Manuale d’uso / di manutenzione del prodotto BWC Series del fabbricante Crown Boiler
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BWC Series High Effi ciency Gas-Fired Hot W ater Direct V ent Condensing Boilers INST ALLA TION INSTRUCTIONS These instructions must be affi xed on or adjacent to the boiler . Models: • BWC150 • BWC225 W ARNING : Improper installation, adjustment, alteration, serv ice or mai nten ance can cause prope rty damage , inj ury , or loss of life.
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T able of Contents I. Product Description 2 II. Specifications 2 III. Before Installing 3 IV . Locating The Boiler 3 V . Air For V entilation 5 VI. V enting 7 V ent System Design 7 Removing An Existing Boiler From Common Chimney 14 V ent/Intake System Assembly 14 VII.
2 I Pr oduct Description The BWC is an aluminum gas fired condensing boiler designed for use in forced hot water heating systems requir- ing supply water temperatures of 180°F or less. This boiler may be vented vertically or horizontally with combus- tion air supplied from outdoors.
III Befor e Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction.
4 Figure 4.1: Clearances T o Combustible Or Non-combustible Material T able 4.2: Clearances From V ent Piping T o Combustible Construction TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MINIMUM CLEARANCE .
V Air for V entilation Air for combustion must always be obtained directly from outdoors, however sufficient air for ventilation must still be provided in the boiler room. Air for ventilation is required to keep various boiler components from over- heating and is always obtained from indoors.
6 Figure 5.1: Boiler Installed In A Confined Space, V entilation Air From Inside • If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per 1000 BTU/hr of total appliance input, install a pair of identical openings into a third room.
7 VI V enting W ARNING Failure to vent this boiler in accordance with these instructions could r esult in unreliable boiler operation, severe damage to the boiler or property , or unsafe operation: * Do not attempt to vent this boiler with galvanized, PVC, or any other vent system not listed in T able 4.
8 3) Minimum V ent and Air Intake Lengths - Minimum vent length is 2ft. Minimum air inlet length is 2ft. 4) Permitted T erminals for Horizontal V enting (V ent Options 1,2) - The vent terminal is either a tee or an elbow supplied by the vent system manufacturer and equipped with a rodent screen.
9 T ABLE 6.2a: SUMMAR Y OF HORIZONT AL VENTING OPTIONS VENT OPTION # 1 2 3 4 5 CLASSIFICA TION USED IN THIS MANUAL HORIZONT AL DIRECT VENT HORIZONT AL DIRECT VENT (RESER VED FOR FUTURE USE) (RESER VED FOR FUTURE USE) (RESER VED FOR FUTURE USE) ILLUSTRA TED IN FIGURE 6.
10 FIGURE 6.3a: LOCA TION OF VENT TERMINAL RELA TIVE TO WINDOWS, DOORS, GRADE FIGURE 6.3b: LOCA TION OF VENT TERMINAL RELA TIVE TO METERS AND FORCED AIR INLETS FIGURE 6.
1 1 • If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if the terminal is subjected to winds in excess of 40 mph. • Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools.
12 T ABLE 6.2b: SUMMAR Y OF VER TICAL VENTING OPTIONS VENT OPTION # 6 7 CLASSIFICA TION USED IN THIS MANUAL VER TICAL DIRECT VENT VER TICAL DIRECT VENT ILLUSTRA TED IN FIGURE 6.
13 T ABLE 6.5: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS MANUF ACTURER VENT SYSTEM SIZE W ALL THIMBLES HORIZONT AL TERMINA TION VER TICAL TERMINA TION HEA T F AB SAF-T VENT EZ SEAL 3 7393GC 7393GCS 5391CI ELBOW : 7314TERM TEE: 7390TEE 9392 4 7493GC 7493GCS 5491CI ELBOW : 7414TERM TEE: 7490TEE 9492 PROTECH SYSTEMS INC.
14 B. Removing an Existing Boiler Fr om a Common Chimney Read this only if the BWC boiler is replacing an existing boiler that is being removed from a common chimney .
15 2) Assembly of Flex-L-Intl. Star-34 V ent System: a) Star-34 General Notes: • Do not cut Star-34 vent components. • Support horizontal piping sections at intervals of 48” or less. • V ertical venting systems must be supported by at least one Star-34 Fire stop.
16 FIGURE 6.8: Z-VENT III CONNECTION T O VENT COLLAR 3) Assembly of Z-Flex Z-V ent III: a) General Notes: • Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw . File or sand the cut end smooth before assembling.
