Crown Boiler Phantom Multiple Boiler User manual

Series

High Efciency Gas-Fired Hot Water

Direct Vent Condensing Boilers

Multiple Boiler Installation Instructions

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

retained for future reference.

Models:

• PHNTM080

• PHNTM100

• PHNTM120

• PHNTM150

• PHNTM180

WARNING: Improper installation, adjustment, alteration,

service or maintenance can cause property damage, injury,

or loss of life. For assistance or additional information, con-

sult a qualied installer, service agency or the gas supplier.

This boiler requires a special venting system. Read these

instructions carefully before installing.

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

www.crownboiler.com

1

IMPORTANT INFORMATION - READ

CAREFULLY

The following terms are used throughout this manual to

bring attention to the presence of hazards of various risk

levels, or to important information concerning product

life.

DANGER

Indicates an imminently hazardous situation

which, if not avoided, will result in death, serious

injury or substantial property damage.

CAUTION

Indicates a potentially hazardous situation

which, if not avoided, may result in moderate or

minor injury or property damage.

WARNING

Indicates a potentially hazardous situation

which, if not avoided, could result in death,

serious injury or substantial property damage.

NOTICE

Indicates special instructions on installation,

operation, or maintenance which are important

but not related to personal injury hazards.

FOLLOW ALL INSTRUCTIONS and warnings

printed in this manual, the Installation & Operating

Instructions Manual, the owner’s manual and

posted on the boiler.

MAINTAIN THE BOILER. To keep your boiler safe

and efficient, have a service technician maintain

this boiler as specified in Part XIII of the 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, vent piping

and vent terminals.

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.

WARNINGS FOR THE HOMEOWNER

2

DANGER

Explosion Hazard. DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this

or any other appliance.

If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use

any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the

gas supplier’s instructions or if the supplier is unavailable, contact the re department.

WARNING

• Asphyxiation Hazard. This boiler requires regular maintenance and service to operate safely.

Follow the instructions contained in this manual.

• Improper installation, adjustment, alteration, service or maintenance can cause property damage,

personal injury or loss of life. Read and understand the entire manual before attempting installation,

start-up operation, or service. Installation and service must be performed only by an experienced,

skilled, and knowledgeable installer or service agency.

• This boiler must be properly vented.

• This boiler needs fresh air for safe operation and must be installed so there are provisions for

adequate combustion and ventilation air.

• Asphyxiation Hazard. The interior of the venting system must be inspected and cleaned before the

start of the heating season and should be inspected periodically throughout the heating season for

any obstructions. A clean and unobstructed venting system is necessary to allow noxious fumes

that could cause injury or loss of life to vent safely and will contribute toward maintaining the

boiler’s efciency.

• Installation is not complete unless a safety relief valve is installed into the tapping located on left

side of appliance or the supply piping. - See the Water Piping and Trim Section of this manual for

details.

• This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start

without service. If damage due to frozen pipes is a possibility, the heating system should not be

left unattended in cold weather; or appropriate safeguards and alarms should be installed on the

heating system to prevent damage if the boiler is inoperative.

• Burn Hazard. This boiler contains very hot water under high pressure. Do not unscrew any pipe

ttings nor attempt to disconnect any components of this boiler without positively assuring the

water is cool and has no pressure. Always wear protective clothing and equipment when installing,

starting up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and

temperature gauges to determine the temperature and pressure of the boiler. This boiler contains

components which become very hot when the boiler is operating. Do not touch any components

unless they are cool.

• Respiratory Hazard. Boiler materials of construction, products of combustion and the fuel contain

alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or

harmful substances which can cause death or serious injury and which are known to the state of

California to cause cancer, birth defects and other reproductive harm. Always use proper safety

clothing, respirators and equipment when servicing or working nearby the appliance.

• Failure to follow all instructions in the proper order can cause personal injury or death. Read all

instructions, including all those contained in component manufacturers manuals which are provided

with the boiler before installing, starting up, operating, maintaining or servicing.

• All cover plates, enclosures and guards must be in place at all times.

