Crown Boiler CWI138 manual

1 D E S I G N E D T O L E A D T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 CWI Series Gas-Fired Natural Draf t W ater Boilers INST ALLA TION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler WARNING :[...]

2 T able of Contents I . Product Description .................................................. 1 II. Specifications ............................................................. 2 III. Before Installing ......................................................... 3 IV . Locating the Boiler ...................................................... 3 V . [...]

3 T ABLE 1: CWI SPECIFICA TIONS 2 II Specifications FIGURE 1: CWI BOILERS - GENERAL CONFIGURA TION INPUT (MBH) (MBH) (Gal/min) "A" "B" "C" "D" (Gal ) CWI069 3 69 57 81.0 83.1 12 3/4 28 40 7/16 4 7.8 CWI103 4 103 86 81.3 83.1 2.50 16 2 8 40 7/16 5 10.0 CWI138 5 138 115 81.6 83.1 3 .00 19 1/4 28 40 7/16 6 12.2 [...]

4 3 III Before Installing 1 ) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the Nati[...]

5 4 • If the right side 24” service clearance is reduced, adequate clearance must be maintained to easily read and access the controls. Alternatively , access may be provided using a door . The right side clearances shown for boilers equipped with tankless heaters allow for removal of the tankless heater . 2) This boiler may be installed direct[...]

6 • Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other openings. For Buildings of Other than Unusually Tight Construction 1) Determine whether the boiler is t[...]

7 6 FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC FIGURE 3: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE[...]

8 FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 7[...]

9 8 • The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used, they must be no finer than ¼” (4 x 4) mesh. VI V enting Vent installation must be in accordance with local building codes, or the local authority having jurisdiction, or the National Fuel Gas Code , NFPA 54/ANSI [...]

10 9 sealed tight. 1 3 ) Do not install the vent damper in any portion of the vent system which is used by appliances other than the boiler being installed. 1 4 ) Vent damper installation is mandatory on all CWI boiler models except the CWI310-CWI379. Install vent damper (see Figure 9) as follows: a ) Open vent damper carton and remove installation[...]

11 10 FIGURE 8: CWI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS FIGURE 9: VENT DAMPER INSTALLATION DETAILS[...]

12 11 * VII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire 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 Chapter 2 of the National Fuel Gas Code . Figure 10 shows typical gas[...]

13 12 VIII System Piping Standard Piping Figure 11 shows typical boiler system connections on a single zone system. Additional information on hydronic system design may be found in Installation of Residential Hydronic Systems (Pub. #200) published by the Hydronics Institute in Berkeley Heights, NJ. The components in this system and their purposes a[...]

14 6) Low Water Cut-Off (Required in some situations) - A low water cutoff is required when the boiler is installed above radiation. In addition, some codes such as ASME CSD-1 require low water cutoffs. Codes may also require that this low water cutoff have a manual reset function. The low water cutoff may be a float type or probe type, but must be[...]

15 14 FIGURE 12: INDIRECT WATER HEATER BOILER SIDE PIPING FIGURE 11: STANDARD BOILER PIPING[...]

16 5) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler and chiller in parallel as shown i n Figure 15. Use isolation valves to prevent chilled water from entering the boiler. 6) Air Handlers - Where the boiler is connected to air handlers through which refrigerated air passes, use flow control valves in t[...]

17 FIGURE 15: BOILER PIPING WITH CHILLER FIGURE 14: ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER 16[...]

18 17 IX T ANKLESS HEA TER PIPING If the CWI is installed with an optional tankless heater, pipe the heater as shown in Figure 17. The components in this system and their functions are as follows: 1) Mixing Valve (Required) - During the heating season, the water exiting the tankless heater may be 180 degrees or more. The mixing valve blends hot wat[...]

19 18 3) Pressure Relief Valve (Required) - Limits the pressure in the tankless heater and piping. Use an ASME constructed valve designed for domestic water service, such as the Watts #3L. Note that this is a pressure relief valve, not a T&P valve. Select a valve with a pressure setting less than or equal to the working pressure marked on the t[...]

20 IX Wiring Single Zone Wiring 1) 120 V olt W iring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt connections are made inside the L8148E or L8124E aquastat relay as follows (also see Figures 18-21): • Hot (“black”) - T erminal “L1” • Neutral (“white”) - T erminal “L2” • Gr[...]

