Crown Boiler CWD083 manual

Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com W ARNING : Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury , or loss of life. For assistance or additional information, consul[...]

2 T ABLE OF CONTENTS I Product Description 1 II Speci fi cations 1 III Before Installing 2 IV Locating the Boiler 2 V Air for Combustion and V entilation 4 VI V enting 9 V ent System Design 9 V ent System Assembly 22 VII Gas Piping 32 VIII System Piping 33 IX W iring 38 CB502 Control System 38 R8285 Control system 44 X Start-up and Checkout 48 XI [...]

1 1 I Pr oduct Description The CWD series boiler is a cast iron gas fi red boiler designed for use in forced hot water heating systems. It is is a low pressure boiler intended for use in closed heating systems with water temperatures under 240F . This boiler may be vented either vertically or horizontally with combustion air supplied from either o[...]

2 2 III Befor e Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code ,[...]

3 3 FIGURE 2a: CLEARANCES WHEN BOILER IS DIRECT VENTED (OUTDOOR COMBUSTION AIR IS USED) FIGURE 2b: CLEARANCES WHEN COMBUSTION AIR IS OBT AINED FROM BOILER ROOM[...]

4 4 T ABLE 2: CLEARANCES FROM VENT PIPING T O COMBUSTIBLE CONSTRUCTION TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MINIMUM CLEARANCE TO COMBUSTIBLE MA TERIAL HEA T F AB SAF-T VENT PROTECH F ASNSEAL PROTECH F ASNSEAL W2 MET AL-F AB CORR/GUARD VER TICAL OR HORIZONT AL A T LEAST ONE SIDE OPEN, COMBUSTIBLE MA TERIAL ON A MAXIMUM OF THREE SIDES 1” HEA [...]

5 5 Step 2: Determine whether the boiler is to be installed in a con fi ned space A con fi ned space is de fi ned by the National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. T o determine whether the boiler room is a con fi ned space: 1) T otal the input of all applia[...]

6 6 Step 5: If Indoor Combustion Air is Used, Provide Air as Follows: 1) Buildings of other than unusually tight construction: Uncon fi ned Space– Natural in fi ltration into the boiler room will normally provide adequate air for combustion and ventilation without additional louvers or openings into boiler room. Con fi ned Space – Provide tw[...]

7 7 FIGURE 4: ALL AIR FROM OUTSIDE USING VENTILA TED CRA WL SP ACE AND A TTIC FIGURE 5: ALL AIR FROM OUTSIDE USING VENTILA TED A TTIC[...]

8 8 FIGURE 6: ALL AIR FROM OUTSIDE USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTSIDE USING HORIZONT AL DUCTS INTO BOILER ROOM[...]

9 9 VI V enting W ARNING Failure to vent this boiler in accordance with these instructions could result in unr eliable boiler operation, severe damage to the boiler or pr operty , or unsafe operation: * Do not attampt to vent this boiler with galvanized, PVC, or any other vent system not listed in T able 4. * Do not attempt to mix components from d[...]

10 10 T ABLE 3a: SUMMAR Y OF HORIZONT AL VENTING OPTIONS VENT OPTION # 12345 CLASSIFICA TION USED IN THIS MANUAL HORIZONT AL DIRECT VENT HORIZONT AL DIRECT VENT (RESER VED FOR FUTURE USE) HORIZONT AL DIRECT EXHAUST HORIZONT AL DIRECT EXHAUST ILLUSTRA TED IN FIGURE 8a OR 8b 8a OR 8b 9 9 VENT PIPE STRUCTURE PENETRA TION W ALL W ALL W ALL W ALL AIR IN[...]

11 11 FIGURE 8a: HORIZONT AL DIRECT VENTING USING SEP ARA TE TERMINALS (VENT OPTIONS 1-2) FIGURE 8b: HORIZONT AL DIRECT VENTING USING COAXIAL TERMINAL (VENT OPTIONS 1-2)[...]

12 12 FIGURE 9: HORIZONT AL DIRECT EXHAUST VENT SYSTEM (VENT OPTIONS 4,5) 2) Maximum V ent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected, the vent pipe size, and the boiler size. See T able 3 for the maximum vent length. In addition to the maximum length of piping shown in T able 3, [...]

13 13 3) Permitted T erminals for Horizontal V enting (V ent Options 1 - 5) - T able 3a shows permitted types of terminals for both the vent and air inlet systems. On horizontal direct vent systems using 4” air inlet pipe (V ent Options 1 and 2), the following Crown co-axial terminals may be used. These terminals have the advantage of requiring o[...]

