Crown Boiler Profile Installation Manual

 PROFILE
Design certified by
American Gas Association
Heating capacities based on
standard test procedures
prescribed by the United States
Department of Energy
MEA 4 461-91-E
Г
049770000
Built in accordance
with the requirements
of the ASME Boiler and
Pressure Vessel Code
Canadian Gas Association
Table of Contents
SECTION PAGE
I. Product Description eee eee eters eset eee 1
ЦП. Boiler Ratings and Specifications ......................xerrieeri eno reee error R RR RER 1
Ш. Before Starting Installation ....................e.e.ee0imiee RR RD ear eee aora 3
IV. When Your Shipment Arrives ...............e.eeereririrerroor io ree e ae eee eee es 3
У. Locating Boiler .....................xieieeeiioera eee. enoucanvarerooooocarecconeronencarerrara recreo 3
VI. Hanging Boiler .......................eereeeciicer e ee ronca eee eee eee eee 5
Vil. Water System Piping ..................... +++... iii. imei rare ano e erre ecerereane coreo. 8
VII. Completing Boiler Assembly .......................... eeiinnancooo een ea naaa cane cecar en eras 9
1X. Gas Piping ....................e.eeeeiireeenercca reee reee. enorerorecarenerarerenroc ne canene 10
X. Electrical Wiring .......................00eeee in e e enero rerrranee ara canne 11
XI. Start-up and Check-out ....................eeeeeeeere eee eee eee. 16
XII. Maintenance ...................eeeeenneer E EEE necevaoranencacanoneaananeo o ere raocececanoroeen. 18
XII. Troubleshooting ........................... een ree DD ener encerrar ecc 19
27
28
Crown PF series boilers are direct vent gas fired wall mounted boilers designed for hot water space heating
only.
The PF incorporates a one piece cast iron heat exchanger. All air for combustion is obtained from outdoors
via the opening between two concentric tubes. Flue gases are exhausted to the outdoors via the inner of the
two concentric tubes. There is no communication of air between the boiler and the indoor space, making this
boiler ideal for tightly insulated construction and other applications where an adequate source of clean indoor
combustion air cannot be guaranteed.
TABLE 1: BOILER RATINGS & CAPACITIES
T AGA Heath Water U ippi
das ВТО, pay Fair Lo te
PF-50 Natural or LP 50,000 42,000 37,000 82.1 190
PF-65 Natural or LP 65,000 55,000 48,000 83.0 190
PF-82 Natural or LP 82,000 68,000 59,000 82.6 190
USA - For altitudes above 2,000 ft. ratings should be reduced at the rate of 4% for each 1,000 ft. above sea level,
Heating capacity is based upon DOE (Department of Energy) test procedure.
CANADA - For Altitudes above 2000 feet - Consult Factory
FIG la: FRONT VIEW SIDE VENTED FIGURE 1b: Side View Rear Vented
2-112 + Relief Valve | — 15 L *
f И Gauge = L 1— 13/8
7-314 7 Return k++ 2.3/4 5
| ) Supply | = IS
Lo! = | JB
| 3-11/32 N DN
NS NY
Г Г N Ab SV
39 NS | RS
N S
| S — RS
NN NN
DT NN
+ — Gas Pipe NS ¥ Gas Pipe 1 LON
F—— 16-3/4~——— Sa 5-5/16
F——— 18-3/4 a
All dimensions + 1/8"
TABLE 2: TABLE 3:
VENT RESTRICTIONS TAPPINGS (Inches NPT)
(inches) Supply 3/4 *Female
Return 3/4 *Female
L Gas 1/2 Female
Standard
Length
ond min. 5-3/8 * With factory supplied fittings. Boiler is also shipped
max.: 21-1/16 with (2) 3/4" NPT x 1" Female sweat adaptors
Optional |
Long Tube Water Content (All Sizes) 1.72 US Gallon
min. 5-3/8
max. 78
TABLE 4:
Minimum Clearances (inches)
[E een reneoceaoen eee ooo raro ecorcoco nene eoearerecoraroeaooeae 1
Front (to door or removable obstruction)............ e... eee ao are e or eaararaa aaieióa, 1
Front (to non-removable obstuction) .......................... prreenercao ancora rea aereo reee. 24
BOOM E rene eeeaaee ee a aa 1-1/4
Casing TOP™ «ooovveiiiiii eee ier in ae ee 9
Vent Terminal to Closest Construction (Horizontal) ee 96
* Relief valve must have sufficient clearance to ceiling so as to allow the relief valve lever to be fully raised. The above |
top clearance will allow this with the factory supplied piping installed according to these instructions. |
1) Be sure that boiler is of correct size and gas type
(Natural or LP) required.
2) Read this installation manual completely.
3)
Be sure that the planned installation 1s in accor-
dance with all local codes. In the absence of
any local codes, install this boiler in accordance
with the National Fuel Gas Code Z223.1-1988.
Where required by the authority having
jurisdiction the installation must conform to the
Standard for Controls and Safety Devices for
Automatically Fired Boiler (ANSI/ASME CSD-1).
In Canada follow the Canadian Installation Codes for
Gas Burning Equipment (CAN/CGA B149.1 and .2) as
well as the Canadian Electrical Code, Part I CSA C22.1.
This boiler is shipped in two cartons as follows:
Carton A:
Main assembly including casing, heat exchanger, burner
control system and control cover.
V.
1) Observe the vent tube length constraints outlined in
Table 2.
2) Observe the minimum clearance from the boiler
casing to other construction outlined in Table 4.
Note that these minimum clearances will
automatically be held if the minimum clearances to
the bracket shown in Figure 2 are observed.
3) Vent terminal must be located no closer than:
712" from any opening through which exhaust
could enter building.
#12" above grade level.
Y Tft. above a public walkway.
y 4ft. horizontally to either side of electric meters,
gas meters, regulators, and relief equipment.
Fi e Ys
Carton B: (Carton B is the same for all size boilers)
4)
5)
6)
/ Door
+ Fan assembly
+ Boiler hanging bracket
v Vent components
/ Relief valve and tridicator
Y Relief valve tee
/ Installation manual
/ Fan assembly mounting screws
7 Wall hanging bracket mounting hardware
Silicone Sealant
Be certain that all of the above components are present
before starting installation.
Where-ever possible vent terminal should be located
on the side of the structure facing away from the
prevailing wind. This boiler is designed to operate
with winds on the vent terminal of up to 40 mph.
Reliable operation at wind speeds above 40 mph
cannot be guaranteed. |
Flue gases contain corrosive products which can
condense on, and damage, construction near the
vent terminal. For this reason avoid placing vent
terminal under overhangs if at all possible.
