Crown Boiler BWF162 User Manual
BWF Series  
Gas-Fired Fan Assisted Hot Water Boilers  
INSTALLATION INSTRUCTIONS  
These instructions must be affixed on or adjacent to the boiler  
WARNING: Improper installa-  
Models:  
tion, adjustment, alteration,  
service or maintenance can  
cause property damage, injury,  
or loss of life. For assistance or  
additional information, consult a  
qualified installer, service  
agency or the gas supplier.  
This boiler requires a special  
venting system. Read these  
instructions carefully before  
installing.  
• BWF061  
• BWF095  
• BWF128  
• BWF162  
• BWF195  
• BWF229  
CROWN  
Boiler Co  
Manufacturer of Hydronic Heating Products  
P.O. Box 14818 3633 I. Street  
Philadelphia, PA 19134  
Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com  
I Product Description  
The BWF series boiler is a cast iron gas fired boiler designed for use in forced hot water heating systems. The BWF is  
intended for installations where a usable chimney is not available. The BWF is normally vented using an approved vertical or  
horizontal AL29-4C stainless steel venting system, which is not included with the boiler. If a suitable chimney is available, the  
BWF series can be vented into it using an optional BWF Category I Vent Kit available from Crown. The BWF requires an  
adequate source of clean combustion air in the boiler room.  
The BWF boiler is not designed for use in gravity or “open” heating systems. Where an adequate source of clean indoor  
combustion air cannot be guaranteed, use a direct vent boiler such as the Crown CSC series.  
II Specifications  
TABLE 1: SPECIFICATIONS  
D.O.E.  
HEATING  
CAPY.  
(BTU/hr)  
51,000  
IBR NET  
RATING AFUE (%) DIMENSION  
(BTU/hr)  
FIG. 1  
WATER  
CONTENT  
(GAL.)  
NO.  
INPUT  
VENT DIA.  
(IN.)  
MODEL*  
SECTIONS (BTU/hr)  
"A" (IN.)  
3
3
3
3
4
4
BWF061EN  
BWF095EN  
BWF128EN  
BWF162EN  
BWF195EN  
BWF229EN  
3
4
5
6
7
8
61,000  
95,000  
44,000  
68,000  
92,000  
83.3  
83.1  
82.8  
82.5  
82.3  
82.0  
14 1/4  
17 1/2  
20 3/4  
24  
27 1/4  
30 1/2  
3.2  
4.0  
4.7  
5.5  
6.3  
7.0  
78,000  
128,000 106,000  
162,000 134,000 117,000  
195,000 161,000 140,000  
229,000 189,000 164,000  
* MODELS SHOWN ARE FOR NATURAL GAS. REPLACE "N" WITH "L" SUFFIX FOR PROPANE MODEL NUMBER (e.g. BWF061EL).  
PERFORMANCE RATINGS ARE THE SAME FOR BOTH FUELS  
2
III Before Installing  
1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance  
with this manual and the 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  
In Canada, installation must be in accordance with CSA B149 (Installation Code for Gas Burning Appliances and  
Equipment).  
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 VI to verify that the boiler can be vented in accordance with these instructions.  
3) Make sure that the boiler is correctly sized:  
•
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.  
•
•
For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.  
For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE Heating  
Capacity required for the Mega-Stor or the net rating required for the heating system, whichever results in the larger  
boiler.  
•
For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s instructions  
for boiler output requirements.  
4) Make sure that the boiler received is configured for the correct gas (natural or LP).  
5) For installations at altitudes above 2000ft, special orifice and pressure switches may be required. Make sure that the boiler  
is configured for use at the correct altitude.  
IV Locating the Boiler  
1) Clearances:  
•
Observe the minimum clearances shown below. These clearances apply to all combustible construction, as well as non-  
combustible walls and doors. Also see Figure 2.  
Front – 6”  
Left Side – 1”  
Right Side – 4”  
Rear – 1”  
Top – 36”  
Vent Pipe – 5”  
•
•
A 24” service clearance from the jacket is recommended on the left, right, and front of the boiler. These clearances may  
be reduced to those shown in Figure 2, however servicing the boiler will become increasingly difficult as these service  
clearances are reduced.  
If the right side 24” service clearance is reduced, adequate clearance must be maintained to easily read both the gauge and  
the limit control. Alternatively, access to the gauge and limit may be provided using a door.  
2) The boiler must be installed on a hard level surface. This surface may be combustible.  
3
3) Do not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop. Do not  
install in a location where sources of hydrocarbons will be stored or used. Some common sources of hydrocarbons include  
bleaches, fabric softeners, paints, cleaners, refrigerants, and cat boxes. Traces of these chemicals can be drawn into the  
boiler, causing severe corrosion damage to the boiler and/or objectionable odors.  
4) The boiler should be located so as to minimize the length of the vent system while still meeting the requirements in  
Section VI.  
5) Do not install this boiler over carpeting.  
6) Do not install this boiler directly on a surface that may get wet. Raise the boiler on a pad.  
4
V Air for Combustion and Ventilation  
Sufficient fresh air must be supplied for both combustion and ventilation. Provisions for combustion, ventilation, and  
dilution air for gas utilization equipment must be made in accordance with local building codes, or in the absence of such  
codes, in accordance with Sections 5.3.3 and 5.3.4 (“Air for Combustion and Ventilation”) of the National Fuel Gas Code,  
NFPA 54/ANSI Z223.1.  
To ensure an adequate combustion and ventilation air supply, start by determining whether the boiler is to be installed in a  
building of unusually tight construction. A building of unusually tight construction is defined by the National Fuel Gas Code  
as having all of the following features:  
•
Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or  
less with openings gasketed and sealed.  
•
•
Weather stripping has been added on openable windows and doors.  
Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and  
floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at  
other openings.  
If the building is of unusually tight construction, see the instructions on page 6. Otherwise, follow the instructions below.  
For Buildings of Other than Unusually Tight Construction  
1) Determine whether the boiler is to be installed in a confined space - A confined space is defined by the National Fuel Gas  
Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To determine  
whether the boiler room is a confined space:  
a. Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest 1000  
BTU/hr.  
b. Find the volume of the room in cubic feet. The volume of the room in cubic feet is:  
Length (ft) x width (ft) x ceiling height (ft)  
In calculating the volume of the boiler room, consider the volume of adjoining spaces only if no doors are installed  
between them. If doors are installed between the boiler room and an adjoining space, do not consider the volume of the  
adjoining space, even if the door is normally left open.  
c. Divide the volume of the boiler room by the input in thousands of BTU/hr. If the result is less than 50, the boiler room is a  
confined space.  
Example:  
A BWF229 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 = (229000 BTU/hr + 30000 BTU/hr) / 1000 = 259  
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3  
350/259 = 1.35 Since 1.35 is less than 50, the boiler room is a confined space.  
If the boiler is in an unconfined space– Natural infiltration into the boiler room will normally provide adequate air for  
combustion and ventilation without additional louvers or openings into boiler room.  
5
If the boiler is 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 3).  
•
•
Each opening must have a free area of 1 square inch per 1000 BTU/hr input of all gas burning appliances in the boiler  
room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per opening.  
If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per  
1000 BTU/hr of total appliance input, install a pair of identical openings into a third room. Connect additional rooms  
with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input.  
The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are  
used, they must be no finer than ¼” (4 x 4) mesh.  
•
•
If providing openings into adjacent rooms is undesirable, combustion and ventilation air can be brought to the boiler  
room from outdoors. See the instructions under “For Buildings of Unusually Tight Construction”  
For Buildings of Unusually Tight Construction  
a) Openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl  
space, which communicates directly with the outdoors.  
b) Two openings are required. The top edge of the upper opening must be within 12 inches of the ceiling. The bottom  
edge of the lower opening must be within 12 inches of the floor.  
c) Size openings and ducts as follows:  
•
•
•
Vertical ducts or openings directly outdoors (Fig 4, Fig 5, Fig 6) – Each opening must have a free cross sectional area  
of 1 square inch per 4000 BTU/hr of the total input of all gas-fired appliances in the boiler room. Minimum opening  
size is 3 inches. Ducts must have the same cross sectional area as the openings to which they connect.  
Openings to outdoors via horizontal ducts (Fig 7) - Each opening must have a free cross sectional area of 1 square  
inch per 2000 BTU/hr of the total input of all gas-fired appliances in the boiler room. Minimum opening size is 3  
inches. Ducts must have the same cross sectional area as the openings to which they connect.  
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.  
6
7
8
VI Venting  
There are three basic ways to vent the BWF boiler:  
•
•
•
Horizontal (“side wall”) venting using an approved AL29-4C stainless steel vent system.  
Vertical venting using an approved AL29-4C stainless steel vent system.  
Chimney venting using a masonry or “B” vent chimney and a special Category I Vent Kit available from Crown.  
WARNING  
DO NOT ATTEMPT TO VENT A BWF SERIES BOILER INTO A MASONRY OR “B”  
VENT CHIMNEY WITHOUT THE CROWN CATEGORY I VENT KIT SHOWN IN  
TABLE III  
Table 3 summarizes these three venting options. One of the columns in Table 3 must describe the planned vent system exactly.  
TABLE 3: SUMMARY OF VENTING OPTIONS  
HORIZONTAL  
DIRECT  
EXHAUST  
CLASSIFICATION USED IN THIS  
MANUAL  
VERTICAL DIRECT  
EXHAUST  
CHIMNEY VENT  
NATL. FUEL GAS CODE  
CLASSIFICATION  
STRUCTURE PENETRATION  
MAXIMUM LENGTH:  
BWF061 - BWF162  
BWF195,BWF229 (using 4" Pipe)  
BWF195,BWF229 (using 3" Pipe)  
MINIMUM LENGTH:  
CATEGORY III  
WALL  
CATEGORY III  
ROOF  
CATEGORY I  
ROOF  
45 FT + 1 EL  
45 FT + 1 EL  
30 FT + 1 EL  
39.5 FT + 2 ELS  
37 FT + 2 ELS  
24.5 FT + 2 ELS  
SIZE PER NATIONAL  
FUEL GAS CODE  
VENTING TABLES FOR  
FAN ASSISTED  
BWF061 - BWF162  
BWF195,BWF229  
NOMINAL DIA.:  
2 FT + 1 EL  
2 FT + 1 EL  
6 FT + 2 ELS  
6 FT + 2 ELS  
APPLIANCE  
BWF061 - BWF162  
3"  
3"  
BWF195,BWF229  
3" or 4"  
3" or 4"  
"B" VENT OR LINED  
MASONRY CHIMNEY  
(SEE N.F.G.C.)  
