D E S I G N E D T L O E A D CWI Series Gas-Fired Natural Draft Water Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models: • CWI069 • CWI103 • CWI138 • CWI172 • CWI207 • CWI241 • CWI276 • CWI310 • CWI345 • CWI379 WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life.
Table of Contents I. Product Description .................................................. 1 II. Specifications ............................................................. 2 III. Before Installing ......................................................... 3 IV. Locating the Boiler ...................................................... 3 V. Air for Combustion & Ventilation .............................. 4 VI. Venting ....................................................................... 8 VII.
II Specifications FIGURE 1: CWI BOILERS - GENERAL CONFIGURATION TABLE 1: CWI SPECIFICATIONS NATURAL OR LP GAS * HEATING I=B=R NET AFUE (%) STNDG. INT. RATING CAPACITY (MBH) PILOT PILOT (MBH) 50 57 81.0 83.1 BASIC BOILER MODEL NUMBER OF SECTIONS CWI069 3 69 12 3/4 28 40 7/16 4 7.8 CWI103 4 103 86 75 81.3 83.1 2.50 16 28 40 7/16 5 10.0 CWI138 5 138 115 100 81.6 83.1 3.00 19 1/4 28 40 7/16 6 12.2 CWI172 6 172 144 125 81.8 83.2 3.50 22 1/2 28 40 7/16 6 14.
III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction. • 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.
“X” (RH CLEARANCE) ALL SIZES LESS TANKLESS HEATER - 18“ CWI103 - CWI241 WITH TANKLESS HTR. - 18“ CWI276 - CWI379 WITH TANKLESS HTR. - 21“ CWI207 - CWI379 WITH HIGH CAPY. TANKLESS HTR. - 24“ “X” FIGURE 2: CWI BOILERS - CLEARANCES TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS, WALLS, AND DOORS. • If the 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.
• 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.
FIGURE 3: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC 76
FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 87
• 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 ¼” (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/ANSI Z 223.1. A typical vent installation is illustrated by Figure 8. The components of vent installation are the vent damper, vent connector and chimney.
sealed tight. 13) Do not install the vent damper in any portion of the vent system which is used by appliances other than the boiler being installed. 14) Vent damper installation is mandatory on all CWI boiler models except the CWI310-CWI379. 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.
FIGURE 8: CWI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS FIGURE 9: VENT DAMPER INSTALLATION DETAILS 11 10
VII 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 utility or Chapter 2 of the National Fuel Gas Code. Figure 10 shows typical gas piping connection to the CWI boiler. A sediment trap must be installed upstream of all gas controls.
VIII 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, ETC.). • 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.
6) 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.
FIGURE 11: STANDARD BOILER PIPING FIGURE 12: INDIRECT WATER HEATER BOILER SIDE PIPING 15 14
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 the boiler piping or other automatic means to prevent gravity circulation during the cooling cycle.
FIGURE 14: ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER FIGURE 15: BOILER PIPING WITH CHILLER 17 16
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 degrees 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.
WARNING A mixing valve does not eliminate the risk of scalding. • Set the 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 specifically designed for such service. Install and maintain these devices in accordance with the manufacturer’s instructions.
IX Wiring WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70). Single Zone Wiring 1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect.
(NOTE 2) 2 HONEYWELL VR8204/VR8304 SERIES GAS VALVES (CWI069 - 345) TH + TR ROBERTSHAW 7000DERHC GAS VALVE (CWI379) 2. VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI310 - CWI379. WHEN DAMPER IS NOT US DAMPER HARNESS IS REPLACED WITH JUMPER PLUG. FIGURE 19: WIRING DIAGRAM, INTERMITTENT IGNITION (EI) SYSTEM LESS TANKLESS HEATER (NOTE 2) HONEYWELL L8124E HIGH LIMIT 2 LOW LIMIT V 8 29 5 A (CW I3 1 0 -3 7 9 O N LY) LESS VENT DAMPER L N 2. VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI310 - CWI379.
(NOTE 2) HONEYWELL L8124E HIGH LIMIT 2 LOW LIMIT H O N E Y W E LL V R 82 04/V R 83 04 S E R I E S G A S VA LV E S (C W I06 9 - 345) TH TR + MAIN VALVE LESS VENT DAMPER PILOT VALVE R O BER TSH AW 70 00D E R H C G A S VA LV E (C W I37 9) 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.
