Crown Boiler PHNTM120 User manual
Series
PHNTM080
PHNTM100
PHNTM120
PHNTM150
PHNTM180
: Improper installation, adjustment, alteration,
service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information, con-
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
9700609
1
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.
FOLLOW ALL INSTRUCTIONS and warnings
printed in this 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
3
Table of Contents
I. Product Description 4
III. Before Installing 5
IV. Locating The Boiler 6
V. Mounting The Boiler 8
VI. Air For Ventilation 11
VII. Venting 12
A. Vent System Design 12
B. Design Requirements Unique to Horizontal Twin Pipe
Venting Systems 18
C. Design Requirements Unique to Vertical Venting Systems 24
D. Design Requirements Unique to Split Vent Systems 32
E. Assembly of CPVC/PVC Vent Systems 39
F. Assembly of DuraVent PolyPro Vent Systems 46
I. Condensate Trap and Drain 59
J. Removing An Existing Boiler From Common Chimney 60
VIII. Gas Piping 62
IX. System Piping 64
A. General System Piping Precaution 64
B. Near Boiler Piping Design 65
C. Standard Piping Installation Requirements 73
D. Piping For Special Situations 75
X. Wiring 76
XI. Start-up and Checkout 84
XII. Operation 91
XIII. Service and Maintenance 106
XIV. Troubleshooting 113
XV. Parts 121
Appendix A: LP Gas Conversion Instructions 136
Appendix B: Special Requirements For Side-Wall 142
Vented Appliances In The Commonwealth
of Massachusetts
4
FIGURE 2.1: GENERAL CONFIGURATION
I Product Description
supply water temperatures of 180°F or less. It is designed for installation on a wall. This boiler may be vented vertically or
horizontally with combustion air supplied from outdoors. It is not designed for use in gravity hot water systems or systems
"A"
SEE TABLE 2.3
16-5/8
CONNECTION SUPPLY WATER
RETURN WATER
PRESSURE GAUGE
OUTSIDE
INSIDE
OF WALL
CONNECTION
OF WALL
ACCESS
TEMPERATURE/
PANEL
SERVICE
DRAIN
VALVE
29-1/16
RELIEF
VALVE
CONDENSATE
CONNECTION
CONNECTION
VENT
PANEL
CONNECTION
AIR INTAKE
CONNECTION
GAS
CONTROL
ACCESS
CONDENSATE
TRAP CLEANOUT
5
MODEL*
MAXIMUM
INPUT
(MBH)
MINIMUM
INPUT
(MBH)
D.O.E.
HEATING
CAPACITY
(MBH)
AHRI NET
RATING*
(MBH)
WATER
VOLUME
(Gal.)
DIM “A”
SUPPLY &
RETURN
CONNECTION
SIZE (NPT)
GAS
CONNECTION
SIZE (NPT)
APPROX.
NET
WEIGHT
(lb)
PHNTM080 80 16 74 64 0.36 17” 1” 1/2” 100
PHNTM100 100 20 92 80 0.44 17” 1” 1/2” 102
PHNTM120 120 24 111 97 0.53 17” 1” 1/2” 105
PHNTM150 150 30 141 123 0.79 21” 1” 1/2” 119
PHNTM180 180 36 167 145 0.79 21” 1” 1/2” 119
* The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15. The manufacturer should be consulted before
selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping
systems, etc.
Table 2.3: Vent Len
g
th
s
M
O
DE
L
NOMINA
L
V
ENT
/
INTAKE
SIZE
(i
n
)
MIN
V
ENT
L
ENGTH
(i
n
)
MAX
V
ENT
LEN
G
TH
A
PPR
O
X
.
D
ERATE A
T
M
A
X VENT
(
%
)
080
2
1
2
60f
t
9
080
3
1
21
35f
t2
100
2
12
6
0
f
t
1
5
100
3
12
1
35
ft
3
120
3
12
1
35
ft
7
150
3
52
1
35f
t
7
1
80
3
5
21
35
ft
9
S
ee Part VII (Ventin
g
) for additional requirements and details
.
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.
and the National Fuel Gas Code, ANSI Z223.1. In Canada, installation must be in accordance with the B149.1
Installation Code.
Standard for Controls
and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1).
2) Read Section VII to verify that the maximum combustion air and exhaust pipe lengths will not be exceeded in the
planned installation. Also verify that the vent terminal can be located in accordance with Section VII.
3) Make sure that the boiler is correctly sized:
method such as the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute
(AHRI).
