Crown Boiler MT100G Operations Instructions

BWC SeriesHigh Effi ciency Gas-Fired Hot Water Direct Vent Condensing BoilersINSTALLATION INSTRUCTIONS These instructions must be affi xed on or ad

83) Minimum Vent and Air Intake Lengths - Minimum vent length is 2ft. Minimum air inlet length is 2ft.4) Permitted Terminals for Horizontal Venti

9TABLE 6.2a: SUMMARY OF HORIZONTAL VENTING OPTIONS VENT OPTION # 1 2 3 4 5CLASSIFICATION USED IN THIS MANUALHORIZONTAL DIRECT VENTHORIZONTAL DIRECT V

10FIGURE 6.3a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADEFIGURE 6.3b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR I

11• If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guara

12TABLE 6.2b: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # 6 7CLASSIFICATION USED IN THIS MANUALVERTICALDIRECT VENTVERTICAL DIRECT VENTILLUSTRATE

13TABLE 6.5: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTSMANUFACTURER VENT SYSTEM SIZEWALL THIMBLESHORIZONTAL TERMINATIONVERTICAL TERMINATIO

14B. Removing an Existing Boiler From a Common Chimney Read this only if the BWC boiler is replacing an existing boiler that is being removed fr

15 2) Assembly of Flex-L-Intl. Star-34 Vent System: a) Star-34 General Notes: • Do not cut Star-34 vent components. • Support ho

16FIGURE 6.8: Z-VENT III CONNECTION TO VENT COLLAR 3) Assembly of Z-Flex Z-Vent III: a) General Notes: • Non-expanded ends of SVE Seri

17 4) Assembly of Heat Fab Saf-T Vent EZ Seal: a) Saf-T Vent General Notes: These instructions cover the installation of Saf-T Vent EZ

18 5) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of

19 d) 4” galvanized smoke pipe will fit inside the inlet collar on the BWC boiler. Depending upon the exact OD of the pipe used, it may be

20VII Gas PipingGas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at an inlet pressure betwe

21VIII System PipingA. General System Piping PrecautionsCAUTIONTHE HEAT EXCHANGER USED IN THE BWC IS MADE FROM A SPECIAL ALUMINUM ALLOY. FAILURE TO T

22Method 1: Primary/Secondary Piping - Boiler in Secondary Loop This method can be used in heat-only applications as shown in Figure 8.2 or with an

Figure 8.2: Piping Method #1 - Heat OnlyFigure 8.3: Piping Method #1 - Heat + Indirect Water Heater 23

24Figure 8.4b: Piping Method #1 - Indirect Water Heater Loop Piping (Shaded)Figure 8.4a: Piping Method #1 - Secondary Loop Piping (Shaded)

25TABLE 8.5: PIPE AND CIRCULATOR SIZING FOR BOILER LOOPBOILER MODEL(a) (b) (c) (d)PIPE SIZE FLOWCIRCULATOR MODELBOILER LOOP MAX EQUIVALENT LENGTH(in N

26TABLE 8.7: FITTING EQUIVALENT LENGTHSFITTINGPIPE SIZE EQUIVALENT LENGTH (ft)90 ELBOW 1 1/4 3.75TURN IN TEE1 1/4 8.00RUN OF TEE 1 1/4 2.50SWING CHEC

27Method 2: Primary/Secondary Piping - Boiler in Primary Loop This method can be used in heat-only applications as shown in Figure 8.8 or with an in

Table of Contents I. Product Description 2 II. Specifications 2 III. Before Installing 3 IV. Locating The Boile

Figure 8.8: Piping Method #2 - Heat OnlyFigure 8.9: Piping Method #2 - Heat + Indirect Water Heater 28

Figure 8.10a: Piping Method #2 - Secondary Loop Piping (Bolded) Figure 8.10b: Piping Method #2 - Primary Loop Piping (Bolded)29

Figure 8.10c: Piping Method #2 - Indirect Water Heater Loop Piping (Bolded)30Figure 8.11: Piping Method #3 - Direct Connection of Boiler to Heating Sy

31C: Standard Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping:1) The rel

323) The return piping may be connected into the boiler through the back or sides of the boiler by rotating the drain elbow and routing the return pi

33Figure 8.14: Chiller PipingFigure 8.13: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger

