Crown BWF061 User Manual

BWF Series

Gas-Fired Fan Assisted Hot Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

Models:

• BWF061

• BWF095

• BWF128

• BWF162

• BWF195

• BWF229

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

CROWN

Boiler Co

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com

Table of Contents

I Product Description………………………... 2 II Specifications……………………………….. 2 III Before Installing…………………………….. IV Locating the Boiler…………………………..

3 V Air for Combustion and Ventilation………… 5 VI Venting………………………………………. Horizontal Vent System Design………..

9 Vertical Vent System Design…………... 14 Vent System Assembly…………………. 18 VII Gas Piping………………………………… 25 VIII System Piping………………………………. 26 IX Wiring……………………………………….. 31 X Start-up and Checkout……………………… 36 XI Service and Maintenance………………….. 40 XII Troubleshooting Charts…………………….. 43 XIII Parts…………………………………………. 47

I Product Description

The BWF series boiler is a cast iron gas fired boiler designed for use in forced hot water heating systems. The BWF is intended for installations where a usable chimney is not available. The BWF is normally vented using an approved vertical or horizontal AL29-4C stainless steel venting system, which is not included with the boiler. If a suitable chimney is available, the BWF series can be vented into it using an optional BWF Category I Vent Kit available from Crown. The BWF requires an adequate source of clean combustion air in the boiler room. The BWF boiler is not designed for use in gravity or “open” heating systems. Where an adequate source of clean indoor combustion air cannot be guaranteed, use a direct vent boiler such as the Crown CSC series.

II Specifications

TABLE 1: SPECIFICATIONS

D.O.E.

MODEL*

BWF061EN 3 61,000 51,000 44,000 83.3 14 1/4 3.2 BWF095EN 4 95,000 78,000 68,000 83.1 17 1/2 4.0 BWF128EN 5 128,000 106,000 92,000 82.8 20 3/4 4.7 BWF162EN 6 162,000 134,000 117,000 82.5 24 5.5 BWF195EN 7 195,000 161,000 140,000 82.3 27 1/4 6.3 BWF229EN 8 229,000 189,000 164,000 82.0 30 1/2 7.0

* MODELS SHOWN ARE FOR NATURAL GAS. REPLACE "N" WITH "L" SUFFIX FOR PROPANE MODEL NUMBER (e.g. BWF061EL). PERFORMANCE RATINGS ARE THE SAME FOR BOTH FUELS

NO.

SECTIONS

INPUT

(BTU/hr)

HEATING

CAPY.

(BTU/hr)

IBR NET

RATING

(BTU/hr)

AFUE (%)

FIG. 1

DIMENSION

"A" (IN.)

VENT DIA.

(IN.)

3 3 3 3 4 4

WATER

CONTENT

(GAL.)

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 authority having jurisdiction.

• In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the

National Fuel Gas Code, ANSI Z223.1

• In Canada, installation must be in accordance with CSA B149 (Installation Code for Gas Burning Appliances and

Equipment).

• Where required by the authority having jurisdiction, this installation must conform to the Standard for Controls and

Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1)

2) Read Section VI to verify that the boiler can be vented in accordance with these instructions.

3) Make sure that the boiler is correctly sized:

• For heating systems employing convection radiation (baseboard or radiators) use an industry accepted sizing method

such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics Institute in Berkeley Heights, NJ.

• For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.

• For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE Heating

Capacity required for the Mega-Stor or the net rating required for the heating system, whichever results in the larger boiler.

• For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s instructions

for boiler output requirements.

4) Make sure that the boiler received is configured for the correct gas (natural or LP).

5) For installations at altitudes above 2000ft, special orifice and pressure switches may be required. Make sure that the boiler

is configured for use at the correct altitude.

IV Locating the Boiler

1) Clearances:

• Observe the minimum clearances shown below. These clearances apply to all combustible construction, as well as non-

combustible walls and doors. Also see Figure 2.

Front – 6” Left Side – 1” Right Side – 4” Rear – 1” Top – 36” Vent Pipe – 5”

• A 24” service clearance from the jacket is recommended on the left, right, and front of the boiler. These clearances may

be reduced to those shown in Figure 2, however servicing the boiler will become increasingly difficult as these service clearances are reduced.

