Crown Boiler Phantom X series User manual
WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information,
Series
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
9700609
2
IMPORTANT INFORMATION - READ CAREFULLY
NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the
installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction
shall be consulted before installations are made.
All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to
important information concerning product life.
The City of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved the Phantom Series boiler. See the Massachusetts Board of
Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval
Code or ask your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.
DANGER
WARNING
DANGER
3
Special Installation Requirements for Massachusetts
A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or
in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the
1. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of
NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the sidewall horizontally
vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance
with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code.
2. In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm
and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the
comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event
that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment,
the installer shall have a period of thirty (30) days to comply with this requirement; provided, however, that during
said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed in compliance
with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. In the event that the
sidewall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the carbon monoxide detector
detector with an alarm and shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the
Massachusetts State Building Code.
of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT
DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for installation of
carbon monoxide detectors and alarms as required above.
B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA
54 as adopted by the Board; and
2. Product Approved sidewall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for residential purposes.
C. When the manufacturer of Product Approved sidewall horizontally vented gas equipment provides a venting system design
or venting system components with the equipment, the instructions for installation of the equipment and the venting system
shall include:
1. A complete parts list for the venting system design or venting system; and
2. Detailed instructions for the installation of the venting system design or the venting system components.
D. When the manufacturer of a Product Approved sidewall horizontally vented gas fueled equipment does not provide the parts
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
E. A copy of all installation instructions for all Product Approved sidewall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or
equipment at the completion of the installation.
4
TABLE OF CONTENTS
I. 5
II. Unpacking Boiler........................................................................................ 8
III. Pre-Installation and Boiler Mounting ........................................................ 9
IV. Venting...................................................................................................... 14
A. General Guidelines............................................................................... 14
B. CPVC/PVC Venting.............................................................................. 19
C. Polypropylene Venting......................................................................... 25
D. Stainless Steel Venting........................................................................ 28
31
F. Multiple Boiler Installation Venting....................................................... 32
V. Condensate Disposal................................................................................. 34
VI. Water Piping and Trim............................................................................... 36
VII. Gas Piping ............................................................................................... 46
VIII. Electrical ................................................................................................... 50
IX. System Start-up ....................................................................................... 62
X. Operation...................................................................................................... 70
A. Overview............................................................................................... 70
B. Supply Water Temperature Regulation................................................ 71
C. Boiler Protection Features.................................................................... 72
D. Multiple Boiler Control Sequencer........................................................ 73
E. Boiler Sequence of Operation.............................................................. 74
1. Normal Operation........................................................................... 74
75
F. Viewing Boiler Status............................................................................ 76
1. Status Screens.............................................................................. 76
2. Detail Screens............................................................................... 77
3. Multiple Boiler Sequencer Screens................................................ 78
79
1. Entering Adjust Mode.................................................................... 79
2. Adjusting Parameters..................................................................... 79
XI. Service and Maintenance ........................................................................ 90
XII. 96
XIII. Repair Parts ............................................................................................. 100
5
designed
for use in forced hot water space heating systems requiring
supply water temperatures of 190°F or less. These boilers
have special coil type stainless steel heat exchangers,
constructed, tested and stamped per Section IV ‘Rules
for Construction of Heating Boilers’ of ASME Boiler and
Pressure Vessel Code, which provide a maximum heat
corrosion. These boilers are not designed for use in gravity
hot water space heating systems or systems containing
water heating, direct domestic hot water heating, etc.).
1/2” 3/4”
1” 1-1/4”
1” 1-1/4”
Condensate Drain J * * Factory Provided Socket End Compression Pipe Joining Clamp
Boiler Two-Pipe CPVC/PVC Vent Connector
0-10000* 0-10000*
0-4500* 0-4500*
Fuel
190
160
30
1.7
21.8
206
*
6
'F' GAS VALVE INLET
34" FPT RELIEF/DRAIN
TAPPING
'H' SUPPLY TAPPING
'G' RETURN TAPPING
'J' CONDENSATE
TRAP DRAIN
LOW VOLTAGE
KNOCKOUTS
(24 VOLTS)
LINE VOLTAGE
KNOCKOUTS
(115 VOLTS)
3X4 PVC/CPVC
VENT ADAPTER
7
8
Output
Net AHRI Ratings Water 1
AFUE
Min.
PHNTM210 42 210 194 169 95.0
PHNTM285 57 285 262 228 95.0
1
A. to approximate installed position.
B. all crate fasteners.
C. outside container.
D. from cardboard positioning sleeve on
shipping skid.
