Crown Boiler BWF095 Bedienungsanleitung

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

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

BWF Series

Gas-Fired Fan Assisted Hot Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

WARNING: Improper installa-

tion, 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.

This boiler requires a special

venting system. Read these

instructions carefully before

installing.

Models:

• BWF061

• BWF095

• BWF128

• BWF162

• BWF195

• BWF229

CROWN

Boiler Co

I Product Description………………………...2

II Specifications………………………………..2

III Before Installing……………………………..

IV Locating the Boiler…………………………..

V Air for Combustion and Ventilation…………5

VI Venting……………………………………….

Horizontal Vent System Design……….. 9

Vertical Vent System Design…………...14

Vent System Assembly………………….18

VII Gas Piping…………………………………25

VIII System Piping……………………………….26

IX Wiring………………………………………..31

X Start-up and Checkout………………………36

XI Service and Maintenance…………………..40

XII Troubleshooting Charts……………………..43

XIII Parts………………………………………….47

Table of Contents

I Product Description

The BWF series boiler is a cast iron gas fired boiler designed for use in forced hot water heating systems. The BWF is

intended for installations where a usable chimney is not available. The BWF is normally vented using an approved vertical or

horizontal AL29-4C stainless steel venting system, which is not included with the boiler. If a suitable chimney is available, the

BWF series can be vented into it using an optional BWF Category I Vent Kit available from Crown. The BWF requires an

adequate source of clean combustion air in the boiler room.

The BWF boiler is not designed for use in gravity or “open” heating systems. Where an adequate source of clean indoor

combustion air cannot be guaranteed, use a direct vent boiler such as the Crown CSC series.

II Specifications

BWF061EN 3 61,000 51,000 44,000 83.3 14 1/4 3.2

BWF095EN 4 95,000 78,000 68,000 83.1 17 1/2 4.0

BWF128EN 5 128,000 106,000 92,000 82.8 20 3/4 4.7

BWF162EN 6 162,000 134,000 117,000 82.5 24 5.5

BWF195EN 7 195,000 161,000 140,000 82.3 27 1/4 6.3

BWF229EN 8 229,000 189,000 164,000 82.0 30 1/2 7.0

* MODELS SHOWN ARE FOR NATURAL GAS. REPLACE "N" WITH "L" SUFFIX FOR PROPANE MODEL NUMBER (e.g. BWF061EL).

PERFORMANCE RATINGS ARE THE SAME FOR BOTH FUELS

WATER

CONTENT

(GAL.)

TABLE 1: SPECIFICATIONS

AFUE (%)

FIG. 1

DIMENSION

"A" (IN.)

D.O.E.

HEATING

CAPY.

(BTU/hr)

VENT DIA.

(IN.)

MODEL* NO.

SECTIONS

INPUT

(BTU/hr)

IBR NET

RATING

(BTU/hr)

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 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

•In Canada, installation must be in accordance with CSA B149 (Installation Code for Gas Burning Appliances and

Equipment).

•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)

2) Read Section VI to verify that the boiler can be vented in accordance with these instructions.

3) Make sure that the boiler is correctly sized:

•For heating systems employing convection radiation (baseboard or radiators) use an industry 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.

•For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.

•For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE Heating

Capacity required for the Mega-Stor or the net rating required for the heating system, whichever results in the larger

boiler.

•For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s instructions

for boiler output requirements.

4) Make sure that the boiler received is configured for the correct gas (natural or LP).

5) For installations at altitudes above 2000ft, special orifice and pressure switches may be required. Make sure that the boiler

is configured for use at the correct altitude.

IV Locating the Boiler

1) Clearances:

•Observe the minimum clearances shown below. These clearances apply to all combustible construction, as well as non-

combustible walls and doors. Also see Figure 2.

Front – 6”

Left Side – 1”

Right Side – 4”

Rear – 1”

Top – 36”

Vent Pipe – 5”

•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 both the gauge and

the limit control. Alternatively, access to the gauge and limit may be provided using a door.

2) The boiler must be installed on a hard level surface. This surface may be combustible.

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

install in a location where sources of hydrocarbons will be stored or used. Some common sources of hydrocarbons include

bleaches, fabric softeners, paints, cleaners, refrigerants, and cat boxes. Traces of these chemicals can be drawn into the

boiler, causing severe corrosion damage to the boiler and/or objectionable odors.