6
(“propane”) using a combustion analyzer in accordance with the instructions in Appendix A.
5) Not all models are suitable for installation at altitudes above 2000ft. See Appendix A for additional information.
IV Locating the Boiler
1) Observe the minimum clearances shown in Figure 4.1. These clearances apply to combustible construction as well as non-
2) Note the recommended service clearances in Figure 4.1. These service clearances are recommended, but may be reduced to
the combustible clearances provided:
a. Access to the front of the boiler is provided through a door.
b. Access is provided to the condensate trap located beneath the boiler.
3) Observe the following clearances from piping to combustible construction:
Non-concentric vent (exhaust): ¼”
Air intake piping: 0”
Hot water piping: ¼”
4) The relief valve and gauge must be installed in the location shown in Figure 2.1 and must be in the same space as the boiler.
5) The boiler should be located so as to minimize the length of the vent system.
6) The combustion air piping must terminate where outdoor air is available for combustion and away from areas that will con-
paint removers, cleaning solvents and detergents.
7
Figure 4.1: Minimum Clearances To Combustible Construction
8
V Mounting The Boiler
A. Wall Mounting
1) If the boiler is installed on a framed wall, minimum acceptable framing is 2 x 4 studs on 16” centers. The boiler
mounting holes are on 16” centers for installation between two studs at the standard spacing. In cases where the
boiler cannot be centered between the studs, or where the studs are spaced closer than 16” apart, the boiler may be
anchored to ¾” plywood or horizontal 2 x 4s anchored to the studs.
2) 5/16” x 2” lag screws and washers are provided for mounting this boiler. These lag screws are intended for mount-
ing the boiler directly onto studs covered with ½” sheathing. When the boiler is attached to other types of construc-
tion, such as masonry, use fasteners capable of supporting the weight of the boiler and attached piping in accor-
dance with good construction practice and applicable local codes.
3) Make sure that the surface to which the boiler is mounted is plumb.
4) Before mounting the boiler, make sure that wall selected does not have any framing or other construction that will
interfere with the vent pipe penetration.
use Figure 5.1 to locate holes “A” and “B”. Make sure that the horizontal centerline of these holes is level. Holes
“C” and “D” may also be drilled at this time or after the boiler is hung on the wall. If the 5/16” x 2” lag screws are
used, drill 3/16” pilot holes.
6) The wall mounting hook is used to secure the boiler to the shipping pallet. Remove this hook from the pallet and
secure to the wall using the 5/16” x 2” lag screws and washers, or other suitable anchors as appropriate (Figure
5.2). Make sure the hook is level.
7) Hang the boiler on the wall hook as shown in Figure 5.2.
8) If not already done in Step (5) locate and drill holes “C” and “D” using the obround slots in the bottom mounting
-
ure 5.2).
9) Verify that the front of the boiler is plumb. If it is not, install washers at holes “C” and “D” between the bottom
C
AUTION
This boiler wei
g
hs as much as 119 pounds
:
9
Fi
gure 5.1 Wa
ll
Layout
/
Mount
i
ng Ho
l
e Locat
i
on
10
F
i
gure 5.2 Bo
il
er Mount
i
ng Brac
k
et Insta
ll
at
i
on
/
Bo
il
er Wa
ll
Mount
i
n
g
11
VI Air for Ventilation
Air for combustion must always be obtained directly from outdoors. See Section VII for intake piping. Adequate air for
-
tion manual or applicable code.
12
VII Venting
A. General Vent System Design
Horizontal (“Side Wall”) Twin Pipe Venting (Figure 7.0a) - Vent system exits the building through an outside wall.
way. A summary of Horizontal Twin Pipe venting options is shown in Table 7.5.
Vertical Twin Pipe Venting (Figure 7.0b)
are routed between the boiler and the terminal(s) using separate pipes for at least part of the way. A summary of Vertical
Twin Pipe venting options is shown in Table 7.13
Split Venting (Figure 7.0c) - Exhaust system exits the building through a roof, and combustion air is drawn from a
terminal mounted on the side wall. A summary of split venting options is shown in Table 7.21
Horizontal (“Side Wall”) Concentric Venting (Figure 7.0d) – The entire vent system is concentric from the boiler to
the termination on the wall. The venting components used in this system are available through Crown distributors.
Installation instructions for this system are covered in a separate vent supplement (Crown PN 980137).
Vertical Concentric Venting (Figure 7.0e) – The entire vent system is concentric from the boiler to the termination on
the roof. The venting components used in this system are available through Crown distributors. Installation instructions
for this system are covered in a separate vent supplement (Crown PN 980137).
