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Series 16
Gas-Fired Natural Draft Water Boilers
INSTALLATION AND OPERATING INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler.
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.
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
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Table of Contents
Related Manuals for Crown Boiler 16 Series
Summary of Contents for Crown Boiler 16 Series
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Page 1: Installation And Operating Instructions
Series 16 Gas-Fired Natural Draft Water Boilers INSTALLATION AND OPERATING INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler. 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. -
Page 3: Table Of Contents
Table of Contents Product Description ....1 Specifications ......2 III. -
Page 4: Specifications
II Specifications... -
Page 5: Before Installing
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 latest edition of the National Fuel Gas Code, ANSI Z223.13. - Page 6 All Models - The following service clearances are recommended from the top and front of the boilers: 16-325, 16-390 – 24 inches 16-455, 16-520, 16-585 – 48 inches These clearances may be reduced to those shown in Table 2, however servicing the boiler will become increas- ingly difficult as these service clearances are reduced.
- Page 7 O v e r A ll M in im u m O v e r A ll O v e r A ll He ig h t Bo ile r Bo ile r Ro o m L e n g t h De p t h Flo o r T o V o lu m e...
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Page 8: Knockdown Boiler Assembly Instructions
V Knockdown Boiler Assembly Instructions A. Prior To Assembly Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs or punctures due to mishandling. Do not use a damaged heat exchanger. All joints between sections have been factory sealed. Inspect the joints between the sections for openings due as a result of shipping and handling. - Page 9 Slide or walk the assembly into its permanent position. DO NOT DROP. The assembly must be level in both directions and supported around the entire base bottom. Shim and grout under base if necessary. 10) The flame roll-out switch has been mounted to the burner access panel at the factory. On boilers with two access panels the panel with the mounted flame roll-out switch should be located on the right.
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Page 10: Jacket Assembly
Figure 5: Installation of Combustible Flooring Base C. Jacket Assembly 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 Section VIII for system piping. 1) Align the left jacket side panel with the screw holes located on the upper flange of the left base end panel and loosely attach the left jacket side panel with two #10 x 1/2”... -
Page 11: Ignition Control & Gas Valve Installation
5) Lay the jacket top panel on top of the jacket side and rear panels. Locate the top of the rear jacket panel to the inside of the jacket top panel. Align the sides of the jacket top panel to be flush with the outside of the jacket side panels. - Page 13 Figure 7: Gas Train - Standard Build Figure 8: Gas Train - CSD-1 Build, 16-455, 16-520,& 16-585...
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Page 14: Control & Trim Installation
F. Control & Trim Installation 1) Table 4 shows the use of all tappings on Series 16 boilers. The tapping letter designations referenced are shown in Figure 4. Control and trim components are as follows: 4 x 4 Junction Box - Install the supplied junction box on the inside of right jacket side panel with two 8-32 x 1/2”... -
Page 15: Air For Combustion & Ventilation
VI 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 the National Fuel Gas Code, NFPA 54/ANSI Z223.1. - Page 16 Figure 10: Boiler Installed In Confined Space, All Air From Inside • 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.
- Page 17 Figure 11: All Air From Outdoors, Ventilated Crawl Space & Attic Figure 12: All Air From Outdoors, Via Ventilated Attic Figure 13: All Air From Outdoors, Using Openings Into Boiler Room...
- Page 18 Figure 14: All Air From Outdoors, Using Horizontal Ducts Into The Boiler Room...
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Page 19: Venting
VII Venting Vent installation must be in accordance with local building codes, or the authority having jurisdiction, or Chapters 7 and 10 of the National Fuel Gas Code, NFPA 54/ANSI Z223.1. A typical vent installation is shown in Figure 15. The components of a vent installation are the draft hood, vent damper (optional), vent connector and chimney. - Page 20 9) Series 16 boilers are supplied with an external draft hood which must be installed as shown in Figure 15 without alteration. Before installing the draft hood, verify that the model number marked on the draft hood matches that of the boiler being installed.
- Page 21 Figure 16: Blocked Vent Switch Installation Details 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, using the plug supplied with the damper.
- Page 22 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.
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Page 23: System Piping
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 WITH CONTINUOUS RETURN TEMPERATURES BELOW 120°F CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. -
Page 24: Piping For Special Situations
this low water cutoff have a manual reset function. The low water cutoff may be a float type or probe type, but must be designed for use in a hot-water system. The low water cutoff should be piped into the boiler supply just above the boiler with no intervening valves between it and the boiler. - Page 26 Figure 19: Recommended Piping for Combination Heating & Cooling (Refrigeration) System...
