d esigned to l ead cwi series - velocity boiler … · cwi series gas-fired natural draft water...

CWI Series Gas-Fired Natural Draft Water Boilers

INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler

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.

Models: • CWI103• CWI138• CWI172

• CWI207 • CWI241• CWI276• CWI311• CWI346• CWI380

Manufacturer of Hydronic Heating ProductsP.O. Box 14818 3633 I. Street

Philadelphia, PA 19134www.crownboiler.com

D E S I G N E D T O L E A D

9902339

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FOLLOW ALL INSTRUCTIONS and warnings printed in this manual and posted on the boiler.

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.

IF YOU ARE NOT QUALIFIED to install or service boilers, do not install or service this one.

THE BOILER MAY LEAK WATER at the end of its useful life. Be sure to protect walls, carpets, and valuables from water that could leak from the boiler.

PROTECT YOUR HOME IN FREEZING WEATHER. A power outage, safety lockout, or component failure will prevent your boiler from lighting. In winter, your pipes may freeze and cause extensive property damage. Do not leave the heating system unattended during cold weather

unless alarms or other safeguards are in place to prevent such damage

DO NOT BLOCK AIR FLOW into or around the boiler. Insufficient air may cause the boiler to produce carbon monoxide or start a fire.

KEEP FLAMMABLE LIQUIDS AWAY from the boiler, including paint, solvents, and gasoline. The boiler may ignite the vapors from the liquids causing explosion or fire.

KEEP CHILDREN AND PETS away from hot surfaces of the boiler, boiler piping, and vent pipe.

CARBON MONOXIDE (CO) is an odorless, deadly gas that may be introduced into your home by any malfunctioning fuel-burning product or vent system failure. Consider installing CO alarms near bedrooms in all levels of the building to warn you and your family of potential CO exposure.

READ THIS ENTIRE MANUAL before attempting installation, start-up, or service. Improper installation, adjustment, alteration, service, or maintenance may cause serious property damage, personal injury, or death.

DO NOT DISCONNECT PIPE FITTINGS on the boiler or in the heating system without first verifying that the system is cool and free of pressure and that your clothing will protect you from a release of hot water or steam. Do not rely solely on the boiler’s temperature and pressure gage when making this judgment.

USE PROPER PERSONAL PROTECTION EQUIPMENT when servicing or working near the boiler. Materials of construction, flue products, and fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, and/or other toxic or harmful substances that can are hazardous to health and life and that are known to the State of California to cause cancer, birth defects, and other reproductive harm.

INSTALL ALL GUARDS, cover plates, and enclosures before operating the boiler.

SIZE THE BOILER PROPERLY relative to the design heat load or, if using domestic hot water priority, the peak hot water load, whichever is larger. A grossly oversized boiler will cycle excessively and this will lead to premature failure of the boiler and its components. Our warranty does not apply to damage from excessive cycling.

ADHERE TO ALL LOCAL CODE REQUIREMENTS. Contact your local code inspector prior to installation. In the absence of a local code, adhere to the National Fuel Gas Code ANSI Z223.1/NFPA 54 or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

ALL WIRING must comply with the National ElectrIcal Code ANSI/NFPA 70 (in the USA) or the Canadian Electrical Code CSA C22.1 (in Canada) and any local regulations.

WARNINGS FOR THE HOMEOWNER

WARNINGS FOR THE INSTALLER

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Table of Contents

I. Product Description .................................................... 2II. Specifications ............................................................. 3III. BeforeInstalling ......................................................... 4IV. LocatingtheBoiler ..................................................... 4V. AirforCombustion&Ventilation .............................. 5VI. Venting ....................................................................... 9VII.GasPiping..................................................................12VIII.SystemPiping..........................................................13IX.TanklessHeaterPiping..............................................18X.Wiring........................................................................20XI.Start-Up&Checkout.................................................24XII.Service&Maintenance.............................................30XIII.Troubleshooting........................................................33XIV.Parts...........................................................................40AppendixA:KnockdownBoilerAssembly.......................46

I Product Description TheCWIseriesboilersarelowpressurecastirongasfiredhotwaterboilersdesignedforuseinclosedhotwaterheatingsystems.TheseboilersareCategoryIdraftdiverterequippedappliances,whichmustbeventedbynaturaldraftusingalinedmasonryorlistedmetalchimneysystem.Anadequatesupplyofairforcombustion,ventilationanddilutionoffluegasesmustbeavailableintheboilerroom. TheCWImaybeusedonforcedorgravityhotwaterheatingsystems.CWI103-CWI279includeatanklessheaterfordomestichotwatergeneration.ThistanklessheaterisoptionalequipmentonCWI311-CWI380

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TABLE 1: CWI SPECIFICATIONS

II Specifications

FIGURE1:CWIBOILERS-GENERALCONFIGURATION

INPUT(MBH) (MBH) (Gal/min)4 "A" "B" "C" "D" (Gal)

CWI103 4 103 86 83.1 2.50 16 28 407/16 5 10.0

CWI138 5 138 115 83.1 3.00 191/4 28 407/16 6 12.2

CWI172 6 172 144 83.2 3.50 221/2 28 407/16 6 14.4

CWI207 7 207 173 83.2 3.75/4.50 253/4 30 407/16 7 16.6

CWI241 8 241 201 83.2 3.75/4.753 29 30 407/16 7 18.8

CWI276 9 276 230 83.2 4.00/5.253 321/4 30 407/16 8 21.0

CWI311 10 310 252 81.42 4.00/5.253 351/2 30 457/16 8 23.2

CWI346 11 345 281 81.42 4.00/5.253 383/4 30 457/16 9 25.4

CWI380 12 379 309 81.42 4.00/5.253 42 30 457/16 9 27.6

AHRINETRATINGSSHOWNAREBASEDONAPIPINGANDPICK-UPALLOWANCEOF1.15

2THERMALEFFICIENCY3RATINGWITHOPTIONAL"HIGHCAPACITY"TANKLESSHEATER

200

4TANKLESSHEATERRATINGSBASEDON40FINLETWATER,140FOUTLETWATERAND190FBOILERWATER.RATINGSAREALSOBASEDON5MINUTEINTERMITTENTDRAWSWITH10MINUTESBETWEENDRAWS.

AHRINETRATING

244

2691CWI311-CWI380NOTAVAILABLEFORUSEWITHLPGAS

BASICBOILERMODEL

NUMBEROF

SECTIONS (MBH)

NATURALORLPGAS1

HEATINGCAPACITY DIMENSIONS(in.)AFUE

(%)

WATERVOL.

75

100

219

TANKLESSHTR.RATING

125

150

175

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III Before Installing1) Safe,reliableoperationofthisboilerdependsuponinstallationbyaprofessionalheatingcontractorinstrictaccordancewiththismanualandtherequirementsoftheauthorityhavingjurisdiction.

• Intheabsenceofanauthorityhavingjurisdiction,installationmustbeinaccordancewiththismanualandtheNational Fuel Gas Code,ANSIZ223.1-latestedition.

• Whererequiredbytheauthorityhavingjurisdiction,thisinstallationmustconformtotheStandard for Controls and Safety Devices for Automatically Fired Boilers(ANSI/ASMECSD-1)-latestedition.

2) Makesurethataproperlysizedchimneyisavailablewhichisingoodcondition.Consulttheauthorityhavingjurisdiction,PartVIofthismanual,andtheNational Fuel Gas Codeforadditionalinformationonventingrequirements. 3) Makesurethattheboileriscorrectlysized.UseanindustryacceptedsizingmethodsuchastheI=B=R Installation Guide for Residential Hydronic Heating Systems (Pub. #200) and I=B=R Heat Loss Calculation Guide(Pub.#H21or#H22)publishedbytheHydronicsInstituteinBerkeleyHeightsNJ.

4) Makesurethattheboilerreceivedisconfiguredforthecorrectgas(naturalorLP).TheCWI311,CWI346andCWI380mayonlybeusedwithnaturalgas.

5) Boilersinstalledataltitudesabove2000ft.mayrequiredifferentburnersandmainburnerorificethanthoseatsealevel.Makesurethattheboilerisconfiguredforuseatthecorrectaltitude.

6) Ifthisboilerwasreceivedasaknockdownboiler,followtheinstructionsinAppendixAtoassembletheboiler.

IV Locating the Boiler

1) Clearances:• Observetheminimumclearancesshownbelow.Theseclearancesapplytoallcombustibleconstruction,aswellas

noncombustiblewalls,ceilingsanddoors.AlsoseeFigure2.

Front–18” RightSide:CWI311-CWI380withoutTanklessHeaters–18”CWI103-CWI207withTanklessHeater-18”CWI241-CWI380withStandardTanklessHeater-21”CWI241-CWI380withHighCapacityTanklessHeater-24” LeftSide–6” Rear–6” Top–17”

WARNING

FAILURE TO OBSERVE THE FOLLOWING LOCATION REQUIREMENTS COULD RESULT IN A FIRE, EXPLOSION OR CARBON MONOXIDE (CO) HAZARD.

Warning

This Product Must be Installed By A Licensed Plumber Or Gas Fitter when Installed Within The Commonwealth Of Massachusetts

If This Boiler is Equipped With a Tankless Heater, Tankless Heater Piping Must be Installed by a Licensed Plumber When Boiler is Installed Within the Commonwealth of Massachusetts

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• A24”serviceclearancefromthejacketisrecommendedontheleft,right,andfrontoftheboiler.TheseclearancesmaybereducedtothoseshowninFigure2,howeverservicingtheboilerwillbecomeincreasinglydifficultastheseserviceclearancesarereduced.

• Iftherightside24”serviceclearanceisreduced,adequateclearancemustbemaintainedtoeasilyreadandac-cessthecontrols.Alternatively,accessmaybeprovidedusingadoor.Therightsideclearancesshownforboilersequippedwithtanklessheatersallowforremovalofthetanklessheater.

2) Thisboilermaybeinstalleddirectlyoveranon-carpetedcombustiblefloor.

3) Theboilermustbeinstalledonahardlevelsurface.

4) Donotinstallthisboilerinalocationwheregasolineorotherflammablevaporsorliquidswillbestoredorused.Donotinstallthisboilerinanareawherelargeamountsofairbornedustwillbepresent,suchasaworkshop.

5) Theboilershouldbelocatedasclosetothechimneyaspossible.

6) Donotinstallthisboilerdirectlyonasurfacethatmaygetwet.Raisetheboileronapad.

V Air for Combustion and Ventilation

WARNING

• INSUFFICIENT COMBUSTION AIR SUPPLY MAY RESULT IN THE PRODUCTION AND RELEASE OF DEADLY CARBON MONOXIDE (CO) INTO THE HOME WHCH CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.

• THIS BOILER IS NOT DESIGNED FOR USE IN A SPACE THAT IS DEPRESSURIZED RELATIVE TO THE OUTDOORS. OPERATING THIS BOILER IN A DEPRESSURIZED SPACE MAY CAUSE SEVERE PERSONAL INJURY OR DEATH.

FIGURE2:CWIBOILERS-CLEARANCESTOALLTYPESOFCOMBUSTIBLECONSTRUCTIONANDNONCOMBUSTIBLECEILINGS,WALLS,ANDDOORS.

“X”

“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“

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Sufficientfreshairmustbesuppliedforcombustion,ventilationandfluegasdilution.Provisionsforcombustion,ventilationandfluegasdilutionairforgasutilizationequipmentventedbynaturaldraftmustbemadeinaccordancewithlocalbuildingcodesor,inabsenceofsuchcodes,inaccordancewithsections5.3.3and5.3.4(“AirforCombustionandVentilation”)oftheNational Fuel Gas Code,NFPA54/ANSIZ223.1.

Toensureanadequatesupplyofcombustion,ventilationandfluegasdilutionairsupply,startbydeterminingwhethertheboileristobeinstalledinabuildingofunusuallytightconstruction.Agooddefinitionofabuildingofunusuallytightconstructionisonewhichhasallofthefollowingfeatures:

• Wallsandceilingsexposedtooutsideatmospherehaveacontinuouswatervaporretarderwitharatingof1permorlesswithopeningsgasketedandsealed

• Weatherstrippinghasbeenaddedonopenablewindowsanddoors

• Caulkingandsealantsareappliedtoareassuchasjointsaroundwindowanddoorframes,betweensoleplatesandfloors,betweenwall-ceilingjoints,betweenwallpanels,atpenetrationsforplumbing,electrical,andgaslines,andatotheropenings.