MATERIAL  
AL29-4C(*)  
AL29-4C(*)  
EXHAUST TERMINAL:  
90 ELBOW, TEE,  
OR VH-1 TERM.  
BWF061 - BWF162  
BWF195,BWF229 (using 4" Pipe)  
BY VENT MFR.  
(TABLE 6)  
LISTED CHIMNEY CAP  
90 ELBOW OR  
TEE  
BWF195,BWF229 (using 3" Pipe)  
CATEGORY I VENT KIT:  
BWF061 - BWF128  
BWF162 - BWF229  
N/A  
N/A  
CROWN # 650140  
CROWN # 650141  
(*) FLEX-L-INTL STAR-34 , ZFLEX SVE SERIES III, HEAT FAB SAF-T VENT ,  
PROTECH SYSTEMS FASNSEAL  
The following instructions describe the design and installation of Horizontal and Vertical Direct Exhaust (Category III)  
systems only. Instructions for Chimney (Category I) venting are provided with the Crown Category I vent kit or are available  
from Crown.  
9
Horizontal Vent System Design  
1) See Figure 8 for the general horizontal exhaust configuration. For the purposes of this manual, a “horizontal exhaust  
system” is one that exits the structure through a wall.  
2) Approved Systems – Use one of these four approved vent systems:  
•
•
•
•
Flex-L-International Star-34  
Z-FLEX SVE Series III (“Z-Vent II”)  
Heat Fab Saf-T Vent  
ProTech Systems FasNSeal  
3) Vent Pipe Size:  
•
•
BWF061 to BWF162– 3”  
BWF-195, BWF-229 –3” or 4”  
4) Maximum Vent Pipe Length:  
•
•
•
•
BWF061 to BWF162: 45 ft + (1) 90 degree elbow + terminal  
BWF195 to BWF229 (using 4” vent pipe): 45 ft + (1) 90 degree elbow + terminal  
BWF195 to BWF229 (using 3” vent pipe): 30 ft + (1) 90 degree elbow + terminal  
Reduce the maximum straight pipe run by the equivalent length from Table 4 for each additional elbow.  
Example:  
A vent system is planned for a BWF162 which has the following components:  
2 ft vertical pipe  
1 90 elbow  
5 ft horizontal pipe  
1 90 elbow  
3 ft horizontal pipe  
1 45 elbow  
4 ft horizontal pipe  
1 termination elbow  
Since the boiler is a BWF162, all piping must be done in 3” pipe. The first 90 degree elbow and the termination  
elbow are not considered. From Table 4, the equivalent length of the 3” 45 elbow is 4.5ft. The equivalent length of  
the 3” 90 degree elbow is 5.5ft. The maximum allowable run of straight pipe on this system is therefore:  
45ft – 4.5 ft –5.5ft = 35ft  
Since the planned installation has only 14 ft of straight pipe, the planned vent system length is acceptable  
TABLE 4: VENT SYSTEM ELBOW EQUIVALENT  
LENGTHS  
NOMINAL SIZE  
FITTING  
90 DEG. ELBOW  
45 DEG. ELBOW  
3 INCH  
5.5  
4.5  
4 INCH  
8
4.5  
HORIZONTAL CONDENSATE TEE TREATED AS STRAIGHT PIPE  
10  
5) Minimum Vent Pipe Length: 2 ft + (1) 90 degree elbow + terminal  
6) Permitted Terminals:  
•
Choice of Tjernlund VH1 series terminal, a 90-degree elbow with rodent screen, or a termination tee with a rodent  
screen. The Tjurnlund VH1 terminals may not be used on BWF195s and BWF 229s when they are vented with 3”  
pipe. If the Tjurnlund terminal is used, select one of the following:  
BWF061 to BWF162: Tjernlund VH1-3 (Crown #50-032) 3” terminal  
BWF195, BWF229: Tjernlund VH1-4 (Crown #50-042) 4” terminal  
•
•
If an elbow or tee is used for the vent termination, it must be of the same type and manufacture as the rest of the vent  
system.  
If a tee is used for the termination it must be installed with the run of the Tee vertical.  
7) Wall thimbles – Wall thimbles are required where the vent pipe passes through combustible walls with less than a 5”  
clearance. Use the appropriate wall thimble shown in Table 5.  
8) Pitch of horizontal piping – A ¼” per foot pitch towards the outside is preferred. Alternatively, the horizontal piping may  
be pitched ¼” per foot towards the boiler, however a condensate trap is required. See (9).  
9) Condensate traps –In some horizontal installations, condensate traps may be needed to prevent condensate from running  
into the boiler or collecting in the vent system. A condensate trap must be used if the horizontal piping does not have a  
continuous slope to the outside. If this is the case, put a trap in the lowest section of horizontal piping (Fig 8b).  
10) Use only a “horizontal” type condensate Tee (Fig 9).  
11) Vertical and horizontal sections of piping must be properly supported. See the “Vent System Assembly” section of this  
manual for more information.  
11  
12) Location of Horizontal Vent Terminal – Observe the following limitations on the terminal location:  
•
•
Terminal must be at least 4 feet below or 4 feet horizontally from any window, door, or gravity air inlet into the  
building (Fig. 10).  
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 (Fig 10).  
•
•
•
The bottom of the terminal must be at least 7 feet above a public walkway.  
The bottom of the terminal must be at least 3 feet above any forced air inlet located within 10 feet.  
A clearance of at least 4 feet horizontally or 4 feet vertically must be maintained between the terminal and gas meters,  
electric meters, regulators, and relief equipment.  
•
•
Do not locate the terminal under decks or similar structures.  
Top of terminal must be at least 4 feet below eves, soffits, or overhangs. Overhang may not exceed 3 feet (Fig. 12).  
Do not use the Tee terminal under an overhang deeper than 6”.  
•
•
Terminal must be at least 3 feet from an inside corner.  
Under certain conditions, water in the flue gas may condense on the structure in areas around the terminal. If these  
areas are made of materials subject to damage by flue gas condensate, they should be protected.  
If possible, install the terminal on a wall away from the prevailing wind. Reliable operation of this boiler cannot be  
guaranteed if the terminal is subjected to winds in excess of 40 mph.  
The noise level in the vicinity of the terminal is approximately 65 dB (roughly the level of a normal conversation).  
Care should be taken when the terminal is positioned in areas where this might be objectionable, such as near  
bedroom windows.  
•
•
TABLE 5: WALL THIMBLES  
VENT MANUFACTURER'S PART #  
VENT SYSTEM  
3 INCH  
4 INCH  
FLEX-L-INTL STAR-34  
Z-FLEX SVE SERIES III  
HEAT FAB SAF-T VENT  
PROTECH SYSTEMS FASNSEAL  
SRWT-03  
2SVSWTF03  
7393GC  
SRWT-04  
2SVSWTF04  
7493GC  
FSWT3  
FSWT4  
12  
13  
Vertical Vent System Design  
1) See Figure 13 for the general vertical stainless steel venting configuration. For the purposes of this manual, a “vertical  
exhaust system” is a Category III vent system that exits the structure through a roof.  
2) Approved Systems – Use one of these four approved vent systems:  
•
•
•
•
Flex-L-International Star-34  
Z-FLEX SVE SeriesIII (“Z-Vent III”)  
Heat Fab Saf-T Vent  
ProTech Systems FasNSeal  
3) Vent Pipe Size:  
•
•
BWF061 to BWF162– 3”  
BWF195, BWF229 – 4”  
TABLE 6: CAPS FOR VERTICAL VENT SYSTEMS  
VENT MANUFACTURER'S PART #  
VENT SYSTEM  
3 INCH  
4 INCH  
FLEX-L-INTL STAR-34  
Z-FLEX SVE SERIES III  
HEAT FAB SAF-T VENT  
PROTECH SYSTEMS FASNSEAL  
SRRC-03  
2SVSRCF03  
5300CI  
SRRC-04  
2SVSRCF04  
5400CI  
FSRC3  
FSRC4  
14  
4) Maximum Vent Pipe Length:  
•
•
•
•
BWF061 to BWF162 – 39.5 ft + (2) 90 degree elbows + cap  
BWF195, BWF229 (using 4” vent pipe): 37 ft + (2) 90 degree elbows + cap  
BWF195, BWF229 (using 3” vent pipe): 24.5 ft + (2) 90 degree elbows + cap  
Reduce the above maximum straight pipe runs by the equivalent length from Table 4 for each additional elbow  
beyond the first two.  
Example:  
A vertical vent system is planned for a BWF162 that has the following components:  
2 ft vertical pipe  
1 90 Elbow  
1 condensate trap which has an is 18 inch long run  
1 90 Elbow  
1 ft vertical pipe  
1 45 elbow  
2 ft sloped pipe  
1 45 elbow  
7 ft vertical pipe  
1 Cap  
Since the boiler is a BWF162, all piping must be done in 3” pipe. The first two 90 elbows and the termination cap are  
not considered. The condensate trap is treated as a straight length of pipe 1.5 feet in length. The result is 13.5 ft of  
straight pipe and two 45 elbows. From Table 4, the equivalent length of the 45 elbow is 4.5ft. The maximum  
allowable run of straight pipe on this system is therefore:  
37.5 ft – 4.5 ft – 4.5 ft = 28.5ft  
Since the planned installation has 13.5 ft of straight pipe, the planned vent length is within the maximum limit.  
5) Minimum Vent Pipe Length - 6 ft + (2) 90 degree elbows + cap  
6) Permitted Terminals – A cap must be used which is compatible with the rest of the vent system. See Table 6 for the  
appropriate cap.  
7) Condensate traps – A condensate trap is required on all vertical-venting systems. Install this trap as shown in Figure 13. If  
there are additional sections of horizontal piping in the vent system, they must either be equipped with their own  
condensate Tees or pitched so that condensate will run into the one required trap.  
8) Use only a “horizontal” type condensate Tee (Fig. 9).  
