D E S I G N E D T O L 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: • CWI103 • CWI138 • CWI172 • CWI207 • CWI241 • CWI276 • CWI311 • CWI346 • CWI380 Warning: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas supplier.
WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings printed in this manual and posted on the boiler. unless alarms or other safeguards are in place to prevent such damage INSPECT THE BOILER ANNUALLY. To keep your boiler safe and efficient, have a service technician follow the Service checklist near the end of this manual. DO NOT BLOCK AIR FLOW into or around the boiler. Insufficient air may cause the boiler to produce carbon monoxide or start a fire.
Table of Contents I. Product Description..................................................... 2 II. Specifications.............................................................. 3 III. Before Installing.......................................................... 4 IV. Locating the Boiler...................................................... 4 V. Air for Combustion & Ventilation............................... 5 VI. Venting........................................................................ 9 VII.
II Specifications FIGURE 1: CWI BOILERS - GENERAL CONFIGURATION TABLE 1: CWI SPECIFICATIONS NATURAL OR LP GAS * HEATING AHRI NET CAPACITY RATING (MBH) (MBH) 75 86 BASIC BOILER MODEL CWI103 NUMBER OF SECTIONS 4 INPUT (MBH) 103 CWI138 5 138 115 100 83.1 CWI172 6 172 144 125 83.2 3.50 CWI207 7 207 173 150 83.2 3.75/4.50 CWI241 8 241 201 175 83.2 3.75/4.75*** 29 CWI276 9 276 230 200 83.2 4.00/5.25*** 32 1/4 30 40 7/16 8 21.0 CWI311 10 310 252 219 81.4** 4.00/5.
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 - CWI380 WITH TANKLESS HTR. - 21“ CWI207 - CWI380 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 7
FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 8
• 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.
14) Vent damper installation is mandatory on all CWI boiler models except the CWI311-CWI380. 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.
FIGURE 8: CWI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS FIGURE 9: VENT DAMPER INSTALLATION DETAILS 11
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.
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
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
FIGURE 16: GRAVITY PIPING IX TANKLESS HEATER PIPING If the CWI is supplied with a 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) HONEYWELL L8124E HIGH LIMIT 2 LOW LIMIT HONEYWELL VR8204/VR8304 SERIES GAS VALVES (CWI103 - 346) + TH TR MAIN VALVE LESS VENT DAMPER PILOT VALVE ROBERTSHAW 7000DERHC GAS VALVE (CWI380) 2. VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI311 - CWI380. WHEN DAMPER IS NOT USED, DAMPER HARNESS IS OMITTED AND TERMINAL B1 IS WIRED DIRECTLY TO FRS.
FIGURE 20: CIRCULATOR ZONE WIRING USING HONEYWELL R845As (FACTORY BOILER WIRING NOT SHOWN - SEE FIGURES 18 - 19) FIGURE 21: ZONE WIRING USING HONEYWELL V8043F ZONE VALVES (FACTORY WIRING NOT SHOWN - SEE FIGURES 18 - 19) 22
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 22: INTERMITTENT IGNITION PILOT BURNER FLAME 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.
FIGURE 23b: MAIN BURNER FLAME - 40mm (“HIGH ALTITUDE”) BURNERS FIGURE 23a: MAIN BURNER FLAME - 1” BURNERS c) Connect a manometer to the manifold (outlet) pressure tap on the gas valve (see Figures 24a and 24b). d) Read the manifold pressure. It should be set at: Manifold Press. (inches w.c.) e) Natural Gas LP Gas 3.5 10.
FIGURE 24a: GAS VALVE DETAIL - HONEYWELL VR8204 AND VR8304 FIGURE 24b: GAS VALVE DETAIL - ROBERTSHAW 7000DERHC 27
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8204 AND VR8304 SERIES GAS VALVES 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 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.
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) 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 ¼-20 nuts and washers holding the flue collector onto the heat exchanger. 7) Carefully remove the flue collector gasket strips and set them aside.