14 14 T ABLE 3b: SUMMAR Y OF VER TICAL VENTING OPTIONS VENT OPTION # 6789 1 0 CLASSIFICA TION USED IN THIS MANUAL VER TICAL DIRECT VENT VER TICAL DIRECT VENT (RESER VED FOR FUTURE USE) VER TICAL DIRECT EXHAUST VER TICAL DIRECT EXHAUST ILLUSTRA TED IN FIGURE 10 10 1 1 1 1 VENT PIPE STRUCTURE PENETRA TION ROOF ROOF ROOF ROOF AIR INT AKE PIPE STRUCTUR[...]

15 15 FIGURE 10: VER TICAL NON-COAXIAL DIRECT VENT SYSTEM (VENT OPTIONS 6, 7) FIGURE 1 1: VER TICAL DIRECT EXHAUST SYSTEM (VENT OPTIONS 9, 10)[...]

16 16 T ABLE 3c : SUMMAR Y OF VER TICAL COAXIAL VENTING OPTIONS VENT OPTION # 1 1 12 13 CLASSIFICA TION USED IN THIS MANUAL VER TICAL COAXIAL DIRECT VENT VER TICAL COAXIAL DIRECT VENT VER TICAL COAXIAL DIRECT VENT VENT PIPE STRUCTURE PENETRA TION ROOF ROOF ROOF AIR INT AKE PIPE STRUCTURE PENETRA TION ROOF ROOF ROOF VENT PIPE SIZE 3” 3” 4” AIR[...]

17 17 FIGURE 12: VER TICAL COAXIAL DIRECT VENT USING CROWN #500005 VENT KIT (VENT OPTION 1 1) FIGURE 13: VER TICAL COAXIAL DIRECT VENT USING HEA T F AB SAF-T VENT SC (VENT OPTIONS 12, 13)[...]

18 18 T ABLE 4: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS MANUF ACTURER VENT SYSTEM SIZE CONDENSA TE TRAP W ALL THIMBLES HORIZONT AL TERMINA TION VER TICAL TERMINA TION HEA T F AB SAF-T VENT EZ SEAL 3 9321 (NOTE 3) 7393GC 7393GCS 5391CI ELBOW : 7314TERM TEE: 7390TEE 5300CI 4 9421 (NOTE 3) 7493GC 7493GCS 5491CI ELBOW : 7414TERM TEE: 749[...]

19 19 12) V ertical and horizontal sections of piping must be properly supported. See vent system manufacturer ’ s instructions for more information. 13) Non-coaxial vent piping must be accessible for periodic inspection. 14) Fire stops and wall thimbles – Use fi re stops where required by code or by the vent system manufacturer . Consult vent[...]

20 20 FIGURE 15a: LOCA TION OF DIRECT VENT TERMINAL RELA TIVE T O WINDOWS, DOORS, GRADE FIGURE 14: HORIZONT AL TERMINAL OFFSETS[...]

21 21 FIGURE 15b: LOCA TION OF DIRECT EXHAUST TERMINAL RELA TIVE TO WINDOWS, DOORS, GRADE FIGURE 15c: LOCA TION OF VENT TERMINAL RELA TIVE TO METERS AND FORCED AIR INLETS FIGURE 15d: POSITIONING VENT TERMINAL UNDER OVERHANGS[...]

22 22 FIGURE 16: USE OF CONDENSA TE TRAPS C. V ent / Intake System Assembly 1) General Assembly Notes: a) Where the use of “silicone” is called for in the following instructions, use GE R TV 106 for the vent collar and coaxial terminal. Air inlet piping sections are sealed with any general-purpose silicone sealant such as GE R TV102. PVC air in[...]

23 23 T ABLE 6: F AN OUTLET ORIFICE BOILER MODEL ORIFICE PA R T # CWD060 620133 CWD083 650136 CWD1 10 620135 CWD138 620136 CWD165 620137 CWD193 620138 CWD220 620139 CWD245 650138 FIGURE 17: INST ALLA TION OF F AN OUTLET ORIFICE 3) Optional Coaxial T erminal Installation – If the optional coaxial terminal is used, it should be installed in the wal[...]

24 24 FIGURE 18a: CROWN COAXIAL TERMINAL EXPLODED VIEW FIGURE 18b: CROWN COAXIAL TERMINAL ASSEMBL Y[...]

