CWL Series - LE Edition Models CWL, NCWL, CWLDV Installation Operation Maintenance Manual www.thermodynamicsboiler.com Thermo-Dynamics Boiler Company ROUTE 61 • P.O. BOX 325 • SCHUYLKILL HAVEN, PA 17972 TEL (570) 385-0731 • FAX (570) 385-5304 WEB www.thermodynamicsboiler.com • EMAIL sales@thermodynamicsboiler.
Product Features • • • • • • • • • ASME Coded Boiler Registered with National Board Factory Mounted/Wired Burner and Controls Fully Insulated Heat Exchanger with Powder-Coated Cabinet Packaged with Standard Five Gallon per Minute Tankless Coil (Domestic Hot Water) NCWL Model Available Without Tankless Coil Equipped with Triple Aquastat, Circulator, and Temperature / Altitude Gauge Provided With Additional Nozzles to Achieve a Variety of Heat Inputs Provided with a Lifetime Limited Warranty Available as Dir
Service Policy Congratulations on the purchase of your boiler. At Thermo-Dynamics Boiler Company we pride ourselves on the design and construction of our product. Our intent is to furnish you with a high quality appliance that will provide you and your family with years of trouble free service. In order to maintain peak performance of your boiler, it is recommended that the burner/boiler be serviced annually, preferably prior to the onset of the winter heating season.
HOMEOWNER INFORMATION Heating Contractor: Address: Phone No.: A) General Installation and service is to be done only by a certified and qualified technician. Never burn garbage or refuse in your boiler or leave combustible material around it. Do not allow the fuel tank to run out of oil. The fuel tank should be kept full during the summer, or periods of non-use, to prevent condensation of moisture on the inside of the tank.
Read This First 1. Installer must be a trained, experienced technician and should read all instructions before installation. 2. Inspect the boiler, jacket and all components to be sure damage has not occurred in shipment. If damage is evident, do not install the boiler. Contact your distributor immediately. A claim must be filed with the freight carrier that transported the boiler from the factory to the distributor. 3. Disconnect power supply before connecting wiring. 4.
Model Specifications HEATING CAPACITY CWL 85 CWL 100 CWL 110 101,000 118,000 127,000 IBR NET RATING 88,000 103,000 110,000 INPUT 119,000 140,000 154,000 FIRING RATE CHIMNEY SIZE OVER FIRE PRESSURE W.C. .85 1.00 1.10 8 x 8 x 15 8 x 8 x 15 8 x 8 x 15 0-+.05 0-+.08 0-+.10 WATER CONTENT 15 GAL. 15 GAL. 15 GAL. COIL CAPACITY 5 GAL. 5 GAL. 5 GAL. A. JACKET HEIGHT* 29-1/2 29-1/2 29-1/2 B. JACKET WIDTH 21 21 21 C. COIL SUPPLY HEIGHT 22 22 22 D.
Installation I GENERAL This hot water steel boiler is a high quality oil fired heating units. The installation of the boiler shall be in accordance with state and local regulations. Refer to local Installation Codes for Oil Burning Equipment, for recommended installation practice. II FREIGHT CLAIMS All units must be inspected for damage upon arrival. Concealed damage claims should be filed immediately against the carrier by the consignor. The carrier is responsible for taking prompt action on all claims.
V. AIR FOR COMBUSTION AND VENTILATION - CHIMNEY VENT APPLICATIONS The unit must be installed where provisions exist for combustion and ventilation air. Ordinarily, provisions may be furnished by the following methods. A) Utility Room or Closet In buildings of tight construction, including most modern homes, you should provide an opening, connecting to a well ventilated attic, crawl space or directly with the outdoors.
VII JACKET AND TRIM ASSEMBLY A. Knock Down Boiler 1. Jacket Assembly - Unpack the jacket parts being careful not to damage the finish. Piping and accessories are installed after the jacket is in place. Assemble the jacket as shown in Figure 5. 2. Trim Assembly a. Install the safety relief valve in the 3/4" tapping in the top of the boiler. The relief valve should be piped to a safe place of discharge. b. Install the limit control in the 3/4" fitting provided in the tankless coil plate. c.
IX TANKLESS WATER HEATING PIPING The tankless heater may be connected as shown in Figure 3. A mixing valve (not supplied) may be used to reduce the water temperature at kitchen or bathroom taps. High temperature water for a dishwasher may be obtained by piping as shown. The nuts that secure the tankless coil flange should be tightened before the boiler is filled with water, after initial firing and every year during annual maintenance. Deterioration due to coil gasket leaks shall void warranty.