Vent terminal cannot be extended beyond outside
wall.
Wall must be capable of supporting boiler.
damage, injury, or death.
This boiler weighs approximately 200 lbs. installed. Failure to properly support it could result in property
1.
FIGURE 2: HANGING BRACKET
MINIMUM CLEARANCES
NAL LLAMAN
O" 8-7/16 ele OF
TT -
` О A
I EL >
o oO >
9 2 |
18-5/8
УХУ Х УХУ
Install mounting plate making sure it is both level &
plumb:
a) Wood framed walls- Boiler mounting plate is
b)
provided with 2 sets of holes on 16 inch centers for
installation on a standard studded wall. If it is not
possible to line these holes up with the studs,
additional 3/8 holes may be located in the mounting
plate. Once the mounting plate holes are located
over studs, mark hole locations on wall. Drill pilot
holes and mount hanging bracket using 5/16 x 2 lag
screws and 5/16 washers provided.
When drilling holes make sure that they are in
center of stud.
Masonary walls- After locating boiler mounting
plate mark hole locations. Drill pilot hole and drive in
5/16 lag shields provided. Secure boiler mounting plate
to wall using 5/16 x 2 lag screws and 5/16 washers
provided.
2)
Because of the large variety of different
materials used in wall construction, as well
as the varying condition of older construction,
it is ultimately the installer's responsibility
to ensure that the above methods of attach-
ment are suitable to the particular wall at the
installation site.
a)
Vent tube opening
ELA - Lay outa 3 3/4" dia. hole in the
center of boiler mounting plate vent opening. Cut out
through wall being careful to keep hole straight.
Side Vent Only |- Using horizontal center marks on
mounting plate opening, extend a level line around
corner. Lay out a vertical center line 5-1/4" in from
corner (Fig. 3). Lay out a 4" dia. hole on this center
line. Cut out being careful to keep hole straight.
Vent tube preparation
- Measure the wall
thickness from its outside face to the inside face of the
mounting plate (Fig. 4a). Add 2-3/8 inches to this
dimension. Measure the total length from the flanged end
of the vent tubes and cut squarely.
| Cutting Side Vent Tube Only
the vent hole from the outside wall face to the vertical
center line of the boiler mounting plate (Fig. 4b).
Subtract 7-1/4 inches from this dimension. Measure this
length from the flanged end of the vent tube and cut square-
- Measure through
ly. Slip rope sealing ring over vent tube and up to flange.
NOTE
It is easier to cut the vent tubes if the vent terminal
is temporarily placed on the end of the vent tube.
The terminal can be held on with tape and will sup-
port the inner vent tube, resulting in a squarer cut.
11 FIGURE 3A: SIDE VENT HOLE LAYOUT
Mounting Plate
«gg
io x
au HA
Appendix À.
This boiler is supplied with a factory designed vent system intended ONLY for use with itself. Do not attempt to connect other
PF series boilers or any other appliances to this vent system. Do not attempt to use any vent components not specified by Crown
Boiler Co. for use on this boiler. If you are removing an old appliance connected to a common venting system on this job site, see
Apply a bead
of silicone here |
FIGURE 3b: VENT TERMINAL REAR VIEW
b) Using the tape provided, wrap the vent tube where it
could come in contact with mortar.
с) Apply a bead of silicone (provided by Crown) around
the LD. of the vent terminal where it fits over the inner
vent tube (Fig. 3b). The vent terminal flue exhaust grill
is designed to discharge flue gases at an angle. Slip the
vent terminal onto the vent tube and rotate it to a
position so that the flue gases will be directed away
from any inside corners, overhangs, or other
obstructions near the terminal after it is installed.
Secure the vent terminal to the vent tube with the screws
provided. MAKE SURE THAT A GOOD SEAL
EXISTS BETWEEN THE VENT TERMINAL AND
INNER VENT TUBE BEFORE PROCEEDING
FURTHER.
-Install the rubber
gasket provided in the boiler mounting plate. Push the
vent tube through this gasket and through the wall until
the flange 1s against the mounting plate.
d) |Side Vented Boilers On
ly |-Install the vent collar provided
in the vent tube opening. Drill holes through the mounting
ears and attach with the screws provided. Push vent
through wall until vent terminal is through sealing collar.
Bend the 4 tabs on the flue sealing collar inwards to retain
the rope sealing ring. Push the vent through the wall until
the flange is clear of the mounting plate.
CUT LENGTH = L_ + 2-3/8 INCHES
FIGURE 4A: CUTTING REAR VENT TUBE
a ;
FIGURE 4B: CUTTING SIDE VENT TUBE
MOUNTING PLATE ©
Cut Length = L, —7-1/4
|
—
b)
3)
b)
с)
Boiler preparation
Move vent cover plate to match vent tube
position (right or rear). Place vent cover
removed over remaining opening. This step is not
necessary for a left side vented boiler as cover
plates are correctly configured for this as shipped.
Note: Flue elbow may be temporarily removed
to gain access to the vent cover wing nuts.
Install 3/4 side outlet tee provided on supply pipe with
the run of the tee in the verticle. Install the relief valve
provided on the top tapping (Fig. 5).
Hanging the boiler
This boiler is heavy. Two people are required
to safely lift boiler onto mounting plate.
Lean boiler against wall directly under mounting
bracket. Two people are required to lift unit.
Lift boiler and place hook on the rear of the boiler
into the slot on the wall mounting plate (Fig. 6).
Remove control cover. Center boiler hook in slot in the
sideways direction. Check that boiler is plumb and
attach boiler to wall with #10 x 1-1/4" screws and 3/16"
Top of Boiler
FIGURE 5: SUPPLY PIPING
Relief Valve
3/4 Side
Outlet Tee
° 1/4 х 3/4
Bushing
_Gauge
washers through lower mounting feet (Fig. 7).
Back
of
Boiler
4
FIGURE 6: HANGING BOILER
Before mounting the fan assembly and casing door,
complete all water piping in accordance with the
following section, pressurize the system, and check
the system for leaks. Pay careful attention to the
following areas as they will not be visible later on:
a) Supply and return joints inside casing
(by the flue collector)
b) 3/4" drain nipple and cap
(lower left corner of heat exchanger)
c) Clean out covers on heat exchanger.
Fix any leaks found in these areas before attempting to
operate boiler.
LA
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7
| Feet.
This edge
plumb. DS
Lower r
Mounting
FIGURE 7: SUPPORT LEGS
EE
NOTE
Although the threaded water piping supplied with this
boiler is 3/4" NPT, installations using PF82's may
require some 1" piping in order to get adequate water
flow through the system. For this reason 3/4" NPT x 1"
female sweat adapters are provided and should be
installed as close to the 3/4" boiler piping as possible if
1" piping 1s required. For more information'on proper
pipe sizing consult Hydronics Institute publication #200.
