Crown MWC116ENT User Manual

Table of Contents

I. Product Description 2 II. Speciﬁ cations 4 III. Before Installing 5 IV. Locating The Boiler 5 V. Mounting The Boiler 7 VI. Air For Ventilation 10 VII. Venting 12

A. Vent System Design 12

B. Removing An Existing Boiler From Common Chimney 19 C. Assembly of Crown 60/100 Concentric Venting 20 D. Assembly of Crown 80/125 Concentric Venting 24 E. Condensate Trap and Drain Line 33 VIII. Gas Piping 34 IX. System Piping 36 X. Domestic Water Piping 43 XI. Wiring 46

XII. Start-up and Checkout 51

XIII. Operation 58 XIV. Service and Maintenance 62 XV. Troubleshooting 66 XVI. Parts 69 Appendix A Special Requirements For Side-Wall 84 Vented Appliances In The Commonwealth of Massachusetts

I Product Description

The MWC Series are gas ﬁ red condensing boilers designed for use in forced hot water heating systems requiring supply water temperatures of 176F or less and return water temperatures greater than 86F. The primary heat exchanger is a copper water tube design. Additional heat is extracted from the ﬂ ue gas in a stainless steel secondary heat exchanger located down stream of the inducer. These boilers include a built in circulator, expansion tank, and automatic air vent. In addition, “combi” models include a plate exchanger for domestic hot water (DHW) generation. All MWC Series boilers are designed for installation on a wall and may be vented vertically or horizontally with combustion air supplied from outdoors.

Key Component

1 Primary Heat Exchanger 2 Secondary Heat Exchanger 3 Inducer 4 Burner 5 Electrodes and Flame Rod 6 Circulator 7 Automatic Air Vent 8 Condensate Trap 9 Control Box

10 Differential Boiler Water Pressure Switch

11 Ignition module/Gas Valve 12 Air Pressure Switch 13 Flue Gas Temperature Limit 14 Supply Temperature Limit

* Expansion Tank * Plate Heat Exchanger (Combi Only) * 3-Way Diverting Valve (Combi Only) * Supply Temperature Sensor * DHW Temperature Sensor (Combi Only) * DHW Flow Switch (Combi Only)

* Not visible

Figure 1.1: MWC Boiler Principle Components

III Before Installing

Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in 1) 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. Natural Gas and Propane Installation Code.

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).

Read Section VII to verify that the maximum combustion air and exhaust pipe lengths will not be 2) exceeded in the planned installation. Also verify that the vent terminal can be located in accordance with Section VII.

Make sure that the boiler is correctly sized:3)

For heating systems employing convection radiation (baseboard or radiators), use an industry a) 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. In sizing the boiler take into consideration the following boiler water ﬂ ow/temperature limitations:b)

Maximum regulated supply temperature is 176F• Maximum ﬂ ow through the boiler is approximately 5.5GPM. •

Minimum boiler temperature rise is approximately 37F at high ﬁ re. • For new radiant heating systems, refer to the radiant tubing manufacturer’s boiler sizing guidelines. c) For combi boilers make sure that the domestic hot water ﬂ ow rate shown in Table 2.2, will be d) adequate to meet the peak demand for domestic hot water.

/NFPA 54 and/or CAN/CSA B 149.1

Make sure that the boiler received is conﬁ gured for the correct gas (natural or LP).5) Make sure that the boiler is conﬁ gured for use at the altitude at which it is to be installed. 6)

NOTICE

This product must be installed by a licensed plumber or gas ﬁ tter when installed within the Commonwealth of Massachusetts. See Appendix A for additional important information about installing this product within the Commonwealth of Massachusetts.

IV Locating the Boiler

Observe the minimum clearances shown in Figure 4.1. These clearances apply to both combustible and 1) non-combustible materials.

Note the recommended service clearances in Figure 4.1. These service clearances are recommended, 2) but may reduced to the combustible clearances provided:

Access to the front of the boiler is provided through a door• Access is provided to the condensate trap located underneath the boiler.•

The relief valve must be installed in the factory speciﬁ ed location.3) The boiler should be located so as to minimize the length of the vent system.4)

The boiler must not be installed on carpeting.5) The combustion air piping must terminate where outdoor air is available for combustion and away from 6)

areas that will contaminate combustion air. Avoid areas near chemical products containing chlorine, chloride based salts, chloro/ﬂ uorocarbons, paint removers, cleaning solvents and detergents.

V Mounting The Boiler

CAUTION

This boiler weighs approximately 110 pounds:

Two people are required to safely lift this boiler onto the wall mounting hook.• Make sure that wall mounting hook is anchored to a structure capable of supporting the • weight of the boiler and attached piping when ﬁ lled with water.