WARNING
E. to its permanent location.
9
WARNING
WARNING
A. Installation must conform to the requirements
of the authority having jurisdiction in or, in the absence
of such requirements, to the National Fuel Gas Code,
ANSI Z223.1/NFPA 54, and/or Natural Gas and
Propane Installation Code, CAN/CSA B149.1.
Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD1.
on
carpeting.
between boiler jacket and
ordinance. Refer to Figure 2 for minimum listed
clearances from combustible material. Recommended
service clearance is 24 in. (610 mm) from left side,
front, top and rear of the boiler. Recommended front
clearance may be reduced to the combustible material
clearance providing:
1. Access to boiler front is provided through a door
or removable front access panel.
located underneath the heat exchanger.
located at
boiler rear.
from water (dripping, spraying, rain, etc.) during
boiler operation and service (circulator replacement,
condensate trap, control replacement, etc.).
in
accordance with applicable provisions of local building
codes, or: USA - National Fuel Gas Code, ANSI
Z223.1/NFPA 54, Air for Combustion and Ventilation;
Canada - Natural Gas and Propane Installation Code,
CAN/CSA-B149.1, Venting Systems and Air Supply for
Appliances.
WARNING
F. The boiler should be located so as to minimize
the length of the vent system. The combustion air
piping must terminate where outdoor air is available for
combustion and away from areas that may contaminate
combustion air. In particular, avoid areas near chemical
paint removers, cleaning solvents and detergents.
dry wall dust etc.
10
G. General
1. Phantom boilers are intended for
installations
a suitable drain pan to prevent any leaks or relief
valve discharge to cause property damage.
2. Phantom boilers are not intended to support
external piping and venting. All external piping and
venting must be supported independently of the
boiler.
to
prevent condensate from backing up inside the
boiler.
4. Boiler Floor Standing Installation:
a. For basement installation provide a solid base
Floor must be able to support weight of boiler,
water and all additional system components.
b. Boiler must be level to prevent condensate from
backing up inside the boiler.
c. Provide adequate space for condensate piping or
a condensate pump if required.
Boiler Clearances to Combustible (and Non-
Combustible) Material:
All models are listed for closet installation with the
following minimum clearances – Top = 1 in. (25 mm),
Front = 1 in. (25 mm), Left Side = 10 in. (250 mm),
Right Side = 2 in. (50 mm), Rear = *6 in. (150 mm)
* Note:
When boiler is vented vertically, the minimum
clearance from the rear of the jacket is increased to
18 in. (460 mm) with a short radius 90° elbow in
order to provide adequate space at boiler rear for
installation of vent and air intake piping and service
access.
Boiler Service Clearances – Applicable to all Boiler
Models:
Top = 24 in. (610 mm), Front = 24 in. (610 mm), Left
Side = 24 in. (610 mm), Right Side = 24 in. (610 mm),
Rear = 24 in. (610 mm)
The above clearances are recommended for service
access but may be reduced to the Combustible Material
Clearances provided:
a. The boiler front is accessible through a door.
b. Access is provided to the condensate trap located
on the left side of boiler.
c. Access is provided to thermal link located at the
boiler rear (PHNTM285 only).
11
Factory Standard
Air Intake
* CPVC/PVC
Vertical or
Horizontal
Unenclosed
at all Sides
or
Pipe Rigid Polypropylene
Polypropylene Liner for
or
Two-Pipe Stainless Steel Vent and Galvanized Steel
Stainless Steel
or
12
heating and/or domestic hot water heating loads,
where employing two (2) Phantom boilers will offer
space savings and boiler redundancy, the Phantom
boilers may be installed stacked one on the top of
the other. Refer to Table 3 “Phantom Boiler Model
Stacking Combinations” for details.
PHNTM210 PHNTM210
PHNTM285 PHNTM285
use the steps
below:
II “Unpacking Boiler” and III “Pre-Installation
& Boiler Mounting” of the manual for details.
bottom boiler.
b. Each Phantom boiler is factory packaged with
two (2) Stacking Boiler Attachment Brackets
(P/N 101679-01) and the bracket mounting
hardware [six (6) self-drilling hex washer head
plated #8 x ½” long screws]. Locate and remove
the brackets and the hardware. The Stacking
Boiler Attachments Bracket has three 7/32”
diameter holes punched in a triangular pattern.