13
FIGURE 7.0 BASIC VENT OPTIONS
FIGURE 7.0a: HORIZONTAL TWIN PIPE
FIGURE 7.0b: VERTICAL TWIN PIPE
FIGURE 7.0c: SPLIT VENTING FIGURE 7.0d & e: HORIZONTAL & VERTICAL CONCENTRIC VENTING
14
All of these systems are considered “direct vent” because the air for combustion is drawn directly from the outdoors into the
boiler. One of the vent option columns in the tables referenced above must match the planned vent and air intake system exactly.
Design details applying to all vent systems are shown in this section. Observe all design requirements in this section, as well as
those unique to the type of system being installed:
1. Approved Vent Systems and Materials – The following materials and vent systems may be used to vent this boiler:
of foam core PVC is not permitted for venting. PVC vent pipe may not be used to vent this boiler in Canada.
Use PVC and/or CPVC for the air intake system. PVC may be used for all air intake piping between the intake terminal and
the boiler.
When CPVC and/or PVC pipe is used, it must be joined using primer and cement that is listed for use with the pipe material
being joined (PVC, CPVC, or CPVC to PVC).
2. Vent Components Supplied with this Boiler – This boiler is supplied with some of the components needed for 3” CPVC/PVC
venting (Vent Option 2). A list of these components is supplied in Table 7.26. Components not supplied may be procured
locally. The CPVC Pipe and elbow supplied with this boiler are not listed to ULC S636 and may not be used in Canada.
3. Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option
selected and the boiler size. See Tables 7.5, 7.13 or 7.21 for the maximum vent lengths. These maximum lengths apply
to both the vent and intake piping (e.g. Option 1 may have up to 60ft of intake and 60ft of vent piping). For all vent
the maximum allowable vent length must be reduced by the amount shown in Table 7.1 for each additional elbow used.
elbows be “1/4 Bend” (Sanitary 90° El) or “Long Sweep 1/4 Bend” type elbows (Figure 7.2). In this manual “sanitary” and
“long sweep” elbows are treated as having the same equivalent length.
Example:
A 3” twin pipe horizontal CPVC/PVC vent system is planned for a horizontally vented 120MBH model which has the
following components in the vent system:
1 ft CPVC Straight Pipe
90 CPVC Elbow (short bend)
1-1/2 ft CPVC Straight Pipe
Coupling
10 ft PVC Straight Pipe
90 PVC Elbow (Sanitary Elbow Design)
15 ft PVC Straight Pipe
PVC Coupling Terminal
The Vent Option #2 column in Table 7.5 describes a horizontal direct vent system using 3” CPVC and PVC pipe. From this
Table 7.1, we see that the equivalent length of the 90 PVC elbow is 4ft and that the equivalent length of the coupling is 0ft.
The total equivalent length of the planned venting system is therefore:
+ 4ft (PVC 90 Sanitary Elbow) + 15ft (Straight PVC) + 0ft (Coupling Terminal) = 31.5ft.
Since Table 7.5 shows a maximum allowable vent length of 135ft, the planned vent system length is acceptable
length. See Sections VII-C or VII-D for details.
15
4. Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in Tables 7.1, 7.13 and 7.21.
5. Clearances to Combustibles - Maintain the following clearances from the vent system to combustible construction:
Vent - 1/4” (also observe clearances through both combustible and non-combustible walls - see 9 below)
Air Intake - 0”
Concentric Portion of Concentric Terminals - 0”
6. Pitch of Horizontal Vent Piping - Pitch all horizontal vent piping so that any condensate which forms in the piping will run
towards the boiler.
TABLE 7.1: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH
CPVC/PVC FITTING EQUIVALENT LENGTH (ft) POLYPRO, POLYFLUE OR INNOFLUE
VENT FITTING
EQUIVALENT LENGTH (ft)
2” 90 ELBOW (“SANITARY BEND”) 2.6 2” 90 ELBOW 4.5
3” 90 ELBOW (“SANITARY BEND”) 4.0 3” 90 ELBOW 8.7
2” 90 ELBOW (“SHORT BEND” ) 6.0 2” 45 ELBOW 2.5
3” 90 ELBOW (“SHORT BEND”) 10.0 3” 45 ELBOW 4.6
2” 45 ELBOW 1.5
3” 45 ELBOW 2.0
2” COUPLING 0.0
3” COUPLING 0.0
FIGURE 7.2: CPVC AND PVC ELBOWS
16
7. Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported. Maximum support spacing is as
follows:
Les instructions d´installation du système d´évacuation doivent préciser que les sections horizontales doivent être
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.
