Crown Boiler CWD060 Installation Instructions Manual
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Crown Boiler CWD060 Installation Instructions Manual

Crown Boiler CWD060 Installation Instructions Manual

Cwd series gas-fired direct vent hot water boilers
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See also: User Manual , Instruction and Installation Manual
CWD Series
Gas-Fired Direct Vent Hot Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affi xed on or adjacent to the boiler
Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com
Models:
CWD060
•
CWD083
•
CWD110
•
CWD138
•
CWD165
•
CWD193
•
CWD220
•
CWD245
•
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause property
damage, injury, or loss of life. For
assistance or additional information,
consult a qualifi ed installer, service
agency or the gas supplier. Read
these instructions carefully before
installing.

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  • Page 1: Installation Instructions

    CWD Series Gas-Fired Direct Vent Hot Water Boilers INSTALLATION INSTRUCTIONS These instructions must be affi xed on or adjacent to the boiler Models: CWD060 • WARNING: Improper installation, CWD083 adjustment, alteration, service or • maintenance can cause property CWD110 • damage, injury, or loss of life.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Product Description Specifi cations Before Installing Locating the Boiler Air for Combustion and Ventilation Venting Vent System Design Vent System Assembly Gas Piping VIII System Piping Wiring CB502 Control System R8285 Control system Start-up and Checkout Service and Maintenance Troubleshooting XIII Parts...

  • Page 3: I Product Description

    I Product Description The CWD series boiler is a cast iron gas fi red boiler designed for use in forced hot water heating systems. It is is a low pressure boiler intended for use in closed heating systems with water temperatures under 240F. This boiler may be vented either vertically or horizontally with combustion air supplied from either outdoors or (under certain conditions) indoors.

  • Page 4: Before Installing

    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 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.
  • Page 5 FIGURE 2a: CLEARANCES WHEN BOILER IS DIRECT VENTED (OUTDOOR COMBUSTION AIR IS USED) FIGURE 2b: CLEARANCES WHEN COMBUSTION AIR IS OBTAINED FROM BOILER ROOM...

  • Page 6: Air For Combustion And Ventilation

    TABLE 2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION MINIMUM CLEARANCE TO COMBUSTIBLE TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MATERIAL HEAT FAB SAF-T VENT AT LEAST ONE SIDE OPEN, PROTECH FASNSEAL VERTICAL OR 1” COMBUSTIBLE MATERIAL ON A PROTECH FASNSEAL W2 HORIZONTAL MAXIMUM OF THREE SIDES METAL-FAB CORR/GUARD...
  • Page 7 Step 2: Determine whether the boiler is to be installed in a confi ned space A confi ned space is defi ned 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.
  • Page 8 Step 5: If Indoor Combustion Air is Used, Provide Air as Follows: 1) Buildings of other than unusually tight construction: Unconfi ned Space– Natural infi ltration into the boiler room will normally provide adequate air for combustion and ventilation without additional louvers or openings into boiler room. Confi...
  • Page 9 FIGURE 4: ALL AIR FROM OUTSIDE USING VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTSIDE USING VENTILATED ATTIC...
  • Page 10 FIGURE 6: ALL AIR FROM OUTSIDE USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTSIDE USING HORIZONTAL DUCTS INTO BOILER ROOM...

