Crown Boiler BERMUDA BSI069 User manual

Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
BSI Series
Gas-Fired Natural Draft Steam Boilers
INSTALLATION INSTRUCTIONS
These instructions must be afxed on or adjacent to the boiler
WARNING: Improper instal-
lation, adjustment, alteration,
service or maintenance can
cause property damage, injury,
or loss of life. For assistance or
additional information, consult a
qualied installer, service agency
or the gas supplier. Read these
instructions carefully before
installing.
Models:
• BSI069
• BSI103
• BSI138
• BSI172
• BSI207
• BSI241
• BSI276
• BSI311
• BSI346
• BSI380
DESIGNED TO LEAD

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FOLLOW ALL INSTRUCTIONS and warnings
printed in this manual and posted on the boiler.
INSPECT THE BOILER ANNUALLY. To keep your
boiler safe and efficient, have a service technician
follow the Service checklist near the end of this
manual.
IF YOU ARE NOT QUALIFIED to install or service
boilers, do not install or service this one.
THE BOILER MAY LEAK WATER at the end of
its useful life. Be sure to protect walls, carpets,
and valuables from water that could leak from the
boiler.
PROTECT YOUR HOME IN FREEZING
WEATHER. A power outage, safety lockout, or
component failure will prevent your boiler from
lighting. In winter, your pipes may freeze and
cause extensive property damage. Do not leave
the heating system unattended during cold weather
unless alarms or other safeguards are in place to
prevent such damage
DO NOT BLOCK AIR FLOW into or around the
boiler. Insufficient air may cause the boiler to
produce carbon monoxide or start a fire.
KEEP FLAMMABLE LIQUIDS AWAY from the
boiler, including paint, solvents, and gasoline.
The boiler may ignite the vapors from the liquids
causing explosion or fire.
KEEP CHILDREN AND PETS away from hot
surfaces of the boiler, boiler piping, and vent pipe.
CARBON MONOXIDE (CO) is an odorless, deadly
gas that may be introduced into your home by
any malfunctioning fuel-burning product or vent
system failure. Consider installing CO alarms near
bedrooms in all levels of the building to warn you
and your family of potential CO exposure.
READ THIS ENTIRE MANUAL before attempting
installation, start-up, or service. Improper
installation, adjustment, alteration, service, or
maintenance may cause serious property damage,
personal injury, or death.
DO NOT DISCONNECT PIPE FITTINGS on the
boiler or in the heating system without first verifying
that the system is cool and free of pressure and
that your clothing will protect you from a release
of hot water or steam. Do not rely solely on the
boiler’s temperature and pressure gage when
making this judgment.
USE PROPER PERSONAL PROTECTION
EQUIPMENT when servicing or working near the
boiler. Materials of construction, flue products, and
fuel contain alumina, silica, heavy metals, carbon
monoxide, nitrogen oxides, and/or other toxic or
harmful substances that can are hazardous to
health and life and that are known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
INSTALL ALL GUARDS, cover plates, and
enclosures before operating the boiler.
SIZE THE BOILER PROPERLY relative to the
design heat load or, if using domestic hot water
priority, the peak hot water load, whichever
is larger. A grossly oversized boiler will cycle
excessively and this will lead to premature failure
of the boiler and its components. Our warranty
does not apply to damage from excessive cycling.
ADHERE TO ALL LOCAL CODE
REQUIREMENTS. Contact your local code
inspector prior to installation. In the absence of
a local code, adhere to the National Fuel Gas
Code ANSI Z223.1/NFPA 54 or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.
ALL WIRING must comply with the National
ElectrIcal Code ANSI/NFPA 70 (in the USA) or the
Canadian Electrical Code CSA C22.1 (in Canada)
and any local regulations.
WARNINGS FOR THE HOMEOWNER
WARNINGS FOR THE INSTALLER

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Table of Contents
I. Product Description.................................................... 2
II. Specications ............................................................. 3
III. BeforeInstalling......................................................... 4
IV. LocatingtheBoiler..................................................... 4
V. AirforCombustion&Ventilation.............................. 5
VI. Venting ....................................................................... 9
VII.GasPiping ................................................................ 12
VIII.SystemPiping..........................................................13
IX.IndirectWaterHeaterPiping...................................16
X.Wiring ...................................................................... 17
XI.Start-Up&Checkout............................................... 23
XII.Service&Maintenance........................................... 29
XIII.Troubleshooting ...................................................... 33
XIV.Parts........................................................................ 40
AppendixA:KnockdownBoilerAssembly......................46
I Product Description
 TheBSIseriesboilersarelowpressurecastirongasredsteamboilersdesignedforuseinclosedsteamheatingsystems.
TheseboilersareCategoryIdraftdiverter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uegasesmustbe
availableintheboilerroom.Theseboilersarenotdesignedforuseinprocessorother“open”steamsystems