1) For safe, reliable operation, the system this boiler
2)
is connected to must have the following components.
e Temperature- pressure gauge (Provided by Crown)
e/Properly sized circulator
9% Properly sized expansion tank
Y Connection to fresh water for filling (automatic
fill preferred)
4 Relief valve (provided by Crown and installed in
Part IV, step F part 2).
4 One automatic air vent and sufficient manual
vents to purge all air from the system.
(Automatic vent supplied by Crown)
Some of these components are available in a package
designed for use with this boiler. See your Crown dealer
for specifications.
This boiler is supplied with an automatic air vent, 3/4"
Tee, and a 3/4" x 1/8" bushing so that the air vent may
be mounted at the boiler return. If this is done, the Tee
is screwed on to the male connection on the right top of
the boiler with its run in the vertical. The bushing and
air vent are then installed on the top of this Tee and the
return connection is made on the side of this Tee.
If you are installing the boiler with a low water cut-off on
the supply as shown in Fig. 8b, install an air vent by the
low water cut-off regardless of whether one is installed on
the retum. AT LEAST ONE AUTOMATIC AIR VENT
MUST BE PROVIDED ON EITHER THE SUPPLY OR
RETURN ON THE TOP OF THIS BOILER.
4)
3)
6}
7)
8)
If the boiler is to be installed above the radiation, a low-
water cut-off must be installed in the system. The best
location for this is the supply piping above the boiler.
Locate this low water cut-off and an automatic air vent
in a cross as shown in Fig, 8b.
This boiler is designed for use in a closed system.
Excessive feeding of fresh water through boiler will
destroy the heat exchanger.
If boiler is to be used in conjuction with a water
chiller, a means must be provided to prevent the
chilled medium from entering the boiler. Install
shut-off valves as shown in Figure 8a.
If the boiler is to be connected to heating coils
located in air handling units where they may be
exposed to refrigerated air circulation, flow control
valves or other automatic means must be used to
prevent gravity circulation during the cooling cycle.
If any part of the heating system is subject to
freezing temperatures, antifreeze should be used to
protect the system from damage. A non toxic
antifreeze must be used. Consult antifreeze
manufacturer for proper ratio of antifreeze to water.
Pipe relief valve to nearby drain or other location
~ Where hot water discharge will not cause injury or
damage. Leave a 6" inch gap between the relief
valve pipe termination and the drain pipe or closest
obstruction. Termination of relief valve must be
unthreaded. Do not pipe relief valve pipe to outdoors
or other potentially freezing location.
| i For Heating: Open B.D Close A,C
For Cooling: Open A, C Close B,D
"FIGURE 8a: TYPICAL CHILLER PIPING
3/4 x 1/8 Bushing T И
IL Г)
Automatic Air Vent Relief Valve
Discharge
-
Probe _/ Boiler
L.W.C.O.
3/4 Cross To System
FIGURE 8b: TYPICAL LOW WATER
CUT OFF PIPING
9) Zoning- Many different ways of zoning systems
exist and the details of such are beyond the scope of
this manual. The following points should however
be kept in mind.
¢ If this boiler is to be used with an indirect water
heater it may be desirable to install the boiler with a
3 way zone valve so that all boiler water is diverted
to the water heater during a call for domestic water.
This “priority zoning’ can also be done using 2
way zone valves, or circulators, and a SPDT
switching system.
«/ If circulators are used for zoning, a flow check
should be installed on the opposite end of the zone
from the circulator to prevent gravity, or other
unwanted circulation.
1) Slide vent tube towards boiler and engage the flange
studs in the casing.
2) Secure vent tube to casing with the four 5mm wing nuts
provided.
- If not already done, remove the
four wing nuts securing the flue elbow to the flue
collector, leaving the silicone pressure tubes attached.
Insert the flue elbow into the inner vent tube and
reinstall wing nuts. Using the silicone supplied,
carefully seal the joint between the flue elbow and the
inner vent tube.
3) | Side Vent Only | - If not already done, remove the
four wing nuts securing the flue elbow to the flue
collector, leaving the silicone pressure tubes attached.
Insert the flue elbow into the aluminum flue elbow
extension provided in the parts bag. Insert the flue
elbow and extension into the inner vent tube and
reinstall wing nuts. Using the silicone supplied,
carefully seal the joints between the flue elbow, elbow
extension, and inner vent tube.
NOTE
It is important NOT to apply the silicone to the
above mentioned joints until AFTER the elbow and
extension (if used) are installed. If silicone is applied
to the male side of these joints prior to inserting
them, it will be extremely difficult to break the joints
if the flue collector must be removed for servicing.
4) Mount fan assembly to boiler with the seven 5mm
screws provided. Plug fan wires into fan plug on
boiler (Fig. 11).
5) Install casing door, making sure that a good seal exists
around the joint between this door and the casing.
6) Seal vent terminal to outside wall with 400 F. silicone
7) Install wall plate provided to cover any damage to the
wall around the vent terminal.
Exhaust Tube
/ Elbow Extension oe venting PT Silicone
‚Р e >
|
FIGURE 9: ELBOW COMPONENTS
pt ar it ie
7
Flue Elbow
Silicone
FIGURE 10: FLUE ELBOW INSTALLA
E
(SIDE VENT SHOWN)
FIGURE 11: FAN INSTALLATION
Smm x 15mm
Dog Point Screw
(7 Required)
OF
>
Sr - |
Fan Plug I |
NOTE
It 1s easier to make the electrical connections in
the junction box prior to installing gas piping.
1) Observe the following when making gas connection.
y Use only ungalvanized steel pipe and black
malable iron fittings unless other materials are
permitted by the authority having jurisdiction
over local gas piping.
¢ Use a pipe dope suitable for use with Natural &
LP gas regardless of the fuel used. Apply dope to
male threads only, keeping first 3 threads free of
dope.
10
¢ Use only ground joint unions.
¢ Install a drip leg to prevent sediment from
reaching the gas valve (Fig. 12).
¢’ Install a manual main shut-off valve. Where
codes require place this outside the control cover
(Fig. 12).
Y Install a union in an accessible location so that
gas train may be removed from boiler if needed for
servicing (Fig. 12).
&” Make sure gas piping is properly sized for the
installation. Consult authority having jurisdiction
over this (usually the gas company) or in the
absence of such an authority, ASNI-7223.1-1988.
A YT TA e
1 Wd |
Do not use an open flame to check for leaks.