17 4) Assembly of Heat Fab Saf-T V ent EZ Seal: a) Saf-T V ent General Notes: These instructions cover the installation of Saf-T V ent EZ Seal. Saf-T V ent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints.
18 5) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of flue gas flow .
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 necessary to crimp this pipe. Secure with a single #10 sheet metal screw through the hole in the inlet collar and seal the outside of the joint with silicone.
20 VII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at an inlet pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or the National Fuel Gas Code .
21 VIII System Piping A. General System Piping Precautions CAUTION THE HEA T EXCHANGER USED IN THE BWC IS MADE FROM A SPECIAL ALUMINUM ALLOY . F AILURE T O T AKE THE FOLLOWING PRECAUTIONS COULD RESUL T IN SEVERE BOILER DAMAGE.
22 Method 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 indirect water heater as shown in Figure 8.3. This method relies on primary/secondary pumping to ensure that the required flow is always maintained through the boiler .
Figure 8.2: Piping Method #1 - Heat Only Figure 8.3: Piping Method #1 - Heat + Indir ect W ater Heater 23.
24 Figure 8.4b: Piping Method #1 - Indir ect W ater Heater Loop Piping (Shaded) Figure 8.4a: Piping Method #1 - Secondary Loop Piping (Shaded).
25 T ABLE 8.5: PIPE AND CIRCULA TOR SIZING FOR BOILER LOOP BOILER MODEL (a) (b) (c) (d) PIPE SIZE FLOW CIRCULA TOR MODEL BOILER LOOP MAX EQUIV ALENT LENGTH (in NPT) (GPM) (ft) BWC150 1 1/4 8.0 T aco 007 148 BWC150 1 1/4 8.0 T aco 0010 224 BWC225 1 1/4 12.
26 T ABLE 8.7: FITTING EQUIV ALENT LENGTHS FITTING PIPE SIZE EQUIV ALENT LENGTH (ft) 90 ELBOW 1 1/4 3.75 TURN IN TEE 1 1/4 8.00 RUN OF TEE 1 1/4 2.50 SWING CHECK 1 1/4 10.
27 Method 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 indirect water heater as shown in Figure 8.9. Like Method 1, this method relies on primary/secondary pumping to ensure that the required flow is always maintained through the boiler .
Figure 8.8: Piping Method #2 - Heat Only Figure 8.9: Piping Method #2 - Heat + Indir ect W ater Heater 28.
Figure 8.10a: Piping Method #2 - Secondary Loop Piping (Bolded) Figure 8.10b: Piping Method #2 - Primary Loop Piping (Bolded) 29.
F i g u r e 8 . 1 0 c : P i p i n g M e t h o d # 2 - I n d i r e c t W a t e r H e a t e r L o o p P i p i n g ( B ol de d ) 30 Figure 8.1 1: Piping Method #3 - Dir ect Connection of Boiler to Heatin.
31 C: Standard Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping: 1) The relief valve is packaged loose with the boiler and must be installed in the location shown in Figure 1. The relief valve is set to open at 30 psi.
32 3) 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 piping through the appropriate knockout. 4) Circulator (Required) - Usually at least two circulators will be required to properly install a BWC Series boiler .
33 Figure 8.14: Chiller Piping Figure 8.13: Isolation of the Boiler Fr om Oxygenated W ater with A Plate Heat Exchanger.
34 IX Wiring 1) Line V oltage (120 V AC) Connections (Fig 9.1) – The line voltage connections are located in the junction box on the right side of the vestibule: • Black – Line voltage “hot”.
Figure 9.1: W iring Connections Diagram 35.
Figure 9.2: Ladder Diagram 36.
Figure 9.3: W iring of Isolation Relay for Contr ol of T wo Heating Circulators 37.
X Start-up and Checkout Use the following procedure for initial start-up of the boiler: 1) If not already done, flush the system to remove sediment, flux, and traces of boiler additives. This should be done with the boiler isolated from the system. 2) Fill the boiler and hydronic system with water meeting the following requirements: pH between 6.
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 LIGHTING This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
40 7) Start the boiler using the lighting instructions on page 39. After the boiler is powered up, it should go through the following sequence. Sequence Display Meaning 1 U.125 or Blank Checking internal software (power-up only) 2 0.SWT Boiler in standby .
41 Figure 10.2: Gas V alve Detail 1 1) Perform a combustion test. On horizontally vented units, the sample probe may be inserted into the terminal. If this is not possible, and if no sample tap is present in the vent system, remove the flue temperature sensor and insert the analyzer probe in the sensor opening.