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TABLE 1: BSI SPECIFICATIONS
II Specications
INPUT
(MBH) (MBH) (Sq. ft) (MBH) "A" "B" "C" "D" (Gal)
BSI069 3 69 57 179 43 81.9 12 3/4 28 40 7/16 4 5.1
BSI103 4 103 85 267 64 82.0 16 28 40 7/16 5 6.5
BSI138 5 138 113 354 85 82.0 19 1/4 28 40 7/16 6 7.9
BSI172 6 172 142 446 107 82.1 22 1/2 28 40 7/16 6 9.3
BSI207 7 207 171 533 128 82.1 25 3/4 30 40 7/16 7 10.7
BSI241 8 241 199 621 149 82.2 29 30 40 7/16 7 12.1
BSI276 9 276 227 708 170 82.2 32 1/4 30 40 7/16 8 13.5
BSI311 10 310 240 750 180 77.5* 35 1/2 30 45 7/16 8 14.9
BSI346 11 345 267 833 200 77.5* 38 3/4 30 45 7/16 9 16.3
BSI380 12 379 294 921 221 77.5* 42 30 45 7/16 9 17.7
* Thermal efficiency
** Volume to normal water line
BASIC
BOILER
MODEL
NUMBER
OF
SECTIONS
DIMENSIONS (in.)
WATER
VOL. **
*** BSI346 - BSI380 Not for use with LP gas.
AHRI Net Ratings are based on a piping and pick-up allowance of 1.333.
NATURAL OR LP GAS***
HEATING
CAPACITY
AHRI NET RATING,
STEAM AFUE %
FIGURE1:BSIBOILERS-GENERALCONFIGURATION

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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
National Fuel Gas Code,ANSIZ223.1-latestedition.
• Whererequiredbytheauthorityhavingjurisdiction,thisinstallationmustconformtotheStandard for Controls and
Safety Devices for Automatically Fired Boilers(ANSI/ASMECSD-1)-latestedition.
2) Makesurethataproperlysizedchimneyisavailablewhichisingoodcondition.Consulttheauthorityhaving
jurisdiction,PartVIofthismanual,andtheNational Fuel Gas Codeforadditionalinformationonventingrequirements.
3) Makesurethattheboileriscorrectlysized.UseanindustryacceptedsizingmethodsuchastheI=B=R Installation
Guide for Residential Hydronic Heating Systems (Pub. #200) and I=B=R Heat Loss Calculation Guide(Pub.#H21or#H22)
publishedbytheHydronicsInstituteinBerkeleyHeightsNJ.
4) Makesurethattheboilerreceivedisconguredforthecorrectgas(naturalorLP).TheBSI311,BSI346andBSI380may
onlybeusedwithnaturalgas.
5) Boilersinstalledataltitudesabove2000ft.requiredifferentburnersandmainburneroricethanthoseatsealevel.Make
surethattheboilerisconguredforuseatthecorrectaltitude.
6) Ifthisboilerwasreceivedasaknockdownboiler,followtheinstructionsinAppendixAtoassembletheboiler.
IV Locating the Boiler
1) Clearances:
• Observetheminimumclearancesshownbelow.Theseclearancesapplytoallcombustibleconstruction,aswellas
noncombustiblewalls,ceilingsanddoors.AlsoseeFigure2.
Front–18”  
RightSide–18” 
LeftSide–6” 
Rear–6”  
Top–17”
• A24”serviceclearancefromthejacketisrecommendedontheleft,right,andfrontoftheboiler.Theseclearances
maybereducedtothoseshowninFigure2,howeverservicingtheboilerwillbecomeincreasinglydifcultasthese
serviceclearancesarereduced.
• Iftherightside24”serviceclearanceisreduced,adequateclearancemustbemaintainedtoeasilyreadandaccess
thecontrols.Alternatively,accessmaybeprovidedusingadoor
2) Thisboilermaybeinstalleddirectlyoveranon-carpetedcombustibleoor.
3) Theboilermustbeinstalledonahardlevelsurface.
Warning
This Product Must be Installed By A Licensed Plumber Or Gas Fitter
when Installed Within The Commonwealth Of Massachusetts

