Number of Sections: 5
Input (MBH): 380
I=B=R Gross Output (MBH): 304
I=B=R Net Rating (MBH Water): 264
I=B=R Net Rating (MBH Steam): 228
I=B=R Net Rating (ft2 Steam): 950
Combustion Effy. (%): 80.5
Steam Water Volume to Normal Water Line (Gal): 24.51
Water Boiler Volume (Gal): 34.13
Output (BHP): 9.1
Arrangement of Steam Riser Connections, Draft Hoods, and Base Assemblies: The 32-380ECS has the same basic
conguration as that shown for the 32-475 in gure 2A of the installation manual.
32-475ECS Specications - Refer to 32-475 specications in the installation manual.
III Before Installing
Refer to installation manual. Also note that a CSD-1 compliant gas train is not available for the 32-475ECS.
IV Locating the Boiler
Refer to installation manual. Minimum required room volume for 32-380ECS is 436 ft3 (Table 2).
V. Knockdown Boiler Assembly Instructions - Refer to installation manual
VI Air for Combustion and Ventilation - Refer to installation manual
1
Page 4
VII Venting
Refer to installation manual. Vent sizing for the 32-380ECS should always be done in accordance with the National Fuel
Gas Code.
A vent damper can be installed on any 32-380ECS or 32-475ECS equipped with a 24 volt control system except for those
with tankless heaters. If a vent damper is installed, the following components are required:
• Efkal Model GVD-12 Vent Damper: Crown PN 96-038
1) Open vent damper carton and remove installation instructions. Read the instructions thoroughly before proceeding. Verify
that vent damper is same size as draft diverter outlet (12”). Unpack vent damper carefully. Do not force closed damper blade. Forcing vent damper closed may result in damaged gear train.
2) Vent damper is factory shipped having approximately ¾” diameter hole in the vent damper blade, which must be left
open even though this boiler is equipped with an intermittent ignition system.
3) Mount the vent damper on the ue collar without modication to either and secure with sheet metal screws. Make
sure screws do not interfere with damper blade operation. Vent damper blade position indicator must be visible to users.
Maintain at least 6 inches between the vent damper device and combustible construction. Also make sure that there is
adequate access to the vent damper for servicing. Figures D and F in the Wiring section show typical damper orientation.
4) Install vent connector pipe and vent ttings from vent damper outlet to chimney or gas vent. Secure with sheet metal
screws and support as required.
WARNING
Install the vent damper directly on top of the boiler so that it is servicing only the boiler.
5) See the Wiring section of this supplement for instructions on making damper electrical connections.
VIII Steam Boiler Piping and Trim Installation
Refer to installation manual. The #67 low water cut-off (LWCO) cannot be used as the primary (operating) LWCO on the
380ECS or 475ECS. Instead, a Hydrolevel CG400 is installed in tapping “G” (Figure 22). A #67 LWCO can be used as
a redundant LWCO (with or without manual reset) in tappings “E” along with the level glass. The CG400 supplied with
this boiler uses the same angeless probe, and is mounted on the boiler in the same manner, as the CG450 described in the
installation manual at the top of page 28. Install the 32-380ECS near boiler piping in accordance with that shown for the
32-475 in Figure 27a in the installation manual.
IX Water Boiler Piping
Refer to installation manual. Boilers covered by this supplement which are not equipped with a tankless heater are supplied
with a Honeywell L8148E limit control installed in Tapping “C” (Figure 29) using the 1/2” well and 1/2 x 1-1/2” bushing
supplied. Boilers equipped with a tankless heater are supplied with a Honeywell L8124E, which is installed using a 3/4”
well in the tankless heater. The L4006A shown in the installation manual is not used.
X Gas Piping - Refer to installation manual
2
Page 5
XI Control System Wiring
WARNING
All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such
Wire the boiler in accordance with the following instructions rather than those in the installation manual. Provide the boiler
with a dedicated branch circuit with a fused disconnect. The minimum rating of this circuit must be 15A. Wire the boiler
using the appropriate wiring diagram shown in Figures A-C in this supplement. In addition, note the following:
1) Steam boiler wiring is shown in Figure A. The junction box, transformer, and thermostat relay are prewired with all low
voltage wire harnesses, except the damper harness (if used).
a) Mount the junction box assembly to the side jacket panel as shown in Figure D using two #10 x 1/2” sheet metal
screws.
