Crown Boiler PHNTM080 User manual

Series
High Efciency Gas-Fired Hot Water
Direct Vent Condensing Boilers
Multiple Boiler Installation Instructions
These instructions must be afxed on or adjacent to the boiler and
retained for future reference.
Models:
• PHNTM080
• PHNTM100
• PHNTM120
• PHNTM150
• PHNTM180
WARNING: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information, con-
sult a qualied installer, service agency or the gas supplier.
This boiler requires a special venting system. Read these
instructions carefully before installing.
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com

1
IMPORTANT INFORMATION - READ
CAREFULLY
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.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate or
minor injury or property damage.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
FOLLOW ALL INSTRUCTIONS and warnings
printed in this manual, the Installation & Operating
Instructions Manual, the owner’s manual and
posted on the boiler.
MAINTAIN THE BOILER. To keep your boiler safe
and efficient, have a service technician maintain
this boiler as specified in Part XIII of the 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, vent piping
and vent terminals.
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.
WARNINGS FOR THE HOMEOWNER

2
DANGER
Explosion Hazard. DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this
or any other appliance.
If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use
any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the
gas supplier’s instructions or if the supplier is unavailable, contact the re department.
WARNING
• Asphyxiation Hazard. This boiler requires regular maintenance and service to operate safely.
Follow the instructions contained in this manual.
• Improper installation, adjustment, alteration, service or maintenance can cause property damage,
personal injury or loss of life. Read and understand the entire manual before attempting installation,
start-up operation, or service. Installation and service must be performed only by an experienced,
skilled, and knowledgeable installer or service agency.
• This boiler must be properly vented.
• This boiler needs fresh air for safe operation and must be installed so there are provisions for
adequate combustion and ventilation air.
• Asphyxiation Hazard. The interior of the venting system must be inspected and cleaned before the
start of the heating season and should be inspected periodically throughout the heating season for
any obstructions. A clean and unobstructed venting system is necessary to allow noxious fumes
that could cause injury or loss of life to vent safely and will contribute toward maintaining the
boiler’s efciency.
• Installation is not complete unless a safety relief valve is installed into the tapping located on left
side of appliance or the supply piping. - See the Water Piping and Trim Section of this manual for
details.
• This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should not be
left unattended in cold weather; or appropriate safeguards and alarms should be installed on the
heating system to prevent damage if the boiler is inoperative.
• Burn Hazard. This boiler contains very hot water under high pressure. Do not unscrew any pipe
ttings nor attempt to disconnect any components of this boiler without positively assuring the
water is cool and has no pressure. Always wear protective clothing and equipment when installing,
starting up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and
temperature gauges to determine the temperature and pressure of the boiler. This boiler contains
components which become very hot when the boiler is operating. Do not touch any components
unless they are cool.
• Respiratory Hazard. Boiler materials of construction, products of combustion and the fuel contain
alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or
harmful substances which can cause death or serious injury and which are known to the state of
California to cause cancer, birth defects and other reproductive harm. Always use proper safety
clothing, respirators and equipment when servicing or working nearby the appliance.
• Failure to follow all instructions in the proper order can cause personal injury or death. Read all
instructions, including all those contained in component manufacturers manuals which are provided
with the boiler before installing, starting up, operating, maintaining or servicing.
• All cover plates, enclosures and guards must be in place at all times.

3
Table of Contents
I. Preface 4
II. Venting Multiple Boilers 4
A. Terminal Spacing 4
B. Condensate Drain Line 5
III. Gas Piping Multiple Boilers 10
IV. System Piping Multiple Boilers 11
A. General System Piping Precautions 11
V. Wiring 14
A. Multiple Boiler Wiring 14
VI. Start-up and Checkout 18
VII. Operation 18
A. General Information 18
   B.ConguringTheControl    18
C. Changing Settings 27
D. Enter Service Contact Information 27
E. Boiler Status 29
F. Staging Process 35
VIII. Service and Maintenance 35
IX. Troubleshooting 35