For Buildings of Other than Unusually Tight Construction 1) Determinewhethertheboileristobeinstalledinaconfinedspace-AconfinedspaceisdefinedbytheNational Fuel

Gas Codeashavingavolumelessthan50cubicfeetper1000BTU/hrinputofallappliancesinstalledinthatspace.Todeterminewhethertheboilerroomisaconfinedspace:

a. TotaltheinputofallappliancesintheboilerroominthousandsofBTU/hr.Roundtheresulttothenexthighest1000BTU/hr.

b. Findthevolumeoftheroomincubicfeet.Thevolumeoftheroomincubicfeetis: Length(ft)xwidth(ft)xceilingheight(ft) Incalculatingthevolumeoftheboilerroom,considerthevolumeofadjoiningspacesonlyifnodoorsareinstalled

betweenthem.Ifdoorsareinstalledbetweentheboilerroomandanadjoiningspace,donotconsiderthevolumeoftheadjoiningspace,evenifthedoorisnormallyleftopen.

c. DividethevolumeoftheboilerroombytheinputinthousandsofBTU/hr.Iftheresultislessthan50,theboilerroomisaconfinedspace.

Example: ACWI172ENandawaterheateraretobeinstalledinaroommeasuring6ft-3inx7ftwithan8ftceiling.Thewater

heaterhasaninputof30000BTU/hr: TotalinputinthousandsofBTU/hr=(172000BTU/hr+30000BTU/hr)/1000=202 Volumeofroom=6.25ftx7ftx8ft=350ft3

350/202=1.73.Since1.73islessthan50,theboilerroomisaconfinedspace.

2) UnconfinedSpace-Naturalinfiltrationintotheboilerroomwillnormallyprovideadequateairforcombustionandventilationwithoutadditionallouversoropeningsintoboilerroom.

3) ConfinedSpace-Providetwoopeningsintotheboilerroom,onenearthefloorandoneneartheceiling.Thetopedgeoftheupperopeningmustbewithin12”oftheceilingandthebottomedgeoftheloweropeningmustbewithin12”ofthefloor(Figure3).

• Eachopeningmusthaveafreeareaof1squareinchper1000BTU/hrinputofallgasburningappliancesintheboilerroom.Theminimumopeningdimensionis3inches.Minimumopeningfreeareais100squareinchesperopening.

• Ifthetotalvolumeofboththeboilerroomandtheroomtowhichtheopeningsconnectislessthan50cubicfeetper1000BTU/hroftotalapplianceinput,installapairofidenticalopeningsintoathirdroom.Connectadditionalroomswithopeningsuntilthetotalvolumeofallroomsisatleast50cubicfeetper1000BTU/hrofinput.

• The“freearea”ofanopeningtakesintoaccounttheblockingeffectofmesh,grills,andlouvers.Wherescreensareused,theymustbenofinerthan¼”(4x4)mesh.

• Ifprovidingopeningsintoadjacentroomsisundesirable,combustionandventilationaircanbebroughtintotheboilerroomfromoutdoors.Seetheinstructionsunder“ForBuildingsofUnusuallyTightConstruction”.

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FIGURE4:ALLAIRFROMOUTDOORS, VENTILATEDCRAWLSPACEANDATTIC

FIGURE5:ALLAIRFROMOUTDOORS, VIA VENTILATED ATTIC

FIGURE3:BOILERINSTALLEDINCONFINEDSPACE, ALLAIRFROMINSIDE

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FIGURE6:ALLAIRFROMOUTDOORS,USING OPENINGSINTOBOILERROOM

FIGURE7:ALLAIRFROMOUTDOORS,USING HORIZONTALDUCTSINTOBOILERROOM

99

For Buildings of Unusually Tight Construction1) Openingsmustbeinstalledbetweentheboilerroomandtheoutdoorsoraventilatedspace,suchasanatticorcrawlspace,whichcommunicatesdirectlywiththeoutdoors.2) Twoopeningsarerequired.Thetopedgeoftheupperopeningmustbewithin12inchesoftheceiling.Thebottomedgeoftheloweropeningmustbewithin12inchesofthefloor.3) Sizeopeningsandductsasfollows:

• Verticalductsoropeningsdirectlyoutdoors(Figure4,Figure5,andFigure6)-Eachopeningmusthaveafreecrosssectionalareaof1squareinchper4000BTU/hrofthetotalinputofallgas-firedappliancesintheboilerroombutnotlessthan100squareinches.Minimumopeningsizeis3inches.

• Openingstooutdoorsviahorizontalducts(Figure7)-Eachopeningmusthaveafreecrosssectionalareaof1squareinchper2000BTU/hrofthetotalinputofallgasfiredappliancesintheboilerroombutnotlessthan100squareinches.Minimumopeningsizeis3inches.

• The“freearea”ofanopeningtakesintoaccounttheblockingeffectofmesh,grills,andlouvers.Wherescreensareused,theymustbenofinerthan¼”(4x4)mesh.

VI Venting

Ventinstallationmustbeinaccordancewithlocalbuildingcodes,orthelocalauthorityhavingjurisdiction,ortheNational Fuel Gas Code,NFPA54/ANSIZ223.1.

AtypicalventinstallationisillustratedbyFigure8.Thecomponentsofventinstallationaretheventdamper,ventconnectorandchimney.

1) AcceptableChimneys-ThefollowingchimneysmaybeusedtoventCWIseriesboilers:

• ListedTypeBorLgasvent-Installinaccordancewiththemanufacturer’sinstructions,thetermsofitslisting,andapplicablecodes.

• MasonryChimney-ThemasonrychimneymustbeconstructedinaccordancewiththeStandard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances(NFPA211)andlinedwithaclaylinerorotherlistedliningsystem.DonotventaCWIseriesboilerintoanunlinedchimney.

2) AcceptableVentConnectors-Thefollowingmaybeusedforventconnectors:

• ListedtypeBorLGasVent

• SingleWallGalvanizedPipe-Use0.018”(26gaugeorheavier).Thesizeandlocationofthechimneymaynotpermittheuseofasinglewallconnectorinsomecases.SeetheNational Fuel Gas Code.Donotusesinglewallpipeforventconnectorsinattics.

• OtherVentConnectorsPermittedbytheNational Fuel Gas Code.

3) ChimneyandVentConnectorSizing-SizethechimneyandventconnectorinaccordancewiththeNational Fuel Gas Code.

4) ExteriorChimneys-Anexteriorchimneyhasoneormoresidesexposedtotheoutdoorsbelowtheroofline.Therearetwoconditionsunderwhichanexteriorchimneymaybeused:

WARNING

• IMPROPER VENTING MAY RESULT IN PROPERTY DAMAGE AND/OR THE RELEASE OF FLUE GASES, WHICH CONTAIN DEADLY CARBON MONOXIDE (CO), INTO THE HOME, WHICH CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.

• DO NOT USE PLASTIC VENTING MATERIALS (SUCH AS CPVC, PVC AND RADEL) TO VENT THIS BOILER.

• INSPECT EXISTING CHIMNEY BEFORE INSTALLING BOILER. FAILURE TO CLEAN OR REPLACE DAMAGED PIPE OR TILE LINING WILL CAUSE SEVERE INJURY OR DEATH.

1010

• In some very restrictivecases,CWIseriesboilersmaybeventedintoanexteriorceramiclinedmasonrychimney.SeetheNational Fuel Gas Codeforinformationonwhenexteriorchimneysmaybeused.

• AnexteriormasonrychimneymaybeusedifitislinedwithBventoralistedchimneyliningsystem.

5) Thisboilermaybeventedusingalistedpowerventer.Thepowerventermustbeinsizedandinstalledinaccordancewiththepowerventermanufacturer’sinstructions,thetermsofthepowerventerlisting,andapplicablecodes.Theboilermustbeelectricallyinterlockedwiththepowerventertopreventboileroperationifthepowerventerfailstooperate.Beforedecidingtouseapowerventer,makecertainthatthefluegasexitingthepowerventerwillnotdamageadjacentconstructionorotherstructures.Alsomakecertainthatthepowerventerterminalwillnotbesubjectedtowindswhichcouldeffectpowerventeroperation.

6) Donotconnecttheventofthisapplianceintoanyportionofamechanicalventsystemoperatingunderpositivepressure.

7) Donotconnecttheboilerintoachimneyflueservinganopenfireplaceorothersolidfuelappliance.

8) Priortoboilerinstallation,inspectchimneyforobstructionsorotherdefectsandcorrectasrequired.Cleanchimneyasnecessary.9)Ventpipeshouldslopeupwardfromdraftdiverternotlessthanoneinchinfourfeet.Noportionofventpipeshouldrundownwardorhavesags.Ventpipemustbesecurelysupported.10) Theverticalsectionofventpipecomingofftheboilershouldbeastallaspossible,whilestillmaintainingtheproperclearancefromthehorizontalventconnectortocombustiblesandtheproperpitchcalledforin(9)above.11) Ventpipeshouldbeinstalledabovethebottomofthechimneytopreventblockage.12) Ventpipemustbeinsertedflushwithinsidefaceofthechimneylinerandthespacebetweenventpipeandchimneysealedtight.13) Donotinstalltheventdamperinanyportionoftheventsystemwhichisusedbyappliancesotherthantheboilerbeinginstalled.14) VentdamperinstallationismandatoryonallCWIboilermodelsexcepttheCWI311-CWI380.Installventdamper(seeFigure9)asfollows:

a) Openventdampercartonandremoveinstallationinstructions.Readtheinstructionsthoroughlybeforeproceeding. Verifythatventdamperissamesizeasdraftdiverteroutlet.SeeFigure1.Unpackventdampercarefully.Do not force closed damper blade. Forcingventdamperclosedmayresultindamagedgeartrainandvoidwarranty.

b) Ventdamperisfactoryshippedhavingapproximately¾”diameterholeintheventdamperblade,whichmust be left openforboilersequippedwithstandingpilot,andshouldbepluggedonboilerswithanintermittentpilot,usingtheplugsuppliedwiththedamper. Mounttheventdamperonthefluecollarwithoutmodificationtoeitherandsecurewithsheetmetalscrews.Makesurescrewsdonotinterferewithdamperbladeoperation.Ventdamperbladepositionindicatormustbevisibletousers.

c) Thedamperwireharnessisshippedwiredintotheboilerjunctionbox.Plugthelooseendofthisharnessintothedamperandsecuretheflexibleconduittothedamperusingaconnectornutprovided.

d) Installventconnectorpipeandventfittingsfromventdamperoutlettochimneyorgasvent.Securewithsheetmetalscrewsandsupportasrequired.

Removing an Existing Boiler from a Common ChimneyInsomecases,whenanexistingboilerisremovedfromacommonchimney,thecommonventingsystemmaybetoolargefortheremainingappliances.Atthetimeofremovalofanexistingboilerthefollowingstepsshallbefollowedwitheachapplianceremainingconnectedtothecommonventingsystemplacedinoperation,whiletheotherappliancesremainingconnectedtothecommonventingsystemarenotinoperation.

a) Sealanyunusedopeninginthecommonventingsystem.b) Visuallyinspecttheventingsystemforpropersizeandhorizontalpitchanddeterminethereisnoblockageor

restriction,leakage,corrosionandotherdeficiencieswhichcouldcauseanunsafecondition.c) Insofaraspractical,closeallbuildingdoorsandwindowsandalldoorsbetweenthespaceinwhichalltheappliances

remainingconnectedtothecommonventingsystemarelocatedandotherspacesofthebuilding.Turnonclothesdryersandanyappliancenotconnectedtothecommonventingsystem.Turnonanyexhaustfans,suchasrangehoodsandbathroomexhausts,sotheywilloperateatmaximumspeed.Donotoperateasummerexhaustfan.Closefireplacedampers.

1111

FIGURE8:CWIBOILERTYPICALVENTSYSTEM INSTALLATION AND COMPONENTS

FIGURE9:VENTDAMPERINSTALLATIONDETAILS

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d) Placeinoperationtheappliancebeinginspected.Followthelightinginstructions.Adjustthermostatsotheappliancewilloperatecontinuously.

e) Testforspillageatthedrafthoodreliefopeningafterfive(5)minutesofmainburneroperation.Usetheflameofamatchorcandle,orsmokefromacigarette,cigar,orpipe.

f) Afterithasbeendeterminedthateachapplianceremainingconnectedtothecommonventingsystemproperlyventswhentestedasoutlinedabove,returndoors,windows,exhaustfans,fireplacedampersandanyothergas-burningappliancestotheirpreviousconditionofuse.

g) AnyimproperoperationofthecommonventingsystemshouldbecorrectedsotheinstallationconformswiththeNationalFuelGasCode,ANSIZ223.1.Whenresizinganyportionofthecommonventingsystem,thecommonventingsystemshouldberesizedtoapproachtheminimumsizeasdeterminedusingtheappropriatetablesintheNationalFuelGasCode,ANSIZ223.1.