Jurisdictions in areas subject to earthquakes may have special requirements for supporting this boiler. These local requirements take precedence over the requirements shown below.

Mounting Steps:

If the boiler is installed on a framed wall, minimum acceptable framing are 2 x 4 studs. The boiler 1) mounting holes are on 11-5/8” centers. Usually the wall studs will be on 16” centers. In such cases, both boiler bracket mounting holes must be anchored to ¾” Plywood, horizontal 2 x 4s anchored to the studs, or some other framing system capable of supporting the boiler. Attachment of either bracket hole to wallboard alone is unacceptable.

When mounting this boiler directly onto studs covered with 1/2” wall board, 5/16 x 2” lag screws are 2) recommended. When the boiler is attached to other types of construction, such as masonry, use fasteners capable of supporting the weight of the boiler and attached piping in accordance with good construction practice and applicable local codes.

Make sure that the surface to which the boiler is mounted is plumb.3) Before mounting the boiler, make sure that wall selected does not have any framing or other construction 4)

that will interfere with the vent pipe penetration. Tape the paper template to the wall in the chosen location. Be sure to level the template.5) Pre-drill two holes in the center of the “oval” slots on the mounting bracket sized for the hardware being 6)

used. Mount the bracket to the wall. Be sure to level the bracket by adjusting the screw in the vertical slot.7) Pre-drill the remaining hole in the mounting bracket and secure the ﬁ nal screw .8) Cut the opening in the wall for the vent system. The recommended hole diameter for the standard 9)

60/100mm venting is 4-3/8”. Hang the boiler on the wall bracket as shown in Figure 5.2.10) Verify that the front and sides of the boiler are plumb.11) See Section VII (“Venting) for instructions on attaching the vent system to the boiler. 12)

A hot water boiler installed above radiation level or as the Authority having jurisdiction,

13) must be provided with a low water cutoff device either as a part of the boiler or at the time of installation.

Figure 5.1 Wall Mounting Hole Locations

VI Air for Ventilation

WARNING

Outdoor combustion air must be piped to the air intake. Never pipe combustion air from areas containing contaminates such as areas where swimming pool chemicals are stored. Contaminated combustion air will damage the boiler and may cause property damage, personal injury or loss of life.

Air for combustion and ventilation, of the National Flue Gas Code, ANSI Z223.1/NFPA 54 CAN/CSA B 149.1 Natural Gas and Propane Installation Code, or applicable provisions of the local building codes.

Air for combustion must always be obtained directly from outdoors, however sufﬁ cient air for ventilation must still be provided in the boiler room. Air for ventilation is required to keep various boiler components from overheating and is always obtained from indoors. To ensure an adequate ventilation air supply, perform the following steps:

Step 1: Determine whether the boiler is to be installed in a conﬁ ned space - A conﬁ ned space is deﬁ ned by

the 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 conﬁ ned space:

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

,ANSI Z223.1.

/NFPA 54 and/or CAN/CSA B 149.1National Fuel Gas Code

Natural Gas and Propane Installation Code.

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

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.

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

Example: A MWC116 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 = (116000 BTU/hr + 30000 BTU/hr) / 1000 = 146 MBTU/hr Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft 350/146 = 2.40. Since 2.33 is less than 50, the boiler room is a conﬁ ned space. Step 2a: If the boiler is to be placed in a conﬁ ned space, provide two openings into the boiler room, one near

the ﬂ oor and one near the ceiling. 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 ﬂ oor (Fig 6.1). The minimum opening dimension is 3 inches.

If the MWC boiler is the only gas-burning appliance in the boiler room, these openings must each • have a minimum free area of 54 square inches. If other gas-burning appliances are in the boiler room, size the openings in accordance with the • appliance manufacturer’s instructions or the National Fuel Gas Code

/NFPA 54 and/or CAN/CSA B 149.1. 54 square inches even if opening requirements for other appliances are less.

Minimum opening free area is

ANSI Z223.1.

Figure 6.1: Boiler Installed In A Conﬁ ned Space, Ventilation Air From Inside

Step 2a (contd.)

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 ﬁ ner than ¼” (4 x 4) mesh.

Step 2b: If the boiler is to be placed in an unconﬁ ned space the natural inﬁ ltration into the boiler room will provide adequate air for ventilation without additional openings into boiler room.

