Crown Boiler BSI138 User Manual
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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,  
adjustment, alteration, service or  
maintenance can cause property  
damage, injury, or loss of life. For  
assistance or additional informa-  
tion, consult a qualified installer,  
service agency or the gas  
• BSI207  
• BSI241  
• BSI276  
• BSI310  
• BSI345  
• BSI379  
• BSI069  
• BSI103  
• BSI138  
• BSI172  
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  
II Specifications  
FIGURE1:BSIBOILERS-GENERALCONFIGURATION  
TABLE 1: BSI SPECIFICATIONS  
BASIC  
NUMBER  
OF  
SECTIONS  
HEATING  
CAPACITY  
(MBH)  
I=B=R NET RATING,  
STEAM  
WATER  
VOL. **  
(Gal)  
BOILER  
MODEL  
BSI069S  
BSI069E  
BSI103S  
BSI103E  
BSI138S  
BSI138E  
BSI172S  
BSI172E  
BSI207S  
BSI207E  
BSI241S  
BSI241E  
BSI276S  
BSI276E  
BSI310S  
BSI310E  
BSI345S  
BSI345E  
BSI379S  
BSI379E  
INPUT  
(MBH)  
AFUE  
(%)  
DIMENSIONS (in.)  
(Sq. ft)  
(MBH)  
"A"  
"B"  
"C"  
"D"  
4
80.0  
81.9  
80.0  
82.0  
80.3  
82.0  
80.6  
82.1  
80.9  
82.1  
80.0  
82.2  
80.3  
82.2  
3
4
69  
57  
179  
43  
12 3/4  
28  
40 7/16  
5.1  
6.5  
103  
138  
172  
207  
241  
276  
310  
345  
379  
85  
267  
354  
446  
533  
621  
708  
800  
892  
979  
64  
16  
28  
28  
28  
30  
30  
30  
30  
30  
30  
40 7/16  
40 7/16  
40 7/16  
40 7/16  
40 7/16  
40 7/16  
45 7/16  
45 7/16  
45 7/16  
5
6
6
7
7
8
8
9
9
5
113  
142  
171  
199  
227  
255  
284  
312  
85  
19 1/4  
22 1/2  
25 3/4  
29  
7.9  
6
107  
128  
149  
170  
192  
214  
235  
9.3  
7
10.7  
12.1  
13.5  
14.9  
16.3  
17.7  
8
9
32 1/4  
35 1/2  
38 3/4  
42  
10  
11  
12  
82.5*  
82.5*  
82.5*  
*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)  
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 ByALicensed 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). The BSI345 and BSI379 may only be  
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.  
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.  
3
FIGURE2:BSI BOILERS-CLEARANCESTOALL  
TYPESOFCOMBUSTIBLECONSTRUCTIONAND  
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.  
4
ForBuildingsofOtherthanUnusuallyTightConstruction  
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:  
TotalinputinthousandsofBTU/hr=(172000BTU/hr+30000BTU/hr)/1000=202  
Volumeofroom=6.25ftx7ftx8ft=350ft3  
350/202 = 1.73. Since 1.73 is less than 50, the boiler room is a confined space.  
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(Figure3).  
•
•
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”.  
ForBuildingsofUnusuallyTightConstruction  
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.  
5
FIGURE3:BOILERINSTALLEDINCONFINEDSPACE,  
ALL AIR FROM INSIDE  
FIGURE4: ALLAIRFROMOUTDOORS,  
VENTILATED CRAWL SPACE AND ATTIC  
FIGURE5: ALLAIRFROMOUTDOORS,  
VIA VENTILATED ATTIC  
6
FIGURE6:ALLAIRFROMOUTDOORS,USING  
OPENINGSINTOBOILERROOM  
FIGURE7:ALLAIRFROMOUTDOORS,USING  
HORIZONTAL DUCTS INTO BOILER ROOM  
7
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.  
8
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.  
RemovinganExistingBoilerfromaCommonChimney  
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  
fireplacedampers.  
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  
NationalFuelGasCode,ANSIZ223.1.  
9
FIGURE8: BSI BOILERTYPICALVENTSYSTEM  
INSTALLATION AND COMPONENTS  
RIGHT SIDE VIEW  
FIGURE 9: VENTDAMPERINSTALLATIONDETAILS  
10  
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.  
*
* State of Massachusetts Requires Manual  
Shut-offValve to be “T” Handle Type  
FIGURE10: GASCONNECTIONTOBOILER  
11  
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 INASYSTEM 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.  
12  
PipingInstallation  
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.  
13  
BOILER MINIMUM PIPE DIA. (IN NPT)  
MODEL "A"  
"B"  
2
2
2
2
3
3
3
3
"C"  
"D"  
BSI069  
BSI103  
BSI138  
BSI172  
BSI207  
BSI241  
BSI276  
BSI310  
BSI345  
BSI379  
*
*
*
*
2
2
2
2
2
2
1 1/2 1 1/4  
1 1/2 1 1/4  
1 1/2 1 1/4  
1 1/2 1 1/4  
1 1/2 1 1/4  
2
2
2
2
2
1 1/2  
1 1/2  
1 1/2  
1 1/2  
1 1/2  
3
3
* SECOND 2" SUPPLY RISER OPTIONAL  
BOILER  
FRONT  
FIGURE11: STEAMBOILERPIPINGFORGRAVITYRETURN  
WRONG -TAKE-OFF  
BETWEEN RISERS  
WRONG-HEADER  
BULLHEADED  
INTO TAKE-OFF  
AND EQUALIZER  
WRONG-TAKE-OFF  
BULLHEADED INTO  
TWO MAINS  
FIGURE 12: COMMON NEAR-BOILER PIPING MISTAKES  
14  
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: INDIRECTWATER HEATER BOILER-SIDE PIPING  
15  
X Wiring  
WARNING  
All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such  
requirements,withtheNationalElectricalCode(ANSI/NFPA70)  
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.  
FeederWiring forBoilers Equipped with Hydrolevel CG400ALow 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. ConnectVXT-24 to CG400Aas 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 CG400Aas 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  
16  
FeederWiring 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.  
IndirectWaterHeaterWiring  
Figure 15 shows field wiring for an indirect water heater. AHoneywell R845Aor 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, firing 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 fire 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.  
CAUTION  
DO NOT INSTALL  
JUMPER BETWEEN 2 & 3  
ON #67 L.W.C.O.  
FIGURE 14a:WIRING MCDONNELL& MILLER 101AORTWO-WIREHYDROLEVELVXT-24FEEDERTOBOILER  
EQUIPPED WITH #67 L.W.C.O.  
17  
CAUTION  
DO NOT INSTALL  
JUMPER BETWEEN 2 & 3  
ON #67 L.W.C.O.  
FIGURE14b:WIRINGMCDONNELL&MILLERWF2-U-24FEEDEROR THREE-WIREHYDROLEVEL  
VXT-24 FEEDER TO BOILER EQUIPPED WITH #67 L.W.C.O.  
FIGURE 15:WIRING INDIRECTWATER HEATERTO BOILER  
18  
BSI Control System – Sequence of Operation  
(Refer to Figures 16 through 19 for ladder and connection diagrams)  
Sequence of Operation, Standing Pilot  
1) When the boiler is energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent  
damper. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will  
close. On boilers equipped with Hydrolevel CG400A probe type low water cut-offs, voltage is also always applied to  
terminals “1” (blue) and “2” (yellow) on the low water cut-off to power the water level sensing circuit. On boilers equipped  
with #67 float type low water cut-offs, power is always applied to terminal “2” on the #67 LWCO.  
2) Assuming that water is above the cut-off level, power will appear at terminal “3” on the CG400 LWCO or terminal “1” on the  
#67 LWCO.  
3) Assuming that steam pressure is below the pressure limit setting, power will appear on one side of relay contact 1R1  
(Gray lead). Relay 1R is the R8225 mounted under the junction box.  
4) A call for heat from the thermostat energizes relay coil 1R causing contacts 1R1 to make. Current then flows through  
contacts 1R1 to pin terminal “2” (orange) at the vent damper and the damper opens.  
5) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin “3” (red) at the damper.  
6) Current passes from terminal “3” on the vent damper though the flame rollout and blocked vent (“spill”) switches.  
Under normal conditions, both of these switches are made and voltage will therefore immediately appear across the combi-  
nation gas control (“gas valve”) terminals “TH” and “TR”.  
7) When the boiler is first placed into operation, the pilot must be lit. The pilot heats a thermocouple which generates a small  
amount of electricity sufficient to hold open the safety shut-off valve in the combination gas control. The circuit connecting  
the thermocouple and the safety shut-off valve is self contained and completely independent of all other wiring on the boiler.  
This safety shut-off valve is upstream of the 24 volt valves in the gas control which open in response to a call for heat. If the  
pilot is not lit, the safety shut-off valve will remain closed and gas will not reach the 24 volt valves.  
8) Assuming that the pilot is established and proven by the thermocouple, the application of 24 volts across the combina-  
tion gas valve terminals energizes the redundant 24 volt solenoid valves in the combination gas control, resulting in gas  
flow through the control and burner operation.  
Sequence of Operation, Intermittent Ignition  
1) When the boiler is energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent  
damper. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will  
close. On boilers equipped with Hydrolevel CG400A probe type low water cut-offs, voltage is also always applied to  
terminals “1” (blue) and “2” (yellow) on the low water cut-off to power the water level sensing circuit. On boilers equipped  
with #67 float type low water cut-offs, power is always applied to terminal “2” on the #67 LWCO.  
2) Assuming that water is above the cut-off level, power will appear at terminal “3” on the CG400 LWCO or terminal “1” on the  
#67 LWCO.  