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4) Donotinstallthisboilerinalocationwheregasolineorotherammablevaporsorliquidswillbestoredorused.Donot
installthisboilerinanareawherelargeamountsofairbornedustwillbepresent,suchasaworkshop.
5) Theboilershouldbelocatedasclosetothechimneyaspossible.
6) Donotinstallthisboilerdirectlyonasurfacethatmaygetwet.Raisetheboileronapad.
V Air for Combustion and Ventilation
Sufcientfreshairmustbesuppliedforcombustion,ventilationanduegasdilution.Provisionsforcombustion,ventilation
anduegasdilutionairforgasutilizationequipmentventedbynaturaldraftmustbemadeinaccordancewithlocalbuilding
codesor,inabsenceofsuchcodes,inaccordancewithsections5.3.3and5.3.4(“AirforCombustionandVentilation”)ofthe
National Fuel Gas Code,NFPA54/ANSIZ223.1.
Toensureanadequatesupplyofcombustion,ventilationanduegasdilutionairsupply,startbydeterminingwhether
theboileristobeinstalledinabuildingofunusuallytightconstruction.Agooddenitionofabuildingofunusuallytight
constructionisonewhichhasallofthefollowingfeatures:
• Wallsandceilingsexposedtooutsideatmospherehaveacontinuouswatervaporretarderwitharatingof1permor
lesswithopeningsgasketedandsealed
• Weatherstrippinghasbeenaddedonopenablewindowsanddoors
• Caulkingandsealantsareappliedtoareassuchasjointsaroundwindowanddoorframes,betweensoleplatesand
oors,betweenwall-ceilingjoints,betweenwallpanels,atpenetrationsforplumbing,electrical,andgaslines,and
atotheropenings.
FIGURE2:BSIBOILERS-CLEARANCESTOALL
TYPESOFCOMBUSTIBLECONSTRUCTIONAND
NONCOMBUSTIBLECEILINGS,WALLS,AND
DOORS.

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For Buildings of Other than Unusually Tight Construction
1) Determinewhethertheboileristobeinstalledinaconnedspace-AconnedspaceisdenedbytheNational Fuel
Gas Codeashavingavolumelessthan50cubicfeetper1000BTU/hrinputofallappliancesinstalledinthatspace.To
determinewhethertheboilerroomisaconnedspace:
a. TotaltheinputofallappliancesintheboilerroominthousandsofBTU/hr.Roundtheresulttothenexthighest1000
BTU/hr.
b. Findthevolumeoftheroomincubicfeet.Thevolumeoftheroomincubicfeetis:
 Length(ft)xwidth(ft)xceilingheight(ft)
 Incalculatingthevolumeoftheboilerroom,considerthevolumeofadjoiningspacesonlyifnodoorsareinstalled
betweenthem.Ifdoorsareinstalledbetweentheboilerroomandanadjoiningspace,donotconsiderthevolumeofthe
adjoiningspace,evenifthedoorisnormallyleftopen.
c. DividethevolumeoftheboilerroombytheinputinthousandsofBTU/hr.Iftheresultislessthan50,theboilerroomis
aconnedspace.
Example:
 ABSI172ENandawaterheateraretobeinstalledinaroommeasuring6ft-3inx7ftwithan8ftceiling.Thewater
heaterhasaninputof30000BTU/hr:
 TotalinputinthousandsofBTU/hr=(172000BTU/hr+30000BTU/hr)/1000=202
 Volumeofroom=6.25ftx7ftx8ft=350ft3
 350/202=1.73.Since1.73islessthan50,theboilerroomisaconnedspace.
2) UnconnedSpace-Naturalinltrationintotheboilerroomwillnormallyprovideadequateairforcombustionand
ventilationwithoutadditionallouversoropeningsintoboilerroom.
3) ConnedSpace-Providetwoopeningsintotheboilerroom,oneneartheoorandoneneartheceiling.Thetopedgeof
theupperopeningmustbewithin12”oftheceilingandthebottomedgeoftheloweropeningmustbewithin12”ofthe
oor(Figure3).
• Eachopeningmusthaveafreeareaof1squareinchper1000BTU/hrinputofallgasburningappliancesintheboiler
room.Theminimumopeningdimensionis3inches.Minimumopeningfreeareais100squareinchesperopening.
• Ifthetotalvolumeofboththeboilerroomandtheroomtowhichtheopeningsconnectislessthan50cubicfeetper
1000BTU/hroftotalapplianceinput,installapairofidenticalopeningsintoathirdroom.Connectadditionalrooms
withopeningsuntilthetotalvolumeofallroomsisatleast50cubicfeetper1000BTU/hrofinput.
• The“freearea”ofanopeningtakesintoaccounttheblockingeffectofmesh,grills,andlouvers.Wherescreensare
used,theymustbenonerthan¼”(4x4)mesh.
• Ifprovidingopeningsintoadjacentroomsisundesirable,combustionandventilationaircanbebroughtintotheboiler
roomfromoutdoors.Seetheinstructionsunder“ForBuildingsofUnusuallyTightConstruction”.
For Buildings of Unusually Tight Construction
1) Openingsmustbeinstalledbetweentheboilerroomandtheoutdoorsoraventilatedspace,suchasanatticorcrawl
space,whichcommunicatesdirectlywiththeoutdoors.
2) Twoopeningsarerequired.Thetopedgeoftheupperopeningmustbewithin12inchesoftheceiling.Thebottomedge
oftheloweropeningmustbewithin12inchesoftheoor.
3) Sizeopeningsandductsasfollows:
• Verticalductsoropeningsdirectlyoutdoors(Figure4,Figure5,andFigure6)-Eachopeningmusthaveafreecross
sectionalareaof1squareinchper4000BTU/hrofthetotalinputofallgas-redappliancesintheboilerroombutnot
lessthan100squareinches.Minimumopeningsizeis3inches.
• Openingstooutdoorsviahorizontalducts(Figure7)-Eachopeningmusthaveafreecrosssectionalareaof1square
inchper2000BTU/hrofthetotalinputofallgasredappliancesintheboilerroombutnotlessthan100squareinches.
Minimumopeningsizeis3inches.
• The“freearea”ofanopeningtakesintoaccounttheblockingeffectofmesh,grills,andlouvers.Wherescreensare
used,theymustbenonerthan¼”(4x4)mesh.