  • Page 11: Venting

    VI Venting WARNING Failure to vent this boiler in accordance with these instructions could result in unreliable boiler operation, severe damage to the boiler or property, or unsafe operation: * Do not attampt to vent this boiler with galvanized, PVC, or any other vent system not listed in Table 4. * Do not attempt to mix components from different approved vent systems.
  • Page 12 TABLE 3a: SUMMARY OF HORIZONTAL VENTING OPTIONS VENT OPTION # (RESERVED HORIZONTAL HORIZONTAL CLASSIFICATION USED IN THIS HORIZONTAL HORIZONTAL FOR FUTURE DIRECT DIRECT MANUAL DIRECT VENT DIRECT VENT USE) EXHAUST EXHAUST ILLUSTRATED IN FIGURE 8a OR 8b 8a OR 8b VENT PIPE STRUCTURE WALL WALL...
  • Page 13 FIGURE 8a: HORIZONTAL DIRECT VENTING USING SEPARATE TERMINALS (VENT OPTIONS 1-2) FIGURE 8b: HORIZONTAL DIRECT VENTING USING COAXIAL TERMINAL (VENT OPTIONS 1-2)
  • Page 14 FIGURE 9: HORIZONTAL DIRECT EXHAUST VENT SYSTEM (VENT OPTIONS 4,5) 2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected, the vent pipe size, and the boiler size. See Table 3 for the maximum vent length. In addition to the maximum length of piping shown in Table 3, the following fi...
  • Page 15 3) Permitted Terminals for Horizontal Venting (Vent Options 1 - 5) - Table 3a shows permitted types of terminals for both the vent and air inlet systems. On horizontal direct vent systems using 4” air inlet pipe (Vent Options 1 and 2), the following Crown co-axial terminals may be used.
  • Page 16 TABLE 3b: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # (RESERVED VERTICAL VERTICAL CLASSIFICATION USED IN THIS VERTICAL VERTICAL FOR FUTURE DIRECT DIRECT MANUAL DIRECT VENT DIRECT VENT USE) EXHAUST EXHAUST ILLUSTRATED IN FIGURE VENT PIPE STRUCTURE ROOF ROOF ROOF ROOF PENETRATION AIR INTAKE PIPE STRUCTURE...
  • Page 17 FIGURE 10: VERTICAL NON-COAXIAL DIRECT VENT SYSTEM (VENT OPTIONS 6, 7) FIGURE 11: VERTICAL DIRECT EXHAUST SYSTEM (VENT OPTIONS 9, 10)
  • Page 18 TABLE 3c : SUMMARY OF VERTICAL COAXIAL VENTING OPTIONS VENT OPTION # VERTICAL VERTICAL VERTICAL CLASSIFICATION USED IN THIS COAXIAL COAXIAL COAXIAL MANUAL DIRECT VENT DIRECT VENT DIRECT VENT VENT PIPE STRUCTURE ROOF ROOF ROOF PENETRATION AIR INTAKE PIPE STRUCTURE ROOF ROOF ROOF...
  • Page 19 FIGURE 12: VERTICAL COAXIAL DIRECT VENT USING CROWN #500005 VENT KIT (VENT OPTION 11) FIGURE 13: VERTICAL COAXIAL DIRECT VENT USING HEAT FAB SAF-T VENT SC (VENT OPTIONS 12, 13)
  • Page 20 TABLE 4: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS CONDENSATE WALL HORIZONTAL VERTICAL MANUFACTURER VENT SYSTEM SIZE TRAP THIMBLES TERMINATION TERMINATION 7393GC ELBOW: 7314TERM 9321 7393GCS TEE: 7390TEE 5300CI (NOTE 3) SAF-T VENT 5391CI EZ SEAL 7493GC 9421 ELBOW: 7414TERM 7493GCS 5400CI (NOTE 3)
  • Page 21 12) Vertical and horizontal sections of piping must be properly supported. See vent system manufacturer’s instructions for more information. 13) Non-coaxial vent piping must be accessible for periodic inspection. 14) Fire stops and wall thimbles – Use fi re stops where required by code or by the vent system manufacturer. Consult vent system manufacturer’s literature for information on suitable fi...
  • Page 22 FIGURE 14: HORIZONTAL TERMINAL OFFSETS FIGURE 15a: LOCATION OF DIRECT VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE...
  • Page 23 FIGURE 15b: LOCATION OF DIRECT EXHAUST TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 15c: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS FIGURE 15d: POSITIONING VENT TERMINAL UNDER OVERHANGS...

