Crown Boiler BSI138ENPZZPSU Installation guide

Brand: Crown Boiler

Model: BSI138ENPZZPSU

Category: Water heaters & boilers

Type: Installation guide

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

www.crownboiler.com

BSI Series

Gas-Fired Natural Draft Steam Boilers

INSTALLATION INSTRUCTIONS

These instructions must be afxed on or adjacent to the boiler

WARNING: Improper instal-

lation, 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.

Models:

• BSI069

• BSI103

• BSI138

• BSI172

• BSI207

• BSI241

• BSI276

• BSI311

• BSI346

• BSI380

D ESIGNED TO L EAD

9902339

FOLLOW ALL INSTRUCTIONS and warnings

printed in this manual and posted on the boiler.

INSPECT THE BOILER ANNUALLY. To keep your

boiler safe and efficient, have a service technician

follow the Service checklist near the end of this

manual.

IF YOU ARE NOT QUALIFIED to install or service

boilers, do not install or service this one.

THE BOILER MAY LEAK WATER at the end of

its useful life. Be sure to protect walls, carpets,

and valuables from water that could leak from the

boiler.

PROTECT YOUR HOME IN FREEZING

WEATHER. A power outage, safety lockout, or

component failure will prevent your boiler from

lighting. In winter, your pipes may freeze and

cause extensive property damage. Do not leave

the heating system unattended during cold weather

unless alarms or other safeguards are in place to

prevent such damage

DO NOT BLOCK AIR FLOW into or around the

boiler. Insufficient air may cause the boiler to

produce carbon monoxide or start a fire.

KEEP FLAMMABLE LIQUIDS AWAY from the

boiler, including paint, solvents, and gasoline.

The boiler may ignite the vapors from the liquids

causing explosion or fire.

KEEP CHILDREN AND PETS away from hot

surfaces of the boiler, boiler piping, and vent pipe.

CARBON MONOXIDE (CO) is an odorless, deadly

gas that may be introduced into your home by

any malfunctioning fuel-burning product or vent

system failure. Consider installing CO alarms near

bedrooms in all levels of the building to warn you

and your family of potential CO exposure.

READ THIS ENTIRE MANUAL before attempting

installation, start-up, or service. Improper

installation, adjustment, alteration, service, or

maintenance may cause serious property damage,

personal injury, or death.

DO NOT DISCONNECT PIPE FITTINGS on the

boiler or in the heating system without first verifying

that the system is cool and free of pressure and

that your clothing will protect you from a release

of hot water or steam. Do not rely solely on the

boiler’s temperature and pressure gage when

making this judgment.

USE PROPER PERSONAL PROTECTION

EQUIPMENT when servicing or working near the

boiler. Materials of construction, flue products, and

fuel contain alumina, silica, heavy metals, carbon

monoxide, nitrogen oxides, and/or other toxic or

harmful substances that can are hazardous to

health and life and that are known to the State of

California to cause cancer, birth defects, and other

reproductive harm.

INSTALL ALL GUARDS, cover plates, and

enclosures before operating the boiler.

SIZE THE BOILER PROPERLY relative to the

design heat load or, if using domestic hot water

priority, the peak hot water load, whichever

is larger. A grossly oversized boiler will cycle

excessively and this will lead to premature failure

of the boiler and its components. Our warranty

does not apply to damage from excessive cycling.

ADHERE TO ALL LOCAL CODE

REQUIREMENTS. Contact your local code

inspector prior to installation. In the absence of

a local code, adhere to the National Fuel Gas

Code ANSI Z223.1/NFPA 54 or CAN/CSA B149.1,

Natural Gas and Propane Installation Code.

ALL WIRING must comply with the National

ElectrIcal Code ANSI/NFPA 70 (in the USA) or the

Canadian Electrical Code CSA C22.1 (in Canada)

and any local regulations.