FIGURE 22: CIRCULATOR ZONE WIRING USING HONEYWELL R845As (FACTORY BOILER WIRING NOT SHOWN - SEE FIGURES 18 - 21) FIGURE 23: ZONE WIRING USING HONEYWELL V8043F ZONE VALVES (FACTORY WIRING NOT SHOWN - SEE FIGURES 18 - 21) 23 22
CWI Control System – 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. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will close.
Sequence of Operation, Intermittent Ignition, 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. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will close. 2) A call for heat from the thermostat energizes relay coil 1R (the relay on the L8148E), causing contacts 1R1 and 1R2 to make. Contact 1R1 starts the circulator.
Safety Control Operation - Standing Pilot and Intermittent Ignition High Limit - Interrupts main burner operation when the supply water temperature exceeds set point. Maximum allowable temperature is 250°F. If the high limit opens, the vent damper will close if the damper switch is in the “automatic” position.
FIGURE 24: STANDING PILOT BURNER FLAME FIGURE 25: INTERMITTENT IGNITION 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.
FIGURE 26b: MAIN BURNER FLAME - 40mm (“HIGH ALTITUDE”) BURNERS FIGURE 26a: MAIN BURNER FLAME - 1” BURNERS WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER-FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD. 15) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a) Connect a manometer to the inlet pressure tap on the gas valve (see Figures 27 and 28). b) Check the inlet pressure with all gas appliances on and off.
16) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. 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.
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 or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. If you cannot reach your gas supplier, call the fire department. C.
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000ERHC SERIES GAS VALVES (STANDING 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 has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. If you cannot reach your gas supplier, call the fire department. C.
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. A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. If you cannot reach your gas supplier, call the fire department. C.
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 device which automatically lights the pilot. Do not try to light the pilot by hand. If you cannot reach your gas supplier, call the fire department. C.
FIGURE 27a: GAS VALVE DETAIL - HONEYWELL VR8200 OR VR8300 (STANDING PILOT) FIGURE 27b: GAS VALVE DETAIL - ROBERTSHAW 7000ERHC AND HONEYWELL V8295 (STANDING PILOT) FIGURE 28a: GAS VALVE DETAIL - HONEYWELL VR8204 AND VR8304 (INTERMITTENT IGNITION) FIGURE 28b: GAS VALVE DETAIL - ROBERTSHAW 7000DERHC (INTERMITTENT IGNITION) 34 33
XI 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.
Heat Exchanger Cleaning Procedure 1) 2) 3) 4) 5) 6) 7) 8) 9) Turn off electrical power and gas supply to the boiler. Disconnect the damper and vent connector from the boiler. Remove the upper front and top jacket panels. If possible, remove the rear and left side jacket panels. Remove the burners. Remove the blocked vent (“spill”) switch. Remove the ¼-20 nuts and washers holding the flue collector onto the heat exchanger. Carefully remove the flue collector gasket strips and set them aside.
XIII Troubleshooting The following pages contain troubleshooting charts 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).
Troubleshooting Chart for CWI Boilers Without Tankless Heaters Caution: Read page 36 before attempting to use this chart START N Thermostat calls for heat Circulator start? Boiler Equipped With Damper? Y Vent damper open? Y Y N N *Pow er off N *Blow n fuse or tripped breaker *Misw ired or loose electrical connection in 120V line 120 volts at L1&L2? 24 volts across B and R (limit sw itch) in L8148E ? Y 120 volts at C1&C2? 120 volts across terminals at circulator? Y N Remove t'stat or zone va
Main burners light? Do burners shut dow n before gage temp exceeds high limit setting +15F? Y Do burner and circulator shut dow n at end of call for heat? Y N N 24 volts across B1 &B2? Y END N *Defective damper N *Defective L8148E *Defective damper harness Y *Loose damper harness connection 24 volts across standing pilot gas valve terminals or terminals 5&6 on S8600 module? *Defective L8148A *Sensing bulb not bottomed out in w ell *Obstruction in path of damper blade Y Refer to standing pi
Troubleshooting Chart for CWI Boilers Equipped with Tankless Heaters and Dampers Caution: Read page 36 before attempting to use this chart START No call for heat, boiler w ater temp.