• If the right side 24” service clearance is reduced, adequate clearance must be maintained to easily read both the gauge and

the limit control. Alternatively, access to the gauge and limit may be provided using a door.

2) The boiler must be installed on a hard level surface. This surface may be combustible.

3) Do not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop. Do not

install in a location where sources of hydrocarbons will be stored or used. Some common sources of hydrocarbons include bleaches, fabric softeners, paints, cleaners, refrigerants, and cat boxes. Traces of these chemicals can be drawn into the boiler, causing severe corrosion damage to the boiler and/or objectionable odors.

4) The boiler should be located so as to minimize the length of the vent system while still meeting the requirements in

Section VI.

5) Do not install this boiler over carpeting.

6) Do not install this boiler directly on a surface that may get wet. Raise the boiler on a pad.

V Air for Combustion and Ventilation

Sufficient fresh air must be supplied for both combustion and ventilation. Provisions for combustion, ventilation, and dilution air for gas utilization equipment must be made in accordance with local building codes, or in the absence of such codes, in accordance with Sections 5.3.3 and 5.3.4 (“Air for Combustion and Ventilation”) of the National Fuel Gas Code, NFPA 54/ANSI Z223.1. To ensure an adequate combustion and ventilation air supply, start by determining whether the boiler is to be installed in a building of unusually tight construction. A building of unusually tight construction is defined by the National Fuel Gas Code as having all

• Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or

• Weather stripping has been added on openable windows and doors.

• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and

If the building is of unusually tight construction, see the instructions on page 6. Otherwise, follow the instructions below.

1) Determine whether the boiler is to be installed in a confined space - A confined space is defined by the National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To determine whether the boiler room is a confined space:

a. Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest 1000

BTU/hr.

b. Find the volume of the room in cubic feet. The volume of the room in cubic feet is:

Length (ft) x width (ft) x ceiling height (ft)

In calculating the volume of the boiler room, consider the volume of adjoining spaces only if no doors are installed between them. If doors are installed between the boiler room and an adjoining space, do not consider the volume of the adjoining space, even if the door is normally left open.

c. Divide the volume of the boiler room by the input in thousands of BTU/hr. If the result is less than 50, the boiler room is a

confined space

Example:

A BWF229 and a water heater are to be installed in a room measuring 6ft – 3 in x 7ft with an 8 ft ceiling. The water heater has an input of 30000 BTU/hr:

Total input in thousands of BTU/hr = (229000 BTU/hr + 30000 BTU/hr) / 1000 = 259

Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3

350/259 = 1.35 Since 1.35 is less than 50, the boiler room is a confined space.

If the boiler is in an unconfined space combustion and ventilation without additional louvers or openings into boiler room.

of the following features:

less with openings gasketed and sealed.

floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other openings.

For Buildings of Other than Unusually Tight Construction

– Natural infiltration into the boiler room will normally provide adequate air for

If the boiler is in a confined space The top edge of the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the floor (Fig 3).

• Each opening must have a free area of 1 square inch per 1000 BTU/hr input of all gas burning appliances in the boiler

room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per opening.

• 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. Connect additional rooms with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input.

• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are

used, they must be no finer than ¼” (4 x 4) mesh.

• If providing openings into adjacent rooms is undesirable, combustion and ventilation air can be brought to the boiler

room from outdoors. See the instructions under “For Buildings of Unusually Tight Construction”

– Provide two openings into the boiler room, one near the floor and one near the ceiling.

For Buildings of Unusually Tight Construction

a) Openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl

space, which communicates directly with the outdoors.

b) Two openings are required. The top edge of the upper opening must be within 12 inches of the ceiling. The bottom

edge of the lower opening must be within 12 inches of the floor.

c) Size openings and ducts as follows:

• Vertical ducts or openings directly outdoors (Fig 4, Fig 5, Fig 6) – Each opening must have a free cross sectional area

of 1 square inch per 4000 BTU/hr of the total input of all gas-fired appliances in the boiler room. Minimum opening size is 3 inches. Ducts must have the same cross sectional area as the openings to which they connect.

