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Crown Boiler CWI069 User's Manual

1. tea 007 CIRCULATOR 95 012 eR 0010 CIRCULATOR 95 015 1 94 1 1 2 FLANGE SET 950150 1 1 1 4 FLANGE SET 95 44 3 4 BOILER DRAIN 95 041 tea 99 8 32 X 1 2 SELF TAPPING SCREW 90 223 4 ea CWI DAMPER HARNESS WITH COIL BOILERS CWI DAMPER HARNESS LESS COIL BOILERS wj AQUASTAT SWITCH HARNESS LESS COIL OR LESS VENT DAMPER AQUASTAT SWITCH HARNESS 9601200 9601500 NOT PICTURED 47 bow AW e i Appendix Knockdown Boiler Assembly Instructions A Before Installing 1 Thoroughly inspect the cast iron heat exchanger for any shipping damage i e cracks in the castings broken lugs or punctures due to mishandling 2 Do not use the heat exchanger if there is any damage to it 3 Inspect the joints between the sections for openings Reseal any openings with high temperature silicone sealant 4 Keep the base in the shipping carton until it is time to perform the assembly This keeps foreign material from contaminating the burners or creating other hazards Do not use the base assembly if there are any signs of visible damage 5 Review all of the installation requ
2. Misw ired or loose electrical connection in 120V line Boiler off on 120 volts N limit 120 volts at across C1 amp C2 terminals at circulator Defective high limit N Y 24 volts betw een pins 1 amp 4 blue amp yellow and 2 amp 4 orange amp yellow on damper end of damper harness See Note 7 on page 28 Remove t stat or zone valve end switch wires from 24 volts T amp TV terminals on across 18148 Install T amp TV temporary jumper across terminals T and TV Seized or defective circulator ee Defective Bad electrical 2 L8148E see connection Note 6 on page betw een C1 or 36 C2 and Loose Obstruction in connection path of damper betw een blade damper harness and Defective L8148E circulator Loose connection in t stat or zone valve end switch wiring damper motor Defective t stat or zone valve end switch Defective Loose damper connection harness betw een damper harness and Defective damper L8148E T stat zone system misw ired consult t stat or zone valve manufacturer s instructions 37 burners light 24 volts across B1 amp B2 58600 module 24 volts across spill switch 24 volts across rollout switch Loose electrical connection in 24 volt w iring betw een B1 or B2 and gas valve or module Do burners shut dow n
3. Clearance Label Located on the top jacket panel b Lighting Instructions Located on the lower left corner of the right side panel next to the gas manifold c Lowest Permissible Water Level Plate Located next to the bottom water gauge tapping d Blow Down Card Located just above the Lowest Permissible Water Level Plate e Wiring Diagram Located on the inside of the removable door f CROWN Nameplate Located on the top center of the outside of the removable door g Rating Plate Located on the upper left of the right side panel D Gas Valve Installation The gas valve assembly has been pre piped with one half of a piping union and is to be connected to the other half of the union located on the gas manifold Connect the pilot tubing from the pilot burner to the gas valve pilot tapping Connect the thermocouple lead to the gas valve standing pilot boilers only E Control and Trim Installation Refer to Figure A3 for Tapping Locations Install the tankless heater or blank cover plate on the opening on the right side of the heat exchanger using the gasket and 3 8 bolts provided Install the high limit well in the tapping in the tankless heater or cover plate Mount the limit control L8148E or L8124E onto the control well Be sure that the temperature sensing bulb is bottomed out in the well Tighten the screw on the bottom of the control so that it is securely clamped onto the well Install a 1 2 x 1 4 bushing and
4. LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000DERHC SERIES GAS VALVES INTERMITTENT PILOT FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition e If you cannot reach your gas supplier call device which automatically lights the pilot the fire department Do not try to light the pilot by hand C Use only your hand to push in or turn the gas BEFORE LIGHTING smell all around the control knob Never use tools If the knob will appliance area for gas Be sure to smell next not push in or turn by hand don t try to repair it to the floor because some gas is heavier than call a qualified service technician Force or air and will settle on the floor attempted repair may result in a fire or explosion TO DO IF VOU SMELL GAS Donotuse this appliance if anv part has been Do not try to light any appliance under water Immediately call a qualified service Do not touch any electric switch do not technician to inspect the appliance and to use any phone in your building replace any part of the control system and any Immediately call your gas supplier from gas control which has been under water neighbor s phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS STOP Read the safety information above on 5 Remove fr
5. COMBUSTION EFFICIENCY RATING WITH OPTIONAL HIGH CAPACITY TANKLESS HEATER 1 1 1 1 2 2 103 138 172 207 241 276 345 79 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 e 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 e Where required by the authority having jurisdiction this installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSUASME CSD 1 latest edition Warning This Product Must be Installed By A Licensed Plumber Or Gas Fitter when Installed Within The Commonwealth Of Massachusetts If This Boiler is Equipped With a Tankless Heater Tankless Heater Piping Must be Installed by a Licensed Plumber When Boiler is Installed Within the Commonwealth of Massachusetts 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 B R Installation Guide for Residential Hydronic Heating Sy
6. CWI Series Gas Fired Natural Draft Water Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models WARNING Improper installation CWI069 CWI207 adjustment alteration service or maintenance can cause propertv 103 1241 damage injury or loss of For eCWI138 CWI276 assistance or additional informa tion consult a qualified installer 172 10 service the gas e CWI345 supplier Read these instructions CWI379 carefully before installing CROWN Boiler Co Manufacturer of Hydronic Heating Products P O Box 14818 36331 Street Philadelphia PA 19134 LISTED Tel 215 535 8900 Fax 215 535 9736 www crownboiler com Table of Contents L Product Description ences 1 IL Speciation ssa no eset ene H 2 M Before Installing eee ete 3 Locating the nice ient 3 V Airfor Combustion amp Ventilation 4 VI Ventifig ate cH HEUREUSE GE URNTEH 8 Gas Pip mie aede eL era eds VIII System Piping 12 IX Tankless Heater Piping essere 17 X Wiring MERI 19 XI Start Up amp Checkout sss 25 XII Service amp Maintenance 34 XIII Troubleshooting eren 36 AA M 43 Appendix A Kno
7. The following parts be obtained from Crown distributor To find the closest Crown distributor consult the area Crown representative or the factorv at Crown Boiler Co Customer Service P O Box 14818 Philadelphia PA 19134 www crownboiler com For boilers installed at elevations above 2000 ft consult the local Crown representative or the factorv for the correct main burner orifice DESCRIPTION CWI EXCHANGER 55 LESS TANKLESS HEATER OPENING CWI EXCHANGER 55 WITH TANKLESS HEATER OPENING l i i l BURNER TRAY 1 BURNERS BURNER TRAY 40mm BURNERS BASE FRONT PANEL ASSY INCLUDES INSULATION BURNER ACCESS PANEL BASE END INSULATION QTY OR CROWN 1 1 1 1 1 1 720601 QUANTITV PER BOILER CROWN 69 850013 750013 1ea e 138 850014 850015 750014 750015 1 1 2 25 3 4 4 700645 700665 700685 751685 700605 700625 2 2 3 3 700644 700664 700684 751684 700604 700624 2 700683 751683 700603 700623 700623 E o a p 172 207 241 276 310 345 3 79 850016 850017 850018 850019 850020 850021 850022 750016 750017 750018 750019 750020 750021 750022 tea tea tea te
8. T stat wires shorted Boiler w ater temperature has dropped below low limit setting Internal boiler wiring problem consult Crown representative Standing Pilot Ignition Svstem Troubleshooting Chart START 24 VOLTS PRESENT ACROSS TH AND TR Caution Read page 36 before ON GAS VALVE BUT MAIN BURNERS DO attempting to use this chart NOT LIGHT Ensure knob Main Y Does pilot Y on gas valve is burners i stav lit2 set toON light N N Turn control on Loose gas valve to thermocouple PILOT Depress Turn control connection at red button and on gas valve Defective gas gas valve light pilot Hold to ON valve button for at Defective least one thermocouple minute Condensation quenching pilot Disconnect thermocouple from gas valve Connect a volt meter to the thermocouple Light the pilot and hold down the red button while reading the voltage across the thermocouple Low line pressure Does pilot stay lit when red button is released Does pilot light Line pressure within the range N indicated on boilers rating plate7 Is voltage at M least 18mV Consult gas M supplier Pilot tubing blocked kinked or leaking or defective thermocouple connection at gas valve Defective thermocouple Pilot orifice blocked Pilot improperly adjusted Defective gas valve Gas line not
9. Test for spillage at the draft hood relief opening after five 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe 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 fireplace dampers and any other gas burning appliances to their previous condition of use 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 4223 1 LLALLA MW FIGURE 8 CWI BOILER TYPICAL VENTSYSTEM INSTALLATION AND COMPONENTS FIGURE 9 VENT DAMPER INSTALLATION DETAILS Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire 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 utilitv or Chapter 2 of the National Fuel Gas Code Figure 10 shows tvpical gas piping connection to the CWI boiler A sediment trap must be installed upstream of all gas controls Install a manual shut off valve outside the jacket and ground join
10. tea tea tea tea tea tea tea tea tea tea tea Tie 26 HEATER OPENING COVER PLATE 27003 tea 750007 750007 28 TANKLESS HEATER GASKET 27001 tea tea tea 29 3 8 USS FLAT WASHER 90038 30 13 8 16X 7 8 HX HEAD CAP SCREW 900450 Gea TANKLESS HEATER 1ea HIGH TANKLESS HTR 1ea NOT PICTURED 43 1 BURNER WITH PILOT BRACKET 0350 PILOT 150502 BURNER WITHPILOT EE Q327 NAT Q348 PILOTS 1 BURNER WITH PILOT BRACKET 150501 2ea 4 8ea 11 1 15 700162 12 ea 14 16 44 GAS ORIFICE 54 DRILL SIZE 950329 44 GAS ORIFICE 455 DRILL SIZE 950330 1 44 GAS ORIFICE 1 25 DRILL SIZE 950336 16 ea 45 LVE STND PILOT NAT GAS 3507010 EXCEPT 40mm BURNERS VR8200C6008 45 GAS VALVE STND PILOT NAT GAS 3507350 40mm BURNERS ONLY VR8200C6032 45 GAS VALVE E l NAT GAS 3507020 VR8204C60