VII Gas Piping

Gaspipingtotheboilermustbesizedtodeliveradequategasfortheboilertofireatthenameplateinputatalinepressurebetweentheminimumandmaximumvaluesshownontheratingplate.Formoreinformationongaslinesizing,consulttheutilityorChapter2oftheNational Fuel Gas Code.Figure10showstypicalgaspipingconnectiontotheCWIboiler.Asedimenttrapmustbeinstalledupstreamofallgascontrols.Installamanualshut-offvalveoutsidethejacketandgroundjointunionasshown.

FIGURE10:GASCONNECTIONTOBOILER

*StateofMassachusettsRequiresManualShut-offValvetobe“T”HandleType

*

WARNING• SHUT OFF GAS SUPPLY BEFORE SERVICING THE BOILER.

• ALL GAS PIPING MUST BE GAS TIGHT. USE GAS RATED THREAD COMPOUND ON ALL THREADED JOINTS TO AVOID LEAKS, WHICH MAY RESULT IN FIRE OR EXPLOSION.

• SIZE GAS PIPING, REGULATORS, VALVES AND METERS SO AS TO PROVIDE AN ADEQUATE GAS FLOW AND PRESSURE TO THE BOILER DURING OPERATION. FAILURE TO DO SO MAY CAUSE POOR COMBUSTION, NOISE, INJURY OR DEATH.

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VIII System Piping

Standard Piping Figure11showstypicalboilersystemconnectionsonasinglezonesystem.Additionalinformationonhydronicsystem

designmaybefoundinInstallation of Residential Hydronic Systems(Pub.#200)publishedbytheHydronicsInstituteinBerkeleyHeights,NJ.Thecomponentsinthissystemandtheirpurposesareasfollows:

1) Reliefvalve(Required)-MountthereliefvalveontherightsideoftheboilerasshowninFigure1usingthe3/4nipplesandelbowprovided.Thereliefvalveshippedwiththeboilerissettoopenat30psi.Thisvalvemaybereplacedwithonehavingapressureuptothe“MAWP,WATER”shownontheratingplate.Ifthevalveisreplaced,thereplacementmusthaveareliefcapacityinexcessoftheDOEheatingcapacityfortheboiler.

Pipethedischargeofthereliefvalvetoalocationwherewaterorsteamwillnotcreateahazardorcausepropertydamageifthevalveopens.Theendofthedischargepipemustterminateinanunthreadedpipe.Ifthereliefvalvedischargeisnotpipedtoadrainitmustterminateatleast6inchesabovethefloor.Donotrunreliefvalvedischargepipingthroughanareathatispronetofreezing.Theterminationofthereliefvalvedischargepipingmustbeinanareawhereitisnotlikelytobecomepluggedbydebris.

2) Circulator(Required)-Althoughthecirculatorisshippedontheboilerreturn,itcanbeinstalledontheboilersupply.Ifthecirculatorismovedtothesupply,itshouldbepositionedjustdownstreamoftheexpansiontankasshowninFigure11.

3) ExpansionTank(Required)-Ifthisboilerisreplacinganexistingboilerwithnootherchangesinthesystem,theoldexpansiontankcangenerallybereused.Iftheexpansiontankmustbereplaced,consulttheexpansiontankmanufacturer’sliteratureforpropersizing.

Theboileranditsgasconnectionmustbeleaktestedbeforeplacingtheboilerinoperation.Whendoingthis,theboileranditsindividualshut-offmustbedisconnectedfromtherestofthesystemduringanypressuretestingofthatsystematpressuresinexcessof1/2psi.Whenpressuretestingthegassystematpressuresof1/2psiorless,isolatetheboilerfromthegassupplysystembyclosingitsindividualmanualshut-offvalve.

WARNING• 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.

• OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.

• DO NOT USE TOXIC ADDITIVES, SUCH AS AUTOMOTIVE ANTIFREEZE, IN A HYDRONIC SYSTEM.

• PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION. THE RELIEF VALVE MAY DISCHARGE SCALDING HOT WATER.

• DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE.

• DO NOT MOVE RELIEF VALVE FROM FACTORY LOCATION.

• DO NOT PLUG RELIEF VALVE DISCHARGE. BLOCKING THE RELIEF VALVE MAY RESULT IN BOILER EXPLOSION.

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4) FillValve(Required)-Eitheramanualorautomaticfillvalvemaybeused.Theideallocationforthefillisattheexpansiontank.

5) AutomaticAirVent(Required)-Atleastoneautomaticairventisrequired.Manualventswillusuallyberequiredinotherpartsofthesystemtoremoveairduringinitialfill.

6) LowWaterCut-Off(Requiredinsomesituations)-Alowwatercutoffisrequiredwhentheboilerisinstalledaboveradiation.Inaddition,somecodessuchasASMECSD-1requirelowwatercutoffs.Codesmayalsorequirethatthislowwatercutoffhaveamanualresetfunction.Thelowwatercutoffmaybeafloattypeorprobetype,butmustbedesignedforuseinahot-watersystem.Thelowwatercutoffshouldbepipedintotheboilersupplyjustabovetheboilerwithnointerveningvalvesbetweenitandtheboiler.

Usealowwatercutoffthatbreaksthe120VACsupplytotheboiler.Donotattempttowirea24-voltlowwatercutoffintotheboilerfactorywiring.

7) ManualResetHighLimit(Requiredbysomecodes)-ThiscontrolisrequiredbyASMECSD-1andsomeothercodes.Installthehighlimitintheboilersupplypipingjustbeyondtheboilerwithnointerveningvalves.Setthemanualresethighlimitasfarabovetheoperatinglimitsettingaspossible,butnotover240°F.Wirethecontroltobreakthe120VACelectricalsupplytotheboiler.

8) FlowControlValve(Requiredundersomeconditions)-Theflowcontrolvalvepreventsflowthroughthesystemunlessthecirculatorisoperating.Aflowcontrolvalvemaybenecessaryonconvertedgravitysystemstopreventgravitycirculation.Flowcontrolvalvesarealsousedtoprevent“ghostflows”incirculatorzonesystemsthroughzonesthatarenotcallingforheat.

9) IsolationValves(Optional)-Isolationvalvesareusefuliftheboilermustbedrained,astheywilleliminatehavingtodrainandrefilltheentiresystem.

10) DrainValve-Thedrainvalveisshippedintheboilerpartsbag.InstallitintheteeunderthecirculatorasshowninFigure1.

Piping for Special SituationsCertaintypesofheatingsystemshaveadditionalrequirements.Someofthemorecommonvariationsfollow:

1) IndirectWaterHeaters-Figure12showstypicalindirectwaterheaterpiping.Boilerpipingisthesameasforanytwo-zonesystem.Figure12showscirculatorzoning,whichisusuallypreferredforindirectwaterheaters.Sizethecirculatorandindirectwaterheaterpipingtoobtaintheboilerwaterflowthroughtheindirectwaterheatercalledforbytheindirectwaterheatermanufacturer.

2) LargeWaterVolumeSystems-ThepipingshowninFigure13willminimizetheamountoftimethattheboileroperateswithreturntemperaturesbelow120°Fonthesesystems.Abypassisinstalledasshowntodivertsomesupplywaterdirectlyintothereturnwater.Thebypasspipeshouldbethesamesizeasthesupply.Thetwothrottlingvalvesshownareadjustedsothatthereturntemperaturerisesabove120°Fduringthefirstfewminutesofoperation.Athree-wayvalvecanbesubstitutedforthetwothrottlingvalvesshown.Ifthecirculatorismountedonthesupply,thebypassmustbeonthedischargesideofthecirculator.

3) LowTemperatureSystems-Somesystems,suchasradianttubingsystems,requirethesystemwatertemperaturetobelimitedtoavaluebelowthetemperatureofthewaterleavingtheCWI.Thesesystemsalsotypicallyhavereturntemperatureswellbelowthe120°Fminimum.

Figure14illustratestheuseofaheatexchangertoconnecttheCWIboilertothistypeofsystem.Theheatexchangerwillpermitthetransferofheatfromtheboilerwatertothelowtemperaturesystemwhileholdingthesystemsupplyandboilerreturntemperatureswithintheirlimits.Forthissystemtoworkproperlytheheatexchangermustbeproperlysizedandthecorrectflowratesarerequiredoneithersideoftheheatexchanger.Consulttheheatexchangermanufacturerforsizinginformation.Thewaterintheboileriscompletelyisolatedfromthewaterinthesystem.Thismeansthatseparatefillandexpansiontanksarerequiredfortheheatingsystemloop.

Thereareseveralotherwaystoconnectlowtemperaturesystemstonon-condensingboilersliketheCWI,suchasfourwaymixingvalveandvariablespeedinjectionpumpingsystems.

4) Systemscontainingoxygen-ManyhydronicsystemscontainenoughdissolvedoxygentocauseseverecorrosiondamagetoacastironboilersuchastheCWI.Someexamplesinclude:

• Radiantsystemsthatemploytubingwithoutanoxygenbarrier.• Systemswithroutineadditionsoffreshwater.• Systemswhichareopentotheatmosphere.

1515

FIGURE12:INDIRECTWATERHEATER BOILERSIDEPIPING

FIGURE11:STANDARDBOILERPIPING

1616

Iftheboileristobeusedinsuchasystem,itmustbeseparatedfromtheoxygenatedwaterbeingheatedwithaheatexchangerasshowninFigure14.

Consulttheheatexchangermanufacturerforproperheatexchangersizingaswellasflowandtemperaturerequirements.Allcomponentsontheoxygenatedsideoftheheatexchanger,suchasthepumpandexpansiontank,mustbedesignedforuseinoxygenatedwater.

5) PipingwithaChiller-Iftheboilerisusedinconjunctionwithachiller,pipetheboilerandchillerinparallelasshowninFigure15.Useisolationvalvestopreventchilledwaterfromenteringtheboiler.

6) AirHandlers-Wheretheboilerisconnectedtoairhandlersthroughwhichrefrigeratedairpasses,useflowcontrolvalvesintheboilerpipingorotherautomaticmeanstopreventgravitycirculationduringthecoolingcycle.

7)GravityHotWaterSystems-TheCWIissuitableforinstallationinagravityhotwatersystem.Figure16showspipingforagravityhotwaterboiler.Thecirculator,1-1/2”x2”bushings,and1-1/2”pipingareremovedandthesystempipingisrundirectlytothe2”supplyandreturntappingsontheboiler.Ifisolationvalvesareinstalled,theyshouldbegatevalvesor“fullport”ballvalves.

Ifitisdesiredtoconvertthegravitysystemtoforcedhotwater,thefactorysuppliedcirculatorandpipingareusedasis.Agravityhotwatersystemisa“largewatervolumesystem”(see(2)above)andshouldbepipedwithabypassasshowninFigure13.Manygravityhotwatersystemshavebalancingorificeinstalledintheradiators.Theseorificemayneedtoberemovedtoobtainproperheatdistributionwhenthesystemisconvertedtoforcedhotwater.

FIGURE13:BOILERBYPASSPIPING

1717

FIGURE15:BOILERPIPINGWITHCHILLER

FIGURE14:ISOLATIONOFBOILERFROMSYSTEMWITHAHEATEXCHANGER

1818

IX TANKLESS HEATER PIPING

IftheCWIissuppliedwithatanklessheater,pipetheheaterasshowninFigure17.Thecomponentsinthissystemandtheirfunctionsareasfollows:

1)MixingValve(Required)-Duringtheheatingseason,thewaterexitingthetanklessheatermaybe180degreesormore.Themixingvalveblendshotwaterleavingthetanklessheaterwithcoldwatersoastomaintainthehotwatersuppliedtothefixturesatafixedtemperature.Thissavesenergy,increasestheamountofusablehotwateravailabletothehomeowner,andreducestheriskofscalding.

Installamixingvalvewithasettingrangeofapproximately110to130F.Followthemanufacturer’sinstructionsforinstallingthisvalve.Usuallya“heattrap”willberequiredbetweenthecoilandthe“hot”connectiononthemixingvalve.

