Crown Boiler BSI379, BSI276, BSI138, BSI345, BSI103 User Manual
...
D E S I G N E D T O L E A D
BSI Series
Gas-Fired Natural Draft Steam Boilers
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Models:
WARNING: Improper installation,
• BSI069
• BSI103
• BSI138
• BSI172
• BSI207
• BSI241
• BSI276
• BSI310
• BSI345
• BSI379
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.
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
1
Table of Contents
I. Product Description .................................................. 1
II. Specifications ............................................................. 2
III. Before Installing ......................................................... 3
IV. Locating the Boiler ...................................................... 3
V. Air for Combustion & Ventilation .............................. 4
VI. Venting ....................................................................... 8
VII. Gas Piping ................................................................ 11
VIII. System Piping .......................................................... 12
IX. Indirect Water Heater Piping............................................15
X. Wiring ........................................................................ 16
XI. Start-Up & Checkout ............................................... 23
XII. Service & Maintenance .......................................... 31
XIII. Troubleshooting ..................................................... 34
XIV. Parts ......................................................................... 41
Appendix A: Knockdown Boiler Assembly..........................47
I Product Description
The BSI series boilers are low pressure cast iron gas fired steam boilers designed for use in closed steam heating systems.
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. These boilers are not designed for use in process or other “open” steam systems
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1
II Specifications
N
FIGURE 1: BSI BOILERS - GENERAL CONFIGURATION
TABLE 1: BSI SPECIFICATIONS
BASIC
BOILER
MODEL
BSI069S 80.0
BSI069E 81.9
BSI103S 80.0
BSI103E 82.0
BSI138S 80.3
BSI138E 82.0
BSI172S 80.6
BSI172E 82.1
BSI207S 80.9
BSI207E 82.1
BSI241S 80.0
BSI241E 82.2
BSI276S 80.3
BSI276E 82.2
BSI310S
BSI310E
BSI345S
BSI345E
BSI379S
BSI379E
*Combustion efficiency
** Volume to normal water line
NOTE: BSI345 and BSI379 not available for use with LP gas.
Suffix E = Intermittent Ignition, Suffix S = Standing Pilot. Add Suffix N for Natural Gas or Suffix L for Propane Gas to basic BSI model
number (example: BSI207SN, BSI207SL)
UMBER
OF
SECTIONS
3 428 40 7/16
4
5
6
7
8
9
10
11
12
INPUT
(MBH) (MBH) (Sq. ft) (MBH) (%) "A" "B" "C" "D" (Gal)
69
103
138
172
207
241
276
310
345
379
HEATING
CAPACITY
57
85
113
142
171
199
227
255
284
312
I=B=R NET RATING,
STEAM AFUE
179
267
354
446
533
621
708
800
892
979
43
64
85
107
128
149
170
192
214
235
82.5*
82.5*
82.5*
DIMENSIONS (in.)
12 3/4
16
19 1/4 28 40 7/16 6
22 1/2 28 40 7/16
25 3/4 30 40 7/16 7
29
32 1/4 30 40 7/16 8
35 1/2
38 3/4 30 45 7/16 9
42
28 40 7/16
30 40 7/16 7
30 45 7/16 8
30 45 7/16 9
5
6
WATER
VOL. **
5.1
6.5
7.9
9.3
10.7
12.1
13.5
14.9
16.3
17.7
3
2
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 requirements of 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-latest edition.
• 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)-latest edition.
Warning
This Product Must be Installed By A Licensed Plumber Or Gas Fitter
when Installed Within The Commonwealth Of Massachusetts
2) Make sure that a properly sized chimney is available which is in good condition. Consult the authority having jurisdiction,
Part VI of this manual, and the National Fuel Gas Code for additional information on venting requirements.
3) Make sure that the boiler is correctly sized. Use an industry accepted sizing method such as the I=B=R Installation
Guide for Residential Hydronic Heating Systems (Pub. #200) and I=B=R Heat Loss Calculation Guide (Pub. #H21 or
#H22) published by the Hydronics Institute in Berkeley Heights NJ.
4) Make sure that the boiler received is configured for the correct gas (natural or LP).
used with natural gas.
