, etc) during a

37Expansion Tank (Included & Required)4) – This boiler is equipped with a built in expansion tank. This tank is suitable for use on systems havi

2I Product DescriptionThe MWC Series are gas fi red condensing boilers designed for use in forced hot water heating systems requiring supply water temp

38B. 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

39Figure 9.4: Supply And Return Tailpiece InstallationC. Piping for Special Situations Certain types of heating systems have additional requirements.

40Figure 9.6: Chiller PipingFigure 9.5: Primary-Secondary Piping

41Figure 9.7: MWC116E*T (Combi) Internal Boiler-Side Piping Schematic

42Figure 9.8: MWC116E*L (Heat-Only) Internal Piping Schematic

43WARNINGLike all domestic water heaters, the MWC is capable of generating water that is hot enough to cause injury or death due to scalding. To minim

44Figure 10.1: DHW PipingFigure 10.2: DHW Tailpiece Installation

45Figure 10.3: MWC116E*T (Combi) Internal DHW-Side Piping Schematic

46XI WiringWARNINGAll wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements,

47Figure 11.1: Accessing Electrical ConnectionsFigure 11.2: “Whip”Boiler EndField Supplied J-Box End

3Figure 1.1: MWC Boiler Principle Components

48Figure 11.3: Location of Terminal Blocks and 7/8 Hole for WhipFigure 11.4: Electrical Connections Inside Control Box.

49Figure 11.5: Field Wiring - 120VAC Thermostat Figure 11.6: Field Wiring - 24V Thermostat Using Installer-Supplied Fan Center

50ye bk wh gy bu rdbkgygygyMtCOMNOCOMNONCbkbubnrdgnyegywhburdbkbuwhgybugnyebk bkubeyngygbkbkbubububurdbkygygL Nrd bu bn gnye gnyegnye bubnburdgnyewhgy

51XII Start-up and CheckoutUse the following procedure for initial start-up of the boiler:If not already done, fl ush the system to remove sediment and

52Check 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

53 The burner may not light on the fi rst try. The most likely cause of this problem on a new installation • is a gas line that has not been completely

54WARNINGThe gas valve manifold pressures are factory set and should rarely need to be adjusted. Failure to adjust the gas valve in strict accordance

55 Manifold Pressure TapInlet Pressure TapModulation LeadsFigure 12.6: Gas Pressure Taps Low Fire Adjustment(Inner Hex Shaft)High Fire Adju

56MWC Series Lighting and Operating InstructionsWARNING: If you do not follow these instructions exactly, a fire or explosion may resultcausing proper

57Remove the monometer and make sure that the inlet and manifold pressure tap screws are closed9) Check the entire gas train for leaks. Fix any leaks

4Table 2.2: RatingsMODEL* APPLICATIONMAX.INPUT (BTU/hr)MINIMUM INPUT (BTU/hr)D.O.E. HEATING CAPY. (BTU/hr)IBR NET RATING (BTU/hr)AFUE (%)DHW Output (G

58XIII OperationLamp 2Lamp 1Lamp 3Heating System KnobDHW Thermostat (Combi Only)Flame Lockout LampFlame Reset ButtonFigure 13.1: Control Pan

59WARNINGThe domestic water thermostat on the Maui is not intended to serve as a scald protection device. Under certain conditions, it is possible for

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 t

61Lamp 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. Fr

62XIV. Service and MaintenanceIMPORTANTWarranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals

63WARNINGSoot deposits in the fl ue passages are a sign that the boiler may be operating at high carbon monoxide (CO) levels. After cleaning the boiler

64Figure 14.2: InducerNeg. Pressure Ta pVenturiWARNINGDo not leave the boiler in service with the Inner Cover removed.• Do not attempt to fi re this

65Figure 14.3: Condensate Trap Removal Condensate TrapSpring ClipFigure 14.4: Location of Pressure Switch Taps and Limit Reset Buttons

66XV. TroubleshootingWARNINGTurn off power to boiler before replacing fuses or working on wiring.Figure 15.2: Fuse LocationLine Voltage ConnectionsF

67Table 15.3: Error CodesLamp Number 1 2 3 Flame L.O. Lamp Meaning Corrective Action Differential Water Pressure Switch Failed to Close Afte

5III Before InstallingSafe, reliable operation of this boiler depends upon installation by a professional heating contractor in 1)strict accordance wi

68Push reset button on Flue Temp Limit (Fig 14.4)Reset Boiler Does Boiler Start?Reset Boiler Push reset button on Supply Temp Limit (Fig 14.4)Does Boi

69XVI PartsThe following parts may be obtained from any Crown distributor. To fi nd the closest Crown distributor, consult the area Crown representativ

70C.h. flow group and three way diverter valve (Model combi)212223 (upper part)2025*28 29 30 31 323334242420107726272036181789423 (lower part)35* Incl

71C.h. flow and return groups (Model c.h. only)2145789203633343528 29 30 31 328910147*7146617* Includes items 20, 28, 29, 30, 31, 32, 3626273

72Pump and main circuit assembly (Model combi)454741574853 5255545062637615856494141603739394042404344594638338445158765764

73Pump and main circuit assembly (Model c.h. only)4547411494853 52555450626376158564941416037393940424043445946383384451587764148

74Gas assembly6768697071727376777866417775747

75Connection pipes79710*80*817710*7980** Not for model c.h. only

76Control panel and ignition device (Model combi)8553848687899091929394958396977272727272778882

77Control panel and ignition device (Model c.h. only)85538486878915091929394958396977272727272778882

6Figure 4.1: Clearances To Combustible Or Non-combustible MaterialClearance From Hot Water Pipes ToCombustibles = 1”

781009910010510610599104981131131137110710710110210310811210877101102103108 901011111109Wiring (Model combi)

791009910010510610599104981131131137115210110210315111215177101102103151 901011111109Wiring (Model c.h. only)

80Fan, combustion chamber and case panels1291211241251261281211221371231381431141191361351321341221277777777277116771181301441201311391401171421411407

81Key no. Description Spare part code1 O-ring gasket 1,78x15,6 BI1001 1312 Drainage valve BI1011 1043 O-ring gasket 17,04x4,00 mm BI1212 1124 Screw M5

82Key no. Description Spare part code47 Main exchanger connection clip BI1182 10648 Condensing heat exchanger inlet pipe BI1262 13649 Automatic air pu

83Key no. Description Spare part code93 Screw 3,5x16 mm self tap RPH BI1165 10194 Electronic control - ignition p.c.b. BI1555 10795 Fuse 2AF BI1165 11

84Key no. Description Spare part code141 Flue thermostat BI1262 104142 Twin fl ue cover plate BI1366 114143 Gasket - Air intake twin kit BI1016 101144

852. APPROVED CARBON MONOXIDE DETECTORS.Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 a

Manufacturer of Hydronic Heating ProductsP.O. Box 14818 3633 I. StreetPhiladelphia, PA 19134Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.cro

7V Mounting The BoilerCAUTIONThis boiler weighs approximately 110 pounds:Two people are required to safely lift this boiler onto the wall mounting hoo