Table 7.1: Summary Of Horizontal Venting Options

VENT OPTION # 1 2 3 4

CLASSIFICATION USED IN THIS MANUAL

ILLUSTRATED IN FIGURE 7.2 7.2 7.2

HORIZONTAL

CONCENTRIC

HORIZONTAL

CONCENTRIC

HORIZONTAL

CONCENTRIC

RESERVED

FOR FUTURE

USE

VENT PIPE PENETRATION THROUGH STRUCTURE

VENT PIPE SIZE

INLET AIR ORIFICE SIZE MAX. VENT LENGTH MIN. VENT LENGTH

VENT TERMINAL

VENT MATERIAL

WALL WALL WALL

60/100 mm

CONCENTRIC

82mm

25in

6in

CROWN #230520

(INCLUDED

WITH BOILER)

CROWN

60/100mm

VENT

COMPO-

NENTS

SHOWN IN

TABLE 7.3a

60/100 mm

CONCENTRIC

Not Used 82mm 8ft - 10in 27ft - 10in

26in 6in

CROWN #230520

(INCLUDED

WITH BOILER)

CROWN

60/100mm

VENT

COMPO-

NENTS

SHOWN IN

TABLE 7.3a

80/125 mm

CONCENTRIC

CROWN #230531

CROWN

80/125mm VENT

COMPONENTS

SHOWN IN

TABLE 7.3b

Figure 7.2: Horizontal Concentric Venting (Vent Options 1-3)

Table 7.5: Vent/ Air Intake Fitting Equivalent Length

VENT FITTING EQUIVALENT LENGTH (ft) 60/100mm 90° CONCENTRIC ELBOW 4.5

60/100mm 45° CONCENTRIC ELBOW 4.0 80/125mm 90° CONCENTRIC ELBOW 8.5 80/125mm 90° SWEEP CONCENTRIC ELBOW 5.5 80/125mm 45° CONCENTRIC ELBOW 3.0 80/125mm 90° CONCENTRIC SUPPORT ELBOW 8.5

Permitted Terminals for Vertical Venting6) - Use Crown PN 230532 with the appropriate ﬂashing (Table 7.3b) Vertical Vent Terminal Locations (Vent Option 5)7) - Observe the following limitations on the location of all

vertical vent terminals (see Figure 7.7):

The top of the vent pipe must be at least 2 feet above any object located within 10 feet.• The bottom of the air inlet terminal must be at least 12” above the normal snow accumulation that can be • expected on the roof. The terminal used in V ent Option #5 has a ﬁxed distance above the storm collar of 19”. If a greater distance is needed to provide the clearance above the snow line, build a chase on the roof and mount the vertical terminal on top of the chase.

Wall thimbles8) – Concentric vent has a “zero” clearance to combustibles and therefore does not require the use of wall thimbles.

Pitch of Horizontal Piping9) - Pitch all horizontal piping so that any condensate which forms in the piping will run towards the boiler. Pitch Crown horizontal concentric venting 5/8” per foot

Supporting Pipe10) - Vertical and horizontal sections of pipe must be properly supported. Support Crown concentric venting near the female end of each straight section of pipe. Exception: Vertical runs of concentric pipe in an unused chimney (Figure 7.36) need only be supported at the terminal and at the base of the run.

Table 7.6: Summary Of Vertical Venting Options

VENT OPTION # 5 6 CLASSIFICATION USED IN THIS

MANUAL ILLUSTRATED IN FIGURE 7.7

VENT PIPE PENETRATION THROUGH STRUCTURE

VENT PIPE SIZE

INLET AIR ORIFICE SIZE MAX. VENT LENGTH MIN. VENT LENGTH

VENT TERMINAL

VERTICAL

CONCENTRIC

ROOF

80/125mm

CONCENTRIC

82mm

27ft - 10in

6in

CROWN #230532

CONCENTRIC

TERMINAL (TABLE

7.3b)

RESERVED FOR

FUTURE USE

CROWN 80/125 mm

VENT MATERIAL

VENT COMPONENTS

SHOWN IN TABLE

7.3b

Figure 7.7: Vertical Concentric Vent System (Vent Option 5)

B. Removing an Existing Boiler From a Common Chimney

Read this only if the MWC boiler is replacing an existing boiler that is being removed from a common

chimney. This section does not apply to the installation of a MWC boiler.

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. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

(a) Seal any unused openings in the common venting system. (b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion and other deﬁ ciencies which could cause an unsafe condition.

all the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close ﬁ replace dampers.

(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust

thermostat so the appliance will operate continuously.

(e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use

the ﬂ ame of a match or candle, or smoke from a cigarette, cigar, or pipe.

(f) After it has been determined that each appliance remaining connected to the common venting

system properly vents when tested as outlined above, return doors, windows, exhaust fans, ﬁ replace dampers and any other gas-burning appliances to their previous condition of use.

(g) Any improper operation of the common venting system should be corrected so the installation

conforms with the National Fuel Gas Code, ANSI Z223.1. Natural Gas and Propane Installation Code.

common venting system, the common venting system should be re sized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1.

/NFPA 54 and/or CAN/CSA B 149.1

When re-sizing any portion of the

/NFPA 54 and/or CAN/CSA B 149.1

WARNING

Never common vent a MWC boiler with other appliances.

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