D E S I G N E D T O L E A D Mega-Stor TM Stainless Steel, Indirect Water Heaters • INSTALLATION AND OPERATING INSTRUCTIONS • ENGINEERING MANUAL • MAINTENANCE • PARTS CAUTION 1. having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products, 5th edition. 2. The pressure of the heat transfer medium must be limited to a maximum of 30 PSIG by an approved safety or relief valve.
CONTENTS I. Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 III. Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 IV. Zone Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 V. Before Starting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I. PRODUCT DESCRIPTION The Crown Mega-Stor series indirect water heater is designed to generate domestic hot water in conjunction with a hot water boiler using forced boiler water circulation. This indirect water heater consists of a stainless steel tank in which a smooth stainless steel coil is located. Boiler water is pumped through the coil and heats the water in the tank.
FIGURE 2.2: MEGA-STOR INDIRECT WATER HEATER Vertical Tank 9HUWLFDO 7DQN % +27 :$7(5 287 06 06 +27 :$7(5 287 $1' 7 3 9$/9( 06 ² 06 6+2:1 :,7+ 237,21$/ 02817,1* .,7 )25 06 + $1' 06 + ,168/$7(' +$1'+2/( -$&.
III. SIZING IMPORTANT The following procedures are used to size indirect water heaters based on the amount of hot water which will be required during a given hour. In doing so it is assumed that this demand will be evenly spread out over the course of the entire hour. THESE SIZING PROCEDURES ARE PROVIDED AS A GUIDE TO ASSIST THE PROFESSIONAL CONTRACTOR IN SIZING MEGA-STOR TANKS.
Table 3.2: Maximum Possible Continuous Draw (180F Boiler Supply, 77F DHW Rise, 135F Outlet) (a) (b) (c) Continuous Draw Min Boiler Output Mega-Stor (Gal/min) (MBH) MS-26 2.0 77 MS-40 2.6 102 MS-53 3.0 114 MS-79 3.6 145 MS-119 6.4 225 MSH-40 1.9 75 MSH-53 2.6 101 Table 3.3: AHRI First Draw Rating* (a) (b) (c) Mega-Stor Draw Rate (GPM) First Draw Rating (Gal) MS-26 MS-40 MS-53 MS-79 MS-119 MSH-40 MSH-53 2.0 2.6 3.0 3.6 6.4 1.9 2.6 22.6 38.2 46.5 69.3 88.3 35.6 44.
IV. ZONE DESIGN IMPORTANT section for information on sizing, piping and circulators for the Mega-Stor zone. In designing the Mega-Stor zone piping system the following points should be considered: 1) Circulator or Zone Valve Zoning? - Circulator zones are usually a better choice.
WORKSHEET 1: PRESSURE DROP CALCULATIONS THROUGH MEGA-STOR ZONE Fitting Description MS-26, MSH-40 Coil MS-40 Coil MS-53, MSH-53 Coil MS-79 Coil MS-119 Coil 1 ft 1” St. Pipe 1 ft 1-1/4” St. Pipe 1 ft 1-1/2” St. Pipe 1” 90 El 1-1/4” El 1-1/2” El 1” Run of Tee 1-1/4” Run of Tee 1-1/2” Run of Tee 1” Branch of Tee 1-1/4” Branch of Tee 1-1/2” Branch of Tee 1” Std. Ball Valve 1-1/4” Std. Ball Valve 1-1/2” Std.
EXAMPLE 1 ' ? ' } ? ~ ? "$ Q + = "; ? ' shown in bold) in column (a). ' # 2) Since 8 GPM is required, use the pressure drops shown in column (b). Multiply each entry in column (a) by the corresponding pressure drop in column (b). Enter the result in column (d). 3) The total of column (d) is 7.94 ft.