b) Connect the gray limit harness to terminals R and B on the L404 pressure limit.
c) Mount the blocked vent switch (BVS) to the draft hood as shown in Figure E using two #10 x 1/2” sheet metal
screws. Route the red BVS harness along the side of the boiler as shown in Figure D and connect the pair of fully
insulated quick connects to the BVS.
d) Route the other end of the BVS harness to the ignition module . Connect the fully insulted quick connect to the
“24 Volt” terminal. Connect the uninsulated connector to the “24 V Ground” piggy back terminal. Secure the BVS
harness to the jacket with the nylon clips provided as shown in Figure D.
e) If a damper is installed, remove the red jumper wire inside the junction box that is indicated by Note #2 in Figure A.
Connect the damper harness to the wiring in the junction box as shown in Figure A. Route the damper harness to the
damper as shown in Figure D, using care to make sure that it does not come in contact with the draft hood or steam
piping.
f) If a redundant LWCO and/or pressure limit are used, wire them so that they interrupt 120VAC power to the boiler.
2) Water Boiler wiring is shown in Figure B for boilers without a tankless heater and in Figure C for boilers with a tankless
heater. The blocked vent switch (BVS) wire harness is factory wired to B1 and B2 on the “aquastat” (L8148E or L8124E).
a) Mount the aquastat to the control well.
b) Mount the blocked vent switch (BVS) to the draft hood as shown in Figure E using two #10 x 1/2” sheet metal
screws. Route the red BVS harness along the side of the boiler as shown in Figure F and connect the pair of fully
insulated quick connects to the BVS.
c) Route the other end of the BVS harness to the ignition module . Connect the fully insulated quick connect to the
“24 Volt” terminal. Connect the uninsulated connector to the “24 V Ground” piggy back terminal. Secure the BVS
harness to the jacket with the nylon clips provided as shown in Figure F.
d) A vent damper cannot be used on boilers equipped with tankless heater. If a damper is installed on a boiler without
the tankless heater, remove the jumper plug inside the L8148E aquastat. Plug the 6-pole end of the damper harness
into the aquastat. Plug the 4-pole end of the harness into the damper. Route the damper harness to the damper as
shown in Figure F, using care to make sure that it does not come in contact with the draft hood.
e) If a LWCO and/or redundant temperature limit are used, wire them so that they interrupt 120VAC power to the
boiler.
3) Provide a Class II circuit between the boiler and the thermostat. Make thermostat connections to the boiler in accordance
with Figure A-C.
4) Make 120VAC connections to the boiler in accordance with Figure A-C.
CAUTION
Make sure that damper and BVS harnesses are secured so that they do not come in contact with draft hood or steam piping.
3
Page 6
“BURNER”
“BURNER”
TH
TR
+
ROBERTSHAW
7000DERHC
GAS VALVE
VENT DAMPER(NOTE 2)
NOTE 2
LESS VENT
DAMPER
2. ON BOILERS LESS VENT DAMPER, DAMPER HARNESS NOT USED. RED AND BLUE
LEADS ARE JUMPED TOGETHER USING RED JUMPER WIRE.
RD
RD
RD
ALARM
ALARM
2
(NOTE2)
2. WHEN DAMPER IS NOT USED, DAMPER HARNESS IS REPLACED WITH JUMPER PLUG.
PILOT VALVE
MAIN VALVE
TH
TR
+
ROBERTSHAW
7000DERHC
GAS VALVE
RD
RD
RD/YE
RD/YE - RED with YELLOW TRACE
RD
BL
ALARM
ALARM
RD/YE
Figure A: Steam Boiler Wiring
Figure B: Water Boiler Wiring (Less Tankless Heater)
4
Page 7
Sequence of Operation - Steam Boiler
1) When the boiler is energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damper. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will close.
On boilers equipped with Hydrolevel CG400A probe type low water cut-offs, voltage is also always applied to terminals
“1” (blue) and “2” (yellow) on the low water cut-off to power the water level sensing circuit.
2) Assuming that water is above the cut-off level, power will appear at terminal “3” on the CG400 LWCO or terminal “1”.
3) Assuming that steam pressure is below the pressure limit setting, power will appear on one side of relay contact 1R1
(Gray lead). Relay 1R is the R8225 mounted under the junction box.