WARNINGS FOR THE HOMEOWNER

WARNINGS FOR THE INSTALLER

Table of Contents

I. Product Description .................................................... 2

II. Specications ............................................................. 3

III. BeforeInstalling ......................................................... 4

IV. LocatingtheBoiler ..................................................... 4

V. AirforCombustion&Ventilation .............................. 5

VI. Venting ....................................................................... 9

VII.GasPiping ................................................................ 12

VIII.SystemPiping.......................................................... 13

IX.IndirectWaterHeaterPiping................................... 16

X.Wiring ...................................................................... 17

XI.Start-Up&Checkout ............................................... 23

XII.Service&Maintenance ........................................... 29

XIII.Troubleshooting ...................................................... 33

XIV.Parts ........................................................................ 40

AppendixA:KnockdownBoilerAssembly......................46

I Product Description

 TheBSIseriesboilersarelowpressurecastirongasred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uegasesmustbe

availableintheboilerroom.Theseboilersarenotdesignedforuseinprocessorother“open”steamsystems

TABLE 1: BSI SPECIFICATIONS

II Specications

INPUT

(MBH) (MBH) (Sq.ft) (MBH) "A" "B" "C" "D" (Gal)

BSI069 3 69 57 179 43 81.9 12 3/4 28 40 7/16 4 5.1

BSI103 4 103 85 267 64 82.0 16 28 40 7/16 5 6.5

BSI138 5 138 113 354 85 82.0 19 1/4 28 40 7/16 6 7.9

BSI172 6 172 142 446 107 82.1 22 1/2 28 40 7/16 6 9.3

BSI207 7 207 171 533 128 82.1 25 3/4 30 40 7/16 7 10.7

BSI241 8 241 199 621 149 82.2 29 30 40 7/16 7 12.1

BSI276 9 276 227 708 170 82.2 32 1/4 30 40 7/16 8 13.5

BSI311 10 310 240 750 180 77.5* 35 1/2 30 45 7/16 8 14.9

BSI346 11 345 267 833 200 77.5* 38 3/4 30 45 7/16 9 16.3

BSI380 12 379 294 921 221 77.5* 42 30 45 7/16 9 17.7

DIMENSIONS(in.)

WATER

VOL. **

***BSI311-BSI380NotforusewithLPgas.

AHRINetRatingsarebasedonapipingandpick-upallowanceof1.333.

NATURAL OR LP GAS***

HEATING

CAPACITY

AHRINETRATING,

STEAM AFUE %

*Thermalefficiency

**Volumetonormalwaterline

BASIC

BOILER

MODEL

NUMBER

SECTIONS

FIGURE1:BSIBOILERS-GENERALCONFIGURATION

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.

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conguredforthecorrectgas(naturalorLP).TheBSI311,BSI346andBSI380may

onlybeusedwithnaturalgas.

5) Boilersinstalledataltitudesabove2000ft.requiredifferentburnersandmainburneroricethanthoseatsealevel.Make

surethattheboileriscongured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.

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difcult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oor.

3) Theboilermustbeinstalledonahardlevelsurface.

Warning

This Product Must be Installed By A Licensed Plumber Or Gas Fitter

when Installed Within The Commonwealth Of Massachusetts

4) Donotinstallthisboilerinalocationwheregasolineorotherammable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

Sufcientfreshairmustbesuppliedforcombustion,ventilationanduegasdilution.Provisionsforcombustion,ventilation

andue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uegasdilutionairsupply,startbydeterminingwhether

theboileristobeinstalledinabuildingofunusuallytightconstruction.Agooddenition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

oors,betweenwall-ceilingjoints,betweenwallpanels,atpenetrationsforplumbing,electrical,andgaslines,and

atotheropenings.

FIGURE2:BSIBOILERS-CLEARANCESTOALL

TYPESOFCOMBUSTIBLECONSTRUCTIONAND

NONCOMBUSTIBLECEILINGS,WALLS,AND

DOORS.

For Buildings of Other than Unusually Tight Construction

1) Determinewhethertheboileristobeinstalledinaconnedspace-Aconnedspaceisdened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conned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conned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connedspace.

2) UnconnedSpace-Naturalinltrationintotheboilerroomwillnormallyprovideadequateairforcombustionand

ventilationwithoutadditionallouversoropeningsintoboilerroom.

3) ConnedSpace-Providetwoopeningsintotheboilerroom,oneneartheoor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

oor(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ner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oor.

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-red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red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nerthan¼”(4x4)mesh.

FIGURE4:ALLAIRFROMOUTDOORS,   

VENTILATED CRAWL SPACE AND ATTIC

FIGURE5:ALLAIRFROMOUTDOORS, 

VIA VENTILATED ATTIC

FIGURE3:BOILERINSTALLEDINCONFINEDSPACE,

ALL AIR FROM INSIDE

FIGURE6:ALLAIRFROMOUTDOORS,USING

OPENINGS INTO BOILER ROOM

FIGURE7:ALLAIRFROMOUTDOORS,USING   

HORIZONTALDUCTSINTOBOILERROOM

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ue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ueservinganopenreplace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ush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.

