Crown Boiler MWC116ELL User Manual

D E S I G N E D

T O L E A D

MWC Series

Mid Efﬁciency Gas-Fired Hot Water

Direct Vent Condensing 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 information, con-

sult a qualiﬁed installer, service agency or the gas supplier.

This boiler requires a special venting system. Read these

instructions carefully before installing.

• MWC116ENT

• MWC116ELT

• MWC116ENL

• MWC116ELL

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

Table of Contents

II.

Product Description

Speciﬁcations

III. Before Installing

IV. Locating The Boiler

Mounting The Boiler

VI. Air For Ventilation

VII. Venting

A. Vent System Design

B. Removing An Existing Boiler From Common Chimney

C. Assembly of Crown 60/100 Concentric Venting

D. Assembly of Crown 80/125 Concentric Venting

E. Condensate Trap and Drain Line

VIII. Gas Piping

IX. System Piping

Domestic Water Piping

XI. Wiring

XII. Start-up and Checkout

XIII. Operation

XIV. Service and Maintenance

XV. Troubleshooting

XVI. Parts

Appendix A Special Requirements For Side-Wall

Vented Appliances In The Commonwealth

of Massachusetts

I Product Description

The MWC Series are gas ﬁred condensing boilers designed for use in forced hot water heating systems

requiring supply water temperatures of 176F or less and return water temperatures greater than 86F. The

primary heat exchanger is a copper water tube design. Additional heat is extracted from the ﬂue gas in a

stainless steel secondary heat exchanger located down stream of the inducer. These boilers include a built in

circulator, expansion tank, and automatic air vent. In addition, “combi” models include a plate exchanger for

domestic hot water (DHW) generation. All MWC Series boilers are designed for installation on a wall and may

be vented vertically or horizontally with combustion air supplied from outdoors.

Key

Component

Primary Heat Exchanger

Secondary Heat Exchanger

Inducer

Burner

Electrodes and Flame Rod

Circulator

Automatic Air Vent

Condensate Trap

Control Box

Differential Boiler Water Pressure Switch

Ignition module/Gas Valve

Air Pressure Switch

Flue Gas Temperature Limit

Supply Temperature Limit

Expansion Tank

Plate Heat Exchanger (Combi Only)

3-Way Diverting Valve (Combi Only)

Supply Temperature Sensor

DHW Temperature Sensor (Combi Only)

DHW Flow Switch (Combi Only)

* Not visible

Figure 1.1: MWC Boiler Principle Components

II Speciﬁcations

Figure 2.1: General Conﬁguration

Table 2.2: Ratings

MINIMUM INPUT (BTU/

DHW Output (GPM)

77F Rise 90F Rise

D.O.E.

HEATING

CAPY.

hr)

MAX.

APPLICATION INPUT

(BTU/hr)

IBR NET

RATING

(BTU/hr)

AFUE

(%)

MODEL*

HEATING

DHW

(BTU/hr)

MWC116E*T

MWC116E*L

Combi

116,000

75,000

49,500

N/A

102,000

89,000

85.0

2.67

N/A

2.25

N/A

Heat Only

* Insert sufﬁx “N” for natural gas and “L” for propane. Ratings are the same for both fuels (Example: MWC116ENT denotes Natural

Gas, Combi).

Table 2.3: Maximum Vent Lengths

Using 60/100mm Concentric Vent System Supplied with the Boiler ................................................................25 in.

Using Optional 60/100mm Concentric Vent Components ...............................................................................8ft -10in

Using Optional 80/125mm Concentric Vent Components................................................................................27 ft

See Vent Section for additional venting options and requirements

Table 2.4: Other Speciﬁcations

Maximum Supply Temperature.............................................176 F

Minimum Continuos Return Temperature.............................86F

Maximum Allowable Working Pressure................................30 psi

Minimum System Pressure (at boiler ...................................4.4 psi

Maximum Achievable Flow Through Boiler .........................5.5 GPM

Minimum Temperature Rise Across Boiler at High Fire........37 F

Maximum Gas Inlet pressure ...............................................10.5” Nat / 13.0” LP

Minimum Gas Inlet Pressure................................................5.3” Nat / 10.5” LP

Electrical Ratings..................................................................120VAC/60Hz/1.8A

Thermostat Voltage ..............................................................120VAC

III Before Installing

1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in

strict accordance with this manual and the authority having jurisdiction.

•

In the absence of an authority having jurisdiction, installation must be in accordance with this manual

and the National Fuel Gas Code, ANSI Z223.1./NFPA 54 and/or CAN/CSA B 149.1

Natural Gas and Propane Installation Code.

•

Where required by the authority having jurisdiction, this installation must conform to the Standard for

Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1).

2) Read Section VII to verify that the maximum combustion air and exhaust pipe lengths will not be

exceeded in the planned installation. Also verify that the vent terminal can be located in accordance with

Section VII.

3) Make sure that the boiler is correctly sized:

a) For heating systems employing convection radiation (baseboard or radiators), use an industry

accepted sizing method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22)

published by the Hydronics Institute in Berkeley Heights, NJ.

b) In sizing the boiler take into consideration the following boiler water ﬂow/temperature limitations:

•

Maximum regulated supply temperature is 176F

Maximum ﬂow through the boiler is approximately 5.5GPM.

Minimum boiler temperature rise is approximately 37F at high ﬁre.

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

d) For combi boilers make sure that the domestic hot water ﬂow rate shown in Table 2.2, will be

adequate to meet the peak demand for domestic hot water.

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

6) Make sure that the boiler is conﬁgured for use at the altitude at which it is to be installed.

NOTICE

This product must be installed by a licensed plumber or gas ﬁtter when installed within the

Commonwealth of Massachusetts. See Appendix A for additional important information about

installing this product within the Commonwealth of Massachusetts.

IV Locating the Boiler

1) Observe the minimum clearances shown in Figure 4.1. These clearances apply to both combustible and

non-combustible materials.

2) Note the recommended service clearances in Figure 4.1. These service clearances are recommended,

but may reduced to the combustible clearances provided:

•

Access to the front of the boiler is provided through a door

Access is provided to the condensate trap located underneath the boiler.

3) The relief valve must be installed in the factory speciﬁed location.

4) The boiler should be located so as to minimize the length of the vent system.

5) The boiler must not be installed on carpeting.

6) The combustion air piping must terminate where outdoor air is available for combustion and away from

areas that will contaminate combustion air. Avoid areas near chemical products containing chlorine,

chloride based salts, chloro/ﬂuorocarbons, paint removers, cleaning solvents and detergents.

Clearance From

Hot Water Pipes To

Combustibles = 1”

Figure 4.1: Clearances To Combustible Or Non-combustible Material

V Mounting The Boiler

CAUTION

This boiler weighs approximately 110 pounds:

•

Two people are required to safely lift this boiler onto the wall mounting hook.

Make sure that wall mounting hook is anchored to a structure capable of supporting the

weight of the boiler and attached piping when ﬁlled with water.

Jurisdictions in areas subject to earthquakes may have special requirements for supporting

this boiler. These local requirements take precedence over the requirements shown below.

Mounting Steps:

1) If the boiler is installed on a framed wall, minimum acceptable framing are 2 x 4 studs. The boiler

mounting holes are on 11-5/8” centers. Usually the wall studs will be on 16” centers. In such cases, both

boiler bracket mounting holes must be anchored to ¾” Plywood, horizontal 2 x 4s anchored to the studs,

or some other framing system capable of supporting the boiler. Attachment of either bracket hole to

wallboard alone is unacceptable.

2) When mounting this boiler directly onto studs covered with 1/2” wall board, 5/16 x 2” lag screws are

recommended. When the boiler is attached to other types of construction, such as masonry, use fasteners

capable of supporting the weight of the boiler and attached piping in accordance with good construction

practice and applicable local codes.

3) Make sure that the surface to which the boiler is mounted is plumb.

4) Before mounting the boiler, make sure that wall selected does not have any framing or other construction

that will interfere with the vent pipe penetration.

5) Tape the paper template to the wall in the chosen location. Be sure to level the template.

6) Pre-drill two holes in the center of the “oval” slots on the mounting bracket sized for the hardware being

used.

7) Mount the bracket to the wall. Be sure to level the bracket by adjusting the screw in the vertical slot.

8) Pre-drill the remaining hole in the mounting bracket and secure the ﬁnal screw.

9) Cut the opening in the wall for the vent system. The recommended hole diameter for the standard

60/100mm venting is 4-3/8”.

10) Hang the boiler on the wall bracket as shown in Figure 5.2.

11) Verify that the front and sides of the boiler are plumb.

12) See Section VII (“Venting) for instructions on attaching the vent system to the boiler.

13) A hot water boiler installed above radiation level or as the Authority having jurisdiction,

must be provided with a low water cutoff device either as a part of the boiler or at the time of installation.

Figure 5.1 Wall Mounting Hole Locations

Figure 5.2 Boiler Mounting

VI Air for Ventilation

WARNING

Outdoor combustion air must be piped to the air intake. Never pipe combustion air from areas containing

contaminates such as areas where swimming pool chemicals are stored. Contaminated combustion

air will damage the boiler and may cause property damage, personal injury or loss of life.

Air for combustion and ventilation, of the National Flue Gas Code, ANSI Z223.1/NFPA 54 CAN/CSA B 149.1

Natural Gas and Propane Installation Code, or applicable provisions of the local building codes.

Air for combustion must always be obtained directly from outdoors, however sufﬁcient air for ventilation must

still be provided in the boiler room. Air for ventilation is required to keep various boiler components from

overheating and is always obtained from indoors. To ensure an adequate ventilation air supply, perform the

following steps:

Step 1: Determine whether the boiler is to be installed in a conﬁned space - A conﬁned space is deﬁned by

the National Fuel Gas Code,ANSI Z223.1./NFPA 54 and/or CAN/CSA B 149.1 Natural Gas and Propane Installation 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 MWC116 and a water heater are to be installed in a room measuring 6ft – 3 in x 7ft with an 8 ft ceiling. The

water heater has an input of 30000 BTU/hr:

Total input in thousands of BTU/hr = (116000 BTU/hr + 30000 BTU/hr) / 1000 = 146 MBTU/hr

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

350/146 = 2.40. Since 2.33 is less than 50, the boiler room is a conﬁned space.

Step 2a: If the boiler is to be placed in a conﬁned space, provide two openings into the boiler room, one near

the ﬂoor and one near the ceiling. The top edge of the upper opening must be within 12” of the ceiling and the

bottom edge of the lower opening must be within 12” of the ﬂoor (Fig 6.1). The minimum opening dimension is

3 inches.

•

If the MWC boiler is the only gas-burning appliance in the boiler room, these openings must each

have a minimum free area of 54 square inches.

If other gas-burning appliances are in the boiler room, size the openings in accordance with the

ANSI Z223.1.

appliance manufacturer’s instructions or the National Fuel Gas Code

Minimum opening free area is

/NFPA 54 and/or CAN/CSA B 149.1.

54 square inches even if opening requirements for other appliances are less.

Figure 6.1: Boiler Installed In A Conﬁned Space, Ventilation Air From Inside

Step 2a (contd.)

•

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.

Step 2b: If the boiler is to be placed in an unconﬁned space the natural inﬁltration into the boiler room will

provide adequate air for ventilation without additional openings into boiler room.

VII Venting

WARNING

Failure to vent this boiler in accordance with these instructions could cause ﬂue gas to enter

the building resulting in severe property damage, personal injury, or death:

•

Do not attempt to vent this boiler with galvanized, PVC, or any other vent components not

listed in Table 7.3.

Do not obtain combustion air from within the building.