4) The boiler should be located so as to minimize the length of the vent system while still meeting the requirements in

Section VI.

5) Do not install this boiler over carpeting.

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 both combustion and ventilation. Provisions for combustion, ventilation, and

dilution air for gas utilization equipment must be made in accordance with local building codes, or in the 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 combustion and ventilation air supply, start by determining whether the boiler is to be installed in a

building of unusually tight construction. A building of unusually tight construction is defined by the National Fuel Gas Code

as having 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.

If the building is of unusually tight construction, see the instructions on page 6. Otherwise, follow the instructions below.

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 BWF229 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 = (229000 BTU/hr + 30000 BTU/hr) / 1000 = 259

Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3

350/259 = 1.35 Since 1.35 is less than 50, the boiler room is a confined space.

If the boiler is in an 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.

If the boiler is in a 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 (Fig 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 to the boiler

room from outdoors. See the instructions under “For Buildings of Unusually Tight Construction”

For Buildings of Unusually Tight Construction

a) 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.

b) 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.

c) Size openings and ducts as follows:

•Vertical ducts or openings directly outdoors (Fig 4, Fig 5, Fig 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. Minimum opening

size is 3 inches. Ducts must have the same cross sectional area as the openings to which they connect.

•Openings to outdoors via horizontal ducts (Fig 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. Minimum opening size is 3

inches. Ducts must have the same cross sectional area as the openings to which they connect.

•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.

VI Venting

There are three basic ways to vent the BWF boiler:

•Horizontal (“side wall”) venting using an approved AL29-4C stainless steel vent system.

•Vertical venting using an approved AL29-4C stainless steel vent system.

•Chimney venting using a masonry or “B” vent chimney and a special Category I Vent Kit available from Crown.

Table 3 summarizes these three venting options. One of the columns in Table 3 must describe the planned vent system exactly.

The following instructions describe the design and installation of Horizontal and Vertical Direct Exhaust (Category III)

systems only. Instructions for Chimney (Category I) venting are provided with the Crown Category I vent kit or are available

from Crown.

WARNING

DO NOT ATTEMPT TO VENT A BWF SERIES BOILER INTO A MASONRY OR “B”

VENT CHIMNEY WITHOUT THE CROWN CATEGORY I VENT KIT SHOWN IN

TABLE III

STRUCTURE PENETRATION WALL ROOF ROOF

MAXIMUM LENGTH:

BWF061 - BWF162 45 FT + 1 EL 39.5 FT + 2 ELS

BWF195,BWF229 (using 4" Pipe) 45 FT + 1 EL 37 FT + 2 ELS

BWF195,BWF229 (using 3" Pipe) 30 FT + 1 EL 24.5 FT + 2 ELS

MINIMUM LENGTH:

BWF061 - BWF162 2 FT + 1 EL 6 FT + 2 ELS

BWF195,BWF229 2 FT + 1 EL 6 FT + 2 ELS

NOMINAL DIA.:

BWF061 - BWF162 3" 3"

BWF195,BWF229 3" or 4" 3" or 4"

BWF061 - BWF162

BWF195,BWF229 (using 4" Pipe)

BWF195,BWF229 (using 3" Pipe) 90 ELBOW OR

TEE

CATEGORY I VENT KIT:

BWF061 - BWF128 CROWN # 650140

BWF162 - BWF229 CROWN # 650141

LISTED CHIMNEY CAP

EXHAUST TERMINAL:

90 ELBOW, TEE,

OR VH-1 TERM. BY VENT MFR.

(TABLE 6)

(*) FLEX-L-INTL STAR-34 , ZFLEX SVE SERIES III, HEAT FAB SAF-T VENT ,

PROTECH SYSTEMS FASNSEAL

NATL. FUEL GAS CODE

CLASSIFICATION CATEGORY III CATEGORY III

MATERIAL AL29-4C(*) AL29-4C(*)

TABLE 3: SUMMARY OF VENTING OPTIONS

N/A N/A

SIZE PER NATIONAL

FUEL GAS CODE

VENTING TABLES FOR

FAN ASSISTED

APPLIANCE

"B" VENT OR LINED

MASONRY CHIMNEY

(SEE N.F.G.C.)

CHIMNEY VENT

VERTICAL DIRECT

EXHAUST

HORIZONTAL

DIRECT

EXHAUST

CATEGORY I

CLASSIFICATION USED IN THIS

MANUAL

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