FIGURE16:GRAVITYPIPING

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. DO NOT USE THE MIXING VALVE AS A SUBSTITUTE FOR PRESSURE BALANCING VALVES OR OTHER DEVICES REQUIRED BY PLUMBING CODES TO PROTECT AGAINST SCALDING.

1919

2)FlowRestrictor(Recommended)-IfwaterisdrawnfromthetanklesscoilatarateinexcessoftheratinginTable1,thetemperatureofthehotwatermaybetoolowtobeofuse.Theuseofaflowrestrictorwillpreventthisproblembylimitingtherateatwhichwatercanpassthroughthetanklessheater.Ifarestrictorisused,selectonehavingaratinginGPMapproximatelyequaltotheratingshowninTable1.Ifpossible,locatethisrestrictoratleast3feetfromthetanklessheaterinletsothatitisnotsubjectedtoexcessivetemperatureswhennowaterisflowingthroughthecoil.

3)PressureReliefValve(Required)-Limitsthepressureinthetanklessheaterandpiping.UseanASMEconstructedvalvedesignedfordomesticwaterservice,suchastheWatts#3L.Notethatthisisapressurereliefvalve,notaT&Pvalve.Selectavalvewithapressuresettinglessthanorequaltotheworkingpressuremarkedonthetanklesscoil.Pipethedischargetoasafelocationusingpipingthesamesizeasthedischargeconnectiononthevalve.InMassachusetts,terminatethereliefvalvedischargepipe12”abovethefloor.

4)HoseBibValves(Recommended)-Thesevalvespermitthecoiltobeperiodically“backflushed”toremovesediment.

5)GlobeorBallValve(Recommended)-Usedtoadjusttheflowthroughtheentiretanklessheatersystemifneeded.

6)Unions(Required)-Tanklessheatersmayrequireperiodicgasketreplacementorothermaintenancewhichrequiresremovaloftheheaterfromtheboiler.Installunionsanywhereinthetanklessheaterpipingthatwillfacilitateremovaloftheheater.

7)BackflowPreventer(RequiredinMassachusetts)-Ifrequiredbylocalcodes,installabackflowpreventerinthecoldwaterconnectiontothetanklesscoiljustupstreamofthepipingshowninFigure17.Installinaccordancewithlocalcodesandthebackflowpreventer’sinstallationinstructions.Alsoinstallapotablewaterexpansiontankontheoutletsideofthebackflowpreventer(betweenthebackflowpreventerandthepipingshowninFigure17).

FIGURE17:TANKLESSHEATERPIPING

2020

IX Wiring

(NOTE 2)

2. VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI311 - CWI380. WHEN DAMPER IS NOT USED,DAMPER HARNESS IS REPLACED WITH JUMPER PLUG.

PILOT VALVE

MAIN VALVE

TH

TR

ROBERTSHAW7000DERHCGAS VALVE(CWI380)

HONEYWELLVR8204/VR8304SERIES GAS VALVES(CWI311 - CWI346)

FIGURE18:WIRINGDIAGRAM,INTERMITTENTIGNITION(EI)SYSTEMLESSTANKLESSHEATER

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).

• DISCONNECT ELECTRICAL POWER TO THE BOILER AND HEATING SYSTEM BEFORE SERVICING. POSITIVELY ASSURE THAT NO VOLTAGE IS PRESENT. LOCK ELECTRICAL BOXES TO PREVENT SOMEONE FROM INADVERTENTLY RESTORING POWER BEFORE THE HEATING SYSTEM IS SAFE TO OPERATE.

• NEVER DEFEAT OR JUMP OUT SAFETY DEVICES.

• PROTECT EACH BOILER CIRCUIT WITH A PROPERLY SIZED OVER-CURRENT PROTECTION DEVICE.

• MAKE ELECTRICAL CONNECTIONS CAREFULLY ACCORDING TO THE BOILER’S WIRING DIAGRAM AND INSTRUCTIONS.

• WIRE ADDITIONAL FIELD SUPPLIED SAFETY LIMITS, SUCH AS LOW WATER CUTOFFS AND TEMPERATURE LIMIT DEVICES, IN SERIES WITH THE 120V CIRCUIT USED TO POWER THE BOILER. DO NOT ALTER THE BOILER’S FACTORY WIRING WHEN ADDING AN ADDITIONAL LIMIT DEVICE.

2121

2

(NOTE 2)

2. VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI311 - CWI380. WHEN DAMPER ISNOT USED, DAMPER HARNESS IS OMITTED AND TERMINAL B1 IS WIRED DIRECTLY TO FRS.AS SHOWN IN LADDER DIAGRAM

HIGH LIMIT

LOWLIMIT

HONEYWELLL8124E

LESS VENTDAMPER

TH

TR

+ROBERTSHAW7000DERHCGAS VALVE(CWI380)

HONEYWELLVR8204/VR8304SERIES GAS VALVES(CWI103 - 346)

PILOT VALVE

MAIN VALVE

FIGURE19:WIRINGDIAGRAM,INTERMITTENTIGNITION(EI)SYSTEMWITHTANKLESSHEATER

Single Zone Wiring

1)120VoltWiring-Theboilershouldbeprovidedwithitsown15Abranchcircuitwithfuseddisconnect.All120voltcon-nectionsaremadeinsidetheL8148EorL8124Eaquastatrelayasfollows(alsoseeFigures18-19):

• Hot(“black”)-Terminal“L1”

• Neutral(“white”)-Terminal“L2”

• Ground(“green”orbare)-GroundscrewoncaseofL8148EorL8124E

2)ThermostatWiring-Followthermostatmanufacturerinstructions.Toinsureproperthermostatoperation,avoidinstalla-tioninareasofpooraircirculation,hotspots(nearanyheatsourceorindirectsunlight),coldspots(outsidewalls,wallsadjacenttounheatedareas,locationssubjecttodrafts).ProvideClassIIcircuitbetweenthermostatandboiler.ConnectthermostatwireleadstoterminalsTandTVinsideaquastatrelay.

Wiring Variations

1) MultipleCirculatorZones–Figure20showswiringfortwoormorecirculatorzonesusingHoneywellR845As.OneR845Aisrequiredforeachcirculatorzone.Circulatorterminals“C1”and“C2”onthelimitcontrolarenotused.ADPSTHoneywellRA832AmaybesubstitutedinplaceoftheR845Ausingthe“X”and“X”terminalsinplaceofthe“5”and“6”terminalsonaR845A.AcallforheatfromanythermostatwillenergizetheDPSTrelayinthatzone’sR845A.Whenthisrelayisenergized,electricalcontinuityiscreatedbetweenterminals3and4,energizingthecirculatorforthatzone.Atthesametime,electricalcontinuityiscreatedbetweenterminals5and6ontheR845A,creatingacurrentpathfromterminal“T”to“TV”onthelimitcontrol.Assumingthatthesupplywatertemperatureisbelowthehighlimitsetting,thenormalignitionsequencewillbeiniti-ated.

2222

FIGURE21:ZONEWIRINGUSINGHONEYWELLV8043FZONEVALVES(FACTORYWIRINGNOTSHOWN-SEEFIGURES18-19)

FIGURE20:CIRCULATORZONEWIRINGUSINGHONEYWELLR845As(FACTORYBOILERWIRINGNOTSHOWN-SEEFIGURES18-19)

2323

Sequence of Operation, Intermittent Ignition, Less Tankless Heater

1)Whentheboilerisenergized,24voltsisimmediatelyappliedtoterminals“1”(blue)and“4”(yellow)ontheventdamper.As-sumingthatthereisnocallforheat,andthatthedamperswitchisinthe“automatic”position,thedamperwillclose.

2) Acallforheatfromthethermostatenergizesrelaycoil1R(therelayontheL8148E),causingcontacts1R1and1R2tomake.Contact1R1startsthecirculator.Contact1R2sendspowertothehighlimit.

3) Assumingthatthehighlimitismade,currentwillflowtopinterminal#2(orange)attheventdamperandthedamperwillopen.

4) Oncetheventdamperisfullyopen,anendswitchinsidethedamperwillmake,energizingpin#3(red)atthedamper.Thispinisconnectedthroughthedamperharnesstoterminal“B1”ontheL8148E.Atthispointintheoperatingsequence,24voltsispresentacross“B1”and“B2”.

5) Undernormalconditions,theflameroll-outswitchandblockedventswitcharemade.Voltagewillthereforeimmediatelyap-pearacrossthe“24V”and“24V(GND)”terminalsontheignitionmodule.

6) Uponapplicationofvoltageacrossthe“24V”and“24V(GND)”terminals,theignitionmodulewillstartanignitionsparkatthepilotandapply24voltsacrossthepilotvalve(terminals“PV”and“MV/PV”).

7) Oncethepilotisestablished,thepilotflamewillactasadiode,convertingtheACcurrentattheelectrodetoahalfwaveDCcurrentatthepilot’sgroundstrap.ThisDCcurrentflowsthroughtheboilertothe“GND(BURNER)”connectionontheigni-tionmodule.Fortheignitionmoduletorecognizethatapilotflameispresent,theDCcurrentflowingintothisterminalmustbeinexcessofapproximately1.0uA.

8) Oncetheignitionmoduledetectsthepresenceofapilotflame,voltageisappliedacrossthemainvalve(terminals“MV”and“MV/PV”),openingthevalveandestablishingmainflame.

9) Thewayinwhichtheignitionmodulehandlesfailuretoestablishpilotorthelossofanalreadyestablishedpilotdependsupontheexactignitionmodulesuppliedwiththeboiler.Formoreinformationonmoduleoperation,consulttheignitionmod-uleinstructionssuppliedwiththeboilerorthelocalCrownrepresentative.

Sequence of Operation, Intermittent Ignition, With Tankless Heater

1)Whentheboilerisenergized,24voltsisimmediatelyappliedtoterminals“1”(blue)and“4”(yellow)ontheventdamper.As-sumingthatthereisnocallforheat,andthatthedamperswitchisinthe“automatic”position,thedamperwillclose.

2) Iftheboilerwatertemperatureislessthanthelowlimitsettingminusthedifferentialsetting,terminals“R”and“B”intheL8124Earemadethroughthelowlimitswitch.ThelowlimitswitchingactionisSPDTwith“R”beingcommon.“R”and“W”arethereforeopenwhenever“R”and“B”aremade.Thismeansthatwhile“R”and“B”aremaderelaycoilR1isdeenergized,regardlessofwhetherornotthereisacallforheat.Thecirculatorwillthereforenotoperateiftheboilerwatertemperatureistoolowtogeneratedomestichotwater.

3) Assumingthatthehighlimitismade,currentwillflowtoterminal“B1”ontheL8124Eandthentoterminal“2”(orange)attheventdamperandthedamperwillopen.

4) Oncetheventdamperisfullyopen,anendswitchinsidethedamperwillmake,energizingpin#3(red)atthedamper.Theredwirefromthispinrunstotheflamerolloutswitch.

5) Undernormalconditions,theflameroll-outswitchandblockedventswitcharemade.Voltagewillthereforeimmediatelyap-pearacrossthe“24V”and“24V(GND)”terminalsontheignitionmodule.

6) Uponapplicationofvoltageacrossthe“24V”and“24V(GND)”terminals,theignitionmodulewillstartanignitionsparkatthepilotandapply24voltsacrossthepilotvalve(terminals“PV”and“MV/PV”).

7) Oncethepilotisestablished,thepilotflamewillactasadiode,convertingtheACcurrentattheelectrodetoahalfwaveDCcurrentatthepilot’sgroundstrap.ThisDCcurrentflowsthroughtheboilertothe“GND(BURNER)”connectionontheigni-tionmodule.Fortheignitionmoduletorecognizethatapilotflameispresent,theDCcurrentflowingintothisterminalmustbeinexcessofapproximately1.0uA.

8) Oncetheignitionmoduledetectsthepresenceofapilotflame,voltageisappliedacrossthemainvalve(terminals“MV”and“MV/PV”),openingthevalveandestablishingmainflame.

2) MultipleZonesusingZoneValves–Figure21showswiringformultiplezonesusingHoneywellV8043Fzonevalves.Thiswiringdiagrammaybeusedforother24-voltzonevalvesaslongastheyareequippedwithendswitches.Donotattempttousethetransformeronthelimitcontroltopowerthezonevalves;useaseparatetransformer.UptofiveV8043Fsmaybepoweredbyone48VAtransformer,suchastheHoneywellAT87A.Acallforheatfromagiventhermostatwillresultintheapplicationof24voltsacrosstheTHandTRterminalsonthecor-respondingzonevalve,energizingthezonevalvemotor.Thezonevalveopensandtheendswitchcontactsarethenmade.Theendswitchesareconnectedinparallelwitheachotherandtothe“T”and“TV”thermostatconnectionssothatanyzonevalvethatopenswillalsostartthecirculatorandfiretheboiler(assumingthehighlimitisnotopen).ZonevalveterminalTH/TRhasnointernalconnectiononthezonevalve;itismerelya“bindingpost”usedtoconnecttwoormorewires.