  • Page 24: Vent System Assembly

    FIGURE 16: USE OF CONDENSATE TRAPS C. Vent / Intake System Assembly 1) General Assembly Notes: a) Where the use of “silicone” is called for in the following instructions, use GE RTV 106 for the vent collar and coaxial terminal. Air inlet piping sections are sealed with any general-purpose silicone sealant such as GE RTV102. PVC air inlet piping sections are connected with PVC cement.
  • Page 25 TABLE 6: FAN OUTLET ORIFICE ORIFICE BOILER MODEL PART # CWD060 620133 CWD083 650136 CWD110 620135 CWD138 620136 CWD165 620137 CWD193 620138 CWD220 620139 CWD245 650138 FIGURE 17: INSTALLATION OF FAN OUTLET ORIFICE 3) Optional Coaxial Terminal Installation – If the optional coaxial terminal is used, it should be installed in the wall before vent assembly is started.
  • Page 26 FIGURE 18a: CROWN COAXIAL TERMINAL EXPLODED VIEW FIGURE 18b: CROWN COAXIAL TERMINAL ASSEMBLY...
  • Page 27 j) Attach the intake tee to the end of the straight section protruding from the inside wall. Use the procedure described in (d) to clean and assemble these parts. k) If the inside terminal section is not supported by the wall through which it passes, install additional supports or bracing to support the terminal.
  • Page 28 5) Assembly of Z-Flex Z-Vent III: a) General Notes: • Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw. File or sand the cut end smooth before assembling. Expanded ends may be cut to adapt the SVE series III to the vent collar or Crown coaxial terminal.
  • Page 29 6) Assembly of Heat Fab Saf-T Vent EZ Seal: a) Saf-T Vent General Notes: These instructions cover the installation of Saf-T Vent EZ Seal. Saf-T Vent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. •...
  • Page 30 manufacturer’s instructions before operating the boiler. 7) Assembly of Heat Fab Saf-T Vent SC - On CWD Boiler installations where Saf-T Vent SC is used, some Saf-T Vent EZ Seal (single wall pipe) will always be required between the boiler and the Saf-T Vent SC. Install this pipe as described above.
  • Page 31 8) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of fl ue gas fl ow. •...
  • Page 32 11) Assembly of Vertical Coaxial Vent System Using Crown #500005 Coaxial Vent Kit (Vent Option #11) a) Start by installing the “B” vent piping. Install and assemble this piping in accordance with the “B” vent manufacturer’s instructions. Seal the joints between sections of “B” vent with GE RTV 106 or Dow 732 RTV sealant. Consult the “B” vent manufacturer’s instructions for the clearance to combustibles (typically 1”) as well as for fi...
  • Page 33 FIGURE 23: INSTALLATION OF VENT SUPPORT PROVIDED IN CROWN #500005 VERT. COAXIAL VENT KIT FIGURE 24: CONDENSATE TRAP/DRAIN DETAIL...

  • Page 34: Gas Piping

    VII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fi re 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 the National Fuel Gas Code.

  • Page 35: System Piping

    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 120F can cause severe heat exchanger corrosion damage.
  • Page 36 8) Flow control valve (Required under some conditions) – The fl ow control valve prevents fl ow through the system unless the circulator is operating. A fl ow control valve may be necessary on converted gravity systems to prevent gravity circulation. Flow control valves are also used to prevent “ghost fl...
  • Page 37 FIGURE 26: BASIC PIPING FIGURE 27: INDIRECT WATER HEATER BOILER-SIDE PIPING...
  • Page 38 FIGURE 28: BYPASS PIPING FIGURE 29: ISOLATION OF BOILER FROM SYSTEM WITH HEAT EXCHANGER...
  • Page 39 FIGURE 30: CHILLER PIPING...