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I Preface
Theseinstructionsaremeanttoprovideinformationspecictomultipleboiler(“Lead-Lag”)installationsofthefollowing
models:
• PHNTM080
• PHNTM100
• PHNTM120
• PHNTM150
• PHNTM180
ForlargerPhantommodels,refertotheinstructionsprovidedwiththatboilerforinformationonmultipleinstallations.
Boilerscoveredbytheseinstructionsapplytotheabovemodelswherethecompletemodelnumberendsin“C”(example:
PHTM180HNT1SUC).Consultthefactorybeforeattemptingmultipleboilerinstallationswheretheabovemodelshavea
different last letter.
These instructions cover only multiple boilers installations consisting solely of the above models. It is also generally
recommended that all boilers on the installation be of the same size.
II Venting Multiple Boilers
TheventandairintakesystemsmustexactlymatchoneoftheventoptionsdescribedinSectionVIIofthePhantom80-180
installation manual. Manifolding of either the vent or intake systems is prohibited.
A. Terminal Spacing
Spacingrequirementsbetweentheterminalsofadjacentboilersisasfollows:
 • HorizontalFittingTerminals(Figures2.1,2.2)–Ahorizontalspacingof36”betweenanyventterminalandany
  intaketerminalisrecommended;however,thisspacingmaybereducedto12”ifnecessary(Figure2.1).Maintaina
  minimumspacingbetweenadjacentintaketerminalsof4”asshowninFigure2.2.
 • LowProleTerminals(Figure2.3)–Maintainaminimumof12”betweentheadjacentinletandoutletopeningsas
  showninFigure2.3.
 • HorizontalIpexorDiversitechConcentricTerminals(Figure2.4)–Attheirclosestpointadjacent“bells”must
  eitherbewithin4”ofeachotherORgreaterthan24”apartasshowninFigure2.4.
 • VerticalFittingTerminals(Figure2.5)–Maintainatleast12”horizontally(centertocenter)betweentheexhaust
  terminalofoneboilerandtheintaketerminalofanotherboilerasshowninFigure2.5.
 • VerticalIpex,Diversitech,orDuraventPPsConcentricTerminals(Figure2.6)-Attheirclosestpointadjacent
  “bells”musteitherbewithin4”ofeachotherORgreaterthan24”apartasshowninFigure2.6.
WARNING
These instructions provide supplemental information. Except where specically stated, they do not replace
the instructions in the manual provided with the boiler. Failure to follow all applicable instructions could
result in property damage, personal injury, or loss of life.
WARNING
• A s p h y x i a t i o n H a z a r d . D o n o t m a n i f o l d ( “ c o m m o n v e n t ” ) a n y p o r t i o n o f m u l t i p l e b o i l e r v e n t o r i n t a k e
systems. Doing so may result in unreliable operation, boiler damage, personal injury, or loss of life.
• F a i l u r e t o m a i n t a i n t h e p r o p e r c l e a r a n c e s b e t w e e n a d j a c e n t t e r m i n a l s m a y r e s u l t i n a s p i r a t i o n
o f  u e g a s i n t o t h e c o m b u s t i o n a i r s u p p l y , r e s u l t i n g i n u n r e l i a b l e o p e r a t i o n , p r o p e r t y d a m a g e ,
personal injury, or loss of life.

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Refertotheinstallationmanualsuppliedwiththeboilerforotherimportantterminalclearances,suchasdistanceabovenormal
snowline.
B. Condensate Drain Line
Condensate drain lines from multiple boilers may be manifolded together. Size the condensate disposal system to carry the
condensaterateperboilershowninTable2.7multipliedbythenumberofboilersinthesystem.