3

Table of Contents

I. Preface 4

II. Venting Multiple Boilers 4

A. Terminal Spacing 4

B. Condensate Drain Line 5

III. Gas Piping Multiple Boilers 10

IV. System Piping Multiple Boilers 11

A. General System Piping Precautions 11

V. Wiring 14

A. Multiple Boiler Wiring 14

VI. Start-up and Checkout 18

VII. Operation 18

A. General Information 18

   B.ConguringTheControl    18

C. Changing Settings 27

D. Enter Service Contact Information 27

E. Boiler Status 29

F. Staging Process 35

VIII. Service and Maintenance 35

IX. Troubleshooting 35

4

I Preface

Theseinstructionsaremeanttoprovideinformationspecictomultipleboiler(“Lead-Lag”)installationsofthefollowing

models:

• PHNTM080

• PHNTM100

• PHNTM120

• PHNTM150

• PHNTM180

ForlargerPhantommodels,refertotheinstructionsprovidedwiththatboilerforinformationonmultipleinstallations.

Boilerscoveredbytheseinstructionsapplytotheabovemodelswherethecompletemodelnumberendsin“C”(example:

PHTM180HNT1SUC).Consultthefactorybeforeattemptingmultipleboilerinstallationswheretheabovemodelshavea

different last letter.

These instructions cover only multiple boilers installations consisting solely of the above models. It is also generally

recommended that all boilers on the installation be of the same size.

II Venting Multiple Boilers

TheventandairintakesystemsmustexactlymatchoneoftheventoptionsdescribedinSectionVIIofthePhantom80-180

installation manual. Manifolding of either the vent or intake systems is prohibited.

A. Terminal Spacing

Spacingrequirementsbetweentheterminalsofadjacentboilersisasfollows:

 • HorizontalFittingTerminals(Figures2.1,2.2)–Ahorizontalspacingof36”betweenanyventterminalandany

  intaketerminalisrecommended;however,thisspacingmaybereducedto12”ifnecessary(Figure2.1).Maintaina

  minimumspacingbetweenadjacentintaketerminalsof4”asshowninFigure2.2.

 • LowProleTerminals(Figure2.3)–Maintainaminimumof12”betweentheadjacentinletandoutletopeningsas

  showninFigure2.3.

 • HorizontalIpexorDiversitechConcentricTerminals(Figure2.4)–Attheirclosestpointadjacent“bells”must

  eitherbewithin4”ofeachotherORgreaterthan24”apartasshowninFigure2.4.

 • VerticalFittingTerminals(Figure2.5)–Maintainatleast12”horizontally(centertocenter)betweentheexhaust

  terminalofoneboilerandtheintaketerminalofanotherboilerasshowninFigure2.5.

 • VerticalIpex,Diversitech,orDuraventPPsConcentricTerminals(Figure2.6)-Attheirclosestpointadjacent

  “bells”musteitherbewithin4”ofeachotherORgreaterthan24”apartasshowninFigure2.6.

WARNING

These instructions provide supplemental information. Except where specically stated, they do not replace

the instructions in the manual provided with the boiler. Failure to follow all applicable instructions could

result in property damage, personal injury, or loss of life.

WARNING

• A s p h y x i a t i o n H a z a r d . D o n o t m a n i f o l d ( “ c o m m o n v e n t ” ) a n y p o r t i o n o f m u l t i p l e b o i l e r v e n t o r i n t a k e

systems. Doing so may result in unreliable operation, boiler damage, personal injury, or loss of life.

• F a i l u r e t o m a i n t a i n t h e p r o p e r c l e a r a n c e s b e t w e e n a d j a c e n t t e r m i n a l s m a y r e s u l t i n a s p i r a t i o n

o f  u e g a s i n t o t h e c o m b u s t i o n a i r s u p p l y , r e s u l t i n g i n u n r e l i a b l e o p e r a t i o n , p r o p e r t y d a m a g e ,

personal injury, or loss of life.

5

Refertotheinstallationmanualsuppliedwiththeboilerforotherimportantterminalclearances,suchasdistanceabovenormal

snowline.

B. Condensate Drain Line

Condensate drain lines from multiple boilers may be manifolded together. Size the condensate disposal system to carry the

condensaterateperboilershowninTable2.7multipliedbythenumberofboilersinthesystem.