X BURNER AND CONTROLS A) Burner Installations Packaged boilers are shipped with the burner installed and prewired. Boilers that are shipped knockeddown must be field assembled. Follow the procedures listed below to install and connect the burner. 1. Remove the burner parts and instructions from the carton. 2. Referring to specifications at the back of the manual, check to see that the burner model and size match the boiler model. 3. Make sure the correct nozzle is in place and is tightly sealed. 4.
Times are approximate and should be considered minimum settings for the length of intake pipe installed. The length of post-purge may be increased on those units using the Beckett AFII or Riello BF-5 oil burners to any value up to its maximum setting if field conditions require a longer purge cycle. The length of post-purge on the Carlin burner is not adjustable. The post purge timing on the Carlin burner is 90 seconds.
2. Two stage fuel unit. If the height difference between the burner and the fuel supply level exceeds 10 ft., a two stage unit should be used, and a return line should be installed. B) Tubing Use continuous heavy walled copper tubing with flare fittings only. Locate fittings in accessible locations. If possible, tubing should be installed under the floor. Running tubing against boiler casings or across ceiling or floor joints should be avoided.
All venting installations must comply with the recommendations of the venting manufacturer and with all state and local codes. XIV WIRING All internal electrical wiring is completed at the factory on packaged boilers. All external wiring must conform with the National Electric Code and local codes. Refer to wiring diagrams in the burner manufacturer’s installation manual and the control manufacturers installation manual for all field wiring. A) Field connections should be protected with a 15 amp fuse.
B) Burner Adjustments Allow the burner to operate steadily for at least 15 minutes. Check the burner settings according to the installer/serviceman labels starting on page 24, and make the following adjustments: When servicing this appliance or any forced draft unit, it is important to properly seal the gasketed areas around the flue collector and burner mounting flange. Check to be sure that the sampling port above the burner has had the port plug installed after servicing.
4. Pump Pressure - Adjust the pump discharge pressure per value on serviceman label. 5. Combustion Air - Reduce the air supply to allow just sufficient air for clean combustion. This is accomplished by loosening the lock screws on the air shutter, and closing the air shutter until a trace of smoke is recorded. Take a CO2 sample. Open the air shutter lowering CO2 about 1-1/2% to 2%. A zero smoke reading should result.
Maintenance I VENT SYSTEM ESCAPING GASES ARE DANGEROUS. THE ENTIRE FLUE AND VENTING SYSTEM SHOULD BE INSPECTED AT LEAST ONCE A YEAR BY A QUALIFIED SERVICEMAN. II OIL FILTER The oil filter cartridge should be replaced annually. III CLEANING The tubular portions of the heat exchanger should be examined annually for scale and soot accumulation. Remove scale and soot with a flexible, 2 inch, soft, round brush and a boiler vacuum cleaner.
Troubleshooting Guide TROUBLE: BURNER DOES NOT START SOURCE PROCEDURE CAUSES REMEDY Thermostat Check Thermostat Thermostat set too low. Turn thermostat up. Thermostat on “off ”or “cool.” Switch to heat. Open thermostat wires. Repair or replace wires. Loose thermostat connectors. Tighten connection. Faulty thermostat. Replace thermostat. Thermostat not level. Level thermostat. Check burner motor overload switch. (If equipped) Burner motor tripped on overload. Push reset button.
TROUBLE: BURNER STARTS BUT DOES NOT ESTABLISH FLAME SOURCE PROCEDURE CAUSES REMEDY Oil Supply Check tank for oil. Empty tank. Fill tank. Check for water in oil tank using a dip stick coated with litmus paste. Water in oil tank. Strip tank of water exceeding 2" in depth. Listen for pump whine. Fuel supply valve closed. Open valve. Open pump bleed port and start burner. Milky oil or no oil indicates loss of prime. Air leak in fuel system. Repair leak, using only flared fittings.
TROUBLE: BURNER FIRES, BUT THEN FAILS ON SAFETY SOURCE PROCEDURE CAUSES REMEDY Cad Cell Check cad cell with ohmmeter. If more than 2000 ohms, cad cell is defective or dirty. Faulty or dirty cad cell Clean or replace cad cell. Primary Control After burner fires, open cad cell circuit if flame looks OK. If burner continues to operate, fault is in primary control. Faulty primary control Replace primary control. Heat Exchanger Restriction Inspect heat exchanger. Plugged heat exchanger.