14) VentdamperinstallationismandatoryonallsizesfromtheBSI069toBSI276.TheBSI311throughBSI380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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.

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exibleconduittothedamperusingaconnectornutprovided.

d) 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.

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deciencies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

replace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ve(5)minutesofmainburneroperation.Usetheame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,replace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.

FIGURE8:BSIBOILERTYPICALVENTSYSTEM   

INSTALLATION AND COMPONENTS

FIGURE9:VENTDAMPERINSTALLATIONDETAILS

RIGHT SIDE VIEW

FIGURE10:GASCONNECTIONTOBOILER

*StateofMassachusettsRequiresManual

Shut-offValvetobe“T”HandleType

VII Gas Piping

 Gaspipingtotheboilermustbesizedtodeliveradequategasfortheboilertore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.

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.

VIII System Piping

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ll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.

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oor.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.

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.

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.

FIGURE12:COMMONNEAR-BOILERPIPINGMISTAKES

FIGURE11:STEAMBOILERPIPINGFORGRAVITYRETURN

"A" "B" "C" "D"

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

BSI311 2 3 2 1 1/2

BSI346 2 3 2 1 1/2

BSI380 2 3 2 1 1/2

MINIMUM PIPE DIA. (IN NPT)BOILER

MODEL

* SECOND 2" SUPPLY RISER OPTIONAL

BOILER

FRONT

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signicant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ow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

X Wiring

1)120VoltWiring-Theboilershouldbeprovidedwithitsown15Abranchcircuitwithfuseddisconnect.All120voltcon-

nections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17):

• 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installa-

tion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

1)UsingHydrolevelVXT-24TWO-WIREfeeder-Donotalterfactoryboilerwiring.ConnectVXT-24toCG400Aasfol-

lows:

• 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fol-

lows:

• 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

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oodthesys-

tem.

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)

Feeder Wiring for Boilers Equipped with McDonnell & Miller #67 Low Water Cut-offs

Figures14aand14bshowfeederwiringforMcDonnell&Miller#101A,McDonnell&MillerWF2-U-24andHydrolevel

VXT-24feedersonboilersequippedwith#67lowwatercutoffs.Thefollowingpointsapplytoallfeederwiringto#67low

watercut-offs:

• Useaseparatetransformertopowerthefeeder.Donotusethetransformerontheboiler.

• Itisnotnecessarytotouchanyofthe24voltfactoryboilerwiringwhenconnectingafeedertoa#67equipped

boiler.

• Do NOTinstallajumperbetweenterminals2and3onthe#67lowwatercutoff.

Indirect Water Heater Wiring

Figure15showseldwiringforanindirectwaterheater.AHoneywellR845AorequivalentDPSTrelayandtransformer

isrequired.ThehighlimitdescribedinPartIXmustalsobesuppliedbytheinstaller.Acallforheatfromtheindirectwater

heaterthermostatwillenergizetherelaymakingbothsetsofcontacts.Onesetofthesecontactsthenenergizesthecirculator.

Theothersetofcontactswillmakethe“T”and“T”contactsontheburnerprimarycontrol,ringtheburner.Iftheboiler

watertemperatureexceedsthehighlimitsettingof180F,thehighlimitwillopenthe“T”-“T”circuitandtheburnerwill

shutdown.

Ifthereisacallforspaceheat,theheatingthermostatwillmakethe“T”-”T”circuitandtheboilerwillrewithoutregard

tothestatusoftheindirectwaterheater.Thelowwatercut-offandpressurelimitcontrolwillinterrupt120voltpowertothe

burnerintheeventofalowwaterorexcessivepressurecondition.

FIGURE14a:WIRINGMCDONNELL&MILLER101AORTWO-WIRE H Y D R O L E V E L  V X T- 2 4  F E E D E R 

 TOBOILEREQUIPPEDWITH#67L.W.C.O.

CAUTION

DO NOT INSTALL

JUMPERBETWEEN2&3

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Crown Boiler BSI138ENPZZPSU Installation guide

Brand: Crown Boiler

Model: BSI138ENPZZPSU

Category: Water heaters & boilers

Type: Installation guide

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Crown Boiler BSI138ENPZZPSU Installation guide

Crown Boiler BSI138ENPZZPSU Installation guide

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