3) Assuming that steam pressure is below the pressure limit setting, power will appear on one side of relay contact 1R1  
(Gray lead). Relay 1R is the R8225 mounted under the junction box.  
4) A call for heat from the thermostat energizes relay coil 1R causing contacts 1R1 to make. Current then flows through  
contacts 1R1 to pin terminal “2” (orange) at the vent damper and the damper opens.  
5) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin “3” (red) at the damper.  
6) Current passes from terminal “3” on the vent damper though the flame rollout and blocked vent (“spill”) switches.  
Under normal conditions, both of these switches are made and voltage will therefore immediately appear across terminals  
“24V” and “24V (GND)” on the ignition module.  
7) Upon application of voltage across the “24V” and “24V (GND)” terminals, the ignition module will start an ignition spark  
at the pilot and apply 24 volts across the pilot valve (terminals “PV” and “MV/PV”).  
8) Once the pilot is established, the pilot flame will act as a diode, converting the AC current at the electrode to a half  
wave DC current at the pilot’s ground strap. This DC current flows through the boiler to the “GND (BURNER)” connection  
on the ignition module. For the ignition module to recognize that a pilot flame is present, the DC current flowing into this  
terminal must be in excess of approximately 1.0 uA.  
9) Once the ignition module detects the presence of a pilot flame, voltage is applied across the main valve (terminals “MV”  
and “MV/PV”), opening the valve and establishing main flame.  
10) The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot  
depends upon the exact ignition module supplied with the boiler. For more information on module operation, consult the  
ignition module instructions supplied with the boiler or the local Crown representative.  
19  
“BURNER”  
“BURNER”  
V8295A  
(BSI310-379 ONLY)  
L
N
FIGURE16: WIRINGDIAGRAM,STANDINGPILOTANDHYDROLEVELCG-400ALOWWATERCUTOFF  
VENT DAMPER (NOTE 2)  
NOTE 3  
LESS VENT  
DAMPER  
V8295A  
(BSI310-379 ONLY)  
L
N
2. VENT DAMPER REQUIRED ON BSI069 - BSI276, OPTIONAL ON BSI310 - BSI379  
3. ON BOILERS LESS VENT DAMPER, DAMPER HARNESS NOT USED. RED AND  
BLUE LEADS SHOWN ARE JUMPERED TOGETHER USING RED JUMPER WIRE  
FIGURE17: WIRINGDIAGRAM,STANDINGPILOTANDMcDONNELL&MILLERMODEL67LOWWATERCUTOFF  
20  
Safety Control Operation - Standing Pilot and Intermittent Ignition  
Hydrolevel CG400A Low Water Cut-off - Interrupts burner operation if the water in the boiler drops below a safe level. As the  
water drops past the cut-off point, the amber lamp on the CG400 will glow. The CG400 will interrupt power to the burners 15  
seconds after the water level drops past the cut-off point. This feature prevents short cycling of the burners due to a bouncing  
water line. The burners will then remain off until 30 seconds after the water level has been raised above the cut-off point.  
The CG400 is also equipped with a feature which will shut down the burners after they have been firing for 10 minutes, regardless  
of the water level status. The CG400 then keeps the burners off for 90 seconds, allowing the water level and any foam which is  
present to settle. During this 90 second interval, the green LED on the CG400 will glow. If the water level is still above the cut-off  
line at the end of this 90 second interval, the CG400 will restart the burners.  
The vent damper will close when the low water cut-off interrupts burner operation.  
McDonnell & Miller #67 Low Water Cut-off - Interrupts burner operation if the water in the boiler drops below a safe level.  
Burner operation is restored when the water level in the boiler is raised above the cut-off point.  
The vent damper will close when the low water cut-off interrupts burner operation.  
Pressure Limit Control - Interrupts burner operation when the pressure in the boiler exceeds the “Cut-in” setting plus the  
differential setting. The “Cut-in” setting is shown on the outside of the control and is adjusted using the screw on the top of the  
control. The differential is adjusted using the white thumb wheel on the inside of the control. Burner operation is restored when  
the pressure in the boiler drops to the “Cut-in” pressure.  
The vent damper will close when the pressure limit control interrupts burner operation.  
VENT DAMPER (NOTE 2)  
NOTE 3  
“BURNER”  
“BURNER”  
LESS VENT  
DAMPER  
HONEYWELL  
VR8204/VR8304  
SERIES GAS VALVES  
(BSI069 - 345)  
ROBERTSHAW  
7000DERHC  
GAS VALVE  
(BSI379)  
+
TH  
TR  
2. VENT DAMPER REQUIRED ON BSI069 - BSI276, OPTIONAL ON BSI310 - BSI379  
3. ON BOILERS LESS VENT DAMPER, DAMPER HARNESS NOT USED. RED AND BLUE  
LEADS ARE JUMPED TOGETHER USING RED JUMPER WIRE.  
FIGURE18: WIRINGDIAGRAM,INTERMITTENTIGNITIONANDHYDROLEVELCG-400ALOWWATERCUTOFF  
21  
Blocked Vent (“Spill”) Switch - Automatically interrupts burner operation in the event that flue gas spills from the draft diverter  
opening. This switch is equipped with a reset button which must be pressed to restore normal burner operation. An open blocked  
vent switch is indicative of a problem with the vent system. If the blocked vent switch opens, the cause of the venting problem  
must be found and corrected by a qualified gas service technician before the blocked vent switch is reset.  
Flame Roll-out Switch - Automatically interrupts burner operation when flames or excessive heat are present in vestibule. The flame  
roll-out switch is a single use device which must be replaced by an identical switch in order to restore normal operation. An open  
flame roll-out switch is usually indicative of a plugged heat exchanger. The cause of the flame roll-out must be found and  
corrected by a qualified gas service technician, and the switch replaced with an identical one, before the boiler is returned to  
operation.  
VENT DAMPER (NOTE 2)  
NOTE 3  
LESS VENT  
DAMPER  
HONEYWELL  
VR8204/VR8304  
SERIES GAS VALVES  
(BSI069 - 345)  
ROBERTSHAW  
7000DERHC  
GAS VALVE  
(BSI379)  
+
TH  
TR  
2. VENT DAMPER REQUIRED ON BSI069 - BSI276, OPTIONAL ON BSI310 -BSI379  
3. ON BOILERS LESS VENT DAMPER, DAMPER HARNESS IS NOT USED. RED AND  
BLUE LEADS SHOWN ARE JUMPED TOGETHER USING RED JUMPER WIRE.  
FIGURE19: WIRINGDIAGRAM,INTERMITTENTIGNITIONANDMcDONNELL&MILLERMODEL  
#67 LOW WATER CUTOFF  
22  
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 to the normal water line (28 3/4 inches above the floor or pad on which the  
boiler is installed)  
2) Check all new gas piping for leaks and purge piping sections that are filled with air. See Part 4 of the National Fuel Gas  
Code for additional information on testing and purging gas lines.  
WARNING  
•
•
NEVER USE A FLAME TO CHECK FOR GAS LEAKS.  
MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE  
MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND LIQUIDS.  
•
DAMPER MUST BE IN OPEN POSITION WHEN APPLIANCE MAIN BURNER IS OPERATING.  
3) Verify that vent system is complete and free of obstructions before attempting to fire boiler.  
4) Inspect all wiring for loose or uninsulated connections.  
5) Make sure the main burners are seated properly in the rear of burner tray and on orifices.  
6) Adjust steam pressure limit control for a cut-in pressure of 0.5 psi and a differential pressure of 1 psi.  
7) Adjust thermostat to the highest setting.  
8) Start the boiler using the appropriate lighting instructions for the gas valve on the boiler on pages 25-28.  
9) 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.  
10) Observe pilot burner flame:  
•
See Figure 20 for standing pilot. Pilot burner should produce single steady medium blue flame covering around 3/8”  
to ½” of thermocouple tip.  
•
See Figure 21 for intermittent ignition. Pilot burner produces three flames. The center one should be a steady medium  
blue flame covering around 3/8” to ½” of spark electrode/flame rod.  
12) Make sure vent damper is in open position when main burners are firing.  
13) Inspect the main burner flames visible through the observation port in burner access panel. The flame should be stable  
and mostly blue (see Figure 22). No yellow tipping should be present; however, intermittent flecks of yellow and orange in  
theflamearenormal.  
14) Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is firing. Fix  
any leaks found immediately.  
15) Run gas valve safety shutdown test:  
•
For standing pilot boiler models, disconnect the thermocouple from gas valve. Both pilot burner and main burners  
should stop firing.  
•
For intermittent ignition boiler models, with main burners firing, disconnect ignition cable from ignition module. Both  
pilot burner and main burners should stop firing.  
23  
16) Check the manifold pressure and adjust if necessary. To do this, use the following procedure:  
WARNING  
FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER-FIRING OF  
THE BOILER AND A CARBON MONOXIDE HAZARD.  
a) Connect a manometer to the inlet pressure tap on the gas valve (see Figures 23 and 24).  
b) Check the inlet pressure with all gas appliances on and off. The inlet pressure at the boiler must be within the  
following limits regardless of what combination of appliances is firing:  
Inlet Press (inches w.c.)  
NaturalGas  
5.0  
LPGas  
11.0  
Min.  
Max.  