2424

XI Start-up and Checkout

9) Thewayinwhichtheignitionmodulehandlesfailuretoestablishpilotorthelossofanalreadyestablishedpilotdependsupontheexactignitionmodulesuppliedwiththeboiler.Formoreinformationonmoduleoperation,consulttheignitionmod-uleinstructionssuppliedwiththeboilerorthelocalCrownrepresentative.

10)Theboilerwillfireuntiltheboilerwatertemperatureisapproximatelyequaltothelowlimitsetting.Oncethewatertem-peraturereachesthispoint,“R”and“B”openand“R”and“W”make.Atthispoint,acallforheatfromthethermostatwillenergize1R,makingcontacts1R1and1R2.Contacts1R1energizethecirculator.Contacts1R2switchcurrentfromthe“hot”sideofthetransformersecondarytothehighlimitswitch.Ifthehighlimitismade,currentflowstoterminal“B1”andtheignitionsequenceisthenthesameasitisforacallforburneroperationfromthelowlimit(see(3)above).

Safety Control Operation - Standing Pilot and Intermittent Ignition

HighLimit-Interruptsmainburneroperationwhenthesupplywatertemperatureexceedssetpoint.Maximumallowabletem-peratureis250°F.Ifthehighlimitopens,theventdamperwillcloseifthedamperswitchisinthe“automatic”position.Thecir-culatorwillcontinuetooperateaslongasthereisacallforheat,regardlessofthestatusofthehighlimit(iftheboilerisequippedwithatanklesscoil,thelowlimitswitchwillpreventthecirculatorfromoperatingiftheboilerwatertemperatureistoolow).Burneroperationautomaticallyresumeswhenthesupplywatertemperaturefallsbelowsetpoint.

BlockedVent(“Spill”)Switch-Automaticallyinterruptsmainburneroperationintheeventthatfluegasspillsfromthedraftdiverteropening.Thisswitchisequippedwitharesetbuttonwhichmustbepressedtorestorenormalburneroperation.An open blockedventswitchisindicativeofaproblemwiththeventsystem.Iftheblockedventswitchopens,thecauseoftheventingproblemmustbefoundandcorrectedbyaqualifiedgasservicetechnicianbeforetheblockedventswitchisreset.

FlameRoll-outSwitch-Automaticallyinterruptsboileroperationwhenflamesorexcessiveheatarepresentinvestibule.Theflameroll-outswitchisasingleusedevicewhichmustbereplacedbyanidenticalswitchinordertorestorenormaloperation.Anopenflameroll-outswitchisusuallyindicativeofapluggedheatexchanger.Thecauseoftheflameroll-outmustbefoundandcorrectedbyaqualifiedgasservicetechnician,andtheswitchreplacedwithanidenticalone,beforetheboilerisreturnedtooperation.

WARNING• GAS LEAKS MAY RESULT IN FIRE OR EXPLOSION.

• 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.

• WATER LEAKS MAY CAUSE EXTENSIVE PROPERTY DAMAGE.

• DAMPER MUST BE IN OPEN POSITION WHEN BURNERS ARE ON.

WARNINGDO NOT LEAVE THE BOILER IN SERVICE IF IT FAILS ANY OF THE FOLLOWING START-UP CHECKS. DOING SO MAY RESULT IN FIRE, EXPLOSION, OR CARBON MONOXOIDE (CO) POISONING.

2525

NOTESAFELIGHTINGANDOTHERPERFORMANCECRITERIAWEREMETWITHTHEGASMANIFOLDANDCONTROLASSEMBLYPROVIDEDONTHEBOILERWHENTHEBOILERUNDERWENTTHETESTSSPECIFIEDINZ21.13.

Usethefollowingprocedureforinitialstart-upoftheboiler:

1) Makesurethattheboilerandsystemarefilledwithwater.2) Checkallnewgaspipingforleaksandpurgepipingsectionsthatarefilledwithair.SeePart4oftheNational Fuel Gas

Codeforadditionalinformationontestingandpurginggaslines.3) Verifythatventsystemiscompleteandfreeofobstructionsbeforeattemptingtofireboiler.4) Inspectallwiringforlooseoruninsulatedconnections.5) Makesurethemainburnersareseatedproperlyintherearofburnertrayandonorifices.6) Adjustthermostattothehighestsetting.

7) Starttheboilerusingtheappropriatelightinginstructionsforthegasvalveontheboileronpages28-29. 8) Uponinitialstart-up,thegastrainwillbefilledwithair.Evenifthegaslinehasbeencompletelypurgedofair,it

maytakeseveraltriesforignitionbeforeaflameisestablished.Onceaflamehasbeenestablishedforthefirsttime,subsequentcallsforburneroperationshouldresultinaflameonthefirsttry.

9) Observepilotburnerflame.SeeFigure22forintermittentignition.Pilotburnerproducesthreeflames.Thecenteroneshouldbeasteadymediumblueflamecoveringaround3/8”to½”ofsparkelectrode/flamerod.

10) Makesureventdamperisinopenpositionwhenmainburnersarefiring.11) Inspectthemainburnerflamesvisiblethroughtheobservationportinburneraccesspanel.Theflameshouldbestable

andmostlyblue(seeFigure23).Noyellowtippingshouldbepresent;however,intermittentflecksofyellowandorangeintheflamearenormal.

12) Checkentiregastrainforleaksusingsoapandwaterorotherapprovedleakdetectionmethodwhileboilerisfiring.Fixanyleaksfoundimmediately.

13) Rungasvalvesafetyshutdowntest.Withmainburnersfiring,disconnectignitioncablefromignitionmodule.Bothpilotburnerandmainburnersshouldstopfiring.

FIGURE22:INTERMITTENTIGNITION PILOTBURNERFLAME

2626

14) Checkthemanifoldpressureandadjustifnecessary.Todothis,usethefollowingprocedure:

a) Connectamanometertotheinletpressuretaponthegasvalve(seeFigures24aand24b).b) Checktheinletpressurewithallgasappliancesonandoff.Theinletpressureattheboilermustbewithinthe

followinglimitsregardlessofwhatcombinationofappliancesisfiring: InletPress(inchesw.c.) NaturalGas LPGas Min. 5.0 11.0 Max. 14.0 13.0 Iftheinletpressurefallsoutsideoftheselimits,findandcorrectthecauseoftheproblembeforeproceedingfurther.

c) Connectamanometertothemanifold(outlet)pressuretaponthegasvalve(seeFigures24aand24b).d) Readthemanifoldpressure.Itshouldbesetat: NaturalGas LPGas ManifoldPress.(inchesw.c.) 3.5 10.0e) Ifamanifoldpressureadjustmentisneeded,maketheadjustmentbyturningthepressureregulator(seeFigures27

and28)screwclockwisetoraisethepressureandcounterclockwisetoreducethepressure.Ifamanifoldpressureadjustmentismade,recheckthelinepressuretobecertainthatitisstillwithinacceptablelimits.Replacethecoverscrewontheregulator.

15)Testthermostatoperationwhiletheboilerisrunning.Turnthethermostattothelowestsetting.Bothpilotburnerandmainburnersshouldstopfiring.Raisethethermostatbacktothehighestsetting.Thepilotburnerandmainburnersshouldrelight.

16) Verifyhighlimitoperation.Allowtheboilerwatertemperaturetoincreasetohilimitsetting.Theburnersshouldshutdownandthecirculatorcontinuerunning.Boththepilotburnerandmainburnersshouldstopfiring.

17) Allowtheboilerwatertemperaturetodropbelowhighlimitsetting.

18) Thepilotburnerandmainburnersshouldrelight.

19)Aftertheboilerhasoperatedforapproximately30minutes,checktheboilerandheatingsystempipingforleaks.Repairanyleaksfoundatonce.

20)Inspecttheventsystemforfluegasleaks.Repairanyleaksfoundbeforeleavingtheboilerinoperation.

FIGURE23a:MAINBURNERFLAME-1”BURNERS FIGURE23b:MAINBURNERFLAME-40mm (“HIGHALTITUDE”)BURNERS

2727

FIGURE24a:GASVALVEDETAIL-HONEYWELLVR8204ANDVR8304

FIGURE24b:GASVALVEDETAIL-ROBERTSHAW7000DERHC

2828

LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL VR8204 AND VR8304 SERIES GAS VALVES

A. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.

B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electric switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

not

If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.not

5. Remove front access panel.

6. Rotate the gas control knob clockwise to OFF.

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas go to the next step.

8. Rotate the gas control knob counter clockwise to “ON”.

9. Replace front access panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.


2. Turn off all electric power to the appliance if service is to be performed.

3. Push in gas control knob slightly and turn clockwise to “OFF”. Do not Force.

WARNING: If you do not follow these instructions exactly, a fire or explosionmay result causing property damage, personal injury or loss of life.

146-80-255 Rev. 0(Electronic Ignition)

TO TURN OFF GAS TO APPLIANCE

FOR YOUR SAFETY READ BEFORE LIGHTING

GAS OUTLET

GAS CONTROL KNOB(SHOWN IN “ON” POSITION)

GAS INLET

GAS VALVE - TOP VIEW

2929

LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW 7000DERHC SERIES GAS VALVES

A. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.

B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electric switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

not

If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.


3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.not

5. Remove front access panel.

6. Rotate the gas control knob clockwise to OFF.

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas go to the next step.

8. Rotate the gas control knob counter clockwise to “ON”.

9. Replace front access panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.


2. Turn off all electric power to the appliance if service is to be performed.

3. Push in gas control knob slightly and turn clockwise to “OFF”. Do not Force.

WARNING: If you do not follow these instructions exactly, a fire or explosionmay result causing property damage, personal injury or loss of life.

TO TURN OFF GAS TO APPLIANCE

FOR YOUR SAFETY READ BEFORE LIGHTING

GASINLET

GAS CONTROL KNOBSHOWN IN "OFF" POSITION

POSITIONINDICATOR

ONOFF

3030

XI Service and Maintenance

Thefollowingroutinemaintenanceshouldbeperformedonanannualbasis:

1) Turnoffelectricalpowerandgassupplytotheboiler2) Inspectthefluepassagesforsignsofblockage.Ifthereisanycarboninthecombustionchamberorthefluepassages,cleantheheatexchangerbeforeproceedingfurther.Seethecleaningprocedurebelow.3) Removeanydebrisfoundinthecombustionchamber,beingcarefulnottodisturbcombustionchamberinsulation.4) Removeallburners,notingthelocationofthepilotmainburner.Ifburnersshowsignsofdeterioration,theyshouldbereplaced(somediscolorationaroundtheburnerportsisnormal).Cleantheburnersbyfirstbrushingtheportswithasoftbristlebrushandthenvacuumingoutanydebristhroughtheventuriopening.5) Inspectthepilotassembly.Cleananydepositsfoundontheelectrodeandgroundingstrap.Theidealgapbetweentheelectrodeandthegroundstrapis1/8”.Inspecttheporcelainforcracksorotherdeterioration.Replacepilotassemblyifdete-riorationisfound.

6) Inspectthecombustionchamberinsulationfordeterioration.7) Inspecttheignitioncableinsulationforcracksorotherdeterioration.Ifdeteriorationisfound,replacecable.8) Reinstallburners,beingcarefultoputthepilotmainburnerinitsoriginallocation.9) Inspectallboilerwiringforlooseconnectionsordeterioration.

10) Inspecttheventsystem:

• Makesurethattheventsystemisfreeofobstructions.• Makesurethatallventsystemsupportsareintact.

WARNING• THE BOILER CONTAINS REFRACTORY CERAMIC FIBER, A POSSIBLE HUMAN

CARCINOGEN. USE A NIOSH APPROVED RESPIRATOR WHEN SERVICING HIGH-TEMPERATURE INSULATION AND GASKET MATERIALS. WASH EXPOSED SKIN GENTLY WITH SOAP AND WATER AFTER CONTACT. WASH EXPOSED CLOTHING SEPERATE FROM NORMAL LAUNDRY.

• LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.