Do not install a barometric damper or drafthood on this boiler.

•

CAUTION

Moisture and ice may form on the surfaces around the vent termination. To prevent

deterioration, surfaces should be in good repair (sealed, painted, etc.).

A. Vent System Design

There are two basic ways to vent this boiler:

•

Horizontal (“Side Wall”) Concentric Venting - Vent system exits the building through an outside

wall. Concentric venting consists of a “pipe within a pipe”. Flue gas exits the building through the inner

pipe and combustion air is drawn into the boiler through the space between the inner and outer pipe.

Vertical Concentric Venting - Vent system exits the building through the roof. Concentric venting

consists of a “pipe within a pipe”. Flue gas exits the building through the inner pipe and combustion

air is drawn into the boiler through the space between the inner and outer pipe.

Both of these systems are considered “direct vent” because in both, combustion is drawn directly from the

outdoors into the boiler. A description of all of these venting options are shown in Tables 7.1 and 7.6. For

clarity, these vent options are numbered from 1 to 6. One of the vent option columns in Tables 7.1 or 7.6 must

match the planned vent and air intake system exactly. In addition, observe the following guidelines:

1) Approved vent systems - Use only one Concentric vent system components supplied by Crown. The

standard boiler is supplied with a concentric vent system having a maximum usable length of 25” (Figure

2.1). For longer runs, additional straight lengths and elbows are available from Crown. In some cases,

larger diameter concentric pipe must be used. Each Crown concentric vent component consists of an

inner pipe of polypropylene and the outer pipe of steel. Integral gaskets on each concentric ﬁtting provide

a gas tight seal. A list of all Crown concentric vent components is shown in Table 7.3.

In this manual, concentric pipe sizes are called out in terms of the inner and outer pipe nominal

diameters in millimeters. For example, “60/100mm” pipe consists of a 60mm exhaust pipe inside a

100mm diameter outer pipe.

2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon

the vent option selected. See Table 7.1 or 7.6 for the maximum vent length. In horizontal vent systems,

the lengths shown in Table 7.1 are in addition to the Elbow Adaptor on top of the boiler. If more elbows

are desired, the maximum allowable vent length must be reduced by the amount shown in Table 7.5 for

each additional elbow used. Termination ﬁttings are never counted, although the length of the concentric

terminal section is counted.

2 (contd.)

Example: A 60/100mm concentric vent system is planned for a horizontally vented MWC116 which

has the following components:

•

60/100mm Elbow Adaptor (supplied with the boiler)

1 ft Straight Pipe

90 elbow

Uncut Terminal Section (supplied with the boiler)

The Vent Option #2 column in Table 7.1 describes a horizontal direct vent system using 60/100mm

concentric vent pipe. From this column, we see that a MWC116 may have a vent length of up to 8ft-

10in. The 60/100 Elbow Adaptor supplied with the boiler is not considered. The length of the terminal

section (not including the plastic terminal itself) is approximately 22 1/2” (1.9ft) installed. From Table

7.5, we see that the equivalent length of the 60/100mm elbow is 4.5ft. The total equivalent length of

the planned venting system is therefore:

1ft (Straight ) + 4.5ft (90 Elbow) + 1.9ft (Uncut Terminal Section) = 7.4ft.

Since Table 7.1 shows a maximum allowable vent length of 8ft-10in, the planned vent system length

is acceptable. Note that the 82mm inlet air oriﬁce supplied with the boiler is not used.

3) Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in Tables 7.1 and 7.6.

4) Permitted Terminals for Horizontal Venting:

•

Vent Option 1, 2 - The 60/100mm concentric vent terminal is supplied with the boiler as part of the

standard vent system.

Vent Option 3 - Use the optional 80/125mm Concentric Vent Terminal (Crown PN 230531)

5) Horizontal Vent Terminal Location - Observe the following limitations on the vent terminal location (also

see Figure 7.4).

•

Vent terminal must be at least 1 foot from any door, window, or gravity inlet into the building.

The bottom of the terminal must be at least 12” above the normal snow line. In no case should it be

less than 12” above grade level.

•

The bottom of the vent terminal must be at least 7 feet above a public walkway.

Do not install the vent terminal directly over windows or doors.

The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10

feet.

•

In the USA, maintain a clearance of at least 4ft horizontally from the vent terminal to gas meters,

electric meters, regulators and relief equipment. In Canada, maintain a 6ft clearance between the

vent terminal and these devices.

•

Do not locate the vent terminal under decks or similar structures.

Top of vent terminal must be at least 5 feet below eves, sofﬁts, or overhangs. Maximum depth of

overhang is 3 ft.

•

Vent terminal must be at least 6 feet from an inside corner.

Vent Terminal must be at least 2ft from adjacent buildings.

Under certain conditions, water in the ﬂue gas may condense, and possibly freeze, on objects around

the vent terminal including on the structure itself. If these objects are subject to damage by ﬂue gas

condensate, they should be moved or protected.

•

If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable

operation of this boiler cannot be guaranteed if these terminals are subjected to winds in excess of 40

mph.

Air intake terminal must not terminate in areas that might contain combustion air contaminates, such

as near swimming pools. See Section IV for more information on possible contaminates.

Table 7.1: Summary Of Horizontal Venting Options

VENT OPTION #

RESERVED

FOR FUTURE

USE

CLASSIFICATION USED IN THIS

MANUAL

HORIZONTAL

CONCENTRIC

HORIZONTAL

CONCENTRIC

HORIZONTAL

CONCENTRIC

ILLUSTRATED IN FIGURE

7.2

VENT PIPE PENETRATION

THROUGH STRUCTURE

WALL

60/100 mm

CONCENTRIC

60/100 mm

CONCENTRIC

80/125 mm

CONCENTRIC

VENT PIPE SIZE

82mm

25in

6in

INLET AIR ORIFICE SIZE

MAX. VENT LENGTH

MIN. VENT LENGTH

Not Used

8ft - 10in

26in

82mm

27ft - 10in

6in

CROWN

#230520

(INCLUDED

WITH BOILER)

CROWN

#230520

(INCLUDED

WITH BOILER)

CROWN

#230531

VENT TERMINAL

CROWN

60/100mm

VENT

COMPO-

NENTS

CROWN

60/100mm

VENT

COMPO-

NENTS

CROWN

80/125mm VENT

COMPONENTS

SHOWN IN

VENT MATERIAL

SHOWN IN

TABLE 7.3a

SHOWN IN

TABLE 7.3a

TABLE 7.3b

Figure 7.2: Horizontal Concentric Venting (Vent Options 1-3)

Table 7.3a: Crown Concentric 60/100 Vent Components (Vent Options 1,2)

USED ON

CROWN PN

DESCRIPTION

SIZE

VENT

COMMENTS

OPTION #

340509

340503

230520

230522

230505

230504

230506

230507

230508

230515

340130

60/100mm ELBOW ADAPTOR

60/100mm STRAIGHT ADAPTOR

TERMINAL SECTION

WALL GROMMET

60/100mm

80/125mm

82mm ID

1,2

INCLUDED WITH STANDARD BOILER

OPTIONAL

1,2

INCLUDED WITH STANDARD BOILER

OPTIONAL - MAY NOT BE CUT

OPTIONAL - CAN BE CUT

OPTIONAL

39” STRAIGHT

78” STRAIGHT

19 1/2” STRAIGHT

1,2

90 DEGREE ELBOW

45 DEGREE ELBOW

39” STRAIGHT

OPTIONAL

OPTIONAL - CAN BE CUT

INCLUDED WITH STANDARD BOILER

82mm AIR INLET ORIFICE

Table 7.3b: Crown Concentric 80/125 Vent Components (Vent Options 3,5)

USED ON

CROWN PN

DESCRIPTION

SIZE

VENT

COMMENTS

OPTION #

340523

230527

230528

230526

230517

230515

230518

230519

230525

230531

230532

230533

230535

80/125 STRAIGHT ADAPTOR

90 DEGREE EL (STANDARD)

90 DEGREE EL (SWEEP)

45 DEGREE EL

80/125mm

3,5

19 1/2” STRAIGHT

CAN BE CUT

39” STRAIGHT

MAY NOT BE CUT

78” STRAIGHT

MAY NOT BE CUT

TELESCOPING STRAIGHT

HORIZONTAL TERMINAL

VERTICAL TERMINAL

FLAT ROOF FLASHING

SLOPED ROOF FLASHING

ADJUSTABLE FROM 12-1/2” TO 16-1/2

(NOTE #1)

(NOTE #2)

(NOTE #3)

SUPPORT ELBOW WITH

CHIMNEY CHASE BRACKET

230530

230536

80/125mm

SUPPORT BAND

3,5

Table 7.3b Notes:

1) Vertical terminal can be used with either of the roof ﬂashings listed beneath it.

2) Sloped roof ﬂashing suitable for roof angles between 25 and 45 degrees.

3) Used at base of vertical run inside unused masonry chimney.

Figure 7.4a: Location Of Vent Terminal Relative To Windows, Doors, Grade

Figure 7.4b: Location Of Vent Terminal Relative To Meters And Forced Air Inlets

Figure 7.4c: Positioning Vent Terminal Under Overhangs

table 7.5: Vent/ air Intake Fitting Equivalent length

VENT FITTING

60/100mm 90° CONCENTRIC ELBOW

EQUIVALENT LENGTH (ft)

4.5

60/100mm 45° CONCENTRIC ELBOW

4.0

8.5

5.5

3.0

8.5

80/125mm 90° CONCENTRIC ELBOW

80/125mm 90° SWEEP CONCENTRIC ELBOW

80/125mm 45° CONCENTRIC ELBOW

80/125mm 90° CONCENTRIC SUPPORT ELBOW

6) Permitted Terminals for Vertical Venting - Use Crown PN 230532 with the appropriate ﬂashing (Table 7.3b)

7) Vertical Vent Terminal Locations (Vent Option 5) - Observe the following limitations on the location of all

vertical vent terminals (see Figure 7.7):

•

The top of the vent pipe must be at least 2 feet above any object located within 10 feet.

The bottom of the air inlet terminal must be at least 12” above the normal snow accumulation that can be

expected on the roof. The terminal used in Vent Option #5 has a ﬁxed distance above the storm collar of

19”. If a greater distance is needed to provide the clearance above the snow line, build a chase on the

roof and mount the vertical terminal on top of the chase.

8) Wall thimbles – Concentric vent has a “zero” clearance to combustibles and therefore does not require the

use of wall thimbles.

9) Pitch of Horizontal Piping - Pitch all horizontal piping so that any condensate which forms in the piping will run

towards the boiler. Pitch Crown horizontal concentric venting 5/8” per foot

10) Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported. Support Crown

concentric venting near the female end of each straight section of pipe. Exception: Vertical runs of concentric

pipe in an unused chimney (Figure 7.36) need only be supported at the terminal and at the base of the run.

table 7.6: Summary of Vertical Venting options

VENT OPTION #

CLASSIFICATION USED IN THIS

MANUAL

VERTICAL

CONCENTRIC

RESERVED FOR

FUTURE USE

ILLUSTRATED IN FIGURE

7.7

VENT PIPE PENETRATION

THROUGH STRUCTURE

ROOF

80/125mm

CONCENTRIC

VENT PIPE SIZE

82mm

27ft - 10in

6in

INLET AIR ORIFICE SIZE

MAX. VENT LENGTH

MIN. VENT LENGTH

CROWN #230532

CONCENTRIC

TERMINAL (TABLE

7.3b)

VENT TERMINAL

VENT MATERIAL

CROWN 80/125 mm

VENT COMPONENTS

SHOWN IN TABLE

7.3b

Figure 7.7: Vertical Concentric Vent System (Vent Option 5)

B. Removing an Existing Boiler From a Common Chimney

Read this only if the MWC boiler is replacing an existing boiler that is being removed from a common

chimney. This section does not apply to the installation of a MWC boiler.