14.0  
13.0  
If the inlet pressure falls outside of these limits, find and correct the cause of the problem before proceeding further.  
c) Connect a manometer to the manifold (outlet) pressure tap on the gas valve (see Figures 23 and 24).  
d) Read the manifold pressure. It should be set at:  
NaturalGas  
3.5  
LPGas  
10.0  
Manifold Press. (inches w.c.)  
e) If a manifold pressure adjustment is needed, make the adjustment by turning the pressure regulator (see Figures 23  
and 24) screw clockwise to raise the pressure and counter clockwise to reduce the pressure. If a manifold pressure  
adjustment is made, recheck the line pressure to be certain that it is still within acceptable limits. Replace the cover  
screw on the regulator.  
FIGURE 20: STANDINGPILOT  
BURNER FLAME  
FIGURE 21: INTERMITTENTIGNITION  
PILOT BURNER FLAME  
24  
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL  
VR8200 AND VR8300 SERIES GAS VALVES (STANDING PILOT)  
FOR YOUR SAFETY READ BEFORE OPERATING  
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. This appliance has a pilot which must be  
lighted by hand. When lighting the pilot, follow  
these instructions exactly.  
If you cannot reach your gas supplier, call  
the fire department.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
B. BEFORE LIGHTING smell all around the  
appliance area for gas. Be sure to smell next  
to the floor because some gas is heavier than  
air and will settle on the floor.  
WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
LIGHTING INSTRUCTIONS  
1. STOP! Read the safety information above on  
8. Turn Knob on gas control counterclockwise  
to “PILOT”.  
this label.  
2. Set the thermostat to lowest setting.  
3. Turn off all electric power to the appliance.  
4. Remove front access panel.  
9. Push down and hold the red reset button while  
you light pilot burner with a match.  
After about one minute, release reset button.  
Pilot should remain lit. If it goes out, turn gas  
control knob clockwise  
to OFF. To relight,  
5. Rotate the gas control knob clockwise  
to OFF.  
repeat steps 5-9.  
If button does not pop up when released, stop  
and immediately call your service technician  
or gas supplier.  
RESET BUTTON  
If the pilot will not stay lit after several tries,  
turn the gas control knob to “OFF” and call  
your service technician or gas supplier.  
GAS INLET  
GAS OUTLET  
10. After pilot remains lit when red reset button is  
released, turn gas control knob counterclockwise  
to ON.  
GAS CONTROL KNOB  
(SHOWN IN “ON” POSITION)  
GAS VALVE - TOP VIEW  
6. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas,  
go to the next step.  
11. Replace front access panel.  
12. Turn on all electric power to the appliance.  
13. Set thermostat to desired setting.  
7. Find pilot - follow metal pilot  
tube from gas control to  
PILOT  
BURNER  
THERMO-  
COUPLE  
pilot burner.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
25  
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW  
7000ERHC SERIES GAS VALVES (STANDING PILOT)  
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. This appliance has a pilot which must be  
lighted by hand. When lighting the pilot, follow  
these instructions exactly.  
If you cannot reach your gas supplier, call  
the fire department.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
B. BEFORE LIGHTING smell all around the  
appliance area for gas. Be sure to smell next  
to the floor because some gas is heavier than  
air and will settle on the floor.  
WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
LIGHTING INSTRUCTIONS  
1. STOP! Read the safety information above on  
8. Turn Knob on gas control counterclockwise  
to “PILOT”.  
this label.  
2. Set the thermostat to lowest setting.  
3. Turn off all electric power to the appliance.  
4. Remove front access panel.  
9. Push down and hold the Knob while  
you light pilot burner with a match.  
After about one minute, release reset button.  
Pilot should remain lit. If it goes out, turn gas  
control knob clockwise  
to OFF. To relight,  
5. Rotate the gas control knob clockwise  
to OFF.  
repeat steps 5-9.  
If button does not pop up when released, stop  
and immediately call your service technician  
or gas supplier.  
POSITION  
INDICATOR  
If the pilot will not stay lit after several tries,  
turn the gas control knob to “OFF” and call  
your service technician or gas supplier.  
PILOT  
O F  
F
O N  
GAS  
INLET  
10. After pilot remains lit when red reset button is  
released, turn gas control knob counterclockwise  
to ON.  
GAS CONTROL KNOB  
SHOWN IN "OFF" POSITION  
6. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas,  
go to the next step.  
11. Replace front access panel.  
12. Turn on all electric power to the appliance.  
13. Set thermostat to desired setting.  
7. Find pilot - follow metal pilot  
tube from gas control to  
PILOT  
BURNER  
THERMO-  
COUPLE  
pilot burner.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
26  
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL  
VR8204 AND VR8304 SERIES GAS VALVES (INTERMITTENT PILOT)  
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. This appliance is equipped with an ignition  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
If you cannot reach your gas supplier, call  
the fire department.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
B. BEFORE LIGHTING smell all around the  
appliance area for gas. Be sure to smell next  
to the floor because some gas is heavier than  
air and will settle on the floor.  
WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information above on  
this label.  
5. Remove front access panel.  
6. Rotate the gas control knob clockwise  
to OFF.  
2. Set the thermostat to lowest setting.  
7. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas  
go to the next step.  
3. Turn off all electric power to the appliance.  
4. This appliance is equipped with an ignition  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
8. Rotate the gas control knob counter clockwise  
to “ON”.  
GAS CONTROL KNOB  
(SHOWN IN “ON” POSITION)  
9. Replace front access panel.  
10. Turn on all electric power to the appliance.  
11. Set thermostat to desired setting.  
GAS INLET  
GAS OUTLET  
12. If the appliance will not operate, follow the  
instructions “To Turn Off Gas To Appliance” and  
call your service technician or gas supplier.  
GAS VALVE - TOP VIEW  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
27  
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW  
7000DERHC SERIES GAS VALVES (INTERMITTENT PILOT)  
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. This appliance is equipped with an ignition  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
If you cannot reach your gas supplier, call  
the fire department.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
B. BEFORE LIGHTING smell all around the  
appliance area for gas. Be sure to smell next  
to the floor because some gas is heavier than  
air and will settle on the floor.  
WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information above on  
this label.  
5. Remove front access panel.  
6. Rotate the gas control knob clockwise  
to OFF.  
2. Set the thermostat to lowest setting.  
7. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas  
go to the next step.  
3. Turn off all electric power to the appliance.  
4. This appliance is equipped with an ignition  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
8. Rotate the gas control knob counter clockwise  
to “ON”.  
POSITION  
INDICATOR  
9. Replace front access panel.  
10. Turn on all electric power to the appliance.  
11. Set thermostat to desired setting.  
F
O F  
O N  
GAS  
INLET  
12. If the appliance will not operate, follow the  
instructions “To Turn Off Gas To Appliance” and  
call your service technician or gas supplier.  
GAS CONTROL KNOB  
SHOWN IN "OFF" POSITION  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
28  
FIGURE22b:MAINBURNERFLAME-40mm  
(“HIGHALTITUDE”)BURNERS  
FIGURE22a: MAINBURNERFLAME-1”BURNERS  
17) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. For standing pilot boiler  
models, pilot burner should remain lit but the main burners should stop firing. For intermittent ignition boiler models both pilot  
burner and main burners should stop firing. Raise the thermostat back to the highest setting. The main burners (for standing  
pilot boiler models) or pilot burner and main burners (for intermittent ignition boiler models) should relight.  
18) Verify low water cutoff operation while the boiler is running. Slowly open drain valve and drain boiler until the water level  
drops below low water cutoff line. Water still should be visible in the gauge glass when the low water cutoff shuts down the  
main burners. For standing pilot boiler models, pilot burner should remain lit when the main burners stop firing. For  
intermittent ignition boiler models both pilot burner and main burners should stop firing. Make sure pressure limit, thermostat  
or other controls have not shut off the boiler. Upon test completion refill the boiler to the normal water level.  
19) Check pressure limit control operation. When steam pressure is registered on pressure gauge, lower pressure limit setting  
below gauge reading. For standing pilot boiler models, pilot burner should remain lit when the main burners stop firing. For  
intermittent ignition boiler models, both pilot burner and main burners should stop firing. Raise pressure limit setting above  
gauge reading. The main burners( for standing pilot boiler models) or pilot burner and main burners ( for intermittent ignition  
boiler models) should relight.  
20) After the boiler has operated for approximately 30 minutes, check the boiler and heating system piping for leaks. Repair any  
leaks found at once.  
21) Inspect the vent system for flue gas leaks. Repair any leaks found before leaving the boiler in operation.  
22) Replacement of a steam boiler tends to break loose accumulated scale from the system. During the first week of operation,  
blow down the #67 low water cut-off at least three times following the blow down instructions on the yellow sticker adjacent  
to the low water cut-off.  
23) After new boiler has been installed and put into continuous operation for several days, clean the boiler of oil, grease,  
sludge, and other contaminants that may have been present in existing piping. This will prevent unsteady water line and  
water carry over into supply main. The boiler boil-out should be done as follows:  
a) Turn off gas supply to boiler per the appropriate Lighting and Operating instructions on page 25 - 28.  
b) Drain water from boiler until about one inch of water is visible in gauge glass.  
c) Run a hose or temporary piping from the boiler drain valve to a location where hot water can be safely discharged.  
Drain approximately five gallons of water from the boiler and mix-in an appropriate amount of an approved boil-out  
compound. Remove safety valve and refill the boiler with prepared solution through funnel inserted into elbow under  
the safety valve. Run a hose or temporary piping from safety valve tapping to a location where hot water can be  
safelydischarged.DONOTINSTALLANYVALVESINTHISLINE.  
d) Light off the boiler per the appropriate instructions on page 25 - 28. Run boiler for several hours, boiling the water,  
without generating steam pressure. Open the water feed valve sufficiently to allow a slight overflow of water through  
the safety valve tapping drain line. Continue boiling until water coming out is clear.  
