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CWL-GS Series
Models CWL GS, CWL GS DV, NCWL GS, NCWL GS DV
Gas Fired Packaged
oiler
Installation
Operation
Maintenance
Manual
www.thermodynamicsboiler.com
Thermo-Dynamics oiler 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.com
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Table of Contents
Related Manuals for Thermo Dynamics CWL GS
Summary of Contents for Thermo Dynamics CWL GS
- Page 1 CWL-GS Series Models CWL GS, CWL GS DV, NCWL GS, NCWL GS DV Gas Fired Packaged oiler Installation Operation Maintenance Manual www.thermodynamicsboiler.com Thermo-Dynamics oiler Company ROUTE 61 • P.O. BOX 325 • SCHUYLKILL HAVEN, PA 17972 TEL (570) 385-0731 • FAX (570) 385-5304...
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Page 3: 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 does not have a pilot. It is *If you cannot reach your gas supplier, call the equipped with an ignition device which auto- fire department. -
Page 4: Table Of Contents
Contents Safety Instructions Service Policy Component Arrangement Installation Operation Maintenance Trouble Shooting Parts List Product Features • ASME Coded Boiler Registered with National Board • Fully Insulated Heat Exchanger with Powder-Coated Cabinet • Packaged with Standard Five Gallon per Minute Tankless Coil For Domestic Hot Water (CWL Models Only) •... -
Page 5: Service Policy
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. - Page 6 IMPORTANT Read carefully and consult drawings before beginning work. The CWL-GS is factory assembled and packaged. Check shipping list as the unit and accom- panying cartons are unpacked. Report shortages or damage to the delivering carrier immedi- ately. Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests as specified in Gas Fired Low-Pressure Steam and Hot Water Boilers ANSI Z21.13.
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Page 7: Component Arrangement
Figure 1 Component Arrangement Installation I. GENERAL CWL-GS Series hot water boilers are high quality, high efficiency gas fired vertical fire tube heating units. The installation of the unit shall be in accordance with regulations of the authorities having jurisdiction. Refer to Local installation Codes for Gas Burning Equipment, for recommended installation practice. - Page 8 TABLE 1 – SPECIFICATIONS Model: Boiler Specifications Firing Rate CFM 1.95 2.28 2.60 Input BTU/HR 120,000 140,000 160,000 DOE Capacity BTU/HR 100,000 115,000 130,000 Net Rate BTU/HR 87,000 100,000 113,000 Val. Cap. Lbs/HR Max. W.P. PSI AFUE 82.6 81.1 80.5 Boiler Dimensions Water Content 15 Gal.
- Page 9 V. LOCATION Place the boiler on a level floor, preferably raised and as near to the chimney or venting device as possible. Allow clearances as follows in accordance with local codes and NFPA-54. (For clearances less than the listed values, consult NFPA-54 Table 6.2.3(B). MINIMUM CLEARANCE TO COMBUSTIBLE MATERIALS Sides - 0”...
- Page 10 The 1-1/4” supply line or riser tapping in the top of the boiler extends approximately 1” below the top or waterline of the boiler, thus allowing only air-free water to enter the supply to the heating system. The air trapped in the top of the boiler must be purged through the 3/4" vent tapping by using an Automatic Float Vent, a Manual Vent or piped into a conventional expansion tank.
- Page 11 vent the circulator operation if the water temperature is below a predetermined low level. Likewise, if the water level reaches a predetermined high limit of 205°F, the burner will automatically shut off. C. Aquastat Relay L7248 (For NCWL Models Only) This control is installed on the top center of the boiler.
- Page 12 Figure 3 Gas Piping The boiler is equipped with a combination gas control. Install a ground joint union ahead of the gas control assembly to permit servicing of the control. SHUT OFF See Figure 3. Install an additional shut-off valve BALL VALVE when a combination gas control is used.
- Page 13 XI. FLUE SYSTEM CHIMNEY VENT MODELS A. Draft In order to ensure positive pressure over the fire (see specification sheet) and superior boiler perfor- mance, the draft in the flue pipe should be set to -0.02. In the event that the pressure is not at the set point, a draft regulator or draft booster may be used to correct for condition.
- Page 15 L7224A,C; L7248A,C,L OIL ELECTRONIC AQUASTAT ® CONTROLLERS Fig. 6. L7224A,C multizone system with circulator connections. Fig. 6. L7224A,C multizone system with circulator connections and EnviraCOM™ thermostat. Fig. 6A. L7248 External Low Limit connections. Fig. 6A. L7248 multizone system with circulator connections. Figure 6.
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Page 16: Operation
Operation I. START UP A. Make sure service switch to boiler is off. B. Make sure boiler has been filled with water until entire system has been purged and desired pressure obtained. C. Make sure all manual shut off valves in the gas line are open. D. - Page 17 HEAD AND AIR ADJUSTMENT To access the head and air adjustment, remove the plastic cover from the rear of the housing, using the supplied 4 mm allen kay. The left dial is the head adjustment dial; the right dial is the air adjustment dial.
