Crown Boiler Nassau Series (all Models) Product manual

 — CROWN/NASSAU
OIL-FIRED CAST IRON
STEAM BOILERS
© Installation
© Operation
® Repair Parts
CROWN BOILER CO.
3633 1 STREET, PHILADELPHIA, PA 19134
(215) 535-8900 * FAX (215) 535-9736 * www.crownboiler.com
NS 10-1 R2 (2.5M)
Boiler Ratings and Capacities
1/2" NPT
TANKLESS
1/2" NPT HEATER . „
PRESSURE TROL — ( OPTIONAL) 2-1/2" NPT 3/4 ASME
PRESSURE GAUGE SUPPLY POP SAFETY
- COMBINATION VALVE
he 3/4 NPT o .
A Low LIMIT 1 1-1/7 NPT 36
7 CONTROL ON | SKIM TAPPING
| {| COIL PLATE ;
1-1/2" NPT ;
RETURN : |
\ | |
: a В - 3
dae |! Jui ;
L— 25 1/2 he A — RETURN
| ( OPTIONAL )
FRONT LEFT SIDE REAR
NASSAU OIL-FIRED STEAM BOILER RATINGS
** Net Net i=B=R | "Maximum | Typical DIMENSIONS-INCHES
BOILER No. | Input | Heating | I=B=R Rating Firing Chimney
MODEL NO.| Sec.| *MBH | Capacity | Ratin Sq. Ft. Rate Size and
| *MBH *MB Radiation GPH Height A B C
NS-118 3 140 118 89 369 100 |8x8x15 16 7 9
NS-145 3 175 145 109 453 125 |8x89x15 16 7 9
NS-156 3 189 156 117 488 135 |8x8'x15 16 7 9
NS-177 4 | 210 177 133 533 150 |8@x&x15 | 202 | 8 | 11
NS-204 4 245 204 153 638 1.75 |@x&@x15 | 20 8 11
NS-215 4 259 215 161 672 1.85 8" x8" x20 204 8 11
* MBH = 1,000 BTU per hour
BTUH = British Thermal Unit Per Hour
GPH = Gallons per Hour Oil at 140,000 BTU per Gallon
** Heating Capacity is based on a 13% CO, with a -.02" w.c. draft over fire, and a #1 smoke or less. The testing on the boilers was done in accordance with
the D.O.E. (Department of Energy) test procedure.
Selection of boiler size should be based upon “Net I=B=R Rating being equal to or greater than the sq. ft. of
radiation already installed in the building. |
The Net 1=B=R Ratings shown are based o on an allowance of 1.333 in accordance with the factors shown on
the I=B=R Standard as published by The Hydronics Institute. |
These boilers may not be directly installed on a combustible floor. These boilers are low pressure sectional
cast iron boilers constructed and hydrostatically tested for a maximum working pressure of 15 psi in accor-
dance with A.S.M.E. (American Society of Mechanical Engineers) Section IV Standards for cast iron heating
boilers. They are capacity rated in accordance with the code of the I=B=R (Hydronics Institute).
IMPORTANT
This boiler is designed for use in closed heating systems requiring little or no make-up water. Excessive
feed water will damage boiler sections and void warranty.
Rules for Safe Installation and Operation
1. Read the Owners Manual for Safe Operation carefully. Failure to follow the rules for safe operation and
the instructions can cause a malfunction of the boiler and result in death, serious bodily injury, and/or
property damage.
2. Check your local codes and utility requirements before installation. The installation must be in accordance
with their directives, or follow NFPA 31 — Installation of Oil Burning Equipment, latest revision.
3. Before servicing, allow boiler to cool. Always shut off any electricity and oil to boiler when working on it.
This will prevent any electrical shocks or burns.
4. Inspect oil line and connections for leaks. |
5. Be certain oil burner nozzle is size required. Overfiring will result in early failure of the boiler sections. This
will cause dangerous operation. |
6. Never vent this boiler into an enclosed space. Always vent to the outside. Never vent to another room or
inside a building.
Be sure there is adequate air supply for complete combustion.
Follow a regular service and maintenance schedule for efficient and safe operation.
9. Keep boiler area clean and free of combustible material, gasoline and other flammable vapors and liquids.
ON
- WHEN SHIPMENT ARRIVES
Check shipment and report any shortage immediately. The following pieces should have been received:
ALL BOILERS
Block (3, 4, or 5 section)
Jacket (3, 4, or 5 section)
Flue Collector (3, 4, or 5 section)
KNOCK DOWN PACKAGE BARE
Accessory Carton Bare Accessory Carton
(with or less coil) (with or less coil)
Burner Box
WARNING
Bare Boilers are not provided with Low Water Cut-Offs
or Pressure Limit Controls. Both of these components
are important safety devices which must be provided
and instalied by the installer in accordance with this manual.
ASSEMBLING KNOCK DOWN BOILER
See Appendix A for instructions on the proper assembly of
this boiler. |
Before You Start
Check to be sure you have the right size boiler before starting the installation. See rating and capacity table
on preceding page. Check the rating plate on the boiler.
You must see that the boiler is supplied with the proper oil, fresh air for combustion, and a suitable electrical
supply. Also, the boiler must be connected to a suitable venting system and an adequate piping system.
Finally, a thermostat, properly located, is needed for control of the heating system. If you have any doubts as
to the various requirements, check with local authorities and obtain professional help where needed. THE
OPERATING INSTRUCTIONS and THE FINAL CHECKS AND ADJUSTMENTS are vital to the proper and
safe operation of the heating system. Take the time to be sure they are all done.
The following steps are all necessary for proper installation and safe operation of your boiler.