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 openings 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.

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 ﬁreplace dampers.

(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust

thermostat so the appliance will operate continuously.

(e) Test for spillage at the draft hood relief opening after 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./NFPA 54 and/or CAN/CSA B 149.1

Natural Gas and Propane Installation Code. When re-sizing any portion of the

common venting system, the common venting system should be re sized to approach the minimum

size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI

Z223.1./NFPA 54 and/or CAN/CSA B 149.1

WARNING

Never common vent a MWC boiler with other appliances.

C. Assembly of Crown 60/100mm Concentric Venting

(IMPORTANT - Skip to Section D for 80/125mm Concentric Vent Assembly)

WARNING

Failure to follow the instructions could result in ﬂue gas leakage into the combustion air or indoor

air, resulting in unsafe or unreliable operation.

• Do not lubricate concentric gaskets with anything other than water.

• Do not attempt to cut any piping except as permitted in this section. When cutting these

sections, make sure

all cuts are square and allow for proper insertion.

• Do not attempt to try to mix this concentric pipe with other venting systems.

1) Concentric vent components supplied with the boiler are packed in a separate carton and include the following:

a) 60/100mm elbow adaptor (Crown PN 340509).

b) 60/100mm terminal section (straight section with a terminal and overall length of 27 3/4” (Crown PN 230520).

c) Two (2) Rubber wall grommets (Crown PN 230522).

d) Vent gasket and screws for attachment of vent system to boiler.

The 82mm air inlet oriﬁce required for Vent Option 1 is packed in the boiler carton.

The 60/100 straight adaptor is optional equipment. It is supplied with the same screws and gasket as the 60/100

elbow adaptor.

2) Start by attaching the elbow adaptor (or straight adaptor, if used instead) to the top of the boiler using the gasket

and four 4.2mm sheet metal screws provided in the vent kit as shown in Figurre 7.20. FFor Vent Option 1, install the

82mm air inlet oriﬁce as shown.

3) If no additional sections of concentric pipe are required, attach the terminal section to the elbow. In most cases, it

will need to be cut before doing so. Use the following procedure to cut the pipe:

a) Measure distance “L” from the outside surface of the exterior wall to the end of the elbow as shown in Figure

7.21.

b) Add 2-1/8” to distance “L”. Carefully mark this length on the pipe as shown in Figure 7.22.

c) Press in the two tabs holding the plastic terminal in the terminal section (Figure 7.22). Carefully pull out the

terminal and the inner pipe.

d) Cut the outer pipe only at the point marked in Step (b) using aviation shears, a hacksaw, or an abrasive

wheel cutter. Be careful to cut the pipe square. De burr the cut end with a ﬁle or emery cloth.

e) Cut the plastic inner pipe so that it will protrude 3/8” beyond the outer pipe when reinstalled in the terminal

section (Figure 7.23). Use a ﬁne tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the

pipe square. De burr the cut edge of the plastic pipe with a ﬁle, razor blade, or ﬁne sandpaper.

f) Reinstall the inner pipe in the terminal section. Slip the outside wall grommet over the terminal section and

position so that it covers the joint between the outer pipe and the terminal (Figure 7.24).

g) Make a mark on the terminal section 1” from the cut end of the outer pipe as shown in Figure 7.24.

h) Pass the terminal section through the wall from the outside. Push the remaining wall grommet over the

terminal section on the inside of the wall. Push the terminal section into the elbow until the mark made in Step

(g) is no longer visible. If necessary, the brown gasket in the inner pipe may be lubricated with a few drops of

water.

i) The terminal section must be attached to the elbow with a single #10 x 1/2” sheet metal screw ( not supplied)

at the top of the elbow. Drill a 1/8” hole in the location shown in Figure 7.25. Use a short drill bit or a drill

stop to ensure that the drill bit does not penetrate the pipe by more than 3/8”. Install a #10 x 1/2” screw

in this hole. Do not use a screw longer than 1/2” long.

j) If not already done, make sure that both wall grommets are ﬁrmly against the interior and exterior wall

surfaces. Seal any cracks or other openings near the terminal through which exhaust could enter the building.

FIGURE 7.20: INSTALLATION OF 60/100 ADAPTORS ON BOILER

FIGURE 7.21: DIMENSION “L”

4) If additional pieces of pipe are used, install them starting at the boiler elbow. Support each section of straight pipe

at its female end.

5) Use locking bands provided to join adjacent sections of non-cuttable pipe as well as ﬁttings. The male end of the

terminal section and other cuttable sections must be held to the female end of the adjoining pipe with at least

three #10 x 1/2” sheet metal screws. Drill a 1/8 hole through both outer pipes to start this screw. Use a drill stop

or other means to ensure that the drill bit does not penetrate more than 3/8” into the outer pipe. Do not

use a sheet metal screw longer than 1/2”.

6) The only straight pipe that can be cut is the terminal section and the 19-1/2” section (Crown PN 230506). To cut

this pipe:

a) Cut pipe from the male end. After marking the desired length of the outer pipe, remove the plastic inner pipe

by pulling it out from the female end.

b) Cut the outer pipe only at the point marked in Step (b) using aviation shears, a hacksaw, or an abrasive

wheel cutter. Be careful to cut the pipe square. De burr the cut end with a ﬁle or emery cloth.

c) Cut the plastic inner pipe so that it will protrude 3/8” beyond the outer pipe when reinstalled in the outer pipe.

Use a ﬁne tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe square. De burr

the cut edge of the plastic pipe with a ﬁle, razor blade, or ﬁne sandpaper.

d) Reinstall the inner pipe.

7) Install the terminal as outlined in Step (4) above. Dimension “L” described in Step 3 is the distance from the

exterior surface of the wall to the end of the last piece of pipe inside the building.

Figure 7.22: Cutting Outer Pipe

Figure 7.23: Cutting Inner Pipe

Figure 7.24: Preparing 60/100mm Terminal Section For Installation In The Wall

Figure 7.25: Attaching 60/100mm Terminal Section

D. Assembly of Crown 80/125mm Concentric Venting

(IMPORTANT - See Section C for 60/100mm Concentric Vent Assembly)

WARNING

Failure to follow the instructions could result in ﬂue gas leakage into the combustion air or indoor

air, resulting in unsafe or unreliable operation.

• Do not lubricate concentric gaskets with anything other than water.

• Do not attempt to cut any piping except as permitted in this section. When cutting these

sections, make sure

all cuts are square and allow for proper insertion.

• Do not attempt to try to mix this concentric pipe with other venting systems.

1) The 60/100mm terminal section and concentric reducing elbow supplied with the boiler are not used in

80/125mm vent systems. The components listed in Table 7.3b are required for 80/125mm installations and

are not supplied with the boiler. Before starting assembly of an 80/125mm vent system, make sure that

the planned installation is in accordance with the “Vent System Design” section of this manual and that

all required 80/125mm vent components are on hand. These components are available through Crown

distributors.

Figure 7.30: Installation Of 80/125 Adaptor On Boiler

2) Installation of the MWC116 with 80/125mm venting requires the use of the 80/125mm appliance adaptor

(Crown PN 340523). This adaptor is installed on top of the boiler as shown in Figure 7.30. For vent options 3

and 5, sandwich the 82mm air inlet oriﬁce between the boiler and the adaptor as shown.

3) Cutting Straight Pipe - The following straight pipe sections may be cut:

Part #

Description

230517

230515

19 1/2” Straight

39” Straight

These sections have a plain male end (without beads - see Figure 7.31a). They are always cut from the

male end. Sections not shown on the above list may not be cut. These sections have beads on the male end

(Figure 7.31b).

Figure 7.31a: Cuttable Straight Section

Figure 7.31b: Non Cuttable Straight Section

3) (contd.) To cut the straight sections listed above refer to Figure 7.32 and the following instructions:

a) Determine the required length of the outer pipe. When doing this allow an additional 1” of length for

insertion into the female end of the adjoining pipe. Mark the cut line on the outer pipe.

b) Remove the plastic inner pipe by pulling it out from the female end.

c) Cut the OUTER PIPE ONLY at the point marked in Step (a) using aviation shears, a hacksaw, or an

abrasive wheel cutter. Be careful to cut the pipe square. De burr the cut end with a ﬁle or emery cloth.

d) Make an insertion mark 1” from the male end of the outer pipe.

e) Cut the plastic inner pipe so that it will protrude 3/8” beyond the male end of the outer pipe when

reinstalled in the outer pipe. Use a ﬁne tooth hacksaw or a PVC saw to cut the plastic pipe and be careful

to cut the pipe square. De burr the cut edge of the plastic pipe with a ﬁle, razor blade, or ﬁne sandpaper.

f) Reinstall the inner pipe.

4) Joining Pipe -

a) Start assembly of the vent system at the boiler. Lubricate the brown gasket in the boiler vent collar with a

few drops of water.

b) Push the male end of the ﬁrst ﬁtting into the boiler collar until it bottoms out. The male end of cuttable

sections should go 1” into the collar until the insertion mark (made in Step 3d above) is covered. On other

ﬁttings, the bead on the male pipe will bottom out on the collar (Figure 7.33b).

c) The male end of cuttable ﬁttings must be held to the collar with three #10 x 1/2” sheet metal screws. Drill

a 1/8 hole through both outer pipes to start this screw. Use a drill stop or other means to ensure that

the drill bit does not penetrate more than 3/8” into the outer pipe. Do not use a sheet metal screw

longer than 1/2” (Figure 7.33a).

d) Use locking bands (provided with all ﬁttings) to secure non-cuttable pipe, as well as ﬁttings, to the boiler

collar (Figure 7.33b).

e) Use the same method to join all remaining vent components except for the terminal.

Figure 7.32: Cutting Straight Pipe

Figure 7.33a: Joining Cuttable Pipe

Figure 7.33b: Joining Non-Cuttable Pipe

5) 80/125mm Horizontal Terminal Installation -

a) Cut a 5-1/2” diameter hole through the exterior wall at the planned location of the horizontal terminal.

b) Measure distance “L” from the outside surface of the exterior wall to the end of the last ﬁtting as shown in

Figure 7.34a.

c) Add 1-1/4” to distance “L”. Carefully mark this length on the pipe as shown in Figure 7.34b.

d) Remove the inner pipe from the terminal, by gently pulling on it from the male end. Set aside.

e) Cut the outer pipe only at the point marked in Step (c) using aviation shears, a hacksaw, or an abrasive

wheel cutter. Be careful to cut the pipe square. De-burr the cut end with a ﬁle or Emory cloth.

f) Reinstall the inner pipe in the terminal, making sure that the female end of this pipe is completely

bottomed out over the aluminum male connection visible behind the air intake grill. Place a mark on the

inner pipe 3/8” beyond the end of the outer pipe (Figure 7.34c). Use a ﬁne tooth hacksaw to cut the pipe

and be careful to cut the pipe square (if necessary, the pipe can be removed from the terminal again for

cutting). De-burr the cut edge of the pipe with a ﬁle, razor blade, or ﬁne sandpaper.

g) Make a mark on the terminal section 1” from the cut end of the outer pipe as shown in Figure 7.34c.

h) Slip the terminal section through the wall from the outside. Pass the terminal through the inner wall plate

and push into the last section of vent pipe until the mark made in Step (g) is not longer visible (Figure

7.34d). Secure the terminal to the last piece of pipe with three #10 x 1/2” sheet metal screws. Drill a 1/8

hole through both outer pipes to start these screws. Use a drill stop or other means to ensure that

the drill bit does not penetrate more than 3/8” into the outer pipe. Do not use a sheet metal screw

longer than 1/2”.

i) Slip the outer wall plate over the terminal and secure to the wall (Figure 7.34d). Apply a 1/8” bead of

weather resistant RTV over the joint between the outside wall plate and the terminal. Secure the other

wall plate to the inside wall.