25 25 j) Attach the intake tee to the end of the straight section protruding from the inside wall. Use the procedure described in (d) to clean and assemble these parts. k) If the inside terminal section is not supported by the wall through which it passes, install additional supports or bracing to support the terminal. Bracing in contact with the c[...]

26 26 5) Assembly of Z-Flex Z-V ent III: a) General Notes: • Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw . File or sand the cut end smooth before assembling. Expanded ends may be cut to adapt the SVE series III to the vent collar or Crown coaxial terminal. See the following i[...]

27 27 6) Assembly of Heat Fab Saf-T V ent EZ Seal: a) Saf-T V ent General Notes: These instructions cover the installation of Saf-T V ent EZ Seal. Saf-T V ent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. • In general, Saf-T V ent pipe sections may not be cut. Exceptions to this are the Saf-T [...]

28 28 manufacturer ’ s instructions before operating the boiler . 7) Assembly of Heat Fab Saf-T V ent SC - On CWD Boiler installations where Saf-T V ent SC is used, some Saf-T V ent EZ Seal (single wall pipe) will always be required between the boiler and the Saf-T V ent SC. Install this pipe as described above. On all systems except vertical coa[...]

29 29 8) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of fl ue gas fl ow . • Support horizontal piping sections at intervals of 6 feet[...]

30 30 1 1) Assembly of V ertical Coaxial V ent System Using Crown #500005 Coaxial V ent Kit (V ent Option #1 1) a) Start by installing the “B” vent piping. Install and assemble this piping in accordance with the “B” vent manufacturer ’ s instructions. Seal the joints between sections of “B” vent with GE R TV 106 or Dow 732 R TV sealan[...]

31 31 FIGURE 23: INST ALLA TION OF VENT SUPPOR T PROVIDED IN CROWN #500005 VER T . COAXIAL VENT KIT FIGURE 24: CONDENSA TE TRAP/DRAIN DET AIL[...]

32 32 VII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fi re at the nameplate input at a line pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or the National Fuel Gas Code . Figure 25 shows typical gas piping conne[...]

33 33 VIII System Piping CAUTION • Install boiler so that the gas ignition system components ar e protected fr om water (dripping, spraying, rain, etc) during appliance operation and service (circulator replacement, etc). • Operation of this boiler with continuous r eturn temperatures below 120F can cause severe heat exchanger corr osion damage[...]

34 34 8) Flow control valve (Required under some conditions) – The fl ow control valve prevents fl ow through the system unless the circulator is operating. A fl ow control valve may be necessary on converted gravity systems to prevent gravity circulation. Flow control valves are also used to prevent “ghost fl ows” in circulator zone syst[...]

35 35 FIGURE 26: BASIC PIPING FIGURE 27: INDIRECT W A TER HEA TER BOILER-SIDE PIPING[...]

36 36 FIGURE 28: BYP ASS PIPING FIGURE 29: ISOLA TION OF BOILER FROM SYSTEM WITH HEA T EXCHANGER[...]

37 37 FIGURE 30: CHILLER PIPING[...]

38 38 IX W iring The CWD Series boiler is of fered with two different types of control systems: • CB502 Control System - Basic operation of the boiler is controlled with a “CB502 control” (Crown part #42-502) located in the left side of the boiler vestibule. This device controls one or two circulator zones without the use of additional contro[...]

39 39 FIGURE 31: CB502 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING FIGURE 32: CB502 CONTROL SYSTEM - F ACTOR Y SWITCH / JUMPER CONFIGURA TION[...]

40 40 B. CB502 System - W iring V ariations 1) T wo Circulator Zones – Figure 33 shows wiring for two circulator zones. The second zone may be either an indirect water heater or a heating zone. No additional electrical controls are required to operate two circulator zones with a standard CWD boiler . 2) Hybrid Zone V alve/Circulator Zone System u[...]

41 41 FIGURE 33: CB502 CONTROL SYSTEM - FIELD WIRING FOR TWO CIRCULA TOR ZONES FIGURE 34: CB502 CONTROL SYSTEM - FIELD WIRING FOR HYBRID CIRCULA T OR/ZONE V AL VE SYSTEM[...]

42 42 FIGURE 35: CB502 CONTROL SYSTEM - INTERNAL LADDER DIAGRAM[...]

43 43 FIGURE 36: CB502 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM[...]