  • Page 40: Wiring

    IX Wiring The CWD Series boiler is offered with two different types of control systems: • CB502 Control System - Basic operation of the boiler is controlled with a “CB502 control” (Crown part #42-502) located in the left side of the boiler vestibule. This device controls one or two circulator zones without the use of additional controls and includes LEDs to show the status of the circulators, inducer, and other boiler controls.
  • Page 41 FIGURE 31: CB502 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING FIGURE 32: CB502 CONTROL SYSTEM - FACTORY SWITCH / JUMPER CONFIGURATION...
  • Page 42 B. CB502 System - Wiring Variations 1) Two Circulator Zones – Figure 33 shows wiring for two circulator zones. The second zone may be either an indirect water heater or a heating zone. No additional electrical controls are required to operate two circulator zones with a standard CWD boiler.
  • Page 43 FIGURE 33: CB502 CONTROL SYSTEM - FIELD WIRING FOR TWO CIRCULATOR ZONES FIGURE 34: CB502 CONTROL SYSTEM - FIELD WIRING FOR HYBRID CIRCULATOR/ZONE VALVE SYSTEM...
  • Page 44 FIGURE 35: CB502 CONTROL SYSTEM - INTERNAL LADDER DIAGRAM...
  • Page 45 FIGURE 36: CB502 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM...

  • Page 46: R8285 Control System

    D. R8285 Control System - Single Zone Wiring 1) Line Voltage (120 VAC) Connections (Fig 37) – The line voltage connections are located in the junction box under the R8285 fan center on the right side of the boiler. • Black – Line voltage “hot” •...
  • Page 47 FIGURE 37: R8285 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING FIGURE 38: R8285 CONTROL SYSTEM - FIELD WIRING FOR TWO CIRCULATOR ZONES...
  • Page 48 FIGURE 39: R8285 CONTROL SYSTEM - ZONE VALVE FIELD WIRING FIGURE 40: R8285 CONTROL SYSTEM - INTERNAL LADDER DIAGRAM...
  • Page 49 FIGURE 41: R8285 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM...

  • Page 50: Start-Up And Checkout

    X Start-up and Checkout WARNING • Never attempt to fi ll a hot empty boiler. • Never use a fl ame to check for gas leaks. • Make sure that the area around the boiler is clear and free from combustible materials, gasoline, and other fl am- mable vapors and liquids.

  • Page 51: For Your Safety Read Before Operating

    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 is equipped with an ignition If you cannot reach your gas supplier, call device which automatically lights the pilot.
  • Page 52 WARNING Failure to follow the following procedure exactly could result in over-fi ring of the boiler and a carbon monoxide hazard. 12) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a) Connect a manometer to the line pressure tap on the gas valve (see Figure 44). b) Check the line pressure with all gas appliances on and off.
  • Page 53 FIGURE 44: GAS VALVE FIGURE 45: MEASURING MANIFOLD PRESSURE...

  • Page 54: Service And Maintenance

    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) Remove the burner tray. To do this: a) Remove the intake cover. b) Remove the four Allen head screws holding the elbow fl ange onto the gas valve. c) Remove the three 10-32 screws holding the manifold gasket plate to the intake box.
  • Page 55 Heat Exchanger Cleaning Procedure WARNING Soot deposits in the fl ue 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 fl ue 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 fl...

  • Page 56: Service Notes

    16) Set the fl ue collector onto the block and press down so that the fl ue collector is set into the silicone applied in the previous step. 17) Slide the fl ue collector lugs back into position and retighten the ¼-20 bolts. DO NOT OVER TIGHTEN. 18) Apply a bead of silicone around the outside of the joint between the heat exchanger and the fl...
  • Page 57 TABLE 7: PRESSURE SWITCH SETTINGS MAKE SETTING* BREAK SETTING* ALTITUDE CROWN PN (inches w.c.) (inches w.c.) SEA LEVEL - 5200 ft 620009 1.26 1.16 ABOVE 5200 ft 620010 1.10 1.00 *Settings shown are based on “plus tolerance” - actual setting may be lower. FIGURE 46a: PRESSURE SWITCH CONNECTIONS...
  • Page 58 FIGURE 46b: MEASURING PRESSURE ACROSS PRESSURE SWITCH...