TROUBLE: BURNER FIRES, BUT THEN LOSES FLAME SOURCE PROCEDURE CAUSES REMEDY Poor Fire Inspect flame for stability. Unbalanced fire. Replace nozzle with specified nozzle. Excessive draft. Reduce draft setting. Insufficient draft. Increase draft. Insufficient combustion air sources. Increase combustion air sources. Air leak in fuel system. Repair leak - use only flare fittings. Water in oil tank. Strip tank of water exceeding 2" in depth. Fuel supply valve closed. Open valve.
TROUBLE: BURNER FIRES, BUT PULSATES SOURCE PROCEDURE CAUSES REMEDY Draft Take a draft reading. Draft should be according to installer/serviceman labels starting on page 24, in the stack. Down drafts. Install vent cap. Insufficient draft. Increase draft setting. Excessive draft. Reduce draft settings, install second draft regulator if necessary. Draft Regulator Inspect draft regulator for correct location on flue system. Improper installation. Move draft regulator to correct location.
TROUBLE: INSUFFICIENT HEAT SOURCE PROCEDURE CAUSES REMEDY Circulator Check if circulator is operational. Coupling worn or broken. Replace coupling. Pump binding. Replace pump. Circulator motor burned out. Replace circulator motor. Wiring from operating control defective. Repair wiring. Operating control defective. Repair or replace operating control. Check if circulator is correct size. Circulator too small. Replace with proper circulator.
TROUBLE: HIGH NET STACK TEMPERATURES SOURCE PROCEDURE CAUSES REMEDY Nozzle Check pump pressure with pump gauge. Nozzle overfiring due to high pump pressure. Reduce pump pressure according to installer/serviceman labels starting on page 30. Heat Exchanger Check heat exchanger surfaces for soot or scale fouling. Heat exchanger fouled. Clean heat exchanger. Baffles Check baffles installed. Baffles not installed. Install baffles.
Parts List CWL Series - LE Edition (Designate boiler and burner model numbers on all orders.) Item No. Part no. Description 1 540550 Beckett AFG Burner (1501) (Direct Vent AFII - Part No. 540580) 2 542200 Carlin EZ-1 Burner (Direct Vent EZ1 - Part No. 542160) 3 541165 Riello 5F Burner (Direct Vent BF5 - Part No.
Preliminary Settings INSTALLER/SERVICEMAN INSTALLER/SERVICEMAN DIRECT VENT Model Number Burner Type Model Number CWL-85DV CWL-100DV CWL-110DV _________________________ Carlin* Carlin* Burner Type Carlin* *Requires Carlin Air Intake Adapter ZERO Carlin Carlin EZ-1PRO EZ-1PRO EZ-1PRO _________________________ Nozzle Type .70 60°W .85 60°W .90 60°W _________________________ Pump Pressure PSI _________________________ 150 150 150 Head/Pin Position _________________________ .75 .85-1.00 .85-1.
INSTALLER/SERVICEMAN INSTALLER/SERVICEMAN DIRECT VENT Model Number Burner Type Burner Model Model Number CWL-85DV CWL-100DV CWL-110DV _________________________ Beckett Beckett Burner Type Beckett ZERO Smoke Reading Beckett Beckett Burner Model AFG AFG AFG _________________________ Nozzle Type .75 70B .85 80A 1.
ELECTRICAL DIAGRAMS FOR CWL SERIES BOILERS 27
BURNER SERVICE SET-UP RECORDS Initial Set Up 1 2 3 1. Date 2. Model Number 3. Firing Rate 4. Pump Pressure* 5. CO2 6. “0” Smoke 7. Gross Stack°F 8. Draft Over Fire 9. Replaced Filter Yes/No 10. Replaced Nozzle Yes/No 11. Clean Pump Filter Yes/No 12. Inspect Coil Gasket 13. Check for Leaks @ plugs/fittings 14. Brush Clean Flue Tube Passages 15. Vacuum Chamber/Flue Tubes 16. Clean Blower Wheel 17. Check/Set Electrodes *See pump pressure according to the installer/serviceman labels starting on page 24.
TDB-080 P/N 595831 MET-4088 12/10-500
