Crown Boiler 32 User Manual

D E S I G N E D T O L E A D

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. Read these instructions carefully before installing.

Series 32

Gas-Fired Natural Draft Steam or Water Boilers

INSTALLATION AND OPERA TING INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler.

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

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

Table 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 & Ventilation 19 VII. Venting 23 VIII. Steam Boiler Piping & Trim Installation 27

A. Heating System Piping 27 B. Indirect Water Heater Piping 36

IX. Water Boiler Piping 37

A. Heating System Piping 37

B. Tankless Heater Piping 42 X. Gas Piping 44 XI. Control System Wiring 45

A. Standard Steam / Water 45

B. CSD-1 Steam / Water 46 XII. Start-Up & Checkout 50 XIII. Service & Maintenance 56 XIV. Parts & Cartons Contents 58

I Product Description

The Series 32 boilers are low pressure cast iron gas fired steam or hot water boilers designed for use in commercial heating applications. These boilers are Category I draft diverter equipped appliances, which must be vented by natural draft using a lined masonry or listed metal chimney system. An adequate supply of air for combustion, ventilation and dilution of flue gases must be available in the boiler room. This boiler is intended for use with natural gas only.

The Series 32 may be used on low pressure steam heating systems or forced hot water heating systems and is intended for installation in “closed” systems only. Hot water Series 32 boilers are available with up to two optional tankless heaters for domestic hot water generation.

II Specifications

Figure 1: Base Model - General Configuration

No. & Size

Flue Outlet

Location

Top Supply

'H' 'J' 'K' 'L' 'M' 'N' 'P' 'R' 'S' 'T' 'U' 10" 12"

Drafthood Size & Location

'G'

Dia.

'F'

Dia.

'E'

Dia.

'D'

Dia.

'C'

Dia.

'B'

Dia.

Jacket

'A'