44 44 D. R8285 Control System - Single Zone W iring 1) Line V oltage (120 V AC) Connections (Fig 37) – The line voltage connections are located in the junction box under the R8285 fan center on the right side of the boiler . • Black – Line voltage “hot” • White – “Neutral” for boiler and circulators • Green – Ground connection[...]

45 45 FIGURE 38: R8285 CONTROL SYSTEM - FIELD WIRING FOR TWO CIRCULA TOR ZONES FIGURE 37: R8285 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING[...]

46 46 FIGURE 39: R8285 CONTROL SYSTEM - ZONE V AL VE FIELD WIRING FIGURE 40: R8285 CONTROL SYSTEM - INTERNAL LADDER DIAGRAM[...]

47 47 FIGURE 41: R8285 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM[...]

48 48 X Start-up and Checkout Use the following procedure for initial start-up of the boiler: 1) Make sure that the boiler and system are fi lled with water . 2) Check all new gas piping for leaks and purge piping sections that are fi lled with air . See the National Fuel Gas Code for additional information on testing and purging gas lines. 3) V [...]

49 49 A. This appliance is equipped with an ignition device which automatically light s 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 . WHA T TO DO IF YOU SMELL GAS Do not try to light [...]

50 50 12) Check the manifold pressure and adjust if necessary . T o do this, use the following procedure: a) Connect a manometer to the line pressure tap on the gas valve (see Figure 44). b) Check the line pressure with all gas appliances on and off. The line pressure at the boiler must be within the following limits regardless of what combination [...]

51 51 FIGURE 44: GAS V AL VE FIGURE 45: MEASURING MANIFOLD PRESSURE[...]

52 52 XI Service and Maintenance The following routine maintenance should be performed on an annual basis: 1) T urn off electrical power and gas supply to the boiler . 2) Remove the burner tray . T o do this: a) Remove the intake cover . b) Remove the four Allen head screws holding the elbow fl ange onto the gas valve. c) Remove the three 10-32 sc[...]

53 53 Heat Exchanger Cleaning Pr ocedur e 1) T urn off electrical power and gas supply to the boiler . 2) Remove the burner tray . T o do this: a) Remove the intake cover . b) Remove the four Allen head screws holding the elbow fl ange onto the gas valve. c) Remove the three 10-32 screws holding the manifold gasket plate to the intake box. d) Remo[...]

54 54 16) Set the fl ue collector onto the block and press down so that the fl ue collector is set into the silicone applied in the previous step. 17) Slide the fl ue collector lugs back into position and retighten the ¼-20 bolts. DO NOT OVER TIGHTEN . 18) Apply a bead of silicone around the outside of the joint between the heat exchanger and t[...]

55 55 T ABLE 7: PRESSURE SWITCH SETTINGS AL TITUDE CROWN PN MAKE SETTING* (inches w .c.) BREAK SETTING* (inches w .c.) SEA LEVEL - 5200 ft 620009 1.26 1.16 ABOVE 5200 ft 620010 1.10 1.00 *Settings shown are based on “plus tolerance” - actual setting may be lower . FIGURE 46a: PRESSURE SWITCH CONNECTIONS[...]

56 56 FIGURE 46b: MEASURING PRESSURE ACROSS PRESSURE SWITCH[...]

57 57 XII T roubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems. If troubleshooting a CB502 control system, go to the box marked “Start” at the top of the chart on page 58 and follow the appropriate path though the chart until a box with a list of possible causes is reached. If troubleshootin[...]

58 58 120 v olts acros s black and whi te trans form er pri mary leads ? Ca ll fr om "H EAT 1" zone "H EAT 1" Ci rculator star t? * Power of f * Blow n fuse or tri pped breaker * M i s wi red or loose electrical connecti on i n 120 v olt line 120 v olts across red and whi te circulator lea ds ? * Loose connecti on i n t's t[...]

59 59 N Y Y Call for heat from "DHW/H2" zone "DHW/H2" circulator star t? Defecti v e CB502 board DHW LED On? 24V across "DHW/H2" T and T * Loose connecti on i n t's t at or zone v alv e end switch wiring * Defecti v e t'st at or zone v alve end s wi tch * T'stat or zone sy st em m is wi r ed-consult zone[...]