Figure 7.34a: Dimension “L”, 80/125mm Horizontal Terminal

Figure 7.34b: Cutting Outer Pipe Of 80/125mm Horizontal Terminal

Figure 7.34c: Cutting Inner Pipe Of 80/125mm Horizontal Terminal

Figure 7.34d: Completing 80/125mm Horizontal Terminal Installation

6) Vertical Terminal Installation - In addition to the vertical terminal, either a Flat Roof Flashing (PN 230533) or

Sloped Roof Flashing (PN 230535) is required for this installation.

a) Determine the center line of the terminal location on the roof. If the roof is ﬂat, cut a 5-1/2” diameter hole

for the terminal. If the roof is sloped, cut a hole large enough for the terminal to pass through the roof while

remaining plumb. Caution: If the boiler is installed directly under the hole, cover it while cutting the

hole to prevent saw dust and other debris from falling into the boiler.

b) Install the roof ﬂashing using standard practice for the rooﬁng system on the structure.

c) If not already done, assemble the venting system inside the building. The last section of pipe needs to be on

the same center line as the terminal and within 19-1/4” of the top edge of the roof ﬂashing (Figure 7.35a).

d) Measure distance “H” from the top edge of the storm collar to the end of the last ﬁtting as shown in Figure

7.35a.

e) Add 1” to distance “H”. Carefully mark this length on the pipe as shown in Figure 7.35b.

f) Cut the outer pipe only at the point marked in Step (e) using aviation shears, a hacksaw, or an abrasive

wheel cutter. Be careful to cut the pipe square. De-burr the cut end with a ﬁle or emery cloth.

g) Place a mark on the aluminum inner pipe 3/8” beyond the end of the outer pipe (Figure 7.35b). Use a ﬁne

tooth hacksaw to cut the aluminum pipe and be careful to cut the pipe square. De-burr the cut edge of the

aluminum pipe with a ﬁle or emery cloth.

h) Make a mark on the terminal section 1” from the cut end of the outer pipe as shown in Figure 7.35b.

i) Slip the terminal section through the roof from the outside. Push into the last section of vent pipe until the

mark the mark made in Step (h) is not longer visible. Secure the terminal to the last piece of pipe with three

#10 x 1/2” sheet metal screws. Drill a 1/8 hole through both outer pipes to start these screws. Use a drill

stop or other means to ensure that the drill bit does not penetrate more than 3/8” into the outer pipe.

Do not use a sheet metal screw longer than 1/2”.

j) Secure the terminal section to the inside of the roof structure using the mounting bracket provided with the

terminal Figure 7.35c).

7) Chimney Chase Installation - A vertical 80/125mm vent system can be installed in an unused masonry chimney.

This installation is similar to other vertical installations with the following exceptions (Also see Figure 7.36):

a) The chimney chase elbow kit (PN230530) is used at the base of the chimney. This kit consists of a support

elbow and a mounting bracket. Slip the elbow over the M10 x 35 screw in the support bracket. Determine

the desired vertical location of the support elbow in the chimney and mark the location of the pin on the back

of the support bracket on the back wall of the chimney. Drill a 7/16”dia x 2-1/2” deep hole at this location to

support the back of the bracket. The front of the elbow mounting bracket is supported by the bottom of the

opening into the chimney or by an installer supplied bracket.

b) Construct a weather-tight ﬂat roof to cover the top of the old chimney. Install the vertical terminal through this

roof using the ﬂat roof ﬂashing.

Figure 7.35a: Dimension “H”

Figure 7.35b: Cutting Vertical Terminal

Figure 7.35c: Completing Vertical Terminal Installation

WARNING

•

Do not attempt to construct a vertical vent system inside a chimney that is used to vent a

ﬁreplace or other appliances.

Do not attempt to construct a vertical vent system inside a chimney ﬂue adjacent to another

ﬂue used by a ﬁreplace or other appliances.

Figure 7.36: Chimney Chase Installation

E. Condensate Trap and Drain Line

All condensate which forms in the boiler or vent system leaves the boiler through the condensate trap.

This trap allows condensate to drain while retaining ﬂue gases in the boiler. This boiler is supplied with a

length of drain hose already attached. Route this hose to a drain or other suitable location to dispose of the

condensate. Note the following when disposing of the condensate:

•

If the condensate drain line must be extended, construct the extension from PVC or CPVC pipe.

Insert the hose provided with the boiler into the end of the extension as shown in Figure 7.40.

Condensate is slightly acidic. Do not use metallic pipe or ﬁttings in the condensate drain line. Do not

route the drain line through areas that could be damaged by leaking condensate.

Some jurisdictions may require that the condensate be neutralized before being disposed of. Dispose

of condensate in accordance with local codes.

•

Do not route, or terminate, the condensate drain line in areas subjected to freezing temperatures.

If the point of condensate disposal is above the trap, it will be necessary to use a condensate pump to

move the condensate to the drain. In such cases, select a condensate pump that is approved for use

with condensing furnaces. If overﬂow from this pump would result in property damage, select a pump

with an overﬂow switch and use this switch to shut down the boiler. Alternatively, if heat is a necessity,

use the overﬂow switch to trigger an alarm.

•

Do not attempt to move the trap from the location shown in Figure 7.40. Do not attempt to substitute

another trap for the one provided with the boiler.

WARNING

Failure to install the condensate trap and condensate drain in accordance with the above

instructions could cause ﬂue gas to enter the building, resulting in personal injury or death.

CAUTION

Boiler condensate is corrosive. Route condensate drain line in a manner such that any

condensate leakage will not cause property damage. Some jurisdictions may require that

condensate be neutralized prior to disposal.

Figure 7.40: Condensate Piping Arrangement

VIII Gas Piping

Gas piping to the boiler must be sized to deliver adequate gas for the boiler to ﬁre at the nameplate input at

an inlet pressure between the minimum and maximum values shown on the rating plate. For more information

ANSI Z223.1 /NFPA 54 and/or CAN/CSA B 149.1

on gas line sizing, consult the utility or the National Fuel Gas Code

Natural Gas and Propane Installation Code.

The gas line is connected to the boiler using the 3/4” NPT female connection in the tailpiece shown in Figure

8.1. This tailpiece is supplied in the boiler’s ﬁtting package, along with the ﬁber gasket shown.

Figure 8.2 shows the ﬁnished gas piping connection to the MWC boiler. A sediment trap must be installed

upstream of all gas controls. Install the factory provided manual shut-off valve outside the jacket with a 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.

Figure 8.1: Gas Tailpiece Installation

Figure 8.2: Gas Connection To Boiler

IX System Piping

CAUTION

•

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

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

Operation of this boiler with continuous return temperatures below 86F can cause severe heat

exchanger corrosion damage.

Operation of this boiler in a system having frequent additions of make-up water can cause severe

heat exchanger damage.

•

Do not use toxic additives, such as automotive antifreeze, in a hydronic system.

Before connecting boiler, make sure that the system is free of sediment, ﬂux and any residual boiler

water additives. Flush the system if necessary to ensure that these contaminates are removed.

A. Standard Piping

Figure 9.1 shows typical boiler system connections on a single zone system. Additional information on hydronic system

design may be found in Installation of Residential Hydronic Systems (Pub. #200) published by the Hydronics Institute in

Berkeley Heights, NJ. The components in this system and their purposes are as follows:

1) Relief valve (Included & Required) – Install the relief valve in the 3/4” connections on the top of the boiler as shown

in Figure 9.3. The relief valve shipped with the boiler is set to open at 30 psi. This valve may be replaced with

one having a setting at or below the Maximum Allowable Working Pressure (MAWP) shown on the ASME plate

attached to the heat exchanger. If the valve is replaced, the replacement must have a relief capacity in excess of

the Minimum Relief Valve Capacity shown on the rating plate.

Pipe the discharge of the 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 relief

valve discharge is not piped to a drain, it must terminate at least 6 inches above the ﬂoor. Do not run relief valve

discharge piping through an area that is prone to freezing. The termination of the relief valve discharge piping must

be in an area where it is not likely to become plugged by debris.

DANGER

•

Pipe relief valve discharge to a safe location.

Do not install a valve in the relief valve discharge line.

Do not move relief valve from factory speciﬁed location.

Do not plug relief valve discharge.

2) Circulator (Included & Required) – This boiler is equipped with a factory piped circulator, which is often the only

circulator required. Figure 9.2 is a performance curve for this circulator. Note that this curve is has been adjusted to

take into the account of all internal boiler piping. This performance curve therefore shows the amount of ﬂow that

can be achieved at various heating system pressure drops.

3) Throttling Valve or Flow Restrictor - This boiler is equipped with a differential pressure switch to prove that there is

ﬂow through the boiler before allowing it to ﬁre. Reliable operation of this switch requires that there be a head loss

across the heating system of at least 5.1ft wc. In order to assure that this head loss will always be present, either a

throttling valve must be installed as shown in Figure 9.1 or the ﬂow restrictor shown in Figure 9.4 must be installed.

Use the following guidelines to determine which device to use:

•

If the boiler is installed an a single zone system, or one having zone valves, install the throttling valve. At start-

up, start with this valve fully open and then close it just enough to obtain reliable operation of the pressure

switch.

•

If the boiler is connected to a primary-secondary system (Figure 9.5), install the oriﬁce in the supply tailpiece

as shown in Figure 9.4.

If the boiler is connected to a circulator zone system, primary-secondary piping must be used. Install the oriﬁce

as shown in Figure 9.4.

Figure 9.1: Basic Piping

CAUTION

Failure to install the throttling valve or ﬂow restrictor described on the boiler supply could result

in unreliable boiler operation

4) Expansion Tank (Included & Required) – This boiler is equipped with a built in expansion tank. This tank is suitable

for use on systems having a water content of up to 40.6 Gal. This tank is pressurized to approximately 14.7 psi.

5) On systems having water content in excess of 40.6 gallons, a second expansion tank must be provided. Locate

this tank as close as possible to the return connection on the boiler.

6) As shipped, the expansion tank is suitable for installations where the vertical distance between the relief valve and

the highest point in the system is 23ft or less. Consult the factory if it is desired to install this boiler on a system

having a greater height.

7) Fill Valve (Required) – Either a manual or automatic ﬁll valve may be used. Connect the ﬁll as shown in Figure 9.1.

8) Automatic Air Vent (Included & Required) – The boiler is equipped with an automatic air vent. Manual vents will

usually be required in other parts of the system to remove air during initial ﬁll.

9) Low Water Protection – This boiler is equipped with a ﬂow switch which will only allow the boiler to ﬁre when there

is ﬂow through the boiler, and therefore water in the heat exchanger.

10) Isolation Valves (Optional - Not Shown) – Isolation valves are useful if the boiler must be drained, as they will

eliminate having to drain and reﬁll the entire system.

11) Drain Valve (Required) – Install a 3/4” boiler drain (not supplied) in the return piping as shown in Figure 9.1.

Figure 9.2: Circulator Performance Curve (Adjusted For Pressure Drop Through

Boiler)

B. Boiler Connections

Boiler supply and return connections are located on the bottom of the boiler as shown in Figure 9.4. Copper 3/4” tail

pieces are provided in the ﬁtting bag along with gaskets. Sweat the ﬁrst copper ﬁttings to these tail pieces and then

connect the tail pieces to the boiler using the gaskets provided. If required, install the ﬂow restrictor in the supply as

shown in Figure 9.4.