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FIGURE2.1:MULTIPLEBOILERHORIZONTALCPVC/PVCDIRECTVENT
FIGURE2.2:MULTIPLEBOILERHORIZONTALCPVC/PVCDIRECTVENTALTERNATE

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FIGURE2.3:MULTIPLEBOILERHORIZONTALVENTINGWITHLOWPROFILETERMINALS
FIGURE2.4:MULTIPLEBOILERHORIZONTALVENTINGWITHCONCENTRICVENTTERMINALS

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FIGURE2.5:MULTIPLEBOILERVERTICALCPVC/PVCDIRECTVENT
FIGURE2.6:MULTIPLEBOILERVERTICALVENTINGWITHCONCENTRICVENTTERMINALS

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TABLE 2.7: MAXIMUM CONDENSATE FLOW
Boiler
Model
*MaximumCondensateFlow,
GPH
PHNTM080 0.9
PHNTM100 1.1
PHNTM120 1.4
PHNTM150 1.7
PHNTM180 2.1
*Assumes100%ofwaterinfuelcondenses

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III Gas Piping Multiple Boilers
ItisrecommendedthatthegaspipingofeachindividualboilerbeinstalledasshowninFigure3.1.Whencommongas
pipingissized,insureitwillhaveadequate capacity for the combined input of the multiple boilers being installed.
Additional gas pressure regulators may need to be installed to properly regulate inlet gas pressure at the smallest individual
boiler.FollowtheinstructionsinSectionVIIIofthePhantom080-180InstallationandOperatingInstructionsManualfor
more detail on gas piping installation and hazards.
FIGURE3.1:GASCONNECTIONTOBOILER
CAUTION
If gas pressure in the building is above 1/2 psig (3.4 kPa), an additional gas pressure regulator is required.
Using one additional regulator for multiple boilers may result in unsafe boiler operation. The additional
regulator must be able to properly regulate gas pressure at the input of the smallest boiler. If the regulator
cannot do this, two or more additional regulators are required. Consult regulator manufacturer and/or local
gas supplier for instructions and equipment ratings.

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Table 4.1: Multiple Boiler Water Manifold Sizing
Boiler Model
Number of Boilers
23 4 5 6 7 8
Recommended Minimum Common Water
Manifold Size (NPT)
PHNTM080 1¼” 1½” 1½” 2” 2” 2” 2½”
PHNTM100 1¼” 1½” 2” 2” 2½” 2½” 2½”
PHNTM120 1½” 2” 2½” 3” 3” 3” 3”
PHNTM150 1½” 2” 2½” 3” 3” 3” 3”
PHNTM180 2” 2½” 2½” 3” 3½” 3½” 3½”
IV System Piping Multiple Boilers
A. General System Piping Precautions
FollowtheinstructionsinSectionIXofthePhantomSeriesInstallationandOperatingInstructionsManualforinstallation
of factory supplied piping, trim and individual near boiler piping design. See Table 4.1 and Figures 4.2 for piping recom-
mendations.
WARNING
• Failure to properly pipe boiler may result in improper operation and damage to boiler or
structure.
• Install boiler so that the gas ignition system components are protected from water (dripping,
spraying, rain, etc.) during boiler operation and service (circulator replacement, etc.).
• Oxygen contamination of boiler water will cause corrosion of iron and steel boiler
components and can lead to boiler failure. Warranty does not cover problems caused by
oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of
water.