11. Check the pilot line and any other gas piping disturbed during the inspection process for leaks Heat Exchanger Cleaning Procedure 1 Turn off electrical power and gas supply to the boiler 2 Disconnect the damper and vent connector from the boiler 3 Remove the upper front and top jacket panels If possible remove the rear and left side jacket panels 4 Remove the burners 5 Remove the blocked vent spill switch 6 Remove the 4 20 nuts and washers holding the flue collector onto the heat exchanger 7 Carefully remove the flue collector gasket strips and set them aside 8 Remove the flue collector from the heat exchanger 9 Clean the flue passageways using a stiff bristle brush Be certain that all foreign material is removed from the gaps between the pins 10 Clean the bottom surfaces of the heat exchanger 11 Puta light in the combustion chamber and look through the flue passages from the top to verify that they have been thoroughly cleaned 12 Replace the flue collector gasket strips If desired RTV silicone sealant with a 500F intermittent duty temperature may be substituted for this rope gasket The flue collector must be thoroughly sealed to the heat exchanger 13 Replace the 4 20 nuts and washers that hold down the flue collector 14 Reattach all the jacket components 15 Reinstall burners being careful to put the pilot main burner in its original location 16 Replace the blocked vent switch 17 Reco
12. Initiate call for heat 24 volts across TV and Z Defective damper 24 volts across gray wire on rollout sw itch and B2 24 volts across B1 on L8124E Defective damper harness 120 volts across 11 L2 Loose damper harness connection Obstruction in path of damper blade Boiler w ater temp above low limit setting 24 volts across standing pilot gas valve terminals or terminals 5 amp 6 on S8600 module Defective transformer in Defective 18124 18124 to standing pilot or intermittent ignition 24 volts troubleshooting chart page 41 or 42 Pow er off Blow fuse or 24 volts tripped breaker betw een pins 184 blue amp yellow Misw ired or 28 4 orange amp yellow on loose electrical damper end of damper connection in harness See 120V line Note 7 on page 36 across spill switch Chimney blockage Chimney system not constructed in accordance with Parts 7 and 10 of National Fuel Gas Code 24 volts across 24 volts across TV amp z Dow n draft Obstruction in path of damper blade Loose connection Defective betw een Loose electrical damper motor damper connection in 24 volt wiring Inadequate combustion air supply in boiler room harness and Defective Loose connection L8124E 18124 betw rollout betw een damper switch orB2
13. SHEET METAL SCREW HEAT EXCHANGER _ I A 20 CARRIAGE BULT 52 16 18 SELF TAPPING SCREW FIGURE A1 BASE HEAT EXCHANGER FLUE COLLECTOR ASSEMBLY 8 9 10 11 12 1 2 3 2 3 4 side panel installed in the previous step and secure with three 10 sheet metal screws Install the left side panel in the same manner as the right side Attach the front corners of the diverter panel to the side jacket panels using 10 sheet metal screws Install the horizontal angle jacket clips in the front edge of the side jacket panels Slide this clip through the rectangular slot that is about halfwav up the front edge of the side jacket panels and secure with the 8 32 self tapping screws provided Slip the Vertical Jacket Clip through the rectangular slot that is near the bottom of the front edge of the side jacket panels Secure with the 8 32 sheet metal screws provided Install the top jacket panel Use 10 sheet metal screws to attach it to the rear jacket panel and the top front corners of the side panels Install the upper front jacket panel Insert the flange on the top of this panel under the top panel Run two 10 sheet metal screws into the horizontal jacket clips through the holes in the bottom of this panel Attach the door knobs to the Lower Front Panel using 8 32 x 1 2 machine screws The labels have been applied at the factorv Verifv the location of the labels according to the list below
14. a half wave DC current at the pilot s ground strap This DC current flows through the boiler to the GND BURNER connection on the ignition module For the ignition module to recognize that a pilot flame is present the DC current flowing into this terminal must be in excess of approximately 1 0 uA Once the ignition module detects the presence of a pilot flame voltage is applied across the main valve terminals and opening the valve and establishing main flame The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot depends upon the exact ignition module supplied with the boiler For more information on module operation consult the ignition module instructions supplied with the boiler or the local Crown representative Sequence of Operation Intermittent Ignition With Tankless Heater 1 When the boiler is energized 24 volts is immediately applied to terminals 1 blue and 4 yellow on the vent damper 2 3 4 8 9 Assuming that there is no call for heat and that the damper switch is in the automatic position the damper will close If the boiler water temperature is less than the low limit setting minus the differential setting terminals and B in the L8124E are made through the low limit switch The low limit switching action is SPDT with R being common and are therefore open whene
15. follows 1 Relief valve Required Mount the relief valve on the right side of the boiler as shown in Figure using the 3 4 nipples and elbow provided The relief valve shipped with the boiler is set to open at 30 psi This valve may be replaced with one having a pressure up to the MAWP WATER shown on the rating plate If the valve is replaced the replacement must have a relief capacity in excess of the DOE heating capacity for the boiler Pipe the discharge of the 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 relief valve discharge is not piped to a drain it must terminate at least 6 inches above the floor Do not run relief valve discharge piping through an area that is prone to freezing The termination ofthe relief valve discharge piping must be in an area where it is not likely to become plugged by debris DANGER PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE DO NOT MOVE RELIEF VALVE FROM FACTORY LOCATION DO NOT PLUG RELIEF VALVE DISCHARGE 2 Circulator Required Although the circulator 1s shipped on the boiler return it can be installed on the boiler supply If the circulator is moved to the supply it should be positioned just downstream of the expansion tank as shown in Figure 11 Expansion Tank Required If this b
16. for use in diagnosing control problems To use these charts go to the box marked Start at the top of the chart on page 37 or 39 and follow the appropriate path though the chart until a box with a list of possible causes is reached If the problem is known to be within the ignition system go directly to the appropriate troubleshooting guide for the boiler standing pilot on page 41 or intermittent ignition on page 42 In using these charts the following should be kept in mind 1 2 3 4 These charts only meant to be used by a professional heating technician as an aid in diagnosing control problems Where applicable follow all precautions outlined in the appropriate lighting instructions on pages 29 32 In general these charts assume that there are no loose or miswired electrical connections Before using these charts inspect all electrical connections on the boiler to make sure that they are tight Also check the wiring on the boiler against the appropriate wiring diagram in Figures 18 21 The possible causes at the end of each branch in these charts are not listed in order of likelihood All controls on the CWI are tested at least once in the manufacturing process and a defective control or component is generally the least likely cause Before replacing a component try to rule out all other possible causes These troubleshooting charts assume that the vent damper is closed at the beginning of the troubleshooting
17. g purged of air Pilot tube blocked kinked or leaking Pilot improperly adjusted Pilot orifice partiall 41 Intermittent Ignition Svstem Troubleshooting Chart START 24 volts is present across 5 and 6 on S8600 module but main burners do not light Spark across ignitor sensor 58600 module Pilot M lights N 24 volts across terminals 2 amp 3 at 58600 24 volts across PV amp at gas valve Break in spark cable insulation Break in pilot porcelain Incorrect pilot spark gap Loose connection in spark cable Loose ground connection Defective EI wiring harness Low line pressure Plugged kinked or leaking pilot tubing Plugged pilot orifice Gas line not purged of air Defective pilot assembly Defective gas valve Defective Y Y S8600 module 42 spark stop when pilot Caution Read page 36 before attempting to use this chart Does lights across terminals 1 amp 2 on S8600 Defective 58600 module 24 volts between MV amp on gas valve Loose connection in ignition cable or ground wire harness Pilot electrode porcelain cracked Pilot flame not covering gap between electrode and grounding strap Defective gas valve Low gas pressure at gas valve inlet Defective S8600 module 5
18. 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 flue 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 flue serving an open fireplace 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 flush with inside fa
19. means that separate fill and expansion tanks are required for the heating system loop There are several other ways to connect low temperature systems to non condensing boilers like the CWI such as four way mixing valve and variable speed injection pumping systems Systems containing oxygen Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a cast iron boiler such as the CWI Some examples include e Radiant systems that employ tubing without an oxygen barrier e Svstems with routine additions of fresh water e Svstems which are open to the atmosphere If the boiler is to be used in such a system it must be separated from the oxygenated water being heated with a heat exchanger as shown in Figure 14 Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature requirements All components on the oxygenated side of the heat exchanger such as the pump and expansion tank must be designed for use in oxygenated water 13 FIGURE 11 STANDARD BOILER PIPING FIGURE 12 INDIRECT WATER HEATER BOILER SIDE PIPING 5 Piping with a Chiller If the boiler is used in conjunction with a chiller pipe the boiler and chiller in parallel as shown in Figure 15 Use isolation valves to prevent chilled water from entering the boiler 6 Air Handlers Where the boiler is connected to air handlers through which refrigerated air passes use flow control valves in t