60 60 120 v olts present ? * Loose connecti on at fan plug or f an capacit or * Defecti ve capacit or * Defect i v e fan 24 v olts pres ent ac r oss yel l o w trans form er lead and purple l ead on press ure s wi tch? *Defecti v e "FAN" relay *Defecti v e CB502 board Conti nued from previ ous page Unplug fan and check for 1 20 V ac r oss [...]

61 61 Wait 30 seconds (prepurge) *Loose harness *Defecti v e CB502 board * Loose, leaki ng, blocked, or rev ersed press ure s wi tch tubes *Leaks i n flue c oll ector joint s *Forei gn object i n fan or fl ue coll ector * Blockage in v enting s y stem * Vent s y st em not i ns t all ed i n accordance wi t h i nstallation manual * Ex cess i ve s i l[...]

62 62 120 v olts acros s black and whi te trans form er pri mary leads on back of R8285 ? Therm ost at call s for heat Ci rculator star t? * Power of f * Blow n fuse or tri pped breaker * M i s wi red or loose electrical connecti on i n 120 v olt line 120 v olts acros s circulator connecti ons? * Loose connecti on i n t's t at or zone v alv e [...]

63 63 Pilot li ght ? 24 v olts betw een 24V and 24V (GND) on i gn. m odul e? See "I ntermit t ent I gni t i on S y stem Troubl eshooti ng Chart" on page 64. M i n i mu m press ure at sw it ch called i n Tabl e 7 present ac r oss switc h? * Blockage in v enting s y st em * Vent s y stem not i ns t all ed i n accordance wi t h i nstallati o[...]

64 64 Does spark s t op when pi l ot li ght s ? 24 v olts ac r oss terminals PV & MV/ P V at m odul e? Pulsi ng Spark ac r oss i gni tor/s ensor gap? Y * M odule i s i n soft l oc k ou t. R ese t by mo me n t a r i ly i nt erupti ng power to boi ler and w ai ti ng for prepurge. * Break i n spark cable insulati on * Break i n pi lot porcelain * [...]

65 65 XIII P AR TS The following parts may be obtained from any Crown distributor . T o fi nd the closest Crown distributor, consult the area Crown representative or the factory at: Crown Boiler Co. Customer Service P .O. Box 14818 Philadelphia Pa. 19134 www .crownboiler .com Main burner ori fi ce shown are for sea level con fi gured boilers. Fo[...]

66 66 BLOCK, BASE, FLUE COLLECTOR COMPONENTS KEY DESCRIPTION PA R T # OR QTY . P AR T # OR QTY . CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 1 BASE 1 6201 13 620114 6201 15 620116 6201 17 6201 18 6201 19 620120 2 NYLON FEET (GLIDES) 7001 11 44444444 3 INT AKE BOX 1 620233 620234 620235 620236 620237 620238 620239 620240 4 1/4-20 X1/2 P [...]

67 67[...]

68 68 BURNER TRA Y COMPONENTS KEY DESCRIPTION P AR T# OR QTY . P AR T # OR QTY . CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 50 FRONT FIREDOOR 1 620543 620544 620545 620546 620547 620548 620549 620550 51 FRONT FIREDOOR INSULA TION 1 620523 620524 620525 620526 620527 620528 620529 620530 52 INSULA TION SUPPOR T BRACKET 620101 22222444 5[...]

69 69[...]

70 70 JACKET COMPONENTS KEY DESCRIPTION PA R T # OR QTY P AR T # OR QTY CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 80 VESTIBULE P ANEL 1 620323 620324 620325 620326 620327 620328 620329 620330 81 LARGE PLASTIC BUSHING 960051 11111111 82 F AN COVER PLA TE 1 620302 620302 620302 60-300 60-300 60-300 60-300 60-300 83 #10 X 1/2 SHEET MET A[...]

71 71[...]

72 72 COMMON CONTROLS & TRIM KEY DESCRIPTION P AR T# OR QTY P AR T # OR QTY CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 * 1/8” SILICONE TUBING 14-008 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 100 HONEYWELL L4080D LIMIT 35-3300 11111111 101 TRIDICA TOR GAUGE 95-069 11111111 102 UT IGNITION MODULE 1003-626A 3503062 111[...]

73 73[...]

74 74 Appendix A: Special Requir ements For Side-W all V ented Appliances In The Commonwealth of Massachusetts IMPOR T ANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: 1. For direct-vent appliances, mechanical-vent heating appliances or do[...]

75 75[...]

T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacturer of Hydronic Heatings Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 CROWN Boiler Co PN 980060 CWDMANV4 04/09[...]