21 20 FIGURE 19: WIRING DIAGRAM, INTERMITTENT IGNITION (EI) SYSTEM LESS TANKLESS HEATER FIGURE 20: WIRING DIAGRAM, STANDING PILOT WITH TANKLESS HEATER 2 (NOTE 2) 2. VENT DAMPER REQUIRED ON AL L BOILE RS EXCEPT CWI 310 - CWI 37 9. W HEN DAMPER IS NOT US DAMPER HARNESS I S REPLAC ED WITH JUMPER PLU G . TH TR + ROBERTSHAW 7000DERHC GAS V AL VE (CWI37 [...]

22 21 FIGURE 21: WIRING DIAGRAM, INTERMITTENT IGNITION (EI) SYSTEM WITH TANKLESS HEATER Wiring V ariations 1) Multiple Circulator Zones – Figure 22 shows wiring for two or more circulator zones using Honeywell R845As. One R845A is required for each circulator zone. Circulator terminals “C1” and “C2” on the limit control are not used. A DP[...]

23 22 FIGURE 23: ZONE WIRING USING HONEYWELL V8043F ZONE V AL VES (F ACTOR Y WIRING NOT SHOWN - SEE FIGURES 18 - 21) FIGURE 22: CIRCULA TOR ZONE WIRING USING HONEYWELL R845As (F ACTOR Y BOILER WIRING NOT SHOWN - SEE FIGURES 18 - 21)[...]

24 23 CWI Control System – Sequence of Operation (Refer to Figures 18 - 21 for ladder and connection diagrams) Sequence of Operation, Standing Pilot, Less Tankless Heater 1) When the boiler is ener gized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damper . Assuming that there is no call for heat, [...]

25 24 Sequence of Operation, Intermittent Ignition, Less Tankless Heater 1) When the boiler is ener gized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damper . Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will close. 2 ) A call for[...]

26 XI S tart-up and Checkout Use the following procedure for initial start-up of the boiler: 1 ) Make sure that the boiler and system are filled with water. 2 ) Check all new gas piping for leaks and purge piping sections that are filled with air. See Part 4 of the National Fuel Gas Code for additional information on testing and purging gas lines. [...]

27 WARNING • 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. • DAMPER MUST BE IN OPEN POSITION WHEN APPLIANCE MAIN BURNER IS OPERATING. 26 1 0 ) Make sure vent damper is in open position when main burners are f[...]

28 27 1 5 ) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a ) Connect a manometer to the inlet pressure tap on the gas valve (see Figures 27 and 28). b) Check the inlet pressure with all gas appliances on and off. The inlet pressure at the boiler must be within the following limits regardless of what [...]

29 28 16) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. For standing pilot boiler models, pilot burner should remain lit but the main burners should stop firing. For intermittent ignition boiler models both pilot burner and main burners should stop firing. Raise the thermostat back to the highest [...]

30 A. This appliance has a pilot which must be light ed by hand. When lighting t he pilot, follow these instructions exactly . B. BEFORE LIGHTING smell all ar ound the applian ce area for gas. Be sur e to smell next to t he floor because so me gas is heavier than air and will settle on the floor . WHA T TO DO IF YOU SMELL G AS Do not t ry to light [...]

31 30 A. This appliance has a pilot which must be light ed by hand. When lighting t he pilot, follow the se in structions exactly . B. BEFORE LIGHTING smell all ar ound the applian ce area for gas. Be sur e to smell next to t he floor because so me gas is heavier than air and will settle on the floor . WHA T TO DO IF YOU SMELL GAS Do not t ry to li[...]

32 31 A. This appliance is equipp ed with an ignition device which automat ically lights the pilot. D o try to lig ht the p ilot by han d. B. BEFORE LIGHTING smell all ar ound the applian ce area for gas. Be sur e to smell next to t he floor because so me gas is heavier than air an d will settle on the floor . WHA T TO DO IF YOU SMELL G AS Do not t[...]

33 32 A. This appliance is equipp ed with an ignition device wh ich automatically light s the pilot. D o try to lig ht the pil ot by han d. B. BEFORE LIGHTING smell all ar ound the applian ce area for gas. Be sur e to smell next to t he floor because so me gas is heavier than air and will settle on the floor . WHA T TO DO IF YOU SMELL GAS Do not t [...]

34 FIGURE 28a: GAS VALVE DETAIL - HONEYWELL VR8204 AND VR8304 (INTERMITTENT IGNITION) FIGURE 27a: GAS VALVE DETAIL - HONEYWELL VR8200 OR VR8300 (STANDING PILOT) FIGURE 27b: GAS VALVE DETAIL - ROBERTSHAW 7000ERHC AND HONEYWELL V8295 (STANDING PILOT) FIGURE 28b: GAS VALVE DETAIL - ROBERTSHAW 7000DERHC (INTERMITTENT IGNITION) 33[...]