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7
FIGURE4:ALLAIRFROMOUTDOORS,   
VENTILATEDCRAWLSPACEANDATTIC
FIGURE5:ALLAIRFROMOUTDOORS, 
VIA VENTILATED ATTIC
FIGURE3:BOILERINSTALLEDINCONFINEDSPACE,
ALLAIRFROMINSIDE

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FIGURE6:ALLAIRFROMOUTDOORS,USING
 OPENINGSINTOBOILERROOM
FIGURE7:ALLAIRFROMOUTDOORS,USING   
HORIZONTALDUCTSINTOBOILERROOM

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VI Venting
Ventinstallationmustbeinaccordancewithlocalbuildingcodes,orthelocalauthorityhavingjurisdiction,ortheNational
Fuel Gas Code,NFPA54/ANSIZ223.1.
AtypicalventinstallationisillustratedbyFigure8.Thecomponentsofventinstallationaretheventdamper(ifused),vent
connectorandchimney.
1) AcceptableChimneys-ThefollowingchimneysmaybeusedtoventBSIseriesboilers:
• ListedTypeBorLgasvent-Installinaccordancewiththemanufacturer’sinstructions,thetermsofitslisting,and
applicablecodes.
• MasonryChimney-ThemasonrychimneymustbeconstructedinaccordancewiththeStandard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliances(NFPA211)andlinedwithaclaylinerorotherlistedlining
system.DonotventaBSIseriesboilerintoanunlinedchimney.
2) AcceptableVentConnectors-Thefollowingmaybeusedforventconnectors:
• ListedtypeBorLGasVent
• SingleWallGalvanizedPipe-Use0.018”(26gaugeorheavier).Thesizeandlocationofthechimneymaynot
permittheuseofasinglewallconnectorinsomecases.SeetheNational Fuel Gas Code.Donotusesinglewall
pipeforventconnectorsinattics.
• OtherVentConnectorsPermittedbytheNational Fuel Gas Code.
3) ChimneyandVentConnectorSizing-SizethechimneyandventconnectorinaccordancewiththeNational Fuel Gas
Code.
4) ExteriorChimneys-Anexteriorchimneyhasoneormoresidesexposedtotheoutdoorsbelowtheroofline.Thereare
twoconditionsunderwhichanexteriorchimneymaybeused:
• In some very restrictivecases,BSIseriesboilersmaybeventedintoanexteriorceramiclinedmasonrychimney.See
theNational Fuel Gas Codeforinformationonwhenexteriorchimneysmaybeused.
• AnexteriormasonrychimneymaybeusedifitislinedwithBventoralistedchimneyliningsystem.
5) Thisboilermaybeventedusingalistedpowerventer.Thepowerventermustbesizedandinstalledinaccordancewith
thepowerventermanufacturer’sinstructions,thetermsofthepowerventerlisting,andapplicablecodes.Theboilermustbe
electricallyinterlockedwiththepowerventertopreventboileroperationifthepowerventerfailstooperate.Beforedeciding
touseapowerventer,makecertainthattheuegasexitingthepowerventerwillnotdamageadjacentconstructionorother
structures.Alsomakecertainthatthepowerventerterminalwillnotbesubjectedtowindswhichcouldeffectpowerventer
operation.
6) Donotconnecttheventofthisapplianceintoanyportionofamechanicalventsystemoperatingunderpositivepressure.
7) Donotconnecttheboilerintoachimneyueservinganopenreplaceorothersolidfuelappliance.
8) Priortoboilerinstallation,inspectchimneyforobstructionsorotherdefectsandcorrectasrequired.Cleanchimneyas
necessary.
9) Ventpipeshouldslopeupwardfromdraftdiverternotlessthanoneinchinfourfeet.Noportionofventpipeshouldrun
downwardorhavesags.Ventpipemustbesecurelysupported.
10) Theverticalsectionofventpipecomingofftheboilershouldbeastallaspossible,whilestillmaintainingtheproper
clearancefromthehorizontalventconnectortocombustiblesandtheproperpitchcalledforin(9)above.
11) Ventpipeshouldbeinstalledabovethebottomofthechimneytopreventblockage.
12) Ventpipemustbeinsertedushwithinsidefaceofthechimneylinerandthespacebetweenventpipeandchimney
sealedtight.
13) Donotinstalltheventdamperinanyportionoftheventsystemwhichisusedbyappliancesotherthantheboilerbeing
installed.