20. or explosion may result causing property damage personal injury or loss of life A This appliance has a pilot which must be e If you cannot reach your gas supplier call lighted by hand When lighting the pilot follow the fire department these instructions exactly C Use only your hand to push in or turn the gas BEFORE LIGHTING smell all around the control knob Never use tools If the knob will appliance area for gas Be sure to smell next not push in or turn by hand don t try to repair it to the floor because some gas is heavier than call a qualified service technician Force or air and will settle on the floor attempted repair may result in a fire or explosion WHAT TO DO IF YOU SMELL GAS Do not use this appliance if any part has been Do not try to light any appliance under water Immediately call a qualified service Do not touch any electric switch do not technician to inspect the appliance and to use any phone in your building replace any part of the control system and any immediately call your gas supplier from gas control which has been under water a neighbor s phone Follow the gas supplier s instructions LIGHTING INSTRUCTIONS STOP Read the safety information above on 8 Turn Knob on gas control counterclockwise this label to PILOT Setthe thermostat to lowest setting Push down and hold the red reset button while you light pilot burner with a match After about one minute release reset button
21. ordered with the boiler has been provided by the factory Blocked Vent Switch Locate the two wires marked 8 Connect these wires to the terminals on the blocked vent switch it does not matter which of these wires is connected to which terminal on the blocked vent switch Install the strain relief provided in the hole in the jacket through which these wires pass Flame Roll Out Switch a Route the wire marked 10 through the bushing located on the left jacket panel and connect it to one side of the flame roll out switch b Route the wire marked 7 through the bushing located on the left jacket panel and connect it to the other side of the flame roll out switch Standing Pilot Gas Valve Honeywell VR8200 VR8300 or Robertshaw Model 7000ERHC S7C Connect wire 6 to the TH terminal on the gas valve Connect wire 5 to the TR terminal on the gas valve Note Boilers equipped with the Robertshaw 7000ERHC are also equipped with a Honeywell Model V8295 gas valve to provide redundancy This valve should be factory pre wired to the 7000 with one black lead connected to the terminal and the other black lead connected to the TR terminal on the 7000 gas valve Honeywell Intermittent Ignition System a Mount the 58600 series ignition control to the left side of the jacket just above the gas manifold using the standoff bracket supplied and 10 sheet metal screws b Locate the intermi
22. present across T and W when there is a call for heat AND the boiler water temperature high enough to satisfy the low limit e fnotalready done temporarily replace the thermostat across TV and T with a jumper If the boiler fires when this is done there is a problem with the thermostat or zone wiring e f24 volts is present across T and W and the relay in the L8148E L8124E does not pull in the relay in this control is probably defective Inspect the coil of this relay for visible heat damage If such damage is found there is a good chance that a second transformer is present in the thermostat or zone valve circuit resulting in the application of 48 volts across the relay coil In older buildings this transformer may be hidden in a location far from the boiler Ifthis second transformer exists it must be found and removed before the L8148E or L8124E is replaced 7 When checking voltage across damper harness pins be careful not to insert the meter probes into the pins Doing so may damage the pin resulting in a loose connection when the harness is reconnected 36 Troubleshooting Chart for CWI Boilers Without Tankless Heaters Caution Read page 36 before attempting to use this chart START N Boiler Equipped Thermostat With Damper calls for heat Pow er off 120 volts at L1 amp L2 24 volts across andR limit sw itch in 18148 Blow fuse tripped breaker
23. 00 45 GAS VALVE STND PILOT NAT GAS 3507110 EXCEPT 40mm BURNERS VR8300C4134 LVE STND PILOT NAT GAS 3507355 40mm BURNERS ONLY VR8300C4183 45 GAS VALVE NAT GAS 3507120 VR8304P4298 45 GAS VALVE STND PILOT NAT GAS 3507300 V8295A1024 3507305 QUANTITY PER BOILER OR CROWN P N KEY DESCRIPTION CROWN P N gt lt gt 45 O gt 2 lt gt 45 GAS VALVE STND PILOT NAT ROBERTSHAW 7000ERHC S7C 45 GAS VALVE NAT GAS ROBERTSHAW 7000DERHC 350310 45 GAS VALVE STND PILOT LP GAS 3507210 VR8200C6040 E PILOT LP GAS 3507220 VR8204C6018 45 GAS VALVE STND PILOT LP GAS 3507230 VR8300C4548 LP GAS 3507240 VR8304P4280 PILOT ASSY STND PILOT NAT GAS 3504050 Q350A1644 PILOT ASSY STND PILOT NAT GAS 3504005 Q327A1949 PILOT ASSY E l NAT GAS 35 4700 den m EIS Te m 0348 1275 l i 0327 1915 PILOT ASSY E I LP GAS 35 4600 0348 1259 HERMOCOUPLE 3501142 GNITION CABLE 3501136 48 JPILOTTUBINGT 49 1 8 SHORT FERRULE INCLUDED WITH 35 1600 GAS VALVE 392449 392449 4 l NAT GAS INCLUDED WITH PILOT l i 51 26 PILOT ORIFICE Q327 PILOT NAT 154 GAS INCLUDED WITH PILOT ASSY i 51 KF24 PILOT ORIFICE 0348 PILOT GAS INCLUDED WITH PILOT ASSY Tea 517 K14 PILOT ORIFICE 0327 PILOT LP GAS INCLUDED WITH PILOT ASSV 51a K16 PILOT ORIFICE 0348 PILOT
24. 4 Remove front access panel Pilot should remain lit If it goes out turn gas control knob clockwise to OFF To relight 5 Rotate the gas control knob clockwise 4 to OFF repeat steps 5 9 e If button does not pop up when released stop and immediately call your service technician or gas supplier e If the pilot will not stay lit after several tries 7 7 3 turn the gas control knob to call GASOUTLETI 1 7 your service technician or gas supplier gt E ag _ After pilot remains when red reset button is BAR GONTROLKNOB released turn gas control knob counterclockwise SHOWN IN POSITION Y to ON Turn off all electric power to the appliance RESET BUTTON GAS VALVE TOP VIEW 6 Wait five 5 minutes to clear out any gas Then Replace front access panel smell for gas including near the floor If you then smell gas STOP Follow B in the safety inform ation above on this label If you don t smell gas go to the next step T Find pilot follow metal pilot tube from gas control to pilot burner PILOT THERMO BURNER COUPLE Turn onall electric power to the appliance Set thermostat to desired setting TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 3 Push in gas control knob slightly and turn clockwise 4 to OFF Do not Force 2 Turn off all electric power to the appliance if servi
25. 6b MAIN BURNER FLAME 40mm ALTITUDE BURNERS WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER FIRING OF THE BOILER AND A CARBON MONOXIDEHAZARD 15 Check the manifold pressure and adjust 1f necessary To do this use the following procedure a b c d e Connect a manometer to the inlet pressure tap on the gas valve see Figures 27 and 28 Check the inlet pressure with all gas appliances on and off The inlet pressure at the boiler must be within the following limits regardless of what combination of appliances is firing Inlet Press inches w c Natural Gas LPGas Min 50 11 0 Max 14 0 13 0 If the inlet pressure falls outside of these limits find and correct the cause of the problem before proceeding further Connect a manometer to the manifold outlet pressure tap on the gas valve see Figures 27 and 28 Read the manifold pressure It should be set at Natural Gas LP Gas Manifold Press inches w c 3 5 10 0 If a manifold pressure adjustment is needed make the adjustment by turning the pressure regulator see Figures 27 and 28 screw clockwise to raise the pressure and counter clockwise to reduce the pressure If a manifold pressure adjustment is made recheck the line pressure to be certain that it is still within acceptable limits Replace the cover screw on the regulator 16 Test thermostat operation while the boiler is running Turn the thermostat to the lowest se
26. 73 850374 850375 850376 850377 850378 850379 850380 850381 850382 82 VESTIBULE PANEL HORIZONTAL JACKET CLIP 800340 VERTICAL JACKET CLIP 800341 85 10 1 2 SHEET METAL SCREW 90 212 28 ea 28 ea 28 ea 28 ea 28 ea 28 ea 86 DOOR KNOB 90 210 2ea 2ea 2ea 2ea 2ea 2ea 2ea 2ea 2ea 2ea 87 8 32 X 1 4 H W H SCREW 90 211 2 2 ea 2ea 2e 2 2 2 2 2 2 IGNITION MODULE E I BOILERS 35 5000 1ea 1ea 1ea 1ea 1ea 1ea 1ea 1ea 1ea 1 1 ala jo 010 e NATURAL GAS ONLY S8600F1000 e IGNITION MODULE E I BOILERS 35 5050 1 1 dea NATURAL OR LP GAS 58600 1013 kl MODULE BRACKET BOILERS 905000 1e 1 1e e 1e 1 1e 1 1 ea 88 VENT DAMPER 96 030 4 SHORT WELL LESS COIL BOILERS 35 1010 4 LONG WELL WITH COIL BOILERS 35 1020 tea tea Rat L8148E1257 LESS COIL 35 3000 1 1 1 1 90 JAQUASTAT L8124E1065 WITH 3503350 1 1e Tea Tea 91 TRIDICATOR GAUGE 95 069 3 4 RELIEF VALVE 30 psi 95 040
27. 8 CWI276 CWI379 WITH TANKLESS HTR 21 CWI207 CWI379 WITH HIGH CAPY TANKLESS HTR 24 SSK SSN D gt SSSA 27 LLL U eL 6 2 K 2 7 7 17 7 2 FIGURE2 CWI BOILERS CLEARANCESTOALL TYPESOFCOMBUSTIBLECONSTRUCTIONAND NONCOMBUSTIBLECEILINGS WALLS AND DOORS e Ifthe 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 The right side clearances shown for boilers equipped with tankless heaters allow for removal of the tankless heater 2 This boiler may be installed directly over a non carpeted combustible floor 3 boiler must be installed on a hard level surface 4 Donot install this boiler in a location where gasoline or other flammable 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 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 Sufficient fresh air must be supplied for combustion ventilation and flue gas dilution Provisions for combustion ventilation and flue gas dilution air for gas utilization equipment vented by natural draft must be made in accordance with local building
28. FORMANCE CRITERIA WERE MET WITH THE GAS MANIFOLD AND CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS SPECIFIED IN 721 13 Use the following procedure for initial start up of the boiler 1 Make sure that the boiler and system are filled with water 2 Check all new gas piping for leaks and purge piping sections that are filled with air See Part 4 of the National Fuel Gas Code for additional information on testing and purging gas lines 3 Verify that vent system is complete and free of obstructions before attempting to fire boiler 4 Inspect all wiring for loose or uninsulated connections 5 Make sure the main burners are seated properly in the rear of burner tray and on orifices 6 Adjust thermostat to the highest setting 7 Start the boiler using the appropriate lighting instructions for the gas valve on the boiler on pages 29 32 8 Upon initial start up the gas train will be filled with air Even if the gas line has been completely purged of air it may take several tries for ignition before a flame is established Once a flame has been established for the first time subsequent calls for burner operation should result in a flame on the first try 9 Observe pilot burner flame e See Figure 24 for standing pilot Pilot burner should produce single steady medium blue flame covering around 3 8 to gt of thermocouple tip e See Figure 25 for intermittent ignition Pilot burner produces three