9) Pitch of horizontal piping – Pitch the lowest horizontal section of piping ¼” per foot towards the boiler. Other horizontal  
sections (if any) must be pitched so that condensate will run towards a condensate Tee.  
10) Fire-stops and wall thimbles – A wall thimble is required where the exhaust pipe passes through combustible walls with  
less than a 5” clearance. Firestops are required where the vent passes through ceilings. These components must be  
compatible with the rest of the exhaust system. Table 5 shows wall thimble model numbers for the approved vent systems.  
Table 7 shows firestop model numbers for the approved vent systems.  
15  
11) Piping supports – Vertical and horizontal sections of piping must be properly supported. See the “Vent System Assembly”  
section of this manual for more information.  
12) Location of vent cap– The lowest discharge opening on the cap must be at least 2 feet above any object located within 10  
feet (Fig. 14):  
16  
TABLE 7: FIRESTOPS FOR VERTICAL VENT SYSTEMS  
VENT MANUFACTURER'S PART #  
VENT SYSTEM  
3 INCH  
4 INCH  
FLEX-L-INTL STAR-34  
SRFS03  
SRFS04  
Z-FLEX SVE SERIES III (SUPPORT)  
Z-FLEX SVE SERIES III (SPACER)  
HEAT FAB SAF-T VENT  
2SVSFSSF03  
2SVSFSF03  
7373GC  
2SVSFSSF04  
2SVSFSF04  
7473GC  
PROTECH SYSTEMS FASNSEAL  
FSFS3  
FSFS4  
Removing an Existing Boiler From a Common Chimney  
In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large  
for the remaining appliances. At the time of removal of an existing boiler, the following steps shall be followed with each  
appliance remaining connected to the common venting system placed in operation, while the other appliances remaining  
connected to the common venting system are not in operation.  
(a) Seal any unused 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.  
(c) Insofar as practical, close all building doors and windows and all doors between the space in which all the appliances  
remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers  
and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and  
bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close 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. When resizing any portion of the common venting system, the common venting system  
should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel  
Gas Code, ANSI Z223.1.  
17  
Vent System Assembly  
1) General Assembly Notes:  
a) Where the use of “silicone” is called for in the following instructions, use only the following sealants:  
•
•
•
•
•
Flex-L-International Star-34 – GE RTV106 or GE IS806  
Z-FLEX SVE Series III (“Z-Vent III”) – Silicone not required for joints between pipe sections.  
Heat Fab Saf-T Vent – GE RTV 106  
ProTech Systems FasNSeal - Silicone not required for joints between pipe sections.  
Use the same silicone used to seal vent pipe sections to seal the boiler vent collar and the Tjurnlund VH-1 terminal (if  
used). For ProTech FasNSeal or Z-Flex Z-Vent III, use GE RTV 106 for the vent collar and Tjurnlund terminal.  
b) Longitudinal welded seams should not be placed at the bottom of horizontal sections of vent pipe.  
c) Do not drill holes in vent pipe.  
d) Do not attempt to mix vent components of different vent system manufacturers.  
2) Vent Collar Installation – The vent collar is shipped loose in the accessory bag along with two collar gaskets, the outlet  
orifice, and four 10-32 mounting screws. Verify that the model number marked on the outlet exhaust orifice matches that  
of the boiler being installed. Mount the collar and orifice as shown in Figure 15. If desired, the first piece of exhaust pipe  
can be connected to the collar before mounting the collar on the boiler.  
3) Tjernlund VH-1 terminal Installation – If the Tjernlund VH-1 terminal is used, follow the instructions provided with the  
terminal to mount it in the wall. This terminal may be installed in direct contact with combustible construction.  
18  
4) Assembly of Flex-L-Intl. Star-34 Vent System:  
a) Star-34 General Notes:  
•
•
•
Do not cut Star-34 vent components.  
Support horizontal piping sections at intervals of 48” or less.  
Vertical venting systems must be supported by at least one Star-34 Firestop. An additional vertical support is required  
after any offset.  
•
Orient Star-34 components so that the arrows on the piping labels are in the direction of flue gas flow.  
b) Start assembly of the vent system at the boiler. Remove the hose clamp shipped on the BWF vent collar. Bend the three  
hose clamp tabs on this collar outward slightly.  
c) Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler. Use a cleaner  
such as Methyl Ethyl Keytone (MEK) or naptha.  
d) On the male end of the pipe, apply a ¼” wide bead of silicone approximately ¼” from the end of the pipe and another ¼”  
bead against the joint side of the stop bead (Fig 17).  
e) Insert the male end of the pipe into the boiler vent collar until it bottoms out.  
f) Apply an additional bead of silicone over the outside of the joint and smooth out. Also apply silicone over the seams in  
the vent collar (Fig 17).  
g) Replace and tighten the clamp on the vent collar.  
h) Clean the female end of the first piece of pipe. Also clean the male end of the next piece of pipe.  
i) Apply silicone as in step (d) (Fig 18).  
j) Align the longitudinal seams of the pipe and insert the male end of the second pipe into the female end of the first pipe.  
k) Insert a StaR joiner band into the inlet of the beaded channel. Feed the joiner band in so that it makes its way around the  
channel and overlaps by approximately ½” (Fig 18).  
l) Cut the excess joiner band so that it lays flat in the beaded channel (Fig 18).  
m) Fill the inlet of the beaded channel with silicone. Smooth the silicone over the channel inlet as well as the silicone  
between the female end and the stop bead of the male end (Fig 18).  
n) Repeat Steps (h) – (m) for the remaining Star-34 components. If a termination elbow or tee is used, use this procedure to  
complete the exhaust system.  
o) To connect Star-34 to the VH-1 terminal, the vent system must be configured so that the female end of the last piece of  
Star-34 will fit over the vent connection on the terminal. Before permanently making this joint, clean both the male end of  
the terminal and the female end of the last piece of pipe with Methyl Ethyl Keytone or Naptha. Apply a ¼ inch bead of  
silicone ¼” from the male end of the terminal. Also apply a ¼” bead of silicone along the weld seam on the inside of the  
female section of the Star-34 pipe. Slip the female end of the vent pipe over the male end of the terminal until it is over at  
least 1 ¼ inches of the terminal. Apply a second bead of silicone over the joint between the vent pipe and the terminal as  
well as over the channel inlet. Do not attempt to use a locking band at this joint. Install a pipe support or other means to  
prevent the Star-34 pipe from separating from the terminal.  
p) Allow the silicone to cure for 24 hours before operating the boiler.  
19  
5) Assembly of Z-Flex SVE Series III:  
a) SVE Series III General Notes:  
•
Non-expanded ends of SVE Series II piping sections may be cut using aviation snips or a 24 thread per inch hacksaw.  
File or sand the cut end smooth before assembling. Expanded ends may be cut to adapt the SVE Series III to the vent  
collar or VH-1 terminal. See the instructions below.  
•
•
Support horizontal piping sections at intervals of 48” or less.  
Vertical venting systems must be supported in at least one point inside the structure using a Z-Flex Fire Stop Support  
or Guy Band. An additional vertical support is required after any offset.  
b) Start assembly of the vent system at the boiler. Remove the hose clamp shipped on the BWF vent collar. Bend the  
three hose clamp tabs on this collar outward slightly.  
c) Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler. Remove  
dirt, grease, and moisture from the surfaces to be sealed. Dry surfaces or allow to dry thoroughly.  
d) On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately ½ inch from the male  
end of the pipe. Apply ¼” beads of silicone along both sides of the longitudinal seam (Fig. 19).  
e) Insert the male end of the pipe into the boiler vent collar until it bottoms out.  
f) Apply an additional bead of silicone over the outside of the joint and smooth out. Also apply silicone over the seams  
in the collar (Fig 19).  
g) Replace and tighten the clamp on the vent collar.  
h) All other joints in the SVE Series III venting system rely on a gasket in the female end of the pipe for a proper seal.  
CAUTION  
•
•
MAKE SURE THAT GASKET IS IN POSITION AND UNDAMAGED IN THE FEMALE END OF THE PIPE.  
MAKE SURE THAT BOTH THE MALE AND FEMALE PIPES ARE FREE OF DAMAGE PRIOR TO  
ASSEMBLY.  
•
IF MALE END OF PIPE IS CUT, IT MUST BE SQUARE AND CAREFULLY DEBURRED PRIOR TO  
ASSEMBLY.  
i) Align the longitudinal seams of the pipe. Insert the male end of the second pipe into the female end of the first pipe as  
far as it will go (at least 1.75 inches). See Figure 20.  
j) Tighten the locking band with a nut driver to a torque of between 40 in-lbs and 50 in-lbs.  
k) Repeat Steps (i) and (j) for the remaining SVE Series III components. If a termination elbow is used, use this  
procedure to complete the exhaust system.  
20  
l) If a termination elbow or tee is used, a locking band or gear clamp must be used at either side of the wall penetration  
to prevent shifting of the vent system in and out of the wall.  
m) To join SVE Series III to the VH-1 terminal, cut off the female end of the pipe that is to be joined to the terminal.  
When making this cut, make sure that it will be possible to insert the cut end of the pipe at least one inch inside the  
terminal. Remove any oil, grease, or moisture from the exterior of the SVE Series III pipe and the female end of the  
terminal. On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately ½ inch from  
the male end of the pipe. Apply ¼” beads of silicone along both sides of the longitudinal seam (Fig. 19). Insert this  
end of the pipe into the terminal connection with at least a 1” overlap. It may be necessary to crimp the end of the  
vent pipe before it can be inserted into the terminal. Apply an additional bead of silicone over the outside of the joint.  
Smooth out the excess silicone. Use one of the following Z-Flex locking bands to mechanically secure the vent pipe  
to the terminal:  
SVE Series III Nominal Size  
Z-Flex #  
3”  
4”  
2SVSLBF03  
2SVSLBF04  
n) Allow the silicone to cure for 24 hours before operating the boiler.  
21  
6) Assembly of Heat Fab Saf-T Vent:  
a) Saf-T Vent General Notes:  
•
In general, Saf-T Vent pipe sections may not be cut. Exceptions to this are the Saf-T vent slip connector and  
connections to the boiler vent collar and the VH-1 terminal. In these cases, use a sharp pair of aviation snips, an  
abrasive cut-off, or a plasma cutter. See the Saf-T Vent instructions for information on cutting the slip connector.  