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14) VentdamperinstallationismandatoryonallsizesfromtheBSI069toBSI276.TheBSI311throughBSI380maybe
orderedwithorwithoutventdamper.Ifsupplied,installventdamper(seeFigure9)asfollows:
a) Openventdampercartonandremoveinstallationinstructions.Readtheinstructionsthoroughlybeforeproceeding.
Verifythatventdamperissamesizeasdraftdiverteroutlet.SeeFigure1.Unpackventdampercarefully.Do not
force closed damper blade. Forcingventdamperclosedmayresultindamagedgeartrainandvoidwarranty.
b) Ventdamperisfactoryshippedhavingapproximately¾”diameterholeintheventdamperblade,whichmust
be left openforboilersequippedwithstandingpilot,andshouldbepluggedonboilerswithanintermittentpilot
system,usingtheplugsuppliedwiththedamper.
Mounttheventdamperontheuecollarwithoutmodicationtoeitherandsecurewithsheetmetalscrews.Make
surescrewsdonotinterferewithdamperbladeoperation.Ventdamperbladepositionindicatormustbevisibleto
users.
c) Thedamperwireharnessisshippedwiredintotheboilerjunctionbox.Plugthelooseendofthisharnessintothe
damperandsecuretheexibleconduittothedamperusingaconnectornutprovided.
d) Installventconnectorpipeandventttingsfromventdamperoutlettochimneyorgasvent.Securewithsheetmetal
screwsandsupportasrequired.
Removing an Existing Boiler from a Common Chimney
Insomecases,whenanexistingboilerisremovedfromacommonchimney,thecommonventingsystemmaybetoolarge
fortheremainingappliances.Atthetimeofremovalofanexistingboilerthefollowingstepsshallbefollowedwitheach
applianceremainingconnectedtothecommonventingsystemplacedinoperation,whiletheotherappliancesremaining
connectedtothecommonventingsystemarenotinoperation.
a) Sealanyunusedopeninginthecommonventingsystem.
b) Visuallyinspecttheventingsystemforpropersizeandhorizontalpitchanddeterminethereisnoblockageor
restriction,leakage,corrosionandotherdeciencieswhichcouldcauseanunsafecondition.
c) Insofaraspractical,closeallbuildingdoorsandwindowsandalldoorsbetweenthespaceinwhichalltheappliances
remainingconnectedtothecommonventingsystemarelocatedandotherspacesofthebuilding.Turnonclothes
dryersandanyappliancenotconnectedtothecommonventingsystem.Turnonanyexhaustfans,suchasrange
hoodsandbathroomexhausts,sotheywilloperateatmaximumspeed.Donotoperateasummerexhaustfan.Close
replacedampers.
d) Placeinoperationtheappliancebeinginspected.Followthelightinginstructions.Adjustthermostatsotheappliance
willoperatecontinuously.
e) Testforspillageatthedrafthoodreliefopeningafterve(5)minutesofmainburneroperation.Usetheameofa
matchorcandle,orsmokefromacigarette,cigar,orpipe.
f) Afterithasbeendeterminedthateachapplianceremainingconnectedtothecommonventingsystemproperlyvents
whentestedasoutlinedabove,returndoors,windows,exhaustfans,replacedampersandanyothergas-burning
appliancestotheirpreviousconditionofuse.
g) Anyimproperoperationofthecommonventingsystemshouldbecorrectedsotheinstallationconformswiththe
NationalFuelGasCode,ANSIZ223.1.Whenresizinganyportionofthecommonventingsystem,thecommon
ventingsystemshouldberesizedtoapproachtheminimumsizeasdeterminedusingtheappropriatetablesinthe
NationalFuelGasCode,ANSIZ223.1.