42 12) T est any external limits or other controls in accordance with the manufacturer ’ s instructions. 13) V erify that the boiler starts and stops in response to calls for heat from the heating thermostat and indirect wa - ter heater thermostat. Make sure that the appropriate circulators also start and stop in response to the thermostats.
XI Operation 1) The BWC boiler uses a microprocessor based control, known as a “MCBA”, to manage all boiler functions including flame supervision and modulation. T wo set point or “target” boiler supply temperatures are stored in the MCBA ’ s memory; one for space heating and one for domestic water production.
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 “domestic hot water reference set point” plus 45°F equals the boiler supply set point when it is responding to a call from the indirect water zone.
STEP + - STORE STEP + - STORE + Short Shows supply set point when responding to call for heat (Note 1) c 190 1 DHW reference set point (Note 2) 68°F - 144°F (Default Setting 135°F) 1 Supply water temperature 1.170 + Long Turn heating on/off c OFF 0 = Off 2 Return water temperature 2.
46 3) T wo basic types of errors codes are shown on the display: • Soft Lockout Codes – When a soft lockout occurs, the boiler will shut down and the display will alter - nate between the number “9” and the letter “b” followed by a two digit service code.
Figure 1 1.4: Outdoor Reset Curve 47 7) The sequence of operation for a BWC series boiler on a call for heat from a thermostat is as described below: a) When power is first turned on, 120V is provided to the MCBA, the combustion fan and the L WCO trans- former .
XII. Service and Maintenance 1) Continuously : a. Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids. b. Keep the area around the combustion air inlet terminal free from contaminates . c. Keep the boiler room ventilation openings open and unobstructed.
i. Remove the burner and vacuum any dust or lint from the burner . W ipe the inside of the burner with a clean soft cloth. Do not wipe the mesh side of the burner . If the burner shows signs of deterioration or corrosion, replace it immediately . Inspect the burner gasket and replace, if necessary .
50 XIII. T roubleshooting A. T roubleshooting problems where no error code is displayed: CONDITION POSSIBLE CAUSES Display Blank, Fan off, L WCO lights off • No 120V AC Power at boiler .
51 B. T rouble shooting problems where a soft lockout code is displayed. When a soft lockout occurs, the boiler will shut down and the display will alternate between the number “9” and the letter “b” followed by a two digit service code. The boiler will automatically restart once the condition that caused the lockout is corrected.
52 C. T rouble shooting problems where a hard lockout code is displayed. When a hard lockout occurs, the boiler will shut down and the display will flash the letter “E” followed by a two digit service code. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset using the RESET button on the display .
53 XIV Parts 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 www .
54 BWC REPLACEMENT P ARTS LIST KEY DESCRIPTION BWC150 BWC225 CROWN P ART # QUANTITY CROWN P ART # QUANTITY 1 Crown Aluminum Nameplate 98-004 1 98-004 1 2 Aluminum Door Knob 90-210 2 90-210 2 3 #8-32 x 1/4” H.
55 BWC REPLACEMENT P ARTS LIST KEY DESCRIPTION BWC150 BWC225 CROWN P ART # QUANTITY CROWN P ART # QUANTITY 47 Nylon Glide Foot 1”Dia x 3/4” Long 7001 1 1 4 7001 1 1 4 48 Combination Base / Rear Pa.
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60 BWC REPLACEMENT P ARTS LIST KEY DESCRIPTION BWC150 BWC225 CROWN P ART # QUANTITY CROWN P ART # QUANTITY 89 #6-32 x 13mm Hex x 92mm, Long Standof f 90071 1 2 90071 1 2 90 M6 x 1.0 x 75mm, Hex Head Screw 240960 16 240960 16 91 Manifold Seal Ring, EPDM 240200 8 240200 8 92 M6 x 1.
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BWC REPLACEMENT P ARTS LIST KEY DESCRIPTION BWC150 BWC225 CROWN P ART # QUANTITY CROWN P ART # QUANTITY Not Shown 1 1-1/2” Releasable Nylon Cable Wire T ie 960025 1 960025 1 Not Shown 6” Nylon Wir.
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66 Appendix A: Special Requir ements For Side-W all V ented Appliances In The Commonwealth of Massachusetts IMPOR T ANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: 1.
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Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .
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 BWC Series 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 BWC Series - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Crown Boiler BWC Series imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Crown Boiler BWC Series ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Crown Boiler BWC Series, 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 BWC Series.
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 BWC Series. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Crown Boiler BWC Series 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.