4) A call for heat from the thermostat energizes relay coil 1R causing contacts 1R1 to make. Current then ows through contacts 1R1 to pin terminal “2” (orange) at the vent damper (if used) and the damper opens.
5) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin “3” (red) at the damper.
If a vent damper is not present, current ows through the red jumper indicated by Note 2 in Figure A directly to the blocked
vent switch.
6) Current passes from terminal “3” on the vent damper through the blocked vent switch. Under normal conditions, this
switch is made and voltage will therefore immediately appear across terminals “24V” and “24V (GND)” on the ignition
module.
7) Upon application of voltage across the “24V” and “24V (GND)” terminals, the ignition module will start an ignition
spark at the pilot and apply 24 volts across the pilot valve (terminals “PV” and “MV/PV”).
8) Once the pilot is established, the pilot ame will act as a diode, converting the AC current at the electrode to a half wave
DC current at the pilot’s ground strap. This DC current ows through the boiler to the “GND (BURNER)” connection on
the ignition module. For the ignition module to recognize that a pilot ame is present, the DC current owing into this terminal must be in excess of approximately 1.0 uA.
9) Once the ignition module detects the presence of a pilot ame, voltage is applied across the main valve (terminals “MV”
and “MV/PV”), opening the valve and establishing main ame.
10) The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot
depends upon the exact ignition module supplied with the boiler. For more information on module operation, consult the
ignition module instructions supplied with the boiler or the local Crown representative.
Safety Control Operation - Steam Boilers
Hydrolevel CG400A Low Water Cut-off - Interrupts burner operation if the water in the boiler drops below a safe level.
As the water drops past the cut-off point, the amber lamp on the CG400 will glow. The CG400 will interrupt power to the
burners 15 seconds after the water level drops past the cut-off point. This feature prevents short cycling of the burners due
to a bouncing water line. The burners will then remain off until 30 seconds after the water level has been raised above the
cut-off point.
The CG400 is also equipped with a feature which will shut down the burners after they have been ring for 20 minutes,
regardless of the water level status. The CG400 then keeps the burners off for 90 seconds, allowing the water level and any
foam which is present to settle. During this 90 second interval, the green LED on the CG400 will glow. If the water level is
still above the cut-off line at the end of this 90 second interval, the CG400 will restart the burners.
The vent damper will close when the low water cut-off interrupts burner operation.
Pressure Limit Control - Interrupts burner operation when the pressure in the boiler exceeds the “Cut-in” setting plus the
differential setting. The “Cut-in” setting is shown on the outside of the control and is adjusted using the screw on the top
of the control. The differential is adjusted using the white thumb wheel on the inside of the control. Burner operation is
restored when the pressure in the boiler drops to the “Cut-in” pressure.
Blocked Vent Switch - Automatically interrupts burner operation in the event of a blocked vent condition. This switch is
5
Page 8
2
HIGH LIMIT
LOW
LIMIT
HONEYWELL
L8124E
TH
TR
+
ROBERTSHAW
7000DERHC
GAS VALVE
PILOT VALVE
MAIN VALVE
RD
RD
RD/YE
RD
RD/YE
ALARM
ALARM
Figure C: Water Boiler Wiring (With Tankless Heater)
Figure D: Steam Boiler Control Installation
6
Page 9
equipped with a reset button which must be pressed to restore normal burner operation. An open blocked vent switch is
indicative of a problem with the vent system. If the blocked vent switch opens, the cause of the venting problem must be
found and corrected by a qualied gas service technician before the blocked vent switch is reset.
Sequence of Operation - Water Boiler, Less Tankless Heater
1) When the boiler is energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent
damper. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper (if
used) will close.
2) A call for heat from the thermostat energizes relay coil 1R (the relay on the L8148E), causing contacts 1R1 and 1R2 to
make. Contact 1R1 starts the circulator. Contact 1R2 sends power to the high limit.
3) Assuming that the high limit is made, current will ow to pin terminal #2 (orange) at the vent damper (if used) and the
damper will open.
4) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin #3 (red) at the damper.
This pin is connected through the damper harness to terminal “B1” on the L8148E. At this point in the operating sequence,
24 volts is present across “B1” and “B2”.
5) Under normal conditions, the blocked vent switch is made. Voltage will therefore immediately appear across the “24V”
and “24V (GND)” terminals on the ignition module.
6) Upon application of voltage across the “24V” and “24V (GND)” terminals, the ignition module will start an ignition
spark at the pilot and apply 24 volts across the pilot valve (terminals “PV” and “MV/PV”).