29  
FIGURE 23a: GASVALVEDETAIL-HONEYWELLVR8200ORVR8300(STANDINGPILOT)  
FIGURE 23b: GASVALVEDETAIL-ROBERTSHAW 7000ERHCANDHONEYWELLV8295(STANDINGPILOT)  
FIGURE 24a: GASVALVEDETAIL-HONEYWELLVR8204ANDVR8304 (INTERMITTENT IGNITION)  
FIGURE 24b: GASVALVEDETAIL-ROBERTSHAW 7000DERHC (INTERMITTENT IGNITION)  
30  
e) Turn off gas supply to boiler per the appropriate Lighting and Operating instructions on pages 25 - 28. Drain hot  
water from boiler through boiler drain valve to a location where hot water can be safely discharged. Refill the boiler  
to normal water line level. If water in the gauge glass does not look clear, repeat above boil-out procedure again until  
water is clears.  
f) Reinstall safety valve and related piping.  
g) Conduct pH and Alkalinity test of water in the system. The pH reading should be in 7 to 11 range.  
NOTE  
When substantial amount of make-up water is used due to lost condensate, or when make-up water is hard or corrosive,  
water treatment is required. Contact qualified water treatment company for recommended water treatment compounds  
and procedures.  
XII Service and Maintenance  
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.  
On at least a weekly basis:  
For boilers equipped with a #67 low water cut-off, blow down the low water cut-off following the instructions on the yellow  
sticker adjacent to the low water cut-off. During this blow down, the low water cutoff should shut down the burners. If it does  
not the low water cut-off should be replaced immediately.  
On an annual basis:  
1) Turn off electrical power and gas supply to the boiler  
2) Inspect the flue passages for signs of blockage. If there is any carbon in the combustion chamber or the flue passages,  
clean the heat exchanger before proceeding further. See the cleaning procedure below.  
3) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation.  
4) Remove all burners, noting the location of the pilot main burner. If burners show signs of deterioration, they should be  
replaced (some discoloration around the burner ports is normal). Clean the burners by first brushing the ports with a soft  
bristle brush and then vacuuming out any debris through the venturi opening.  
5) Inspect the pilot assembly:  
•
•
Standing Pilots - Check the thermocouple for deterioration (some discoloration of the thermocouple is normal). If any  
deterioration is present, replace the thermocouple. Inspect the pilot assembly for deposits and deterioration. Clean or  
replace the pilot assembly as necessary.  
Intermittent Pilots - Clean any deposits found on the electrode and grounding strap. The ideal gap between the  
electrode and the ground strap is 1/8”. Inspect the porcelain for cracks or other deterioration. Replace pilot assembly  
if deterioration is found.  
6) Inspect the combustion chamber insulation for deterioration.  
7) (Intermittent Pilot Boilers) - Inspect the ignition cable insulation for cracks or other deterioration. If deterioration is found,  
CAUTION  
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE  
IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING  
31  
replace cable.  
8) Reinstall burners, being careful to put the pilot main burner in its original location.  
9) Inspect all boiler wiring for loose connections or deterioration.  
10) Inspect the vent system:  
•
•
•
•
Make sure that the vent system is free of obstructions.  
Make sure that all vent system supports are intact.  
Inspect joints for signs of condensate or flue gas leakage.  
Inspect venting components for corrosion or other deterioration. Replace any defective vent components.  
11) Inspect the boiler and system for leaks.  
12) Inspect the low water cut-off:  
•
•
For Hydrolevel CG400A low water cut-offs - Remove and inspect the probe for scale and sediment buildup. Clean any  
sediment or scale from the probe with a scouring pad or steel wool. Consult the Hydrolevel CG400 manual for any  
additional maintenance information. Test the low water cut-off before placing the boiler back into service.  
For McDonnell & Miller #67 low water cut-offs - Remove and inspect switch and float mechanism. Inspect float bowl  
for mud accumulation. Clean as required. Replace the switch and float mechanism every five years or 100,000 cycles.  
Consult the McDonnell and Miller #67 manual for any additional maintenance information. Test the low water cut-off  
before placing the boiler back into service.  
13) Allow the boiler to cool to room temperature. Remove the drain valve and 2 x 3/4 bushing on the left side of the boiler. Use  
a flashlight to inspect the bottom row of pushnipples for accumulated scale or mud. If a significant amount is present, use the  
following procedure to clean the inside of the heat exchanger:  
a) Temporarily install a 1 1/4 inch or larger full port ball valve in place of the boiler drain. Temporarily pipe the outlet  
of this valve to a location where hot water and steam can be safely discharged.  
b) Make sure that this valve is closed and that the water level is at the normal water line.  
c) If a king valve is present in the steam main takeoff, close it.Alternatively, temporarily replace enough of the  
vents on the mains and/or radiators with plugs so that 2-5 psi can be developed when the boiler is fired.  
d) Fire the boiler and allow it to steam until 2-5 psi is registered on the gauge.  
e) Turn off the burners and immediately fully open the 1-1/4 valve.  
f) Allow the boiler to blow down until either the water runs clear or the water level reaches the bottom of the gauge  
glass.  
g)Allow all parts of the boiler to cool to room temperature. Drain the boiler completely and remove the 1-1/4 valve.  
h) If significant mud or scale is still present in the bottom of the boiler, repeat steps (b) through (g) until all mud or  
scale is removed.  
i) Once all mud or scale is removed, replace the 1-1/4 valve and temporary blow-down piping with the standard drain  
valve. After all parts of the boiler are at room temperature, refill the boiler to the normal water line.  
14) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas piping  
NOTE  
A large accumulation of mud or scale in the bottom of the heat exchanger is usually a sign of excessive feedwater make-up.  
Such accumulations can cause severe heat exchanger damage. If mud or scale accumulations are found:  
•
•
Make sure that all vents are in working order. Vents should not permit any passage of steam or water.  
Check all steam and return piping for leaks. Be aware that buried return piping can leak and go undetected  
during normal operation.  
32  
disturbed during the inspection process for leaks.  
Heat Exchanger Cleaning Procedure  
1) Turn off electrical power and gas supply to the boiler  
2) Disconnect the damper and vent connector from the boiler.  
3) Remove the upper front and top jacket panels. If possible, remove the rear and left side jacket panels  
4) Remove the burners.  
5) Remove the blocked vent (“spill”) switch  
6) Remove the ¼-20 nuts and washers holding the flue collector onto the heat exchanger.  
7) Carefully remove the flue collector gasket strips and set them aside.  
8) Remove the flue collector from the heat exchanger.  
9) Clean the flue passageways using a stiff bristle brush. Be certain that all foreign material is removed from the gaps  
between the pins  
10) Clean the bottom surfaces of the heat exchanger  
11) Put a light in the combustion chamber and look through the flue passages from the top to verify that they have been  
thoroughly cleaned.  
12) Replace the flue collector gasket strips. If desired, RTV silicone sealant with a 500F intermittent duty temperature may be  
substituted for this rope gasket. The flue collector must be thoroughly sealed to the heat exchanger.  
13) Replace the ¼-20 nuts and washers that hold down the flue collector  
14) Reattach all the jacket components.  
15) Reinstall burners, being careful to put the pilot main burner in its original location.  
WARNING  
SOOT DEPOSITS IN THE FLUE PASSAGES ARE A SIGN THAT THE BOILER MAY BE OPERATING AT HIGH  
CARBON MONOXIDE (CO) LEVELS. AFTER CLEANING THE BOILER OF SOOT DEPOSITS, CHECK THE CO  
LEVEL IN THE FLUE GAS TO INSURE THAT THE BOILER IS OPERATING PROPERLY.  
If it is necessary to check CO, use a combustion analyzer, or other instrument which is designed to measure CO in flue gas.  
A CO “sniffer” designed for testing CO levels in ambient air cannot be used to check boiler combustion. Take a flue gas  
sample by inserting a sample probe through the draft diverter opening and into the flue collector so that the sample is taken  
in the area directly over the heat exchanger. Do not take a sample until the boiler has been firing for at least five minutes.  
Anormal CO reading for a BSI series boiler is less than 50ppm (0.005%). Areading of more than 100ppm (0.01%) is indica-  
tive of a combustion problem.  
Some causes of excessive CO include:  
•
•
•
•
•
•
•
Incorrectly sized main burner orifice for the altitude at which boiler is installed  
Crooked or out-of-round orifice holes (never attempt to drill orifice for this boiler in the field)  
Partially plugged flue passages  
Improper manifold pressure  
Foreign material in burner venturis or burner ports  
Leak in seal between flue collector and heat exchanger  
Inadequate supply of combustion air  
16) Replace the blocked vent switch.  
17) Reconnect the damper and vent system.  
33  
XIII Troubleshooting  
The following pages contain troubleshooting charts for use in diagnosing control problems. To use these charts, go to the  
box marked “Start” at the top of the chart on page 35 or 37 and follow the appropriate path though the chart until a box with a  
list of possible causes is reached. If the problem is known to be within the ignition system, go directly to the appropriate  
troubleshooting guide for the boiler (standing pilot on page 39 or intermittent ignition on page 40). In using these charts, the  
following should be kept in mind:  
1) These charts are only meant to be used by a professional heating technician as an aid in diagnosing control problems.  
2) Where applicable, follow all precautions outlined in the appropriate lighting instructions on pages 25 - 28.  
3) In general, these charts assume that there are no loose or miswired electrical connections. Before using these charts,  
inspect all electrical connections on the boiler to make sure that they are tight. Also, check the wiring on the boiler  
against the appropriate wiring diagram in Figures 16 - 19.  