Len

Overall

Number

Boiler Model

32-475W(S)N 36 3/4 12 ----- -----18 3/827 3/16-----1

32-570W(S)N 42 1/4 10 10 ----16 5/16 ----12 15/1632 5/8----2-

32-665W(S)N 47 5/8 10 12 ----19 1/16 ----15 11/1638 1/16----11

32-760W(S)N 53 1/8 12 12 ----21 3/4 ----15 11/1643 1/2-----2

32-855W(S)N 58 1/2 12 12 ----24 7/16 ----18 3/848 15/16 -----2

32-950W(S)N 64 12 12 ----27 3/16 ----18 3/854 3/8-----2

32-1045W(S)N 69 3/8 10 12 12 - - - 19 1/16 21 3/4 - - - 15 11/16 27 3/16 32 5/8 - - - 1 2

Table 1A: Dimensional Data

32-1140W(S)N 74 7/8 12 12 12 - - - 21 3/4 21 3/4 - - - 15 11/16 32 5/8 32 5/8 - - - - 3

32-1235W(S)N 80 1/4 10 12 12 - - - 21 3/4 27 3/16 - - - 18 3/8 32 5/8 38 1/16 - - - 1 2

32-1330W(S)N 85 3/4 12 12 12 - - - 24 7/16 27 3/16 - - - 18 3/8 38 1/16 38 1/16 - - - - 3

32-1425W(S)N 91 1/8 12 12 12 - - - 27 1/4 27 3/16 - - - 18 3/8 38 1/16 43 1/2 - - - - 3

32-1520W(S)N 96 5/8 12 12 12 12 - - 21 3/4 21 3/4 21 3/4 - - 15 11/16 43 1/2 43 1/2 - - - - 4

32-1615W(S)N 102 10 12 12 12 - - 19 1/16 24 7/16 27 3/16 - - 18 3/8 32 5/8 32 5/8 27 3/16 - - 1 3

32-1710W(S)N 107 1/2 12 12 12 12 - - 21 3/4 24 7/16 27 3/16 - - 18 3/8 32 5/8 38 1/16 27 3/16 - - - 4

32-1805W(S)N 112 7/8 12 12 12 12 - - 24 7/16 27 1/4 27 3/16 - - 18 3/8 32 5/8 32 5/8 38 1/16 - - - 4

32-1900W(S)N 118 3/8 12 12 12 12 - - 27 1/4 27 1/4 27 3/16 - - 18 3/8 32 5/8 38 1/16 38 1/16 - - - 4

32-1995W(S)N 123 3/4 10 10 12 12 12 - 16 5/16 21 3/4 27 3/16 27 3/16 - 18 3/8 38 1/16 38 1/16 38 1/16 - - 2 3

32-2090W(S)N 129 1/4 12 12 12 12 12 - 21 3/4 21 3/4 24 7/16 27 3/16 - 18 3/8 32 5/8 32 5/8 27 3/16 27 3/16 - - 5

32-2185W(S)N 134 5/8 12 12 12 12 12 - 21 3/4 24 7/16 27 3/16 27 3/16 - 18 3/8 38 1/16 32 5/8 27 3/16 27 3/16 - - 5

32-2280W(S)N 140 1/8 12 12 12 12 12 - 24 7/16 27 3/16 27 3/16 27 3/16 - 18 3/8 32 5/8 32 5/8 32 5/8 32 5/8 - - 5

32-2375W(S)N 145 1/2 12 12 12 12 12 - 27 3/16 27 3/16 27 3/16 27 3/16 - 18 3/8 32 5/8 32 5/8 32 5/8 38 1/16 - - 5

32-2470W(S)N 151 10 10 12 12 12 12 16 5/16 21 3/4 27 3/16 27 3/16 27 3/16 18 3/8 32 5/8 32 5/8 38 1/16 38 1/16 - 2 4

32-2565W(S)N 156 3/8 10 12 12 12 12 12 19 1/16 24 7/16 27 3/16 27 3/16 27 3/16 18 3/8 38 1/16 32 5/8 38 1/16 38 1/16 - 1 5

32-2660W(S)N 161 7/8 12 12 12 12 12 12 21 3/4 24 7/16 27 3/16 27 3/16 27 3/16 18 3/8 32 5/8 32 5/8 32 5/8 27 3/16 27 3/16 - 6

32-2755W(S)N 167 1/4 12 12 12 12 12 12 24 7/16 27 3/16 27 3/16 27 3/16 27 3/16 18 3/8 32 5/8 32 5/8 32 5/8 32 5/8 27 3/16 - 6

32-2850W(S)N 172 3/4 12 12 12 12 12 12 27 3/16 27 3/16 27 3/16 27 3/16 27 3/16 18 3/8 32 5/8 32 5/8 32 5/8 32 5/8 32 5/8 - 6

1. All Dimensions Are Approximate.

NATURAL GAS ONLY

BASIC BOI LER

MODEL

NUMBER

SECTIONS

INPUT

HEATIN G

CAPACITY

I= B = R NET RAT IN G

Steam

Water

Combustion

Effy. %

WATER

VOL.

WATER

VOL.

(MBH) (MBH) (Sq. ft) (MBH) (MBH) (Gal) (Gal)

32-475W(S)N 6 475 380 1188 285 330 80-1/2 28.58 39.80

BHP

OUT PUT

11.4

32-570W(S)N 7 570 456 1425 342 397 80-1/2 32.65 45.47 32-665W(S)N 8 665 532 1663 399 463 80-1/2 36.72 51.14 32-760W(S)N 9 760 608 1900 456 529 80-1/2 40.79 56.81 32-855W(S)N 10 855 684 2138 513 595 80-1/2 44.86 62.48

32-950W(S)N 11 950 760 2376 570 661 80-1/2 48.93 68.15 32-1045W(S)N 12 1045 836 2613 627 727 80-1/2 53.00 73.82 32-1140W(S)N 13 1140 912 2851 684 793 80-1/2 57.07 79.49 32-1235W(S)N 14 1235 988 3088 741 859 80-1/2 61.14 85.16 32-1330W(S)N 15 1330 1064 3326 798 925 80-1/2 65.21 90.83 32-1425W(S)N 16 1425 1140 3563 855 991 80-1/2 69.28 96.50 32-1520W(S)N 17 1520 1216 3801 912 1057 80-1/2 73.35 102.17 32-1615W(S)N 18 1615 1292 4050 972 1123 80-1/2 77.42 107.84 32-1710W(S)N 19 1710 1368 4312 1035 1190 80-1/2 81.49 113.51 32-1805W(S)N 20 1805 1444 4575 1098 1256 80-1/2 85.56 119.18 32-1900W(S)N 21 1900 1520 4839 1161 1322 80-1/2 89.63 124.85 32-1995W(S)N 22 1995 1596 5102 1225 1388 80-1/2 93.70 130.52