2) Testing gas pipi b) The boiler and its individual shut-off valve must be
ВЕН PTS disconnected from the gas supply piping system
a) Gas piping must be tested for leaks immediately during any pressure testing of that system at test
after turning on gas to the boiler. To do this pressures greater than 1/2 psi.
pray the pip ing with & soap suds solution. Forming c) The individual shut-off valve of the boiler must be
matter small. at once 7 ’ closed during any pressure test of the gas supply
- piping system at pressures less than or equal to 1/2 psi.
FIGURE 12: TYPICAL GAS PIPING
o-
Gas Valve
Ground Joint Union
Gas Cock
1) Wiring must be in accordance with all codes. In the 3) Boiler system must be connected to its own 15 amp
2)
absence of any codes, boiler must be wired and
grounded in accordance with the National Electric
code (ANSI/NFPA 70-1990).
High voltage connections - Four high voltage
pigtails are located in the utility box to the left of
the gas valve. These are:
Black- “Hot” to boiler
White- ““Neutral”” for boiler and circulator
Red- “Hot” for circulator
Green- Equipment ground
11
circuit. À remote emergency shut-off switch should be
installed ahead of all other boiler controls. If the boiler
is in a closet, install the emergency switch just outside
the closet.
Bring a cable or cables into the utility box along the gas
line so that they will be in the control cover's ‘‘“U”’ slot
when the cover is installed. Make connections inside
utility box and install utility box cover.
If a circulator with an amp draw of more than 12
amps is used a contactor is required.
4) Low voltage connections - Remove the two 8-32 x 1/2
screws from the control tray and swing it down
(Fig. 13a, 13b). The low voltage terminal strip is in
the forward left corner. Terminals are as follows:
T,T- Connect to thermostat , zone valve, end switch, or
other dry contacts which are intended to start the
boiler upon closing (Fig. 14b).
1,2- Auxilary 24VAC power source for 3 way
motorized zone valve or other device requiring less
than 15.6 VA of power.
5)
IMPORTANT
If terminals 1 & 2 are connected to a device
drawing more than 0.65 AMPS the boiler
transformer may be destroyed.
Make 24 volt connections by running low voltage wiring
from the low voltage terminal strip through the clips on
the left edge of the control tray. These wires can then be
‘routed out of the boiler either along the gas pipe or
through metal conduit installed in the 7/8" knock-out to
the left of the control tray.
Zone wiring- Fig. l4c, d, and e show common zone
wiring for 3 way domestic water zone valves, 2 way
zone valves, and circulator zoning respectively.
(See Gas Valve
Figure 15 Detail)
High Limit
Control Tray
(See Figure 13b Detail)
FIGURE 13A: GENERAL CONTROL LAY-OUT
| Lift tray off
rear hooks
to remove
12
FIGURE 13B: CONTROL TRAY TOP VIEW
Wiring Hamesses omitted for clarity
High voltage terminal strip
Pressure Switch
Negative Pressure
58670
Ignition Module Connector
‘Thermostat Cable Clip
Transformer
Low Voltage ~~
Terminal Strip |
| Circulator Relay
Fan/Latch Relay
FIGURE 14A: 115 VOLT WIRING - FOR USE WITH FIGURES 14B, C, D
Emergency L.W.C.O.
i Contacts (If used |
Switch ( ) n Black Lead
— о о— со —
H A White Lead
N |
Gnd HD n RedLead
G С " AE EE ree
i |
Н Circulator
1
O hi —
A ol en |
Wire Nut
Field Wiring 24 Volt Transformer
Factory Wiring (Fig. 14D only)
FIGURE 14B: 24 VOLT WIRING - SINGLE ZONE
Low Voltage
Terminal Strip
O 2
O 1
О OT
О OT
24 Volt Heat Anticipator Setting = 1.0
Thermostat
13
FIGURE 14C: 24 VOLT WIRING - PRIORITY ZONING OF AN INDIRECT
WATER HEATER WITH A 3 WAY ZONE VALVE
Orange
Flair- Superior LW.H. Aquastat 2
UWO 14002 Yellow 3
3 Way Zone Valve 1
Blue
T
Blue
T
Low Voltage
Terminal Strip
Pipe:
АВ - To Retum
A - From 1.W.H.
B - From Heating Radiation 24V Heating Thermostat Set Heat Anticipator
to 1.0
ELL V8043F ZONE VALVES
FIGURE 14D: 24 VOLT WIRING - ZONING WITH HONEYW
| Low Voltage
11 Terminal Strip
24 Volt 24 Volt O 2
Thermostat Thermostat
_ _ O 1
O T
O T
Set Heat Anticipators
| | to 0.32
5 y y
End Switch End Switch | |
| TH-TR TH TR TH-TR TH TR T°
| RTT RR О
Transformer
(24V connections Shown)
14
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XI. START-UP
1) Fill the boiler system with water and purge of all air. 2) Fire boiler: Turn on electrical power from remote
Pressurize to desired operating pressure (typically disconnect switch.
15ps1). |
NOTE
Safe lighting and other performance criteria
were met with gas manifold and control
Never attempt to fill a hot empty boiler. assembly provided on this boiler when the
boiler underwent the tests specified in ANSI
221, 135-1991.
if you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
A. This appliance is equipped with an ignition device ° If you cannot reach your gas supplier, call the
which automatically lights the pilot. Do not try to fire department.
light the pilot by hand.
C. Use only your hand to push in or turn the gas
B. BEFORE OPERATING smell all around the control knob. Never use tools. If the knob will
appliance area for gas. Be sure to smell next to not push in or turn by hand, don't try to repair it,
the floor because some gas is heavier than air and call a qualified service technician. Force or
will settle on the floor. attempted repair may result in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS D. Do not use this appliance if any part has been
Do not try to light any appliance. under water. Immediately call a qualified service
Do not touch any electric switch; do not use any technician to inspect the appliance and to replace
phone in your building.
immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructi
any part of the control system and any gas
control which has been under water.
. . . 5. Remove control access panel.
i
1. STOP! Read the safety information above on this 6. Push in gas control knob slightly and turn
label. , clockwise to "OFF."
2. Set the thermostat to lowest setting. - NOTE: Knob cannot be turned to "OFF" unless
3. Turn off all electric power to the appliance. knob is pushed in slightly. Do not force.
4. This appliance is equipped with an ignition device 7 Wait five (5) minutes to clear out any gas. |
which automatically lights the pilot. Do not try you then smell gas, STOP! Follow "B" in the
to light the pilot by hand. safety information above on this label. If you
| don't smell gas, go to next step.
8. Turn gas control knob counterclockwise to
"ON"
3. Replace control access panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance"
and call your service technician or gas
supplier.