5) Boilers installed at altitudes above 2000 ft. require different burners and 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 Appendix A to assemble the boiler.
The BSI345 and BSI379 may only be
IV Locating the Boiler
1) Clearances:
• Observe the minimum clearances shown below. These clearances apply to all combustible construction, as well as
noncombustible walls, ceilings and doors. Also see Figure 2.
Front – 18”
Right Side – 18”
Left Side – 6”
Rear – 6”
Top – 17”
• 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 and access the
controls. Alternatively, access may be provided using a door
2) This boiler may be installed directly over a non-carpeted combustible floor.
3) The boiler must be installed on a hard level surface.
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3
FIGURE 2: BSI BOILERS - CLEARANCES TO ALL
TYPES OF COMBUSTIBLE CONSTRUCTION AND
NONCOMBUSTIBLE CEILINGS, WALLS, AND
DOORS.
4) 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.
5) The boiler should be located as close to the chimney as possible.
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 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 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 supply of combustion, ventilation and flue gas dilution air supply, start by determining whether the
boiler is to be installed in a building 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.
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For Buildings of Other than Unusually Tight Construction
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 BSI172EN and a water heater are to be installed in a room measuring 6 ft - 3 in x 7 ft with an 8 ft ceiling. The water heater
has an input of 30000 BTU/hr:
Total input in thousands of BTU/hr = (172000 BTU/hr + 30000 BTU/hr)/1000 = 202
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft
350/202 = 1.73. Since 1.73 is less than 50, the boiler room is a confined space.
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2) Unconfined Space - Natural infiltration into the boiler room will normally provide adequate air for combustion and
ventilation without additional louvers or openings into boiler room.
3) 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 (Figure 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 into the boiler
room from outdoors. See the instructions under “For Buildings of Unusually Tight Construction”.
For Buildings of Unusually Tight Construction
1) 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.
2) 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.
3) Size openings and ducts as follows:
• Vertical ducts or openings directly outdoors (Figure 4, Figure 5, and Figure 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 but not less
than 100 square inches. Minimum opening size is 3 inches.
• Openings to outdoors via horizontal ducts (Figure 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 but not less than 100 square inches.
Minimum opening size is 3 inches.
• 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.
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576
FIGURE 3: BOILER INSTALLED IN CONFINED SPACE,
ALL AIR FROM INSIDE
FIGURE 4: ALL AIR FROM OUTDOORS,
VENTILATED CRAWL SPACE AND ATTIC
FIGURE 5: ALL AIR FROM OUTDOORS,
VIA VENTILATED ATTIC
FIGURE 6: ALL AIR FROM OUTDOORS, USING
OPENINGS INTO BOILER ROOM
FIGURE 7: ALL AIR FROM OUTDOORS, USING
HORIZONTAL DUCTS INTO BOILER ROOM
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VI Venting
Vent installation must be in accordance with local building codes, or the local authority having jurisdiction, or the National
Fuel Gas Code, NFPA 54/ANSI Z 223.1.
A typical vent installation is illustrated by Figure 8. The components of vent installation are the vent damper (if used), vent
connector and chimney.
1) Acceptable Chimneys - The following chimneys may be used to vent BSI series boilers:
• Listed Type B or L gas vent - Install in accordance with the manufacturer’s instructions, the terms of its listing, and
applicable codes.
• Masonry Chimney - The masonry chimney must be constructed in accordance with the Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliances (NFPA 211) and lined with a clay liner or other listed lining
system. Do not vent a BSI series boiler into an unlined chimney.
2) Acceptable Vent Connectors - The following may be used for vent connectors:
• Listed type B or L Gas Vent
• Single Wall Galvanized Pipe - Use 0.018” (26 gauge or heavier). The size and location of the chimney may not permit
the use of a single wall connector in some cases. See the National Fuel Gas Code. Do not use single wall pipe for
vent connectors in attics.
• Other Vent Connectors Permitted by the National Fuel Gas Code.
3) Chimney and Vent Connector Sizing - Size the chimney and vent connector in accordance with the National Fuel Gas
Code.