• FAILURE TO MAINTAIN THE BOILER IN PROPER WORKING CONDITION MAY LEAD TO FIRE, EXPLOSION, PERSONAL INJURY OR DEATH AND EXTENSIVE PROPERTY DAMAGE.

• TURN OFF ALL GAS AND ELECTRIC POWER SUPPLIES TO THE BOILER BEFORE SERVICING. CONTACT WITH OR RELEASE OF DANGEROUS FLAMMABLE GAS, ELECTRICAL VOLTAGE, MOVING PARTS AND VERY HOT WATER UNDER PRESSURE MAY CAUSE SERIOUS PERSONAL INJURY, PROPERTY DAMAGE OR DEATH.

• LOCK ELECTRICAL BOXES AND GAS VALVES CLOSED TO PREVENT SOMEONE FROM INADVERTENTLY RESTORING POWER OF GAS BEFORE THE HEATING SYSTEM IS SAFE TO OPERATE.

• WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPONENTS. REPAIR ANY LEAKS FOUND IMMEDIATELY.

3131

Heat Exchanger Cleaning Procedure

1) Turnoffelectricalpowerandgassupplytotheboiler.2) Disconnectthedamperandventconnectorfromtheboiler.3)Removetheupperfrontandtopjacketpanels.Ifpossible,removetherearandleftsidejacketpanels.4) Removetheburners.5) Removetheblockedvent(“spill”)switch.6) Removethe¼-20nutsandwashersholdingthefluecollectorontotheheatexchanger.7) Carefullyremovethefluecollectorgasketstripsandsetthemaside.8) Removethefluecollectorfromtheheatexchanger.

9) Cleanthefluepassagewaysusingastiffbristlebrush.Becertainthatallforeignmaterialisremovedfromthegaps betweenthepins.

10) Cleanthebottomsurfacesoftheheatexchanger.11) Putalightinthecombustionchamberandlookthroughthefluepassagesfromthetoptoverifythattheyhavebeen thoroughlycleaned.12) Replacethefluecollectorgasketstrips.Ifdesired,RTVsiliconesealantwitha500Fintermittentdutytemperaturemaybesubstitutedforthisropegasket.Thefluecollectormustbethoroughlysealedtotheheatexchanger.13) Replacethe¼-20nutsandwashersthatholddownthefluecollector.14) Reattachallthejacketcomponents.15) Reinstallburners,beingcarefultoputthepilotmainburnerinitsoriginallocation.16) Replacetheblockedventswitch.17)Reconnectthedamperandventsystem.

• Inspectjointsforsignsofcondensateorfluegasleakage.• Inspectventingcomponentsforcorrosionorotherdeterioration.Replaceanydefectiveventcomponents.

11) Inspecttheboilerandhydronicsystemforleaks.12) Placetheboilerbackinoperationusingtheprocedureoutlinedin“Start-up”.Checkthepilotlineandanyothergaspip-ingdisturbedduringtheinspectionprocessforleaks.

WARNINGSOOT DEPOSITS IN THE FLUE 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 FLUE 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 flue gas. A CO “sniffer” designed for testing CO levels in ambient air cannot be used to check boiler com-bustion. Take a flue gas sample by inserting a sample probe through the draft diverter opening and into the flue collector so that the sample is taken in the area directly over the heat exchanger. Do not take a sample until the boiler has been firing for at least five minutes. A normal CO reading for an CWI series boiler is less than 50ppm (0.005%). A reading of more than 100ppm (0.01%) is indicative of a combustion problem. Some causes of excessive CO include:

• Incorrectly sized main burner orifice for the altitude at which boiler is installed • Crooked or out-of-round orifice holes (never attempt to drill orifice for this boiler in the field) • Partially plugged flue passages • Improper manifold pressure • Foreign material in burner venturis or burner ports • Leak in seal between flue collector and heat exchanger

• Inadequate supply of combustion air

3232

Notes

3333

XIII Troubleshooting

Thefollowingpagescontaintroubleshootingchartsforuseindiagnosingcontrolproblems.Tousethesecharts,gototheboxmarked“Start”atthetopofthechartonpage34or36andfollowtheappropriatepaththoughthechartuntilaboxwithalistofpossiblecausesisreached.Iftheproblemisknowntobewithintheignitionsystem,godirectlytotheappropriatetroubleshootingguidefortheboiler.Inusingthesecharts,thefollowingshouldbekeptinmind:

1) Thesechartsareonlymeanttobeusedbyaprofessionalheatingtechnicianasanaidindiagnosingcontrolprob-lems.

2) Whereapplicable,followallprecautionsoutlinedintheappropriatelightinginstructionsonpages28-29.

3) Ingeneral,thesechartsassumethattherearenolooseormiswiredelectricalconnections.Beforeusingthesecharts,inspectallelectricalconnectionsontheboilertomakesurethattheyaretight.Also,checkthewiringontheboileragainsttheappropriatewiringdiagraminFigures18-19.

4) Thepossiblecausesattheendofeachbranchinthesechartsarenotlistedinorderoflikelihood.AllcontrolsontheCWIaretestedatleastonceinthemanufacturingprocessandadefectivecontrolorcomponentisgenerallytheleastlikelycause.Beforereplacingacomponent,trytoruleoutallotherpossiblecauses.

5) Thesetroubleshootingchartsassumethattheventdamperisclosedatthebeginningofthetroubleshootingprocess.Withthe120voltsappliedtotheboilerandnocallforheat,thedampershouldgototheclosedposition.Ifitdoesnot,dothefollowing:

• Confirmthat120voltsisappliedtotheboilerandthatthereisnocallforheat.• Makesurethattheswitchonthedamperisinthe“automatic”position.• Unplugtheharnessfromthedamperandcheckfor24voltsacrosspin#1(blue)andpin#4(yellow).• Ifvoltageispresent,thedamperisdefectiveorthereisanobstructioninthepathofthedamperblade.• Ifnovoltageispresent,thereiseitheralooseconnectioninthedamperharnessorthelimitcontrol(L8148E

orL8124E)isdefective.

6) IfthechartsindicatethattheL8148EorL8124Eisdefective,dothefollowingbeforereplacingit:

• Checkfor24voltsacrossTVandZ.Ifnovoltageispresent,thetransformerintheL8148EorL8124Eisdefective.Itispossiblethatthistransformerhasbeendestroyedbyashortcircuitintheboilerwiring.Beforereplacingthecontrol,carefullyinspectalllowvoltagewiringontheboilerforplaceswhereitistouchingtheframeoftheboilerorwiringontheothersideofthetransformer.

• If24voltsispresentacrossTVandZ,checkfor24voltsbetweenTandW.OnL8148Es,ifnovoltageispresent,makesurethatthebrassjumperispresentbetweenWandZandthatthescrewsholdingthisjumperinplacearebothtight.IftheboilerisequippedwithaL8124E,voltagewillonlybepresentacrossTandW whenthereisacallforheatANDtheboilerwatertemperaturehighenoughtosatisfythelowlimit.

• Ifnotalreadydone,temporarilyreplacethethermostatacrossTVandTwithajumper.Iftheboilerfireswhenthisisdone,thereisaproblemwiththethermostatorzonewiring.

• If24voltsispresentacrossTandWandtherelayintheL8148EorL8124Edoesnotpullin,therelayinthiscontrolisprobablydefective.Inspectthecoilofthisrelayforvisibleheatdamage.Ifsuchdamageisfound,thereisagoodchancethatasecondtransformerispresentinthethermostatorzonevalvecircuit,resultingintheapplicationof48voltsacrosstherelaycoil.Inolderbuildings,thistransformermaybehiddeninaloca-tionfarfromtheboiler.Ifthissecondtransformerexists,itmustbefoundandremovedbeforetheL8148EorL8124Eisreplaced.

7)Whencheckingvoltageacrossdamperharnesspins,becarefulnottoinsertthemeterprobesintothepins.Doingsomaydamagethepin,resultinginalooseconnectionwhentheharnessisreconnected.

3434

Troubleshooting Chart for CWI Boilers Without Tankless HeatersCaution: Read page 33 before attempting to use this chart

Thermostat calls for heat

Circulator start?

120 volts at L1&L2?

120 volts at C1&C2?

N

N*Power off

*Blown fuse or tripped breaker

*Miswired or loose electrical connection in 120V line

Remove t'stat or zone valve end switch wires from T&TV terminals on L8148E. Install temporary jumper across terminals Tand TV.

Does circulator run now?

*Defective L8148E-see Note 6 on page 33.

*Loose connection in t'stat or zone valve end switch wiring

*Defective t'stat or zone valve end switch

*T'stat or zone system miswired-consult t'stat or zone valve manufacturer's instructions

Vent damper open?

24 voltsacross B and R(limit switch) in

L8148E ?

*Boiler off on limit

*Defective high limit.

24 volts between pins

1&4 (blue&yellow)and 2&4 (orange&yellow) on damper end of damper

harness? See Note 7 on page 33.

* Loose connection between damper harness and L8148E

*Defective damper harness.

* Defective L8148E

*Obstruction in path of damper blade

*Defective damper motor

*Loose connection between damper harness and damper

Y

START

24 volts across T&TV?

120 volts across

terminals at circulator?

*Seized or defective circulator

*Bad electrical connection between C1 or C2 and circulator

N

Y

N

Y

N

Y

Y

Y

N

N

Y

N

Y

Y

N

Y

N

Boiler Equipped

With Damper?

3535

Main burners light?

24 volts across

B1&B2?

Refer to ignition system troubleshooting chart (page 38).

*Defective damper

*Defective L8148E

*Defective damper harness

*Loose damper harness connection

*Obstruction in path of damper blade24 volts across

standing pilot gas valve terminals or terminals 5&6 on S8600 module?

24 volts across spill

switch?

*Chimney blockage

*Chimney system not constructed in accordancewith Parts 7 and 10 of National Fuel Gas Code.

*Down draft

*Inadequate combustion air supply in boiler room

Y

N

N

Y

Y

24 volts across rollout switch?

*Loose electrical connection in 24 volt wiring between B1 or B2and gas valve or module

*Rollout switch open. Replace with exact replacement (see parts list). Check for blocked heat exchanger.

Y

N

N

Y

N

Do burner and circulator shut down at end of call for heat?

END

Pull wire off of Tterminal on

aquastat. Does boiler shut down?

*T'stat orzone valve wiring calling for heat

*T'stat wires shorted

*Internal boiler wiring problem, consult Crown representative

Do burnersshut down before

gage temp exceeds high limit

setting +15F?

*Defective L8148A

*Sensing bulb notbottomed out inwell

N

Y Y

NN

Y

3636

Troubleshooting Chart for CWI Boilers Equipped with Tankless Heaters and DampersCaution: Read page 33 before attempting to use this chart

No call for heat, boiler water

temp. at least 20F below low

limit setting

*Power off

*Blown fuse or tripped breaker

*Miswired or loose electrical connection in 120V line

Vent damper open?

24 voltsacross B1and

TV on L8124E ?

*Boiler water temp above low limit setting

*Defective L8124E

24 volts between pins

1&4 (blue&yellow)and 2&4 (orange&yellow) on damper end of damper

harness? See Note 7 on page 33.

* Loose connection between damper harness and L8124E

*Defective damper harness.


*Defective damper motor

*Loose connection between damper harness and damper

Main burners light?

24 volts across gray wire on rollout switch

and B2?

Y

Refer to ignition system troubleshooting chart (page 38).

START

*Defective damper

*Defective damper harness

*Loose damper harness connection


24 volts across standing pilot gas valve terminals or terminals 5&6 on S8600 module?

24 volts across spill

switch?

*Chimney blockage

*Chimney system not constructed in accordancewith Parts 7 and 10 of National Fuel Gas Code.

*Down draft

*Inadequate combustion air supply in boiler room

Y

N

N

Y

Y

24 volts across rollout switch?

*Loose electrical connection in 24 volt wiring between rollout switch or B2 and gas valve or module

*Rollout switch open. Replace with exact replacement (see parts list). Check for blocked heat exchanger.

Y

N

Y

N

N

Y

N

Y

N

Allow boiler water temperature to

reach low limit + differential setting. Initiate call for heat

24 volts across TV

and Z?

120 volts across L1 &

L2?

N

* Defective transformer in L8124E

YY

N

N

24 volts across TV

& Z?

* Defective L8124E

Y N

3737

Circulator start?

120 volts at C1&C2?

N

Remove t'stat or zone valve end switch wires from T&TV terminals on L8124E. Install temporary jumper across terminals Tand TV.

Does circulator run now?