See Figure 3 “Stacking Boiler Attachment
Bracket Placement”.
c. Phantom boiler left and right side panels have a
series of dimples at panel top and bottom. These
dimples are positioning dimples for Stacking
Boiler Attachment Bracket mounting screws.
Side panel bottom positioning dimples are evenly
spaced from boiler front and back, while side
pattern to compensate for Phantom boiler model
variable depth.
d. Position the upper boiler on the top of the bottom
with each other.
Bracket onto the upper boiler left side panel,
at the panel lower left corner and align
bracket two upper holes with corresponding
side panel lower dimples.
with a matching bottom boiler left side panel
top positioning dimple.
top and bottom boiler left side panels with
the mounting screws.
e. Repeat above procedure to install second
Stacking Boiler Attachment Bracket and secure
the stacked boiler right side panels together at
the front right corner.
f. Install the third Stacking Boiler Attachment
Bracket to secure top and bottom boiler left side
panels at the rear left corner. Align the bracket
holes with corresponding positioning dimples in
the top boiler and bottom boiler left side panels,
then secure bracket with the screws.
g. Repeat above procedure to install the forth
Stacking Boiler Attachment Bracket to secure
stacked boiler right side panels at the rear right
corner.
guidelines:
a. Venting - Top and bottom boilers must have their
individual vent piping and vent terminals.
WARNING
For side-wall venting individual model vent
terminals must terminate not closer than 12
inches horizontally and three (3) feet vertically
from each other in order to prevent combustion
air contamination. For vertical through the roof
venting, individual vertical vent terminals, if
level with each other, must be spaced no closer
than 12 inches horizontally. If vertical terminals
cannot end in one plane, they must be spaced no
closer than three (3) feet horizontally.
Follow instructions in Section IV “Venting”
vent termination. Follow instructions in Section
V “Condensate Disposal” for each individual
condensate disposal. Terminating individual
boiler condensate lines into common pipe prior
13
to drain disposal is permissible, providing
to handle combined condensate volume of
stackable combination.
b. Gas Piping - Follow instructions in Section
VII “Gas Piping” of the manual for sizing
and installation of an individual boiler. When
common gas piping is sized, insure it will have
combination.
c. Water Piping and Trim - Follow instructions
in Section VI “Water Piping and Trim” of the
manual for system piping and boiler secondary
piping selection/sizing based on combined
.
Follow instructions of Section VI “Water
Piping and Trim” for each individual boiler trim
installation.
d. Electrical - Follow instructions in Section VIII
“Electrical” of the manual to wire individual
boilers.
14
A. General Guidelines
a. Install vent system in accordance with National
Fuel Gas Code, ANSI Z223.1/NFPA 54 or
Natural Gas and Propane Installation Code,
CAN/CSA B149.1 Installation Code for Canada,
or, applicable provisions of local building codes.
restrictions and installation inspection in your
area.
b. The Phantom is a Direct Vent (sealed
combustion) boiler. Combustion air must be
supplied directly to the burner enclosure from
outdoors.
c. The following combustion air/vent system
options are listed for use with the Phantom
boilers (refer to Table 4):
i. Two-Pipe CPVC/PVC Vent/Combustion
Air System - Separate CPVC/PVC pipe
serves to expel products of combustion and
separate PVC pipe delivers fresh outdoor
details.
ii. Two-Pipe Polypropylene Vent/Combustion
polypropylene pipe serves to expel
products of combustion and separate rigid
polypropylene or PVC pipe delivers fresh
outdoor combustion air. Refer to Part C for
iii. Two-Pipe Stainless Steel Vent/Combustion
Air System - Separate stainless steel pipe
serves to expel products of combustion
and separate PVC or galvanized steel pipe
delivers fresh outdoor combustion air. Refer
2. Vent/Combustion Air Piping
a. Do not exceed maximum vent/combustion air
lengths listed in Table 5. Vent/combustion air
length restrictions are based on equivalent length
of vent/combustion air pipe (total length of
Do not include vent/combustion air terminals
in equivalent feet calculations. Use vent/
combustion air equivalent length worksheet
provided in Table 6B.
b. Maintain minimum clearance to combustible
materials. See Figure 2 for details.
c. Enclose vent passing through occupied or
unoccupied spaces above boiler with material
WARNING
Natural Gas and Propane
Installation Code
15
Factory Standard
Two-Pipe,
CPVC/PVC Vent and
PVC Air Intake
CPVC/PVC
Horizontal
Standard
pipe and PVC air intake pipe terminating
4, 5, 6A, 6B,
7A
B.