Orient Saf-T Vent components so that the arrows on the piping labels are in the direction of flue gas flow.  
Support horizontal piping sections at intervals of 6 feet or less.  
•
•
•
Vertical venting systems must be supported by at least one Heat Fab support. An additional vertical support is  
required after any offset.  
b) Start assembly of the vent system at the boiler. Remove the hose clamp shipped on the CSC vent collar. Bend the three  
hose clamp tabs on this collar outward slightly.  
c) Cut the male “spigot” off of the first piece of pipe (Fig 21). If necessary, crimp the cut end of the pipe so that it can be  
inserted at least 1” into the collar.  
d) Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler with an alcohol  
pad.  
e) On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately ½ inch from the male end  
of the pipe. Also apply a ¼” bead of silicone along the first 2 ½” of the longitudinal weld.  
f) Insert the male end of the pipe into the boiler vent collar until it bottoms out.  
g) Apply an additional bead of silicone over the outside of the joint and smooth out (Fig 21). Also apply silicone over the  
seams in the vent collar.  
h) Replace and tighten the clamp on the vent collar.  
i) Clean the male end of the next piece of pipe. Also clean the female end of the first piece of pipe.  
j) Apply a ¼” bead of silicone around the male end of the second piece of pipe between ¼” and 3/8” from the end of the  
pipe. Also run a ¼” bead of silicone along the longitudinal welded seam from the end of the pipe to the top of the spigot  
(Fig 22).  
k) Align the longitudinal seams of the pipe and insert the male end of the second pipe into the female end of the first pipe  
until it bottoms out.  
l) With a moistened finger or flat tool, spread out any silicone that oozes out of the joint.  
m) Bend the locking tabs over the locking ring as shown in Figure 22.  
n) Apply silicone over any visible voids around the joint and smooth it into any crevices.  
o) Repeat Steps (i) – (n) for the remaining Saf-T-Vent components. If a termination elbow or tee is used, use this procedure  
to complete the exhaust system.  
q) To join Saf-T Vent to a VH-1 terminal, cut the locking tabs off of the female end of the Saf-T Vent pipe to be joined to  
the terminal. Apply a ¼” bead of silicone around the terminal connection about ¼” from the end. Slip the Saf-T Vent pipe  
over the terminal and apply a second bead of silicone over the joint. Smooth the excess silicone over the joint, making  
sure that there are no visible voids in the silicone. Install a pipe support or other means to prevent the Saf-T Vent pipe  
from separating from the terminal.  
p) Allow the silicone to cure for 24 hours before operating the boiler.  
22  
7) Assembly of Protech FasNSeal:  
a) FasNSeal General Notes:  
•
•
•
•
Do not cut 4” FasNSeal pipe. The male end of 3” FasNSeal may be cut. Cut must be square to ensure a proper seal.  
Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of flue gas flow.  
Support horizontal piping sections at intervals of 6 feet or less.  
Vertical venting systems must be supported by at least one FasNSeal support. An additional vertical support is  
required after any offset.  
b) Start assembly of the vent system at the boiler. Remove the hose clamp shipped on the BWF vent collar. Bend the three  
hose clamp tabs on this collar outward slightly.  
c) Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler. Remove dirt,  
grease, and moisture from the surfaces to be sealed. Dry surfaces or allow to dry thoroughly.  
d) On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately 1/4 inch from the male end  
of the pipe.  
e) Insert the male end of the pipe into the boiler vent collar until it bottoms out.  
f) Apply an additional bead of silicone over the outside of the joint and the seams on the vent collar and smooth out (Fig 23).  
g) Replace and tighten the clamp on the vent collar.  
h) All other joints in the FasNSeal venting system rely on a gasket in the female end of the pipe for a proper seal.  
CAUTION  
•
•
•
MAKE SURE THAT GASKET IS IN POSITION AND UNDAMAGED IN THE FEMALE END OF THE PIPE.  
MAKE SURE THAT BOTH THE MALE AND FEMALE PIPES ARE FREE OF DAMAGE PRIOR TO ASSEMBLY.  
IF 3” PIPE IS CUT, CUT END MUST BE SQUARE AND CAREFULLY DEBURRED PRIOR TO ASSEMBLY.  
i) Align the longitudinal seams of the pipe. Insert the male end of the second pipe into the female end of the first pipe until  
the bead on the male end contacts the flare on the female end (Fig. 24).  
j) Tighten the locking band with a nut driver.  
k) Repeat Steps (i) and (j) for the remaining FasNSeal components. If a termination elbow or tee is used, use this procedure  
to complete the exhaust system.  
l) To join FasNSeal to a 3” VH-1 terminal, use a Protech FSA-M-3 “Modine Appliance Adapter” (Protech #300444). Apply  
a ¼” bead of silicone to the terminal connection about ¼” from its end. Slip the female end of the adapter over the  
terminal end so that there is an overlap of at least 1 ¾ inches. Tighten the hose clamp to mechanically lock the pipe onto  
the terminal. Apply and smooth silicone over the outside of the joint including the hose clamp in the FasNSeal pipe.  
Connect the female end of the venting system to the male end of the adapter per Steps (i) and (j) above.  
23  
m) To join FasNSeal to a 4” VH-1 terminal slip the female end of the FasNSeal pipe over the terminal connection so there is  
an overlap of at least 1 ¾”. Tighten the hose clamp to mechanically lock the pipe onto the terminal. Apply and smooth  
silicone over the outside of the joint including the hose clamp in the FasNSeal pipe.  
n) Allow the silicone to cure for 24 hours before operating the boiler.  
8) Condensate Traps:  
a) Trap should have the basic configuration shown in Figure 25. All tubing is 3/8” I.D.  
b) All drain tubing must be acid resistant.  
c) At least the first 6 inches of tubing must be silicone with a 400F temperature rating.  
d) Pipe condensate to a drain or other suitable location. Make sure that condensate disposal method is in accordance with  
local regulations. Ensure condensate is not subjected to freezing temperatures.  
24  
VII Gas Piping  
Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at a line pressure  
between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the  
utility or Part 2 of the National Fuel Gas Code.  
Figure 26 shows typical gas piping connections to the BWF boiler. A sediment trap must be installed upstream of all gas  
controls. Install a manual shutoff valve outside the jacket and ground joint union as shown.  
The boiler and its gas connection must be leak tested before placing the boiler in operation. When doing this, the boiler and  
its individual shut-off must be disconnected from the rest of the system during any pressure testing of that system at pressures  
in excess of ½ psi. When pressure testing the gas system at pressures of ½ psi or less, isolate the boiler from the gas supply  
system by closing its individual manual shut-off valve.  
*
* State of Massachusetts Requires Manual  
Shut-off to be “T” Handle Type  
25  
VIII System Piping  
CAUTION  
•
INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM WATER  
(DRIPPING, SPRAYING, RAIN, ETC) DURING APPLIANCE OPERATION AND SERVICE (CIRCULATOR  
REPLACEMENT, ETC).  
•
•
•
OPERATION OF THIS BOILER WITH CONTINUOUS RETURN TEMPERATURES BELOW 120F CAN CAUSE  
SEVERE HEAT EXCHANGER CORROSION DAMAGE.  
OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN  
CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.  
DO NOT USE TOXIC ADDITIVES, SUCH AS AUTOMOTIVE ANTIFREEZE, IN A HYDRONIC SYSTEM.  
Standard Piping  
Figure 27 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  
Berkely Heights, NJ. The components in this system and their purposes are as follows:  
1) Relief valve (Required) – Mount the relief valve in the ¾ tapping on the right side of the boiler as shown in Figure 1 using  
the ¾ nipples and elbow provided. The relief valve shipped with the boiler is set to open at 30 psi. This valve may be  
replaced with one having a setting of up to the “Maximum Allowable Working Pressure” shown on the rating plate. If the  
valve is replaced, the replacement must have a relief capacity in excess of the DOE heating capacity for the boiler.  
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 could be subjected to freezing temperatures. 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 INSTALL RELIEF VALVE IN ANY OTHER LOCATION THAN THAT SHOWN IN FIGURE 1.  
DO NOT PLUG RELIEF VALVE DISCHARGE.  
2) Circulator (Required) – Although the circulator is shipped on the boiler return, it can be installed on the boiler supply. If  
the circulator is moved to the supply, it should be positioned just downstream of the expansion tank as shown in Figure  
27.  
3) Expansion Tank (Required) – If this boiler is replacing an existing boiler with no other changes in the system, the old  
expansion tank can generally be reused. If the expansion tank must be replaced, consult the expansion tank  
manufacturer’s literature for proper sizing.  
4) Fill Valve (Required) – Either a manual or automatic fill valve may be used. The ideal location for the fill is at the  
expansion tank.  
5) Automatic Air Vent (Required) – At least one automatic air vent is required. Manual vents will usually be required in  
other parts of the system to remove air during initial fill.  
6) Low Water Cut-Off (Required in some situations) – A low water cut-off is required when the boiler is installed above  
radiation. In addition, some codes such as ASME CSD-1 require low water cut-offs. Codes may also require that this low  
water cut-off have a manual reset function. The low water cut-off may be a float type or probe type but must be designed  
for use in a hot-water system. The low water cut-off should be piped into the boiler supply just above the boiler with no  
intervening valve between it and the boiler.  
Use a low water cut-off that breaks the 120 VAC supply to the boiler. Do not attempt to wire a 24- volt low water cut-  
off into the boiler factory wiring.  
26  
7) Manual Reset High Limit (Required by some codes) – This control is required by ASME CSD-1 and some other codes.  
Install the high limit in the boiler supply piping just beyond the boiler with no intervening valves. Set manual reset high  
limit as far above the operating limit setting as possible, but not over 240F. Wire the control to break the 120 VAC  
electrical supply to the boiler.  
8) Flow control valve (Required under some conditions) – The flow control valve prevents flow through the system unless  
the circulator is operating. A flow control valve may be necessary on converted gravity systems to prevent gravity  
circulation. Flow control valves are also used to prevent “ghost flows” in circulator zone systems through zones that are  
not calling for heat.  