The relief valve is installed using the union connection on top of the boiler as shown in Figure 9.3. Route the relief

valve discharge to a safe location as described on Page 36.

Figure 9.3: Relief Valve Installation

Figure 9.4: Supply And Return Tailpiece Installation

C. Piping for Special Situations

Certain types of heating systems have additional requirements. Some examples follow:

1) Primary-Secondary Piping – Primary-secondary piping is required when circulator zoning is used or when the

system ﬂow rate must be greater than 5.5 GPM. In these cases, the piping shown in Figure 9.5 is used so that the

ﬂow through the system is completely independent of the ﬂow through the boiler. This ensures reliable operation of

the boiler’s ﬂow switch.

When assembling the piping shown in Figure 9.5, be sure to observe the minimum dimensions shown. The

minimum pipe size of the primary piping in the vicinity of the tees is 1 1/4”. At least 11” (8 diameters) of 1-1/4”

straight pipe must be installed upstream of the tees as shown. At least 5 1/2” (4 diameters) of 1-1/4” straight pipe

must be installed downstream of the tees.

2) Piping with a Chiller – If the boiler is used in conjunction with a chiller, pipe the boiler and chiller in parallel as

shown in Figure 9.6. Use isolation valves to prevent chilled water from entering the boiler.

3) Air Handlers – Where the boiler is connected to air handlers through which refrigerated air passes, use ﬂow control

valves in the boiler piping or other automatic means to prevent gravity circulation during the cooling cycle.

D. Internal Boiler Piping

Schematics of the internal boiler piping are shown in Figures 9.7 and 9.8 for the MWC116E*T (combi) and

MWC116E*L (heat-only) models respectively. A schematic of the internal domestic hot water piping for the MWCE*T is

shown in Figure 10.3.

Figure 9.5: Primary-Secondary Piping

Figure 9.6: Chiller Piping

Figure 9.7: MWC116E*T (Combi) Internal Boiler-Side Piping Schematic

Figure 9.8: MWC116E*L (Heat-Only) Internal Piping Schematic

X. Domestic Water Piping

CAUTION

If the MWC is connected to a water supply having a hardness in excess of 200PPM, scale

may prematurely form in the DHW heat exchanger, signiﬁcantly shortening its life. If

necessary, soften the water upstream of the cold water connection to the MWC.

If the MWC is equipped for domestic hot water (DHW) production, connect the domestic hot water piping

as shown in Figure 10.1. Connections to the boiler are made with 1/2” copper tail pieces as shown in Figure

10.2. Solder the ﬁrst ﬁtting to these tail pieces before mounting them on the boiler. The components in this

system and their functions are as follows:

1) Anti-scald Devices (Required - Not Shown) - Install anti-scald protection devices in accordance with local

codes. In the absence of any local Codes, install such devices as required by the Uniform Plumbing Code

(IAPMO UPC).

WARNING

Like all domestic water heaters, the MWC is capable of generating water that is hot enough to

cause injury or death due to scalding. To minimize the risk of scalding:

•

Set domestic hot water (DHW) thermostat as low as possible (see the Start-up Section of this

manual for the location of this thermostat.

•

Feel water before showering or bathing.

If anti-scald or anti-chill protection is required, use devices speciﬁcally designed for such

service. Install and maintain these devices in accordance with the manufacturer’s instructions.

2) Flow Restrictor (Recommended) - If domestic hot water is drawn from the MWC at a rate in excess of

the rating in Table 2.2, the temperature of the hot water may be too low to be of use. The use of a ﬂow

restrictor will prevent this problem by limiting the rate at which water can pass through the DHW heat

exchanger. If a restrictor is used, select one having a rating in GPM approximately equal to that shown in

Table 2.2.

3) Pressure Relief Valve (Required) - Limits the pressure in the domestic hot water piping. Use a valve

designed for DHW service, such as the Watts #3L or #53L. Note that this is a pressure relief valve, not a

T&P valve. Select a valve with a pressure setting less than or equal to 145 psi. Pipe the discharge to a

safe location using piping the same size as the discharge connection on the valve.

4) Hose Bib Valves (Recommended) - These valves permit the DHW plate heat exchanger be periodically

“back ﬂushed” to remove sediment.

5) Globe or Ball Valve (Recommended) - Used to aid in back ﬂushing the heat exchanger and to isolate the

DHW piping if it must be serviced. In addition, the upstream valve may be used to limit the DHW ﬂow if

necessary.

Figure 10.1: DHW Piping

Figure 10.2: DHW Tailpiece Installation

Figure 10.3: MWC116E*T (Combi) Internal DHW-Side Piping Schematic

XI Wiring

WARNING

All wiring and grounding must be done in accordance with the authority having jurisdiction

or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70),

and / or, the Canadian Electrical Code Part I ,CSA C22.1,Electrical Code.

1) All electrical connections are line voltage (120 VAC) and are located under the cover on the cover on the top of the

control box (Fig 11.1). To access these connections, use the following procedure:

a) Remove the three screws on the top of the front jacket panel and lift off the panel.

b) There are three screws in the bottom of each side jacket panel: two near the front and one near the back.

Remove the two screws near the front and loosen the screw near the back.

c) Spread the side jacket panels apart slightly, slide the control box forward and then rotate the control box down

as shown in Figure 11.1.

d) Remove the cover shown in Figure 11.1 to access the electrical connections.

2) Crown supplies the “Whip” shown in Figure 11.2 to route the power and thermostat wiring from an installer supplied

junction box into the boiler’s control box. This Whip is designed to provide proper strain relief at the boiler and also

permits the control box to be easily slid in and out of the boiler with all wiring connections intact. A 7/8 hole is located

in the metal rail behind the control box as shown in Figure 11.3. Power and thermostat wiring is routed into the boiler

from underneath (Figure 11.5) and the BX connector on the “boiler end” of the Whip is secured in this 7/8” opening.

3) Route the whip leads into the electrical connection compartment. DO NOT CUT THE WHIP LEADS ON THE

BOILER END.

4) Two terminal blocks are located in the electrical connection compartment: one for power connections and one for the

thermostat connections. Figure 11.3 shows the location of these terminal blocks in the connection compartment.

5) Connect the whip leads to the terminals as shown in Figure 11.4:

Whip Color

Black

White

To Factory Wire Color

Brown

Blue

Description

120VAC “Hot”

120 VAC Neutral

Ground

Green

Green/Yellow

Orange (either) Blue

Orange (either) Red

120VAC Thermostat

Important: Remove the factory installed jumper from the thermostat terminals (Figure 10.4)

6) Reinstall the compartment cover removed in Step #1d.

7) Figure 11.5 shows connections at the junction box end of the whip. Provide a dedicated circuit for the boiler with

at least one emergency shut-off switch located in accordance with applicable codes. The thermostat connections

provided are 120VAC. If a thermostat is directly connected to these leads, it and all intervening wiring, must be

suitable for use with 120VAC power. If it is desired to control the boiler with a low voltage thermostat, or other low

voltage control system, use a fan center to do so as shown in Figure 11.6

WARNING

Attempting to directly connect a low voltage thermostat and/or low voltage wiring to the orange

thermostat leads could cause property damage and/or create hazard of ﬁre or electricutuion.

Figure 11.1: Accessing Electrical Connections

Field Supplied

J-Box End

Boiler End

Figure 11.2: “Whip”

Figure 11.3: Location of Terminal Blocks and 7/8 Hole for Whip

Figure 11.4: Electrical Connections Inside Control Box.

Figure 11.5: Field Wiring - 120VAC Thermostat

Figure 11.6: Field Wiring - 24V Thermostat Using Installer-Supplied Fan Center

Flue

thermostat

Safety

thermostat

Air pressure

switch

Ignition

electrodes

Flame detection

electrode

Electric supply

terminal block

Fan

External controls

terminal block

COM

bn gnye bu

wh gy

gnye

ye wh bu

gnye

bu bn

gnye

ye bk wh gy bu

bk rd bu bu

bk bk

gy gy

gnyebu gy

rdrd rd

bu wh

wh bk rd

gnye gy bu

COM

**Three way

**diverter valve

**D.h.w.

**NTC

**D.h.w.

**flow switch

Prmary circuit C.h. temperature

flow switch probe NTC

Pump

Gas valve

*--- directly connected to the electronic ignition board

** - Not for model c.h. only

bn - brown

bu - blue

bk - black

gn - green

gnye - green / yellow

gy - grey

or - orange

rd - red

Caution: Label all wires prior to disconnection when

servicing controls. Wiring errors can cause

improper and dangerous operation.

Verify proper operation after servicing

wh - white

vt - violet

ye - yellow

Figure 11.7: Internal Boiler Wiring

XII Start-up and Checkout

NOTE

Safe lighting and other performance criteria were met with the gas train assembly provided

on the boiler when the boiler underwent the tests speciﬁed in Z21.13.

WARNING

Never attempt to ﬁll a hot empty boiler

Use the following procedure for initial start-up of the boiler:

1) If not already done, ﬂush the system to remove sediment and debris. This should be done with the boiler

isolated from the system.

2) Fill the boiler and hydronic system with water and purge the system of air. To do this:

a) Unscrew the cap on the automatic air vent by one turn and leave open permanently. This air vent is

located on top of the circulator (Figure 12.1).

b) Open the ﬁll valve and pressurize the boiler to approximately 15psi

c) Bleed air out of each manual air vent in the system until a steady stream of water appears. Start with

the lowest manual vents in the system and work towards the highest. If a manual ﬁll valve is used,

periodically add water to the system so that the pressure at the boiler is maintained at approximately

15 psi.

d) Remove the shaft cover screw on the front of the circulator (Figure 12.2). Using a screw driver,

manually spin the shaft in the direction of rotation shown on the pump until a small amount of water

appears at the end of the shaft. Replace the shaft cover screw.

e) At the end of the purging process, make sure that the pressure gauge on the boiler reads between 5

and 19 psi.

f) Make sure that a manual air vents are closed. If an automatic ﬁll valve is used, make sure that it is set

to the automatic position.

Auto Air

Vent Cap

Figure 12.1: Location of Automatic Air Vent Cap

Shaft Screw Cover

Figure 12.2: Location of Circulator Shaft Cover

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

CAUTION

Leaks in the hydronic system can result in the addition of excessive amounts of make-

up water. This can cause severe damage to the boiler’s heat exchanger from corrosion or

calcium deposits. Repair any leaks in the system immediately.

3) Check all new water and gas piping for leaks and purge piping sections that are ﬁlled with air. Fix any

leaks found immediately. See the National Fuel Gas Code, ANSI Z223.1./NFPA 54 and/or CAN/CSA B 149.1

for additional information on testing and purging gas lines.

Natural Gas and Propane Installation Code,

4) Vent system must be complete and free of obstructions before attempting to ﬁre boiler.

5) Inspect all line voltage wiring for loose or uninsulated connections.

6) Start the boiler using the lighting instructions on page 56. After the power to the boiler is turned on:

a) Initiate a call for heat from the thermostat. Once this is done, Lamp 1 on the control panel (Figure

12.3) should ﬂash every 4 seconds.

b) Rotate the Heating System Knob clockwise from “0” to the maximum supply water temperature

setting (at approximately 5:00) . Lamp 1 should then ﬂash every two seconds and the boiler

should light after approximately 15 - 30 seconds. Once the boiler has lit, Lamps 1 and 3 will ﬂash

continuously.

