For assistance or additional information, consult a qualified installer, service agency or the gas supplier. Read these instructions carefully before installing. Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 Tel: (215) 535-8900 • Fax: (215) 535-9736 • 2 Table of Contents I. Product Description . . . . . . . . . . . . . . . . . . . 1 II. Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2 III. Before Installing . . . . . . . . . . . . . . . . . . . . . . 3 IV. Locating the Boiler . . . . . . . . . . . . . . . . . . . . 3 V. Knockdown Boiler Assembly Instructions 6 A. PriorToAssembly . . . . . . . . . . . . . . . 6 B. Boiler Assembly, Installation & Leak Testing . . . . . . . . . . . . . . . . . . 6 C. Jacket Assembly . . . . . . . . . . . . . . . . . 8 D. Ignition Control & Gas Valve Installation Standard Control System . . . . . . . 9 CSD-1 Control System . . . . . . . . . 9 E. Control & Trim Installation . . . . . . . 12 VI. Air for Combustion & Ventilation . . . . . . . . 13 VII. Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 VIII. System Piping . . . . . . . . . . . . . . . . . . . . . . . .21 A. Heating System Piping . . . . . . . . . . . 21 B. Piping for Special Situations . . . . . . 22 IX. Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 25 X. Control System Wiring . . . . . . . . . . . . . . . . 26 A. Standard . . . . . . . . . . . . . . . . . . . . . . 27 B. CSD-1 . . . . . . . . . . . . . . . . . . . . . . . . 27 XI. Start-Up & Checkout . . . . . . . . . . . . . . . . . .31 XII. Service & Maintenance . . . . . . . . . . . . . . . . 35 XIII. Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 I Product Description The Series 16 boiler is a cast iron hot water boiler designed for use in closed forced circulation hot water heating systems found in large homes, multifamily dwellings, small businesses, office complexes and other commercial heating applications. These boilers are Category I draft hood equipped appliances, which must be vented by natural draft using a lined masonry or listed metal chimney system. An adequate supply of air for combustion, ventilation and dilution of flue gases must be available in the boiler room. This boiler is intended for use with natural gas or LP / Propane gas. 1 42 II Specifications III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the latest edition of the National Fuel Gas Code, ANSI Z223.13. • Where required by the authority having jurisdiction, this installation must conform to the latest edition of the Standard for Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1). 2) Make sure that a properly sized chimney is available and is in good condition. Consult the authority having jurisdiction, Part VII of this manual and the National Fuel Gas Code for additional information on venting requirements. Series 16 boilers are equipped with an external draft hood which must be installed without alteration. Make sure adequate head room exists to install Series 16 boiler models with the unaltered draft hood while maintaining proper clearances from the vent connector to combustible materials. 3) Make sure that the boiler is correctly sized by utilizing an industry accepted sizing method. 4) Make sure that the boiler to be installed is configured for the correct gas (natural or LP). 5) Boilers installed at altitudes above 2000 ft. require different main burner orifice than those at sea level. Make sure that the boiler is configured for use at the correct altitude. 6) Follow the instructions in Section V to assemble the boiler. WARNING This Product Must Be Installed By A Licensed Plumber Or Gas Fitter When Installed Within The Commonwealth Of Massachusetts. IV Locating the Boiler 1) Do not install this boiler directly on a combustible floor. This boiler may be installed over a non-carpeted combustible floor by using the following special bases available from Crown. Boiler Model Combustible Flooring Base # 16-325 500506 16-390 500507 16-455 500508 16-520 500509 16-585 500510 2) Series 16 clearance and other boiler room space requirements depend upon the size of the boiler: Models 16-325, 16-390 – These sizes are approved for alcove installation. Install with the minimum clearances shown in Table 2. The clearances shown in Table 2 apply to all combustible construction as well as non-combustible walls, floors, ceilings and doors (also see Figure 2). Models 16-455, 16-520, 16-585 – These sizes must be installed in a boiler room that is “large in comparison to the boiler”. Such a room is defined as having a volume at least 16 times that of th...