9) Isolation Valves (Optional) – Isolation valves are useful if the boiler must be drained, as they will eliminate having to  
drain and refill the entire system.  
10) Drain Valve – The drain valve is shipped in the boiler parts bag. Install it in the ¾” opening in the tee on the boiler return  
(Figure 1).  
Piping for Special Situations  
Certain types of heating systems have additional requirements. Some of the more common variations follow:  
1) Indirect Water Heaters – Figure 28 shows typical indirect water heater piping. Boiler piping is the same as for any two-  
zone system. Figure 28 shows circulator zoning, which is usually preferred for indirect water heaters. Size the circulator  
and indirect water heater piping to obtain the boiler water flow through the indirect water heater called for by the indirect  
water heater manufacturer.  
27  
2) Gravity and “Large Water Volume” Systems – The piping shown in Figure 29 will minimize the amount of time that the  
boiler operates with return temperatures below 120F on these systems. A bypass is installed as shown to divert some  
supply water directly into the return water. The bypass pipe should be the same size as the supply. The two throttling  
valves shown are adjusted so that the return temperature rises above 120F during the first few minutes of operation. A  
three-way valve can be substituted for the two throttling valves shown. If the circulator is mounted on the supply, the  
bypass must be on the discharge side of the circulator.  
3) Low Temperature Systems – Some systems, such as radiant tubing systems, require the system water temperature to be  
limited to a value below the temperature of the water leaving the boiler. These systems also typically have return  
temperatures well below the 120F minimum.  
Figure 30 illustrates the use of a heat exchanger to connect a BWF boiler to this type of system. The heat exchanger will  
permit the transfer of heat from the boiler water to the low temperature system while holding the system supply and boiler  
return temperatures within their limits. For this system to work properly, the heat exchanger must be properly sized and  
the correct flow rates are required on either side of the heat exchanger. Consult the heat exchanger manufacturer for sizing  
information. The water in the boiler is completely isolated from the water in the system. This means that separate fill and  
expansion tanks are required for the heating system loop.  
There are several other ways to connect low temperature systems to the non-condensing boilers like the BWF such as  
four way mixing valve and variable speed injection pumping systems.  
4) Systems containing oxygen – Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage  
to a cast iron boiler such as the BWF. Some examples include:  
•
•
•
Radiant systems that employ tubing without an oxygen barrier.  
Systems with routine additions of fresh water.  
Systems which are open to the atmosphere.  
If the boiler is to be used in such a system, it must be separated from the oxygenated water being heated with a heat  
exchanger as shown in Figure 30.  
Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature requirements.  
All components on the oxygenated side of the heat exchanger, such as the pump and expansion tank, must be designed for  
use in oxygenated water.  
5) 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 31. Use isolation valves to prevent chilled water from entering the boiler.  
28  
6) 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.  
29  
30  
IX 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).  
Single Zone Wiring  
1) Line Voltage (120 VAC) Connections (Fig 32) – The line voltage connections are located in the junction box under the  
R8285 fan center on the right side of the boiler.  
•
•
•
Black – Line voltage “hot”  
White – “Neutral” for boiler and circulators  
Green – Ground connection  
2) The circulator is factory wired. If a different circulator is wired to the boiler, its full load current draw must not exceed  
12A.  
3) Connect the 24-volt thermostat to terminals “R” and “G” on the R8285 fan center. Set the heat anticipator to 0.34 Amps.  
31  
Wiring Variations  
1) Multiple Circulator Zones – Figure 33 shows wiring for two or more circulator zones using Honeywell R845As. One  
fewer R845A is used than the total number of circulator zones. A DPST Honeywell RA832A may be substituted in place  
of the R845A using the “X” and “X” terminals in place of the “5” and “6” terminals on a R845A.  
A call for heat from the “zone #1” thermostat causes the zone #1 circulator to start and the boiler to fire exactly as in a  
single zone system (see “Sequence of Operation”). A call for heat from any other thermostat will energize the DPST relay  
in that zone’s R845A. When this relay is energized, electrical continuity is created between terminals 3 and 4, energizing  
the circulator for that zone. At the same time, electrical continuity is created between terminals 5 and 6 on the R845A,  
creating a current path from terminal “R” to “Y” on the R8285 fan center in the BWF. Assuming that the supply water  
temperature is below the high limit setting, the normal ignition sequence will be initiated. If this happens when there is no  
call from the zone #1 thermostat, the relay on the R8285A will not be energized and the zone #1 circulator will remain  
off.  
2) Multiple Zones using Zone Valves – Figure 34 shows wiring for multiple zones using Honeywell V8043F zone valves.  
This wiring diagram may be used for other 24-volt zone valves as long as they are equipped with end switches. Do not  
attempt to use the transformer on the R8285 to power the zone valves; use a separate transformer. Up to five V8043Fs  
may be powered by one 48VA transformer, such as the Honeywell AT87A.  
A call for heat from a given thermostat will result in the application of 24 volts across the TH and TR terminals on the  
corresponding zone valve, energizing the zone valve motor. The zone valve opens and the end switch contacts are then  
made. The end switches are connected in parallel with each other and to the BWF “thermostat” connections so that any  
zone valve that opens will also start the circulator and fire the boiler (assuming the high limit is not open). Zone valve  
terminal TH/TR has no internal connection on the zone valve; it is merely a “binding post” used to connect two or more  
wires.  
32  
33  
BWF Control System – Sequence of Operation  
(Refer to Figures 35 and 36 for BWF ladder and connection diagrams)  
1) A call for heat from the thermostat energizes relay coil 1K (the relay on the R8285), causing contacts 1K1 and 1K2 to  
make. Contact 1K1 starts the circulator. Contact 1K2 sends power to the high limit.  
2) Assuming that the high limit is made, current will flow through the normally closed contacts on the pressure switch to  
relay coil “2K” (the R8222 relay coil). Contacts 2K1 make, starting the combustion blower. Contacts 2K2 make, creating  
a current path in parallel with the normally closed pressure switch contacts.  
3) As the combustion fan comes up to full speed, the normally closed contacts on the vacuum switch break. Power remains  
applied to the 2K coil, however, through the 2K2 contacts. Once the combustion fan has created an adequate vacuum at  
the vacuum switch tapping, the normally open contacts on the pressure switch will make, sending power to the ignition  
module via the normally closed flame rollout switch.  
4) Upon application of voltage across the “24V” and “24V (GND)” terminals, the ignition module will enter a 30-second  
pre-purge period. After 30 seconds has passed, the module will start an ignition spark at the pilot and apply 24 volts  
across the pilot valve (terminals “PV” and “MV/PV”)  
5) Once the pilot is established, the pilot flame will act as a diode, converting the AC current at the electrode to a half wave  
DC current at the pilot’s ground strap. This DC current flows through the boiler to the “GND (BURNER)” connection on  
the ignition module. For the ignition module to recognize that a pilot flame is present, the DC current flowing into this  
terminal must be in excess of approximately 1.0 uA.  
6) Once the ignition module detects the presence of a pilot flame, voltage is applied across the main valve (terminals “MV”  
and “MV/PV”), opening the valve and establishing main flame.  
7) If the ignition module does not detect the presence of a pilot flame after 90 seconds, the ignition spark will stop, the pilot  
valve will close, and the ignition module will wait for approximately 5 minutes before restarting the ignition sequence.  
During this time both the circulator and combustion fan will continue to run. If the pilot is never established, the ignition  
sequence will continue to be restarted at 5-minute intervals.  
8) Assuming that main flame is established, the boiler will fire until either the call for heat is satisfied or until the water  
temperature exceeds the high limit setting. If the high limit setting is exceeded, relay coil 2K will be de-energized, turning  
off the burners and combustion fan. The circulator will continue to run until the call for heat is satisfied, regardless of the  
water temperature.  
9) At the end of a burner cycle, the normally closed contacts on the vacuum switch should make after the fan is de-  
energized. If this does not happen, there will be no current path to relay coil 2K upon the next call for heat and the boiler  
will not fire.  
10) The flame rollout switch is a normally closed thermal switch that is positioned at the burner compartment opening. In the  
event that flames exit this opening, the flame rollout switch will open, de-energizing the ignition module and closing the  
gas valve. Once opened, this switch must be replaced.  
34  
35  
IX Start-up and Checkout  
NOTE  
SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS MANIFOLD AND  
CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS SPECIFIED  
IN Z21.13  
Use the following procedure for initial start-up of the boiler:  
1) Make sure that the boiler and system are filled with water.  
WARNING  
•
IF ANTIFREEZE IS USED IN THE SYSTEM, IT MUST BE A NONTOXIC TYPE SUCH AS PROPYLENE  
GLYCOL.  
•
NEVER ATTEMPT TO FILL A HOT EMPTY BOILER.  
2) Check all new piping for leaks and purge piping sections that are filled with air. See Part 4 of the National Fuel Gas Code  
for additional information on testing and purging gas lines.  
WARNING  
•
•
NEVER USE A FLAME TO CHECK FOR GAS LEAKS.  
MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE  
MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND LIQUIDS.  
3) Vent system must be complete and free of obstructions before attempting to fire boiler. Make sure that the silicone cure  
time called for in the vent assembly instructions has passed before firing boiler.  
4) Inspect all line voltage wiring for loose or uninsulated connections.  
5) Start the boiler using the lighting instructions on page 36.  
NOTE  
The combustion chamber insulation panels in this boiler contain a cornstarch based binder which may emit a strong  
odor as it is burned out of the insulation when the boiler is fired for the first time. An hour or more of continuous  
firing may be required to burn off all of this binder. Open any windows and outside doors in the boiler room to  
maximize ventilation while this binder is burned out.  
6) Inspect the pilot and main flames. These flames should be stable and mostly blue (Fig. 37, 38). No yellow tipping should  
be present; however, intermittent flecks of yellow and orange in the flames are normal.  
7) Check the manifold pressure and adjust if necessary. To do this, use the following procedure.  
WARNING  
FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVERFIRING OF THE  
BOILER AND A CARBON MONOXIDE HAZARD.  
a) Connect a manometer to the line pressure tap on the gas valve  
b) Check the line pressure with all gas appliances on and off. The line pressure at the boiler must be within the following  
limits regardless of what combination of appliances is firing:  
Line Press (inches w.c.) Natural Gas  
LP Gas  
11.0  
13.0  
Min.  