1. LOCATING THE BOILER 6. ELECTRICAL WIRING
2. OIL SUPPLY AND PIPING 7. THERMOSTAT LOCATION
3. FRESH AIR FOR COMBUSTION 8. CHECKING & ADJUSTING
4. PIPING CONNECTIONS 9. MAINTENANCE
5. CHIMNEY & VENT PIPE CONNECTIONS
Locating the Boiler
If your boiler is part of a planned heating system, locate it as nearly as possible where shown on your plan. if
boiler is to be part of an existing system, it is usually best to put it where the old one was. If you plan to
change location, you will need additional materials as well as an adequate base. The following rules apply:
The boiler must be level and located near piping.
Use a raised base if floor can become wet or damp.
The vent pipe connection should be as short as possible.
Maintain clearances for fire safety as well as servicing, See Figure 2 for minimum clearances. 18” clear-
ance must be maintained at a side where passage is required for access to another side for cleaning,
servicing, inspection, or replacement of any parts that normally may require such attention. Boilers must
be installed at least 6” from combustible material on all sides and above. Allow at least 24” front clearance
for servicing. Allow at least 20” left side clearance for servicing boilers equipped with a tankless coil.
5. FRESH AIR for combustion must be available at the front of the boiler. FRESH AIR for ventilation must be
available to the front AND rear of the boiler. Air passages must be free of obstructions at all times.
Ventilating and combustion air must enter boiler room without restrictions.
6. If the boiler is to be installed over a combustible floor, it must be supported on either a 2” Cladlite pad or
2” concrete blocks. This pad must cover the entire area under the boiler. In addition, the boiler and burner
must be installed over a pan which will catch oil from any oil leaks.
7. Be sure installation is in accordance with the requirements of the local authorities having jurisdiction.
Compliance with these regulations is required. In the absence of local codes follow NFPA 31 —
Installation of Oil Burning Equipment.
> © № >
FIGURE 2 - MINIMUM CLEARANCE DIMENSIONS
» © v9 9 ey . ‘a © у © 9.5 wo 9 o зе
м. | ! a"
9 * 6" MIN. 20" WITH COIL Ad
© t
9, y
O.
9, a
u” . BOILER <5" MIN. > с
=, qe 24" MIN, —} FRONT >
y > —— | »
‚” 6” MIN. v
- | v
Installation Requirements
FIGURE 3
eE
i { 1 jy
pr
u na
SERVICE LINE ELECTRIC un |
LINE pa
OVERCURRENT e
ENTRANCE PROTECTED -
SWITCH SAFETY =
FILL PIPE SWITCH DRAFT =
1-1/4" REGULATOR mn
{ VENT PIPE | =
| Nm VENT © с =
LINES TO OTHER PIPE ecuador ==
APPLIANCES MF
— м Г
TO RADIATION == vy =
ju res
je jue
TANK == Е
ré pren
SHUT OFF OIL BURNER 1 E
je
» bno —
FILTER ый
О =4
GENERAL PRINCIPAL REQUIREMENTS FOR A TYPICAL INSTALLATION
Fresh Air for Combustion
WARNING
Be sure to provide enough fresh air for combustion.
Enough air ensures proper combustion and assures that no
hazard will develop due to the lack of oxygen.
You must provide for enough fresh air to assure proper combustion. The fire in the boiler uses oxygen. It must
have a continuous supply. The air in a house contains only enough oxygen to suppy the burner for a short
time. Outside air must enter the house to replace that used by the burner. Study following examples 1 and 2
to determine your fresh air requirements.
CASE 1: Boiler Located in Unconfined Space
If your boiler is in an open area (unpartitioned basement) in a conventional house, the air that leaks through
the cracks around doors and windows will usually be adequate to provide air for combustion. The doors
should not fit tightly. Do not caulk the cracks around the windows.
An unconfined space is defined as a space whose volume is not less than 50 cubic feet per 1,000 Btu per
hour of the total input rating of all appliances installed in that space.
CASE 2: Boiler Located in Confined Space
A.
All Air from inside the Building: The confined space shall be provided with two permanent openings
communicating directly with an additional room(s) of sufficient volume so that the combined volume of all
spaces meets the criteria for an unconfined space. The total input of all combustion equipment installed in
the combined space shall be considered in making this determination. Each opening shall have a minimum
free area of one square inch per 1,000 Btu per hour of the total input rating of all combustion equipment in
the confined space, but not less than 100 square inches. One opening shall be within 12 inches of the top
and one within 12 inches of the bottom of the enclosure. See Figure 4.
Example: Your boiler is rated at 100,00 Btu per hour. The water heater is rated at 30,000 Btu per hour.
The total is 130,000 Btu per hour. You need two grilles, each with 130 square inches of FREE opening.
Metal grilles have about 60% FREE area. To find the louvered area needed, multiply the FREE area
required by 1.7 (130 x 1.7 = 221.0 sq. in. louvered area). In this example two grilles, each having an 8” x
30” (240 sq. in.) louvered area would be used. Fig. 4 shows the grille locations.
. All Air from Outdoors: The confined shall be provided with two permanent openings, one commenc
ing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure.
The openings shall communicate directly, or by ducts, with the outdoors or spaces (craw! or attic) that
freely communicate with the outdoors.
1. When directly communicating with the outdoors, each opening shall have a minimum free area of
one square inch per 4,000 Btu per hour of total input rating of all equipment in the enclosure.
2. When communicating with the outdoors through vertical ducts, each opening shall have a minimum
free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the
enclosure.
NOTE
If you use a fireplace or a kitchen or bathroom exhaust fan,
you should install an outside air intake. These devices will
rob the boiler and water heater of combustion air.
3. When communicating with the outdoors through horizontal ducts, each opening shall have a
minimum free area of one square inch per 2,000 Btu per hour of total input rating of all equipment
in the enclosure.