Optional
Snorkel
terminals.
4, 6A, 6B
7B
Optional
Vertical
Vertical
pipe and PVC air intake pipe terminating
vertical terminals.
13 7C
Two-Pipe, Rigid
Liner for Vertical
Polypropylene or PVC
Pipe Air Intake
Rigid
Polypropylene
Polypropylene
Liner for vertical
Horizontal
Standard
Polypropylene vent pipe and Rigid
Polypropylene or PVC air intake pipe
4, 5, 6A, 6B
9, 12, 14 10A, 10B
C.
Optional Snorkel
terminals.
4, 6A, 6B
9, 12, 14 10A, 10B
Optional
Vertical
Vertical
Polypropylene vent liner and Rigid
venting and Rigid Polypropylene or PVC
intake and separate terminals.
14, 15 10A, 10B
Two-Pipe,
Stainless Steel Vent and
PVC/Galvanized Steel
Air Intake
Stainless Steel
Horizontal
Standard
steel vent pipe and PVC/galvanized steel
air intake piping and separate terminals.
4, 5, 6A, 6B
9, 12, 16
11A, 11B D.
Optional Snorkel
terminals.
4, 6A, 6B
9, 12, 16
Optional
Vertical
Vertical
stainless steel vent liner and Rigid stainless
steel vent pipe and PVC/galvanized steel
intake piping and separate terminals.
17, 17A
Boiler Model
Vent
Nominal
Pipe
Diameter
Minimum
Equivalent
Equivalent
Nominal
Pipe
Diameter
Minimum
Equivalent
Equivalent
PHNTM210 4 in.
2.5 ft.
135 ft.
3 in.
2.5 ft.
135 ft.
PHNTM285 100 ft.
4 in.
100 ft.
16
resistance rating requirement may not need to be
met, but is recommended.
d. Slope horizontal vent pipe minimum 1/4 in/ft
(21 mm/m) downward towards the boiler.
Les chaudières de catégories I, II et IV doivent
présenter des tronçons horizontaux dont la pente
montante est d’au moins 1/4 po par pied (21
mm/m) entre la chaudière et l’évent.
e. If possible, slope horizontal combustion air
pipe minimum 1/4 in/ft (21 mm/m) downward
towards terminal. If not, slope towards boiler.
f. Use noncombustible ¾ in. pipe strap to support
horizontal runs and maintain vent location and
slope while preventing sags in pipe. Do not
restrict thermal expansion or movement of vent
system. Maximum support spacing 4 ft. (1.2 m).
Avoid low spots where condensate may pool.
Do not penetrate any part of the vent system with
fasteners.
Les instructions d´installation du système
d´évacuation doivent préciser que les sections
horizontales doivent être supportées pour
Les instructions divent aussi indiquer les
renseignements suivants:
les chaudières de catégories II et IV doivent être
installées de façon à empêcher l´accumulation de
condensat: et
si nécessaire, les chaudières de catégories II et IV
doivent être pourvues de dispositifs d´évacuation
du condensat.
g. For multiple boiler installations with vertical
roof terminals, separate vent pipes from multiple
boilers may be piped through a common conduit
or chase so that one roof penetration may be
made.
Component Description
vs. Component Nominal Diameter
Component Nominal Diameter
17
3. Vent/Combustion Air Terminals
Install venting system components on exterior
instructions (refer to Figure 4).
a. Use only listed vent/combustion air terminals.
i. Horizontal Sidewall Venting: Use tee
terminals for both vent and combustion air
as shown in Figure 5. Alternate snorkel
terminations are shown in Figure 6A and
Figure 6B.
ii. Vertical Roof Venting: Use straight
coupling on vent and two 90° elbows turned
downwards for combustion air as shown in
Figure 7 and Figure 8.
Nominal Diameter Quantity
Equivalent
Equivalent
Nominal Diameter Quantity
per Pc
Equivalent
3 in.
3 in.
1
4 in.
4 in.
1
Nominal Diameter Quantity
Equivalent
Equivalent
Nominal Diameter Quantity
per Pc
Equivalent
3 in.
3 in.
4 in.
4 in.
Nominal Diameter
Quantity
ft or m
Equivalent
ft/ft or m/m
Equivalent
Nominal Diameter
Quantity
ft or m
ft/ft or m/m
Equivalent
3 in.
13 in.
4 in.
14 in.