8. Allowing for Thermal Expansion -
The boiler will always act as an anchor to one end of the vent system. If at all possible, select and install hangers and
wall thimbles so that the vent system can expand towards the terminal. When a straight run of pipe exceeds 20ft and
must be restrained at both ends, an offset or expansion loop must be provided (Figures 7.3a, 7.3b). When a straight
horizontal run of pipe exceeds 20ft and is restrained at one end with an elbow at the other, avoid putting a hanger or
are not permitted.
Part VII-F, G & H of this manual for details.
9. Running PVC Vent Pipe Inside Enclosures and Through Walls - PVC vent pipe must be installed in a manner that permits
adequate air circulation around the outside of the pipe:
Do not enclose PVC venting - Use CPVC in enclosed spaces, even if PVC is installed upstream.
PVC venting may not be used to penetrate combustible or non-combustible walls unless all of the following conditions
are met:
a. The wall penetration is at least 66 inches from the boiler as measured along the vent.
b. The wall is 12” thick or less
c. An airspace of at least that shown in Figure 7.4 is maintained around the OD of the vent.
If any of these conditions cannot be met, use CPVC for the wall penetration.
10. – The vent system manufacturer may have additional vent system design requirements.
two sets of instructions, the more restrictive requirements shall govern.
17
FIGURE 7.3: EXPANSION LOOPS FOR CPVC/PVC PIPE
FIGURE 7.3bFIGURE 7.3a
FIGURE 7.3c
FIGURE 7.4: WALL PENETRATION CLEARANCES FOR PVC VENT PIPE
18
B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems
Table 7.5 summarizes all horizontal twin pipe vent options. Illustrations of horizontal twin pipe vent systems are shown in
Figures 7.6 – 7.10. In addition to the requirements in Part VII-A, observe the following design requirements:
1. Permitted Terminals for Horizontal Venting:
Terminal Option A: Fittings (Acceptable for Vent Options 1-8) – Vent terminates in a plain end (coupling for PVC, bell
Outer edge of both terminals must be within 10” of the wall surface (Figures 7.6, 7.9). The section of DuraVent Polypro,
Use of rodent screens is generally recommended for both terminations. Two rodent screens suitable for 3” PVC terminals
Size/Vent System Rodent Screen (“Bird Guard”)
2” Polypro DuraVent # 2PPS-BG
3” Polypro DuraVent # 3PPS-BG
2” InnoFlue Centrotherm # IASPP02
3” InnoFlue Centrotherm # IASPP03
on snorkels as shown in Figure 7.12. When this is done, the equivalent length of all pipe on the exterior of the building,
snorkeled.
– This terminal is shown in Figure 7.7. If
the terminal is oriented vertically (alternate orientation shown in Fig 7.7) the exhaust opening must be on the top as shown.
See Part VII-E of this manual and the Ipex instructions provided with the terminal, for installation details.
– This terminal is shown in Figure
7.7. If the terminal is oriented vertically (alternate orientation shown in Fig 7.7) the exhaust opening must be on the top as
shown. See Part VII-E of this manual and the Diversitech instructions provided with the terminal, for installation details.
Terminal Option D: Ipex FGV Concentric Terminal (Acceptable for Vent Options 1,2) - This terminal is shown in Figure 7.8
and may be used with CPVC/PVC vent systems. This terminal is available in various lengths and in both PVC and CPVC.
Terminals acceptable for use with these vent options are as follows:
Ipex PN FGV Concentric Terminal Description
196005 2 x 16” PVC
196105 2 x 28” PVC
196125 2 x 40” PVC
196006 3 x 20” PVC
196106 3 x 32” PVC
196116 3 x 44” PVC
197107 3 x 32” CPVC
197117 3 x 44” CPVC
See Part VII-E of this manual and the Ipex instructions provided with the terminal, for installation details.
Terminal Option E: Diversitech Concentric Terminal (Acceptable for Vent Options 1,2) - This terminal is shown in Figure 7.8
and may be used with CPVC/PVC vent systems. See Part VII-E of this manual and the Diversitech instructions provided with
the terminal, for installation details.
Terminal Option F: DuraVent PolyPro Concentric Terminal (Acceptable for Vent Options 3,4) - This terminal is shown in
Figure 7.10 and may be used with DuraVent 2” or 3” PolyPro vent systems. See Part VII-F of this manual and the DuraVent
instructions provided with the terminal, for installation details.
This manual suits for next models
4
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