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FIGURE8:BSIBOILERTYPICALVENTSYSTEM   
INSTALLATION AND COMPONENTS
FIGURE9:VENTDAMPERINSTALLATIONDETAILS
RIGHT SIDE VIEW

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FIGURE10:GASCONNECTIONTOBOILER
*StateofMassachusettsRequiresManual
Shut-offValvetobe“T”HandleType
VII Gas Piping
 Gaspipingtotheboilermustbesizedtodeliveradequategasfortheboilertoreatthenameplateinputataline
pressurebetweentheminimumandmaximumvaluesshownontheratingplate.Formoreinformationongaslinesizing,
consulttheutilityorChapter2oftheNational Fuel Gas Code.
Figure10showstypicalgaspipingconnectiontotheBSIboiler.Asedimenttrapmustbeinstalledupstreamofallgas
controls.Installamanualshut-offvalveoutsidethejacketandgroundjointunionasshown.
Theboileranditsgasconnectionmustbeleaktestedbeforeplacingtheboilerinoperation.Whendoingthis,theboilerand
itsindividualshut-offmustbedisconnectedfromtherestofthesystemduringanypressuretestingofthatsystematpressures
inexcessof1/2psi.Whenpressuretestingthegassystematpressuresof1/2psiorless,isolatetheboilerfromthegassupply
systembyclosingitsindividualmanualshut-offvalve.
*

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CAUTION
• INSTALLBOILERSOTHATTHEGASIGNITIONSYSTEMCOMPONENTSAREPROTECTED
 FROMWATER(DRIPPING,SPRAYING,RAIN,ETC.)DURINGAPPLIANCEOPERATIONANDSERVICE
 (CIRCULATORREPLACEMENT,ETC.).
• OPERATIONOFTHISBOILERINASYSTEMHAVINGSIGNIFICANTAMOUNTSOFDISSOLVED
 OXYGENCANCAUSESEVEREHEATEXCHANGERCORROSIONDAMAGE.
VIII System Piping
General Piping Notes
Figure11showsrecommendednearboilerpipingformostcommontypesofgravityreturnsteamsystems.Additional
informationonsteamsystemdesignmaybefoundinInstallation Guide for Residential Hydronic Heating Systems (Pub.
#200)publishedbytheHydronicsInstituteinBerkeleyHeightsNJ.
Oneoftheprimarypurposesofthisnearboilerpipingistoseparatetinywaterdropletsfromthesteamexitingtheboiler
sothat“dry”steamissenttothesystem.Ifthenearboilerpipingisnotcorrect,wetsteamwillenterthesystemandthe
followingproblemsmayoccur:
• Shortcyclingonlowwater
• BoilerorsystemFlooding
• Hammering
• Failuretoheatoneormoreradiators
AvoidthethreecommonpipingmistakesshowninFigure12.Thisapplieseveniftheexistingboilerhasoneofthepiping
mistakesshowninFigure12andappearstobeworking.Iftwoormoresteammainsmustbeconnectedtotheboiler,connect
aseparatetake-offforeachmainintotheheaderbetweentheriser(s)andequalizer.Alsonotethefollowingpoints:
1)Asizereductionmustbemadetoconnecttheheadertotheequalizer.Thisreductionmustbemadeintheequalizerline.
Donotmakethissizereductioninthehorizontalheader.
2)Onepipesteamsystemsrequireairventsoneachradiator,aswellasattheendofeachmain.Forthesystemtowork
properly,theseventsmustbeproperlyinstalled,sized,andbeingoodcondition.Inspectandreplaceanydefectivevents.If
therearenoventsattheendsofthemains,installthem.
3)DonotattempttomanifoldmultipleBSIswithgravityreturns.
4)Forinstallationswithcondensateorboilerfeedpumps,followthepumpmanufacturer’spipinginstructions.Suchsystems
generallydonotrequireHartfordloops.
5)Donotuseacheckvalveinplaceof,orinadditionto,aHartfordlooponagravityreturnsystem.
6)Pipethellconnectionfromacleansourceofcoldwater.Whenthewatersupplyisfromawell,makesurethatastrainer
isinstalledinthewellsystem.
7)PipingwithaChiller-Iftheboilerisusedinconjunctionwithachiller,pipetheboilerinparallelwithchiller.Use
isolationvalvestopreventchilledwaterfromenteringtheboiler.