Gas Control Knob
Shown in "ON"
Position
16
3) Check-out
a) Ignition system safety check- Fire boiler and carefully
disconnect ignition cable from the S8670E. Main and
burner flame should immediately extinguish. If it does
not, consult the gas utility or Crown representative. Do
not leave In operation.
If main flame extinguishes, turn off power to the
boiler and reconnect spark cable. Boiler may then
be restarted
b) High limit check- Set the high limit to the desired
setting (180° F is typical for baseboard or standing
radiation). Raise or temporarily jump the thermostat so
as to run the boiler until the water temperature reaches
the limit setting. At the water temperature + 10°F the
burners should shut down and the circulator continue to
operate.
¢) Thermostat check and adjustment - Lower thermostat
to point shown on thermostat thermometer and make sure
that the burners and circulator shut-off at approximately
this setting. Set thermostat heat anticipator. On a zoned
system this step must be done for each thermostat.
d) Main burner check-out- Main burner flame
should be mostly blue in color and well defined (Fig.
17). No yellow should be present although orange
flecks may intermittently appear. If yellow is present in
the flame:
¢# Check the manifold pressure at the gas valve.
This should be:
4.0 in w.c. for Natural gas
8.0 in w.c. for LP Gas
y Check gas orifice size against parts list in the back of
this manual. Check for burrs or score marks in
orifice opening.
If the boiler is natural gas fired, the input may
alternately be checked by clocking the gas meter.
The input is then approximately:
BTU/hr input= (1000 BTU/fE3) x (4Cu. ft clocked) x {3600 Shr.)
(4 Seconds clocked)
¢ Check the orifice and burner venturi for any foreign
matter.
e Check to make sure that the flue orifice and air
intake orifice are of the correct size.
¢ Check that there is no recirculation of flue gases
into combustion air system.
y Check casing for combustion air leakage.
Manifold Pressure Regulator
FIGURE 15: GAS VALVE
PV, MV/PV, and MV
” Electrical Corrections
— 1/8” Manifold Pressure Tap
1/8" Line Pressure
Tap
— Ground Correction
Pilot Tube Connection
Manual Gas Control
Knob
Pilot adjustment
> (Actual adjustment located under
this screw)
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if
service is to be performed.
3. Remove control access panel.
TO TURN OFF GAS TO APPLIANCE
4. Push in gas control knob slightly and turn
5. Replace control access panel
to "OFF." Do not force.
clockwise -—a
17
$)
Pilot check-out- Pilot should be blue, stable, and
completely cover the gap between the electrode
and grounding strap (Fig. 18). If necessary, it
may be adjusted by removing the cover screw
shown in Fig. 15. Using a 1/8" flat bladed screw
driver, turn the pilot adjusting screw clockwise
to lower the pilot and counter clockwise to raise
it.
Casing seal check — With the boiler operating
run your hand around the casing door joint and
all other joints and seals to make sure no air is
leaking from these areas.
Low Water Cut-off Check-out — Check the low
water cut off for proper operation at the intervals
specified by the low water cut-off manufacturer.
Consult the low water cut-off manufacturer's
instructions for the proper manner in which to
do this.
FIGURE 16: PILOT FLAME
„= Possible
Yellow or
Orange Tip
Blue Flame
FIGURE 17: MAIN FLAME CHARACTERISTICS
Completely Blue Flame
-OK
Blue Flames, Yellow Tips
-Orange-Yellow Tipping normal on LP
Excessive tipping may indicate lack of adequate air
(See part 3d)
Lifting Flame %
- Slight lifting is normal on start-up
Excessive lifting after several minutes of
operation may indicate excessive manifold pressure.
Yellow Flames
-Unacceptable - See part 3d
AINTENANCE
In order to ensure safe reliable operation the follow-
ing maintenance procedures should be performed by
a qualified serviceman on an annual basis.
1) Check flue passages for cleanliness - Remove
control cover, casing cover, fan assembly, and
18
fire door. Remove the flue elbow, flue collector, and
baffles (if used). Place a light in the combustion
chamber. Using a mirror (held at a 45° angle over
the top of heat exchanger) examine the flue passages.
Remove any visible deposits from the flue ways with
a small flue brush. In order to prevent such
deposits from falling onto burners place a piece of cardboard
on top of burner assembly before brushing out flue collector.
2)
|)
b)
с)
d)
À rapid accumulation of soot in a gas boiler
1s indicative of a hazardous condition. The
cause of such sooting should be located and
corrected (See section X part 3d)
Shine a light down both the inlet and exhaust tubes
(this may have to be done from the vent terminal
end). Inspect both air intake and vent tubes for
foreign objects or deterioration of tubes. Also
inspect vent terminal for blockage. Clean and repair
as necessary
Sequence of normal operation (Reference Fig. 18,
Fig. 19).
Upon a call for heat thermostat terminals are made,
energizing relay coil 1K. This closes contacts 1K 1
which energizes circulator.
If the high limit contacts are made, and the C-NC
pressure switch contacts are made, current flows
through the 2K relay coil. This energizes the
combustion fan via contacts 2K2 and simultaneously
provides an alternate route to coil 2K around th
C-NC contacts via contacts 2K1. |
The purpose of this ““latch”” system is to provide a
check, before attempting to start the burners, that
the pressure switch is not stuck in the “pressure
OK” position.
The fan moves air through the boiler providing a
pressure differential across the pressure sensing
tubes in the flue elbow. If a pressure differential of
at least a 1.74 +£0.07" w.c. is present, the C-NC
contacts will break and the C-NO contacts will make.
This energizes the Honeywell S8670-based intermittent
ignifton system.
Upon begin energized, the S8670 module waits for
a 30 second prepurge period to pass before attempt-
ing to light the pilot. At the end of this time, an
ignition spark 1s started and 24VAC is applied to the
pilot valve in the VR8204 (terminals PV-MV/PV).
à 6 ES
uy 5
3)
4)
5)
e)
g)
19
After cleaning and inspecting heat exchanger and
vent tubes, reassemble flue collector, flue elbow,
and fan assembly, replacing any deteriorated
gaskets.
Burner assembly should be inspected for foreign
matter in the venturi and blade holes. Any such
matter should be blown out with compressed air or
vacuumed out. Once burner has been inspected the
fire door may be reinstalled.
Fan motor 1s equipped with ball bearings, and
should not be lubricated.
Reassemble casing cover, and control cover.
Perform checks outlined in Section X.
Upon establishment of a pilot flame, AC current
coming up the ignition cable is rectified to a DC
current by the pilot flame. This signal passes from
the pilot grounding strap through the frame of the
boiler to the ground screw in the utility box. It then
travels to the ‘“Grd’’ terminal on the S8670 via the
green wire. |
If the S8670 senses a current greater than 1.2uA DC it
deenergizes the spark and energizes the main valve
on the VR8204 gas valve (Terminals MV-MV/PV).