13.6

15.9

18.2

20.4

22.7

25.0

27.2

29.5

31.8

34.1

36.3

38.6

40.9

43.1

45.4

47.7

32-2090W(S)N 23 2090 1672 5366 1288 1454 80-1/2 97.77 136.19 32-2185W(S)N 24 2185 1748 5628 1351 1520 80-1/2 101.84 141.86 32-2280W(S)N 25 2280 1824 5890 1414 1586 80-1/2 105.91 147.53 32-2375W(S)N 26 2375 1900 6143 1474 1652 80-1/2 109.98 153.20 32-2470W(S)N 27 2470 1976 6392 1534 1718 80-1/2 114.05 158.87 32-2565W(S)N 28 2565 2052 6638 1593 1784 80-1/2 118.12 164.54 32-2660W(S)N 29 2660 2128 6884 1652 1850 80-1/2 122.19 170.21 32-2755W(S)N 30 2755 2204 7130 1711 1917 80-1/2 126.26 175.88 32-2850W(S)N 31 2850 2280 7376 1770 1983 80-1/2 130.33 181.55

1. Water Volume T o tal To No rm al Water Line (St eam Boiler).

2. Water Volume T otal (Water Bo ile r ).

3. Ratings Based on 33,475 Btuh Per Boiler Horsepower

Table 1B: Specifications

49.9

52.2

54.5

56.8

59.0

61.3

63.6

65.8

68.1

Figure 2a: Series 32 Steam Boilers - Arrangement Of Steam Riser Connections, Draft Hoods And Base Assemblies

Figure 2b: Series 32 Water Boilers - Arrangement Of Water Supply Connections, Draft Hoods And Base Assemblies

III Before Installing

WARNING

All Series 32 boilers must be installed in rooms that are large in comparison with the size of the equipment and must be installed with the clearances listed in Table 2. Such a room will have a volume equal to at least 16 times the total volume of the boiler.

WARNING

This Product Must be Installed By A Licensed Plumber Or Gas Fitter when Installed Within The Commonwealth Of Massachusetts.

If This Boiler is Equipped With a Tankless Heater, Tankless Heater Piping Must be Installed by a Licensed Plumber When Boiler is Installed Within the Commonwealth of Massachusetts.

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.

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

edition of the National Fuel Gas Code, ANSI Z223.1.

• Where required by the authority having jurisdiction, this installation must conform to the latest edition of the

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

2) Make sure that a properly sized chimney is available and is in good condition. Consult the authority having jurisdiction, Part VII of this manual, and the National Fuel Gas Code for additional information on venting requirements.

3) Make sure that the boiler is correctly sized.

4) This boiler is designed and listed for use with natural gas only.

5) Boilers installed at altitudes above 2000 ft. require different main burner orifice than those at sea level. Make sure that the boiler is configured for use at the correct altitude.

6) If this boiler was received as a knockdown boiler, follow the instructions in Section V to assemble the boiler.

IV Locating the Boiler

1) Minimum required boiler room volumes are shown in Table 2. To find the volume of the boiler room calculate:

Boiler Room Volume (ft3) = Length (ft) x W idth (ft) x Height (ft)

If the height is greater than 8 ft for the room height, use 8 ft for the height in the above equation.

2) Observe the minimum clearances as shown in Table 3. These clearances apply to all combustible construction, as well as noncombustible walls, ceilings and doors. Also see Figure 3.

3) This boiler must be installed on a non-combustible floor. A concrete pad is not sufficient to protect combustible flooring.

4) The boiler must be installed on a hard level surface.

5) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or used. Do

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

Over All

Boiler

Model

32-475 36 3/4 32 1/4 46 5/8 32.0 511.7 32-570 42 1/4 32 1/4 46 5/8 36.7 587.4 32-665 47 5/8 32 1/4 46 5/8 41.4 663.1 32-760 53 1/8 32 1/4 46 5/8 46.2 738.8 32-855 58 1/2 32 1/4 46 5/8 50.9 814.5

32-950 64 32 1/4 46 5/8 55.6 890.2 32-1045 69 3/8 32 1/4 46 5/8 60.4 965.9 32-1140 74 7/8 32 1/4 46 5/8 65.1 1041.6 32-1235 80 1/4 32 1/4 46 5/8 69.8 1117.3 32-1330 85 3/4 32 1/4 46 5/8 74.6 1193.0 32-1425 91 1/8 32 1/4 46 5/8 79.3 1268.7 32-1520 96 5/8 32 1/4 46 5/8 84.0 1344.4 32-1615 102 32 1/4 46 5/8 88.8 1420.1 32-1710 107 1/2 32 1/4 46 5/8 93.5 1495.8 32-1805 112 7/8 32 1/4 46 5/8 98.2 1571.5 32-1900 118 3/8 32 1/4 46 5/8 103.0 1647.2 32-1995 123 3/4 32 1/4 46 5/8 107.7 1722.9 32-2090 129 1/4 32 1/4 46 5/8 112.4 1798.6 32-2185 134 5/8 32 1/4 46 5/8 117.1 1874.3 32-2280 140 1/8 32 1/4 46 5/8 121.9 1950.1 32-2375 145 1/2 32 1/4 46 5/8 126.6 2025.8 32-2470 151 32 1/4 46 5/8 131.3 2101.5 32-2565 156 3/8 32 1/4 46 5/8 136.1 2177.2 32-2660 161 7/8 32 1/4 46 5/8 140.8 2252.9 32-2755 167 1/4 32 1/4 46 5/8 145.5 2328.6 32-2850 172 3/4 32 1/4 46 5/8 150.3 2404.3

Over All

Length

Jacket

Over All

Depth

Jacket

Height

Floor To

Top Of Jacket

Boiler

Volume

(Ft3)

Minimum

Room

Volum e

(Ft3)

Table 2: Minimum Room Volumes Based On Sixteen Times Boiler Volume By Model Size

Figure 3: Clearances To Combustible Construction

Minimum Clearance - Jacket

To Com bustible O r Non-

C ombustible Con struction

Left Side 24" 18" (Controls) 27" 32" 42" R ight Si de 24" 18" (C ontrols) 27" 32" 42" Front 24" 36" (Cleaning-Burner Removal) -------- -------- -------R ear 24" 36" (Cleaning) -------- -------- -------Top 24" --------------------- -------- -------- --------

Service Cl earance To N on-

C ombustible Construction

C learances Required For Removal Of Tank l ess Heater

T-1 T-2 T-3

Table 3: Minimum Clearances to Combustibles

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.

V Knockdown Boiler Assembly Instructions

A. Prior To 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. Replace it with an undamaged heat exchanger section.

3) Keep the base in the shipping carton until it is time to perform the assembly. This keeps foreign material from contaminating the burners or creating other hazards. Do not use the base assembly if there are any signs of visible damage.

4) Review all of the installation requirements in this installation manual.

5) Verify that all needed components are on hand. A complete list of all sections and cartons that should be on hand, along with their contents, can be found in the Parts Section. A summary of the cartons and their contents is shown below. All boilers except the 32-475 use multiple base modules and therefore require multiple Base Cartons and Intermediate Cartons. All boilers lar ger than the 32-855 require multiple Section Joiner Cartons. Some parts, such as jacket screws and jacket mounting brackets are packed in both the Base Carton and the Base Side Panel Carton.

PACKAGE

BASE CARTON

I NTE RMEDI ATE CARTON

SE CTION JOINER CARTON

BASE SIDE PANEL CARTO N JACKET SID E PANEL CARTO N

W ATER TRIM CARTON

STEAM TRIM CARTON

BOI LER CARTON

TANKLESS H E ATER CARTO N

BAS E MOD UL E

SUMMARY OF CONTENTS

BRACKETS AND HARDW ARE F O R ATTACHI NG J ACKE T AND FL UE C O L L ECTOR FRONT , TO P, RE AR JACKE T PANEL S FLUE CO L L E CTO R PUSHNIPPLES TI E RO D HARDW ARE PUS H N IPPLE LUBRIC ANT SE CTION SEALING CO MPOUND BAS E SID E PANEL S BRACKETS AND HARDWARE FO R ATTACHI NG JACKE T AND FLUE CO L L E CTO R TO S IDES OF BOIL ER LE FT AND RI G HT S IDE JACKE T PANELS LIMI T CO NTROLS GAUGE LOW WATER CUT-OFF (CSD-1 BOILERS ONLY) TANKLESS COIL OPENING CO VER PLATES AND HARDW ARE