4) The possible causes at the end of each branch in these charts are not listed in order of likelihood. All controls on the BSI  
are tested at least once in the manufacturing process and a defective control or component is generally the least likely  
cause. Before replacing a component, try to rule out all other possible causes.  
5) These troubleshooting charts assume that the vent damper is closed at the beginning of the troubleshooting process.  
With the 120 volts applied to the boiler and no call for heat, the damper should go to the closed position. If it does not,  
do the following:  
•
•
•
•
•
Confirm that 120 volts is applied to the boiler and that there is no call for heat.  
Make sure that the switch on the damper is in the “automatic” position.  
Unplug the harness from the damper and check for 24 volts across pin #1 (blue) and pin #4 (yellow).  
If voltage is present, the damper is defective or there is an obstruction in the path of the damper blade.  
If no voltage is present, there is either a loose connection in the damper harness or the transformer is defective.  
6) If the charts indicate that the transformer is defective, it is possible that this transformer has been destroyed by a short  
circuit in the boiler wiring. Before replacing the transformer, carefully inspect all low voltage wiring on the boiler for  
places where it is touching the frame of the boiler or wiring on the other side of the transformer.  
7) If the charts indicate that the R8225 relay is defective, there is a good chance that a second transformer is present in the  
thermostat circuit, resulting in the application of 48 volts across the relay coil. In older buildings, this transformer may be  
hidden in a location far from the boiler. If this second transformer exists, it must be found and removed before the R8225 is  
replaced.  
8) When checking voltage across damper harness pins, be careful not to insert the meter probes into the pins. Doing so may  
damage the pin, resulting in a loose connection when the harness is reconnected.  
34  
Troubleshooting Chart for BSI Boilers Equipped with  
Hydrolevel CG400A Low Water Cut-offs and Vent Dampers  
Caution: Read page 34 before attempting to use this chart  
START  
Vent  
damper  
open?  
Y
Is there an audible  
click as R8225 relay  
pulls in w hen the  
thermostat calls for  
heat?  
N
Thermostat  
calls for heat  
Y
Is yellow  
LED lit on  
LWCO?  
Y
N
24 volts betw een  
P2 and 2 on  
CG400 LWCO?  
N
120 volts across  
N
black and w hite  
transformer  
leads?  
* Jumper missing  
betw een 1 and P1 on  
CG400  
* Poor connection  
betw een transformer  
and terminals 1 & 2 on  
CG400  
Y
24 volts across  
blue and yellow  
w ires inside  
Y
junction box?  
N
N
Y
24 volts present  
betw een each  
pressure limit  
connection and  
yellow transformer  
connection?  
* Boiler off on low w ater  
* Loose probe connection  
* Poor ground path from  
heat exchanger to CG400  
case  
N
*Pow er of f  
*Blow n fuse or  
tripped  
Is 24 volts  
present across  
brow n and  
breaker  
yellow leads on  
R8225 relay?  
*Misw ired or  
loose 120 volt  
connection  
N
Y
* Boiler off on pressure limit  
* Defective pressure limit  
Y
* Def ective  
R8225  
See Note #7  
on page 34  
Disconnect  
* Def ective  
transformer  
See Note #6 on  
page 34  
thermostat and  
temporarily jump  
boiler thermostat  
connections  
Y
24 volts present  
across blue lead on  
R8225 and yellow  
transformer leads?  
together  
* Bad connection in  
thermostat w iring  
* Defective thermostat  
* Thermostat misw ired or  
misapplied  
* Loose  
N
connection  
betw een  
transformer  
and R8225  
coil  
* Defective R8225  
Y
N
Does relay  
pull in now ?  
35  
Do burners  
shut down when  
pressure  
exceeds limit  
setting?  
Do burners shut  
down when water  
level drops below  
cut-off point?  
Main  
burners  
light?  
Y
Y
Y
END  
N
N
N
24 volts across  
red damper lead  
and yellow  
* Defective damper  
* Defective or loose  
damper harness  
* Obstruction in  
path of damper  
blade  
N
* Defective  
pressure limit  
control  
* Blockage in  
siphon tube  
transformer  
lead?  
Y
*Grounded probe or probe  
lead  
* Defective L.W.C.O.  
DO NOT OPERATE BOILER  
UNTIL THIS PROBLEM IS  
CORRECTED  
24 volts across  
standing pilot gas  
valve terminals or  
terminals 5&6 on  
S8600 module?  
* Refer to standing pilot  
or intermittent ignition  
troubleshooting chart  
(page 39 or 40).  
Y
24 volts  
across spill  
switch?  
N
Y
*Chimney blockage  
*Chimney system not  
contructed in accordance  
with Parts 7 and 10 of  
National Fuel Gas Code .  
*Down draft  
N
24 volts across 1&4  
(blue&yellow) and 2&4  
(orange&yellow ) on  
damper end of  
*Inadequate combustion air  
supply in boiler room  
Y
harness?  
24 volts  
across rollout  
switch?  
Y
*Rollout switch open.  
Replace with exact  
replacement (see parts  
list). Check for blocked  
heat exchanger.  
N
N
* Defective or loose  
damper harness  
* Defective damper  
motor  
*Obstruction in path  
of damper blade  
*Loose electrical  
connection in spill  
switch or rollout  
switch wiring or gas  
valve common  
* Defective or  
loose damper  
harness  
36  
Troubleshooting Chart for BSI Boilers Equipped with  
McDonnell & Miller #67 Low Water Cut-offs and Vent Dampers  
Caution: Read page 34 before attempting to use this chart  
START  
Vent  
damper  
open?  
Y
Is there an audible  
click as R8225 relay  
pulls in w hen the  
thermostat calls for  
heat?  
N
Thermostat  
calls for heat  
Y
24 volts  
betw een terminal # 1  
on 67 LWCO and  
yellow tranformer  
connection?  
N
120 volts across  
black and w hite  
transformer  
leads?  
N
Y
24 volts across  
blue and yellow  
w ires inside  
Y
junction box?  
N
N
Y
24 volts present  
betw een each  
pressure limit  
connection and  
yellow transformer  
connection?  
N
* Boiler off on low w ater  
*Pow er of f  
*Blow n fuse or  
tripped  
Is 24 volts  
present across  
brow n and  
breaker  
yellow leads on  
R8225 relay?  
*Misw ired or  
loose 120 volt  
connection  
N
Y
* Boiler off on pressure limit  
* Defective pressure limit  
Y
* Def ective  
R8225  
See Note #7  
on page 34  
Disconnect  
* Def ective  
transformer  
See Note #6 on  
page 34  
thermostat and  
temporarily jump  
boiler thermostat  
connections  
Y
24 volts present  
across blue lead on  
R8225 and yellow  
transformer leads?  
together  
* Bad connection in  
thermostat w iring  
* Defective thermostat  
* Thermostat misw ired or  
misapplied  
* Loose  
N
connection  
betw een  
transformer  
and R8225  
coil  
* Def ectiv e R8225  
Y
N
Does relay  
pull in now ?  
37  
Do burners  
shut down when  
pressure  
exceeds limit  
setting?  
Do burners shut  
down when water  
level drops below  
cut-off point?  
Main  
burners  
light?  
Y
Y
Y
END  
N
N
N
24 volts across  
red damper lead  
and yellow  
* Defective damper  
* Defective or loose  
damper harness  
* Obstruction in  
path of damper  
blade  
N
* Defective  
pressure limit  
control  
* Blockage in  
siphon tube  
transformer  
lead?  
Y
*LWCO float bowl filled with  
mud  
* Defective LWCO  
DO NOT OPERATE BOILER  
UNTIL THIS PROBLEM IS  
CORRECTED  
24 volts across  
standing pilot gas  
valve terminals or  
terminals 5&6 on  
S8600 module?  
* Refer to standing pilot  
or intermittent ignition  
troubleshooting chart  
(page 39 or 40).  
Y
24 volts  
across spill  
switch?  
N
Y
*Chimney blockage  
*Chimney system not  
contructed in accordance  
with Parts 7 and 10 of  
National Fuel Gas Code .  
*Down draft  
N
24 volts across 1&4  
(blue&yellow) and 2&4  
(orange&yellow ) on  
damper end of  
*Inadequate combustion air  
supply in boiler room  
Y
harness?  
24 volts  
across rollout  
switch?  
Y
*Rollout switch open.  
Replace with exact  
replacement (see parts  
list). Check for blocked  
heat exchanger.  
N
N
* Defective or loose  
damper harness  
* Defective damper  
motor  
*Obstruction in path  
of damper blade  
*Loose electrical  
connection in spill  
switch or rollout  
switch wiring or gas  
valve common  
* Defective or  
loose damper  
harness  
38  
Standing Pilot Ignition System Troubleshooting Chart  
START  
Caution: Read page 34 before  
(24 VOLTS PRESENT ACROSS TH AND TR  
ON GAS VALVE, BUT MAIN BURNERS DO  
NOT LIGHT)  
attempting to use this chart  
Y
Ensure knob  
on gas valve is  
set toON  
Main  
burners  
light?  
Y
Y
Does pilot  
stay lit?  
Pilot lit?  
N
END  
N
N
*Loose  
thermocouple  
connection at  
Turn control on  
gas valve to  
PILOT. Depress  
red button and  
light pilot. Hold  
button for at  
least one  
Turn control  
on gas valve  
to ON.  
*Defective gas  
valve  
gas valve.  
*Defective  
thermocouple.  
minute.  
*Condensation  
quenching pilot.  
Y
Disconnect  
thermocouple from  
gas valve. Connect a  
volt meter to the  
thermocouple. Light  
the pilot and hold  
down the red button  
while reading the  
voltage across the  
thermocouple.  