4) Exterior Chimneys - An exterior chimney has one or more sides exposed to the outdoors below the roof line. There are two
conditions under which an exterior chimney may be used:
• In some very restrictive cases, BSI series boilers may be vented into an exterior ceramic lined masonry chimney. See
the National Fuel Gas Code for information on when exterior chimneys may be used.
• An exterior masonry chimney may be used if it is lined with B vent or a listed chimney lining system.
5) This boiler may be vented using a listed power venter. The power venter must be sized and installed in accordance with
the power venter manufacturer’s instructions, the terms of the power venter listing, and applicable codes. The boiler must
be electrically interlocked with the power venter to prevent boiler operation if the power venter fails to operate. Before
deciding to use a power venter, make certain that the flue gas exiting the power venter will not damage adjacent
construction or other structures. Also make certain that the power venter terminal will not be subjected to winds which
could effect power venter operation.
6) Do not connect the vent of this appliance into any portion of a mechanical vent system operating under positive
pressure.
7) Do not connect the boiler into a chimney flue serving an open fireplace or other solid fuel appliance.
8) Prior to boiler installation, inspect chimney for obstructions or other defects and correct as required. Clean chimney as
necessary.
9) Vent pipe should slope upward from draft diverter not less than one inch in four feet. No portion of vent pipe should run
downward or have sags. Vent pipe must be securely supported.
10) The vertical section of vent pipe coming off the boiler should be as tall as possible, while still maintaining the proper
clearance from the horizontal vent connector to combustibles and the proper pitch called for in (9) above.
11) Vent pipe should be installed above the bottom of the chimney to prevent blockage.
12) Vent pipe must be inserted flush with inside face of the chimney liner and the space between vent pipe and chimney
sealed tight.
13) Do not install the vent damper in any portion of the vent system which is used by appliances other than the boiler being
installed.
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14) Vent damper installation is mandatory on all sizes from the BSI069 to BSI276. The BSI310 through BSI379 may be ordered
with or without vent damper. If supplied, install vent damper (see Figure 9) as follows:
a) 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. See Figure 1. Unpack vent damper carefully. Do not force
closed damper blade. Forcing vent damper closed may result in damaged gear train and void warranty.
b) Vent damper is factory shipped having approximately ¾” diameter hole in the vent damper blade, which must be left
open for boilers equipped with standing pilot, and should be plugged on boilers with an intermittent pilot system,
using the plug supplied with the damper.
Mount the vent damper on the flue collar without modification 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.
c) The damper wire harness is shipped wired into the boiler junction box. Plug the loose end of this harness into the
damper and secure the flexible conduit to the damper using a connector nut provided.
d) Install vent connector pipe and vent fittings from vent damper outlet to chimney or gas vent. Secure with sheet metal
screws and support as required.
Removing an Existing Boiler from a Common Chimney
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 opening 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 deficiencies which could cause an unsafe condition.
c) Insofar as practical, close all building doors and windows and all doors between the space in which 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
fireplace 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 five (5) minutes of main burner operation. Use the flame 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, fireplace 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. When resizing any portion of the common venting system, the common
venting system should be resized to approach the minimum size as determined using the appropriate tables in the
National Fuel Gas Code, ANSI Z223.1.
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FIGURE 8: BSI BOILER TYPICAL VENT SYSTEM
INSTALLATION AND COMPONENTS
RIGHT SIDE VIEW
FIGURE 9: VENT DAMPER INSTALLATION DETAILS
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VII Gas Piping
Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at a line pressure
between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the
utility or Chapter 2 of the National Fuel Gas Code.
Figure 10 shows typical gas piping connection to the BSI boiler. A sediment trap must be installed upstream of all gas
controls. Install a manual shut-off valve outside the jacket and ground joint union as shown.
The boiler and its gas connection must be leak tested before placing the boiler in operation. When doing this, the boiler
and its individual shut-off must be disconnected from the rest of the system during any pressure testing of that system at
pressures in excess of 1/2 psi. When pressure testing the gas system at pressures of 1/2 psi or less, isolate the boiler from the
gas supply system by closing its individual manual shut-off valve.
FIGURE 10: GAS CONNECTION TO BOILER
*
* State of Massachusetts Requires Manual
Shut-off Valve to be “T” Handle Type
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VIII System Piping
CAUTION
• INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED
FROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERATION AND SERVICE
(CIRCULATOR REPLACEMENT, ETC.).
• OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN
CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.
General Piping Notes
Figure 11 shows recommended near boiler piping for most common types of gravity return steam systems. Additional
information on steam system design may be found in Installation Guide for Residential Hydronic Heating Systems (Pub.
#200) published by the Hydronics Institute in Berkeley Heights NJ.
One of the primary purposes of this near boiler piping is to separate tiny water droplets from the steam exiting the boiler so
that “dry” steam is sent to the system. If the near boiler piping is not correct, wet steam will enter the system and the
following problems may occur:
• Short cycling on low water
• Boiler or system Flooding
• Hammering
• Failure to heat one or more radiators
Avoid the three common piping mistakes shown in Figure 12. This applies even if the existing boiler has one of the piping
mistakes shown in Figure 12 and appears to be working. If two or more steam mains must be connected to the boiler, connect a
separate take-off for each main into the header between the riser(s) and equalizer. Also note the following points:
1) A size reduction must be made to connect the header to the equalizer. This reduction must be made in the equalizer line. Do
not make this size reduction in the horizontal header.
2) One pipe steam systems require air vents on each radiator, as well as at the end of each main. For the system to work
properly, these vents must be properly installed, sized, and be in good condition. Inspect and replace any defective vents. If
there are no vents at the ends of the mains, install them.
3) Do not attempt to manifold multiple BSIs with gravity returns.
4) For installations with condensate or boiler feed pumps, follow the pump manufacturer’s piping instructions. Such systems
generally do not require Hartford loops.
5) Do not use a check valve in place of, or in addition to, a Hartford loop on a gravity return system.
6) Pipe the fill connection from a clean source of cold water. When the water supply is from a well, make sure that a strainer is
installed in the well system.
7) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler in parallel with chiller. Use isolation
valves to prevent chilled water from entering the boiler.
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Piping Installation
1) Remove parts bag from boiler crate.
2) Install safety valve (spindle must be in vertical position) into tapping on boiler left side (see Figure 1) using the 3/4” NPT
nipples and elbow supplied.
3) Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property
damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the safety valve
discharge is not piped to a drain it must terminate at least 6 inches above the floor. The termination of the safety valve
discharge piping must be in an area where it is not likely to become plugged by debris or subjected to freezing.
DANGER
• PIPE SAFETY VALVE DISCHARGE TO A SAFE LOCATION.
• DO NOT INSTALL A VALVE IN THE SAFETY VALVE DISCHARGE LINE.
• DO NOT MOVE SAFETY VALVE FROM FACTORY LOCATION.
• DO NOT PLUG SAFETY VALVE DISCHARGE.
• DO NOT INSTALL A SAFETY VALVE WITH A SETTING GREATER THAN 15 PSI.
4) Install drain valve into tapping on boiler left side using the 2 x 3/4 bushing provided (see Figure 1).
5) Connect system supply and return to boiler. See Figure 11. The BSI069 - BSI172 require only one supply riser. Two supply
risers are required on the BSI207 and larger sizes.
6) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler in parallel with chiller. Use isolation
valves to prevent chilled water from entering the boiler.
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131514
BOI L ER
FRONT
MODEL
BSI069 * 2 1 1/2 1 1/4
BSI103 * 2 1 1/2 1 1/4
BSI138 * 2 1 1/2 1 1/4
BSI172 * 2 1 1/2 1 1/4
BSI207 2 3 1 1/2 1 1/4
BSI241 2 3 2 1 1/2
BSI276 2 3 2 1 1/2
BSI310 2 3 2 1 1/2
BSI345 2 3 2 1 1/2
BSI379 2 3 2 1 1/2
* SECOND 2" SUPPLY RI SER OPTIONAL
MINIMUM PI PE DI A. (IN NPT )BOILER
"A" "B" "C" "D"
FIGURE 11: STEAM BOILER PIPING FOR GRAVITY RETURN
WRONG - HEADER
BULLHEADED
INTO TAKE-OFF
AND EQUALIZER
WRONG - TAKE-OFF
BULLHEADED INTO
TWO MAINS
WRONG - TAKE-OFF
BETWEEN RISERS
FIGURE 12: COMMON NEAR-BOILER PIPING MISTAKES
IX Indirect Water Heater Piping
All BSI series boilers are equipped with tappings to permit the connection of a Crown Mega-Stor, or other indirect water
heater. In this type of system, hot boiler water is drawn from below the water line and passed through the heat exchanger in
the indirect water heater. This section describes boiler-side piping only. Refer to the indirect water heater instruction manual
for domestic water piping. The components in this system and their functions are as follows:
1)
Circulator - Mount the circulator as shown in Figure 13. The circulator should be located as low and as close to the boiler
as practical. Do not install valves, or other devices having a significant pressure drop, between the boiler and the circulator
inlet. All piping between the boiler and the circulator inlet should be 1”, regardless of the size of the piping required in the
rest of the system. See Figure 15 in Part X for wiring information.