29. GURES 18 21 TO TERMINAL TV IN L8I48E OR L8124E TO ADDITIONAL ZONE VALVE lt ENDSWITCHES USED TERMINAL T ON L8148E OR 18124 HEATING ZONE 1 24 VAC THERMOSTAT TR HONEYWELL VBO43F ZUNE VALVE 24 VOLT TRANSFORMER SEE TEXT FUSED DISCONNECT L20 6D 1 TO TERMINAL 117 ON L8148E OR L8124E NELITRAL TO TERMINAL L2 ON L8148E DR L8124E 120 VAC FIELD WIRING NOTE GROUND WIRING NOT SHOWN GROUNO IN 24 VAC FIELD WIRING ACCOROANCE WITH APPLICABLE CODES FIGURE 23 ZONE WIRING USING HONEY WELL V8043F ZONE VALVES FACTORY WIRING NOT SHOWN SEE FIGURES 18 21 CWI Control Svstem Sequence of Operation Refer to Figures 18 21 for ladder and connection diagrams Sequence of Operation Standing Pilot Less Tankless Heater 1 When the boiler is energized 24 volts is immediately applied to terminals 1 blue and 4 yellow on the vent damper 2 3 4 5 Assuming that there is no call for heat and that the damper switch is in the automatic position the damper will close A for heat from the thermostat energizes relay coil 1R the relay on the L8148E causing contacts and 1 R2 to make Contact IRI starts the circulator Contact IR2 sends power to the high limit Assuming that the high limit is made current will flow to pin terminal 2 orange at the vent damper and the damper will open Once the vent damper is fully open an end switch ins
30. Install in accordance with local codes and the backflow preventer s installation instructions Also install a potable water expansion tank on the outlet side of the backflow preventer between the backflow preventer and the piping shown in Figure 18 TANKLESS HEATER SHOWN WITH CONTROL REMOVED UNIONS FLOW RESTRICTOR PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE DISCHARGE SEE 3 BALL OR GLOBE VALVE 1 COLD WATER IN HOSE BIB VALVES FIGURE 17 TANKLESS HEATER PIPING IX Wiring WARNING 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 Single Zone Wiring 1 120 Volt Wiring The boiler should be provided with its own 15A branch circuit with fused disconnect All 120 volt connections are made inside the L8148E or L8124E aquastat relay as follows also see Figures 18 21 Hot black Terminal L1 Neutral white Terminal L2 Ground green or bare Ground screw on case of L8148E L8124E 2 Thermostat Wiring Follow thermostat manufacturer instructions To insure proper thermostat operation avoid installation 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 circu
31. LP 1 1 1 1 GAS INCLUDED WITH PILOT ASSY 45 O gt lt gt lt m 45 O gt lt gt lt B 1 ES 20 A gt n n lt 1 1 1 ea 1 47 1 1 1 1 ea 1 2 4 gt 0 n m 0 ie e 3 3 m 2 2 fm 2 T u I m 20 2 o A f 4 1ea 61 40 BURNER LESS PILOT BRACKET 150541 1 2 ea 62 MANIFOLD 40mm BURNERS 1 ea 701253 701254 701255 701256 701257 701258 701259 701260 MAIN BURNER ORIFICE CONSULT CROWN REPRESENTATIVE FOR 3 4 5 8 SIZE These Valves Piped in Series to Provide Redundent Shut off 1 4 Pilot Tubing Used with Robertshaw Valves B 3 3 les 2 2 A 5 5 u z 9 2 A m AR N 45 470 44 43 QTY OR QUANTITY PER BOILER OR CROWN BENT piu dien CROWNP N 69 103 138 172 207 241 310 34 5 76 RIGHT SIDE JACKET PANEL 1ea 850300 850300 850300 850300 8503002 8503002 8503002 8503005 8503005 8503005 PANEL TOP JACKET PANEL LOWER FRONT PANEL 1ea e FRONT PANEL 1ea 850354 850355 850357 850358 850360 850361 81 DIVERTER PANEL 1 8503
32. Less Tankless Heater 1 When the boiler is energized 24 volts is immediatelv applied to terminals 1 blue and 4 vellow on the vent damper 2 3 4 5 8 9 Assuming that there is no call for heat and that the damper switch is in the automatic position the damper will close A call for heat from thermostat energizes relay coil the relay on the L8148E causing contacts 1 R2 to make Contact IRI starts the circulator Contact IR2 sends power to the high limit Assuming that the high limit is made current will flow to pin terminal 2 orange at the vent damper and the damper will open Once the vent damper is fully open an end switch inside the damper will make energizing pin 3 red at the damper This pin is connected through the damper harness to terminal 1 on the L8148E At this point in the operating sequence 24 volts is present across B1 and B2 Under normal conditions the flame roll out switch and blocked vent switch are made Voltage will therefore immediately appear across the 24V and 24V GND terminals on the ignition module Upon application of voltage across the 24V and 24V GND terminals the ignition module will start an ignition spark at the pilot and apply 24 volts across the pilot valve terminals PV and MV PV Once the pilot is established the pilot flame will act as a diode converting the AC current at the electrode to
33. SURE REGULATOR UNDER SCREW GAS CONTROL KNOB FIGURE 27b GAS VALVE DETAIL ROBERTSHAW 7000 AND HONEY WELL V8295 STANDING PILOT PILOT ALIJLISTMENT OUTLET PRESSURE UNDER SCREW SIDE PILUT CONNECTION OUTLET PRESSURE REGULATOR UNDER SCREW GAS CONTROL KNDH FIGURE 28b GAS VALVEDETAIL ROBERTSHAW 7000DERHC INTERMITTENT IGNITION 33 Service and Maintenance The following routine maintenance should be performed on an annual basis 1 Turn off electrical power and gas supply to the boiler 2 Inspect the flue passages for signs of blockage If there is any carbon in the combustion chamber or the flue passages clean the heat exchanger before proceeding further See the cleaning procedure below 3 Remove any debris found in the combustion chamber being careful not to disturb combustion chamber insulation 4 Remove all burners noting the location of the pilot main burner If burners show signs of deterioration they should be replaced some discoloration around the burner ports is normal Clean the burners by first brushing the ports with a soft bristle brush and then vacuuming out any debris through the venturi opening 5 Inspect the pilot assembly Standing Pilots Check the thermocouple for deterioration some discoloration of the thermocouple is normal If any deterioration is present replace the thermocouple Inspect the pilot assembly for deposits and deterioration Cl
34. W gt TO00DERHC GAS VALVE LADDER DIAGRAM LEGEND 2 VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI310 CWI379 WHEN DAMPER IS NOT USED DAMPER HARNESS IS OMITTED AND TERMINAL B1 IS WIRED DIRECTLY TO FRS AS SHOWN IN LADDER DIAGRAM FIGURE 21 WIRING DIAGRAM INTERMITTENT IGNITION EI SYSTEM WITH TANKLESS HEATER Wiring Variations 1 Multiple Circulator Zones Figure 22 shows wiring for two or more circulator zones using Honeywell R845As One R845A 15 required for each circulator zone Circulator terminals C1 and C2 on the limit control are not used A DPST Honeywell RA832A may be substituted in place of the R845A using the X and X terminals in place of the 5 and 6 terminals on 845 A for heat from any thermostat will energize the DPST relay in that zone s 845 When this relay is energized electrical continuity is created between terminals 3 and 4 energizing the circulator for that zone At the same time electrical continuity is created between terminals 5 and 6 R845A creating a current path from terminal to TV on the limit control Assuming that the supply water temperature is below the high limit setting the normal ignition sequence will be initiated 2 Multiple Zones using Zone Valves Figure 23 shows wiring for multiple zones using Honeywell V8043F zone valves This wiring diagram may be used for other 24 volt zone val
35. a tea tea tea 751686 751687 751688 751689 751690 700606 700607 700608 700609 700610 700611 700612 700626 700627 700628 700629 700630 700631 700632 2 ea 2ea 2 2 BASE REAR INSULATION 11 12 13 14 15 88 x 3 4 SELF TAPPING SCREW 10 x 1 2 SHEET METAL SCREW 5 16 USS FLAT WASHER 5 16 18 LOCK NUT 16 18 x 1 1 4 SELF TAPPING SCREW RAFT DIVERTER ASSEMBLY 17 20 21 22 23 14 USS FLAT WASHER 24 14 20 WING NUT BLOCKED VENT SWITCH ASSY INCLUDES MOUNTING BRACKET A 2A 7 7 7 Lt 6 7 9 L 10 LU 12 L 13 4 L 15 1 17 L 18 p 20 L 21 22 L 23 24 90 048 90 212 900102 900103 900101 12 x 1 SEALING STRIP 900145 14 20 x 1 1 4 CARRIAGE BOLT 90 201 90 215 900125 960123 720603 720604 4 ea 20 ea 4 2 ft 720605 4 20 48 25 1 2 4 4 4 850124 3 3 ft 4 ea 2 4 4 4 850125 3 5 ft 4 ea 1 1 2 2 ea 720606 720607 720608 720609 720610 2 ea 720612 720611 4ea 4ea 4ea 4ea 4ea Gea
36. and harness and Defective gas valve or damper damper module harness Rollout switch open Replace with exact replacement see parts list Check for blocked heat exchanger 39 Circulator start setting Defective L8124E 120 volts at Main burners light Boiler w ater temperature exceeds high limit C1 amp C2 Remove t stat or zone valve end switch wires from T amp TV terminals on L8124E Install temporary jumper across terminals T and TV Does circulator run now Loose connection in t stat or zone valve end switch wiring Defective t stat or zone component T stat or zone system misw ired consult t stat or zone valve manufacturer s instructions 24 volts across T amp TV Defective L8124E see Note 6 on page 36 Boiler w ater temperature has dropped below low limit setting Do burners shut dow n before gage temp exceeds high limit setting 15F Do burner and circulator shut dow n at end of call for heat 120 volts across terminals at circulator Seized or defective circulator Bad electrical connection betw een C1 or C2 and circulator Defective L8124E Sensing bulb not bottomed out in boiler shut dow Pull wire off of T terminal on aquastat Does T stat or zone valve wiring calling for heat
37. as 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 finer than 8 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 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 floor 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 i
38. before gage temp exceeds high limit setting 15F 24 volts across standing pilot gas valve terminals or terminals 5 amp 6 on Defective damper Defective L8148E Defective damper harness Loose damper harness connection Obstruction in path of damper blade Defective L8148A Sensing bulb not bottomed out in w ell Refer to standing pilot or intermittent ignition troubleshooting chart page 41 or 42 Chimney blockage Chimney system not constructed in accordance w ith Parts 7 and 10 of National Fuel Gas Code Dow n draft Inadequate combustion air supply in boiler room Rollout sw itch open Replace with exact replacement see parts list Check for blocked heat exchanger 38 Do burner and circulator shut dow n at end of call for heat Pull w ire off of T terminal on aquastat Does boiler shut dow n T stat or zone valve wiring calling for heat T stat wires shorted Internal boiler wiring problem consult Crown representative Troubleshooting Chart for CWI Boilers Equipped with Tankless Heaters Dampers Caution Read page 36 before attempting to use this chart Allow boiler water temperature to reach low limit No call for heat Main burners boiler w ater temp at least 20F below low limit setting light differential setting