*
Nominal Diameter
Quantity
ft or m
ft/ft or m/m
Equivalent
3 in.
2.5 ft.
12.5 ft.
4 in.
2.5 ft.
1 2.5 ft.
Nominal Diameter
Quantity
ft
ft/ft
Equivalent
3 in.
1
4 in.
1
18
b. Maintain correct clearance and orientation
between vent and combustion air terminals.
i. Space centerlines of vent and combustion
air terminals minimum 12 in. (300 mm)
apart. More than 12 in. (300 mm) spacing is
recommended.
ii. If possible, locate vent and combustion
air terminals on the same wall to prevent
nuisance shutdowns. If not, boiler may
be installed with roof vent terminal and
sidewall combustion air terminal.
iii. When installed on the same wall, locate
vent terminal at same height or higher than
combustion air terminal.
iv. When using tee terminals, do not locate vent
terminal directly above air intake as dripping
condensate may freeze on and block intake.
c. Locate bottom of vent and combustion air
terminals at least 12 in. (300 mm) [18 in.
(460 mm) in Canada] above the normal snow line
and at least 12 in. (300 mm) above grade level.
d. Locate vent and combustion air terminals at
least 12 in. (300 mm) from any door, window, or
gravity inlet into the building.
e. Do not install vent terminal directly above
windows or doors.
f. Locate bottom of vent terminal at least 3 ft. (900
mm) above any forced air inlet located within 10
ft. (3.0 m).
g. If window and/or air inlet is within 4 ft. (1.2 m)
of an inside corner, maintain at least 6 ft. (1.8 m)
spacing between terminal and adjoining wall of
inside corner.
h. Locate bottom of vent terminal at least 7 ft.
(2.1 m) above a public walkway.
i. Maintain minimum clearance of at least 4 ft.
(1.2 m) [3 ft. (900 mm)in Canada] horizontally
between vent terminal and gas meters, electric
meters, regulators, and relief equipment. Do
not install vent terminal above or below this
equipment.
j. Do not locate the vent terminal under decks or
similar structures.
k. Top of terminal must be at least 24” below
ventilated
no case may the overhang exceed 48”. Where
permitted by the authority having jurisdiction
and local experience, the terminal may be located
closer to unventilated
vertical separation depends upon the depth of the
l. Maintain minimum 12 in. (300 mm) horizontal
spacing between vent terminal and a building
corner.
19
may condense, and possibly freeze, on objects
around the terminal including on the structure
itself. If these objects are subject to damage by
protected.
n. If possible, install the vent and combustion air
terminals on a wall away from the prevailing
wind. Reliable operation of this boiler cannot be
guaranteed if terminals are subjected to winds in
excess of 40 mph (64 km/hr).
o. Do not locate combustion air terminal in areas
that might contain combustion air contaminates,
such as near swimming pools.
p. For multiple boiler installations with horizontal
wall terminals, maintain minimum 12 in.
(300 mm) horizontal distance between adjacent
boiler vent terminals. Maintaining greater
spacing is recommended to avoid frost damage
to building surfaces where vent terminations are
placed.
q. For multiple boiler installations with vertical
roof terminals, maintain minimum 12 in.
(300 mm) horizontal distance between adjacent
boiler vent terminals.
B. CPVC/PVC Venting
WARNING
1. Components
a. See Table 7A for CPVC/PVC vent and
combustion air components included with boiler.
b. See Table 7B for CPVC/PVC installer provided
vent and combustion air components required for
optional horizontal snorkel terminals shown in
Figure 6B.
c. See Table 7C for CPVC/PVC installer provided
vent and combustion air components required
for optional vertical roof terminals shown in
Figure 7.
Refer to Figure 9 and following steps:
a. Position the CPVC/PVC vent connector and
gasket onto boiler rear panel and insert vent
connector inner stainless steel vent pipe into heat
exchanger vent outlet.
b. Align vent connector plate and gasket clearance
holes with rear panel engagement holes. Then,
secure the connector and gasket to the panel with
six mounting screws.
20
230803 1 N/A
230804 1 2
3” Stainless Steel Rodent Screen 230833 1 N/A
4” Stainless Steel Rodent Screen 230834 1 2
230823 1 N/A
230824 N/A 1
230813 1 N/A
230814 N/A 1
105133-01 N/A N/A
105133-02 1 N/A
105133-03 N/A 1
Gasket 230841 N/A N/A
Gasket 102185-02 1 1
WARNING
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