Crown Boiler 32-380ECS, 32-475ECS User Manual

D e s i g n e D t o L e a D

Series 32ECS

Gas-Fired Natural Draft Steam or Water Boilers

INSTALLATION SUPPLEMENT FOR:

32-380ECS
32-475ECS

EQUIPPED WITH 24 VOLT CONTROL SYSTEMS

WARNING: Improper installation,

adjustment, alteration, service or
maintenance can cause property
damage, injury, or loss of life. For
assistance or additional information,

consult a qualied installer, service

agency or the gas supplier. Read
these instructions carefully before
installing.

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

Tel: [phone] • Fax: [phone] • www.crownboiler.com

I Product Description

This supplement covers information not included in the standard Series 32 installation manual that is unique to the

following models:

32-380WNLECS, 32-475WNLECS
32-380WNTECS, 32-475WNTECS
32-380SNLECS, 32-475SNLECS

Follow the Series 32 installation instructions except where noted in this supplement.

II Specications

32-380ECS Dimensional Data (Refer to Figure 1 in Installation Manual):

Jacket Overall Length (“A”): 31 1/4”
Vent Collar Dia. (“B”): 12”
Vent Centerline (“N”): 15 5/8”
Number of Flue Outlets: 1

32-380ECS Specications:

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
conguration as that shown for the 32-475 in gure 2A of the installation manual.

32-475ECS Specications - Refer to 32-475 specications 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

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:

• Efkal Model GVD-12 Vent Damper: Crown PN 96-038

• Damper Harness (Steam Boilers): Crown PN 9601300

• Damper Harness (Water Boilers): Crown PN 9601550

To install the damper:

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 modication 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

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