39. ce is to be performed 29 LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000ERHC SERIES GAS VALVES STANDING PILOT FOR VOUR SAFETV READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance has a pilot which must be lighted by hand When lighting the pilot follow these instructions exactly BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water LIGHTING INSTRUCTIONS STOP Read the safety inf
40. ce of the chimney liner and the space between vent pipe and chimney sealed tight 13 Do not install the vent damper in anv portion of the vent svstem which is used bv appliances other than the boiler being installed 14 Vent damper installation is mandatory on all CWI boiler models except the CW13 10 CW1379 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 94 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 using the plug supplied with the damper Mount the vent damper on the flue collar without modification 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 flexible conduit to the damper using a connector nut provided 4 Install vent connector pipe and vent fittings from ven
41. ce the ignition module detects the presence of a pilot flame voltage is applied across the main valve terminals MV and opening the valve and establishing main flame The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot depends upon the exact ignition module supplied with the boiler For more information on module operation consult the ignition module instructions supplied with the boiler or the local Crown representative 10 The boiler will fire until the boiler water temperature 15 approximately equal to the low limit setting Once the water temperature reaches this point and open and R and make At this point a call for heat from the thermostat will energize making contacts and 1 R2 Contacts energize the circulator Contacts I R2 switch current from the hot side of the transformer secondary to the high limit switch If the high limit is made current flows to terminal B1 and the ignition sequence is then the same as it is for a call for burner operation from the low limit see 3 above 24 Safetv Control Operation Standing Pilot and Intermittent Ignition High Limit Interrupts main burner operation when the supply water temperature exceeds set point Maximum allowable tempera ture is 250 F If the high limit opens the vent damper will close if the damper switch is in the automatic
42. ckdown Boiler Assembly 49 I Product Description The CWI series boilers are low pressure cast iron gas fired hot water boilers designed for use in closed hot water 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 flue gases must be available in the boiler room The CWI may be used on forced or gravity hot water heating systems It is available with an optional tankless heater for domestic hot water generation Specifications SUPPLY TAPPING TEMP PRESSURE GAUGE COMBINATION LIMIT 2 RETURN TAPPING ALTERNATE 2 RETURN FLOOR LINE LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW NOTE 2 TAPPINGS REDUCED 1 1 4 ON 1069 CWI276 2 TAPPINBS REDUCED 1 1 2 ON CWI310 FIGURE 1 CWI BOILERS GENERAL CONFIGURATION TABLE 1 CWI SPECIFICATIONS NATURAL OR LP GAS BASIC NUMBER HEATING I B R NET AFUE 96 TANKLESS BOILER OF INPUT CAPACITY RATING HTR RATING MODEL SECTIONS MBH MBH PILOT PILOT Gal min 1069 0 CWII03 m us 144 202 232 259 288 2 CWI207 CWI276 CWI1310 1345 CWI379 CWI345 AND CWI379 NOT AVAILABLE FOR USE WITH LP GAS
43. 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 flue gas dilution air supply start by determining whether the boiler is to be installed in a building of unusually tight construction A good definition of a building of unusually tight construction is one which has all of the following features e Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm less with openings gasketed and sealed e Weather stripping has been added openable windows and doors 1 2 3 1 e Caulking and sealants are applied to areas such as joints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines and at other openings For Buildings of Other than Unusually Tight Construction Determine whether the boiler is to be installed in a confined space A confined space is defined 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 18 a confined space 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 Fi
44. couple which generates a small amount of electricity sufficient to hold open the safety shut off valve in the combination gas control The circuit connecting the thermocouple and the safety shut off valve is self contained and completely independent of all other wiring on the boiler This safety shut off valve is upstream of the 24 volt valves in the gas control which open in response to a call for heat If the pilot is not lit the safety shut off valve will remain closed and gas will not reach the 24 volt valves Assuming that the pilot is established and proven by the thermocouple the application of 24 volts across the combination gas valve terminals energizes the redundant 24 volt solenoid valves in the combination gas control resulting in gas flow through the control and burner operation The boiler will fire until the boiler water temperature is approximately equal to the low limit setting Once the water temperature reaches this point and open and and W make At this point a call for heat will energize IR making contacts and 2 Contacts energize the circulator Contacts 182 switch current from the hot side of the transformer second ary to the high limit switch If the high limit is made current flows to terminal B1 and the ignition sequence is then the same as it is for a call for burner operation from the low limit see 3 above Sequenceof Operation Intermittent Ignition
45. ean or replace the pilot assembly as necessary e Intermittent Pilots Clean any deposits found on the electrode and grounding strap The ideal gap between the electrode and the ground strap is 1 8 Inspect the porcelain for cracks or other deterioration Replace pilot assembly if deterioration is found 6 Inspect the combustion chamber insulation for deterioration 7 Intermittent Pilot Boilers Inspect the ignition cable insulation for cracks or other deterioration If deterioration is found replace cable 8 Reinstall burners being careful to put the pilot main burner in its original location 9 Inspect all boiler wiring for loose connections or deterioration CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING 10 Inspect the vent system Make sure that the vent system is free of obstructions Make sure that all vent system supports are intact e Inspect joints for signs of condensate or flue gas leakage e nspect venting components for corrosion or other deterioration Replace any defective vent components 11 Inspect the boiler and hydronic system for leaks CAUTION WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPO NENTS REPAIR ANY LEAKS FOUND IMMEDIATELY 12 Place the boiler back in operation using the procedure outlined in Start up
46. er this is the same material used between the heat exchanger and base Install this gasketing on the top of the heat exchanger Figure A1 A few dabs of silicone may be used to keep this gasketing from shifting when the flue collector is installed 6 Install the flue collector as shown in Figure Al Secure with the 1 4 20 carriage bolt nuts and washers provided 7 Carefully inspect the joint between the flue collector and the heat exchanger to verify that the gasket is properly positioned 8 Install the blocked vent switch using the 8 sheet metal screw provided as shown in Figure A1 D Jacket Installation NOTE Before installing the jacket make sure to plug any tappings which are not going to be used Also make sure that no tappings are plugged which will be needed See Figure of this appendix as well as Part of the installation manual 1 Attach the diverter Panel to the vestibule panel using two 10 sheet metal screws Install these screws in the outside holes 2 Slip this diverter vestibule panel assembly behind the draft diverter opening in the draft diverter assembly Figure A2 Attach to the diverter assembly using 10 sheet metal screws 3 Attach the right side panel to the base and vestibule panel using four 10 sheet metal screws 4 Orient the rear jacket panel so that the two notches are up Slip the rear panel under the flange on the rear of the 49 FILE COLLECTOR 1 4 WING NUT 1 4 WASHER 80 X 1 2
47. es or more The mixing valve blends hot water leaving the tankless heater with cold water so as to maintain the hot water supplied to the fixtures at a fixed temperature This saves energy increases the amount of usable hot water available to the homeowner and reduces the risk of scalding Install a mixing valve with a setting range of approximately 110 to 130F Follow the manufacturer s instructions for installing this valve Usually heat trap will be required between the coil and the connection on the mixing valve 2 Flow Restrictor Recommended If water is drawn from the tankless coil at a rate in excess of the rating in Table 1 the temperature of the hot water may be too low to be of use The use of a flow restrictor will prevent this problem by limiting the rate at which water can pass through the tankless heater If a restrictor is used select one having a rating in GPM approximately equal to the rating shown in Table 1 If possible locate this restrictor at least 3 feet from the tankless heater inlet so that it is not subjected to excessive temperatures when no water is flowing through the coil 17 mixing valve does not eliminate the risk of scalding e Setthe mixing valve and boiler low limit adjustments as low as possible Feel water before showering or bathing If anti scald or anti chill protection is required use devices specificallv designed for such service Install and maintai
48. flames The center one should a steady medium blue flame covering around 3 8 to gt of spark electrode flame rod 25 COMBINATION IGNITION CENTER ELECTRODE SENSING GROUND STRAP FIGURE 24 STANDING PILOT FIGURE 25 INTERMITTENT IGNITION BURNER FLAME PILOT BURNER FLAME 10 Make sure vent damper is in open position when main burners are firing 11 Inspect the main burner flames visible through the observation port in burner access panel The flame should be stable and mostly blue see Figure 26 No yellow tipping should be present however intermittent flecks of yellow and orange in the flame are normal 12 Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is firing Fix any leaks found immediately WARNING NEVER USE A FLAME TO CHECK FOR GAS LEAKS MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS DAMPER MUST BE IN OPEN POSITION WHEN APPLIANCE MAIN BURNER IS OPERATING 13 Run gas valve safety shutdown test e For standing pilot boiler models disconnect the thermocouple from gas valve Both pilot burner and main burners should stop firing e For intermittent ignition boiler models with main burners firing disconnect ignition cable from ignition module Both pilot burner and main burners should stop firing FIGURE26a MAIN BURNER FLAME 1 BURNERS FIGURE 2
49. he boiler piping or other automatic means to prevent gravity circulation during the cooling cycle 7 Gravity Hot Water Systems The 1 is suitable for installation in a gravity hot water system Figure 16 shows piping for a gravity hot water boiler The circulator 1 1 2 x 2 bushings and 1 1 2 piping are removed and the system piping is run directly to the 2 supply and return tappings on the boiler If isolation valves are installed they should be gate valves or full port ball valves If it is desired to convert the gravity system to forced hot water the factory supplied circulator and piping are used as 18 A gravity hot water system is a large water volume system see 2 above and should be piped with a bypass as shown in Figure 13 Many gravity hot water systems have balancing orifice installed in the radiators These orifice may need to be removed to obtain proper heat distribution when the system is converted to forced hot water FIGURE 13 BOILER BYPASS PIPING 15 FIGURE 14 ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER FIGURE 15 BOILER PIPING WITH CHILLER FIGURE 16 GRAVITY PIPING IX TANKLESS HEATER PIPING If the CWI is installed with an optional tankless heater pipe the heater as shown in Figure 17 The components in this system and their functions are as follows 1 Mixing Valve Required During the heating season the water exiting the tankless heater may be 180 degre
50. hermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 30 3 Push in gas control knob slightly and turn clockwise 4 to OFF Do not Force LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8204 AND VR8304 SERIES GAS VALVES INTERMITTENT PILOT FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life If you cannot reach your gas supplier call A This appliance is equipped with an ignition the fire department device which automatically lights the pilot Do not try to light the pilot by hand C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do touch any electric sw
51. ide the damper will make energizing pin 3 red at the damper This pin is connected through the damper harness to terminal on the L8148E At this point in the operating sequence 24 volts 15 present across B1 and B2 Under normal conditions the flame roll out switch and blocked vent switch are made Voltage will therefore immediately appear across the combination gas control gas valve terminals and TR When the boiler is first placed into operation the pilot must be lit The pilot heats a thermocouple which generates a small amount of electricity sufficient to hold open the safety shut off valve in the combination gas control The circuit connecting the thermocouple and the safety shut off valve is self contained and completely independent of all other wiring on the boiler This safety shut off valve is upstream of the 24 volt valves in the gas control which open in response to a call for heat If the pilot is not lit the safety shut off valve will remain closed and gas will not reach the 24 volt valves Assuming that the pilot is established and proven by the thermocouple the application of 24 volts across the combination gas valve terminals energizes the redundant 24 volt solenoid valves in the combination gas control resulting in gas flow through the control and burner operation Sequence of Operation Standing Pilot With Tankless Heater 1 When the boiler is energized 24 volts is immediatel
52. irements in this installation manual B Base Assembly Preparation 1 The combination base burner manifold is shipped assembled from the factory The combination gas valve is shipped assembled and can be found in the Base Box 2 Smear a thin layer of silicone in several places across the top of the base to adhere the fiber gasket strip 3 Install the fiber gasket strip which was shipped in the Base Box Figure A1 4 Place the base assembly in the location where the boiler is to be installed Refer to Section III and in the installa tion manual for additional information on placement C Heat Exchanger and Flue Collector Installation 1 Position the heat exchanger above the base with the return connection located toward the front of the boiler and the lugs located on each end of the boiler centered over the studs which on each end of the base Figure 1 Lower the heat exchanger over the studs taking care not to disturb the studs which may push out if the heat exchanger comes in contact with them Also take care not to disturb the ceramic fiber gasket 2 Once the heat exchanger has been placed on the base inspect the gasket for proper seal Repair or replace gasket if necessary 3 Secure the heat exchanger with 5 16 lock nuts with nylon inserts and washers from the hardware bag 4 Loosen nuts on tie rods until they are finger tight 5 Fiber gasket strips are used to seal the flue collector to the heat exchang
53. it between thermostat and boiler Connect thermostat wire leads to terminals T and TV inside L8 148E aquastat relay NOTE 2 V8295A GAS VALVE CWI310 379 ONLY 1 2 VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI310 CWI379 WHEN DAMPER 15 NOT USED DAMPER HARNESS IS REPLACED WITH JUMPER PLUG FIGURE 18 WIRING DIAGRAM STANDING PILOTLESS TANKLESS HEATER 2 1 1 1 NT 1 1 1 1 4 15 mm m m mn MAIN VALVE PILOT VALVE HONEVWELL VR8204 VR8304 SERIES GAS VALVES 1069 345 ROBERTSHAW 7000DERHC GAS VALVE CWI379 NO 2 VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI310 CWI379 WHEN DAMPER IS NOT US DAMPER HARNESS IS REPLACED WITH JUMPER PLUG FIGURE 19 WIRINGDIAGRAM INTERMITTENTIGNITION EI SYSTEMLESS TANKLESS HEATER NOTE 2 HONEYWELL L8124E A LESS VENT L L N L 8295 V8295A DAMPER lt A fe GAS VALVE CWI310 379 ONLY a CWI310 379 ONLY DIAGRAM 1 2 VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI310 CWI379 WHEN DAMPER IS NOT USED DAMPER HARNESS IS OMITTED AND TERMINAL B1 IS WIRED DIRECTLY TO FRS AS SHOWN IN LADDER DIAGRAM FIGURE20 WIRING DIAGRAM STANDING PILOT WITHTANKLESS HEATER HONEVWELL L8124E HIGH LIMIT I jA 1 MAIN VALVE LESS VENT R DAMPER PILOT s 1069 345 3 ROBERTSHA
54. itch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS STOP Read the safety information above on 5 Remove front access panel this label Set the thermostat to lowest setting 6 Rotate the gas control knob clockwise 4 to OFF 7 Wait five 5 minutes to clear out any gas Then Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand smell for gas including near the floor If you then smell gas STOP Follow B in the safety inform ation above on this label If you don t smell gas go to the next step Rotate the gas control knob counter clockwise to ON GAS CONTROL KNOB SHOWN IN POSITION Replace front access panel Turn onall electric power to the appliance GAS INLET GAS OUTLET Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier GAS VALVE TOP VIEW TO TURN OFF GAS TO APPLIANCE 3 Push in gas control knob slightly and turn 1 Set the thermostat to lowest setting clockwise 4 to OFF Do not Force 2 Turn off all electric power to the appliance if service is to be performed 31
55. n these devices in accordance with the manufacturer s instructions Do not use the mixing valve substitute for pressure balancing valves or other devices required bv plumbing codes to protect against scalding 3 Pressure Relief Valve Required Limits the pressure in the tankless heater and piping Use an ASME constructed valve designed for domestic water service such as the Watts 3L Note that this is a pressure relief valve nota T amp P valve Select a valve with a pressure setting less than or equal to the working pressure marked on the tankless coil Pipe the discharge to a safe location using piping the same size as the discharge connection on the valve In Massachusetts terminate the relief valve discharge pipe 12 above the floor 4 Hose Bib Valves Recommended These valves permit the coil to be periodically backflushed to remove sediment 5 Globe or Ball Valve Recommended Used to adjust the flow through the entire tankless heater system if needed 6 Unions Required Tankless heaters may require periodic gasket replacement or other maintenance which requires removal of the heater from the boiler Install unions anywhere in the tankless heater piping that will facilitate removal of the heater 7 Backflow Preventer Required in Massachusetts If required by local codes install a backflow preventer in the cold water connection to the tankless coil just upstream of the piping shown in Figure 18
56. nch per 4000 BTU hr of the total input of all gas fired 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 fired appliances in the boiler room but not less than 100 square inches Minimum opening size is 3 inches 5 FIGURE 3 BOILERINSTALLED INCONFINED SPACE ALL AIR FROM INSIDE FIGURE4 ALL AIR FROM OUTDOORS VENTILATED CRAWL SPACE AND ATTIC FIGURE 5 ALL AIR FROM OUTDOORS VIA VENTILATED ATTIC FIGURE 6 ALL AIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM FIGURE 7 ALL AIRFROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM e free area of an opening takes into account the blocking effect of mesh grills and louvers Where screens used they must be no finer than 4 4 x 4 mesh 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 ANSIZ 223 1 A typical vent installation is illustrated by Figure 8 The components of vent installation are the vent damper vent connector and chimney 1 Acceptable Chimneys The following chimneys may be used to vent CWI series boilers Listed Type B or L gas vent Install in accordance with the manufacturer s instructions the te
57. nd the boiler with no intervening valves Set the manual reset high limit as far above the operating limit setting as possible but not over 240 F Wire the control to break the 120 VAC electrical supply to the boiler Flow Control Valve Required under some conditions The flow control valve prevents flow through the system unless the circulator is operating A flow control valve may be necessary on converted gravity systems to prevent gravity circulation Flow control valves are also used to prevent ghost flows in circulator zone systems through zones that are not calling for heat Isolation Valves Optional Isolation valves are useful if the boiler must be drained as they will eliminate having to drain and refill the entire system Drain Valve The drain valve is shipped in the boiler parts bag Install it in the tee under the circulator as shown in Figure 1 Piping for Special Situations Certain types of heating systems have additional requirements Some of the more common variations follow 1 2 3 4 Indirect Water Heaters Figure 12 shows typical indirect water heater piping Boiler piping is the same as for any two zone system Figure 12 shows circulator zoning which is usually preferred for indirect water heaters Size the circulator and indirect water heater piping to obtain the boiler water flow through the indirect water heater called for by the indirect water heater manufacturer Large Water Vol