6

FIGURE2.1:MULTIPLEBOILERHORIZONTALCPVC/PVCDIRECTVENT

FIGURE2.2:MULTIPLEBOILERHORIZONTALCPVC/PVCDIRECTVENTALTERNATE

7

FIGURE2.3:MULTIPLEBOILERHORIZONTALVENTINGWITHLOWPROFILETERMINALS

FIGURE2.4:MULTIPLEBOILERHORIZONTALVENTINGWITHCONCENTRICVENTTERMINALS

8

FIGURE2.5:MULTIPLEBOILERVERTICALCPVC/PVCDIRECTVENT

FIGURE2.6:MULTIPLEBOILERVERTICALVENTINGWITHCONCENTRICVENTTERMINALS

9

TABLE 2.7: MAXIMUM CONDENSATE FLOW

Boiler

Model

*MaximumCondensateFlow,

GPH

PHNTM080 0.9

PHNTM100 1.1

PHNTM120 1.4

PHNTM150 1.7

PHNTM180 2.1

*Assumes100%ofwaterinfuelcondenses

10

III Gas Piping Multiple Boilers

ItisrecommendedthatthegaspipingofeachindividualboilerbeinstalledasshowninFigure3.1.Whencommongas

pipingissized,insureitwillhaveadequate capacity for the combined input of the multiple boilers being installed.

Additional gas pressure regulators may need to be installed to properly regulate inlet gas pressure at the smallest individual

boiler.FollowtheinstructionsinSectionVIIIofthePhantom080-180InstallationandOperatingInstructionsManualfor

more detail on gas piping installation and hazards.

FIGURE3.1:GASCONNECTIONTOBOILER

CAUTION

If gas pressure in the building is above 1/2 psig (3.4 kPa), an additional gas pressure regulator is required.

Using one additional regulator for multiple boilers may result in unsafe boiler operation. The additional

regulator must be able to properly regulate gas pressure at the input of the smallest boiler. If the regulator

cannot do this, two or more additional regulators are required. Consult regulator manufacturer and/or local

gas supplier for instructions and equipment ratings.

11

Table 4.1: Multiple Boiler Water Manifold Sizing

Boiler Model

Number of Boilers

2 3 4 5 6 7 8

Recommended Minimum Common Water

Manifold Size (NPT)

PHNTM080 1¼” 1½” 1½” 2” 2” 2” 2½”

PHNTM100 1¼” 1½” 2” 2” 2½” 2½” 2½”

PHNTM120 1½” 2” 2½” 3” 3” 3” 3”

PHNTM150 1½” 2” 2½” 3” 3” 3” 3”

PHNTM180 2” 2½” 2½” 3” 3½” 3½” 3½”

IV System Piping Multiple Boilers

A. General System Piping Precautions

FollowtheinstructionsinSectionIXofthePhantomSeriesInstallationandOperatingInstructionsManualforinstallation

of factory supplied piping, trim and individual near boiler piping design. See Table 4.1 and Figures 4.2 for piping recom-

mendations.

WARNING

• Failure to properly pipe boiler may result in improper operation and damage to boiler or

structure.

• Install boiler so that the gas ignition system components are protected from water (dripping,

spraying, rain, etc.) during boiler operation and service (circulator replacement, etc.).

• Oxygen contamination of boiler water will cause corrosion of iron and steel boiler

components and can lead to boiler failure. Warranty does not cover problems caused by

oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of

water.

12

FIGURE4.2:MULTIPLEBOILERPIPINGWITHINDIRECTTANKPIPING

13

FIGURE4.3:RECOMMENDED“IMMERSION”TYPEHEADERSENSORINSTALLATIONDETAIL

14

DANGER

Positively assure all electrical connections are unpowered before attempting installation or

service of electrical components or connections of the boiler or building. Lock out all electrical

boxes with padlock once power is turned off.

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 /NFPA 70). In

Canada, all wiring and grounding must be done in accordance with the Canadian Electrical

Code, Part 1 (CSA C22.1 - latest edition).

 Failure to properly wire electrical connections to the boiler may result in serious physical

harm.

 Electrical power may be supplied from more than one circuit. Make sure all power is off

before attempting any electrical work.