2) “Y” Strainer - Install a “Y” strainer to prevent sediment from accumulating inside the indirect water heater.
3) Check Valve - Prevents gravity circulation through the indirect water heater when the boiler is responding to a call for
heat.
4) Boiler Limit Control - Use a SPST break-on-rise temperature limit control such as the Honeywell L4006A. Do not set the
limit above 180F as doing so may cause the boiler to steam when there is no call for heat. See Figure 15 for wiring
information.
5) Valves and Unions - Install shut-off valves, drain valves, and unions in locations that will facilitate maintenance of the
system. Do not install any valves between the boiler and circulator inlet.
IMPORTANT
• Some indirect water heaters may not be suitable for use with a steam boiler. Consult the water heater
manufacturer’s guidelines before installing it in this type of system.
• Boiler water temperatures and flow rates in this type of system may be considerably lower than those upon which the
water heater manufacturer’s ratings are based. This may result in substantially longer water heater recovery times.
FIGURE 13: INDIRECT WATER HEATER BOILER-SIDE PIPING
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X Wiring
WARNING
All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such
requirements, with the National Electrical Code (ANSI/NFPA 70)
1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt
connections are made inside the junction box on the left side of the boiler. Remove the transformer to gain access to this
box (also see Figures 16 through 19):
• Hot (“black”) - Wire nut to black transformer lead
• Neutral (“white”) - Wire nut to white transformer lead
• Ground (“green” or bare) - Ground screw inside junction box.
2) Thermostat Wiring - Follow thermostat manufacturer instructions. To insure proper thermostat operation, avoid installation
in areas of poor air circulation, hot spots (near any heat source or in direct sunlight), cold spots (outside walls, walls
adjacent to unheated areas, locations subject to drafts). Provide Class II circuit between thermostat and boiler. Connect
thermostat wire leads to the blue transformer lead and brown relay lead inside the junction box. Set the heat anticipator to
0.2A.
Feeder Wiring for Boilers Equipped with Hydrolevel CG400A Low Water Cut-offs
CAUTION
Do not attempt to connect a McDonnell & Miller model #101A feeder, or other feeder without a delay, to a BSI boiler
equipped with a Hydrolevel CG400 low water cutoff. Doing so could destroy the boiler transformer and/or flood the system.
1) Using Hydrolevel VXT-24 TWO-WIRE feeder - Do not alter factory boiler wiring. Connect VXT-24 to CG400A as follows:
• Connect the BLACK lead on the feeder to terminal A on the LWCO
• Connect the WHITE lead on the feeder to terminal 2 on the LWCO
2) Using Hydrolevel VXT-24 THREE-WIRE feeder - Do not alter factory boiler wiring. Connect VXT-24 to CG400A as follows:
• Connect the BLACK lead on the feeder to terminal 1 on the LWCO
• Connect the WHITE lead on the feeder to terminal 2 on the LWCO
• Connect the RED lead on the feeder to terminal A on the LWCO
3) Using McDonnell & Miller WF2-U-24 feeder - Do not alter factory boiler wiring. Connect WF2-U-24 to CG400A as follows:
• Connect terminal W on the feeder to terminal A on the LWCO
• Connect terminal N on the feeder to terminal 2 on the LWCO
• Connect terminal H on the feeder to terminal 1 on the LWCO
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