*Low line  
pressure.  
Does pilot  
stay lit when  
red button is  
released?  
Y
N
Does pilot  
light?  
N
Line pressure  
within the range  
indicated on  
boiler's rating  
plate?  
N
Y
Is voltage at  
least 18mV?  
Consult gas  
supplier.  
Y
N
*Pilot tubing  
blocked, kinked  
or leaking  
*Loose or defective  
thermocouple  
connection at gas valve  
*Defective thermocouple  
*Pilot orifice  
blocked  
*Pilot improperly  
adjusted  
*Defective gas valve  
*Gas line not  
purged of air  
*Pilot tube blocked, kinked, or  
leaking  
*Pilot improperly  
adjusted.  
*Pilot orifice partially plugged  
39  
Intermittent Ignition System Troubleshooting Chart  
START  
Caution: Read page 34 before  
attempting to use this chart  
(24 volts is present across 5 and 6 on S8600  
module, but main burners do not light)  
Spark  
Does  
Main  
burner  
lights?  
Y
Y
Y
Y
across  
ignitor/sensor  
gap?  
Pilot  
lights?  
spark stop  
when pilot  
lights?  
END  
N
N
N
N
24VAC  
across  
terminals 1&2  
on S8600?  
N
24 volts  
across  
terminals 2&3  
at S8600?  
N
Y
*Defective  
S8600 module  
Can you  
hear  
Y
*Defective  
S8600  
module  
Y
sparking?  
N
24 volts  
between MV &  
MV/PV on gas  
valve?  
24 volts  
across PV &  
MV/PV at gas  
valve?  
N
Y
*Faulty  
S8600  
module  
N
Y
*Loose connection in  
ignition cable or  
ground wire  
*Defective EI  
wiring  
harness.  
*Break in  
spark cable  
insulation  
*Defective EI  
harness  
*Pilot electrode  
porcelain cracked  
*Break in pilot  
porcelain  
* Low line pressure  
*Pilot flame not  
covering gap  
between electrode  
and grounding  
strap  
*Plugged, kinked or leaking  
pilot tubing  
*Incorrect pilot  
spark gap  
*Defective  
gas valve  
*Plugged pilot orifice  
*Loose  
connection in  
spark cable  
*Low gas pressure  
at gas valve inlet  
*Gas line not purged of air  
*Defective pilot assembly  
*Defective gas valve  
*Loose  
ground  
connection  
*Defective S8600  
module  
40  
XIV 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  
www.crownboiler.com  
For boilers installed at elevations above 2000 ft, consult the local Crown representative or the factory for the correct main burner  
orifice.  
QTY. OR  
CROWN P.N.  
1 ea.  
750001  
850002  
750003  
275075  
275070  
1 ea.  
QUANTITY PER BOILER OR CROWN P.N.  
172 207 241 276  
850013 850014 850015 850016 850017 850018 850019 850020 850021 850022  
KEY #  
DESCRIPTION  
310  
345  
379  
69  
103  
138  
1
*
*
*
*
BSI HEAT EXCHANGER ASSY.  
BSI/CWI LEFT END SECTION  
BSI RIGHT END SECTION  
BSI/CWI INTERMEDIATE SECTION  
UPPER PUSHNIPPLE  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
2 ea.  
1 ea.  
1 ea.  
2 ea.  
3 ea.  
3 ea.  
1 ea.  
1 ea.  
3 ea.  
4 ea.  
4 ea.  
1 ea.  
1 ea.  
4 ea.  
5 ea.  
5 ea.  
1 ea.  
1 ea.  
5 ea.  
6 ea.  
6 ea.  
1 ea.  
1 ea.  
6 ea.  
7 ea.  
7 ea.  
1 ea.  
1 ea.  
7 ea.  
8 ea.  
8 ea.  
1 ea.  
1 ea.  
8 ea.  
9 ea.  
9 ea.  
1 ea.  
1 ea.  
9 ea.  
10 ea.  
10 ea.  
1 ea.  
1 ea.  
10 ea.  
11 ea.  
11 ea.  
*
LOWER PUSHNIPPLE  
2
3
4
4
BASE TRAY  
700643 700644 700645 700646 700647 700648 700649 700650 700651 700652  
700672  
700692  
BASE WRAPPER  
1 ea.  
1 ea.  
1 ea.  
700663 700664 700665 700666 700667 700668 700669 700670 700671  
700683 700684 700685 700686 700687 700688 700689 700690 700691  
751683 751684 751685 751686 751687 751688 751689 751690  
BURNER TRAY (1" BURNERS)  
BURNER TRAY (40mm BURNERS)  
BASE FRONT PANEL ASSY. (INCLUDES  
INSULATION)  
5
1 ea.  
700603 700604 700605 700606 700607 700608 700609 700610 700611 700612  
700632  
2 ea.  
6
7
8
9
BURNER ACCESS PANEL  
BASE END INSULATION  
BASE REAR INSULATION  
BASE LEG ASSY.  
1/4-20 X 1/2" SELF TAPPING SCREW  
1/2" x 2" SEALING STRIP  
ROLLOUT SWITCH G4AM0600240C  
ROLLOUT SWITCH BRACKET  
#8 x 3/4" SELF TAPPING SCREW  
#10 x 1/2" SHEET METAL SCREW  
5/16 USS FLAT WASHER  
5/16-18 LOCK NUT  
5/16-18 x 1-1/4 SELF TAPPING SCREW  
DRAFT DIVERTER ASSEMBLY  
1/2" x 1" SEALING STRIP  
1 ea.  
720601  
1 ea.  
700623 700624 700625 700626 700627 700628 700629 700630 700631  
2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea.  
720603 720604 720605 720606 720607 720608 720609 720610 720611 720612  
700110  
900100  
900146  
960122  
900121  
90-048  
90-212  
900102  
900103  
900101  
1 ea.  
4 ea.  
20 ea.  
3.7 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
4 ea.  
20 ea.  
4.2 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
4 ea.  
20 ea.  
4.8 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
4 ea.  
20 ea.  
5.3 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
4 ea.  
21 ea.  
5.9 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
4 ea.  
21 ea.  
6.4 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
4 ea.  
21 ea.  
7.0 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
4 ea.  
21 ea.  
7.5 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
6 ea.  
25 ea.  
8.0 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
6 ea.  
25 ea.  
8.5 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
10  
11  
12  
13  
14  
15  
16  
17  
18  
20  
21  
22  
23  
24  
850123 850124 850125 850126 850127 850128 850129 850130 850131 850132  
4.6 ft  
4 ea.  
4 ea.  
4 ea.  
4.9 ft  
4 ea.  
4 ea.  
4 ea.  
5.2 ft  
4 ea.  
4 ea.  
4 ea.  
5.5 ft  
4 ea.  
4 ea.  
4 ea.  
900145  
90-201  
90-215  
900125  
3 ft  
3.3 ft  
4 ea.  
4 ea.  
4 ea.  
3.5 ft  
4 ea.  
4 ea.  
4 ea.  
3.8 ft  
4 ea.  
4 ea.  
4 ea.  
4.1 ft  
4 ea.  
4 ea.  
4 ea.  
4.4 ft  
4 ea.  
4 ea.  
4 ea.  
1/4-20 x 1-1/4" CARRIAGE BOLT  
1/4" USS FLAT WASHER  
1/4-20 WING NUT  
4 ea.  
4 ea.  
4 ea.  
BLOCKED VENT SWITCH ASSY.  
(INCLUDES MOUNTING BRACKET)  
25  
960123  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
* NOT PICTURED  
41  
42  
QTY. OR  
CROWN P.N.  
QUANTITY PER BOILER OR CROWN P.N.  
KEY #  
41  
DESCRIPTION  
310  
345  
379  
69  
103  
138  
172  
207  
241  
276  
1" BURNER WITH PILOT BRACKET  
(Q350 PILOT)  
1" BURNER WITH PILOT BRACKET  
(Q327 NAT, Q348 PILOTS)  
1" BURNER WITH PILOT BRACKET  
(Q327 LP PILOT)  
150502  
150500  
150503  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
41  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
41  
42  
43  
44  
44  
44  
44  
44  
44  
44  
45  
1" BURNER LESS PILOT BRACKET  
MANIFOLD (1" BURNERS)  
NAT GAS ORIFICE (#42 DRILL SIZE)  
NAT GAS ORIFICE (#44 DRILL SIZE)  
NAT GAS ORIFICE (#47 DRILL SIZE)  
NAT GAS ORIFICE (#48 DRILL SIZE)  
150501  
1 ea.  
950298  
950300  
950303  
950304  
950329  
950330  
950336  
2 ea.  
700153  
3 ea.  
4 ea.  
700154  
6 ea.  
700155  
8 ea.  
700156  
11 ea.  
700157  
13 ea.  
700158  
15 ea.  
700159  
17 ea.  
700160  
20 ea.  
700161  
22 ea.  
700162  
5 ea.  
5 ea.  
7 ea.  
7 ea.  
9 ea.  
9 ea.  
12 ea.  
12 ea.  
14 ea.  
14 ea.  
16 ea.  
16 ea.  
18 ea.  
18 ea.  
21 ea.  
23 ea.  
LP GAS  
LP GAS  
LP GAS  
ORIFICE (#54 DRILL SIZE)  
ORIFICE (#55 DRILL SIZE)  
ORIFICE (#1.25mm DRILL SIZE)  
3 ea.  