Notes 32
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 34 or 36 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.
Troubleshooting Chart for CWI Boilers Without Tankless Heaters Caution: Read page 33 before attempting to use this chart Start N Thermostat calls for heat Circulator start? Boiler Equipped With Damper? Y Vent damper open? Y N N *Power off N *Blown fuse or tripped breaker *Miswired or loose electrical connection in 120V line 120 volts at l1&l2? 24 volts across B and r (limit switch) in L8148E ? Y 120 volts at C1&C2? Y 120 volts across terminals at circulator? N Remove t'stat or zone valve e
Main burners light? Do burners shut down before gage temp exceeds high limit setting +15F? Y N Do burner and circulator shut down at end of call for heat? Y 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 well *Obstruction in path of damper blade Y Refer to ignition syste
Troubleshooting Chart for CWI Boilers Equipped with Tankless Heaters and Dampers Caution: Read page 33 before attempting to use this chart Start No call for heat, boiler water temp.
Do burners shut down before gage temp exceeds high limit setting +15F? Y Circulator start? Main burners light? N Y Y Do burner and circulator shut down at end of call for heat? N Y END N N *Boiler water temperature exceeds high limit setting 120 volts at C1&C2? *Defective L8124E * Defective L8124E 120 volts across terminals at circulator? Y N N Y Remove t'stat or zone valve end switch wires from t&tV terminals on L8124E. Install temporary jumper across terminals t and tV.
Intermittent Ignition System Troubleshooting Chart Caution: Read page 33 before attempting to use this chart Start (24 volts is present across 24V and 24V (GND) on ignition module but main burners do not light) Spark across ignitor/sensor gap? Y Does spark stop when pilot lights? Y Pilot lights? N N N * Defective ignition module Y Y N N Y * Defective ignition module Y END N 24VAC across terminals MV & MV/PV on module? 24 volts across PV & MV/PV at gas valve? * Defective ignition module 24
Notes 39
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 # DESCrIPtIoN 42 43 44 44 44 44 44 44 45 1" BURNER WITH PILOT BRACKET (Q348 PILOTS) 1" BURNER LESS PILOT BRACKET MANIFOLD (1" BURNERS) 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 (E.I., NAT GAS) 45 GAS VALVE (E.I., NAT GAS) 45 45 GAS VALVE (E.I., NAT GAS) (ROBERTSHAW 7000DERHC) GAS VALVE (E.I. PILOT, lP GaS) 45 GAS VALVE (E.I.
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KEY # 75 76 77 78 79 80 81 82 83 84 85 86 87 * * * 88 89 89 90 90 91 92 93 93 94 94a 95 99 * * * * * * QtY. or CroWN P.N. LEFT SIDE JACKET PANEL 1 ea. RIGHT SIDE JACKET PANEL 1 ea. REAR JACKET PANEL 1 ea. TOP JACKET PANEL 1 ea. LOWER FRONT PANEL 1 ea. UPPER FRONT PANEL 1 ea. DIVERTER PANEL 1 ea. VESTIBULE PANEL 1 ea. HORIZONTAL JACKET CLIP 800340 VERTICAL JACKET CLIP 800341 #10 X 1/2" SHEET METAL SCREW 90-212 DOOR KNOB 90-210 8-32 X 1/4" H.W.H. SCREW 90-211 IGNITION MODULE (E.I.
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Appendix A: 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.
FIGURE A1: BASE, HEAT EXCHANGER, FLUE COLLECTOR ASSEMBLY 47
5) Install the left side panel in the same manner as the right side. 6) Attach the front corners of the diverter panel to the side jacket panels using #10 sheet metal screws. 7) 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 49
F. Electrical Wiring Connections (Also refer to wiring diagrams in Part X of the installation manual) 1) A pre-wired limit control (L8148E or L8124E) specific to the control package ordered with the boiler has been provided by the factory. 2) 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) 51
Notes 52
Notes 53
Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.