SSO RTE D FITTING S LIMI T CO NTROLS GAUGE LOW WATER CUT-OFFS TANKLESS COIL OPENING CO VER PLATES AND HARDW ARE

SSO RTE D FITTING S INSTA LLA TION M ANUA L USER'S M A NUA L WARRA NTY PUS H N IPPLE GAUGE RATING PLAT E S EAL AN T FOR SEALING HEAT EX CHANGE R TO BAS E POP SAFETY OR RE LIEF VALV E FI TTING S FOR MOUNTING POP SAFE TY OR REL IEF VALVE TANKLESS HEATER (IF US ED)

B. Base Assembly

1) Each base module is tested and shipped assembled.

a. All boilers are assembled using base modules with inputs of 285, 380 and 475 MBH b. The model 475 boiler requires only a single base module. All other boiler combinations require multiple

base module subassemblies. See Figure 2 for the proper order of assembly.

c. Join Base Sub-assemblies together. Use (4) 3/8”-16 x 3/4” screws, nuts and washers to attach subassemblies. (See

Figure 4)

d. Assemble the base in the location where the boiler is to be installed. Refer to Sections III and IV in this

manual for additional information on placement.

e. Once the base modules are assembled, install the base end panels. These base end panels must be installed

prior to assembling the sections.

f. The base must be level in both directions and supported under all feet. Shim and grout under base if

necessary. g. Verify that the front and sides of the base are square. h. Place cardboard covering over the top of the burners to protect them during the assembly of the boiler

sections.

Figure 4: Multiple Base Assembly

C. Section Assembly

CAUTION

Seating the nipples in accordance with the above instructions will make drawing the sections together easier and assure water tight joints.

CAUTION

Some boilers use intermediate sections with supply tappings. When these sections are used, it is critical that they are located in the correct position. When assembling the sections refer to Figure 2 to verify that they are assembled in the correct order.

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. Left end sections are identified by “LEH” cast on the section. Right end sections are identified by “REH” cast on the section.

4) Apply the Loctite 592 lubricant/sealant furnished to two nipples and the nipple ports in the left section.

5) Start each nipple by hand in the nipple port and bump carefully with a wooden block to set. As this is done, check the nipple frequently with the nipple gauge to verify that the nipple is square in the port and not cocked (see Figure 5). Continue to bump the nipple until the nipple gauge just touches the ground surface as measured in two directions 90 degrees apart.

6) Apply the “joint sealer” to all ground surfaces on the left end section.

7) Carefully join the first intermediate section with the left end section. Bump lightly to secure.

8) Install 5/8" nuts and washers on one end of each of three 9 ¾” tie rods. Install one of these tie rods in each of the three bosses in the left and intermediate section. Lubricate the other end of each of these tie rods with heavy oil or grease. Install 5/8" nuts and washers on the lubricated ends. Finger tighten.

9) Draw the two sections together slowly and evenly , tightening each tie rod a little at a time so that the sections are evenly spaced. KEEP THE NIPPLES ALIGNED WITH THE NIPPLE PORTS – DO NOT DRAW UP THE SECTIONS IF THE NIPPLES ARE COCKED. Continue drawing up the sections in this manner until the ground surfaces on each section are touching.

10) Repeat Steps (4-9) to assemble the remaining sections. After approximately five sections have been drawn together, use a pinch bar to insert the wood wedges supplied under the last intermediate section to raise it above the base. This will make it easier to assemble subsequent sections, particularly the right end section. As each section is drawn up, move the wedges under that section.

11) After all sections have been drawn up, verify that the bottom lugs on the left end section are still against the left end base panel. Using a pinch bar, remove the wood wedges and carefully lower the right end of the assembled block onto the base.

12) Install four block anchors using 3/8 x 2" cap screws, nuts and washers (Figure 6).

13) Loosen all tie rod nuts so that they are finger tight.