4. When ducts are used, they shall be of the same cross-sectional area as the free area of the
openings to which they connect. The minimum dimension of rectangular air ducts shall be not less
than three inches.
FIGURE 5 - FRESH AIR DUCT CAPACITIES
FIGURE 4 - AIR OPENINGS FOR CLOSET OR Fresh Air Duct Capacities for Ducts Supplying Fresh Air
UTILITY ROOM INSTALLATIONS to boiler in tightly constructed houses. British Thermal
Units per hour input (Btuh)*.
I | Fresh Ar 1/4” Mesh Wood Metal
| za Duct Screen Louvers Louvers
GRILLE TC 110 ` Size Btuh Btuh Btuh
| + !
| 31” х 12” 144,000 36,000 108,000
; I | 8" x8" 256,000 64,000 192,000
as Но 4 8” x 12” 384,000 96,000 288,000
- MB di 7 8”x 16” 512,000 128,000 384,000
L——7 SomBustION || | 7
AIR GRILLE Ll
*Based on opening covered by 1/4” mesh screen, wood louvers,
or metal louvers.
FIGURE 6 - FRESH AIR DUCT FOR TIGHTLY SEALED HOUSE
Qu
FRESH
AIR
DUCT
|- BOILER
Boilers may be factory supplied with a tankless
heater coil. The use of this coil eliminates the need
for a hot water storage tank. Instantaneous heating
of water in the coil will provide a flow of hot water for
domestic use.
IMPORTANT
Do not use a tankless coil if your water is
excessively hard with lime or other deposits
which will accumulate inside the coil.
TANKLESS COIL PIPING
Piping is shown in Figure 7B.
FIGURE 7B
Boilers With Tankless Heater Coil
FIGURE 7A
Recommended Tankless Coil Piping
Mixad
Hot Water
to Fixtures
8-12°
NS Boiler
with Coil
(Aquastat not shown)
Thermostatic Mixing
Valve
{Watts 70A or equivalent)
A thermostatic mixing valve does not eliminate
the risk of scalding.
* Set the L4006 as low as practical.
* Feel water before bathing or showering.
* if anti-scaid or anti-chill protection is required, use
Cold Water devices specifically designed for such service.
Install these devices in accordance with their
manufacturers instructions.
WARNING
Installation-System Piping
The near boiler piping, that is the piping around the boiler, must be considered as part of the boiler for proper
water level control, and to produce dry steam. Correct near boiler piping is crucial to the proper operation of
the boiler and the heating system. Follow these recommendations carefully.
1.
2.
Place boiler in the selected location, as near chimney as possible.
Install the pop safety valve, using the furnished 3/4” 90° ell, into the 3/4” pipe nipple on the back of the
‘boiler. Make a discharge pipe, using 3/4” pipe (not fumished) to carry the water or steam to a nearby drain.
Do not connect the discharge pipe directly to a drain but leave an air gap. No shutoff of any description
shall be placed between the pop safety valve and the boiler, or on discharge pipes between such safety
valves and the atmosphere. Installation of the pop safety valve shall conform to the requirements of the
ANSI/ASME Boiler and Pressure Vessel Code, Section IV. The manufacturer is not responsible for any
water damage.
. This boiler is equipped with two 2-1/2” supply connections on top and two 1-1/2" retum connections, one
each on front and back sides of the boiler. Unused connections must be plugged.
. Recommended near boiler piping for gravity return systems is shown in Figure 8. This configuration uses
one supply and one return tapping. This setup can be used on any size boiler in this series.
* RECOMMENDED BUT NOT REQUIRED WATER FEED WHEN NOT IN USE
FIGURE 8
<<
as
KING — ^® \ "т a
PIPE SAME SIZE AS VIVE ÓN 7 6" TL 10
BOILER TAPPING N
(2 1/2" MIN) y €
POP SAFETY VALVE SD ya ETURN
(PIPE DISCHARGE L 1/2 MIN.
TO SAFE LOCATION) OR © A pe size
KIM TAP > Ll 15" MIN
i
28"MIN. - DIM "А"
A y |
(BALL DR GATE / `
VALVE AV
6" BELOW NORMAL WATER LINE
BALL OR GATE VALVE »
WET RETURN
(IF USED)
DRAIN VALVE
FOR FLUSHING SYSTEM
> (BALL TR GATE VALVE RECOMMENDED)
2 CLOSE NIPPLE
NO WARNING:
CONNECTION FÜR PLUG BLOW DOWN & DRAIN VALVE
5. For installers choosing to use both supply tappings, Figure 8A shows the correct way to pipe this sys-
tem. Figure 8B shows the wrong way to pipe a header with two risers.
* Headers must be fitted with header offsets or swing joints, or be equipped with expansion joints, so that
thermal expansion and contraction of the header will not damage the boiler.
» System takeoffs from the header must be between the equalizer and the riser to the header nearest the
equalizer. System takeoffs must never be between two risers.
6. System takeoffs from the header must never be bullheaded. If the steam main goes in two directions,
there must be two takeoffs from the header, one for each main.
7. All boilers in gravity return systems must be equipped with a Hartford Loop as shown in Figures 8 and 8A.
8. When piping the vertical risers from the boiler to the header, the bottom of the header must be a mini-
mum of 24 inches above the water level line on the right side of the boiler.
9. Steam riser(s) and header shall be 2-1/2” pipe size.
10. Equalizer line shall be minimum 1-1/2" pipe size.
11. The boiler has a 1-1/2” tapping in rear section for skimming.
FIGURE 8A - RECOMMENDED NEAR BOILER PIPING USING TWO SUPPLY TAPPINGS
WARNING:
POP SAFETY VALVE &
OTHER SAFETY CONTROLS
NOT SHOWN. INSTALL IN
ACCORDANCE WITH FIG. 8.