More information on the boiler controls and indicator lamps is presented in the Operation Section of this

manual. Note: On a new installation, there is a good chance that one of the following two problems will

occur:

•

The differential water pressure switch may not close. If this switch does not close after 180 seconds,

the boiler will lockout. Lamp #2 will stay on continuously and Lamp #1 will ﬂash. If this happens, look

for air in the system or insufﬁcient pressure drop across the boiler supply and return connections.

If the latter problem is suspected, close the throttle valve on the supply further. If no throttling valve

is present, make sure that the ﬂow restrictor is installed (See Part IX). To reset the boiler, turn the

Heating System Knob to “0” for a few seconds and then return it to the max water temperature

setting.

(

)

Figure 12.3: Control Panel

•

The burner may not light on the ﬁrst try. The most likely cause of this problem on a new installation

is a gas line that has not been completely purged. Other possibilities include inadequate inlet gas

pressure or a boiler that is conﬁgured for the wrong fuel. If the boiler does not light on the ﬁrst try, it

will go into a lockout condition. When this happens, the Flame Lockout Lamp (Figure 12.3) will be

illuminated. In addition, Lamps 1 and 3 will ﬂash and Lamp 2 will be on continuously. To reset the

boiler, push the Flame Reset Button shown in Figure 12.3 AND rotate the Heating System Knob back

to “0” for a few seconds.

7) Inspect the ﬂame visible through the window. The ﬂame should be stable and mostly blue (Fig.12.4).

No yellow tipping should be present; however, intermittent ﬂecks of yellow and orange in the ﬂame are

normal.

8) Check the inlet and manifold pressures. To do this, use the following procedure:

a) Remove the inner cover (ﬁgure 12.5). Note: this is necessary in order to read the manifold pressure

accurately because the gas valve regulator is referenced to the burner area.

Figure 12.4: Main Burner Flame

b) Loosen the screw in the gas inlet tap on the gas valve and connect a manometer (see Figure 12.6).

c) Make sure the boiler is at high ﬁre. To do this:

•

On heat only boilers, make sure that the heating system knob is rotated fully clockwise and that

the supply temperature is less than 150F during the entire conduct of this test.

For combi units, rotate the DHW knob fully clockwise and open enough hot water ﬁxtures to keep

the exiting hot water temperature under 110F during the entire conduct of this test.

d) Check the inlet pressure with all the MWC, and all other gas appliances turned 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.)

Minimum

Natural Gas

5.6

LP Gas

10.4

Maximum

10.5

13.0

If the inlet pressure falls outside of these limits, ﬁnd and correct the cause of the problem before

proceeding further.

e) Connect a manometer to the manifold (outlet) pressure tap on the gas valve (Figure 12.6).

f) Read the high ﬁre manifold pressure. It should be set at:

Natural Gas

LP Gas

Manifold Press. (inches w.c.)

4.8 +/-0.25” w.c.

10.3 +/- 0.50” w.c.

g) If an adjustment is necessary, pry the clear plastic cap off of the regulator. Turn the outer brass nut

clockwise to increase the manifold pressure or counter-clockwise to reduce the pressure.

h) Check the low ﬁre manifold pressure. To do this, turn off the boiler and remove one of the modulation

leads (Figure 12.6). Turn the boiler back on. Read the low ﬁre manifold pressure. It should be set at:

WARNING

The gas valve manifold pressures are factory set and should rarely need to be adjusted.

Failure to adjust the gas valve in strict accordance with these instructions could result in

unreliable operation, property damage, personal injury or death due to carbon monoxide

poisoning. When making adjustments, pay particular attention to the following precautions:

•

Be certain that the inlet pressure are within the limits shown before attempting to make

manifold pressure adjustments.

Be sure that the boiler is not modulating when making the high ﬁre adjustment

Be sure to remove the inner cover before reading or adjusting the manifold pressure.

•

Model Number

Fuel

Natural

L.F, Manifold Pressure (in w.c.)

2.2 +/- 0.10

4.8 +/- 0.10

1.0 +/-0.10

2.0 +/-0.10

MWC116ENL (Heat Only)

MWC116ELL (Heat Only)

MWC116ENT (Combi)

MWC116ELT (Combi)

If an adjustment is necessary, turn the inner black hex shaft clockwise to increase the manifold

pressure or counter-clockwise to reduce the pressure (Figure 12.7).

j) Turn off the boiler, reconnect the modulation lead removed in Step (h) and restart the boiler.

k) Recheck the manifold pressure at high ﬁre

l) Recheck the inlet pressure

m) Replace the inner cover.

Figure 12.5: Inner Cover Removal

Figure 12.6: Gas Pressure Taps

(

)

(

)

Figure 12.7: Gas Pressure Adjustments (Pry Off Transparent Cover to Access)

MWC Series Lighting and Operating Instructions

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

’

;

’

OPERATING INSTRUCTIONS

(

)

(

)

(

)

b s

(

)

(

)

“

”

(

)

’

(

)

“

”

(

)

(

)

TO TURN OFF GAS TO APPLIANCE

9) Remove the monometer and make sure that the inlet and manifold pressure tap screws are closed

10) Check the entire gas train for leaks. Fix any leaks found immediately.

11) Run the gas valve safety shut-down test. With the boiler ﬁring, close the gas cock upstream of the boiler.

The gas valve should close as soon as loss of ﬂame is detected (within a few seconds of closing the gas

cock). The boiler should then make one attempt to relight before going into a hard lockout. To reset the

boiler, push the red reset button, rotate the heating system knob back to zero for a few seconds, then

rotate the heating system knob fully clockwise.

12) Run a combustion test with the boiler operating at high ﬁre. CO2 or O2 readings should be reasonably

close to the values shown in Table 12.8. The CO level should be less than 50PPM. Consult the factory if

the CO level is exceeded or if the CO2 or O2 are signiﬁcantly different from the valves shown.

Table 12.8: High Fire Combustion Readings

Fuel

Approx. O₂(%)

Approx. CO₂(%)

Maximum CO (PPM)

Natural Gas

Propane

9.7

9.5

6.3

7.5

13) Verify that the ﬂue system is tight and securely assembled in accordance with the Venting section in this

manual.

14) Replace all jacket panels

15) After the boiler has operated for at least 30 minutes recheck the boiler and system for leaks. Repair ant

leaks found before leaving the boiler in operation.

16) Test any external limits or other controls in accordance with the manufacturer’s instructions.

17) Verify that the boiler starts and stops in response to calls for heat from the heating thermostat/s. Make

sure that the appropriate circulators also start and stop in response to the thermostats.

18) Set the Heating System Knob and the DHW knob for the desired target supply and DHW temperatures

(see the Operation section for more information on how to do this).

XIII Operation

(

)

Figure 13.1: Control Panel

Figure 13.1 shows the control panel for the MWC boiler. The purpose of the adjustments and lamps on this panel are

as follows:

1) Lamps 1, 2, 3 - These lamps show the status of the boiler by lighting and/or ﬂashing in various combinations.

Table 13.4 shows lamp codes that will be seen during normal operation. Lamp codes indicating a problem are

shown in Section XV.

2) Heating System Knob - A detail of the heating system knob is shown in Figure 13.2. This knob has three discrete

settings:

•

Off - Boiler will not respond to a call for heat or domestic hot water (DHW). The boiler will ﬁre, if necessary,

to protect itself from freezing. In addition, it will operate the circulator and the 3-way valve for a few seconds

every 24 hours to prevent these devices from sticking.

The “Off” setting is also used to reset the boiler after it experiences a lockout. To reset the boiler, rotate the

Heating System Knob to “Off” for a few seconds and then return it to its original position (if the lockout is due

to a loss of ﬂame, it will ALSO be necessary push the Flame Reset Button).

•

Summer Operation (Combi Only) - Boiler will not respond to a call for heat from the heating thermostat, but

will respond to a call for DHW.

Target Supply Temperature Setting - When the Heating System Knob is rotated clockwise to any position

from “Off” the boiler will respond to a call for heat. During the call for heat, the boiler will attempt to maintain

a “target” supply temperature. This target supply temperature can bet set anywhere between 100F and 178F

(Figure 13.2) .

3) DHW Thermostat (Combi Boilers Only) - This knob determines the target domestic hot water (DHW) temperature.

It is adjustable from 95F to 131F (Figure 13.3). If a call for heat is present at the same time as a call for DHW, the

call for DHW has priority; no heat will be delivered to the heating system until the call for DHW is satisﬁed.

4) Flame Reset Button - This button is used to reset the boiler in the event that it locks out due to failure to establish

a ﬂame. In addition to pressing this button, it is also necessary to rotate the Heating System Knob back to “0” for a

few seconds to reset the boiler.

5) Flame Lockout Lamp - Illuminates if the boiler locks out due to failure to establish a ﬂame.

Figure 13.2: Heating System Knob

NOTE

Since a room thermostat will almost always be used to initiate a call for heat (either directly or

through zone controls), it is generally recommended that the Heating System Knob be left at

the appropriate Target Supply Temperature year round.

Figure 13.3: Domestic Hot Water (DHW) Thermostat

WARNING

The domestic water thermostat on the Maui is not intended to serve as a scald protection device.

Under certain conditions, it is possible for the DHW temperature to climb signiﬁcantly above the

DHW Thermostat set point. Like all domestic water heaters, the MWC is capable of generating

water that is hot enough to cause injury or death due to scalding. To minimize the risk of scalding:

•

Set domestic hot water (DHW) thermostat as low as possible (see the Start-up Section of this

manual for the location of this thermostat.

•

Feel water before showering or bathing.

If anti-scald or anti-chill protection is required, use devices speciﬁcally designed for such

service. Install and maintain these devices in accordance with the manufacturer’s instructions.

Sequence of Operation

(Also Refer to Figures 9.7, 9.8, 10.3, 11.7)

1) Upon a call for heat from the room thermostat, the circulator is started.

2) If the differential pressure switch connected between the supply and return sees a pressure in excess of 5.1 ft

w.c., it closes, allowing the start sequence to continue. If the switch does not see 5.1ft w.c. after 180seconds, the

boiler goes into lockout.

3) If the common and normally closed contacts on the air pressure switch are made, the inducer starts.

4) The air pressure switch measures the difference between the combustion air pressure in the cabinet and the

negative pressure generated at a venturi located in the inducer discharge. In this way it measures the air ﬂow

through the boiler. If the pressure across the air pressure switch exceeds approximately 0.64” w.c., the switch will

close. If the air pressure does not close after 4 minutes of inducer operation, the boiler will go into lockout.

5) After the air pressure switch closes, current can pass through the normally closed supply water and ﬂue gas

safety limits to the ignition module, initiating a call for burner operation.

6) The ignition module generates an ignition spark and opens the valve. The presence of ﬂame is detected through

a separate ﬂame rod. If no ﬂame is detected after 10 seconds, the boiler will go into lockout. If the ﬂame is proven

and this proof is subsequently lost at any point during the burner cycle, the boiler will attempt to re-light once, then

go into lockout.

7) When responding to a call for heat, the boiler will attempt to maintain the target supply temperature selected by

the Heating System Knob. The boiler does this by monitoring the supply temperature sensor shown in Figure

9.7/9.8 and modulating the input based on the difference between the current supply temperature and the

target supply temperature. Modulation is achieved by varying a 0-24VDC voltage across a coil on the gas valve

regulator (0V=minimum input).

8) If the supply water temperature exceeds the target supply temperature while the call for heat is present, the

burner will shut down and the circulator will continue to run. The burner will relight when the supply temperature

drops below the target temperature.

9) If the supply temperature exceeds 221F (which should never happen unless there is a problem with the supply

sensor), the manual reset supply water high limit will open.