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Page 27: Gas Piping
IX Gas Piping 1) Gas piping to the boiler must be sized to deliver an adequate supply of gas for the boiler to fire at the nameplate input with the inlet pressure at the gas valves between the minimum and maximum valves shown on the rating plate. -
Page 28: Control System Wiring
X Control System 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) Provide the boiler with a dedicated branch circuit with a fused disconnect. The minimum rating of this circuit must be 15A. -
Page 29: Standard
5) When a call for heat is satisfied, the damper relay coil is de-energized - closing the contacts which energize the damper motor. This causes the damper to close. When the damper blade reaches the fully closed position, the damper motor is de-energized. 6) Should a power failure occur, the damper blade will stop in the position it was in when power was lost. - Page 30 Figure 21: Series 16 Standard Boiler Wiring...
- Page 31 Figure 22: Series 16 - CSD-1 Boiler Wiring...
- Page 32 Safety Control Operation Temperature Limit Control – The temperature limit control interrupts burner operation when the supply water tempera- ture exceeds the set point. Maximum allowable water temperature in a water boiler is 250F. The L4080D will reset itself when the water temperature drops below the set point less the differential (typically 15F). The circulator will continue to operate for as long as the thermostat or operating control calls for heat.
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Page 33: Start-Up & Checkout
NOTE SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS MANIFOLD AND CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS SPECIFIED IN Z21.13. XI Start-up and Checkout Use the following procedure for initial start-up of the boiler: 1) Make sure that the boiler is filled with water. - Page 34 8) Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take several tries for ignition before a flame is established. Once a flame has been established for the first time, subsequent calls for burner operation should result in a flame on the first try.
- Page 35 14) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. Both pilot burner and main burners should stop firing and the vent damper (if used) should close. Raise the thermostat back to the highest setting. The vent damper (if used) should open and the pilot burner and main burners should relight. 15) Verify high limit operation.
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Page 36: Operating Instructions
LIGHTING INSTRUCTIONS FOR BASE MODULES EQUIPPED WITH ROBERTSHAW 7000DERHC SERIES GAS VALVES FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. -
Page 37: Service & Maintenance
XII Service and Maintenance The following routine maintenance should be performed: On a continuous basis: 1) Keep the area around the boiler free and clear from combustible materials, gasoline, and other flammable vapors and liquids. 2) Keep the area around the boiler and boiler room ventilation openings clear of objects which might obstruct the flow of combustion and ventilation air. - Page 38 Heat Exchanger Cleaning Procedure 1) Turn off electrical power and gas supply to the boiler. 2) Disconnect the vent connector from the boiler. 3) Remove the blocked vent switch and the draft hood. 4) Remove the door panel and the top jacket panel. 5) Remove the burner access panels.
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Page 39: Parts
XIII PARTS The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area Crown representative or the factory at: Crown Boiler Co. Customer Service P.O. Box 14818 Philadelphia PA. 19134 (215) 535-8900 www.crownboiler.com... - Page 41 BASE / MANIFOLD ASSEMBLY QTY PER MODEL CROWN PART DESCRIPTION 16-325 16-390 16-455 16-520 16-585 BASE END PANEL 260660 16-325 260646 16-390 260647 BASE CHANNEL 16-455 260648 16-520 260649 16-585 260650 16-325 260666 16-390 260667 BASE REAR PANEL ASSEMBLY 16-455 260668 16-520 260669...
- Page 42 Figure 27: Exploded View - Base / Heat Exchanger / Flue Collector - Assembly...
- Page 43 BASE / HEAT EXCHANGER / FLUE COLLECTOR - ASSEMBLY QTY PER MODEL CROWN PART DESCRIPTION 16-325 16-390 16-455 16-520 16-585 16-325 See Figure 26 16-390 See Figure 26 BASE ASSEMBLY 16-455 See Figure 26 16-520 See Figure 26 16-585 See Figure 26 16-325 260016 16-390...
- Page 45 JACKET PANEL CARTON QTY PER MODEL CROWN PART DESCRIPTION 16-325 16-390 16-455 16-520 16-585 RIGHT SIDE JACKET PANEL 260300 LEFT SIDE JACKET PANEL 260301 16-325 260306 16-390 260307 REAR JACKET PANEL 16-455 260308 16-520 260309 16-585 260310 16-325 260386 16-390 260387 VESTIBULE PANEL 16-455...
- Page 47 CONTROL COMPONENTS CARTON QTY PER MODEL CROWN PART DESCRIPTION 16-325 16-390 16-455 16-520 16-585 IGNITION MODULE MOUNTING BRACKET 905000 IGNITION MODULE, S8610M 1011 (STD ONLY) 3505015 CONTROL CENTER R8285D5001 WITH R8222U DPST RELAY 3505555 GAS VALVE TRAIN ASSEMBLY (NAT GAS) (STD ONLY) GAS VALVE TRAIN ASSEMBLY (LP GAS) (STD ONLY) OPERATING LIMIT L4080D1218 35-3300...
- Page 48 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 PN:980416 S 1 6 - 0 6 / 0 4...