Table of Contents
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WL Series - LE Edition
Models
WL, N WL,
WLDV
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
Summary of Contents for Thermo Dynamics CWL
- Page 1 WL Series - LE Edition Models WL, N WL, WLDV 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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Page 3: Product Features
• 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 Direct Vent and Rear Vent Models CWL-LE NCWL CWL-DV ontents Service Policy... -
Page 4: 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 5: Homeowner Information
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. -
Page 6: Read This First
Read This First Installer must be a trained, experienced technician and should read all instructions before installation. 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. - Page 7 AFUE RATING - W/O DAMPER 84.3 83.2 82.1 *Specifications apply to CWL-LE, NCWL and CWL-DV except when using REAR FLUE KIT, jacket height increases by 4-1/4 inches Figure 1 - Model Dimensions “0” Clearance Sides and Back pproved for combustible Floors...
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Page 8: Installation
C) To move the unit, push against the flue box or skids. Pushing or pulling the jacket or burner will result in damage. D) Be sure to level the unit by inserting shims under the elevated base. E) CWL Series - LE rear flue kit with built-in draft regulator. -
Page 9: Venting System
THE TV-175 DIRECT VENT KIT. SURFACE DISCOLORATION OF THE BUILDING MAY OCCUR DUE TO IMPROPER BOIL- ER/BURNER ADJUSTMENT. THERMO DYNAMICS BOILER COMPANY WILL NOT ACCEPT ANY LIABILITY FOR SUCH DISCOLORATION. Install TV-175 Direct Vent Kit in accordance with installation instructions provided with the kit. -
Page 10: Boiler Piping
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 acces- sories are installed after the jacket is in place. Assemble the jacket as shown in Figure 5. 2. - Page 11 Deterioration due to coil gasket leaks shall void warranty. * Venting - Refer to Section VI BOILER PIPING ** Relief Valve discharge and drain valve piping should be piped to a safe place of discharge. CWL Boiler Piping Figure 3...
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Page 12: Burner And Controls
X BURNER AND CONTROLS A) Burner Installations Packaged boilers are shipped with the burner installed and prewired. Boilers that are shipped knocked- down 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. -
Page 13: Sequence Of Operation
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 burn- ers 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. - Page 14 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 loca- tions.
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Page 15: Warranty
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 manu- facturer’s installation manual and the control manufacturers installation manual for all field wiring. -
Page 16: Burner Adjustments
The CWL-Series is a forced draft boiler and requires a positive pressure over the fire. If chim- ney draft causes the overfire draft to become negative, the draft regulator must be installed. The over- fire draft must not be less than +.005 (positive). -
Page 17: Burner 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. -
Page 18: Maintenance
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 accumu- lation. -
Page 19: Troubleshooting Guide
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. - Page 20 TROUBLE: BURNER STARTS BUT DOES NOT ESTABLISH FLAME SOURCE PROCEDURE CAUSES REMEDY Empty tank. Fill tank. Oil Supply Check tank for oil. Water in oil tank. Strip tank of water exceeding Check for water in oil tank using a dip stick coated with litmus 2"...
- Page 21 TROUBLE: BURNER FIRES, BUT THEN FAILS ON SAFETY SOURCE PROCEDURE CAUSES REMEDY Faulty or dirty cad cell Clean or replace cad cell. Cad Cell Check cad cell with ohmmeter. If more than 2000 ohms, cad cell is defective or dirty. Primary After burner fires, open cad cell Faulty primary control...
- Page 22 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. Oil Supply If burner loses flame prior to the Air leak in fuel system.
- Page 23 TROUBLE: BURNER FIRES, BUT PULSATES SOURCE PROCEDURE CAUSES REMEDY Down drafts. Install vent cap. Draft Take a draft reading. Draft should be according to installer/service- Insufficient draft. Increase draft setting. man labels starting on page 24, Excessive draft. Reduce draft settings, install in the stack.
- Page 24 TROUBLE: INSUFFICIENT HEAT SOURCE PROCEDURE CAUSES REMEDY Coupling worn or broken. Replace coupling. Circulator Check if circulator is operational. Pump binding. Replace pump. Circulator motor burned out. Replace circulator motor. Wiring from operating control Repair wiring. defective. Operating control defective. Repair or replace operating control.
- Page 25 TROUBLE: HIGH NET STACK TEMPERATURES SOURCE PROCEDURE CAUSES REMEDY Nozzle Check pump pressure with pump Nozzle overfiring due to high Reduce pump pressure according gauge. pump pressure. to installer/serviceman labels starting on page 30. Heat Check heat exchanger surfaces Heat exchanger fouled. Clean heat exchanger.
- Page 26 Parts List CWL Series - LE Edition (Designate boiler and burner model numbers on all orders.) Item No. Part no. Description 540550 Beckett AFG Burner (1501) (Direct Vent AFII - Part No. 540580) 542200 Carlin EZ-1 Burner (Direct Vent EZ1 - Part No. 542160) 541165 Riello 5F Burner (Direct Vent BF5 - Part No.
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Page 27: Preliminary Settings
Preliminary Settings INSTALLER/SERVICEMAN INSTALLER/SERVICEMAN DIRECT VENT Model Number CWL-85 CWL-100 CWL-110 _________________________ Model Number CWL-85DV CWL-100DV CWL-110DV _________________________ Burner Type Carlin Carlin Carlin Burner Type Carlin* Carlin* Carlin* Burner Model EZ-1PRO EZ-1PRO EZ-1PRO _________________________ Burner Model EZ-1 EZ-1 EZ-1 _________________________ Nozzle Type .70 60°W... - Page 28 ZERO Smoke Reading ZERO ZERO ZERO AFII 100 DIRECT VENT SERIES: CWL 85 HAGO B AFII 100 DIRECT VENT SERIES: CWL 85 HAGO B CWL 100 HAGO B CWL 100 HAGO B CWL 110 HAGO ES CWL 110 HAGO ES NOTICE: Above settings are approximate.
- Page 29 ELECTRICAL DIAGRAMS FOR CWL SERIES BOILERS...
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Page 31: Burner Service Set-Up Records
BURNER SERVICE SET-UP RECORDS Initial Set Up 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. - Page 32 TDB-080 P/N 595831 MET-4088 12/10-500...
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