12
FIGURE4.2:MULTIPLEBOILERPIPINGWITHINDIRECTTANKPIPING

13
FIGURE4.3:RECOMMENDED“IMMERSION”TYPEHEADERSENSORINSTALLATIONDETAIL

14
DANGER
Positively assure all electrical connections are unpowered before attempting installation or
service of electrical components or connections of the boiler or building. Lock out all electrical
boxes with padlock once power is turned off.
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 /NFPA 70). In
Canada, all wiring and grounding must be done in accordance with the Canadian Electrical
Code, Part 1 (CSA C22.1 - latest edition).
 Failure to properly wire electrical connections to the boiler may result in serious physical
harm.
 Electrical power may be supplied from more than one circuit. Make sure all power is off
before attempting any electrical work.
 Each boiler must be protected with a properly sized over-current device.
 Never jump out or make inoperative any safety or operating controls.
 The wiring diagrams contained in this manual are for reference purposes only. Each boiler
is shipped with a wiring diagram attached to the front door. Refer to this diagram and the
wiring diagram of any controls used with the boiler. Read, understand and follow all wiring
instructions supplied with the controls.
V. WIRING
A. MULTIPLE BOILER WIRING
Install over-current protection in accordance with the authority having jurisdiction or, in the absence of such requirements, follow
the National Electric Code, NFPA 70, and/or Canadian Electrical Code Part 1, CSA C22.1. Do not provide overcurrent protec-
tion greater than 15 amperes. If this single 15A circuit is insufcient for the combined load of all boilers and pumps, provide ad-
ditional 15A circuits and divide the boilers among them. Follow the instructions in Section X of the Phantom 80-180 Installation
manual with the following exceptions:
One, and only one, of the boilers must be designated as the “Master”. This boiler manages demands for heat (and sometimes
DHW). Any boiler can be designated as the Master, but eld wiring to the Master is different from that for the other boilers
(“Slaves”), so the Master must be chosen before the system is wired. Note that the “Master” boiler is not necessarily the same as
the “Lead” boiler. (i.e. the rst boiler to re upon a call for heat).
See typical eld wiring in Figure 5.1. Key points are:
1) System pump (s) must be connected to the Master. If this will result in a combined pump draw at the Master in excess of 6.3A,
use an isolation relay between the Master’s system pump terminals and the pump(s). System pump terminals on Slaves are not
used.
2) The heating thermostat is connected the “Heat T’Stat” (or Enviracom thermostat) terminals on the Master as shown. Heating
thermostat connections on the Slaves are not used.
3) If an indirect water heater is used, connect the indirect water heater thermostat to the “DHW T’Stat” terminals on the Master.
Also connect the indirect water heater pump to the “DHW Pump” terminals on the Master.

15
4)HeadersensorP/N103104-01mustbeusedinPhantomMultipleboilerapplications.Installitinthesystempipingasshownin
Figure4.2(alsoseeFig4.3forinstallationdetail).WireittotheMasterboilerasshowninFigure5.1.Observetheprecautions
againstelectricalnoisethataredescribedforsensorwiringinPartXoftheboilerinstallationmanual.
5)OutdoorSensor–Ifused,wiretotheMasterasshowninFigure5.1.
6)LWCOand/orexternallimits–Ingeneral,iflowwatercut-offsand/orexternallimitsarerequired,separateonesmustbe 
providedforeachboiler.Consulttheauthorityhavingjurisdiction.
7)MODBUSCommunicationWiring–TheMastercommunicateswiththeSlavesusingtheMODBUSconnectionsonthelow
voltagePCB.ThesimplestwaytomaketheseconnectionsisusingEthernet(PCnetwork)cables.Usethestandard“straight
through”cablesforthisandplugthemintotheModbusreceptaclesasshowninFigure5.1.
Alternatively,Modbusconnectionscanalsobemadeusingthe“A,“B”,and“-V”screwsterminalslocateddirectlyabovethe
Ethernetreceptacles.Todothis,connectall“A”,“B”,and“-V”terminalstogetherasshowninFigure5.2.