Figure 5: Use Of Nipple Gauge

Figure 6: Assembly Of Sections

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. Install a ball or gate valve in one of the

tappings on the top of the block and connect the other end of this valve to a drain. Install a gauge in any other convenient tapping. Plug all remaining unused tappings (See Figure 8).

b) Fill the boiler until a steady stream of water is observed going down the drain. c) Slowly close the valve until the pressure in the boiler reads between 10 and 50 psi. DO NOT EXCEED. d) Carefully examine all parts of the boiler block assembly for leaks. e) Drain the boiler and remove all plugs from tappings that will be used for connections and trim (see

Piping Sections in this manual).

16) Use the supplied Resbond sealant to seal the joint between the assembled block and the base.

17) Inspect the joints between the sections for any areas that are not flue gas tight. Seal any areas found with the remaining Resbond sealant.

Figure 7: Tankless Heater Installation

Figure 8: Testing Boiler Assembly For Leaks

D. Draft Hood Installation

1) The model 32-475 requires only one draft hood. All other boilers require multiple draft hoods. WHEN MUL-

TIPLE HOODS ARE USED THEY MUST BE ARRANGED SO THAT EACH HOOD IS OVER A CORRESPONDING SIZED BASE MODULE.

2) Use the 1" x ½” Cerablanket strips provided to seal the draft hoods to the block assembly. To do this, lay the strips along the top of the block in the locations that will be under the edges of the draft hood (see Figure 9). Overlap the Cerablanket strips at the corners.

3) Install the rear panel support brackets using #10 x ½ sheet metal screws (Figure 3).

4) On the left end section, insert a 5/8 x 4 threaded stud through the available hole in the top rear tie rod lug. Use a 5/ 8 nut and washer on each side of the lug to attach this stud, making sure that the stud is approximately centered on the lug (See Figure 10). In the same manner, install 5/8 x 4" studs on the right end section and on all intermediate sections that span the joint between base modules.

5) Place the left-most draft hood on the boiler. Insert two 5/16 x 3 carriage bolts through the holes in the lip on the front of the hood with the head of the bolts on the underside of this lip. Thread a 5/16 washer and brass wing nuts on each of these bolts. Slip the bolt heads into the pockets on the top of the intermediate sections (Figure 11). Tighten just sufficiently enough to hold the hood in place.

6) Hang a rear tie rod channel bracket on the 4" stud installed in the left end section (Figure 12a).

NOTE

Installation of the draft hoods will be easier if one person supports the rear of the hood while another installs the carriage bolts, nuts and washers.

CAUTION

Before tightening the draft hood hold-down nuts, make sure the gasketing is properly located under the draft hood. Recheck the positioning of the gaskets after tightening the nuts and make adjustments as necessary.

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. Loosely secure with a wing nut and washer (Figure 12b). Install a second rear tie rod channel bracket on the other side of the draft hood.

8) Using a plumb bob, adjust the rear tie rod channel brackets so the jacket mounting holes in the rear tie rod channel

brackets line up with the holes in the jacket rear panel support brackets on the base modules.

9) Tighten the 5/16 wing nuts on the front and back of the draft hood.

10) Repeat Steps 5-9 to install the remaining draft hoods.

Figure 9: Draft Hood Gasket Installation Figure 10: Hardware Arrangement for Rear Tie

Rod Mounting Bracket Installation

Figure 11: Front Attachment Of Draft Hood Figure 12a: Mounting Rear Tie Rod Channel

Bracket

Figure 12b: Rear Attachment Of Draft Hood

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.

D. Jacket Assembly Instructions

1) On the left and right side base panels attach the jacket side panel zee bracket and the jacket top support

bracket end angle with #10 x 1/2” sheet metal screws as shown in Figure 13.

2) Jacket top support brackets are required at the joints between base modules and at each end of the base

assembly. Attach the jacket top support brackets to the base front panel(s) with #10 x 1/2” sheet metel screws as shown in Figure 13. Also fasten the jacket top support brackets located on each end of the assembly to the jacket top support bracket end angles using #10 x 1/2” sheet metal screws.

3) Remove the appropriate knockouts from the side jacket panels.

4) Hang the left hand jacket side panel assembly in the slot of the jacket top support bracket and over the rear

brackets of the boiler assembly. Fasten the jacket side panel to the jacket side panel zee bracket, the jacket rear panel support bracket, the rear tie rod channel bracket and the jacket top support bracket using

#10 x 1/2” sheet metal screws.