 Each boiler must be protected with a properly sized over-current device.

 Never jump out or make inoperative any safety or operating controls.

 The wiring diagrams contained in this manual are for reference purposes only. Each boiler

is shipped with a wiring diagram attached to the front door. Refer to this diagram and the

wiring diagram of any controls used with the boiler. Read, understand and follow all wiring

instructions supplied with the controls.

V. WIRING

A. MULTIPLE BOILER WIRING

Install over-current protection in accordance with the authority having jurisdiction or, in the absence of such requirements, follow

the National Electric Code, NFPA 70, and/or Canadian Electrical Code Part 1, CSA C22.1. Do not provide overcurrent protec-

tion greater than 15 amperes. If this single 15A circuit is insufcient for the combined load of all boilers and pumps, provide ad-

ditional 15A circuits and divide the boilers among them. Follow the instructions in Section X of the Phantom 80-180 Installation

manual with the following exceptions:

One, and only one, of the boilers must be designated as the “Master”. This boiler manages demands for heat (and sometimes

DHW). Any boiler can be designated as the Master, but eld wiring to the Master is different from that for the other boilers

(“Slaves”), so the Master must be chosen before the system is wired. Note that the “Master” boiler is not necessarily the same as

the “Lead” boiler. (i.e. the rst boiler to re upon a call for heat).

See typical eld wiring in Figure 5.1. Key points are:

1) System pump (s) must be connected to the Master. If this will result in a combined pump draw at the Master in excess of 6.3A,

use an isolation relay between the Master’s system pump terminals and the pump(s). System pump terminals on Slaves are not

used.

2) The heating thermostat is connected the “Heat T’Stat” (or Enviracom thermostat) terminals on the Master as shown. Heating

thermostat connections on the Slaves are not used.

3) If an indirect water heater is used, connect the indirect water heater thermostat to the “DHW T’Stat” terminals on the Master.

Also connect the indirect water heater pump to the “DHW Pump” terminals on the Master.

15

4)HeadersensorP/N103104-01mustbeusedinPhantomMultipleboilerapplications.Installitinthesystempipingasshownin

Figure4.2(alsoseeFig4.3forinstallationdetail).WireittotheMasterboilerasshowninFigure5.1.Observetheprecautions

againstelectricalnoisethataredescribedforsensorwiringinPartXoftheboilerinstallationmanual.

5)OutdoorSensor–Ifused,wiretotheMasterasshowninFigure5.1.

6)LWCOand/orexternallimits–Ingeneral,iflowwatercut-offsand/orexternallimitsarerequired,separateonesmustbe 

providedforeachboiler.Consulttheauthorityhavingjurisdiction.

7)MODBUSCommunicationWiring–TheMastercommunicateswiththeSlavesusingtheMODBUSconnectionsonthelow

voltagePCB.ThesimplestwaytomaketheseconnectionsisusingEthernet(PCnetwork)cables.Usethestandard“straight

through”cablesforthisandplugthemintotheModbusreceptaclesasshowninFigure5.1.

Alternatively,Modbusconnectionscanalsobemadeusingthe“A,“B”,and“-V”screwsterminalslocateddirectlyabovethe

Ethernetreceptacles.Todothis,connectall“A”,“B”,and“-V”terminalstogetherasshowninFigure5.2.

16

FIGURE5.1:TYPICALFIELDWIRINGFORMULTIPLEBOILERSYSTEM

WITHINDIRECTWATERHEATERPIPEDPERFIGURE4.2

17

FIGURE5.2:MODBUSWIRINGWITHOUTETHERNETCABLES

18

VI Start-up and Checkout

RefertoSectionXI(Start-upandCheckout)inthePhantom80-180installationmanual.Boilersarestarted,adjusted,and

inspectedasindividualboilers.TheyarethenconguredtooperateasamultipleboilersysteminSectionVIIofthismanual

(Operation).

Becausetheslaveshavenothermostatsconnectedtothem,itwillbenecessarytotemporarilyjumptheDHWThermostat

terminalsoneachslaveinordertoreitsothatitcanbecheckedout.