If the pilot flame is not detected by the S8670 after a 90
second trial for ignition, it will deenergize the
pilot valve and spark. It will then wait 5 minutes
and try to establish pilot again. During this time the
fan and circulator will continue to operate. If no
pilot is ever detected, this cycle will continue
indefinitely.
After the main flame is established, the pilot will
continue to burn. Both main and pilot flames will
continue to burn until the thermostat or high limit
opens. When either device opens the 2K relay coil is
deenergized and the system returns to its original
status.
If the high limit opens, only the 2K coil is opened.
The 1K coil remains energized, keeping the
circulator running until the call for heat is satisfied.
2)
a)
b)
The following four pages contain a troubleshooting
chart for use in locating and solving control
problems. To use it do the following:
Go to the start box on the next page and follow
the instructions contained in that box.
Follow the line out of that box into diamond
which asks "does the circulator start.” If the
circulator is operating follow the path leaving
this diamond to the right (the "Y" for yes path).
If it is not operating leave the diamond by the
bottom ("N" for no path). Continue in this
manner, following the boxed instructions and
answering the questions in diamonds, until you
come to a box with a list of possible causes
denoted with asterisks (*). One of these causes
is probably behind the problem being
experienced.
If you rule out all the causes in a particular box,
first retrace the path taken to get to this box and
make sure that all questions have been
accurately answered. If you arrive at the same
box, check the wiring against the connections
diagram in Fig. 19. If all wiring is in accordance
with this diagram, contact a Crown
representative for further assistance.
IMPORTANT
Although the causes listed in the boxes
above are in no particular order, all controls
are factory tested at least once in the assembly
process and A DEFECTIVE CONTROL IS
GENERALLY THE LEAST LIKELY CAUSE.
If you suspect you have a defective control,
double check your path through the trouble-
shooting chart before you replace it.
It is also important to remember that THE
LIKELIHOOD OF COMING ACROSS TWO
IDENTICAL DEFECTIVE CONTROLS IN A
ROW IS ALMOST NIL. If this seems to be
happening, chances are that either there is
nothing wrong with the control or it is being
damaged by some other problem (a short
burning out a transformer, for example).
20
Start: Turn off emergency
switch, turn it back on, and
make sure that thermostat
is calling for heat.
Is 110 volts
present across 1 & 3 В
on transformer? ~~
* Loose connection between
transformer and low voltage
terminal strip.
* Defective transformer.
Does
” Does combustion ©
Circulator
rd Is 24 volts >
Present between
1 & 2 on low voltage
Disconnect thermostat or zone
valve end switch connections
from T & T on low voltage
terminal strip. TEMPORARILY
jump T & T together.
> fanoperate? 7
Is 115 volts
present between
transformer terminal
Q 43 and on fan latch
> relay terminal 452 7
Does |
< circulator №
* Loose connection between
transformer and house fuse
box.
* Open fuse or circuit
breaker.
Is 24 volts
present across
* Loose electrical
connection in
gray or brown
wiring.
> circulator relay? 7
* Loose connection in
110 volt circulator
wiring.
* "Frozen" or defective
circulator.
* Defective circulator relay,
* Loose connection in
black and white fan leads.
* Loose connection in pin
connectors between
control tray and fan.
* Defective Fan.
* Field thermostat
wiring is not
calling for heat.
Check for bad electrical
connection. Consult
thermostat or zone valve
instructions. .
21
* Pressure switch C
and NC terminals are
not "made." Possible
cause of this are:
a) Kinked pressure
sensing tubes.
b) Condensate or blockage
in pressure sensing
tubes.
с) Defective pressure
switch.
Di will not "retry” until 5 minutes has
Wait 30 seconds. Note: If fan has
been running more than 120
seconds continuously, the ignition
system may be "locked out.” If this
has happened the ignition system
~~" Does spark > ee
DSK Start at po 7
passed from the time of lockout. Next Page
Instead of waiting 5 minutes for this
to occur, the ignition system may be
“reset” by turning the 115 volt
power to the boiler off and back on.
The ignition spark should then start
after approximately 30 seconds.
Disconnect yellow and brown
leads from S8670E. Connect
a volt meter to these leads.
Is 24 Volts =
present between —
= terminals 13 and 8
on fan/latch relay?
Is 24 volts
< present across »
* Loose connection in wiring
Y or pin connector between high
limit and control tray.
* Boiler is off on high limit.
* High limit is defective.
* Make sure that S8670E
is not "locked out.”
* Inspect spark cable
for poor connection
or broken insulation.
* Inspect pilot for cracked
porcelain or misoriented
electrode/grounding strap.
* Defective 58670E.
“154 Vois SN
present between
terminals 13
= and 14 on ,
> fanflatch relay? ~
* Defective fan/latch
relay or relay base.
ls at least 1.7" w.c. of
pressure present between
„the pressure switch hose ,
connections? 7
* Pressure sensing tubes are reversed.
Make sure that the connections
with red rings are connected
together and go to the left
("red") pressure switch connection.
* Pressure sensing tubes are reversed.
* Kinked pressure sensing tube.
* Condensate or blockage in pressure
sensing tubes.
* Leaky pressure sensing tube.
* Flue orifice missing.
* Blockage in vent tubes.
* Loose or missing casing door.
* Sooted heat exchanger.
* Damaged or missing gaskets under fan.
* Defective fan.
Make sure that the connections
with red rings are connected
together and go to the left
("red") pressure switch connection.
* Defective pressure switch.
From Previous Page
Does spark >
shut off after
Disconnect blue and white
leads from the PV and MV/PV terminals
on the 58670E ignition module,
Connect a volt meter to these
terminals. MAKE SURE THAT MODULE
IS NOT LOCKED OUT WHILE METER
IS READ. IF MODULE IS NOT LOCKED
OUT A SPARK WILL BE PRESENT AT
THE PILOT.
fat
не
Is 24 volts present
between PV and MV/PV
WHILE SPARK IS
PRESENT AT
PILOT?
* Bad electrical connection between
58670E and gas valve in blue or
white wires.
* Closed manual gas valve.
* Gas lines not purged of air.
* Plugged or leaking pilot line.
* Damaged pilot assembly.
* Defective gas valve.
|
* Defective S8670E.
Does main flame
come on?
Disconnect the ground
lead from the 44 (GND)
terminal on the S8670E.
Connect a DC micro-amp
meter between the ground
lead and the #4 connection.
Disconnect the red lead
from the MV terminal on
the S8670E module.