  • Page 59: Troubleshooting

    XII Troubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems. If troubleshooting a CB502 control system, go to the box marked “Start” at the top of the chart on page 58 and follow the appropriate path though the chart until a box with a list of possible causes is reached.
  • Page 60 START Call from "HEAT 1" "DHW/H2" (No call for "HEAT 1" Circulator heat from zone used? LED On? zone start? either zone) HEAT LED On? 24volts transformer secondary? *Defective 120 volts transformer across red and harness white circulator *Defective leads? CB502 24V across "HEAT 1"...
  • Page 61 Call for heat "DHW/H2" from Continued on circulator "DHW/H2" next page start? zone LED On? 24V across "DHW/H2" T and T 120 volts across blue and white Defective circulator leads? CB502 board *Loose connection between boiler J-box and circ * Loose connection in t'stat or zone valve end switch wiring * Defective t'stat or zone...
  • Page 62 Continued LIMIT PRESS from previous Fan On? LED on? LED on? page * Missing or loose LED on? "RESET CONTROL" 24V between jumper brown lead on *Missing or loose limit and yellow "CN1" jumper lead on transformer? *Defective CB502 board * Boiler water temp over L4080D setpoint...
  • Page 63 Do burners shut Wait 30 Main down before Pilot seconds burners gauge temp light? (prepurge) light? exceeds high limit setting +15F? 24 volts See "Intermittent between 24V Ignition System Troubleshooting 24V (GND) on Chart" on page 64 ign. module? * Defective L4080D * Sensing bulb not bottomed out in well Do burner,...
  • Page 64 START Induced Wait 30 Circulator draft fan seconds start? start? (prepurge) Unplug fan and Thermostat check for 120 volts calls for heat across black and white connections 24volts across R on female half of and C on R8285 plug. fan center? 120 volts 120 volts across present?
  • Page 65 Main Do burners shut Pilot burners down before light? light? gauge temp exceeds high limit setting +15F? See "Intermittent 24 volts Ignition System between 24V Troubleshooting Chart" on page 64. 24V (GND) on Do burner, ign. module? circulator and fan shut down at end of call for * Defective L4080D heat?
  • Page 66 START IMPORTANT: ALL PILOT TROUBLESHOOTING (24 volts is present across 24V and 24V (GND) on ON THIS CHART MUST BE PERFORMED AFTER Ignition Module, 30 second prepurge period has THE 30 SECOND PREPURGE HAS ENDED AND passed) BEFORE THE END OF THE 90 SECOND TRIAL FOR IGNITION PERIOD.

  • Page 67: Parts

    XIII PARTS The following parts may be obtained from any Crown distributor. To fi nd 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 Main burner orifi...
  • Page 68 BLOCK, BASE, FLUE COLLECTOR COMPONENTS PART PART # OR QTY. KEY DESCRIPTION # OR CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 QTY. BASE 620113 620114 620115 620116 620117 620118 620119 620120 NYLON FEET (GLIDES) 700111 INTAKE BOX 620233 620234 620235 620236 620237...
  • Page 70 BURNER TRAY COMPONENTS PART# PART # OR QTY. DESCRIPTION CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 QTY. FRONT FIREDOOR 620543 620544 620545 620546 620547 620548 620549 620550 FRONT FIREDOOR INSULATION 620523 620524 620525 620526 620527 620528 620529 620530 INSULATION SUPPORT BRACKET 620101 MICA SIGHT GLASS 60-050...
  • Page 72 JACKET COMPONENTS PART # OR QTY PART# DESCRIPTION CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 VESTIBULE PANEL 620323 620324 620325 620326 620327 620328 620329 620330 LARGE PLASTIC BUSHING 960051 FAN COVER PLATE 620302 620302 620302 60-300 60-300 60-300 60-300 60-300 #10 X 1/2 SHEET METAL SCREW 90-212...
  • Page 74 COMMON CONTROLS & TRIM PART# PART # OR QTY KEY DESCRIPTION CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 1/8” SILICONE TUBING 14-008 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT HONEYWELL L4080D LIMIT 35-3300 TRIDICATOR GAUGE 95-069...

  • Page 76: Appendix A:special Requirements For

    Appendix A: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: 1. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfi...
  • Page 78 CROWN Boiler Co Manufacturer of Hydronic Heatings Products P.O. Box 14818 3633 I. Street PN 980060 Philadelphia, PA 19134 CWDMANV4 Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com 04/09...

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