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14
Piping Installation
1)Removepartsbagfromboilercrate.
2)Installsafetyvalve(spindlemustbeinverticalposition)intotappingonboilerleftside(seeFigure1)usingthe3/4”NPT
nipplesandelbowsupplied.
3)Pipethedischargeofthesafetyreliefvalvetoalocationwherewaterorsteamwillnotcreateahazardorcauseproperty
damageifthevalveopens.Theendofthedischargepipemustterminateinanunthreadedpipe.Ifthesafetyvalvedischarge
isnotpipedtoadrainitmustterminateatleast6inchesabovetheoor.Theterminationofthesafetyvalvedischargepiping
mustbeinanareawhereitisnotlikelytobecomepluggedbydebrisorsubjectedtofreezing.
4)Installdrainvalveintotappingonboilerleftsideusingthe2x3/4bushingprovided(seeFigure1).
5)Connectsystemsupplyandreturntoboiler.SeeFigure11.TheBSI069-BSI172requireonlyonesupplyriser.Twosupply
risersarerequiredontheBSI207andlargersizes.
6)PipingwithaChiller-Iftheboilerisusedinconjunctionwithachiller,pipetheboilerinparallelwithchiller.Use
isolationvalvestopreventchilledwaterfromenteringtheboiler.
DANGER
• PIPESAFETYVALVEDISCHARGETOASAFELOCATION.
• DONOTINSTALLAVALVEINTHESAFETYVALVEDISCHARGELINE.
• DONOTMOVESAFETYVALVEFROMFACTORYLOCATION.
• DONOTPLUGSAFETYVALVEDISCHARGE.
• DONOTINSTALLASAFETYVALVEWITHASETTINGGREATERTHAN15PSI.

15
15
FIGURE12:COMMONNEAR-BOILERPIPINGMISTAKES
FIGURE11:STEAMBOILERPIPINGFORGRAVITYRETURN
"A" "B" "C" "D"
BSI069 * 2 1 1/2 1 1/4
BSI103 * 2 1 1/2 1 1/4
BSI138 * 2 1 1/2 1 1/4
BSI172 * 2 1 1/2 1 1/4
BSI207 2 3 1 1/2 1 1/4
BSI241 2 3 2 1 1/2
BSI276 2 3 2 1 1/2
BSI311 2 3 2 1 1/2
BSI346 2 3 2 1 1/2
BSI380 2 3 2 1 1/2
MINIMUM PIPE DIA. (IN NPT)BOILER
MODEL
* SECOND 2" SUPPLY RISER OPTIONAL
BOILER
FRONT

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16
IX Indirect Water Heater Piping
AllBSIseriesboilersareequippedwithtappingstopermittheconnectionofaCrownMega-Stor,orotherindirectwater
heater.Inthistypeofsystem,hotboilerwaterisdrawnfrombelowthewaterlineandpassedthroughtheheatexchangerin
theindirectwaterheater.Thissectiondescribesboiler-sidepipingonly.Refertotheindirectwaterheaterinstructionmanual
fordomesticwaterpiping.Thecomponentsinthissystemandtheirfunctionsareasfollows:
1) Circulator-MountthecirculatorasshowninFigure13.Thecirculatorshouldbelocatedaslowandasclosetotheboiler
aspractical.Donotinstallvalves,orotherdeviceshavingasignicantpressuredrop,betweentheboilerandthecirculator
inlet.Allpipingbetweentheboilerandthecirculatorinletshouldbe1”,regardlessofthesizeofthepipingrequiredinthe
restofthesystem.SeeFigure15inPartXforwiringinformation.
2) “Y”Strainer-Installa“Y”strainertopreventsedimentfromaccumulatinginsidetheindirectwaterheater.
3) CheckValve-Preventsgravitycirculationthroughtheindirectwaterheaterwhentheboilerisrespondingtoacallfor
heat.
4) BoilerLimitControl-UseaSPSTbreak-on-risetemperaturelimitcontrolsuchastheHoneywellL4006A.Donotset
thelimitabove180Fasdoingsomaycausetheboilertosteamwhenthereisnocallforheat.SeeFigure15forwiring
information.
5) ValvesandUnions-Installshut-offvalves,drainvalves,andunionsinlocationsthatwillfacilitatemaintenanceofthe
system.Donotinstallanyvalvesbetweentheboilerandcirculatorinlet.
IMPORTANT
•Someindirectwaterheatersmaynotbesuitableforusewithasteamboiler.Consultthewaterheater 
manufacturer’sguidelinesbeforeinstallingitinthistypeofsystem.
• Boilerwatertemperaturesandowratesinthistypeofsystemmaybeconsiderablylowerthanthoseuponwhichthe
waterheatermanufacturer’sratingsarebased.Thismayresultinsubstantiallylongerwaterheaterrecoverytimes.
FIGURE13:INDIRECTWATERHEATERBOILER-SIDEPIPING

