Manuale d’uso / di manutenzione del prodotto 32 del fabbricante Crown Boiler
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1 D E S I G N E D T O L E A D T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I.
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3 T able of Contents I. Product Description 1 II. Specifications 2 III. Before Installing 7 IV . Locating the Boiler 7 V . Knockdown Boiler Assembly Instructions 10 VI. Air for Combustion & V entilation 19 VII. V enting 23 VIII. S team Boiler Piping & T rim Installation 27 A.
4 Figure 1: Base Model - General Configuration 2 II Specifications.
5 3 T able 1A: Dimensional Data Jacket Overall Len g t h 'A' 'B' Dia. 'C' Dia. 'D' Dia. 'E' Dia. 'F' Dia.
6 T able 1B: Specifications 4 Wa t e r (MB H) (MB H) (S q . ft ) (MB H) (M B H ) (G al ) (G al ) 32-475W(S )N 6 475 380 1188 285 330 80-1/ 2 28.58 39.80 11.4 32-570W(S )N 7 570 456 1425 342 397 80-1/ 2 32.65 45.47 13.6 32-665W(S )N 8 665 532 1663 399 463 80-1/ 2 36.
7 5 Figure 2a: Series 32 S team Boilers - Arrangement Of S team Riser Connections, Draft Hoods And Base Assemblies.
8 6 Figure 2b: Series 32 W ater Boilers - Arrangement Of W ater Supply Connections, Draft Hoods And Base Assemblies.
9 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 requirements of the authority having jurisdiction.
10 T able 2: Minimum Room V olumes Based On Sixteen T imes Boiler V olume By Model Size 8 B o ile r Mo d el Ove r A ll Le ngth Jack e t O ve r A ll De p t h Jack e t Ove r A ll H e ight F loor To Top O f Jack e t Bo i l e r Vo l um e (F t3) M i n i mu m Ro o m Vol um e (F t3 ) 32- 475 36 3/4 32 1/4 46 5/8 32.
11 6) 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 boiler on a pad.
12 V Knockdown Boiler Assembly Instructions 10 A. Prior T o Assembly 1) Thoroughly inspect the cast iron heat exchanger sections for any shipping damage, i.e. cracks in the castings, broken lugs or punctures due to mishandling. 2) Do not use a damaged heat exchanger section.
13 11 Figure 4: Multiple Base Assembly.
14 12 C. Section Assembly 1) Clean the boiler sections inside and out to remove dirt due to shipping and handling. 2) Clean all nipples and nipple ports with kerosene immediately prior to section assembly . 3) Set the left end section on the base so that the locating lugs on the bottom of the section go inside the front and rear base panels.
15 13 Figure 6: Assembly Of Sections Figure 5: Use Of Nipple Gauge.
16 14 14) Install the tankless coil/s and/or cover plates using the gaskets and 3/8 x 7/8 bolts and washers provided (see Figure 7). 15) T est assembled block for leaks. Unless local codes have other requirements, use the following procedure: a) Run a hose from the water service to one of the lower tappings.
17 15 6) 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 the square mounting holes underneath the draft hood. Drop a 5/16 x 5" carriage bolt through this hole and through the hole in the rear tie rod channel bracket.
18 16 Figure 12b: Rear Attachment Of Draft Hood Figure 1 1: Front Attachment Of Draft Hood Figure 12a: Mounting Rear T ie Rod Channel Bracket.
19 17 NOTE Before installing the jacket, make sure to plug any tappings which are not going to be used. Also make sure that no tappings are plugged which will be needed later for piping the boiler . See Sections VIII and IX for piping and trim installation.
20 18 Figure 14: Exploded V iew Of Jacket Assembly.
21 19 VI Air For Combustion and V entilation Sufficient fresh air must be supplied for combustion, ventilation and flue gas dilution. Provisions for combustion, ventilation and flue gas dilution air f.
22 20 • If providing openings into adjacent rooms is undesirable, combustion and ventilation air can be brought into the boiler room from outdoors. See the instructions under “For Buildings of Unusually Tight Construction ”.
23 21 Figure 16: All Air Fr om Outdoors, V entilated Crawl Space & Attic Figure 17: All Air Fr om Outdoors, V ia V entilated Attic Figure 18: All Air Fr om Outdoors, Using Openings Into Boiler Roo.
24 22 Figure 19: All Air Fr om Outdoors, Using Horizontal Ducts Into The Boiler Room.
25 23 VII V enting V ent installation must be in accordance with local building codes, or the authority having jurisdiction, or the National Fuel Gas Code, NFP A 54/ANSI Z223.1 . T ypical vent installations are shown in Figures 20 and 21. The vent system shown in Figure 20 uses a common vent for all boiler modules.
26 6) Lateral venting should slope upwards towards the chimney not less than one inch in four feet. No portion of vent pipe should run downward or have sags.