Max.  
5.0  
14.0  
36  
FOR YOUR SAFETY READ BEFORE LIGHTING  
WARNING: If you do not follow these instructions exactly, a fire or explosion  
may result causing property damage, personal injury or loss of life.  
A. This appliance is equipped with an ignition  
If you cannot reach your gas supplier, call  
the fire department.  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
B. BEFORE LIGHTING smell all around the  
appliance area for gas. Be sure to smell next  
to the floor because some gas is heavier than  
air and will settle on the floor.  
WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information above on  
this label.  
5. Remove front access panel.  
6. Rotate the gas control knob clockwise  
to OFF.  
2. Set the thermostat to lowest setting.  
7. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas  
go to the next step.  
3. Turn off all electric power to the appliance.  
4. This appliance is equipped with an ignition  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
8. Rotate the gas control knob counter clockwise  
to “ON”.  
GAS CONTROL KNOB  
(SHOWN IN “ON” POSITION)  
9. Replace front access panel.  
10. Turn on all electric power to the appliance.  
11. Set thermostat to desired setting.  
GAS INLET  
GAS OUTLET  
12. If the appliance will not operate, follow the  
instructions “To Turn Off Gas To Appliance” and  
call your service technician or gas supplier.  
GAS VALVE - TOP VIEW  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
37  
c) If the line pressure falls outside of these limits, find and correct the cause of the problem before proceeding further.  
d) Connect a manometer to the manifold pressure tap on the gas valve (Fig. 41a).  
e) Read the manifold pressure. It should be set at:  
Natural Gas  
3.5  
LP Gas  
10.0  
Manifold Press. (inches w.c.)  
f) If a manifold pressure adjustment is needed, make the adjustment by turning the regulator screw clockwise to raise the  
pressure and counter clockwise to reduce the pressure (Fig 39).  
g) If a manifold pressure adjustment is made, repeat steps (a)-(c) to be certain that the line pressure is still within acceptable  
limits.  
h) Replace the cover screw on the regulator.  
8) Perform a test of the flame supervision system. While the boiler is firing, disconnect the red ignition cable from the  
“Spark” terminal on the ignition module. Both the main and pilot flames should extinguish immediately.  
9) Allow the boiler temperature to increase to the high limit setting. Confirm that the high limit shuts down the burners and  
the combustion fan.  
10) Pinch or disconnect the vacuum switch tube that is connected to the fan. The burner should go out after a few seconds.  
11) Confirm that the thermostat(s) cycle the burner and appropriate circulators  
12) After the boiler has operated for approximately 30 minutes, check the boiler and heating system piping for leaks. Repair  
any leaks found at once.  
13) Inspect the vent system for flue gas leaks. Repair any leaks found before leaving the boiler in operation.  
FIGURE 37a: MAIN BURNER FLAME  
(1” BURNERS)  
FIGURE 37b: MAIN BURNER FLAME  
(50mm BURNERS)  
38  
FIGURE 38: PILOT BURNER FLAME  
39  
X Service and Maintenance  
The following routine maintenance should be performed on an annual basis:  
1) Turn off power to the boiler.  
2) Inspect the flue passages for signs of blockage. If there is any carbon in the combustion chamber or the flue passages,  
clean the heat exchanger before proceeding further. See the cleaning procedure below.  
3) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation.  
4) Remove all burners, noting the location of the pilot main burner. If burners show signs of deterioration, they should be  
replaced (some discoloration around the burner ports is normal). Clean the burners by first brushing the ports with a soft  
bristle brush and then vacuuming out any debris through the venturi opening.  
5) Inspect the pilot assembly. Clean any deposits found on the electrode and grounding strap. The ideal gap between the  
electrode and the ground strap is 1/8”. Inspect the porcelain for cracks or other deterioration. Replace pilot assembly if  
deterioration is found.  
6) Inspect the combustion chamber insulation for deterioration.  
7) Inspect the ignition cable insulation for cracks or other deterioration. If deterioration is found, replace cable.  
8) Reinstall burners, being careful to put the pilot main burner in its original location.  
9) Inspect all boiler wiring for loose connections or deterioration.  
CAUTION  
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE  
IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.  
10) Inspect the vacuum switch hose for deterioration. Clean out any condensate or other blockage found in this tube.  
11) Disconnect the vent system from the boiler using the four 10-32 screws in the vent collar. Inspect the blower wheel and  
fan housing for corrosion damage. If damage is found, replace the fan assembly.  
12) Inspect the vent system:  
a) Make sure that the vent terminal is free of obstructions.  
b) Make sure that all vent system supports are intact.  
c) Inspect joints for signs of condensate or flue gas leakage.  
d) If the vent system contains a condensate trap, make sure that the trap is in good condition and clear of blockages.  
e) If this boiler is equipped with the optional Category I Vent Kit, refer to the vent kit instructions for additional  
maintenance information.  
13) Inspect the boiler and hydronic system for leaks.  
CAUTION  
WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM  
COMPONENTS. REPAIR ANY LEAKS FOUND IMMEDIATELY.  
14) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas piping  
disturbed during the inspection process for leaks.  
Heat Exchanger Cleaning Procedure  
1) Turn off power to the boiler.  
2) Disconnect the vent system from the boiler by removing the four 10-32 screws holding the vent collar in place.  
3) Remove the top jacket panel. If possible, remove the rear and left side jacket panels.  
4) Unplug the fan and remove the fan cover plate.  
5) Disconnect the pressure switch hose.  
6) Remove the burners.  
7) Remove the two ¼-20 nuts and washers holding the flue collector onto the heat exchanger.  
8) Score the silicone seal around the flue collector with a utility knife or similar tool.  
9) Pry the flue collector off of the heat exchanger, being careful not to damage the flue collector or fan.  
10) Clean the flue passageways using a stiff bristle brush. Be certain that all foreign material is removed from the gaps  
between the pins.  
40  
11) Clean the bottom surfaces of the heat exchanger.  
12) Put a light in the combustion chamber and look through the flue passages from the top to verify that they have been  
thoroughly cleaned.  
13) Apply a heavy (1/4”) bead of RTV-732 silicone sealant with a 500F intermittent duty temperature rating around the  
perimeter of the heat exchanger.  
14) Set the flue collector onto the block and press down so that the flue collector is set into the silicone applied in the previous  
step.  
15) Replace the ¼-20 nuts and washers that hold down the flue collector.  
16) Apply a bead of silicone around the outside of the joint between the heat exchanger and the flue collector.  
17) Reattach all the jacket components except for the fan cover plate.  
18) Install the fan cover plate.  
19) Plug in the fan and reconnect the vacuum switch tube.  
20) Reconnect the vent system.  
WARNING  
SOOT DEPOSITS IN THE FLUE PASSAGES ARE A SIGN THAT THE BOILER MAY BE OPERATING AT HIGH  
CARBON MONOXIDE LEVELS. AFTER CLEANING THE BOILER OF SOOT DEPOSITS, CHECK BOTH CO AND  
CO2 LEVELS IN THE VENT BEFORE LEAVING THE BOILER IN OPERATION. CO AND CO2 READINGS SHOULD  
BE BELOW THE MAXIMUM LIMITS SHOWN IN TABLE 8.  
Service Notes  
1) Measuring CO and CO2 – If it is necessary to check CO or CO2, the best place to take a gas sample will usually be at the  
vent terminal. Table 8 shows typical and maximum readings for CO and CO2 on both natural and LP gas. Do not leave  
the boiler in operation if either the CO or CO2 exceeds the maximum limit in this table. Some causes of excessive CO or  
CO2 include:  
•
•
•
•
•
•
•
•
•
•
•
•
Incorrectly sized or drilled burner orifice  
Partially plugged flue passages  
Improper manifold pressure  
Partial blockage of vent system  
Foreign material in burner venturis or burner ports  
Distorted burner ports  
Distorted burner venturi bracket  
Damaged fan impeller or housing  
Damaged or missing fan gasket  
Leak in seal between flue collector and heat exchanger  
Inadequate supply of combustion air  
Damaged base  
TABLE 8: TYPICAL AND MAXIMUM  
ACCEPTABLE CO2 AND CO READINGS IN FLUE  
GAS  
NATURAL GAS  
LP GAS  
8.5  
10.5  
20  
TYPICAL CO2 (%)  
MAXIMUM CO2 (%)  
TYPICAL CO (PPM)  
MAX. CO (PPM)  
7.5  
9.0  
20  
70  
70  
2) Orifice Size – Refer to the parts list in the back of this manual for sea level orifice sizes. 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.  
41  
3) Vacuum Switch – This boiler is equipped with a vacuum switch that is designed to prevent burner operation if the  
combustion fan does not operate properly or there is a blockage in the vent system. This switch “makes” (permits  
burner operation) as the vacuum increases. Figure 40 shows the correct method of reading the switch vacuum. The  
vacuums in Table 9 are the minimums required for reliable operation. After the boiler fires, the vacuum will drop for  
several minutes before stabilizing. The vacuum shown under “Burners On” in Table 9 is the minimum reading which  
should be observed after the vacuum has stabilized. The Table 9 readings correspond to sea level vacuum switch  
settings. Consult your Crown representative for possible variations in settings at altitudes over 2000ft.  
TABLE 9: MINIMUM. VACUUM SWITCH  
READINGS (in. W.C.)  
DURING  
MODELS  
BURNERS ON  
-0.51  
PREPURGE  
-0.57  
BWF061, BWF095  
BWF128, BWF162  
BWF195, BWF229  
-0.96  
-1.21  
-0.89  
-1.14  
42  
XII Troubleshooting  
The following three pages contain troubleshooting charts for use in diagnosing control problems. To use these charts, go  
to the box marked “Start” at the top of the next page and follow the appropriate path though the chart until a box with a  
list of possible causes is reached. If the problem is known to be within the ignition system, go directly to the Intermittent  
Ignition Troubleshooting guide on page 46. In using these charts, the following should be kept in mind:  
1) These charts are only meant to be used by a professional heating technician as an aid in diagnosing control problems.  
2) Where applicable, follow all precautions outlined in the lighting instructions on page 37.  