5) Repeat the instructions in step 3 to install the right side panel.

6) Attach the jacket rear panel assembly(s) to the jacket rear panel support brackets and the tie rod channel

brackets using #10 x 1/2” sheet metal screws.

7) Before installing the jacket top panel(s) locate the position of any intermediate supply risers and remove the

appropriate knockouts.

8) Install the jacket top panel(s) by placing the left and right flanges of the jacket top panel(s) in the slots of the

jacket top support brackets and attach using #10 x 1/2” sheet metal screws.

9) Attach the door knobs to the removable jacket front panel(s) with 8-32 x 1/2” machine screws.

10) Hang the jacket front panel(s) over the front flange of the jacket top panel while making sure the bottom of

the door drops into the slots in the gas manifold bracket.

Figure 13: Jacket Mounting Bracket Arrangement

Figure 14: Exploded View Of Jacket Assembly

VI Air For Combustion and Ventilation

Warning

An adequate supply of combustion and ventilation air must be provided

to assure proper combustion.

Sufficient fresh air must be supplied for combustion, ventilation and flue gas dilution. Provisions for combustion, ventilation and flue gas dilution air for gas utilization equipment vented by natural draft must be made in accordance with local building codes or, in absence of such codes, in accordance with the National Fuel Gas Code, NFPA 54/ANSI Z223.1.

1) Start by determining whether the boiler is to be installed in a building of conventional construction or of unusually

tight construction. A good definition of a building of unusually tight construction is one which has all of the

following features:

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

1 perm or less with openings gasketed and sealed.

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

2) Determine the volume of the boiler room space. Rooms communicating directly with the boiler room space, in

which the fuel burning appliances are installed, through openings not furnished with doors, are considered a part of the boiler room space.

Volume (ft³) = Length (ft) x Width (ft) x 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.

3) Determine total input of all fuel burning appliances in the boiler room space. Add inputs of all fuel burning appliances

in the boiler room space and round the result to the next highest 1000 Btu per hour.

4) Determine type of boiler room space to be used. Divide Volume by Total Input (in MBH) of all fuel burning appliances

in the boiler room space. If the result is greater than or equal to 50 ft³/MBH, then it is considered an unconfined space. If the result is less than 50 ft³/MBH, then the boiler room space is considered a confined space.

A. For Buildings Not Of Unusually Tight Construction

1) Unconfined space - Fresh air infiltration through cracks and around windows and doors normally provides

adequate air for combustion and ventilation without additional louvers or openings into the boiler room.

2) Confined space - Provide two openings into the boiler room, one near the floor 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 floor. See Figure 15.

• 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 1/4” (4 x 4) mesh.

Figure 15: Boiler Installed In Confined Space, All Air From Inside

Important When determining the “free area” of an opening the blocking effects of mesh screens, grills, louvers and the like should be taken into account. Where screens are used, they must be no finer than 1/4” (4 x 4) mesh.

• 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”.

B. For Buildings Of Unusually Tight Construction

1) Provide outdoor air through two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely exchanging air with the outdoors. 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. The minimum dimension of each air opening is 3 inches. Size each opening per the following instructions:

a. Direct communication with outdoors (Figure 18) require a minimum free area of 1 square inch per 4,000 Btu per

hour input based on all fuel burning appliances in the boiler room space but not less than 100 square inches. The

minimum opening size is 3 inches.

b. Vertical ducts or Openings (Figure 16 and Figure 17) require a minimum free area of 1 square inch per 4,000 Btu

per hour input of all fuel burning appliances in the boiler room space but not less than 100 square inches. The crosssectional area of the duct shall be the same as the required free area opening. The minimum opening size is 3 inches.

c. Horizontal ducts to the outdoors (Figure 19) require a minimum free area of 1 square inch per 2,000 Btu per hour

input of all fuel burning appliances in the boiler room space but not less than 100 square inches. The cross-sectional area of the duct shall be the same as the required free area opening. The minimum opening size is 3 inches.

d. Louvers and Grilles of Ventilation Ducts - All outside openings should be screened or louvered. Louvers will

prevent the entrance of rain and snow. Louvers and grilles must be fixed in the open position. If motorized louvers are used, they must be interlocked to prevent boiler operation in the event the louvers do not fully open.

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Crown Boiler 32 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual