Crown Boiler BSI241 Specifications

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

10914) Vent damper installation is mandatory on all sizes from the BSI069 to BSI276. The BSI310 through BSI379 may be orderedwith or without vent damp

1110 FIGURE 8: BSI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS FIGURE 9: VENT DAMPER INSTALLATION DETAILSRIG

1211 FIGURE 10: GAS CONNECTION TO BOILER* State of Massachusetts Requires ManualShut-off Valve to be “T” Handle Type*VII Gas PipingGas piping to th

1312CAUTION• INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTEDFROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING

14Piping Installation1) Remove parts bag from boiler crate.2) Install safety valve (spindle must be in vertical position) into tapping on boiler left

1514WRONG - HEADERBULLHEADEDINTO TAKE-OFFAND EQUALIZERWRONG - TAKE-OFFBULLHEADED INTOTWO MAINSWRONG - TAKE-OFFBETWEEN RISERSFIGURE 12: COMMON NEAR-BOI

16IX Indirect Water Heater Piping All BSI series boilers are equipped with tappings to permit the connection of a Crown Mega-Stor, or other indirec

17X Wiring1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 voltconnections are ma

18Feeder Wiring for Boilers Equipped with McDonnell & Miller #67 Low Water Cut-offsFigures 14a and 14b show feeder wiring for McDonnell & Mill

1918FIGURE 14b: WIRING MCDONNELL & MILLER WF2-U-24 FEEDER OR THREE-WIRE HYDROLEVEL VXT-24 FEEDER TO BOILER EQUIPPED WITH #67 L.W.C.O.

2Table of ContentsI. Product Description ... 1II. Specifications ...

20BSI Control System – Sequence of Operation(Refer to Figures 16 through 19 for ladder and connection diagrams)Sequence of Operation, Standing Pilot1)

2120 FIGURE 16: WIRING DIAGRAM, STANDING PILOT AND HYDROLEVEL CG-400A LOW WATER CUTOFF“BURNER”“BURNER”LNV8295A(BSI310-379 ONLY) FIGURE 17: WIRING

22Safety Control Operation - Standing Pilot and Intermittent IgnitionHydrolevel CG400A Low Water Cut-off - Interrupts burner operation if the water in

23 FIGURE 19: WIRING DIAGRAM, INTERMITTENT IGNITION AND McDONNELL & MILLER MODEL #67 LOW WATER CUTOFFBlocked Vent (“Spill”) Switch - A

24XI Start-up and CheckoutUse the following procedure for initial start-up of the boiler:1) Make sure that the boiler is filled with water to the nor

252416) Check the manifold pressure and adjust if necessary. To do this, use the following procedure:a) Connect a manometer to the inlet pressure tap

2625A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly.B. BEFORE LIG

2726A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly.B. BEFORE LIG

2827A. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.B. BEF

2928A. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.B. BEF

32TABLE 1: BSI SPECIFICATIONSII SpecificationsFIGURE 1: BSI BOILERS - GENERAL CONFIGURATION*Combustion efficiency** Volume to normal water lineNOTE:

3029 FIGURE 22a: MAIN BURNER FLAME - 1” BURNERSFIGURE 22b: MAIN BURNER FLAME - 40mm (“HIGH ALTITUDE”) BURNERS17) Test thermostat operation whi

3130 FIGURE 24a: GAS VALVE DETAIL - HONEYWELL VR8204 AND VR8304 (INTERMITTENT IGNITION) FIGURE 23a: GAS VALVE DETAIL - HONEYWELL VR8200 OR VR8

32XII Service and MaintenanceOn a continuous basis:1) Keep the area around the boiler free and clear from combustible materials, gasoline, and other f

33replace cable.8) Reinstall burners, being careful to put the pilot main burner in its original location.9) Inspect all boiler wiring for loose conne

3414) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas pipingdisturbed during the

35XIII Troubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems. To use these charts, go to thebox

36Troubleshooting Chart for BSI Boilers Equipped withHydrolevel CG400A Low Water Cut-offs and Vent DampersCaution: Read page 34 before attempting to u

373624 volts across 1&4 (blue&yellow) and 2&4 (orange&yellow ) on damper end of harness?NYMain burners light?24 volts across red damp

3837Troubleshooting Chart for BSI Boilers Equipped withMcDonnell & Miller #67 Low Water Cut-offs and Vent DampersCaution: Read page 34 before atte

3924 volts across 1&4 (blue&yellow) and 2&4 (orange&yellow ) on damper end of harness?NYMain burners light?24 volts across red dampe

43III Before Installing1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance

40Standing Pilot Ignition System Troubleshooting ChartPilot lit?Main burners light?YTurn control on gas valve to PILOT. Depress red button and light

4140Does spark stop when pilot lights?24 volts across terminals 2&3 at S8600?Spark across ignitor/sensor gap?YCan you hear sparking?*Faulty S8600

4241XIV PARTS The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area Crownrepresent

4342

4443** These Valves Piped in Series to Provide Redundant Shut-off***1/4 Pilot Tubing Used with Robertshaw Valves69 103 138 172 207 241 276310 345 3794

4544

464569 103 138 172 207 241 276310 345 37975 LEFT SIDE JACKET PANEL 1 ea. 850301 850301 850301 850301 8503012 8503012 8503012 8503015 8503015 850301576

4746

48A. Before Installing1) Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs orpunctures

4948FIGURE A1: BASE, HEAT EXCHANGER, FLUE COLLECTOR ASSEMBLY

544) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or used. Do notinstall this boiler i

505) Install the left side panel in the same manner as the right side.6) Attach the front corners of the diverter panel to the side jacket panels usin

5150FIGURE A2: JACKET INSTALLATION

52F. Electrical Wiring Connections(Also refer to wiring diagrams in Part X of the installation manual)1) A pre-wired junction box assembly specific to

5352FIGURE A3: TAPPING LOCATIONS (SEE TEXT FOR TAPPING USES)

54Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.comManufacturer of Hydronic Heating ProductsP.O. Box 14818 3633 I. StreetPhiladelph

6For Buildings of Other than Unusually Tight Construction1) Determine whether the boiler is to be installed in a confined space - A confined space is

76 FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILAT

8 FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL D

98VI VentingVent installation must be in accordance with local building codes, or the local authority having jurisdiction, or the NationalFuel Gas Co