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Page 18: Maintenance
Maintenance I. IMPORTANT ESCAPING GASES ARE DANGEROUS. THE ENTIRE FLUE AND VENTING SYSTEM SHOULD BE INSPECTED AT LEAST ONCE A YEAR BY A QUALIFIED SERVICEMAN. II. HEAT EXCHANGER The tubular portions of the heat exchanger should be examined annually for scale and soot accu- mulation. - Page 19 A. General NEVER BURN GARBAGE OR REFUSE IN YOUR HEATING UNIT. NEVER TRY TO IGNITE GAS BY TOSSING BURNING MATERIAL INTO YOUR BOILER AND NEVER LEAVE COMBUSTIBLE MATERIAL AROUND IT. B. Combustion Air Supply Your burner requires an ample amount of clean air in order to completely and efficiently burn its fuel. If an ample supply is not available, erratic operation, noisy combustion, and fuel odors in the air may result.
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Page 20: Trouble Shooting
TROUBLE SHOOTING GUIDE TROUBLE: TOO MUCH HEAT SOURCE PROCEDURE CAUSES REMEDY CIRCULATOR CHECK TO SEE IF OPERATING CIRCULATOR DOES NOT STOP REPAIR CONTROL IS OPERATING PROPERLY RUNNING THERMOSTAT CHECK THERMOSTAT SETTINGS THERMOSTAT SET TO HIGH RESET THERMOSTAT AND CALIBRATION THERMOSTAT DEFECTIVE REPLACE THERMOSTAT THERMOSTAT OUT OF RECALIBRATES... - Page 21 TROUBLE: BURNER FIRES BUT PULSATES SOURCE PROCEDURE CAUSES REMEDY COMBUSTION AIR INSPECT INSTALLATION FOR IMPROPER INSTALLATION PROVIDE OPENINGS THAT COMBUSTION AIR PROVISIONS COMMUNICATE WITH OUTSIDE OPEN AIR BAND WIDE AND TAKE IMPROPER ADJUSTMENT ADJUST CO 2 LEVEL-START WITH CO 2 READING AIR BAND WIDE OPEN GAS SUPPLY BLEED GAS LINE...
- Page 22 TROUBLE: BURNER FIRES, BUT THEN FAILS ON SAFETY SOURCE PROCEDURE CAUSES REMEDY FLAME CHECK CAD CELL WITH FAULTY FLAME SENSOR CLEAN OR REPLACE SENSOR OHMMETER. IF MORE THAN 2000 OHMS, CAD CELL IS DEFECTIVE OR DIRTY PRIMARY CONTROL AFTER BURNER FIRES OPEN CAD FAULTY PRIMARY CONTROL REPLACE PRIMARY CONTROL CELL CIRCUIT IF FLAME LOOK...
- Page 23 TROUBLE: INSUFFICIENT HEAT SOURCE PROCEDURE CAUSES REMEDY CIRCULATOR CHECK IF CIRCULATOR IS COUPLING WORN OR BROKEN REPLACE COUPLING OPERATIONAL PUMP BINDING REPLACE PUMP CIRCULATOR MOTOR BURNED OUT REPLACE CIRCULATOR MOTOR WIRING FROM OPERATING REPAIR WIRING CONTROL DEFECTIVE OPERATING CONTROL DEFECTIVE REPAIR OR REPLACE OPERATING CONTROL CHECK IF CIRCULATOR IS...
- Page 24 TROUBLE: BURNER DOES NOT START SOURCE PROCEDURE CAUSES REMEDY THERMOSTAT CHECK THERMOSTAT SETTINGS THERMOSTAT SET TO LOW TURN THERMOSTAT UP THERMOSTAT ON “OFF” OR “COOL” SWITCH TO HEAT JUMPER TT TERMINALS ON OPEN THERMOSTAT WIRES REPAIR OR REPLACE WIRES AQUASTAT LOOSE THERMOSTAT TIGHTEN CONNECTIONS CONNECTORS...
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Page 25: Parts List
Heatwise SU-2A Gas Burner 542243 Heatwise SU-2A DV Gas Burner 535030 007 Circulator Pump 552102 Aquastat Control L7224C (on CWL GS/CWL GS DV) 552116 Aquastat Control L7248 (on NCWL GS/NCWL GS DV) 575020 Relief Valve (3/4" Male) 559560 Altitude Gauge 1/4" x 2-1/2" Round... -
Page 26: Manifold Pressure
INSTALLER/SERVICEMAN INSTALLER/SERVICEMAN Fixed Pressure and Variable Orifice Fixed Pressure and Variable Orifice Model Number Model Number CWL-GS-120 CWL-GS-140 CWL-GS-160 CWL-GS-120 CWL-GS-140 CWL-GS-160 _________________________ _________________________ Burner Type Heat Wise Heat Wise Heat Wise Burner Type Heat Wise Heat Wise Heat Wise Burner Model SU-2A SU-2A... - Page 27 INSTALLER/SERVICEMAN INSTALLER/SERVICEMAN Fixed Pressure and Variable Orifice Fixed Pressure and Variable Orifice Model Number Model Number NCWL-GS-120 NCWL-GS-140 NCWL-GS-160 NCWL-GS-120 NCWL-GS-140 NCWL-GS-160 _________________________ _________________________ Burner Type Heat Wise Heat Wise Heat Wise Burner Type Heat Wise Heat Wise Heat Wise Burner Model SU-2A SU-2A...
- Page 28 P/N 595830 MET-235 100-2/10...
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