Connect a volt meter
between the MV terminal
and the #4 terminal
on the TRANSFORMER.
pln
~~" Isatleast © Se
1.2 pA DC present ™
WHILE PILOT
IS BURNING? A0
1824 volts
present between
these terminals? Ar)
* Defective S8670F
* Bad connection in red
wire between 58670E
and gas valve,
* Blockage in main
burner orifice or
manifold piping.
* Defective gas valve.
* Bad connection in
spark cable.
* Poor ground
connection between
pilot assembly and
58670E (part of the
ground path is
through the frame
of the boiler).
* Damaged pilot assembly
* Improper pilot flame
(lame should look like that
shown in Fig. 16, page 17).
* Defective S8670E.,
23
PRA.
zara
Does the °
7 burner shut =,
down before the water
temperature reaches the
high limit setting + 15°
~~ Does burner ‘
and circulator shut
~. degrees while the thermostat 7
Ns still calling for heat? rd
* High limit bulb is not
bottomed out in its well.
* High limit capillary
tube is kinked or broken.
* Gray and blue leads to
high limit are
electrically touching
(probably due to damaged
insulation and/or bent
quick-connects).
* Defective high limit.
down at the end
x. of a call >
É
Does Burner “a
and circulator shut a
down when the field wi-ing
is disconnected
= from the boiler >
™~ T&T terminals? ~~
er
ЕЕ
ty
i)
ыы Pr NE ooo
END
* Field wiring is still calling
for heat. Make sure that all
wiring is per the zone valve
and/or thermostat manufacturer's
instructions. Also look for a
“short” in the leads going to
the T & T terminals.
* Boiler wiring not in accordance
with Figs. 18 and 19 of this manual.
* Blue or gray leads in direct electrical
contact with pink lead or terminal
#5 of transformer.
* Contacts in circulator or fan/latch
relay welded together.
* Other problem internal to the boiler
- consult a Crown representative
immediately.
24
FIGURE 18: BOILER LADDER DIAGRAM
N
120 VAC
H |
|| o © ©
1K1 Circulator
Circulator Contacts
[|
LE
2K2 Fan
Fan Contacts
Transformer
Room 1K
Thermostat Circulator Relay
Ignition
System
C /
2K
High | | Fan/Latch Relay
Limit Pressure Coil
Switch
|
ti
2K1
Latch Contacts
© O
1 2
24 VAC
Auxiliary
Power Supply
Factory Wiring
NOTE: System is shown in the deenergized position
with thermostat open and high limit closed.
Field Wiring
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26
The following information is provided to assist the installer who is permanently
removing a gas fired appliance from a common venting system. It is provided for
informational purposes only and is not directly relevant to the installation of a PF series
boiler. NEVER ATTEMPT TO CONNECT A PF BOILER INTO A CHIMNE
At the time of removal of an existing (a)
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 (e)
operation.
(a)
(5)
(©)
Seal any unused openings in the common
venting system.
Visually inspect the venting system for (1)
proper size and horizontal pitch and
determine there is no blockage or
restriction, leakage, corrosion and other
deficiencies which could cause an unsafe
condition.
Insofar as is practical, close all building
doors and windows and all doors between
the space in which the appliances (5)
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.
Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
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.
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
appliance to their previous conditions of
use.”
Any improper operation of the common
venting system should be corrected so the
installation conforms with the National
Fuel Gas Code, ANSI 7223.1-1988. 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 Appendix G in the
National Fuel Gas Code, ANSI Z223.1-
1988.
27
| PARTS
Tf ED 5 à E g/d Y
à FE o a By wil dd FE EF Y
IMPORTANT
1) This boiler uses a mixture of metric and english threaded fasteners. These fasteners are specified in the
following parts lists ("M5" and "5 millimeter" are the same thread diameter). All specified metric fasteners are
available through Crown Distributors and may also be found in some hardware or auto supply stores.
2) It is extremely important that the casing and fan seals be maintained (see Part XI, for more information on
this). When replacing parts be sure to have silicone sealant and any extra gaskets on hand which might be
damaged during the replacement process.
3) All replacement parts {except for screws and other common hardware) must be factory original unless
otherwise noted. They must be installed by a qualified serviceman.
4) Replacement parts are available through Crown distributors only. We do not sell direct.
28
CASING AND VENT COMPONENTS
KEY # DESCRIPTION CROWN QUANTITY PER BOILER
PART #
1 Vent Terminal Mounting Screw Pkg. 10-193 Pkg. C
2 Vent Terminal 10-135 1
3 Wall Plug 10-194 Pkg. B
4 Wall Plug Screw > 10-194 Pkg. B
5 Rope Sealing Ring 10-136 1
6 Vent Tubes, Standard 10-124
6 Vent Tubes, 76 in. 10-195
7 Sealing Collar (side vent only) 10-137 1
8 Casing Door 10-211 1
9 Casing Door Gasket 10-152 1
10 Sight Glass Gasket 10-153 2
11 Sight Glass 10-156 1
12 Sight Glass Retainer 10-154 1
13 6-32 Hex Nut 90-011 3
14 M6 x 15 Casing Door Screws 10-196 2
15 Retainers for Casing Door Screws 10-197 2
16 8-32 x 1/2 Philips Head Machine Screws 90-014 18
17 Utility Box 96-001 1
* Cover for Utility Box 96-002 1
18 Strain Relief Adapter 10-173 1
19 Strain Relief 10-033 1
20 Line Voltage Harness 10-161, 10-032 1 each