VII Operation

InformationinthissectionsupersedesthatinPartXII(“Operation”)ofthePhantom80-180Installationmanual.

A. General Information

ThisboilerusesthemicroprocessorbasedHoneywellR7910B“boilercontrol”tomanageallboilerfunctionsincludingame

supervisionandmodulation.Twosetpointor“target”boilersupplytemperaturesarestoredinthecontrol’smemory;onefor

spaceheating(CH)andonefordomestichotwater(DHW)production.Ifanoutdoortemperaturesensorisconnectedtothe

boiler,andenabled,thespaceheatingsupplysetpointwillautomaticallyshiftdownwardastheoutdoortemperatureincreases.

Formoreinformationonthisfeatureseethediscussiononboilerwaterresetbelow.

Thecontrolmodulatestheboilerinputbyvaryingthefanspeed.Asthefanspeedincreases,sodoestheamountofgasdrawn

intotheblower.Asaresult,afairlyconstantair-fuelratioismaintainedacrossallinputs.Thecontroldeterminestheinput

neededbylookingatbothcurrentandrecentdifferencesbetweenthesupplytemperatureandthesetpointtemperature.Asthe

supplytemperatureapproachesthesetpointtemperature,thefanwillslowdownandtheinputwilldrop.Theminimuminputis

approximately1/5ofmaximuminput.

Thisboilercontrolalsomonitorsboilerreturnanduetemperatures.Inaddition,allothersafetycontrolsareconnectedintothe

R7910B.TheR7910Busesinputsfromallofthesecontrolstoeithershutdowntheboilerwhenanunsafeconditionexistsor,in

some cases, to correct the problem.

Upto8Phantomsmaybepipedandwiredtogetherasdescribedearlierinthismanualtocreateamultipleboiler(“Lead-lag”)

system.Whenthisisdone,oneboileractsasthe“Master”.TheMasterreceivesdemandsfromloadssharedbytheboilersand

determinesringorderandrateforallboilersinthesystem.TheexactmannerinwhichthisisdoneisdescribedinPartFofthis

section.

Finally, the basic boiler control manages up to three pumps:

 • BoilerLoopPump(builtintoeachboiler)

• DHW pump

• System pump

RefertothePipingSectionforthelocationofthesepumps.

The touch screen display on this boiler has three basic functions:

 1) ToallowtheprofessionalHVACtechniciantoset-upthisboilersothatitwillworkproperlyinthesystemtowhichitis

connected.

 2) ToindicatethecurrentstatusoftheboilerandtoprovideinformationthatwillassisttheprofessionalHVACtechnicianin

  solvingproblemswiththeboilerand/orsystem.

 3) Toadvisethehomeownerifthereisaproblemrequiringprofessionalservice.

AmapofthebasicmenustructureisshowninFigure7.0.Inordertopreventunauthorizedoraccidentaladjustments,accessto

menus,whichchangesettingsandboileroperation,ispasswordprotected.Ingeneral,ifamenuisnottouchedfor255seconds,

thedisplaybacksuptothepreviousmenu.OncetheHomeScreenisreturnedto,thepasswordmustbereenteredinorderto

regainaccesstoprotectedmenus(thisfeaturepreventstheboilerfrombeingpermanentlyleftinoperationwithoutpassword

protection).

B. Conguring the Control

UsetheCongurationMenutoprovidetheboilerwithbasicinformationaboutthetypeofsystemtowhichitisconnected.Ona

newinstallationconguretheboilerrstandthengototheSettingsMenutosetparameterssuchastargetwatertemperatures.A

mapoftheCongurationMenustructureisshowninFigure7.1.Toconguretheboiler:

 1) FromtheHomeScreen(showninFigure7.0),press“MENU”toentertheMainMenu:

  a) Press“CONFIGURE”

  b) Whenpromptedforapassword,usethe“+1”keytoraisethepasswordto“014”.PressSUBMIT,thenNEXT(ifyou

   accidentlyscrollpast014,pressEXITtoreturntothemainmenuandstartover).

  c) ReviewtheWarningandpressACCEPTtocontinuetotheCongurationMenu.

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Crown Boiler Phantom Multiple Boiler User manual

Crown Boiler Phantom Multiple Boiler User manual

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