Ва STEAM MAINS
PERL SIE ue >=
(2 1/2")
6° TU 10°
CONNECT RISER TD BOILER WITH
2 1/2" ELBOW AND NIPPLE
(NOT TT
REDUCING ELL POINTING
DOWN MAIN VENT
(RY MAIN
1172" MIN. RETURN
PIPE SIZE
15” MIN.
28° MIN. - DIM, À
he
—
Sen,
WET RETURN
e
ua GATE VALVE (NOT FURNISHED)
DRAIN VALVE FURNISHED)
| FOR FLUSHT™VG SYSTEM
1 1/2" FULL PORT BALL VALVE
FOR BOTTOM BLOW DOWN
AND DRAINING BOILER
& SYSTEM (NOT FURNISHED)
WATER FEED
FIGURE 8B - COMMON NEAR BOILER PIPING MISTAKES
THIS PIPING CONFIGURATION
IS INCORRECT TO SHOW
COMMON MISTAKES
Sp
WRONG - DO NOT BULLHEAD, WING - TAKE OFFS МАТ BETWEEN
USE TWO TAKE FAS RISER & HRUALIZER
VRONG - SWING JOINTS ARE MISSING
A
| de
; E — A _ +
— - — a - — "nn
que Fo
e De Tr ET |
e (+) | e y
WARNING:
POP SAFETY VALVE é OTHER
SAFETY CONTROLS NOT SHOWN.
INSTALL THESE ITEMS ON
ACCORDANCE WITH FIG. 8
12.
13.
14.
15.
The near boiler piping shall include a 1-1/2” ball or gate valve in the return piping as shown in Figure 8A
for bottom blowdown and draining. Plug this valve when it is not in use.
For gravity return systems, the bottom of the lowest steam carrying pipe, be it a dry return, or the end of
the steam main, must be at least 28” above the normal water level line on the right side of the boiler.
This is known as “Dimension A.”
For pumped return systems, follow the condensate pump or boiler feed pump manufacturer's instructions
for proper installation and hookup.
In connecting the cold water supply to the water inlet valve, make sure that a clean water supply is
available. When the water supply is from a well or pump, a sand strainer should be installed at the pump.
куни PE A
TS N sd nes ne
Chimney and Chimney Connection
CHECK YOUR CHIMNEY
Follow local codes. In the absence of local codes,
follow ANSI/NFPA 31 Installation of Oil Burning
Equipment, latest edition.
This is a very important part of your heating system.
No boiler, however efficient its design, can perform
satisfactorily if the chimney that serves it is inad-
equate. Check your chimney to make certain that it is
the right size, properly constructed and in sound
condition.
It is cheaper to rebuild a poor chimney than to pay
excessive fuel bills. If yours is an old masonry
chimney, a new steel liner or a new prefabricated
chimney may be the best solution.
The following chart shows recommended minimum
chimney sizes based on Table 3 and Figure 6 of the
I=B=R Testing and Rating Standard for Heating
Boilers, Sixth Edition, June 1989.
RECOMMENDED MINIMUM CHIMNEY SIZES
FRING | cHiMNEY | NOMINAL | ROUND SQUARE
RATE | HEIGHT | CHIMNEY | UNER- LINER-
(gph) (ft) AREA INSIDE INSIDE
9P DIAMETER | DIMENSIONS
60-1.301 15 8” x 8” 6” | 634X634"
1.31-1.80| 15 8" x 8” 7 | 634X634
1.81-200| 20 8" x 8” 8” | 634x634
For elevations above 2,000 ft. above sea level, add 3 feet to
chimney heights. (Refer to Figure 10.)
For additional chimney design and sizing information,
consult the ASHRAE 1992 HVAC Systems and
Applications Handbook, Chapter 31, Chimney, Gas
Vent and Fireplace Systems; or the National Stan-
dard for Chimneys, Fireplaces, Vents and Solid Fuel
Buming Appliances, ANSI/NFPA 211.
CHIMNEY CONNECTOR AND DRAFT REGULATOR
Your boiler requires 7” diameter chimney connector
pipe on 3 section, 8” diameter chimney connector pipe
on 4 section. You can also use the draft regulator
packed with boiler. Properly installed, the regulator will
control the draft automatically. It is better to install it in
a horizontal section of the pipe; but it may be in an
angled or vertical section. Just make certain that the
“top” is at top — and that the short pipe section which
holds the Vane is horizontal. Install it as close as
practical to the boiler.
10
FIGURE 10 - CHIMNEY REQUIREMENTS
MUST BE REQUIRED MINIMUM
HEIGHT. MUST BE AT LEAST
3 FT. HIGHER THAN HIGHEST
PART OF PASSAGE THROUGH
ROOF. MUST BE AT LEAST 2 FT.
HIGHER THAN ANY NEIGHBOR-
ING OBJECT. MUST HAVE AN
UNOBSTRUCTED TOP OPENING.
MUST BE AT LEAST
4 INCHES THICK - _ mX T
AND BE LINED.
ALTERNATE POSITIONS
MUST SLOPE UP
AT LEAST 1/4 INCH
PER FOOT OF
HORIZONTAL RUN
DRAWBAND
LAST PIECE
INSTALLED
|
x TIGHT, SMOOTH,
mm
—
nga”
Ц
(
TX
SEALED IN
THIMBLE
TIGHT
CLEAN-OUT
DOOR
DRAFT REGULATOR
VANE
FH MA
CRIMPED END
BALANCED WEIGHT
KA CORRECTLY SIZED.