10) If the condensate trap becomes blocked, the condensate level will rise to the point where it covers two electrical

contacts: a contact connected to ground, and a contact in the ﬂame rod lead. The condensate will complete an

electrical circuit between these two contacts, grounding out the unrectiﬁed ﬂame signal. This will be detected by

the ignition module as a loss of ﬂame and result in a lockout.

11) If the ﬂue temperature exceeds 248F, the manual reset supply water high limit will open. This protects the PPs

venting from excessive temperatures.

12) When responding to a call for heat, combi boilers use exactly the same sequence of operation as heat-only

models. When a combi boiler receives a call for domestic hot water (DHW), it responds as follows:

a) The ﬂow switch shown in Figure 11.7 detects a call for DHW draw when a hot water ﬁxture is opened having

a ﬂow rate in excess of approximately 0.5 GPM.

b) The main control drives the 3-way diverting valve so that all boiler water ﬂow is directed though the plate heat

exchanger.

c) If not already running, the circulator starts

d) The boiler ﬁres after going through the same start sequence described in steps (3-6) above.

e) The boiler monitors the exiting DHW temperature using the sensor shown in Figure 11.7. The boiler’s

microprocessor control determines the target boiler supply temperature that is needed to meet the DHW

demand and modulates the input accordingly.

Table 13.4: Flash Codes During Normal Operation

(See Part XV for Error Codes)

Lamp Number

Meaning

(Short pulse every 4 seconds): Heating System Knob in

“Off” position. Boiler will not respond to call for heat or

DHW. Frost protection and pump/valve exercise function

still active

(1 second pulse every 2 seconds): Heating System Knob

set to target supply temperature. Boiler will respond to a

call for heat.

Boiler responding to a call for heat

Boiler responding to a call for DHW

Boiler responding to a call for frost protection

Flashing lamp, alone Flashing lamp,

Lamp OFF

Lamp ON

or simultaneously

with another lamp.

alternate with

another lamp

XIV. Service and Maintenance

IMPORTANT

Warranty does not cover boiler damage or malfunction if the following steps are not

performed at the intervals speciﬁed.

1) Continuously:

a) Keep the area around the boiler free from combustible materials, gasoline and other ﬂammable vapors

and liquids.

b) Keep the area around the combustion air inlet terminal free from contaminates .

c) Keep the boiler room ventilation openings open and unobstructed.

2) Monthly Inspections:

a) Inspect the vent system to verify that it is open, unobstructed and free from leakage or deterioration.

Call the service technician to make repairs if needed.

b) Inspect the condensate drain system to verify it is leak tight, open and unobstructed. Call the service

technician if the condensate drain system requires maintenance.

c) Inspect the water and gas lines to verify they are free from leaks. Call the service technician to make

repairs if required.

d) Check the pressure on the boiler and make sure that it is approximately 15psi. If the pressure is less

than 5psi, add water to bring the pressure up to 15psi.

CAUTION

Water leaks can cause severe corrosion damage to the boiler or other system components. Im-

mediately repair any leaks found.

3) Annual Inspections and Service: In addition to the inspections listed above the following should be

performed by a qualiﬁed service technician once every year:

a) Follow the procedure for turning the boiler off found in the MWC Series Lighting and Operating

Instructions.

b) Inspect the wiring to verify the conductors are in good condition and attached securely.

c) Access the combustion chamber. To do this remove the front and side jacket panels as shown in

Figure 11.1 Remove the inner cover as shown in Figure 12.5. Remove the Combustion Chamber

cover as shown in Figure 14.1.

d) Inspect the ﬁns on the primary heat exchanger. If any dirt is observed on the ﬁns, cover the burner to

protect it from falling debris and clean the heat exchanger with a soft brush.

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause

improper and dangerous operation. Verify proper operation after servicing.

Figure 14.1: Removing Combustion Chamber Cover

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 (see Start-up section). A CO “sniffer” designed for testing CO levels in

ambient air cannot be used to check boiler combustion.

A normal CO reading for an MWC series boiler is less than 50ppm (0.005%). A higher reading is

indicative of a combustion problem.

Some causes of excessive CO include:

• Incorrectly sized or drilled burner oriﬁce

• Partially plugged ﬂue passages

• Improper manifold pressure

• Partial blockage of vent or intake system

• Foreign material in burner venturis or burner ports

• Disconnected regulator reference tube

• Damaged fan impeller or housing

• Damaged or missing inducer or ﬂue gas gaskets

• Distorted or missing combustion chamber or ﬂue collector components.

• Flue gas recirculation in damaged or improperly assembled concentric venting

e. Inspect the burner ports for debris. The burner can be cleaned with a soft brush. If the burner shows signs of

deterioration, replace it.

f. Inspect the electrodes and ﬂame rod for deposits. Clean as necessary.

g. Disconnect and remove the inducer from the boiler. The inducer is equipped with sealed ball bearings and

does not require lubrication. Inspect the impeller and the pressure switch venturi (Figure 14.2) for dirt or

debris. Clean as necessary with a soft brush.

h. Inspect the secondary (stainless steel) heat exchanger coil for debris. Clean as necessary by ﬂushing with

clean water. A soft nylon brush may be used in accessible areas. Drain and ﬂush the inside of the heat

exchanger and condensate collector as required. Do not use any cleaning agents or solvents.

i. Reinstall the inducer. If either of the inducer gaskets show signs of deterioration, replace them.

j. Inspect the vent system and terminal for obstructions and clean as necessary.

k. For direct vent appliances, proper reassembly and resealing of the vent-air intake system.

l. Inspect internal boiler piping for leaks and/or deteriorating gaskets. Repair as necessary.

m. Remove, inspect, and clean the condensate trap (Figure 14.3). Disconnect the wires from the trap. Use

pliers to compress the spring clip on the drain hose (the hose leading from the secondary heat exchanger)

and slide it upwards. Disconnect the drain hose from the trap. After removing the condensate trap from the

boiler, disassemble the trap in a tray or pan, being careful to note the way in which the ﬂoat ball and

retainer ﬁt into the trap. Flush all parts of the trap with water and reassemble. Reinstall the trap on the boiler.

ﬂoat ball

n. Reinstall the combustion chamber cover, inner cover, and all jacket panels and any wiring removed during

the inspection/.cleaning process.

o. Perform the start-up and checkout procedure described in Section XII of this manual.

Service Notes

1) Oriﬁce Size – Sea level oriﬁce sizes are:

Natural Gas – 1.30 mm

LP Gas – 0.85 mm

Consult your Crown representative for correct oriﬁce sizes for use at altitudes above 2000 ft. Oriﬁce for this boiler

cannot be drilled in the ﬁeld.

2) Operating the Boiler with Inner Cover Removed – For inspection and troubleshooting purposes, this boiler may

be started and run with the Inner Cover (Figure 12.5) removed.

3) Pressure Switch – If necessary, the air pressure switch signal may be read using a slant tube or electronic

monometer connected across the taps on top of the boiler (Figure 14.4). The N.O. contacts on the pressure

switch make, allowing the boiler to ﬁre, when the switch signal exceeds the “make setting” shown below. Once

the switch is made, the boiler will ﬁre as long as the pressure at the switch is above the “break setting” shown

below. It is normal for the pressure reading across the switch to drop as the boiler heats up.

Make Setting - 0.64 w.c.

Break Setting - 0.59 w.c.

4) Limit Reset Buttons - Manual reset buttons for the ﬂue temperature and supply water limits are located on the

top of the boiler as shown in Figure 14.4. To access the buttons, unscrew the plastic covers.

WARNING

•

Do not leave the boiler in service with the Inner Cover removed.

Do not attempt to ﬁre this boiler with the Combustion Chamber Cover (Fig. 14.1) removed

Figure 14.2: Inducer

Figure 14.3: Condensate Trap Removal

Figure 14.4: Location of Pressure Switch Taps and Limit Reset Buttons

XV. Troubleshooting

WARNING

Turn off power to boiler before replacing fuses or working on wiring.

Table 15.1: No Error Code Displayed

CONDITION

POSSIBLE CAUSES

• No 120VAC Power at boiler. Check breaker and wiring

between breaker panel and boiler

• Fuse on main PCB is blown (Figure 15.2). Check for short in

boiler wiring, then replace with an idenitcal 4.0A fuse.

Boiler does not run, no lights are on or ﬂashing

Lamp 1 ﬂashes every two seconds, but boiler does not

respond to a call for heat.

• Problem with thermostat or zone wiring

• Domestic draw less than 0.5GPM

Combi boiler does not respond to a call for domestic hot water • Defective ﬂow switch (LED inside ﬂow switch will glow red

(DWH).

when it resonds to a call for DHW).

• Inlet and outlet connections reversed.

• Draw rate is in excess of that shown in Table 2.2

• Inlet and/or manifold pressures incorrect (see Start-up

Section).

• Plate heat exchanger is fouled.

• DHW ﬁlter is dirty

Combi boiler responds to a call for DHW, but hot water output

is inadequate.

• Air in radiation

• Inlet and/or manifold pressures incorrect (see Start-up

Section).

• No ﬂow, or insufﬁent ﬂow, through system.

• Boiler is undersized.

Boiler responds to a call for heat, but room temperature never

gets high enough to satisfy room thermostat

• Insufﬁcient radiation

• Flue gas recirculation into combustion air

• See causes for inadequate heat or DHW above

Boiler short cycles AND heat (or DHW) output is inadequate

Figure 15.2: Fuse Location

Table 15.3: Error Codes

Flame

L.O.

Lamp

Lamp Number

Meaning

Corrective Action

Reset the boiler by turning the Heating System Knob to “0”

for a few seconds, then returning it to its original position.

Then:

Differential Water Pressure

Switch Failed to Close After

180s

•

Verify that that boiler and system are purged of air

Verify that there is at least 4.5psi at the boiler

gauge

•

Verify that cirulator is running

Close the throttling valve on the supply more or

install flow restrictor in supply (see piping section)

Reset the boiler by turning the Heating System Knob to “0”

for a few seconds then returning it to its original position.

Failure to Establish Flame Push Flame Reset Button. Then verify that:

Blocked Condensate Trap

•

Gas line is purged of air (new installations)

Inlet gas and manifold pressures are correct (see

Start-up Section)

Reversed Line Voltage

Polarity

•

Manifold pressure is correct (see Start-up section)

Electrodes have a gap of 0.149” – 0.157”

Electrodes, flame rod, and wiring are in good

condition

Condensate trap is draining correctly

120VAC exists between the hot (brown)

connection and ground and not between the

neutral (blue) and ground.

(Note: LED #2 will not

illuminate until error has

been present for 4 minutes)

•

Air Pressure Switch Problem

Supply Limit Open

Flue Gas Limit Open

Use the flow chart in this section to diagnose the exact

problem.

(Note: LED #2 will not

illuminate until error has

been present for 4 minutes)

Defective Supply Sensor

Defective DHW Sensor

Replace Supply Sensor

Replace DHW Sensor

Consult Factory

Excessive Temperature on

Primary Circuit

Consult Factory

Flashing lamp, alone Flashing lamp,

Lamp OFF

Lamp ON

or simultaneously

with another lamp.

alternate with

another lamp

Figure 15.4 Flow Chart for Isolating Limit and APS Errors (See Table 15.3)

Push reset button on Flue Temp Limit

(Fig 14.4)

Reset Boiler

Push reset button on Supply Temp

Limit (Fig 14.4)

Does Boiler

Start?

Does Boiler

Start?

