Crown Boiler BWC150 Spécifications

BWC Series   INSTALLATION INSTRUCTIONS 

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

116) Permitted Terminals for Vertical Venting (Vent Options 6, 7) - A rodent screen is installed in the end of the vent pipe. Vent manufacturer par

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

14 Read this only if the BWC boiler is replacing an existing boiler that is being removed from a common chimney. This section does not apply

15 3) Assembly of Metal-Fab Corr/Guard Vent System: a) Corr/Guard General Notes:• Do not cut Corr/Guard vent components.• Refer to Corr/Guard instal

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 Serie

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 t inside the inlet collar on the BWC boiler. Depending upon the exact OD of the pipe used, it may be

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VII Gas PipingGas piping to the boiler must be sized to deliver adequate gas for the boiler to re at the nameplate input at an inlet pressure between

VIII System PipingA. General System Piping PrecautionsTABLE 8.1: FLOW REQUIREMENTS THROUGH BOILERBOILER MODELMIN. REQUIRED FLOW (GPM)MAX. ALLOWABLE F

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 i

Figure 8.2: Piping Method #1 - Heat OnlyCalculate total equivalent length from Table 8.7: 20 Straight Pipe + 6 Elbows x 3.75 + 2 Turns in Tees x 8 +

Figure 8.3: Piping Method #1 - Heat + Indirect Water Heater 27

Table of Contents I. Product Description 2 II. Specications 2 III. Before Installing 3 IV. Locating The Boiler 3 V

Figure 8.4b: Piping Method #1 - Indirect Water Heater Loop Piping (Shaded)Figure 8.4a: Piping Method #1 - Secondary Loop Piping (Shaded)28

29TABLE 8.7: FITTING EQUIVALENT LENGTHSFITTINGPIPE SIZE EQUIVALENT LENGTH (ft)90 ELBOW 1 1/4 3.75TURN IN TEE 1 1/4 8.00RUN OF TEE 1 1/4 2.50SWING CHE

30Figure 8.8: Piping Method #2 - Direct Connection of Boiler to Heating System Method 2: Direct Connection to Heating System (Generally NOT Recommend

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 8.11: Chiller PipingFigure 8.10: 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 red 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, ush the system to remove sediment, ux

WATER QUALITY AND BOILER WATER ADDITIVESIMPORTANT NOTEThis boiler is equipped with an aluminum heat exchanger that can be seriously damaged by failure

      

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

42Figure 10.2a: Honeywell Gas Valve Detail11) Perform a combustion test. On horizontally vented units, the sample probe may be inserted into the ter

Table 10.3: Typical Sea Level CO2/O2 Combustion WARNINGEACH BWC SERIES BOILER IS TESTED AT THE FACTORY AND ADJUSTMENTS TO THE AIR-FUEL MIXTURE ARE NO

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

45 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

USE MODE KEY TO TOGGLE BETWEEN MODES(Mode returns to Standby from other modes if no key is pressed for 20 min.)

47 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

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

Figure 11.4: Outdoor Reset Curve487) The sequence of operation for a BWC series boiler on a call for heat from a thermostat is as described below:

XII. Service and MaintenanceIMPORTANTWARRANTY DOES NOT COVER BOILER DAMAGE OR MALUFUNCTION IF THE FOL-LOWING STEPS ARE NOT PERFORMED AT THE INTERVALS

d. Remove the ignition electrode and inspect it for oxides. Clean the oxides off the electrode with sandpaper. Inspect the ceramic insulator

51XIII. TroubleshootingA. Troubleshooting problems where no error code is displayed:CONDITION POSSIBLE CAUSESDisplay Blank, Fan off, LWCO lights off

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

53C. Trouble shooting problems where a hard lockout code is displayed. When a hard lockout occurs, the boiler will shut down and the display wil

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55XIV PartsThe following parts may be obtained from any Crown distributor. To nd the closest Crown distributor, consult the area Crown representativ

56BWC REPLACEMENT PARTS LISTKEY DESCRIPTIONBWC150 BWC225CROWN PART #QUANTITYCROWN PART #QUANTITY1 Crown Aluminum Nameplate 98-004 1 98-004 12 Aluminum

57BWC REPLACEMENT PARTS LISTKEY DESCRIPTIONBWC150 BWC225CROWN PART #QUANTITYCROWN PART #QUANTITY47 Nylon Glide Foot 1”Dia x 3/4” Long 700111 4 700111

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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61Gas Train Assembly (Honeywell Valve)

Gas Train Assembly (Dungs Valve)62

63BWC 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 #QUANTITY140 3 x 63mm O-Ring 230003 1 NA 1141 Fan Inlet Block 230

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

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69Appendix A: Special Requirements For Side-Wall Vented AppliancesIn The Commonwealth of MassachusettsIMPORTANTThe Commonwealth of Massachusetts requ

PN: 980040 Rev. 6BWC - 12/12Manufacturer of Hydronic Heating ProductsP.O. Box 14818 3633 I. StreetPhiladelphia, PA 19134www.crownboiler.com

6Figure 5.1: Boiler Installed In A Conned 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