• Openings to outdoors via horizontal ducts (Fig 7) - Each opening must have a free cross sectional area of 1 square

inch per 2000 BTU/hr of the total input of all gas-fired appliances in the boiler room. Minimum opening size is 3 inches. Ducts must have the same cross sectional area as the openings to which they connect.

• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are

used, they must be no finer than ¼” (4 x 4) mesh.

VI Venting

There are three basic ways to vent the BWF boiler:

• Horizontal (“side wall”) venting using an approved AL29-4C stainless steel vent system.

• Vertical venting using an approved AL29-4C stainless steel vent system.

• Chimney venting using a masonry or “B” vent chimney and a special Category I Vent Kit available from Crown.

DO NOT ATTEMPT TO VENT A BWF SERIES BOILER INTO A MASONRY OR “B” VENT CHIMNEY WITHOUT THE CROWN CATEGORY I VENT KIT SHOWN IN TABLE III

Table 3 summarizes these three venting options. One of the columns in Table 3 must describe the planned vent system exactly

TABLE 3: SUMMARY OF VENTING OPTIONS

WARNING

CLASSIFICATION USED IN THIS MANUAL

NATL. FUEL GAS CODE CLASSIFICATION STRUCTURE PENETRATION WALL ROOF ROOF MAXIMUM LENGTH: BWF061 - BWF162 45 FT + 1 EL 39.5 FT + 2 ELS BWF195,BWF229 (using 4" Pipe) 45 FT + 1 EL 37 FT + 2 ELS BWF195,BWF229 (using 3" Pipe) 30 FT + 1 EL 24.5 FT + 2 ELS MINIMUM LENGTH: BWF061 - BWF162 2 FT + 1 EL 6 FT + 2 ELS BWF195,BWF229 2 FT + 1 EL 6 FT + 2 ELS NOMINAL DIA.: BWF061 - BW F162 3" 3" BWF195,BWF229 3" or 4" 3" or 4"

MATERIAL AL29-4C(*) AL29-4C(*)

EXHAUST TERMINAL:

BWF061 - BW F162 BWF195,BWF229 (using 4" Pipe)

BWF195,BWF229 (using 3" Pipe)

HORIZONTAL

DIRECT

EXHAUST

CATEGORY III CATEGORY III

90 ELBOW, TEE,

OR VH-1 TERM. BY VENT MFR.

90 ELBOW OR

TEE

VERTICAL DIRECT

EXHAUST

(TABLE 6)

CHIMNEY VENT

CATEGORY I

SIZE PER NATIONAL

FUEL GAS CODE

VENTING TABLES FOR

FAN ASSISTED

APPLIANCE

"B" VENT OR LINED

MASONRY CHIMNEY

(SEE N.F.G.C.)

LISTED CHIMNEY CAP

CATEGORY I VENT KIT: BWF061 - BWF128 CROWN # 650140 BWF162 - BWF229 CROWN # 650141

(*) FLEX-L-INTL STAR-34 , ZFLEX SVE SERIES III, HEAT FAB SAF-T VENT , PROTECH SYSTEMS FASNSEAL

N/A N/A

The following instructions describe the design and installation of Horizontal and Vertical Direct Exhaust (Category III) systems only. Instructions for Chimney (Category I) venting are provided with the Crown Category I vent kit or are available from Crown.

Horizontal Vent System Design

1) See Figure 8 for the general horizontal exhaust configuration. For the purposes of this manual, a “horizontal exhaust

system” is one that exits the structure through a wall.

2) Approved Systems – Use one of these four approved vent systems:

• Flex-L-International Star-34

• Z-FLEX SVE Series III (“Z-Vent II”)

• Heat Fab Saf-T Vent

• ProTech Systems FasNSeal

3) Vent Pipe Size:

• BWF061 to BWF162– 3”

• BWF-195, BWF-229 –3” or 4”

4) Maximum Vent Pipe Length:

• BWF061 to BWF162: 45 ft + (1) 90 degree elbow + terminal

• BWF195 to BWF229 (using 4” vent pipe): 45 ft + (1) 90 degree elbow + terminal

• BWF195 to BWF229 (using 3” vent pipe): 30 ft + (1) 90 degree elbow + terminal

• Reduce the maximum straight pipe run by the equivalent length from Table 4 for each additional