To install the chimney connector, start at the boiler and preferably take off from the flue collector collar with an
elbow — then install the draft regulator next, making it horizontal. When the regulator is in place, start at the
chimney and work back to the regulator. Join the two sections with a Drawband. The horizontal pipe must slope
up toward the chimney at least 1/4 inch per foot. It must not leak and must be firmly supported. Join sections
with at least three sheet-metal screws. Support every second section with a stovepipe wire.
MINIMUM VENT PIPE CLEARANCE |
Wood and other combustible materials must not be closer than 18” from any surface of the vent pipe.
Equipment and Optional Accessories — What They Do
POP SAFETY VALVE
You must have a properly sized pop safety valve on your boiler. Steam expands as it is heated. If there is no
place for the steam to expand into, pressure will build up inside the boiler and system. Should this happen, the
pop safety valve will automatically open at a pre-determined pressure. This will relieve the strain on the boiler
and system. Run a pipe from the safety valve outlet (pipe must be same size as outlet and the open end must
not be threaded) to an open drain, or other suitable drainage point not subject to freezing. Failure to do so may
cause water damage or injury should the relief valve open. Do not cap off the drain line from this valve!
STEAM PRESSURE GAUGE
Every system should have a pressure gauge installed in the boiler. This gauge enables you to monitor the pressure in the
system. If the safety devices fail to shut off your boiler at the proper settings, notify your service technician immediately.
WATER LEVEL GAUGE
The water level in the boiler can be seen through the glass tube in the water level gauge at side of boiler. Correct water
level is stamped on front jacket panel. The water level should be checked regularly for the proper level.
STEAM PRESSURE CONTROL
The steam pressure limit control (pressuretrol) shuts off the burner if the steam pressure in the boiler reaches
the cut-off setpoint (i.e. the sum of the cut-in and the differential setpoints). Burner refires when the steam
pressure drops to the cut-in setpoint. System pressure requirements are based on the size and condition of the
pipes, and the load.
For good system operation, the cut-in setting of the pressuretrol should never be less than twice the system
pressure drop. In a typical single family residence with a clean one pipe heating system and cast iron radiation,
this means that the cut-in will usually be set at the minimum setting, i.e. 1/2 psi.
Steam radiation is usually sized based on square feet of equivalent direct radiation (EDR). This is based on a steam
pressure in the radiator of just less than 1 psi. Therefore, in our example system from above, we would set the differential
adjustment at 1 psi, i.e. the steam pressure required in the radiators. This will give us a cut-off setpoint of 1-1/2 psi.
The above is an example of a typical one pipe system. For larger systems or other types of systems such as
two pipe systems, or systems with convectors or fan coil units, the pressuretrol settings will need to be deter-
mined on a system-by-system basis.
The cut-in setpoint is determined by the system pressure drop to the furthest radiator or terminal unit. Double
the system pressure drop as a safety factor, resulting in the rule that the cut-in setting should never be less than
twice the system pressure drop. |
The differential setpoint is the steam pressure required at the terminal heating units.
Now your boiler will operate in the correct pressure range. It will maintain enough steam pressure to send the
steam out to the furthest radiator, and not go over the optimum steam pressure that is required at the radiators.
LOW WATER CUT-OFF
The low water cut-off shuts off the burner when the water level is below a safe point. The burner will start when
the water is refilled to a safe level.
DRAIN VALVE
This manual valve provides a means of draining all water from the boiler and system. it should be installed in the 3/4” tee
where the water supply line enters the boiler (Fig. 8) You can also use this valve to lower the water level if it is too high.
11
STEAM VENTS
Before a steam system will operate properly, suitable steam vents must be installed in each radiator as weli as
the retum main. Some systems require steam traps in the return line at the radiation unit.
The “Hartford loop” is a piping arrangement which must be included (Fig. 8) for proper operation of the steam system.
Starting Your Boiler
HOW A STEAM SYSTEM OPERATES
The water in the boiler is heated until it reaches the boiling point. As the water boils it turns into steam. The
steam rises from the top of the water through the supply main to the radiation units. As it passes through the
radiators it releases its heat and condenses into water. The water returns to the boiler through the return main.
FILLING SYSTEM WITH WATER
On steam heating systems the boiler is partially filled with water. It is very important to the proper operation of
the entire system that your boiler be filled to the proper level. The correct water level on cold start condition is
about halfway up the glass water level gauge as marked on the boiler jacket. To fill:
1. Close the boiler drain valve.
2. Open the valves at the top and bottom of the glass water level gauge. Also open the drain valve at the
bottom of the gauge.
3. Open the fill valve and allow water to run into the boiler.
| WARNING — Never run water into a hot empty boiler. |
4. Allow boiler to fill until water runs out the gauge drain valve. Then close the gauge drain valve.
5. Continue to fill boiler until water reaches the indicated water line. This is about halfway up the glass tube.
Always keep the water at this level when system is off.
| IMPORTANT
Skimming a new steam boiler on an existing system may need to be done
several times to remove all oil, grease and sediment.
The Float Low Water Cut-Off should be blown down after skimming. Following blowdown, allow the boiler to
cool and then add fresh water slowly.
The float chamber of the low water cut-off must be flushed clean and maintained clear of sediment to allow free
movement of the float. This must be done frequently during initial operation of the boiler and at least once per
week thereafter. Follow instructions on tag attached to control.
Never throttle a steam radiator valve on a one-pipe system. it must be fully open or fully closed. Otherwise water
is held in the radiator units. This will cause knocking sounds.
Skimming may be required again after a few days operation.
Checking and Adjusting
WARNING
The burner and control system of this boiler must be checked by a professional
heating contractor prior to placing the boiler in service. This includes making
sure that all safety devices work as they are supposed to. It also includes
adjusting the burner using combustion test instruments.