*Defective L8124E-see Note 6 on page 33.

* Boiler water temperature has dropped below low limit setting

*Loose connection in t'stat or zone valve end switch wiring

*Defective t'stat or zone component

*T'stat or zone system miswired-consult t'stat or zone valve manufacturer's instructions

N

Do burner and circulator shut down at end of call for heat?

END

Pull wire off of Tterminal on

aquastat. Does boiler shut down?

*T'stat orzone valve wiring calling for heat

*T'stat wires shorted

* Boiler water temperature has dropped below low limit setting

*Internal boiler wiring problem, consult Crown representative

*Defective L8124E

*Sensing bulb notbottomed out inwell

*Seized or defective circulator

*Bad electrical connection between C1 or C2 and circulator

Y

N

Y

N

YN

YY Y

NN

Y

Y

N Main burners light?

*Boiler water temperature exceeds high limit setting

* Defective L8124E

Y

N

24 volts across T&TV?

120 volts across

terminals at circulator?

Do burnersshut down before

gage temp exceeds high limit

setting +15F?

3838

Spark across

ignitor/sensor gap?

Y

Can you hear

sparking?

* Defective ignition module

* Break in spark cable insulation

* Break in pilot porcelain

* Incorrect pilot spark gap

* Loose connection in spark cable

* Loose groundconnection

N

Pilot lights?

Y

NN


24 volts across PV &

MV/PV at gas valve?

* Defective EI wiring

harness.

N

* Loose connection in ignition cable or ground wire

* Pilot electrode porcelain cracked

* Pilot flame not covering gap between electrode and grounding strap

* Low gas pressure at gas valve inlet


Main burnerlights?

N

Y

24VAC across

terminals MV & MV/PV on

module?

Y

N

N

* Defective ignitionmodule

24 volts between MV &MV/PV on gas

valve?

* Defective gas valve

*Defective EI harness

END

START(24 volts is present across 24V and 24V (GND) on

ignition module but main burners do not light)

N

Y

Y

N

Y

Y

Y

* Low line pressure

* Plugged, kinked or leaking pilot tubing

* Plugged pilot orifice

* Gas line not purged of air

* Defective pilot assembly

* Defective gas valve

Does spark stop when pilot

lights?

24 volts across

terminals PV& MV/PV at

module?

Intermittent Ignition System Troubleshooting Chart

Caution: Read page 33 before attempting to use this chart

3939

Notes

4040

XIV PARTS

ThefollowingpartsmaybeobtainedfromanyCrowndistributor.TofindtheclosestCrowndistributor,consulttheareaCrownrepresentativeorthefactoryat:

CrownBoilerCo.Customer ServiceP.O.Box14818PhiladelphiaPA.19134www.crownboiler.com

Forboilersinstalledatelevationsabove2000ft,consultthelocalCrownrepresentativeorthefactoryforthecorrectmainburnerorifice.

103 138 172 207 241 276 311 346 380CWI HEAT EXCHANGER ASSY.LESS TANKLESS HEATER OPENINGCWI HEAT EXCHANGER ASSY.(WITH TANKLESS HEATER OPENING)

* BSI/CWI LEFT END SECTION 750001 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.* CWI RH SECTION (LESS HTR OPENING) 850002 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.* CWI RH SECTION (WITH HTR OPENING) 750002 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.* BSI/CWI INTERMEDIATE SECTION 750003 2 ea. 3 ea. 4 ea. 5 ea. 6 ea. 7 ea. 8 ea. 9 ea. 10 ea.* UPPER PUSHNIPPLE 275075 3 ea. 4 ea. 5 ea. 6 ea. 7 ea. 8 ea. 9 ea. 10 ea. 11 ea.* LOWER PUSHNIPPLE 275070 3 ea. 4 ea. 5 ea. 6 ea. 7 ea. 8 ea. 9 ea. 10 ea. 11 ea.2 BASE TRAY 1 ea. 700644 700645 700646 700647 700648 700649 700650 700651 7006523 BASE WRAPPER 1 ea. 700664 700665 700666 700667 700668 700669 700670 700671 7006724 BURNER TRAY (1" BURNERS) 1 ea. 700684 700685 700686 700687 700688 700689 700690 700691 7006924 BURNER TRAY (40mm BURNERS) 1 ea. 751684 751685 751686 751687 751688 751689 751690

5 BASE FRONT PANEL ASSY. (INCLUDES INSULATION) 1 ea. 700604 700605 700606 700607 700608 700609 700610 700611 700612

6 BURNER ACCESS PANEL 1 ea. 700624 700625 700626 700627 700628 700629 700630 700631 7006327 BASE END INSULATION 720601 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea.8 BASE REAR INSULATION 1 ea. 720604 720605 720606 720607 720608 720609 720610 720611 7206129 BASE LEG ASSY. 700110 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 6 ea. 6 ea.10 1/4-20 X 1/2" SELF TAPPING SCREW 900100 20 ea. 20 ea. 20 ea. 21 ea. 21 ea. 21 ea. 21 ea. 25 ea. 25 ea.11 1/2" x 2" SEALING STRIP 900146 4.2 ft 4.8 ft 5.3 ft 5.9 ft 6.4 ft 7.0 ft 7.5 ft 8.0 ft 8.5 ft12 ROLLOUT SWITCH G4AM0600240C 960122 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.13 ROLLOUT SWITCH BRACKET 900121 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.14 #8 x 3/4" SELF TAPPING SCREW 90-048 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.15 #10 x 1/2" SHEET METAL SCREW 90-212 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea.16 5/16 USS FLAT WASHER 900102 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea.17 5/16-18 LOCK NUT 900103 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea.18 5/16-18 x 1-1/4 SELF TAPPING SCREW 900101 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea.20 DRAFT DIVERTER ASSEMBLY 1 ea. 850124 850125 850126 850127 850128 850129 850130 850131 85013221 1/2" x 1" SEALING STRIP 900145 3.3 ft 3.5 ft 3.8 ft 4.1 ft 4.4 ft 4.6 ft 4.9 ft 5.2 ft 5.5 ft22 1/4-20 x 1-1/4" CARRIAGE BOLT 90-201 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea.23 1/4" USS FLAT WASHER 90-215 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea.24 1/4-20 WING NUT 900125 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea.

26 HEATER OPENING COVER PLATE 270003 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.27 TANKLESS HEATER 1 ea. 750007 750007 750007 750007 750007 750008 750008 750008 75000827 HIGH CAPY. TANKLESS HTR. (OPT.) 1 ea. 750010 750010 750010 750010 750010 75001028 TANKLESS HEATER GASKET 270001 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.29 3/8 USS FLAT WASHER 90-036 6 ea. 6 ea. 6 ea. 6 ea. 6 ea. 6 ea. 6 ea. 6 ea. 6 ea.30 3/8-16 X 7/8 HX HEAD CAP SCREW 900450 6 ea. 6 ea. 6 ea. 6 ea. 6 ea. 6 ea. 6 ea. 6 ea. 6 ea.31 FLUE BAFFLE 850100 9 ea. 10 ea. 11 ea.

1 ea.1 ea. 1 ea. 1 ea. 1 ea.1 ea. 1 ea. 1 ea.

750022750019 750020 750021

850021 850022

1 1 ea. 750014 750015 750016 750017 750018

850016 850017 850018 8500191 ea. 850014 850015 850020

1 ea.

BLOCKED VENT SWITCH ASSY. (INCLUDES MOUNTING BRACKET)

960123

BLOCKED VENT SWITCH ASSY. (INCLUDES MOUNTING BRACKET)

960126

QTY. OR CROWN P.N.

DESCRIPTION QUANTITY PER BOILER or CROWN P.N.

* NOT PICTURED

KEY #

25

1

25

4242

***1/4” Pilot Tubing Used with Robertshaw Valves

103 138 172 207 241 276 311 346 380

42 1" BURNER LESS PILOT BRACKET 150501 4 ea. 6 ea. 8 ea. 11 ea. 13 ea. 15 ea. 17 ea. 20 ea. 22 ea.43 MANIFOLD (1" BURNERS) 1 ea. 700154 700155 700156 700157 700158 700159 700160 700161 70016244 NAT GAS ORIFICE (#44 DRILL SIZE) 950300 5 ea. 7 ea. 9 ea.44 NAT GAS ORIFICE (#47 DRILL SIZE) 950303 12 ea. 14 ea. 16 ea.44 NAT GAS ORIFICE (#48 DRILL SIZE) 950304 18 ea. 21 ea. 23 ea.44 LP GAS ORIFICE (#54 DRILL SIZE) 95032944 LP GAS ORIFICE (#55 DRILL SIZE) 950330 5 ea. 7 ea.44 LP GAS ORIFICE (#1.25mm DRILL SIZE) 950336 9 ea. 12 ea. 14 ea. 16 ea.45 GAS VALVE (E.I., NAT GAS) 3507020

(VR8204C6000)45 GAS VALVE (E.I., NAT GAS) 3507120

(VR8304P4298)45 GAS VALVE (E.I., NAT GAS)

(ROBERTSHAW 7000DERHC)45 GAS VALVE (E.I. PILOT, LP GAS) 3507220

(VR8204C6018)45 GAS VALVE (E.I., LP GAS) 3507240

(VR8304P4280)46a PILOT ASSY. (E.I., NAT GAS) 35-4700

(Q348A1275)46a PILOT ASSY. (E.I., LP GAS) 35-4600

(Q348A1259)47a IGNITION CABLE 1 ea. 3501124 3501124 3501130 3501130 3501130 3501136 3501136 3501136 350113648 PILOT TUBING*** 1 ea. 90-042 90-042 90-043 90-043 90-043 900041 900041 90004149 35-1600

(392449)50 35-1650

(392449-4)51a

51a

61 40mm BURNER LESS PILOT BRACKET 150541 2 ea. 3 ea. 4 ea. 5 ea. 6 ea. 7 ea.62 MANIFOLD (40mm BURNERS) 1 ea. 701254 701255 701256 701257 701258 701259

*** 1/4" PILOT TUBING USED ON BOILERS WITH ROBERTSHAW VALVES

1 ea. 1 ea.

1 ea.

1 ea.1 ea.

1 ea. 1 ea.

1 ea.

QTY. OR CROWN P.N.

1 ea.

1 ea.

1 ea.

1 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.

1 ea.

1 ea. 1 ea.1 ea.

1 ea.

1 ea.

1 ea.

1 ea.

1 ea.

MAIN BURNER ORIFICE-CONSULT CROWN REPRESENTATIVE FOR CORRECT SIZE

3 ea.

KEY #

41

1 ea.1 ea. 1 ea.

1 ea. 1 ea.

1 ea.

1 ea.

1 ea.

1 ea. 1 ea.

1 ea.

1 ea.1 ea.1 ea.1 ea.150500

1 ea. 1 ea. 1 ea. 1 ea.

1" BURNER WITH PILOT BRACKET(Q348 PILOTS)

DESCRIPTION

1 ea. 1 ea. 1 ea.

1 ea.

3507310 1 ea.

1 ea.

1 ea. 1 ea. 1 ea.

1 ea.

1 ea.

1/8 SHORT FERRULE (INCLUDED WITH GAS VALVE)

1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.

1/8 LONG FERRULE (INCLUDED WITH PILOT ASSEMBLY)

1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.

KF24 PILOT ORIFICE (Q348 PILOT NAT GAS) - INCLUDED WITH PILOT ASSY.

1 ea. 1 ea. 1 ea. 1 ea.

K16 PILOT ORIFICE (Q348 PILOT LPGAS) - INCLUDED WITH PILOT ASSY.

60 40mm BURNER WITH PILOT BRACKET(Q348 PILOTS)

150542

4 ea. 5 ea. 6 ea. 7 ea. 8 ea.63

4444

103 138 172 207 241 276 311 346 38075 LEFT SIDE JACKET PANEL 1 ea. 850301 850301 850301 8503012 8503012 8503012 8503015 8503015 850301576 RIGHT SIDE JACKET PANEL 1 ea. 850300 850300 850300 8503002 8503002 8503002 8503005 8503005 850300577 REAR JACKET PANEL 1 ea. 850304 850305 850306 850307 850308 850309 850310 850311 85031278 TOP JACKET PANEL 1 ea. 850324 850325 850326 850327 850328 850329 850330 850331 85033279 LOWER FRONT PANEL 1 ea. 850364 850365 850366 850367 850368 850369 850320 850321 85032280 UPPER FRONT PANEL 1 ea. 850354 850355 850356 850357 850358 850359 850360 850361 85036281 DIVERTER PANEL 1 ea. 850374 850375 850376 850377 850378 850379 850380 850381 85038282 VESTIBULE PANEL 1 ea. 850384 850385 850386 850387 850388 850389 850390 850391 85039283 HORIZONTAL JACKET CLIP 800340 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea.84 VERTICAL JACKET CLIP 800341 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea.85 #10 X 1/2" SHEET METAL SCREW 90-212 28 ea. 28 ea. 28 ea. 28 ea. 28 ea. 28 ea. 28 ea. 28 ea. 28 ea.86 DOOR KNOB 90-210 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea.87 8-32 X 1/4" H.W.H. SCREW 90-211 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea.