FIGURE 4.2: COMPLETED WORKSHEET 3 PRESSURE DROP CALCULATIONS THROUGH MEGA-STOR ZONE HEAD LOSS (FT W.C.) Flow Fitting Description MS-26 Coil, MSH-40 Coil MS-40 Coil MS-53, MSH-53H Coil MS-79 Coil MS-119 Coil 1 ft 1” St. Pipe 1 ft 1-1/4” St. Pipe 1 ft 1-1/2” St. Pipe 1” 90 El 1-1/4” El 1-1/2” El 1” Run of Tee 1-1/4” Run of Tee 1-1/2” Run of Tee 1” Branch of Tee 1-1/4” Branch of Tee 1-1/2” Branch of Tee 1” Std. Ball Valve 1-1/4” Std. Ball Valve 1-1/2” Std.
V. BEFORE STARTING INSTALLATION 1) Be sure that the planned installation is in accordance with all local codes. 2) Be certain the domestic water supply to the tank has physical and chemical characteristics that fall within the limits shown " + ] > ; ] consulted. 3) Read and understand all installation requirements in this manual.
VII. PIPING 1) BOILER SIDE PIPING Figures 7.1 thru 7.4 show typical boiler side piping for several common situations. Regardless of which system is used it is impera ! " ! ] ' ' pump. To determine the pipe/pump sizes required see page 6. The systems shown in Figures 7.1 thru 7.
FIGURE 7.1: BOILER-SIDE PIPING USING CIRCULATOR ZONES FIGURE 7.
FIGURE 7.3: BOILER-SIDE PIPING USING A THREE WAY ZONE VALVE FIGURE 7.
2) DOMESTIC SIDE PIPING BASIC DOMESTIC PIPING Figure 7.6A shows typical domestic water piping for a Mega-Stor. All components except the control are provided by the installer. The function of the components shown are as follows: a) Temperature Control (required) - This control is provided by Crown and must be installed in the aquastat well location of the water heater indicated in Figure 2.2. Remove the cover and loosen the clamping screws.
FIGURE 7.5: AQUASTAT INSTALLATION MEGA-STOR PIPING WITH A “TEMPERATURE LIMITING VALVE” Usually, the maximum temperature of the outlet water will stay near the setting of the Mega-Stor control.
FIGURE 7.
FIGURE 7.6B: CORRECT TEMPERATURE & PRESSURE VALVE PIPING FOR MS-26, MS-40, MS-53 FIGURE 7.
FIGURE 7.8: DOMESTIC HOT WATER PIPING USING A MIXING VALVE FIGURE 7.
FIGURE 7.
VIII. WIRING The following general notes apply to all wiring: 1) Wiring must be done in accordance with all codes. In the absence of any codes the system must be wired in accordance with the National Electric Code (ANSI/ZFPA 70-1990). 2) The Mega-Stor is equipped with Honeywell L4006A series temperature control. This control has a set of contacts = = CIRC ZONE WIRING (NON PRIORITY) Figure 8.
CIRCULATOR ZONE WIRING (PRIORITY) Figure 8.2 is a connections diagram for priority circulator zoning. This system is similar to non-priority circulator zoning except that a Honeywell R8285B relay is used in place of the R845A on the Mega-Stor zone. This relay is equipped with its own 24 volt transformer and D.P.D.T. contacts. The Mega-Stor control is connected to terminals R and G so that when the Mega-Stor control calls for heat the relay is energized.
FIGURE 8.2: CIRCULATOR ZONING (PRIORITY) FIGURE 8.
FIGURE 8.4: ZONE VALVE WIRING (2-WAY VALVES, PRIORITY) IX. START-UP AND CHECK-OUT 1) Make sure that the system is free of leaks and that air is purged from the system. WARNING ! IMPORTANT Fix any leaks found before proceeding further. Leakage from the boiler piping can result in severe damage to the boiler.
J ; > ] tic water needs. Because hot water presents a scald hazard, it is best to set the thermostat at 120ºF or lower and raise it only if necessary to provide adequate hot water. See Table 9.2 for more information about scalding.
XI. PARTS Key # 1 5 6 7 8 10 Part # 35-3200 20-021 20-022 20-023 90-025 20-024* Description Thermostat (L4006A2114) Handhole Cover “O” Ring Gasket Handhold Cover Bracket M10 Nut Handhold Jacket Cover Notes: All part numbers are per item. *This part not used on MS-79 or MS-119 25 Qty.
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Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.