12
aj”
CROWN NASSAU
BECKETT BURNER APPLICATION SHEET
NS-118 NS-145 NS-156 NS-177 NS-204 NS-215
BURNER MODEL AFG AFG AFG AFG AFG AFG
AIR TUBE COMBINATION MB MD MD MD MD MD
BURNER HEAD SETTING 0 1 1 3 3
NOZZLE wonach | DEAN | DEAN | pes | oe | oe
PUMP PRESSURE (PSI) 140 140 140 140 140 140
STARTING BAND SETTING 1 2 2 10 4 5
STARTING SHUTTER SETTING 10 10 10 10 10 10
DRAFT OVER FIRE (IN W.C.) 0.02 -0.02 -0.02 -0.02 -0.02 -0.02
SMOKE (BACHARACH SCALE) 0-TRACE 0-TRACE 0-TRACE 0-TRACE 0-TRACE O-TRACE
MAXIMUM CO, 13.0 13.0 13.0 13.0 13.0 13.0
REFRACTORY BLANKET NO NO NO 17-012 17-012 17-012
Note: Best final CO, is dependent upon such field conditions as oil, chemistry, ambient temperatures and available draft. If
any of these conditions are unstable, the CO, level should be reduced below 13.0% so as to reduce the likelyhood of the
smoke level exceeding #1. Under no circumstances should the CO, level be left above 13.0% or under 11.0%.
13
14
CHECKING CONTROLS Co o
To check the Low Water Cut-Off, tum off power to the boiler or tum the thermostat down to the lowest setting.
Drain water to below the visible bottom of the water gauge glass. Turn power on and turn the thermostat to call
for heat. The oil burner should not run on a call for heat when the water is low.
To check the pressure limit, run the boiler until the pressure reaches system demand. Then tum the pressure
screw and drop the pressure setting until the boiler shuts down. This will show that the pressure limit is operat-
ing properly.
OIL BURNER ADJUSTMENT
Refer to the NS burner application sheet and oil burner manual provided with this manual for burner set-up
information.
ADJUST OPERATING CONTROLS
Instructions for each control and bummer are included.
Set thermostat heat anticipator at .20. Instructions for the final adjustment of the thermostat are packaged with
the thermostat.
CHECK THERMOSTAT OPERATION
When set above temperature indicated on the thermometer, boiler burner should start. Make certain the thermo-
stat turns off the boiler when room temperature reaches the selected setting and starts the boiler operating
when room temperature falls a few degrees.
Finally, set the thermostat for the desired temperature. Special conditions in your home and the location of the
thermostat will govern this setting.
Maintaining Your Boiler
Check the water level every day or two. Verify the water line shown by operating the drain valve on the gauge. Be sure
top and bottom valves on gauge are always open so that actual water level will be shown at all times.
POP SAFETY VALVE
This valve should open automatically when the steam pressure exceeds the safe limit (per instructions pack-
aged with valve). Should it ever fail to open under these conditions, shut down your system. Have the valve
replaced immediately.
LOW WATER CUT-OFF |
The Low Water Cut-Off will interrupt the electrical current to the bumer when the water line in the boiler drops to
a low level. It is very important to keep the float chamber free from sediment, a condition essential to depend-
ability. To keep any accumulation from interfering with float action is to ‘BLOW DOWN" or flush out the control
regularly. This must be done two-three times the first week after installation and once a week thereafter during
the heating season. Do it while the boiler is in operation. First note water level in gauge glass. Open blow-off
valve at bottom of control; water will pour out, flushing away sediment. Drain until water is clear, about a pail,
then close valve. If water level in gauge glass has dropped, add water to boiler to restore level. Consult low
water cut-off manufacturer's instructions included with boiler.
NOTE: Opening blow-off valve checks cut-off operation too. As float drops with falling water level, burner will
shut off. After valve is closed and normal operating conditions are restored, bumers will resume firing.
Boilers should not be drained between heating seasons. Only when the water in the system becomes dirty
should the boiler be drained, flushed or boiled out, and refilled. Steam boilers may be entirely filled with water
during the summer months to exclude air.
CLEANING YOUR BOILER
Under normal operating conditions, with the burner properly adjusted, we recommend that you have the flue
passages, burner adjustment, and operation of the controls checked once each yearby a Service Technician.
Before the start of each season (or whenever system has been shut down for some time) recheck the whole
system for leaks . . . and recheck the boiler and vent pipe for leaks. Replace or patch any boiler seals that are faulty.
BOILER FLUE PASSAGES
Flue Passages between sections should be examined yearly and cleaned. See instructions on page 15.
FOAMING, PRIMING OR SURGING
These terms are used to describe a fluctuating water line — when water leaves the boiler.
It is caused by any combination of the following:
1. Threading oil and organic matter in the boiler water. (Mineral oil, or core sand does not cause surging.)
2. Faulty quick vents that do not release air until a sizeable pressure is built up — replace. If dirty, clean so
that you can easily blow through valve.
3. Improper header design — when steam flows in opposite direction of equalizer line on “Hartford loop.”
Generally a 15” horizontal run between riser and main takeoff will allow entrained water to fall out of the
steam vapor so it can return to boiler. (See page 7, Fig. 8)
4. Adjustment of steam limit control to a wide differential increases difficulty if quick vents are old style, slow-
releasing type or dirty. Always set steam limit control differential as low as possible.
5. Soap and detergents cause extreme surging — clean thoroughly by skimming the boiler.
CAUTION
Never refill a hot boiler with cold water — thermal shock may crack a section.
CAUTION
Never allow electrician or oil burner mechanics to try out their work by turning on oil
burner for even one second unless boiler is filled to the proper operating level.