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17
X Wiring
1) 120VoltWiring-Theboilershouldbeprovidedwithitsown15Abranchcircuitwithfuseddisconnect.All120voltcon-
nectionsaremadeinsidethejunctionboxontheleftsideoftheboiler.Removethetransformertogainaccesstothisbox
(alsoseeFigures16through17):
• Hot(“black”)-Wirenuttoblacktransformerlead
• Neutral(“white”)-Wirenuttowhitetransformerlead
• Ground(“green”orbare)-Groundscrewinsidejunctionbox.
2) ThermostatWiring-Followthermostatmanufacturerinstructions.Toinsureproperthermostatoperation,avoidinstalla-
tioninareasofpooraircirculation,hotspots(nearanyheatsourceorindirectsunlight),coldspots(outsidewalls,walls
adjacenttounheatedareas,locationssubjecttodrafts).ProvideClassIIcircuitbetweenthermostatandboiler.Connect
thermostatwireleadstothebluetransformerleadandbrownrelayleadinsidethejunctionbox.Settheheatanticipator
to 0.2A.
Feeder Wiring for Boilers Equipped with Hydrolevel CG400A Low Water Cut-offs
1)UsingHydrolevelVXT-24TWO-WIREfeeder-Donotalterfactoryboilerwiring.ConnectVXT-24toCG400Aasfol-
lows:
• ConnecttheBLACKleadonthefeedertoterminalAontheLWCO
• ConnecttheWHITEleadonthefeedertoterminal2ontheLWCO
2)UsingHydrolevelVXT-24THREE-WIREfeeder-Donotalterfactoryboilerwiring.ConnectVXT-24toCG400Aas
follows:
• ConnecttheBLACKleadonthefeedertoterminal1ontheLWCO
• ConnecttheWHITEleadonthefeedertoterminal2ontheLWCO
• ConnecttheREDleadonthefeedertoterminalAontheLWCO
3)UsingMcDonnell&MillerWF2-U-24feeder-Donotalterfactoryboilerwiring.ConnectWF2-U-24toCG400Aasfol-
lows:
• ConnectterminalW onthefeedertoterminalA ontheLWCO
• ConnectterminalNonthefeedertoterminal2ontheLWCO
• ConnectterminalHonthefeedertoterminal1 ontheLWCO
CAUTION
DonotattempttoconnectaMcDonnell&Millermodel#101Afeeder,orotherfeederwithoutadelay,toaBSIboiler
equippedwithaHydrolevelCG400lowwatercutoff.Doingsocoulddestroytheboilertransformerand/oroodthesys-
tem.
WARNING
Allwiringandgroundingmustbedoneinaccordancewiththeauthorityhavingjurisdictionor,intheabsenceofsuch
requirements,withtheNationalElectricalCode(ANSI/NFPA70)

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Feeder Wiring for Boilers Equipped with McDonnell & Miller #67 Low Water Cut-offs
Figures14aand14bshowfeederwiringforMcDonnell&Miller#101A,McDonnell&MillerWF2-U-24andHydrolevel
VXT-24feedersonboilersequippedwith#67lowwatercutoffs.Thefollowingpointsapplytoallfeederwiringto#67low
watercut-offs:
• Useaseparatetransformertopowerthefeeder.Donotusethetransformerontheboiler.
• Itisnotnecessarytotouchanyofthe24voltfactoryboilerwiringwhenconnectingafeedertoa#67equipped
boiler.
• Do NOTinstallajumperbetweenterminals2and3onthe#67lowwatercutoff.
Indirect Water Heater Wiring
Figure15showseldwiringforanindirectwaterheater.AHoneywellR845AorequivalentDPSTrelayandtransformer
isrequired.ThehighlimitdescribedinPartIXmustalsobesuppliedbytheinstaller.Acallforheatfromtheindirectwater
heaterthermostatwillenergizetherelaymakingbothsetsofcontacts.Onesetofthesecontactsthenenergizesthecirculator.
Theothersetofcontactswillmakethe“T”and“T”contactsontheburnerprimarycontrol,ringtheburner.Iftheboiler
watertemperatureexceedsthehighlimitsettingof180F,thehighlimitwillopenthe“T”-“T”circuitandtheburnerwill
shutdown.
Ifthereisacallforspaceheat,theheatingthermostatwillmakethe“T”-”T”circuitandtheboilerwillrewithoutregard
tothestatusoftheindirectwaterheater.Thelowwatercut-offandpressurelimitcontrolwillinterrupt120voltpowertothe
burnerintheeventofalowwaterorexcessivepressurecondition.
FIGURE14a:WIRINGMCDONNELL&MILLER101AORTWO-WIRE H Y D R O L E V E L  V X T- 2 4  F E E D E R 
 TOBOILEREQUIPPEDWITH#67L.W.C.O.
CAUTION
DO NOT INSTALL
JUMPERBETWEEN2&3
ON #67 L.W.C.O.