21 #10 x 3/16 Sheet Metal Screw 90-007 6
22 Pipe Seal Plate 10-023 2
23 Pipe Seal Gasket 10-024 2
24 M5 Wing Nut 10-019 16
25 Pinhole Grommett 10-026 5
26 Pressure Sensing Tubes 10-020 2
27 Pressure Sensing Tube Grommetts 10-021 4
28 Ignition Wire Grommett 10-021 1
29 Control Cover Bracket 10-036 1
30 1/4-20 Knurled Screw 10-051 1
31 Retainer for (30) 10-052 1
32 Control Cover 10-212 1
33 5/16 x 27 Lag Screw 90-010 6
34 5/16 Flat Washer 90-008 6
35 5/16 “Long” Lag Shield 90-009 6
36 Boiler Mounting Bracket 10-128 1
37 Rear Vent Gasket (rear venting only) 10-129 1
38 Smm x 850mm Rope 10-120 1
39 Casing 10-110 1
40 Retaining Clips 10-043 8
41 M5 x 15 Cap Screw 90-017 2
42 1/4 - 20 x 1/2 Truss Hd. Screw 90-005 4
43 Control Tray Chassis (Metal only) 10-086 1
44 Boiler Hook 10-118 1
45 M8 x 10mm Cap Screw 10-119 2
46 Vent Cover Gasket 10-116 3
47 Vent Cover 10-117 3
48 Support Channels 10-112 2
49 M5 x 12mm Machine Screw 10-115 6
50 Chassis Suppport Bracket 10-027 1
51 1/4-20 x 5/8 Machine Screw 90-015 2
52 1/4-20 Thin Nut 90-004 2
53 #10 x 1 1/4 Sheet Metal Screw 90-018 2
54 3/16 USS Washer 90-020 2
55 #10 Plastic Anchor 90-019 2
29
INNER CASING COMPONENTS
KEY # DESCRIPTION CROWN QUANTITY PER BOILER
PART #
56 Vent Tube Gasket 10-134 1
57 Elbow Extension (side vent only) 10-142 i
58 Upper Silicone Pressure Sensing Tubing 10-046 2
59 Flue Elbow 10-017 1
61 Flue Elbow Gasket 10-018 1
62 Flue Orifice for:
PF 50 10-016
PF 65 10-015
PF 82 10-014
63 Flue Collector 10-013 1
64 Fan Mounting Plate Gasket 10-146 1
65 Fan Mounting Plate 10-144 1
66 M5mmx15mm Dog Point Screw 10-045 15
67 Fan Gasket 10-145 1
68 M8mm Hex Nut 10-009 24
69 3/4 x 8 1/2 Nipple 95-001 2
70 Flue Collector Gasket {12mm x 850mm Rope) 10-199 1
71 Flue Baffle (PF 65 and 82 only) 10-012 1
72 M8mm Thin Hex Nut 10-122 4
73 High Limit Well 10-083 1
74 High Limit Retainer Pin 10-044 1
75 M8 x 32mm Stud 10-121 À
76 Heat Exchanger 10-078 1
77a Heat Exchanger Cover 10-079 2
77b Heat Exchanger Cover Gasket 10-080 2
78 M8 Washer 10-082 16
79 M8x27 Studs 10-081 16
80 “Dart Clip 10-062 2
81 Firedoor Insulation 10-061 1
82 Firedoor Assy, Metal Only 10-200 1
83 Firedoor Sight Glass 10-063 1
Firedoor Assembly Complete 10-215
84 #6 x 1/4 Sheet Metal Screw 90-002 2
85 M8 x 18mm Stud 10-008 4
86 Firebox 10-001 1
87 Side Firebox Insulation 10-002 2
—- Rear Firebox Insulation 10-003 1
88 Cerablanket Strip 10-011 1
89 Left Side Baffle 10-004 1
90 Right Side Baffle 10-005 1
91 M5 Hex Nut 10-010 8
92 Bottom Radiation Shield 10-006 1
93 Radiation Shield Spacers 10-007 4
31
- 68,78
86
38
90
9
76
93
— 773, 77h
79
==
©
Rely
32
01
BURNER ASSEMBLY
KEY DESCRIPTION CROWN QUANTITY PER BOILER
PART #
94 Pilot Assembly
For Natural Gas (Q345A 2014) 10-066@ 1
For Propane (Q345A 2006) 10-157 1
(Includes key parts 97 or 98)
95 Ignition wire assembly (Honeywell 394803) 10-041 1
96 10-32 x 3/16 Machine Screws 90-007 2
97 Pilot Orifice
For Nat Gas Boilers (0.018") 85-002
For LP Gas Boilers (0.012') 85-001
98 Pilot Tube Ferrule (long) 85-003
99 Pilot Tube (1/8 OD) 10-067 1
101 Burner 10-065 1
102 3/8" Gas Valve Elbow (Honeywell 393670) 10-077 1
103 8-32 x 1/2 Screw Part of 10-077 2
104 8-32 x 1-1/4 Screw Part of 10-077 2
105 “O” Ring Part of 10-077 1
106 Main Burner Orifice:
PF 50 (#22 Drill) 10-073 1
PF 65 (#17 Drill) 10-072 1
PF 82 (#12 Drill) 10-071 1
PF 50LP (#41 Drill) 10-076 1
PF 65LP (436 Drill) 10-075 1
PF 82LP (432 Drill) 10-074 1
107 Gas Valve
Nat Gas (VR8204A-2274 10-068* 1
LP Gas (VR8204A-2282) 10-158 1
108 Pilot Tube Ferrule (Short) 85-004
109 Gas Valve Brace 10-037 1
110 8-32 x 1/4 Truss Hd. Machine Screw 90-016 2
PF50 Burner Assy. Complete 10-201
PF65 Burner Assy. Complete 10-202
PF82 Burner Assy. Complete 10-203
PF50LP Burner Assy. Complete 10-204
PF65LP Burner Assy. Complete 10-205
PF82LP Burner Assy. Complete 10-206
*
@ A Honeywell Tradeline Q345A1313 may be used as a replacement for this.
If a replacement VR8204A2274 is not available, a VR8204A2241 (used on some Crown ABF's, XE's and JBF's)
may be used with the manifold pressure readjusted to 4.0" w.c..
-
FAN AND FAN HARDWARE
KEY DESCRIPTION CROWN QUANTITY PER BOILER
PART #
111 8-32x1 1/2 Screw 90-013 3
112 8-32 Lock Washer 90-003 3
113 Fan 10-143 1
114 Strain Relief 10-148 1
115 Pin Connector Male Shell 10-149 1
116 Pins for Key #115 10-150 2
117 Wire Harness “N” 10-040 1
Fan Asssy. Complete 10-207
CONTROL COMPONENTS
KEY DESCRIPTION CROWN QUANTITY
PART # PER BOILER
118 High Voltage Terminal Strip 10-095 1
119 58670E1007 a 10-087 + 1
120 Differential Pressure Switch 10-089 1
121 Low Voltage Terminal Strip 10-093 1
122 Marker Strip 10-094 1
123 Honeywell AT140 10-088 1
124 Circulator Relay 10-090 1
125 Fan/Latch Relay Base 10-092 1
126 Fan/Latch Relay 10-091 1
Honeywell 1418982012 High Limit 10-030 1
Control Tray Wire Harnes Sets:
High Voltage Wire Harness Set 10-216 1
Low Voltage Wire Harness Set 10-217 1
Gas Valve Wire Harness 10-106 1
Gas Valve Harness Strain Relief 10-108 1
6-32x1/2 Machine Screws for Key #124 90-002 2
Jumpers for Terminal Strips 10-096 3
Control Assy. Complete 10-208
Notes:
+ NOT interchangable with 58600 modules used on other Crown Boilers.
8-32x1/2 Machine Scews (Key #40) used to attach all controls and devices to tray except for circulator relay.
FAN AND FAN HARDWARE
CONTROL TRAY TOP VIEW
Wiring Harnesses omitted for clarity
118
120
119
40
123
121
124
122
125,126
36