IGNITION MODULE (E.I. BOILERS) 35-5000(NATURAL GAS ONLY) (S8600F1000)IGNITION MODULE (E.I. BOILERS) 35-5050(NATURAL OR LP GAS) (S8600M1013)

* MODULE BRACKET (E.I. BOILERS) 905000 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.88 VENT DAMPER 1 ea. 96-031 96-032 96-032 96-033 96-033 96-035 96-035 96-036 96-03689 3/4 SHORT WELL (LESS COIL BOILERS) 35-1010 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.89 3/4 LONG WELL (WITH COIL BOILERS) 35-1020 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.90 AQUASTAT (L8148E1257) LESS COIL 35-3000 1 ea. 1 ea. 1 ea.90 AQUASTAT (L8124E1065) WITH COIL 3503350 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.91 TRIDICATOR GAUGE 95-069 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.92 3/4" RELIEF VALVE (30 psi) 95-040 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.93 TACO 007 CIRCULATOR 95-012 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.93 TACO 0010 CIRCULATOR 95-015 1 ea. 1 ea. 1 ea.94 1-1/2" TACO FLANGE SET 950150 1 ea. 1 ea. 1 ea.94a 1-1/4" TACO FLANGE SET 95-014 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.95 3/4" BOILER DRAIN 95-041 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.99 8-32 X 1/2" SELF TAPPING SCREW 90-223 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea. 4 ea.

* BLOCKED VENT SWITCH HARNESS 9601270 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.AQUASTAT - R.O. SWITCH HARNESS(LESS COIL OR LESS VENT DAMPER)AQUASTAT - R.O. SWITCH HARNESS(WITH COIL AND VENT DAMPER)

* INTERMITTENT IGNITION HARNESS 9601100 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.

1 ea.

1 ea. 1 ea. 1 ea.

1 ea.1 ea. 1 ea.1 ea. 1 ea.1 ea.

1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.

QTY. OR CROWN P.N.

1 ea.

1 ea. 1 ea.1 ea. 1 ea. 1 ea. 1 ea.1 ea.

QUANTITY PER BOILER or CROWN P.N.

1 ea.

* NOT PICTURED

DESCRIPTION

1 ea. 1 ea.CWI DAMPER HARNESS(WITH COIL BOILERS)

1 ea.

*

*

KEY #

*

* 9601555

* CWI DAMPER HARNESS(LESS COIL BOILERS)

9601550

1 ea.* 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.

9601200

9601500

1 ea. 1 ea.

1 ea. 1 ea. 1 ea.

1 ea.

4646

A.BeforeInstalling

1) Thoroughlyinspectthecastironheatexchangerforanyshippingdamage,i.e.cracksinthecastings,brokenlugsorpuncturesduetomishandling.

2) Donotusetheheatexchangerifthereisanydamagetoit.3) Inspectthejointsbetweenthesectionsforopenings.Resealanyopeningswithhightemperaturesiliconesealant.4) Keepthebaseintheshippingcartonuntilitistimetoperformtheassembly.Thiskeepsforeignmaterialfrom

contaminatingtheburnersorcreatingotherhazards.Donotusethebaseassemblyifthereareanysignsofvisibledamage.

5) Reviewalloftheinstallationrequirementsinthisinstallationmanual.

B.BaseAssemblyPreparation

1) Thecombinationbase-burner-manifoldisshippedassembledfromthefactory.(Thecombinationgasvalveisshippedassembledandcanbefoundinthe“BaseBox”).

2) Smearathinlayerofsiliconeinseveralplacesacrossthetopofthebasetoadherethefibergasketstrip.3) Installthefibergasketstrip,whichwasshippedinthe“BaseBox”(FigureA1).4) Placethebaseassemblyinthelocationwheretheboileristobeinstalled.RefertoSectionIIIandIVintheinstal-

lationmanualforadditionalinformationonplacement.

C.HeatExchangerandFlueCollectorInstallation

1) Positiontheheatexchangerabovethebasewiththereturnconnectionlocatedtowardthefrontoftheboilerandthelugs,locatedoneachendoftheboiler,centeredoverthestuds,whichareoneachendofthebase(FigureA1).Lowertheheatexchangeroverthestuds,takingcarenottodisturbthestudswhichmaypushoutiftheheatexchangercomesincontactwiththem.Also,takecarenottodisturbtheceramicfibergasket.

2) Oncetheheatexchangerhasbeenplacedonthebase,inspectthegasketforproperseal.Repairorreplacegasketifnecessary.

3) Securetheheatexchangerwith5/16”locknutswithnyloninsertsandwashersfromthehardwarebag.4) Loosennutsontierodsuntiltheyarefingertight.5) Fibergasketstripsareusedtosealthefluecollectortotheheatexchanger(thisisthesamematerialusedbetween

theheatexchangerandbase).Installthisgasketingonthetopoftheheatexchanger(FigureA1).Afewdabsofsiliconemaybeusedtokeepthisgasketingfromshiftingwhenthefluecollectorisinstalled.

6) InstallthefluecollectorasshowninFigureA1.Securewiththe1/4-20carriagebolt,nuts,andwashersprovided.7) Carefullyinspectthejointbetweenthefluecollectorandtheheatexchangertoverifythatthegasketisproperly

positioned. 8) Installtheblockedventswitchusingthe#8sheetmetalscrewprovidedasshowninFigureA1

Appendix A: Knockdown Boiler Assembly Instructions

D.JacketInstallation

1) AttachthediverterPaneltothevestibulepanelusingtwo#10sheetmetalscrews.Installthesescrewsintheout-sideholes.

2) Slipthisdiverter/vestibulepanelassemblybehindthedraftdiverteropeninginthedraftdiverterassembly(FigureA2).Attachtothediverterassemblyusing#10sheetmetalscrews.

3) Attachtherightsidepaneltothebaseandvestibulepanelusingfour#10sheetmetalscrews.4) Orienttherearjacketpanelsothatthetwonotchesareup.Sliptherearpanelundertheflangeontherearofthe

sidepanelinstalledinthepreviousstepandsecurewiththree#10sheetmetalscrews.

NOTEBeforeinstallingthejacket,makesuretopluganytappingswhicharenotgoingtobeused.Alsomakesurethatnotappingsarepluggedwhichwillbeneeded.SeeFigureA3ofthisappendix,aswellasPartXIIIoftheinstallationmanual.

4747FIGUREA1:BASE,HEATEXCHANGER,FLUECOLLECTORASSEMBLY

4848

5) Installtheleftsidepanelinthesamemannerastherightside.6) Attachthefrontcornersofthediverterpaneltothesidejacketpanelsusing#10sheetmetalscrews.7) Installthehorizontal(angle)jacketclipsinthefrontedgeofthesidejacketpanels.Slidethisclipthroughtherect-

angularslotthatisabouthalfwayupthefrontedgeofthesidejacketpanelsandsecurewiththe8-32selftappingscrewsprovided.

8) SliptheVerticalJacketClipthroughtherectangularslotthatisnearthebottomofthefrontedgeofthesidejacketpanels.Securewiththe8-32sheetmetalscrewsprovided.

9) Installthetopjacketpanel.Use#10sheetmetalscrewstoattachittotherearjacketpanelandthetop-frontcornersofthesidepanels.

10) Installtheupper-frontjacketpanel.Inserttheflangeonthetopofthispanelunderthetoppanel.Runtwo#10sheetmetalscrewsintothehorizontaljacketclipsthroughtheholesinthebottomofthispanel.

11) AttachthedoorknobstotheLower-FrontPanelusing8-32x1/2machinescrews.12) Thelabelshavebeenappliedatthefactory.Verifythelocationofthelabelsaccordingtothelistbelow:

a) ClearanceLabel-Locatedonthetopjacketpanel.b) LightingInstructions-Locatedonthelowerleftcorneroftherightsidepanelnexttothegasmanifoldc) LowestPermissibleWaterLevelPlate-Locatednexttothebottomwatergaugetapping.d) BlowDownCard-Locatedjustabovethe“LowestPermissible”WaterLevelPlatee) WiringDiagram-Locatedontheinsideoftheremovabledoorf) “CROWN”Nameplate-Locatedonthetopcenteroftheoutsideoftheremovabledoorg) RatingPlate-Locatedontheupperleftoftherightsidepanel

D. Gas Valve Installation

1) The gas valve assembly has been pre-piped with one half of a piping union and is to be connected to the other half of the union located on the gas manifold.

2) Connect the pilot tubing from the pilot burner to the gas valve pilot tapping.3) Connect the thermocouple lead to the gas valve (standing pilot boilers only).

E. Control and Trim Installation (Refer to Figure A3 for Tapping Locations)

1) Install the tankless heater or blank cover plate on the opening on the right side of the heat exchanger using the gasket and 3/8 bolts provided.

2) Install the high limit well in the tapping in the tankless heater or cover plate.3) Mount the limit control (L8148E or L8124E) onto the control well. Be sure that the temperature sensing bulb is

bottomed out in the well. Tighten the screw on the bottom of the control so that it is securely clamped onto the well.

4) Install a 1/2 x 1/4 bushing and the tridicator gauge into tapping “C”. Tighten with wrench applied to the square shank on the back of the gauge. Do not apply pressure on the gauge case since this may ruin the calibration of the gauge.

5) Installreliefvalve(spindlemustbeinverticalposition)intotapping“H”ontheboilerleftside(SeeFigure1intheinstallationmanual)usingthe¾”NPTnipplesandelbowsupplied.Pipethedischargeofthesafetyreliefvalvetoalocationwherewaterorsteamwillnotcreateahazardorcausepropertydamageifthevalveopens.Theendofthedischargepipemustterminateinanunthreadedpipe.Thesafetyvalvedischargepipingmustbeinanareawhereitisnotlikelytobecomepluggedbydebrisorsubjectedtofreezing.

6) Installthe1-1/2returnpipingandcirculatorintapping“D”.SeeSectionVIIISystemPipingintheinstallationmanualforinstructionsoncompletingthepipingofthisboiler.

4949FIGUREA2:JACKETINSTALLATION

5050

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). Install the strain relief provided in the hole in the jacket through which these wires pass.

3) Flame Roll-Out Switch: a) Route the wire marked “10” through the bushing located on the left jacket panel and connect it to one side of the flame

roll-out switch.b) Route the wire marked “7” through the bushing located on the left jacket panel and connect it to the other side of the

flame roll-out switch.4) Intermittent Ignition System:

a) Mount the Honeywell or UT ignition control to the left side of the jacket just above the gas manifold using the standoff bracket supplied and #10 sheet metal screws.

b) Locate the intermittent ignition harness plugged into the gas valve assembly. This harness has red, blue, and yellow wires and has molex plugs on both ends. Plug the loose end of the harness into the ignition module.

c) Plug the green burner ground wire numbered “4” to burner ground connection on the ignition module. Check that the ground wire has been routed under the burners and that the other end is attached to the pilot assembly under the lower mounting screw.

d) Plug the red wire with the yellow trace to the 24V (gnd) terminal on the ignition module.e) Plug the black wire with the white trace to the 24 volt terminal on the ignition module.f) Plug the orange Pilot Ignition Cable to the spark terminal on the ignition module. Verify that this cable has been

routed under the burners and that the other end is plugged onto the pilot assembly electrode.

G. Complete Installation Followtheinstructionsthatstartonpage1ofthismanualtocompleteboilerinstallation.

5151

FIGUREA3:TAPPINGLOCATIONS(SEETEXTFORTAPPINGUSES)

5252

Notes

5353

Notes

P/N9804347/15Rev3

Manufacturer of Hydronic Heating ProductsP.O. Box 14818 3633 I. Street

Philadelphia, PA 19134www.crownboiler.com

d esigned to l ead cwi series - velocity boiler … · cwi series gas-fired natural draft water...

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