SYSTEM CHECKS AFTER FIRST STARTING — STEAM SYSTEMS
Read the instructions packaged with your controls and make checks and adjustments accordingly. Start the
burner and set the Thermostat for the desired room temperature. When adjusting the Steam Pressure control,
watch the steam Pressure Gauge and use its pressure reading — as it will be more accurate than the control.
BOILER WATER TREATMENT
In steam systems where the system is tight, free from leaks, and all the steam is returned to the boiler as
condensate, the amount of make up water is small. Water treatment is not required.
BETWEEN HEATING SEASONS
Boilers should not be drained between heating seasons. Boilers in closed hot water heating systems may be
left as is. Steam boilers should be entirely filled with water during the summer months to exclude air.
15
16
A) —+
ON SQ
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Oil Boiler/Burner Cleaning Instructions
Shut off all electrical power to the boiler/burner and shut off fuel supply.
Remove the sheet metal smoke pipe from the top of the boiler, inspect pipe and
chimney for signs of corrosion and deterioration. Clean base of chimney.
Remove top jacket panel.
Remove the two brass wing nuts holding the flue collector top.
Check the gasket on the underside of the flue collector and replace as necessary.
Remove the oil bumer
- ОВ -
Remove the oil burner/fire door assembly (four hex nuts). This is the recommended method, as it allows
full access to the combustion chamber and less potential damage to the target wall during the cleaning
process.
Remove the burner drawer assembly. Clean any soot accumulations.
Replace the burner nozzle with one of the exact size, type, and manufacture recommended.
Note: Using a nozzle, other than is recommended, may change the performance of this boiler and/or
cause a hazardous condition.
Clean electrode assembly and set electrodes as per burner manufacturer's recommendations.
Reinstall drawer assembly and check for proper head location as per the manufacturer's recommendations.
Inspect the target wall and fire door insulation for cracking and deterioration. If there is any signs of crack-
ing or deterioration, replace before reassembling the boiler.
Remove soot from fireside surfaces by brushing diagonally through the flue passages (see drawing). Care
should be taken not to damage the target wall with the flue brush.
Carefully vacuum soot accumulations from the combustion chamber area, being particularly careful not to
damage the target wall with the vacuum.
Reinstall the burner/fire door assembly.
Reinstall the flue collector top and secure with the two brass wing nuts.
Reinstall the top jacket panel. Reconnect the flue pipe.
Inspect and clean the oil burner blower wheel.
Oil the bumer motor (DO NOT OVER OIL).
Remove the oil pump cover and clean/replace the pump screen. Carefully reassemble.
Replace the fuel filter (if applicable).
Reconnect the electrical and fuel supplies.
Fire the bumer, checking for proper combustion using combustion test instruments making adjustments as
necessary.
Insure that all safety controls and operating controls are functioning proppery.
IMPORTANT OPERATING AND MAINTENANCE REQUIREMENTS
® KEEP YOUR BOILER AND THE AREA AROUND IT CLEAN
® NEVER BURN REFUSE OR ANY MATERIAL OTHER THAN
THE SPECIFIED FUEL IN YOUR BOILER
® HAVE YOUR BOILER CHECKED EACH YEAR BY A QUALIFIED TECHNICIAN
You may avoid inconvenience and service calls by checking these points before you
call for service.
IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT...
Possible Cause What to do
Thermostat is not set correctly Reset thermostat above room temperature
Oil Tank is empty Fill oil tank
No power to boiler Check overcurrent protection. Check to be sure power
supply circuit is “ON.”
Water Level is too low Add water until water line reaches level indicated on jacket
IF RADIATORS GET HOT WHEN THERMOSTAT IS NOT CALLING FOR HEAT
(BOILERS WITH TANKLESS COILS ONLY)
Possibe Cause What To Do
Water level is too low Add water until water line reaches level indicated
on jacket.
HAVE A QUALIFIED BOILER SERVICE TECHNICIAN CHECK
ANY PROBLEM YOU ARE UNABLE TO CORRECT.
18
Steam Wiring Diagram With Tankless Heater Coil
247 THERMOSTAT LEADS
— PB DT EN QO) -
Ie /
7
-
|
i
|
|
|
|
|
i
|
(
115 VC VIRDG
——— РПОЙ. VIRING
~ = ~~ 24 К М
24VAC VIRING NOT
PROVIDED
— E a A. a
— er ae Eee sa
DIL BURNER
PRIMARY [INTRIL
A ry Er Te ABS = Si WY ERE e De Mis y A e
#67 L.¥.C.0.
— HOT CALACK)
! FROM 120/80
PINER SUPPLY
n
o NEUTRAL. CANTE)
>— HITE (NEUTRAL) VIRE TD
ARNER PRINIRY CONTROL
!
Steam Wiring Diagram Less Tankless Heater Coil
24V THERMISTAT LEADS
(THERMOSTAT NOT PRIVIOED)
PMOL
PRESSURE- TROL
OPTIONAL AO Tn
120 VAC FEEDER
.
|
|
|
i :
|
| :
: |
!