Example:

A vent system is planned for a BWF162 which has the following components:

2 ft vertical pipe 1 90 elbow 5 ft horizontal pipe 1 90 elbow 3 ft horizontal pipe 1 45 elbow 4 ft horizontal pipe 1 termination elbow

Since the boiler is a BWF162, all piping must be done in 3” pipe. The first 90 degree elbow and the termination elbow are not considered. From Table 4, the equivalent length of the 3” 45 elbow is 4.5ft. The equivalent length of the 3” 90 degree elbow is 5.5ft. The maximum allowable run of straight pipe on this system is therefore:

45ft – 4.5 ft –5.5ft = 35ft

Since the planned installation has only 14 ft of straight pipe, the planned vent system length is acceptable

elbow.

TABLE 4: VENT SYSTEM ELBOW EQUIVALENT

LENGTHS

NOMINAL SIZE FITTING 3 INCH 4 INCH 90 DEG. ELBOW 5.5 8 45 DEG. ELBOW 4.5 4.5

HORIZONTAL CONDENSATE TEE TREATED AS STRAIGHT PIPE

5) Minimum Vent Pipe Length: 2 ft + (1) 90 degree elbow + terminal

6) Permitted Terminals:

• Choice of Tjernlund VH1 series terminal, a 90-degree elbow with rodent screen, or a termination tee with a rodent

screen. The Tjurnlund VH1 terminals may not be used on BWF195s and BWF 229s when they are vented with 3” pipe. If the Tjurnlund terminal is used, select one of the following:

BWF061 to BWF162: Tjernlund VH1-3 (Crown #50-032) 3” terminal BWF195, BWF229: Tjernlund VH1-4 (Crown #50-042) 4” terminal

• If an elbow or tee is used for the vent termination, it must be of the same type and manufacture as the rest of the vent

system.

• If a tee is used for the termination it must be installed with the run of the Tee vertical.

7) Wall thimbles – Wall thimbles are required where the vent pipe passes through combustible walls with less than a 5”

clearance. Use the appropriate wall thimble shown in Table 5.

8) Pitch of horizontal piping – A ¼” per foot pitch towards the outside is preferred. Alternatively, the horizontal piping may

be pitched ¼” per foot towards the boiler, however a condensate trap is required. See (9).

9) Condensate traps –In some horizontal installations, condensate traps may be needed to prevent condensate from running

into the boiler or collecting in the vent system. A condensate trap must be used if the horizontal piping does not have a continuous slope to the outside. If this is the case, put a trap in the lowest section of horizontal piping (Fig 8b).

10) Use only a “horizontal” type condensate Tee (Fig 9).

11) Vertical and horizontal sections of piping must be properly supported. See the “Vent System Assembly” section of this

manual for more information.

12) Location of Horizontal Vent Terminal – Observe the following limitations on the terminal location:

• Terminal must be at least 4 feet below or 4 feet horizontally from any window, door, or gravity air inlet into the

building (Fig. 10).

• The bottom of the terminal must be at least 12” above the normal snow line. In no case should it be less than 12”

above grade level (Fig 10).

• The bottom of the terminal must be at least 7 feet above a public walkway.

• The bottom of the terminal must be at least 3 feet above any forced air inlet located within 10 feet.

• A clearance of at least 4 feet horizontally or 4 feet vertically must be maintained between the terminal and gas meters,

electric meters, regulators, and relief equipment.

• Do not locate the terminal under decks or similar structures.

• Top of terminal must be at least 4 feet below eves, soffits, or overhangs. Overhang may not exceed 3 feet (Fig. 12).

Do not use the Tee terminal under an overhang deeper than 6”.

• Terminal must be at least 3 feet from an inside corner.

• Under certain conditions, water in the flue gas may condense on the structure in areas around the terminal. If these

areas are made of materials subject to damage by flue gas condensate, they should be protected.

• If possible, install the terminal 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.

• The noise level in the vicinity of the terminal is approximately 65 dB (roughly the level of a normal conversation).

Care should be taken when the terminal is positioned in areas where this might be objectionable, such as near bedroom windows.