7) Once the pilot is established, the pilot ame will act as a diode, converting the AC current at the electrode to a half wave
DC current at the pilot’s ground strap. This DC current ows through the boiler to the “GND (BURNER)” connection on
the ignition module. For the ignition module to recognize that a pilot ame is present, the DC current owing into this terminal must be in excess of approximately 1.0 uA.
8) Once the ignition module detects the presence of a pilot ame, voltage is applied across the main valve (terminals “MV”
and “MV/PV”), opening the valve and establishing main ame.
9) The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot depends
upon the exact ignition module supplied with the boiler. For more information on module operation, consult the ignition
module instructions supplied with the boiler or the local Crown representative.
Sequence of Operation, Intermittent Ignition, With Tankless Heater
1) If the boiler water temperature is less than the low limit setting minus the differential setting, terminals “R” and “B” in
the L8124E are made through the low limit switch. The low limit switching action is SPDT with “R” being common. “R”
and “W” are therefore open whenever “R” and “B” are made. This means that while “R” and “B” are made relay coil R1 is
deenergized, regardless of whether or not there is a call for heat. The circulator will therefore not operate if the boiler water
temperature is too low to generate domestic hot water.
2) Assuming that the high limit is made, current will ow to terminal “B1” on the L8124E.
3) Under normal conditions, the blocked vent switch is made. Voltage will therefore immediately appear across the “24V”
and “24V (GND)” terminals on the ignition module.
4) Upon application of voltage across the “24V” and “24V (GND)” terminals, the ignition module will start an ignition
spark at the pilot and apply 24 volts across the pilot valve (terminals “PV” and “MV/PV”).
5) Once the pilot is established, the pilot ame will act as a diode, converting the AC current at the electrode to a half wave
DC current at the pilot’s ground strap. This DC current ows through the boiler to the “GND (BURNER)” connection on
the ignition module. For the ignition module to recognize that a pilot ame is present, the DC current owing into this terminal must be in excess of approximately 1.0 uA.
7
Page 10
Figure E: Blocked Vent Switch Installation
Figure F: Water Boiler Control Installation (Less Tankless Heater Version Shown)
8
Page 11
6) Once the ignition module detects the presence of a pilot ame, voltage is applied across the main valve (terminals “MV”
and “MV/PV”), opening the valve and establishing main ame.
7) The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot depends
upon the exact ignition module supplied with the boiler. For more information on module operation, consult the ignition
module instructions supplied with the boiler or the local Crown representative.
8) The boiler will re until the boiler water temperature is approximately equal to the low limit setting. Once the water
temperature reaches this point, “R” and “B” open and “R” and “W” make. At this point, a call for heat from the thermostat
will energize 1R, making contacts 1R1 and 1R2. Contacts 1R1 energize the circulator. Contacts 1R2 switch current from
the “hot” side of the transformer secondary to the high limit switch. If the high limit is made, current ows to terminal “B1”
and the ignition sequence is then the same as it is for a call for burner operation from the low limit (see (3) above).
Safety Control Operation - Water Boilers
High Limit - Interrupts main burner operation when the supply water temperature exceeds set point. Maximum allowable
temperature is 250°F. If the high limit opens, the vent damper will close if the damper switch is in the “automatic” position. The circulator will continue to operate as long as there is a call for heat, regardless of the status of the high limit (if
the boiler is equipped with a tankless coil, the low limit switch will prevent the circulator from operating if the boiler water
temperature is too low). Burner operation automatically resumes when the supply water temperature falls below set point.
Blocked Vent (“Spill”) Switch - Automatically interrupts main burner operation in the event that ue gas spills from
the draft diverter opening. This switch is equipped with a reset button which must be pressed to restore normal burner
operation. An open blocked vent switch is indicative of a problem with the vent system. If the blocked vent switch opens,
the cause of the venting problem must be found and corrected by a qualied gas service technician before the blocked vent
switch is reset.
XII - Start-up and Checkout - In addition to start-up procedure shown in the installation manual, also verify
that the vent damper (if installed) is in the open position when the burners are ring.
XIII Service in Maintenance - Refer to installation manual.
XIV Parts - Parts lists on following pages describe cartons and components unique to the 32-380ECS and 32-475ECS.
Refer to the installation manuals where indicated for universal parts lists.