58. nd 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 Divide the volume of the boiler room by the input in thousands of BTU hr Ifthe result is less than 50 the boiler room is a confined space Example CWII72EN 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 ofroom 6 25 ft x 7 ftx 8 ft 350 ft 350 202 1 73 Since 1 73 is less than 50 the boiler room is a confined space Unconfined Space Natural infiltration into the boiler room will normally provide adequate air for combustion and ventilation without additional louvers or openings into boiler room Confined Space Provide two openings into the boiler room one near the floor 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 floor Figure 3 Each opening must have a free area of 1 square inch per 1000 BTU hr input of all g
59. nnect the damper and vent system WARNING SOOT DEPOSITS IN THE FLUE PASSAGES ARE A SIGN THAT THE BOILER MAY BE OPERATING AT HIGH CARBON MONOXIDE CO LEVELS AFTER CLEANING THE BOILER OF SOOT DEPOSITS CHECK THE CO LEVEL IN THE FLUE GAS TO INSURE THAT THE BOILER IS OPERATING PROPERLY If it is necessary to check CO use a combustion analyzer or other instrument which is designed to measure CO in flue gas A CO sniffer designed for testing CO levels in ambient air cannot be used to check boiler combustion Take flue gas sample by inserting a sample probe through the draft diverter opening and into the flue collector so that the sample is taken in the area directly over the heat exchanger Do not take a sample until the boiler has been firing for at least five minutes A normal CO reading for a CWI series boiler is less than 50ppm 0 005 A reading of more than 100ppm 0 01 is indicative of a combustion problem Some causes of excessive CO include e ncorrectly sized main burner orifice for the altitude at which boiler is installed e Crooked or out of round orifice holes never attempt to drill orifice for this boiler in the field e Partially plugged flue passages e Improper manifold pressure Foreign material in burner venturis or burner ports e Leak in seal between flue collector and heat exchanger e Inadequate supply of combustion air 35 XIII Troubleshooting The following pages contain troubleshooting charts
60. oiler is replacing an existing boiler with no other changes in the svstem the old expansion tank can generally be reused If the expansion tank must be replaced consult the expansion tank manufacturer s literature for proper sizing 3 4 Fill Valve Required Either a manual or automatic fill valve may be used The ideal location for the fill is at the expansion tank Automatic Air Vent Required At least one automatic air vent is required Manual vents will usually be required in other y q parts ofthe system to remove air during initial fill 2 6 8 9 10 Low Water Cut Off Required in some situations A low water cutoff is required when the boiler is installed above radiation In addition some codes such as ASME CSD 1 require low water cutoffs Codes may also require that this low water cutoff have a manual reset function The low water cutoff may be a float type or probe type but must be designed for use in a hot water system The low water cutoff should be piped into the boiler supply just above the boiler with no intervening valves between it and the boiler Use a low water cutoff that breaks the 120 VAC supply to the boiler Do not attempt to wire a 24 volt low water cutoff into the boiler factory wiring Manual Reset High Limit Required by some codes This control is required by ASME CSD 1 and some other codes Install the high limit in the boiler supply piping just beyo
61. ont access panel this label Set the thermostat to lowest setting 6 Rotate the gas control knob clockwise lt 4 to OFF 7 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then This appliance is equipped with an ignition smell gas STOP Follow B in the safety inform device which automatically lights the pilot ation above on this label If you don t smell gas Do not try to light the pilot by hand go to the next step Turn off all electric power to the appliance Rotate the gas control knob counter clockwise POSITION gt to ON INDICATOR Replace front access panel Turn on all electric power to the appliance UNO Set thermostat to desired setting 4 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier GAS CONTROLKNOB SHOWN IN OFF POSITION TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 3 Push in gas control knob slightly and turn clockwise 4 to OFF Do not Force 2 Turn off all electric power to the appliance if service is to be performed 32 7000 DUTLET PRESSURE THERMOCOUPLE TAP S PILOT ADJUSTMENT UNDER CAP SCREW GAS INLET PILOT CONNECTION INLET PRESSURE TAP ON SIDE HONEYWELL 295 PRES
62. ormation above on this label Set the thermostat to lowest setting Turn off all electric power to the appliance Remove front access panel Rotate the gas control knob clockwise POSITION INDICATOR 4 GAS CONTROL KNOB SHOWN IN OFF POSITION Wait five 5 minutes to clear out gas Then smell for gas including near the floor If vou then smell gas STOPI Follow B in the safetv inform ation above on this label If vou don t smell gas go to the next step Find pilot follow metal pilot tube from gas control to N pilot burner PILOT THERMO BURNER COUPLE a to OFF 8 Turn Knob gas control counterclockwise x to PILOT Push down and hold the Knob while you light pilot burner with a match After about one minute release reset button Pilot should remain lit If it goes out turn gas control knob clockwise 4 to OFF To relight repeat steps 5 9 e If button does not pop up when released stop and immediately call your service technician or gas supplier e If the pilot will not stay lit after several tries turn the gas control knob to OFF and call your service technician or gas supplier After pilot remains lit when red reset button is released turn gas control knob counterclockwise to front access panel Turn onall electric power to the appliance Set thermostat to desired setting TO TURN OFF GAS TO APPLIANCE 1 Set the t
63. position The circulator will continue to operate as long as there is a call for heat regardless of the status of the high limit if the boiler is equipped with a tankless coil the low limit switch will prevent the circulator from operating if the boiler water temperature is too low Burner operation automatically resumes when the supply water temperature falls below set point Blocked Vent Spill Switch Automatically interrupts main burner operation in the event that flue gas spills from the draft diverter opening This switch is equipped with a reset button which must be pressed to restore normal burner operation An open blocked vent switch is indicative of a problem with the vent system If the blocked vent switch opens the cause of the venting problem must be found and corrected by a qualified gas service technician before the blocked vent switch is reset Flame Roll out Switch Automatically interrupts boiler operation when flames or excessive heat are present in vestibule The flame roll out switch is a single use device which must be replaced by an identical switch in order to restore normal operation An open flame roll out switch is usually indicative of a plugged heat exchanger The cause of the flame roll out must be found and corrected by a qualified gas service technician and the switch replaced with an identical one before the boiler is returned to operation Start up and Checkout NOTE SAFE LIGHTING AND OTHER PER
64. process With the 120 volts applied to the boiler and no call for heat the damper should go to the closed position If it does not do the following e Confirm that 120 volts is applied to the boiler and that there is no call for heat Make sure that the switch on the damper is in the automatic position e Unplug the harness from the damper and check for 24 volts across pin 1 blue and pin 4 yellow e f voltage is present the damper is defective or there is an obstruction in the path of the damper blade fno voltage is present there 18 either a loose connection in the damper harness or the limit control L8148E or L8124E 18 defective Ifthe charts indicate that the L8148E or L8124E 18 defective do the following before replacing it e Check for 24 volts across TV and Z If no voltage is present the transformer in L8148E or L8124E is defective It is possible that this transformer has been destroyed by a short circuit in the boiler wiring Before replacing the control carefully inspect all low voltage wiring on the boiler for places where it is touching the frame ofthe boiler or wiring on the other side ofthe transformer e 1124 volts is present across and Z check for 24 volts between T W On L8148Es if no voltage is present make sure that the brass jumper is present between W and Z and that the screws holding this Jumper in place are both tight If the boiler is equipped with a L8124E voltage will only be
65. rms 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 CWI series boiler into an unlined chimney 2 Acceptable Vent Connectors The following may be used for vent connectors e Listed type B or L Gas Vent e 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 Insome very restrictive cases CWI 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 e Anexterior masonry chimney may be used if it is lined with vent or a listed chimney lining system 5 This boiler may be vented using a listed power venter The power venter must be in sized and
66. stems Pub 200 and I B R Heat Loss Calculation Guide Pub H21 or 22 published by the Hydronics Institute in Berkeley Heights NJ 4 Make sure that the boiler received 1s configured for the correct gas natural or LP The CWI345 and CWI379 may only be used with natural gas 5 Boilers installed at altitudes above 2000 ft may require different burners and main burner orifice than those at sea level Make sure that the boiler is configured for use at the correct altitude 6 Ifthis boiler was received as a knockdown boiler follow the instructions in Appendix A to assemble the boiler IV Locating the Boiler 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 Sizes without Tankless Heaters 18 CWI103 CWI207 with Tankless Heater 18 CWTD241 CWI379 with Standard Tankless Heater 21 CWD4A1 CWI379 with High Capacity Tankless Heater 24 Left Side 6 Rear 6 Top 17 e A24 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 difficult as these service clearances are reduced EEE X RH CLEARANCE ALL SIZES LESS TANKLESS HEATER 18 CWI103 CWI241 WITH TANKLESS 1