TABLE 5: WALL THIMBLES

VENT MANUFACTURER'S PART # VENT SYSTEM 3 INCH 4 INCH FLEX-L-INTL Z-FLEX HEAT FAB PROTECH SYSTEMS

STAR-34

SVE SERIES II

SAF-T VENT

FASNSEAL

SRWT-03 SRWT-04

2SVSWTF03 2SVSWTF04

7393GC 7493GC

FSWT3 FSWT4

Vertical Vent System Design

1) See Figure 13 for the general vertical stainless steel venting configuration. For the purposes of this manual, a “vertical

exhaust system” is a Category III vent system that exits the structure through a roof.

2) Approved Systems – Use one of these four approved vent systems:

• Flex-L-International Star-34

• Z-FLEX SVE SeriesIII (“Z-Vent III”)

• Heat Fab Saf-T Vent

• ProTech Systems FasNSeal

3) Vent Pipe Size:

• BWF061 to BWF162– 3”

• BWF195, BWF229 – 4”

TABLE 6: CAPS FOR VERTICAL VENT SYSTEMS

VENT MANUFACTURER'S PART # VENT SYSTEM 3 INCH 4 INCH FLEX-L-INTL Z-FLEX HEAT FAB PROTECH SYSTEMS

STAR-34

SVE SERIES II

SAF-T VENT

FASNSEAL

SRRC-03 SRRC-04

2SVSRCF03 2SVSRCF04

5300CI 5400CI

FSRC3 FSRC4

4) Maximum Vent Pipe Length:

• BWF061 to BWF162 – 39.5 ft + (2) 90 degree elbows + cap

• BWF195, BWF229 (using 4” vent pipe): 37 ft + (2) 90 degree elbows + cap

• BWF195, BWF229 (using 3” vent pipe): 24.5 ft + (2) 90 degree elbows + cap

• Reduce the above maximum straight pipe runs by the equivalent length from Table 4 for each additional

elbow

beyond the first two.

Example:

A vertical vent system is planned for a BWF162 that has the following components:

2 ft vertical pipe 1 90 Elbow 1 condensate trap which has an is 18 inch long run 1 90 Elbow 1 ft vertical pipe 1 45 elbow 2 ft sloped pipe 1 45 elbow 7 ft vertical pipe 1 Cap

Since the boiler is a BWF162, all piping must be done in 3” pipe. The first two 90 elbows and the termination cap are not considered. The condensate trap is treated as a straight length of pipe 1.5 feet in length. The result is 13.5 ft of straight pipe and two 45 elbows. From Table 4, the equivalent length of the 45 elbow is 4.5ft. The maximum allowable run of straight pipe on this system is therefore:

37.5 ft – 4.5 ft – 4.5 ft = 28.5ft

Since the planned installation has 13.5 ft of straight pipe, the planned vent length is within the maximum limit.

5) Minimum Vent Pipe Length - 6 ft + (2) 90 degree elbows + cap

6) Permitted Terminals – A cap must be used which is compatible with the rest of the vent system. See Table 6 for the

appropriate cap.

7) Condensate traps – A condensate trap is required on all vertical-venting systems. Install this trap as shown in Figure 13. If

there are additional sections of horizontal piping in the vent system, they must either be equipped with their own condensate Tees or pitched so that condensate will run into the one required trap.

8) Use only a “horizontal” type condensate Tee (Fig. 9).

9) Pitch of horizontal piping – Pitch the lowest horizontal section of piping ¼” per foot towards the boiler. Other horizontal

sections (if any) must be pitched so that condensate will run towards a condensate Tee.

10) Fire-stops and wall thimbles – A wall thimble is required where the exhaust pipe passes through combustible walls with

less than a 5” clearance. Firestops are required where the vent passes through ceilings. These components must be compatible with the rest of the exhaust system. Table 5 shows wall thimble model numbers for the approved vent systems. Table 7 shows firestop model numbers for the approved vent systems.

11) Piping supports – Vertical and horizontal sections of piping must be properly supported. See the “Vent System Assembly”

section of this manual for more information.

12) Location of vent cap– The lowest discharge opening on the cap must be at least 2 feet above any object located within 10

feet (Fig. 14):

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