27 25 Figure 21: Series 32 V enting (Each Module Individually V ented) Figure 20: T ypical Series 32 V enting (Common Module V enting).
28 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.
29 27 VIII S team Boiler Piping & T rim Installation 1) Figures 27 shows the recommended near boiler piping for most common types of gravity return steam systems. Use Table 6 to determine the riser, header and equalizer piping sizes for the appropriate boiler model.
30 28 Hydrolevel CG450 – This is a probe type L WCO and is installed in tapping “G”. On the CSD-1 control package, and other boilers with redundant low water cut-offs, the CG450 is the operating low water cut-of f and should be used to control a feeder (if used).
31 29 T able 5 Figure 22: S team Boiler T apping Locations Tapp ing U ses C h art For Steam B oil ers 1 C om pone nt De s c r iption Ta pping Ta pping St a nda r d C SD-1 L o cati o n S i ze ( i n ) E.
32 f. Boiler Drain Valve - Install with a 3” x ¾” bushing into one of the two return tappings “B”. The drain valve may also be installed in the return piping, but it must be installed in the leg of a tee so that it is directly opposite and as close as possible to the return tapping.
33 Figure 25: Common Near -Boiler Piping Mistakes T able 6: S team Boiler Riser & Header Pipe Sizes Steam Steam R eturn C ondens ate E qual i z er Boi l er H eader R i s er P ipe H eader R etur n .
34 Figure 26: T ypical Near -Boiler Piping When Using A Boiler Feed Pump 32.
35 Figure 27a: Recommended S team Boiler Piping: 1 or 2 Supply Connections, Gravity Return 33.
36 Figure 27b: Recommended S team Boiler Piping: 3 Supply Connections, Gravity Return 34.
37 35 Figure 27c: Recommended S team Boiler Piping: 4, 5 or 6 Supply Connections, Gravity Return.
38 36 B. Indirect W ater Heating Piping (S team Boilers) The steam version of the Series 32 boiler is equipped with tappings to permit the connection of a Crown Mega-Stor, or other indirect water heater. In this type of system, hot boiler water is drawn from below the water line and passed through the heat exchanger in the indirect water heater.
39 37 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 120°F CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.
40 38 DANGER • CONFIRM RELIEF V AL VE HAS THE CORRECT PRESSURE SETTING AND CAP ACITY FOR THE BOILER. • PIPE THE PRESSURE RELIEF VALVE DISCHARGE TO A SAFE LOCATION. • DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE. • DO NOT PLUG RELIEF VALVE DISCHARGE.
41 39 Tappi ng Uses Char t For W at er Boi l er s 1 C ompone nt D escr i p t io n T ap p i n g T ap p i n g S t an d ar d C S D - 1 L o cat i o n S ize ( i n ) E q u i p m en t P ackag e S uppl y P i .
42 40 Figure 30: T ypical W ater Boiler System Piping.
43 41 T able 8: W ater Boiler Supply & Return Pipe Sizes Figure 31: Recommended Boiler Piping For Combination Heating & Cooling Systems Suppl y Suppl y Water R etur n R etur n Water Boi ler H .
44 42 B. TANKLESS HEATER PIPING If the Series 32 water boiler is installed with an optional tankless heater, pipe the heater as shown in Figure 32. The components in this system and their functions are as follows: 1) Mixing Valve (Required) - During the heating season, the water exiting the tankless heater may be 180 degrees or more.
45 43 8) Multiple Tankless Heaters - If two tankless heaters are installed in the boiler, it is recommended that each heater be installed in parallel with its own mixing valve, relief valve, flow restrictor, etc.. This will permit either heater to be removed from service for maintenance while still providing some domestic water to the building.
46 44 X Gas Piping 1) Gas piping to the boiler must be sized to deliver an adequate supply of gas for the boiler to fire at the nameplate input with the inlet pressure at the gas valves between the minimum and maximum valves shown on the rating plate.
47 45 XI Control System 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).
48 46 6) Once the ignition module detects the presence of a pilot flame, voltage is applied across the main valve, opening the valve and establishing main flame. 7) The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot depends upon the exact ignition module supplied with the boiler .
49 47 Figure 35: Series 32 S tandard Boiler Wiring.
50 48 Figure 36: Series 32 - CSD-1 Boiler Wiring.
51 Safety Control Operation T emperature Limit Control (W ater Boilers) – The temperature limit control interrupts burner operation when the supply water temperature exceeds the set point. Maximum allowable water temperature in a water boiler is 250F .
52 50 XII S tart-up and Checkout Use the following procedure for initial start-up of the boiler: 1) Make sure that the boiler is filled with water. 2) Check all new gas piping for leaks and purge piping sections that are filled with air. See the National Fuel Gas Code for additional information on testing and purging gas lines.