Flue Temp Limit was open and

will probably open again. Look

for:

Supply Temp Limit was open and will probably

open again. Look for:

* Fouled flue passages

* Manifold pressure too high

* Incorrect Burner Orifice

* A problem with the supply sensor

* Water-side blockage in one of the boiler heat

exchangers or internal boiler piping

Reset Boiler

Does Inducer

(Fan) start before

error code

Is 120VAC present

across Inducer?

reappears?

* Defective Inducer

Air pressure switch is not proving airflow:

* Blockage in Vent or Intake

* Vent system too long or undersized (see Vent Section)

* Condensate in pressure switch tubing

* Leaking or kinked pressure switch tubing

* Blockage in primary or secondary heat exchanger

* Fouled Inducer Venturi

Air switch stuck in closed position:

* Condensate in pressure switch tubing

* Kinked pressure switch tubing

* Defective air pressure switch

XVI 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

C.h. return group and d.h.w. heat exchanger (Model combi)

* Includes items 1, 12, 19

C.h. flow group and three way diverter valve (Model combi)

23 (upper part)

25*

28 29 30 31 32

23 (lower part)

* Includes items 23, 28, 29, 30, 31, 32, 20, 36

C.h. flow and return groups (Model c.h. only)

146

147*

145

28 29 30 31 32

* Includes items 20, 28, 29, 30, 31, 32, 36

Pump and main circuit assembly (Model combi)

53 52

Pump and main circuit assembly (Model c.h. only)

148

149

53 52

Gas assembly

Connection pipes

10*

80*

* Not for model c.h. only

Control panel and ignition device (Model combi)

Control panel and ignition device (Model c.h. only)

150

Wiring (Model combi)

113

100

101

102

105

113

103

109

104

100

107

105

106

107

108

112

101

102

103

111

108

110

109

Wiring (Model c.h. only)

113

100

101

102

105

113

103

109

104

100

105

106

152

151

112

101

102

103

111

151

110

109

Fan, combustion chamber and case panels

114

115

116

140

139

141

138

142

137

117

143

144

136

118

119

135

134

133

132

120

131

121

130

122

129

122

123

121

124

128

127

126

125

Key no.

Description

Spare part code

BI1001 131

BI1011 104

BI1212 112

BI1131 107

BI1271 504

BI1271 102

BI1001 108

BI1001 124

BI1001 123

BI1001 106

BI1091 102

BI1091 103

BI1161 101

BI1271 501

BI1271 101

BI1001 102

BI1001 115

BI1271 100

KI1043 144

BI1001 111

BI1001 129

BI1011 107

BI1201 100

BI1101 101

BI1141 501

BI1011 117

BI1251 503

KI1001 128

BI1001 117

BI1011 103

BI1011 111

BI1011 110

BI1011 109

BI1011 502

BI1011 505

BI1011 105

BI1011 108

BI1141 505

BI1262 122

BI1262 112

BI1172 101

BI1262 117

BI1002 113

BI1262 110

BI1262 118

BI1262 114

BI1262 135

KI1043 114

O-ring gasket 1,78x15,6

Drainage valve

O-ring gasket 17,04x4,00 mm

Screw M5x25 mm - Hexagon socket cap

Return group kit (Model combi)

Domestic water restrictor

Flat gasket 3/4"

Toothed lock washer external 6,4 mm

Screw M6x8 mm - BZP RPH

Flat gasket 1/2"

11A

11B

Flow limiter 10 Litres/min

Flow limiter 12 Litres/min

Flow limiter 14 Litres/min

Magnetic ﬂow switch and ﬁlter kit

D.h.w. ﬂow switch

Exchanger Domestic Hot Water

O-ring gasket 1,78x12,42 mm by-pass pipe

By-pass pipe (Model combi)

O-ring gasket 18,64x3,53 mm

By-pass pipe ﬁxing fork

O-ring gasket 1,78x14 mm

O-ring gasket 2,62x23,47 mm

Diverter valve actuator

Diverter valve actuator ﬁxing spring

Diverter valve kit

O-ring gasket 2,7x13,6 mm

Flow group kit (Model combi)

O-ring gasket 9,25x1,78 mm (NTC)

Temperature probe (special)

Central heating pressure switch membrane

Central heating pressure switch disk

Central heating pressure switch spring

Screw M4x12 mm Stainless steel SCH

Microswitch guide bush

Microswitch kit

Microswitch box ﬁxing clip

Screw 2,9x13 mm AB self tapping BZP - RCH

By-pass kit

Condensing heat exchanger

O-ring gasket 2,62x17.86 mm

Condensing heat exchanger connection clip

Connection spring

Grommet

Condensate discharge pipe

Condensate trap (withdrawn)

O-ring gasket 1,9X16 mm

Main exchanger

O-ring gasket 17,04x3,53

Key no.

66A

78A

Description

Spare part code

BI1182 106

BI1262 136

BI1212 107

BI1262 116

BI1262 120

KI1042 101

KI1042 115

BI1262 115

BI1262 137

BI1172 113

BI1262 138

BI1105 108

BI1262 113

BI1262 134

BI1202 105

BI1262 107

BI1182 105

BI1262 133

BI1262 132

BI1203 502

BI1203 503

BI1203 103

BI1123 102

BI1123 103

BI1123 101

BI1002 115

BI1013 115

BI1013 111

BI1013 112

BI1203 104

BI1203 105

BI1013 110

BI1183 105

BI1203 106

BI1124 120

BI1124 118

BI1124 119

BI1555 109

BI1555 108

BI1555 111

BI1475 119

BI1555 112

BI1555 113

BI1475 105

BI1475 110

BI1555 114

KI1066 208

BI1475 109

Main exchanger connection clip

Condensing heat exchanger inlet pipe

Automatic air purger valve

Pump connection fork

Fork

Screw 5X16

Pump (complete)

Pump gasket

Main exchanger outlet pipe (Model combi)

Probe holder

O-ring gasket 2,62X9,92 mm

Expansion vessel connection pipe

Flat gasket 3/8" O.D 15 mm, i.d. 8.5 mm

Condensing heat exchanger outlet pipe

Expansion vessel

Safety valve 30 psi

Safety valve connection pipe (Model combi)

Injectors with gaskets 130 - NG

Injectors with gaskets 85 - LPG

Burner

Detection electrode

Ignition electrode - right

Ignition electrode - left

Grommet

Tapping screw 3,5x9,5 mm recessed pan head

Taptite screw M4x8 mm Recessed pan head

Screw self tapping 3,9x9,5 mm type AB Recessed Pan Head

Gas valve

Gas pipe to the manifold

Tapping Screw ISO No8 B 4,2x9,5 Recessed Pan Head

Gas manifold with injectors NG

Gas manifold with injectors LPG

C.h. connection pipe

D.h.w. and d.c.w. connection pipe

Gas connection pipe

Full sequence control device

Fan and APS device

Temperature-pressure gauge

O-ring gasket 1,78 x 6,75 mm

Cover panel

Knob

Shaft

Control panel plug

Control panel box (Model combi)

Cable holder

Terminal block

Key no.

Description

Spare part code

BI1165 101

BI1555 107

BI1165 112

BI1475 111

BI1475 112

BI1615 104

BI1615 111

BI1615 108

BI1035 111

BI1035 110

BI1035 109

BI1615 102

BI1615 112

BI1615 110

BI1615 113

BI1615 115

BI1615 109

BI1615 114

BI1615 116

BI1615 117

BI1615 107

BI1016 104

BI1406 124

BI1406 112

BI1124 104

BI1406 125

BI1256 101

BI1406 114

BI1416 100

BI1326 100

BI1406 119

BI1406 127

BI1206 118

BI1406 105

BI1336 114

BI1406 500

BI1326 108

BI1406 120

BI1406 111

BI1406 126

BI1406 123

BI1406 122

BI1406 113

BI1406 128

BI1016 107

BI1036 101

BI1262 139

BI1406 117

Screw 3,5x16 mm self tap RPH

Electronic control - ignition p.c.b.

Fuse 2AF

Service panel cover

Control panel cover

Screw 3,5X9,5 mm self tap RPH

Flame detection electrode cable

Detection to trap wiring

Full nut M5 Hexagon

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

Toothed lock washer external 5,3x10 mm stainless

Machine Screw M5x10 mm Recessed Pan Head

Trap to earth wiring

Ignition electrode cable

Pump-diverter valve cable (Model combi)

Flow switches, temp. probes and modulator cable (Model combi)

Ignition p.c.b. cable

Electronic control p.c.b.-fan and APS device connection cable

Power supply and external control cable

Earth wiring

Fan cable

Flue pipe gasket

Air restrictor d. 82 mm

Flue outlet gasket

Wall mounting plate

Air pressure switch

Venturi device tube

Air deﬂector - right

Side case panel

Combustion chamber side panel

Combustion chamber front panel

Front case panel

Window (glass + rubber frame)

Sealed chamber lid

Screw 4,8x13 mm AB self tapping RPH BZP

Sealed chamber gaskets kit

Combustion chamber rear panel

Fan holder bracket

Fan inlet gasket

Fan

Wire saddle

Flue hood

Fan outlet gasket

Venturi

Flue pressure switch tube

Air switch pressure test point

Overheat thermostat

Screw M4x5 mm - BZP RPH

Key no.

141

Description

Spare part code

BI1262 104

BI1366 114

Flue thermostat

142

Twin ﬂue cover plate

Gasket - Air intake twin kit

Air restrictor d. 45 mm

Return group (Model c.h. only)

143

BI1016 101

BI1406 129

144

145

BI1171 107

BI1171 106

BI1171 103

BI1262 140

BI1262 141

BI1555 115

BI1615 118

BI1615 119

146

147

148

149

150

151

152

By-pass pipe (Model c.h. only)

Flow group kit (Model c.h. only)

Safety valve connection pipe (Model c.h. only)

Main exchanger outlet pipe (Model c.h. only)

Control panel box (Model c.h. only)

Flow switch, temp. probe and modulator cable (Model c.h. only)

Pump cable (Model c.h. only)

Appendix A: Special Requirements For Side-Wall Vented Appliances

In The Commonwealth of Massachusetts

IMPORTANT

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for

installation of side-wall vented gas appliances as follows:

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or struc-

ture used in whole or in part for residential purposes, including those owned or operated by the Com-

monwealth and where the side wall exhaust vent termination is less than seven (7) feet above ﬁnished

grade in the area of the venting, including but not limited to decks and porches, the following require-

ments shall be satisﬁed:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS.

At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber

or gasﬁtter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up

is installed on the ﬂoor level where the gas equipment is to be installed. In addition, the installing plumber

or gasﬁtter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is

installed on each additional level of the dwelling, building or structure served by the side wall horizontal

vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of

qualiﬁed licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space

or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed

on the next adjacent ﬂoor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of

installation, the owner shall have a period of thirty (30) days to comply with the above requirements;

provided, however, that during said thirty (30) day period, a battery operated carbon monoxide de-

tector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS.

Each carbon monoxide detector as required in accordance with the above provisions shall comply with

NFPA 720 and be ANSI/UL 2034 listed and IAS certiﬁed.

3. SIGNAGE.

A metal or plastic identiﬁcation plate shall be permanently mounted to the exterior of the building at a mini-

mum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally

vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half

(1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION.

The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve

the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage

installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most cur-

rent edition of NFPA 54 as adopted by the Board;

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure

separate from the dwelling, building or structure used in whole or in part for residential purposes.

manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting

system design or venting system components with the equipment, the instructions provided by the

manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system compo-

nents; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does

not provide the parts for venting the ﬂue gases, but identiﬁes “special venting systems”, the following

requirements shall be satisﬁed by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equip-

ment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that

system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled

equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design in-

structions shall remain with the appliance or equipment at the completion of the installation.

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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