! |
|
: |
| '
: ]
1 :
в |
f ;
L U
#67 L.W.C.O,
115 UC VIRDE
————— OPTION. VIRING
-——— 24 VAC VIRING
2AVAC WIRING HOT
PROVIDES
MILTE (NEUTRAL > VIRE TO
BLRNER PRIMARY CONTROL
' Steam Block Assembly
FLUE COLLECTOR
3 Sec. 796-0000)
4 Sec. 738-00-3004
COVER PLATE A)
(17-003)
TANKLESS HEATERCOIL —
(21-003)
ъ — мм GRASS WING NUTS
<< > { 13704007 )
А” 1/4 NUT (2)
6° NIPPLE
( 40100004 }
Sv FRONT COVER GASKET
= ( 1469306} )
FRONT COVER PLATE
( 14627001 )
COIL GASKET
(17-001)
©
EB
=
{ 14614016 )
FIRE DOOR INSULATION
ya { 14614015 )
| O OBSERVATION DOOR
Sa ( 40300005 )
BLOCK
7 NIPPLE
( 43300976 ) TARGET WALL FIRE DOOR
ME RODS (2) INSULATION ( 40300004 )
Steam Jacket Assembly
4
>С
/
ОЕ
27 IT Key MODEL NUMBERS
> DESCRIPTION
NO. | ¿SECTION | 4SECTION
1 738-00-1030 | 738-00-1030 | FRONT PANEL
> 2 638-00-1220 | 638-00-1220 | TIE BAR
> ° 3 738-00-1020 | 738-00-1020 | REAR PANEL
4 738-00-1053 | 738-00-1054 | R.S. PANEL
5 738-00-1043 | 738-00-1044 | L.S. PANEL
6 738-00-1013 | 738-00-1014 | TOP PANEL
19
20
Appendix A: Knock-down Assembly Instructions
Note: Bare boilers must be assembled as shown in the following instructions with the installer providing a
burner, controls, and most of the fittings called for below.
1)
2)
4)
5)
6)
WARNING
Bare Boilers are not provided with Low
Water Cut-Offs or Pressure Limit Controls.
Both of these components are important
safety devices which must be provided and
installed by the installer in accordance with
this manual. a
Do not attempt to use a probe type low water
cut-off on this boiler.
The burner used on a bare boiler must be
exactly as specified in the enclosed NS
burner application sheet.
Locate the block in the spot where the boiler is to be installed.
Set the flue collector on top of the block. Secure with the two #14 x 3/4” sheet metal screws provided.
Using the tube of silicone provided, carefully seal the flue collector to the block.
Install the two 1-1/2” plugs in the tappings in the back of the boiler. If only one of the 2-1/2" taps is to be
used, plug the unused tap with the plug provided.
Install the jacket:
Note: Jacket installation hardware is in a bag in the jacket carton.
a) Mount the two 5/16 x 2-1/2 studs in the lower two tappings in the back of the block. Screw the short
thread end of these studs into the block.
b) Mount the four 5/16 x 1-3/8 hex studs in the upper two tappings in the back of the block and the two
tappings in the front of the block.
c) Slip the tie bar (key #2 on page 18) over the studs installed in Step (a). This bar should extend past
the right side of the block as viewed from the front of the boiler.
d) Slip the front and rear panels over the studs installed in Steps (a) and (b). Use the two 5/16 hex nuts to
hold the back panel onto the lower studs. Use 5/16 acorn nuts on the remaining four studs.
e) Mount the side panels. These panels have lips which fit into slots in the edges of the front and back
panels. | |
f) Mount the top panel. Secure it to the front and back panels with the sheet metal screws provided.
Install either the tankless coil or coil cover plate. Use the gasket, 3/8 x 3/4 cap screws, and 3/8 washers.
Tighten these bolts in a “cross pattern” so that the gasket is uniformly compressed.
7) If the boiler is with coil, install the control well and L4006 control in the 3/4 tapping in the coil. Make sure
the control bulb is bottomed out in the well.
8) Screw the 3/4 x 3" nipple provided into the 3/4 tapping on the back of the boiler. Mount the 3/4 elbow onto
this nipple and tighten so that it is directed up. Install the pop-safety valve in this elbow.
9) Install the low water cut-off and glass gauge set in the two 1/2” tappings in the front of the boiler (Fig. A1).
10) Mount a 1/2 x 1/4 bushing, 1/4 x 3" nipple, and 1/4 tee in the remaining open tapping on the front of the
boiler. Install the pressure gauge in the run of the 1/4 tee. Install the straight pig tail and pressure limit
control on the bull of this tee.
11) Mount the three 5/16 x 1-5/8 studs in the tappings near the burner opening. Mount the burner and secure
with the 5/16 nuts and washers provided.
12) Wire the boiler in accordance with the appropriate drawing on page 17 using the wiring hamesses provided.
13) Boiler assembly is now complete. Follow the instructions starting on page 4 to complete the installation.
FIG. A1: NASSAU TRIM LOCATION
2 1/2 PUB
(SE IF ONLY DE
SUPPLY TAPPING /— 15 PSI POP SAFETY VALVE
IS USED [
L40064 CONTROL — y
(ITH (OIL GUILERS DA.Y) Q
VAR ya a
YX AX — ON ©
AO VASHER (10 REID.) See J | „®’
PRESSURE LIMIT CONTROL Pe | P= V4 X 3 NIPPLE
1/4* X 1/2" BUSHING ` < 9
1/4" SIRAIGNT PIG-TAJL OQ
14" X 3* NIPPLE o „SI | 172 PLUS
1/4" TEE
} >
PRESSURE GUAGE Pal T
„$ ` ’
PF Le
NN. №7 e 40 | 1/2 CLOSE NIPALE
LOY VATER CUT-0FF QL AD COLPLING
> с (NOT INCLUDED - SEE NITE)
VARNING! р
DO NIT ATTENPT TO _ -
TO LISE A PROBE TYPE | „”
UN VATER OT IN | 7
THIS BOILER
us Hr — MN -—
| A 9/16 X 1 5/8 STD (3 READ. )
5/16 NUT AND WASHER (3 RED.)
NOTE: …
1-1/2" NIPPLE AND COUPLING
MAKE PLACING A BUCKET UNDER
SKIM PLUG EASTER
21
dll CROWN BOILER CO.
3633 1 STREET, PHILADELPHIA, PA 19134
(215) 535-8900 * FAX (215) 535-9736 * www.crownboiler.com