Do burners shut dow n before gage temp exceeds high limit setting +15F? Y Circulator start? Main burners light? N Y Y Do burner and circulator shut dow n at end of call for heat? N Y END N N *Boiler w ater temperature exceeds high limit setting *Defective L8124E * Defective L8124E 120 volts at C1&C2? 120 volts across terminals at circulator? Y N N Y Remove t'stat or zone valve end sw itch w ires from T&TV terminals on L8124E. Install temporary jumper across terminals T and TV.
Standing Pilot Ignition System Troubleshooting Chart START (24 VOLTS PRESENT ACROSS TH AND TR ON GAS VALVE, BUT MAIN BURNERS DO NOT LIGHT) Y Pilot lit? Ensure knob on gas valve is set to ON Caution: Read page 36 before attempting to use this chart Main burners light? Y Does pilot stay lit? N N Turn control on gas valve to PILOT. Depress red button and light pilot. Hold button for at least one minute. Turn control on gas valve to ON.
Intermittent Ignition System Troubleshooting Chart START (24 volts is present across 5 and 6 on S8600 module, but main burners do not light) Spark across ignitor/sensor gap? Y Pilot lights? Does spark stop when pilot lights? Y N N Y N 24 volts across PV & MV/PV at gas valve? N Y *Defective S8600 module 24 volts between MV & MV/PV on gas valve? N N Y *Break in spark cable insulation END N *Defective S8600 module Y Y 24VAC across terminals 1&2 on S8600? N *Faulty S8600 module Main bur
XIV PARTS The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area Crown representative or the factory 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 factory for the correct main burner orifice.
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KEY # 41 41 41 42 43 44 44 44 44 44 44 44 45 45 45 45 DESCRIPTION 1" BURNER WITH PILOT BRACKET (Q350 PILOT) 1" BURNER WITH PILOT BRACKET (Q327 NAT, Q348 PILOTS) 1" BURNER WITH PILOT BRACKET (Q327 LP PILOT) 1" BURNER LESS PILOT BRACKET MANIFOLD (1" BURNERS) NAT GAS ORIFICE (#42 DRILL SIZE) NAT GAS ORIFICE (#44 DRILL SIZE) NAT GAS ORIFICE (#47 DRILL SIZE) NAT GAS ORIFICE (#48 DRILL SIZE) LP GAS ORIFICE (#54 DRILL SIZE) LP GAS ORIFICE (#55 DRILL SIZE) LP GAS ORIFICE (#1.25mm DRILL SIZE) GAS VALVE (STND.
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KEY # DESCRIPTION 75 76 77 78 79 80 81 82 83 84 85 86 87 LEFT SIDE JACKET PANEL RIGHT SIDE JACKET PANEL REAR JACKET PANEL TOP JACKET PANEL LOWER FRONT PANEL UPPER FRONT PANEL DIVERTER PANEL VESTIBULE PANEL HORIZONTAL JACKET CLIP VERTICAL JACKET CLIP #10 X 1/2" SHEET METAL SCREW DOOR KNOB 8-32 X 1/4" H.W.H. SCREW IGNITION MODULE (E.I. BOILERS) (NATURAL GAS ONLY) IGNITION MODULE (E.I. BOILERS) (NATURAL OR LP GAS) MODULE BRACKET (E.I.
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Appendix A: Knockdown Boiler Assembly Instructions A. Before Installing 1) 2) 3) 4) 5) Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs or punctures due to mishandling. Do not use the heat exchanger if there is any damage to it. Inspect the joints between the sections for openings. Reseal any openings with high temperature silicone sealant. Keep the base in the shipping carton until it is time to perform the assembly.
FIGURE A1: BASE, HEAT EXCHANGER, FLUE COLLECTOR ASSEMBLY 51 50
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 halfway up the front edge of the side jacket panels and secure with the 8-32 self tapping screws provided.
FIGURE A2: JACKET INSTALLATION 53 52
F. Electrical Wiring Connections (Also refer to wiring diagrams in Part X of the installation manual) 1) 2) 3) 4) 5) A pre-wired limit control (L8148E or L8124E) specific to the control package 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).
FIGURE A3: TAPPING LOCATIONS (SEE TEXT FOR TAPPING USES) 55 54
Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.