34IX Wiring 1) Line Voltage (120 VAC) Connections (Fig 9.1) – The line voltage connections are located in the juncti

Figure 9.1: Wiring Connections Diagram35

Figure 9.2: Ladder Diagram36

Figure 9.3: Wiring of Isolation Relay for Control of Two Heating Circulators 37

2I Product DescriptionThe BWC is an aluminum gas fired condensing boiler designed for use in forced hot water heating systems requir-ing supply water

X Start-up and CheckoutUse the following procedure for initial start-up of the boiler:1) If not already done, flush the system to remove sediment, flux

A.•C.B.D.•••1. 6.2. 7.3.4. 8.9.5. 10.11.12.1. 3.2. 4.FOR YOUR SAFETY READ BEFORE LIGHTINGThis appliance does not have a pilot. It is equipped with an

407) Start the boiler using the lighting instructions on page 39. After the boiler is powered up, it should go through the following sequence. Sequ

41Figure 10.2: Gas Valve Detail11) Perform a combustion test. On horizontally vented units, the sample probe may be inserted into the terminal. I

4212) Test any external limits or other controls in accordance with the manufacturer’s instructions.13) Verify that the boiler starts and stops in res

XI Operation1) The BWC boiler uses a microprocessor based control, known as a “MCBA”, to manage all boiler functions including flame supervision a

44 In standby mode, it is possible to view both the heating supply set point temperature and the “domestic hot water reference set point”. The “do

STEP + - STORE STEP + - STORE+ ShortShows supply set point when responding to call for heat (Note 1)c 1901DHW reference set point (Note 2)68°F - 144°F

46 3) Two basic types of errors codes are shown on the display: • Soft Lockout Codes – When a soft lockout occurs, the boiler will shut down

Figure 11.4: Outdoor Reset Curve477) The sequence of operation for a BWC series boiler on a call for heat from a thermostat is as described below:

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

XII. Service and Maintenance1) Continuously: a. Keep the area around the boiler free from combustible materials, gasoline and other

i. Remove the burner and vacuum any dust or lint from the burner. Wipe the inside of the burner with a clean soft cloth. Do not wipe the

50XIII. TroubleshootingA. Troubleshooting problems where no error code is displayed:CONDITION POSSIBLE CAUSESDisplay Blank, Fan off, LWCO lights off

51B. Trouble shooting problems where a soft lockout code is displayed. When a soft lockout occurs, the boiler will shut down and the display will

52C. Trouble shooting problems where a hard lockout code is displayed. When a hard lockout occurs, the boiler will shut down and the display wil

53XIV PartsThe following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area Crown representativ

54BWC REPLACEMENT PARTS LISTKEY DESCRIPTIONBWC150 BWC225CROWN PART #QUANTITYCROWN PART #QUANTITY1 Crown Aluminum Nameplate 98-004 1 98-004 12 Aluminum

55BWC REPLACEMENT PARTS LISTKEY DESCRIPTIONBWC150 BWC225CROWN PART #QUANTITYCROWN PART #QUANTITY47 Nylon Glide Foot 1”Dia x 3/4” Long 700111 4 700111

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4Figure 4.1: Clearances To Combustible Or Non-combustible MaterialTable 4.2: Clearances From Vent Piping To Combustible ConstructionTYPE OF VENT PIPE

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60BWC REPLACEMENT PARTS LISTKEY DESCRIPTIONBWC150 BWC225CROWN PART #QUANTITYCROWN PART #QUANTITY89 #6-32 x 13mm Hex x 92mm, Long Standoff 900711 2 900

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BWC REPLACEMENT PARTS LISTKEY DESCRIPTIONBWC150 BWC225CROWN PART #QUANTITYCROWN PART #QUANTITYNot Shown 11-1/2” Releasable Nylon Cable Wire Tie 960025

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66Appendix A: Special Requirements For Side-Wall Vented AppliancesIn The Commonwealth of MassachusettsIMPORTANTThe Commonwealth of Massachusetts requ

V Air for Ventilation Air for combustion must always be obtained directly from outdoors, however sufficient air for ventilation must still be provid

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

6Figure 5.1: Boiler Installed In A Confined Space, Ventilation Air From Inside• If the total volume of both the boiler room and the room to which the

7VI VentingWARNINGFailure to vent this boiler in accordance with these instructions could result in unreliable boiler operation, severe damage to the