Crown Boiler CWI Series Installation Instructions Manual
Cwi series gas-fired natural draft water boilers
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Also See for CWI Series:
- User's information manual (10 pages) ,
- Instructions for field conversion (12 pages)
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CWI Series
Gas-Fired Natural Draft Water Boilers
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
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Models:
CWI069
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CWI103
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CWI138
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CWI172
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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.com
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CWI207
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CWI241
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CWI276
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CWI310
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CWI345
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CWI379
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WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause property
damage, injury, or loss of life. For
assistance or additional informa-
tion, consult a qualified installer,
service agency or the gas
supplier. Read these instructions
carefully before installing.
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Table of Contents
Related Manuals for Crown Boiler CWI Series
Summary of Contents for Crown Boiler CWI Series
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Page 1: Installation Instructions
CWI Series Gas-Fired Natural Draft Water Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Manufacturer of Hydronic Heating Products Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com Models: CWI207 CWI069 • • CWI241 CWI103 •... -
Page 2: Table Of Contents
Appendix A: Knockdown Boiler Assembly...49 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. -
Page 3: Specifications
FIGURE 1: CWI BOILERS - GENERAL CONFIGURATION TABLE 1: CWI SPECIFICATIONS BASIC NUMBER BOILER INPUT MODEL SECTIONS (MBH) CWI069 CWI103 CWI138 CWI172 CWI207 CWI241 CWI276 CWI310 CWI345 CWI379 * CWI345 AND CWI379 NOT AVAILABLE FOR USE WITH LP GAS ** COMBUSTION EFFICIENCY *** RATING WITH OPTIONAL "HIGH CAPACITY"... -
Page 4: Before Installing
Guide for Residential Hydronic Heating Systems (Pub. #200) and I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics Institute in Berkeley Heights NJ. 4) Make sure that the boiler received is configured for the correct gas (natural or LP). The CWI345 and CWI379 may only be used with natural gas. -
Page 5: Air For Combustion & Ventilation
The boiler must be installed on a hard level surface. Do not 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. - Page 6 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. If the result is less than 50, the boiler room is a confined space.
- Page 7 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...
- Page 8 FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM...
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Page 9: Venting
• In some 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. - Page 10 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: Open vent damper carton and remove installation instructions.
- Page 11 FIGURE 8: CWI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS FIGURE 9: VENT DAMPER INSTALLATION DETAILS...
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Page 12: 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. -
Page 13: System Piping
Berkeley Heights, NJ. The components in this system and their purposes are as follows: 1) Relief valve (Required) - Mount the relief valve on the right side of the boiler as shown in Figure 1 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”... -
Page 14: Piping For Special Situations
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. - Page 15 FIGURE 11: STANDARD BOILER PIPING FIGURE 12: INDIRECT WATER HEATER BOILER SIDE PIPING...
- Page 16 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.
- Page 17 FIGURE 14: ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER FIGURE 15: BOILER PIPING WITH CHILLER...
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Page 18: Tankless Heater Piping
FIGURE 16: GRAVITY 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. - Page 19 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.
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Page 20: Wiring
National Electrical Code (ANSI/NFPA 70). 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): •... - Page 21 (NOTE 2) FIGURE 19: WIRING DIAGRAM, INTERMITTENT IGNITION (EI) SYSTEM LESS TANKLESS HEATER (NOTE 2) HONEYWELL L8124E 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 20: WIRING DIAGRAM, STANDING PILOT WITH TANKLESS HEATER HONEYWELL...
- Page 22 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;...
- Page 23 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)
- Page 24 “R” and “B” are made. This means that while “R” and “B” 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.
- Page 25 “R” and “B” are made. This means that while “R” and “B” 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.
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Page 26: Start-Up & Checkout
250°F. If the high limit opens, the vent damper will close if the damper switch is in the “automatic” 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). - Page 27 (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.
- Page 28 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. 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.)
- Page 29 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 approximately 30 minutes, check the boiler and heating system piping for leaks. Repair any leaks found at once.
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Page 30: For Your Safety Read Before Operating
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. - Page 31 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.
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Page 32: Operating Instructions
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. - Page 33 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.
- Page 34 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)
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Page 35: Service & Maintenance
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”. Check the pilot line and any other gas piping disturbed during the inspection process for leaks. - Page 36 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.
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Page 37: Troubleshooting
These troubleshooting charts assume that the vent damper is closed at the beginning of the troubleshooting 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: •... - Page 38 C1 or C2 and circulator Vent damper open? 24 volts L8148E ? *Boiler off on limit *Defective high limit. 24 volts betw een pins 1&4 (blue&yellow )and 2&4 (orange&yellow ) on damper end of damper harness? See Note 7 on page 28.
- Page 39 National Fuel Gas Code. 24 volts *Dow n draft across rollout *Inadequate combustion air sw itch? supply in boiler room *Rollout sw itch open. *Loose electrical Replace w ith exact connection in 24 replacement (see parts volt w iring list). Check for blocked betw een B1 or B2 heat exchanger.
- Page 40 24 * Defective volt w iring L8124E betw een rollout sw itch or B2 and gas valve or module Allow boiler w ater temperature to reach low limit + differential setting. Initiate call for heat *Defective damper *Defective damper harness...
- Page 41 TV. Does *Defective circulator L8124E-see run now ? Note 6 on page * Boiler w ater temperature *Loose connection in t'stat or has dropped zone valve end sw itch w iring below low limit setting *Defective t'stat or zone...
- Page 42 Hold button for at least one minute. Does pilot light? Line pressure within the range indicated on boiler's rating plate? Consult gas supplier. *Pilot tubing blocked, kinked or leaking *Pilot orifice blocked *Gas line not...
- Page 43 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 lights? gap? 24 volts across terminals 2&3 at S8600? Can you hear sparking? 24 volts across PV &...
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Page 44: 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. - Page 46 1 ea. 2 ea. 3 ea. 1 ea. 701253 701254 701255 2 ea. 3 ea. 4 ea. QUANTITY PER BOILER OR CROWN P.N. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.
- Page 48 AQUASTAT - R.O. SWITCH HARNESS (LESS COIL OR LESS VENT DAMPER) AQUASTAT - R.O. SWITCH HARNESS (WITH COIL AND VENT DAMPER) INTERMITTENT IGNITION HARNESS * NOT PICTURED QTY. OR QUANTITY PER BOILER OR CROWN P.N. CROWN P.N. 1 ea. 850301 850301 850301 1 ea.
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Page 50: Appendix A: Knockdown Boiler Assembly
Install the fiber gasket strip, which was shipped in the "Base Box" (Figure A1). Place the base assembly in the location where the boiler is to be installed. Refer to Section III and IV in the installa- tion manual for additional information on placement. - Page 51 FIGURE A1: BASE, HEAT EXCHANGER, FLUE COLLECTOR ASSEMBLY...
- Page 52 Install relief valve (spindle must be in vertical position) into tapping “H” on the boiler left side (See Figure 1 in the installation manual) using the ¾” 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.
- Page 53 FIGURE A2: JACKET INSTALLATION...
- Page 54 (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).
- Page 55 FIGURE A3: TAPPING LOCATIONS (SEE TEXT FOR TAPPING USES)
- Page 56 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.com...