3) In general, these charts assume that there are no loose or miswired electrical connections. Before using these charts,  
inspect all electrical connections on the boiler to make sure that they are tight. Also, check the wiring on the boiler against  
the wiring diagram in Figure 36.  
4) The possible causes at the end of each branch in these charts are not listed in order of likelihood. All controls on the  
BWF are tested at least once in the manufacturing process and a defective control or component is generally the least  
likely cause. Before replacing a component, try to rule out all other possible causes.  
5) If the charts indicate that the transformer in the R8285 is defective, it is possible that this transformer has been  
destroyed by a short circuit in the boiler wiring. Before replacing the R8285, carefully inspect all low voltage wiring on  
the boiler for places where it is touching the frame of the boiler or wiring on the other side of the transformer.  
6) If the charts indicate that the relay on the R8285 or the R8222 relay is defective, inspect the coil of the relay for visible  
heat damage. If such damage is found, there is a good chance that a second transformer is present in the thermostat or  
zone valve circuit, resulting in the application of 48 volts across the relay coil. In older buildings, this transformer may be  
hidden in a location far from the boiler. If this second transformer exists, it must be found and removed before the relay is  
replaced.  
43  
BWF Troubleshooting Chart  
Caution: Read page 43 before attempting to use this chart  
START  
Induced  
draft fan  
start?  
Wait 30-50  
seconds  
(prepurge)  
Y
Y
Circulator  
start?  
Continued on  
next page  
N
N
Unplug fan and  
check for 120 volts  
across black and  
white connections  
on female half of  
plug.  
Thermostat  
calls for heat  
24volts across R  
and C on R8285  
fan center?  
N
Y
Y
120 volts  
present?  
120 volts across  
black and white  
transformer  
primary leads on  
back of R8285 ?  
24 volts across  
G and C on  
R8285 fan  
center?  
Y
N
N
* Loose  
Y
Reconnect fan  
connection at  
fan plug or fan  
capacitor  
N
* Loose connection in  
t'stat or zone valve end  
switch wiring  
* Power off  
* Defective  
capacitor  
* Defective fan  
* Defective t'stat or zone  
valve end switch  
* T'stat or zone system  
miswired-consult zone  
valve or t'stat  
* Blown fuse or  
tripped breaker  
* Miswired or  
loose electrical  
connection in  
120 volt line  
24 volts  
present across  
yellow and  
purple  
N
manufacturer's  
instructions.  
connections on  
R8222?  
* Defective  
transformer.  
Replace R8285.  
See note 5 on  
page 43  
24 volts present  
across yellow  
and orange  
connections on  
R8222?  
N
Y
120 volts across  
N
* Defective  
circulator  
R8222 relay -  
see note 6 on  
page 43.  
* Socket not fully  
seated on relay  
connections?  
Y
* Defective relay on  
R8285 - see note 6 on  
page 43  
Y
* Boiler off on  
high limit  
* Defective  
high limit  
* Relay not fully seated  
in socket  
* Loose connection in  
circulator wiring  
* Kinked or blocked  
* Seized or  
defective  
circulator  
vacuum switch tubing  
* Defective vacuum  
switch  
44  
BWF Troubleshooting Chart (contd.)  
Caution: Read page 43 before attempting to use this chart.  
END  
Continued  
from previous  
page  
Main  
burners  
light?  
Y
Y
Pilot  
light?  
Do burners shut  
down before gauge  
temp exceeds  
high limit setting  
+15F?  
Y
N
N
N
See "Intermittent  
Ignition System  
Troubleshooting  
Chart" on next page  
24 volts  
between  
Y
5
terminals and  
6
on S8670?  
Do burner,  
circulator and  
fan shut down at  
end of call for  
heat?  
Y
N
*
Defective L4080B  
*
Sensing bulb not bottomed  
out in well  
N
24 volts  
NO  
terminal on  
between  
Y
vacuum switch  
C
and on  
R8285D?  
* Rollout switch  
open. Replace  
switch with exact  
replacement,  
Crown Part #  
960122. Check for  
blocked heat  
exchanger  
Does boiler shut  
down when t'stat  
wire is removed from  
N
N
R
terminal on  
R8285?  
Y
Minimum  
vacuum at  
switch called for  
in Table 9 on  
page 42 ?  
*
*
Blockage in venting system  
Vent system not installed in  
N
*
Internal boiler wiring  
problem, consult  
Crown representative  
accordance with installation manual  
*
Excessive silicone on I.D. of vent  
system joints  
*
Blockage, condensate or leakage in  
vacuum switch tubing  
Y
*
*
*
*
Improperly sealed flue collector  
Damaged or missing fan gasket  
Defective fan  
*
T'stat or zone valve  
Wind at horizontal vent terminal in  
*
Defective  
vacuum switch  
wiring calling for heat  
* T'stat wires shorted  
excess of 40 mph  
45  
Intermittent Ignition System Troubleshooting Chart  
START  
(24 volts is present across 5 and 6 on S8670, 30-50  
second prepurge period has passed, but main  
burners do not light)  
Spark  
Does  
Main  
burner  
lights?  
Y
Y
Y
Y
across  
ignitor/sensor  
gap?  
Pilot  
lights?  
spark stop  
when pilot  
lights?  
END  
N
N
N
N
24VAC  
across  
terminals 1&2  
N
24 volts  
across  
terminals 2&3  
N
on S8670?  
at S8670?  
Y
* Defective  
S8670 module  
Can you  
hear  
Y
* Defective  
S8670  
module  
Y
sparking?  
N
24 volts  
between MV &  
MV/PV on gas  
valve?  
24 volts  
across PV &  
MV/PV at gas  
valve?  
N
Y
* Defective  
S8670  
module  
N
Y
* Loose connection  
in ignition cable or  
ground wire  
* Defective EI  
wiring  
harness.  
* Break in  
spark cable  
insulation  
*Defective EI  
harness  
* Pilot electrode  
porcelain cracked  
* Break in pilot  
porcelain  
* Low line pressure  
* Pilot flame not  
covering gap  
between electrode  
and grounding  
strap  
* Plugged, kinked or leaking  
pilot tubing  
* Incorrect  
pilot spark gap  
* Defective  
gas valve  
* Plugged pilot orifice  
* Loose  
connection in  
spark cable  
* Low gas pressure  
at gas valve inlet  
* Gas line not purged of air  
* Defective pilot assembly  
* Defective gas valve  
* Loose  
ground  
connection  
* Defective S8670  
module  
46  
XI PARTS  
The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area  
Crown representative or the factory at:  
Crown Boiler Co.  
Customer Service  
P.O. Box 14818  
Philadelphia Pa. 19134  
(215)-535-8900  
www.crownboiler.com  
Main burner orifice and vacuum switch part numbers shown are for sea level configured boilers. For boilers installed at  
elevations above 2000 ft, consult the local Crown representative or the factory for the correct main burner orifice and vacuum  
switch.  
In some cases, the following parts lists do not include Crown part numbers because they were not available at the time of  
printing. Order these parts by their description, specifying the boiler model number on which they are to be used.  
QTY. OR  
CROWN P.N.  
1 ea.  
QUANTITY PER BOILER OR CROWN P.N.  
KEY #  
DESCRIPTION  
61  
700013  
1 ea.  
1 ea.  
1 ea.  
95  
128  
162  
195  
229  
700018  
1 ea.  
1 ea.  
6 ea.  
14 ea.  
700648  
700668  
700688  
701688  
1
*
*
*
*
2
3
4
4
COMPLETE HEAT EXCHANGER ASSY.  
LEFT END SECTION  
RIGHT END SECTION  
INTERMEDIATE SECTION  
PUSHNIPPLE  
700014  
1 ea.  
700015  
1 ea.  
700016  
1 ea.  
700017  
1 ea.  
700001  
700002  
700003  
700000  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
3 ea.  
4 ea.  
5 ea.  
4 ea.  
6 ea.  
8 ea.  
10 ea.  
700646  
700666  
700686  
701686  
12 ea.  
700647  
700667  
700687  
701687  
BASE TRAY  
700643  
700663  
700683  
701683  
700644  
700664  
700684  
701684  
700645  
700665  
700685  
701685  
BASE WRAPPER  
BURNER TRAY (1" BURNERS)  
BURNER TRAY (50mm BURNERS)  
BASE FRONT PANEL ASSY. (INCLUDES  
INSULATION)  
5
1 ea.  
700603  
700604  
700605  
700606  
700607  
700608  
6
7
8
BURNER ACCESS PANEL  
BASE END INSULATION  
BASE REAR INSULATION  
BASE LEG ASSY.  
1/4-20 X 1/2" SELF TAPPING SCREW  
1/2" x 2" SEALING STRIP  
ROLLOUT SWITCH G4AM0600240C  
ROLLOUT SWITCH BRACKET  
#8 x 3/4" SELF TAPPING SCREW  
#10 x 1/2" SHEET METAL SCREW  
5/16 USS FLAT WASHER  
5/16-18 LOCK NUT  
5/16-18 x 1-1/4 SELF TAPPING SCREW  
FLUE BAFFLE  
FLUE COLLECTOR ASSY.  
FAN GASKET  
FAN ASSY.  
REPLACEMENT FAN CAPACITOR  
FAN OUTLET ORIFICE  
COLLAR GASKET  
VENT COLLAR  
#10 FLAT WASHER  
10-32 X 1/2" R.H. SCREW  
#10 x 3/4" SHEET METAL SCREW  
1/4-20 x 1-1/4" CARRIAGE BOLT  
1/4-20 NUT  
1/4" USS FLAT WASHER  
10.1 oz TUBE SILICONE SEALANT  
(FOR SEALING FLUE COLLECTOR)  
1 ea.  
720601  
1 ea.  
700623  
2 ea.  
720603  
4 ea.  
20 ea.  
3.7 ft  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
4 ea.  
4 ea.  
2 ea.  
651123  
1 ea.  
1 ea.  
1 ea.  
650133  
2 ea.  
60-603  
4 ea.  
4 ea.  
4 ea.  
2 ea.  
2 ea.  
2 ea.  
700624  
2 ea.  
720604  
4 ea.  
20 ea.  
4 ft  
700625  
2 ea.  
720605  
4 ea.  
20 ea.  
4.2 ft  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
4 ea.  
4 ea.  
4 ea.  
651125  
1 ea.  