67. t 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 b 4 8 Seal any unused opening in the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 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 fireplace dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so the appliance will operate continuously
68. t 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 svstem during anv pressure testing of that svstem at pressures in excess of 1 2 psi When pressure testing the gas svstem at pressures of 1 2 psi or less isolate the boiler from the gas supplv svstem closing its individual manual shut off valve State of Massachusetts Requires Manual FIGURE 10 GASCONNECTIONTOBOILER System Piping 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 OPERATION OF THIS BOILER WITH CONTINUOUS RETURN TEMPERATURES BELOW 120 F CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE DO NOT USE TOXIC ADDITIVES SUCH AS AUTOMOTIVE ANTIFREEZE IN A HYDRONIC SYSTEM Standard Piping Figure 11 shows typical boiler system connections on a single zone system Additional information on hydronic system design may be found in Installation of Residential Hydronic Systems Pub 200 published by the Hydronics Institute in Berkeley Heights NJ The components in this system and their purposes are as
69. the tridicator gauge into tapping Tighten with wrench applied to the square shank on the back of the gauge Do not apply pressure on the gauge case since this may ruin the calibration of the gauge Install relief valve spindle must be in vertical position into tapping H on the boiler left side See Figure in the installation manual using the 94 NPT nipples and elbow supplied 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 The safety valve discharge piping must be in an area where it is not likely to become plugged by debris or subjected to freezing Install the 1 1 2 return piping and circulator in tapping D See Section VIII System Piping in the installation manual for instructions on completing the piping of this boiler 51 294 19044 49 01 10194 19915 BUD4 Ja4JaAI 071 Olf 9004 2 414524 qouy 2000 Javod apis 34014 9004 4U044 4840 Buiddo 4113 3 921342 1 2 1 8 904 3pIS 439 0113 10102140 2 P H 2 A 2 2 QO 3 52 1 2 3 4 F Electrical Wiring Connections Also refer to wiring diagrams in Part X of the installation manual A pre wired limit control L8148E 1 8124 specific to the control package
70. ttent ignition harness plugged into the gas valve assembly This harness has red blue and yellow wires and has molex plugs on both ends Plug the loose end of the harness into the S8600 module c Plugthe green burner ground wire numbered 4 to terminal 4 on the S8600 Check that the ground wire has been routed under the burners and that the other end is attached to the pilot assembly under the lower mounting screw d Plugthe red wire with the yellow trace numbered 5 to terminal 5 on the S8600 module Plug the black wire with the white trace numbered 6 to terminal 6 the S8600 module f Plug the orange Pilot Ignition Cable numbered 9 to terminal 9 on the 58600 module Verify that this cable has been routed under the burners and that the other end is plugged onto the pilot assembly electrode G Complete Installation Follow the instructions that start on page 1 of this manual to complete boiler installation 53 TANKLESS HEATER PENING NITH TANKLESS HEATER BOILERS ONLY H IN PLATE WHEN TANKLESS HEATER IS USED LEFT SIDE VIEV RIGHT SIDE VIEW FIGURE TAPPING LOCATIONS SEE FOR TAPPING USES AA vy 4 Boiler Manufacturer of Hydronic Heating Products Box 14818 3633 I Street Philadelphia PA 19134 Tel 215 535 8900 Fax 215 535 9736 www crownboiler com
71. tting For standing pilot boiler models pilot burner should remain lit but the main burners should stop firing For intermittent ignition boiler models both pilot burner and main burners should stop firing Raise the thermostat back to the highest setting The main burners for standing pilot boiler models or pilot burner and main burners for intermittent ignition boiler models should relight 17 Verifv high limit operation Allow the boiler water temperature to increase to hi limit setting The burners should shut down and the circulator continue running For standing pilot boiler models pilot burner should remain lit but the main burners should stop firing For intermittent ignition boiler models both the pilot burner and main burners should stop firing 18 Allow the boiler water temperature to drop below high limit setting 19 The main burners for standing pilot boiler models or pilot burner and main burners for intermittent ignition boiler models should relight 20 After the boiler has operated for approximatelv 30 minutes check the boiler and heating svstem piping for leaks Repair anv leaks found at once 21 Inspect the vent svstem for flue gas leaks Repair anv leaks found before leaving the boiler in operation LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8200 AND VR8300 SERIES GAS VALVES STANDING PILOT FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire
72. ume Systems The piping shown in Figure 13 will minimize the amount of time that the boiler operates with return temperatures below 120 F on these systems A bypass is installed as shown to divert some supply water directly into the return water The bypass pipe should be the same size as the supply The two throttling valves shown are adjusted so that the return temperature rises above 120 F during the first few minutes of operation A three way valve can be substituted for the two throttling valves shown If the circulator is mounted on the supply the bypass must be on the discharge side of the circulator Low Temperature Systems Some systems such as radiant tubing systems require the system water temperature to be limited to a value below the temperature of the water leaving the CWI These systems also typically have return temperatures well below the 120 F minimum Figure 14 illustrates the use of a heat exchanger to connect the CWI boiler to this type of system The heat exchanger will permit the transfer of heat from the boiler water to the low temperature system while holding the system supply and boiler return temperatures within their limits For this system to work properly the heat exchanger must be properly sized and the correct flow rates are required on either side of the heat exchanger Consult the heat exchanger manufacturer for sizing information The water in the boiler is completely isolated from the water in the system This
73. ver R and are made This means that while and are made relay coil RI is deenergized regardless of whether or not there is a call for heat The circulator will therefore not operate if the boiler water temperature 18 too low to generate domestic hot water Assuming that the high limit is made current will flow to terminal B1 on the L8124E and then to terminal 2 orange at the vent damper and the damper will open Once the vent damper is fully open an end switch inside the damper will make energizing pin 3 red at the damper The red wire from this pin runs to the flame rollout switch Under normal conditions the flame roll out switch and blocked vent switch are made Voltage will therefore immediately appear across the 24V and 24V GND terminals on the ignition module Upon application of voltage across the 24V and 24 GND terminals the ignition module will start an ignition spark at the pilot and apply 24 volts across the pilot valve terminals and MV PV Once the pilot is established the pilot flame will act as a diode converting the AC current at the electrode to a half wave DC current at the pilot s ground strap This DC current flows through the boiler to the GND BURNER connection on the ignition module For the ignition module to recognize that a pilot flame is present the DC current flowing into this terminal must be in excess of approximately 1 0 uA On
74. ves as long as they are equipped with end switches Do not attempt to use the transformer on the limit control to power the zone valves use a separate transformer Up to five V8043Fs may be powered by one 48VA transformer such as the Honeywell AT87A A call for heat from a given thermostat will result in the application of 24 volts across the TH and TR terminals on the corresponding zone valve energizing the zone valve motor The zone valve opens and the end switch contacts are then made The end switches are connected in parallel with each other and to the T and TV thermostat connections so that any zone valve that opens will also start the circulator and fire the boiler assuming the high limit is not open Zone valve terminal TH TR has no internal connection on the zone valve it is merely a binding post used to connect two or more wires 21 ZUNE 1 ZUNE 42 1 TERMINALS Cl AND C2 NOT USED FUSED DISCONNECT ON LB148E OR L8124E BOILER 120 60 1 HOT LIMIT CONTROL POWER SUPPLY NEUTRAL 2 GROUND WIRING NOT SHOWN GROUND IN ACCORDANCE WITH APPLICABLE CODES NOTE 120 VAC FIELD WIRING 24 VAC FIELD WIRING heal CIRCULATOR CIRCULATOR TO TERMINAL Ll ON LBI48E OR L8124 TO TERMINAL L2 ON L814BE OR L8124E FIGURE 22 CIRCULATOR ZONE WIRING USING HONEY WELL R845As FACTORY BOILER WIRING NOT SHOWN SEE FI
75. y applied to terminals 1 blue and 4 yellow on the vent damper 2 3 4 5 8 Assuming that there is no call for heat and that the damper switch is in the automatic position the damper will close If the boiler water temperature is less than the low limit setting minus the differential setting terminals R and B in the L8124E are made through the low limit switch The low limit switching action 15 SPDT with being common and are therefore open whenever R and are made This means that while and are made relay coil R1 is deenergized regardless of whether or not there is a call for heat The circulator will therefore not operate if the boiler water temperature is too low to generate domestic hot water Assuming that the high limit is made current will flow to terminal B1 on the L8124E and then to terminal 2 orange at the vent damper and the damper will open Once the vent damper is fully open an end switch inside the damper will make energizing pin 3 red at the damper The red wire from this pin runs to the flame rollout switch Under normal conditions the flame roll out switch and blocked vent switch are made Voltage will therefore immediately appear across the combination gas control gas valve terminals TH and TR When the boiler is first placed into operation the pilot must be lit The pilot heats a thermo

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