53 51 WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER-FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD. 13) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a. Connect a manometer to the inlet pressure tap on the gas valve (see Figures 39 - 41).
54 52 16) (Steam Boilers) - Verify low water cutoff operation while the boiler is running. Slowly open drain valve and drain boiler until the water level drops below low water cutoff line. Water still should be visible in the gauge glass when the low water cutoff shuts down the main burners.
55 Figure 40: Gas Valve Detail - Robertshaw 7000DERHC Figure 39: Gas Valve Detail - Honeywell VR8304 53 Figure 41: CSD-1 Gas T rain.
56 A. This appl ian c e is equi pp ed w i th an ign ition device w hich automat ic ally lights th e pilot. Do t ry to lig ht the p ilot by han d. B. BE FO RE LIG HTING s mell a ll aro und t he applia n ce ar ea for ga s. Be sure to smel l next to t he floor becaus e so me ga s is h eavier than air an d will settle on the floo r .
57 A. This appl ian c e is equi pp ed w i th an ign ition device w hich automat ically lights th e pilot. Do try to l ig ht the p ilot by han d. B. BE FO RE LIG HTING s mell a ll aro und t he applia n ce ar ea for ga s. Be sure to smel l next to t he floor becaus e so me ga s is h eavier than air an d will settle on the floo r .
58 CAUTION W A TER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE T O THE BOILER OR OTHER SYSTEM COMPO- NENTS. REP AIR ANY LEAKS FOUND IMMEDIA TEL Y 56 XIII Service and Maintenance The following routine main.
59 12) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas piping disturbed during the inspection process for leaks. Heat Exchanger Cleaning Pr ocedure 1) T urn of f electrical power and gas supply to the boiler 2) Disconnect the vent connectors from the boiler .
60 XIV P AR TS The following parts may be obtained from any Crown distributor . T o find the closest Crown distributor, consult the area Crown representative or the factory at: Crown Boiler Co. Customer Service P .O. Box 14818 Philadelphia P A. 19134 (215) 535-8900 www .
61 59 285 380 475 285 380 475 A B C D E PART # (STANDARD) 310000 310001 310002 310002 310003 311004 311005 311006 310404 310405 310406 311020 311021 311022 311023 311024 311010 310400 3 11025 311030 P.
62 60 285 380 4 75 285 BA SE A SSE M BLY ( ST D ) 3101 14 1 380 BA SE A SSE M BLY ( ST D ) 3101 15 1 475 BA SE A SSE M BLY ( ST D ) 3101 16 1 285 BA SE A SSE M BLY ( C SD - 1) 310114 5 1 380 BA SE A S.
63 61 "A " "B" "C " "D " "E " 7" P U SH N I P P LE 310005 5 6 7 8 9 3" P U SH N I P P LE 310006 5 6 7 8 9 5/8 X 9 3/4 T I E R OD 90031 0 1 5.
64 285 380 475 1 BA SE F R O N T P A N E L (285) 310 604 1 1 BA SE F R O N T P A N E L (380) 310 605 1 1 BA SE F R O N T P A N E L (475) 310 606 1 2a BA SE F R ON T LE G (R H ) 310110 1 1 1 2b BA SE F.
65 63 Figure 42: Exploded V iew - Base Parts.
66 64 285 380 475 20 M A N I FO LD A S SY , C OM P LE T E ( 285) 310 15 4 1 20 M A N I FO LD A S SY , C OM P LE T E ( 380) 310 15 5 1 20 M A N I FO LD A S SY , C OM P LE T E ( 475) 310 15 6 1 21 1/4- .
67 65 Figure 43: Exploded V iew - Gas Manifold / Burners / Pilot Assembly.
68 66 L4006A 201 5 35- 3510 1 L4006E 1109 M A N . R E SE T ( C SD - 1 ON LY ) 35- 310 0 1 1/2 LO N G W E LL 35-1006 1 H Y D R OLE V E L 55 0 LWC O (C SD - 1 ON LY ) 45 0550 1 1- 1/ 2 X 1 / 2 BLK BU SH.
69 67 BOILER MODEL 98-111 980888 980425 980 92 0 900365 95-040 95-081 95-134 950500 95-096 95-027 95-057 95-105 950185 950114 950190 950110 95-047 95-033 95-058 95-031 32-475W 111111 1111 32-570W 1111.
70 68 BOILER MODEL 98-111 980888 980425 980 92 0 900365 950510 950515 950520 950525 950530 950124 950180 950175 950170 95-096 950185 95-047 32-475S 111111 11 11 32-570S 111111 11 11 32-665S 11111 1 11.
71 PN 980888 Rev .2 10/08 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Crown Boiler 32 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Crown Boiler 32 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Crown Boiler 32 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Crown Boiler 32 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Crown Boiler 32, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Crown Boiler 32.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Crown Boiler 32. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Crown Boiler 32 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