16
FIGURE5.1:TYPICALFIELDWIRINGFORMULTIPLEBOILERSYSTEM WITHINDIRECTWATERHEATERPIPEDPERFIGURE4.2

17
FIGURE5.2:MODBUSWIRINGWITHOUTETHERNETCABLES

18
VI Start-up and Checkout
RefertoSectionXI(Start-upandCheckout)inthePhantom80-180installationmanual.Boilersarestarted,adjusted,and
inspectedasindividualboilers.TheyarethenconguredtooperateasamultipleboilersysteminSectionVIIofthismanual
(Operation).
Becausetheslaveshavenothermostatsconnectedtothem,itwillbenecessarytotemporarilyjumptheDHWThermostat
terminalsoneachslaveinordertoreitsothatitcanbecheckedout.
VII Operation
InformationinthissectionsupersedesthatinPartXII(“Operation”)ofthePhantom80-180Installationmanual.
A. General Information
ThisboilerusesthemicroprocessorbasedHoneywellR7910B“boilercontrol”tomanageallboilerfunctionsincludingame
supervisionandmodulation.Twosetpointor“target”boilersupplytemperaturesarestoredinthecontrol’smemory;onefor
spaceheating(CH)andonefordomestichotwater(DHW)production.Ifanoutdoortemperaturesensorisconnectedtothe
boiler,andenabled,thespaceheatingsupplysetpointwillautomaticallyshiftdownwardastheoutdoortemperatureincreases.
Formoreinformationonthisfeatureseethediscussiononboilerwaterresetbelow.
Thecontrolmodulatestheboilerinputbyvaryingthefanspeed.Asthefanspeedincreases,sodoestheamountofgasdrawn
intotheblower.Asaresult,afairlyconstantair-fuelratioismaintainedacrossallinputs.Thecontroldeterminestheinput
neededbylookingatbothcurrentandrecentdifferencesbetweenthesupplytemperatureandthesetpointtemperature.Asthe
supplytemperatureapproachesthesetpointtemperature,thefanwillslowdownandtheinputwilldrop.Theminimuminputis
approximately1/5ofmaximuminput.
Thisboilercontrolalsomonitorsboilerreturnanduetemperatures.Inaddition,allothersafetycontrolsareconnectedintothe
R7910B.TheR7910Busesinputsfromallofthesecontrolstoeithershutdowntheboilerwhenanunsafeconditionexistsor,in
some cases, to correct the problem.
Upto8Phantomsmaybepipedandwiredtogetherasdescribedearlierinthismanualtocreateamultipleboiler(“Lead-lag”)
system.Whenthisisdone,oneboileractsasthe“Master”.TheMasterreceivesdemandsfromloadssharedbytheboilersand
determinesringorderandrateforallboilersinthesystem.TheexactmannerinwhichthisisdoneisdescribedinPartFofthis
section.
Finally, the basic boiler control manages up to three pumps:
 • BoilerLoopPump(builtintoeachboiler)
• DHW pump
• System pump
RefertothePipingSectionforthelocationofthesepumps.
The touch screen display on this boiler has three basic functions:
 1) ToallowtheprofessionalHVACtechniciantoset-upthisboilersothatitwillworkproperlyinthesystemtowhichitis
connected.
 2) ToindicatethecurrentstatusoftheboilerandtoprovideinformationthatwillassisttheprofessionalHVACtechnicianin
  solvingproblemswiththeboilerand/orsystem.
 3) Toadvisethehomeownerifthereisaproblemrequiringprofessionalservice.
AmapofthebasicmenustructureisshowninFigure7.0.Inordertopreventunauthorizedoraccidentaladjustments,accessto
menus,whichchangesettingsandboileroperation,ispasswordprotected.Ingeneral,ifamenuisnottouchedfor255seconds,
thedisplaybacksuptothepreviousmenu.OncetheHomeScreenisreturnedto,thepasswordmustbereenteredinorderto
regainaccesstoprotectedmenus(thisfeaturepreventstheboilerfrombeingpermanentlyleftinoperationwithoutpassword
protection).
B. Conguring the Control
UsetheCongurationMenutoprovidetheboilerwithbasicinformationaboutthetypeofsystemtowhichitisconnected.Ona
newinstallationconguretheboilerrstandthengototheSettingsMenutosetparameterssuchastargetwatertemperatures.A
mapoftheCongurationMenustructureisshowninFigure7.1.Toconguretheboiler:
 1) FromtheHomeScreen(showninFigure7.0),press“MENU”toentertheMainMenu:
  a) Press“CONFIGURE”
  b) Whenpromptedforapassword,usethe“+1”keytoraisethepasswordto“014”.PressSUBMIT,thenNEXT(ifyou
   accidentlyscrollpast014,pressEXITtoreturntothemainmenuandstartover).
  c) ReviewtheWarningandpressACCEPTtocontinuetotheCongurationMenu.