GAS VALVE (STND. PILOT, NAT GAS)  
(EXCEPT 40mm BURNERS)  
GAS VALVE (STND. PILOT, NAT GAS)  
(40mm BURNERS ONLY)  
3507010  
(VR8200C6008)  
3507350  
VR8200C6032  
3507020  
(VR8204C6000)  
3507110  
(VR8300C4134)  
3507355  
VR8300C4183  
3507120  
(VR8304P4298)  
3507300  
(V8295A1024)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
45  
45  
45  
45  
45  
45  
45  
45  
45  
45  
45  
45  
46  
46  
46a  
46  
46a  
GAS VALVE (E.I., NAT GAS)  
GAS VALVE (STND. PILOT, NAT GAS)  
(EXCEPT 40mm BURNERS)  
GAS VALVE (STND. PILOT, NAT GAS)  
(40mm BURNERS ONLY)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
GAS VALVE (E.I., NAT GAS)  
1 ea.  
1 ea.  
1 ea.  
GAS VALVE (STND. PILOT, NAT GAS)**  
1 ea.  
1 ea.  
1 ea.  
GAS VALVE (STND. PILOT, NAT GAS)**  
(ROBERTSHAW 7000ERHC-S7C)  
GAS VALVE (E.I., NAT GAS)  
3507305  
3507310  
(ROBERTSHAW 7000DERHC)  
LP GAS  
GAS VALVE (STND. PILOT,  
GAS VALVE (E.I. PILOT,  
GAS VALVE (STND. PILOT,  
LP GAS  
)
3507210  
(VR8200C6040)  
3507220  
(VR8204C6018)  
3507230  
(VR8300C4548)  
3507240  
(VR8304P4280)  
3504050  
(Q350A1644)  
3504005  
(Q327A1949)  
35-4700  
(Q348A1275)  
35-4020  
(Q327A1915)  
35-4600  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
LP GAS  
)
LP GAS  
)
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
GAS VALVE (E.I.,  
)
PILOT ASSY. (STND. PILOT, NAT GAS)  
PILOT ASSY. (STND. PILOT, NAT GAS)  
PILOT ASSY. (E.I., NAT GAS)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
LP GAS  
PILOT ASSY. (STND. PILOT,  
)
LP GAS  
PILOT ASSY. (E.I.,  
)
(Q348A1259)  
1 ea.  
47  
47a  
48  
THERMOCOUPLE  
IGNITION CABLE  
PILOT TUBING***  
35-1040 35-1040 35-1040 35-1040 35-1040 35-1040 3501141 3501142 3501142 3501142  
3501136 3501136 3501136 3501136  
3501124 3501124 3501124 3501130 3501130 3501130  
90-042  
1 ea.  
1 ea.  
900041  
900041  
900041  
90-042  
90-042  
90-043  
90-043  
90-043  
1/8 SHORT FERRULE (INCLUDED WITH  
GAS VALVE)  
49  
35-1600  
(392449)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1/8 LONG FERRULE (INCLUDED WITH  
PILOT ASSEMBLY)  
50  
51  
35-1650  
(392449-4)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
CAR12 PILOT ORIFICE (Q350 PILOT,  
NAT GAS) - INCLUDED WITH PILOT  
A26 PILOT ORIFICE (Q327 PILOT, NAT  
GAS) - INCLUDED WITH PILOT ASSY.  
KF24 PILOT ORIFICE (Q348 PILOT, NAT  
GAS) - INCLUDED WITH PILOT ASSY.  
51  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
51a  
51  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
LP  
K14 PILOT ORIFICE (Q327 PILOT,  
GAS  
) - INCLUDED WITH PILOT ASSY.  
LP  
K16 PILOT ORIFICE (Q348 PILOT  
51a  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
GAS  
) - INCLUDED WITH PILOT ASSY.  
40mm BURNER WITH PILOT BRACKET  
(Q350 PILOTS)  
40mm BURNER WITH PILOT BRACKET  
(Q327, Q348 PILOTS)  
60  
60  
150540  
150542  
1 ea.  
1 ea.  
1 ea.  
61  
62  
40mm BURNER LESS PILOT BRACKET  
MANIFOLD (40mm BURNERS)  
150541  
1 ea.  
1 ea.  
701253  
2 ea.  
701254  
3 ea.  
701255  
4 ea.  
701256  
5 ea.  
701257  
6 ea.  
701258  
7 ea.  
701259  
8 ea.  
701260  
MAIN BURNER ORIFICE-CONSULT  
CROWN REPRESENTATIVE FOR  
CORRECT SIZE  
63  
2 ea.  
3 ea.  
4 ea.  
5 ea.  
6 ea.  
7 ea.  
8 ea.  
9 ea.  
** These Valves Piped in Series to Provide Redundant Shut-off  
***1/4 Pilot Tubing Used with Robertshaw Valves  
43  
44  
QTY. OR  
CROWN P.N.  
1 ea.  
QUANTITY PER BOILER OR CROWN P.N.  
172 207 241 276  
850301 8503012 8503012 8503012 8503015 8503015 8503015  
850300 8503002 8503002 8503002 8503005 8503005 8503005  
KEY #  
DESCRIPTION  
310  
345  
379  
69  
103  
138  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
LEFT SIDE JACKET PANEL  
RIGHT SIDE JACKET PANEL  
REAR JACKET PANEL  
TOP JACKET PANEL  
LOWER FRONT PANEL  
UPPER FRONT PANEL  
DIVERTER PANEL  
VESTIBULE PANEL  
HORIZONTAL JACKET CLIP  
VERTICAL JACKET CLIP  
#10 X 1/2" SHEET METAL SCREW  
DOOR KNOB  
8-32 X 1/4" H.W.H. SCREW  
IGNITION MODULE (E.I. BOILERS)  
(NATURAL GAS ONLY)  
IGNITION MODULE (E.I. BOILERS)  
(NATURAL OR LP GAS)  
MODULE BRACKET (E.I. BOILERS)  
VENT DAMPER  
850301  
850300  
850303  
850323  
850363  
850353  
850373  
850383  
2 ea.  
850301  
850300  
850304  
850324  
850364  
850354  
850374  
850384  
2 ea.  
850301  
850300  
850305  
850325  
850365  
850355  
850375  
850385  
2 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
800340  
800341  
90-212  
90-210  
90-211  
850306  
850326  
850366  
850356  
850376  
850386  
2 ea.  
850307  
850327  
850367  
850357  
850377  
850387  
2 ea.  
850308  
850328  
850368  
850358  
850378  
850388  
2 ea.  
850309  
850329  
850369  
850359  
850379  
850389  
2 ea.  
850310  
850330  
850370  
850360  
850380  
850390  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
850311  
850331  
850371  
850361  
850381  
850391  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
850312  
850332  
850372  
850362  
850382  
850392  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
28 ea.  
2 ea.  
28 ea.  
2 ea.  
28 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
35-5000  
(S8600F1000)  
35-5050  
(S8600M1013)  
905000  
1 ea.  
*
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
*
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
*
88  
89  
90  
90a  
91  
92  
93  
94  
95  
96  
*
98  
99  
100  
*
*
*
1 ea.  
96-030  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-031  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-032  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-032  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-033  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-033  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-035  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-035  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-036  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-036  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
GLASS SET  
950077  
400676  
400821  
95-070  
FLOAT TYPE L.W.C.O. (#67 CR-2)  
PROBE TYPE L.W.C.O. (CG400)  
PRESSURE GUAGE  
3/4" SAFETY VALVE (15 psi)  
90 DEGREE PIG-TAIL  
PRESSURE LIMIT (PA404A1009)  
3/4" BOILER DRAIN  
JUNCTION BOX  
TRANSFORMER MOUNTING PLATE  
24V TRANSFORMER (AT140D1012)  
8-32 X 1/2" SELF TAPPING SCREW  
SPST RELAY (R8225B1049)  
DAMPER WIRE HARNESS  
BLOCKED VENT SWITCH HARNESS  
J-BOX - R.O. SWITCH HARNESS  
#67 L.W.C.O. - J-BOX HARNESS  
CG400 L.W.C.O - J-BOX HARNESS  
PRESSURE LIMIT - J-BOX HARNESS  
INTERMITTENT IGNITION HARNESS  
RED JUMPER HARNESS (LESS-DAMPER  
95-079  
95-060B  
35-5020  
95-041  
960155  
960156  
3502300  
90-223  
3505540  
9601300  
9601270  
9601280  
9601367  
9601405  
9601210  
9601100  
*
*
*
*
*
9601355  
1 ea.  
1 ea.  
1 ea.  
BOILERS ONLY  
)
* NOT PICTURED  
45  
46  
Appendix A: Knockdown Boiler Assembly Instructions  
A. Before Installing  
1) Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs or  
punctures due to mishandling.  
2) Do not use the heat exchanger if there is any damage to it.  
3) Inspect the joints between the sections for openings. Reseal any openings with high temperature silicone sealant..  
4) Keep the base in the shipping carton until it is time to perform the assembly. This keeps foreign material from  
contaminating the burners or creating other hazards. Do not use the base assembly if there are any signs of visible  
damage.  
5) Review all of the installation requirements in this installation manual.  
B. BaseAssembly Preparation  
1) The combination base-burner-manifold is shipped assembled from the factory. (The combination gas valve is  
shipped assembled and can be found in the "Base Box".)  
2) Smear a thin layer of silicone in several places across the top of the base to adhere the fiber gasket strip.  
3) Install the fiber gasket strip, which was shipped in the "Base Box" (Figure A1).  
4) Place the base assembly in the location where the boiler is to be installed. Refer to Section III and IV in the installa-  
tion manual for additional information on placement.  
C. Heat Exchanger and Flue Collector Installation  
1) Position the heat exchanger above the base with the return connection located toward the front of the boiler and the  
lugs, located on each end of the boiler, centered over the studs, which are on each end of the base (Figure A1).  