1 ea.  
1 ea.  
650135  
2 ea.  
60-603  
4 ea.  
4 ea.  
4 ea.  
2 ea.  
2 ea.  
2 ea.  
700626  
2 ea.  
720606  
4 ea.  
20 ea.  
4.5 ft  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
4 ea.  
4 ea.  
5 ea.  
651126  
1 ea.  
1 ea.  
1 ea.  
650136  
2 ea.  
60-603  
4 ea.  
4 ea.  
4 ea.  
2 ea.  
2 ea.  
2 ea.  
700627  
2 ea.  
720607  
4 ea.  
21 ea.  
4.8 ft  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
4 ea.  
4 ea.  
6 ea.  
651127  
1 ea.  
1 ea.  
1 ea.  
650137  
2 ea.  
60-604  
4 ea.  
4 ea.  
4 ea.  
2 ea.  
2 ea.  
2 ea.  
700628  
2 ea.  
720608  
4 ea.  
21 ea.  
5.1ft  
9
700110  
900100  
900146  
960122  
900121  
90-048  
90-212  
900102  
900103  
900101  
650100  
1 ea.  
650002  
60-001  
60-003  
1 ea.  
60-600  
1 ea.  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
22a  
23  
24  
25  
26  
27  
28  
29  
30  
31  
*
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
4 ea.  
4 ea.  
3 ea.  
651124  
1 ea.  
1 ea.  
1 ea.  
650134  
2 ea.  
60-603  
4 ea.  
4 ea.  
4 ea.  
2 ea.  
2 ea.  
2 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
4 ea.  
4 ea.  
7 ea.  
651128  
1 ea.  
1 ea.  
1 ea.  
650138  
2 ea.  
60-604  
4 ea.  
4 ea.  
4 ea.  
2 ea.  
2 ea.  
2 ea.  
90-057  
90-058  
90-054  
90-201  
90-202  
90-215  
90-045  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
* NOT PICTURED  
47  
48  
QTY. OR  
CROWN P.N.  
150500  
QUANTITY PER BOILER OR CROWN P.N.  
KEY #  
DESCRIPTION  
61  
1 ea.  
2 ea.  
650153  
3 ea.  
95  
1 ea.  
128  
1 ea.  
162  
1 ea.  
195  
1 ea.  
229  
1 ea.  
13 ea.  
650158  
41  
42  
43  
44  
44  
44  
44  
44  
44  
44  
45  
1" BURNER WITH PILOT BRACKET  
1" BURNER LESS PILOT BRACKET  
MANIFOLD (1" BURNERS)  
150501  
1 ea.  
950300  
950301  
950302  
950304  
950330  
950336  
4 ea.  
650154  
6 ea.  
650155  
8 ea.  
650156  
11 ea.  
650157  
NAT GAS ORIFICE (#44 DRILL SIZE)  
NAT GAS ORIFICE (#45 DRILL SIZE)  
NAT GAS ORIFICE (#46 DRILL SIZE)  
NAT GAS ORIFICE (#48 DRILL SIZE)  
LP GAS ORIFICE (#55 DRILL SIZE)  
LP GAS ORIFICE (1.25mm DRILL SIZE)  
LP GAS ORIFICE (#56 DRILL SIZE)  
GAS VALVE (NAT GAS)  
5 ea.  
7 ea.  
9 ea.  
12 ea.  
12 ea.  
14 ea.  
14 ea.  
3 ea.  
1 ea.  
5 ea.  
1 ea.  
7 ea.  
1 ea.  
9 ea.  
1 ea.  
950331  
3507020  
(VR8204C6000)  
3507120  
(VR8304P4298)  
3507220  
(VR8204C6018)  
3507245  
(VR8304P3522)  
35-4700  
(Q348A1275)  
35-4600  
(Q348A1259)  
1 ea.  
45  
45  
45  
46  
46  
GAS VALVE (NAT GAS)  
GAS VALVE (LP GAS)  
GAS VALVE (LP GAS)  
PILOT ASSY. (NAT GAS)  
PILOT ASSY. (LP GAS)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
47  
48  
49  
IGNITION CABLE  
PILOT TUBING  
1/8 SHORT FERRULE (INCLUDED WITH  
GAS VALVE)  
1/8 LONG FERRULE (INCLUDED WITH  
PILOT ASSEMBLY)  
KF24 PILOT ORIFICE (NAT GAS)  
(INCLUDED WITH PILOT ASSY.)  
K16 PILOT ORIFICE (LP GAS)  
(INCLUDED WITH PILOT ASSY.)  
3501124 3501124 3501124 3501130 3501130 3501130  
1 ea.  
35-1600  
(392449)  
35-1650  
(392449-4)  
90-042  
90-042  
90-042  
90-043  
90-043  
90-043  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
50  
51  
51  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
50MM BURNER COMPONENTS - USED ON INSTALLATIONS ABOVE 2000ft:  
60  
61  
62  
63  
63  
63  
63  
64  
65  
66  
67  
*
50mm BURNER WITH PILOT BRACKET  
50mm BURNER LESS PILOT BRACKET  
MANIFOLD (50mm BURNERS)  
150550  
150551  
1 ea.  
1 ea.  
1 ea.  
651153  
2 ea.  
1 ea.  
2 ea.  
651154  
1 ea.  
3 ea.  
651155  
1 ea.  
4 ea.  
651156  
1 ea.  
5 ea.  
651157  
1 ea.  
6 ea.  
651158  
ORIFICE SIZE DEPENDS UPON ALTITUDE - CONSULT  
FACTORY REPRESENTATIVE FOR CORRECT ORIFICE  
3 ea.  
4 ea.  
4 ea.  
4 ea.  
700505  
700525  
2 ea.  
5 ea.  
5 ea.  
5 ea.  
700506  
700526  
2 ea.  
6 ea.  
6 ea.  
6 ea.  
700507  
700527  
3 ea.  
7 ea.  
7 ea.  
7 ea.  
700508  
700528  
3 ea.  
LP GAS ORIFICE (#53 DRILL SIZE)  
ORIFICE HITCH PIN  
LOWER INJECTION SHIELD  
UPPER INJECTION SHIELD  
1/4-20 BRASS WING NUT  
10-32 x 3/16" SCREW  
2 ea.  
2 ea.  
700503  
700523  
2 ea.  
3 ea.  
3 ea.  
700504  
700524  
2 ea.  
950370  
1 ea.  
1 ea.  
146-95-301  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
* NOT PICTURED  
49  
1” Burner Components  
50mm Burner Components  
50  
CAUTION  
Vacuum switch part numbers shown below for use on boilers  
installed at altitudes below 2000 ft.  
QTY. OR  
CROWN P.N.  
650301  
650300  
1 ea.  
QUANTITY PER BOILER OR CROWN P.N.  
KEY #  
DESCRIPTION  
61  
1 ea.  
1 ea.  
650303  
650323  
650313  
650333  
1 ea.  
95  
1 ea.  
128  
1 ea.  
162  
1 ea.  
195  
1 ea.  
229  
1 ea.  
1 ea.  
650308  
650328  
650318  
650338  
1 ea.  
650348  
2 ea.  
6 ea.  
6 ea.  
1 ea.  
24 ea.  
2 ea.  
2 ea.  
650011  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
94  
95  
96  
97  
98  
99  
100  
*
LEFT SIDE JACKET PANEL  
RIGHT SIDE JACKET PANEL  
REAR JACKET PANEL  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
650304  
650324  
650314  
650334  
1 ea.  
650305  
650325  
650315  
650335  
1 ea.  
650306  
650326  
650316  
650336  
1 ea.  
650307  
650327  
650317  
650337  
1 ea.  
TOP JACKET PANEL  
1 ea.  
1 ea.  
1 ea.  
60-300  
1 ea.  
DOOR  
INNER PANEL  
FAN COVER PLATE  
JACKET BAR  
DOOR BRACKET  
650346  
2 ea.  
6 ea.  
6 ea.  
1 ea.  
24 ea.  
2 ea.  
2 ea.  
650010  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
650347  
2 ea.  
6 ea.  
6 ea.  
1 ea.  
24 ea.  
2 ea.  
2 ea.  
650011  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
60-303  
90-052  
90-053  
96-055  
90-212  
90-210  
90-211  
1 ea.  
3505010  
3505556  
3505555  
95-041  
95-012  
95-061  
3503400  
35-1006  
95-040  
95-067  
1 ea.  
2 ea.  
6 ea.  
6 ea.  
1 ea.  
24 ea.  
2 ea.  
2 ea.  
650009  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
6 ea.  
6 ea.  
1 ea.  
24 ea.  
2 ea.  
2 ea.  
650009  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
6 ea.  
6 ea.  
1 ea.  
24 ea.  
2 ea.  
2 ea.  
650010  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
8-32 X 1/2" SCREW  
8-32 NUT  
4 X 4 JUNCTION BOX  
#10 X 1/2" SHEET METAL SCREW  
DOOR KNOB  
8-32 X 1/4" H.W.H. SCREW  
SEA LEVEL VACUUM SWITCH  
IGNITION MODULE (S8670E1007)  
RELAY (R8222D1022)  
FAN CENTER (R8285D5001)  
3/4" BOILER DRAIN  
CIRCULATOR (TACO 007)  
1-1/4" TACO ISOLATION VALVE SET  
HIGH LIMIT CONTROL (L4080B1212)  
1/2" LONG WELL  
3/4" RELIEF VALVE (30 psi)  
TRIDICATOR GAUGE  
BWF WIRE HARNESS #1 (MAIN)  
BWF WIRE HARNESS #2 (BROWN)  
BWF WIRE HARNESS #3 (PINK)  
BWF WIRE HARNESS #4 (RED)  
BWF WIRE HARNESS #5 (ORANGE)  
INTERMITTENT IGNITION HARNESS  
IGNITION GROUND WIRE HARNESS  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
9601105 9601105 9601105 9601106 9601106 9601106  
*
*
*
*
*
*
9601110  
9601115  
9601120  
9601125  
9601100  
9601101  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
* NOT PICTURED  
51  
52  
CROWN  
Boiler Co  
Manufacturer of Hydronic Heating Products  
P.O. Box 14818 3633 I. Street  
Philadelphia, PA 19134  
Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com  

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