Lower the heat exchanger over the studs, taking care not to disturb the studs which may push out if the heat  
exchanger comes in contact with them. Also, take care not to disturb the ceramic fiber gasket.  
2) Once the heat exchanger has been placed on the base, inspect the gasket for proper seal. Repair or replace gasket if  
necessary.  
3) Secure the heat exchanger with 5/16" lock nuts with nylon inserts and washers from the hardware bag.  
4) Loosen nuts on tie rods until they are finger tight.  
5) Fiber gasket strips are used to seal the flue collector to the heat exchanger (this is the same material used between  
the heat exchanger and base). Install this gasketing on the top of the heat exchanger (Figure A1). A few dabs of  
silicone may be used to keep this gasketing from shifting when the flue collector is installed.  
6) Install the flue collector as shown in Figure A1. Secure with the 1/4-20 carriage bolt, nuts, and washers provided.  
7) Carefully inspect the joint between the flue collector and the heat exchanger to verify that the gasket is properly  
positioned.  
8) Install the blocked vent switch using the #8 sheet metal screw provided as shown in Figure A1.  
D. Jacket Installation  
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. See Figure A3 of this appendix, as well as Parts XIII and IX of the installation manual.  
1) Attach the diverter Panel to the vestibule panel using two #10 sheet metal screws. Install these screws in the  
outside holes.  
2) Slip this diverter/vestibule panel assembly behind the draft diverter opening in the draft diverter assembly (Figure  
A2). Attach to the diverter assembly using #10 sheet metal screws.  
3) Attach the right side panel to the base and vestibule panel using four #10 sheet metal screws.  
4) Orient the rear jacket panel so that the two notches are up. Slip the rear panel under the flange on the rear of the  
side panel installed in the previous step and secure with three #10 sheet metal screws.  
47  
FIGUREA1: BASE, HEAT EXCHANGER, FLUE COLLECTORASSEMBLY  
48  
5) Install the left side panel in the same manner as the right side.  
6) Attach the front corners of the diverter panel to the side jacket panels using #10 sheet metal screws.  
7) Install the horizontal (angle) jacket clips in the front edge of the side jacket panels. Slide this clip through the  
rectangular slot that is about halfway up the front edge of the side jacket panels and secure with the 8-32 self  
tapping screws provided.  
8) Slip the Vertical Jacket Clip through the rectangular slot that is near the bottom of the front edge of the side jacket  
panels. Secure with the 8-32 sheet metal screws provided.  
9) Install the top jacket panel. Use #10 sheet metal screws to attach it to the rear jacket panel and the top-front corners  
of the side panels.  
10) Install the upper-front jacket panel. Insert the flange on the top of this panel under the top panel. Run two #10 sheet  
metal screws into the horizontal jacket clips through the holes in the bottom of this panel.  
11) Attach the door knobs to the Lower-Front Panel using 8-32 x 1/2 machine screws.  
12) The labels have been applied at the factory. Verify the location of the labels according to the list below:  
a) Clearance Label - Located on the top jacket panel.  
b) Lighting Instructions - Located on the lower left corner of the right side panel next to the gas manifold  
c) Lowest Permissible Water Level Plate - Located next to the bottom water gauge tapping.  
d) Blow Down Card - Located just above the "Lowest Permissible" Water Level Plate  
e) Wiring Diagram - Located on the inside of the removable door  
f) "CROWN" Nameplate - Located on the top center of the outside of the removable door  
g) Rating Plate - Located on the upper left of the right side panel  
D. GasValve Installation  
1) The gas valve assembly has been pre-piped with one half of a piping union and is to be connected to the other half of  
the union located on the gas manifold.  
2) Connect the pilot tubing from the pilot burner to the gas valve pilot tapping.  
3) Connect the thermocouple lead to the gas valve (standing pilot boilers only).  
E. Control andTrim Installation  
(Refer to FigureA3 for Tapping Locations)  
1) Install the pressure limit control into tapping “H” with the siphon. A ¾” x ¼” bushing has been factory installed. Do  
not twist or otherwise bend the control upon installation.  
2) Install the pressure gauge into tapping “B”. A ¾” x ¼” bushing has been factory installed. Tighten with wrench  
applied to the square shank on the back of the gauge. Do not apply pressure on the gauge case since this may ruin the  
calibration of the gauge.  
3) Steam boiler with McDonnell Miller #67 float Low Water Cutoff  
a) Install the low water cutoff per the instructions packed with the control.  
b) Screw brass nipples with one side of the brass union into tappings “C”.  
c) Attach the gauge glass / low water cutoff assembly to the other side of the brass union.  
d) If not already present on the jacket, attach the blow-down card to the left side jacket panel, just above the “Lowest  
Permissible Water Level” plate.  
e) Provide blow down discharge piping.  
4) Steam Boiler with Probe Low Water Cutoff  
a) Install low water cutoff probe into tapping “B”. Handle probe with care.  
b) Attach low water cutoff control to probe per the instructions packed with the control.  
c) Install the gauge glass fittings and ½” extensions into tappings “C”. The lower fitting has a small drain cock.  
d) Install gauge glass and protective rods in fittings.  
5) Install safety valve (spindle must be in vertical position) into tapping “H” on the boiler left side (See Figure 1 in the  
installation manual) using the ¾” NPT nipples and elbow supplied. 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. The safety valve discharge piping must be in an area where it is  
not likely to become plugged by debris or subjected to freezing.  
6) Install drain valve into tapping “J” on the boiler left side using 2 x ¾ bushing provided. (See Figure 1 in the installation  
manual).  
7) See Section VIII System Piping in the installation manual for instructions on completing the piping of this boiler  
including the safety valve and drain valve provided by the factory.  
49  
FIGUREA2: JACKETINSTALLATION  
50  
F. ElectricalWiring Connections  
(Also refer to wiring diagrams in Part X of the installation manual)  
1) A pre-wired junction box assembly specific to the control package ordered with the boiler has been provided by the factory.  
2) Orient the junction box so the black relay, which is mounted to the outside of the junction box, is facing down.  
3) Mount the junction box assembly to the right side jacket using the holes provided (See Figure 1 in the installation manual).  
To do this, temporarily remove the transformer and attach the box with two #10 sheet metal screws through the holes on the  
back side of the box.  
4) Pressure Limit Switch - Route the grey wire pair through the bushing on the pressure limit control and connect one of the  
leads numbered “0” to one of the two terminals on the switch and the other lead numbered “0” to the other terminal on the  
switch.  
5) Blocked Vent Switch - Locate the two wires marked “8” (one of these wires is black, the other is black with a white trace).  
Connect these wires to the terminals on the blocked vent switch (it does not matter which of these wires is connected to  
which terminal on the blocked vent switch). Install the strain relief provided in the hole in the jacket through which these  
wires pass.  
6) Flame Roll-Out Switch:  
a) Route the black wire marked “10” through the bushing located on the left jacket panel and connect it to one side of the  
flame roll-out switch.  
b) Route the red wire marked “7” through the bushing located on the left jacket panel and connect it to the other side of the  
flame roll-out switch.  
7) McDonnell Miller Series 67 Low Water Cutoff:  
a) Route the black wire numbered “1” and the black wire with the white trace numbered “2” through the fitting on the end  
of the low water cutoff.  
b) Connect lead numbers “1” and “2” to the low water cutoff terminals marked “1” and “2” respectively.  
8) Hydrolevel CG-400 Probe Low Water Cutoff:  
a) Mount the end of the BX cable containing the 3-wire Molex plug and the single red wire to the control box with the BX  
cable fitting nut supplied.  
b) Insert the Molex plug into the receptacle mounted on the CG400 terminal board.  
c) Attach the red wire to the terminal marked “BURNER”.  
9) Standing Pilot Gas Valve (Honeywell VR8200, VR8300 or Robertshaw Model 7000ERHC-S7C) - Connect wire “6” (black with  
a white trace) to the “TH” terminal on the gas valve. Connect wire “5” (red with a yellow trace) to the TR terminal on the gas  
valve.  
Note: Boilers equipped with the Robertshaw 7000ERHC are also equipped with a Honeywell Model V8295 gas valve to  
provide redundancy. This valve should be factory pre-wired to the 7000ERHC with one black lead connected to the “TH”  
terminal and the other black lead connected to the “TR” terminal on the 7000ERHC gas valve.  
10) Honeywell Intermittent Ignition System:  
a) Mount the S8600 series ignition control to the left side of the jacket just above the gas manifold using the standoff  
bracket supplied and #10 sheet metal screws.  
b) Locate the intermittent ignition harness plugged into the gas valve assembly. This harness has red, blue, and yellow  
wires and has molex plugs on both ends. Plug the loose end of the harness into the S8600 module.  
c) Plug the green burner ground wire numbered “4” to terminal 4 on the S8600. Check that the ground wire has been routed  
under the burners and that the other end is attached to the pilot assembly under the lower mounting screw.  
d) Plug the red wire with the yellow trace, numbered “5”, to terminal 5 on the S8600 module.  
e) Plug the black wire with the white trace, numbered “6”, to terminal 6 on the S8600 module.  
f) Plug the orange Pilot Ignition Cable, numbered “9”, to terminal 9 on the S8600 module. Verify that this cable has been  
routed under the burners and that the other end is plugged onto the pilot assembly electrode.  
G. Complete Installation  
Follow the instructions that start on page 1 of this manual to complete boiler installation.  
51  
FIGUREA3: TAPPING LOCATIONS (SEETEXT FOR TAPPING USES)  
52  
CROWN  
Boiler Co  
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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