35 34 XI Service and Maintenance The following routine maintenance should be performed on an annual basis: 1 ) Turn off electrical power and gas supply to the boiler 2 ) Inspect the flue passages for signs of blockage. If there is any carbon in the combustion chamber or the flue passages, clean the heat exchanger before proceeding further . See the[...]

36 Heat Exchanger Cleaning Procedure 1 ) T urn off electrical power and gas supply to the boiler . 2 ) Disconnect the damper and vent connector from the boiler . 3) Remove the upper front and top jacket panels. If possible, remove the rear and left side jacket panels. 4 ) Remove the burners. 5 ) Remove the blocked vent (“spill”) switch. 6 ) Rem[...]

37 36 XIII T roubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems. T o use these charts, go to the box marked “Start” at the top of the chart on page 37 or 39 and follow the appropriate path though the chart until a box with a list of possible causes is reached. If the problem is known to be w[...]

38 T roubleshooting Chart for CWI Boilers Without T ankless Heaters Caution : Read page 36 before attempting to use this chart 37 Boiler E quipped Wit h Da mp e r ? Th e r m o s t a t c all s f or heat C ir c ulator st a rt ? 120 v olts at L1 & L2 ? 120 v olts at C1 & C2 ? N N * Po w e r o f f * Bl ow n f us e or tr ipped br eaker * M i s w[...]

39 38 Ma i n bur ner s l ight ? 24 v olts ac r os s B1 & B2 ? R ef er to s t an ding pil ot or in t e r m it t e n t ig n it io n tr oubles hoot ing c ha r t ( page 41 or 42) . * D ef ec tiv e dam p er * D ef ec tiv e L8148E * D ef ec tiv e dam p er har nes s * Loos e dam per har nes s c onnec ti on * Ob s tr uc t io n in pa t h of dam per blad[...]

40 39 T roubleshooting Chart for CWI Boilers Equipped with T ankless Heaters and Dampers Caution : Read page 36 before attempting to use this chart N o c all f or heat, b o i l e r w at e r tem p. at l eas t 20F b elow l ow l im it s etti n g * Po w e r o f f * Bl ow n f us e or tr ipped br eak er * M is w ired or l oos e el e c tr ic al c onne c t[...]

41 40 120 v ol ts ac r os s ter m i nals at ci rcu l a t o r? Do b u r n e r s s hut dow n bef or e gage tem p ex c eeds high li m it se t t i n g + 1 5F ? C ir c ulator st a rt ? 120 v ol ts at C1 & C2 ? N R em ov e t 's t at or z o ne v al v e end sw i tch w i res f ro m T & TV ter m i nals on L812 4E . I n s tall tem por ar y j um p[...]

42 St anding Pilot Ignition System T roubleshooting Chart Pilot li t ? Ma in bu rners li ght ? Y T u rn c ont rol on gas v al v e t o PIL O T . D ep r ess red b ut t o n and lig ht p ilo t. H o ld but t on fo r at leas t one minu t e. Does pi lot li ght ? N * P i l ot t ubi ng b lo cke d , ki n ke d or leak ing * Pi lot or ifice bloc k ed * G a s l[...]

43 42 Doe s s par k s t op w h e n p i lo t li ght s ? 24 v olt s a cr o ss t er m i nal s 2& 3 at S 8600? Sp ar k a cr o ss i g ni t or / s ens or gap? Y Can y o u hea r s park i ng? * Fau lt y S 8600 module * Br ea k in s park c ab l e ins u l ation * Bre ak in pilo t porc elai n * Incorrec t pi lot s park gap * Loos e c onnec t ion i n s par[...]

44 43 XIV P AR TS The following parts may be obtained from any Crown distributor . T o find the closest Crown distributor , consult the area Crown representative or the factory at: Crown Boiler Co. Customer Service P .O. Box 14818 Philadelphia P A. 19134 www .crownboiler .com For boilers installed at elevations above 2000 ft, consult the local Crow[...]

45 44[...]

46 45 69 103 138 172 207 241 276 310 345 379 42 1" BURNER LESS PILOT BRACKET 150501 2 ea. 4 ea. 6 ea. 8 ea. 11 ea. 13 ea. 15 ea. 17 ea. 20 ea. 22 ea. 43 MANIFO LD (1" BURNERS) 1 ea. 700153 700154 700155 700156 700157 700158 700159 700160 700161 7 00162 44 NAT GAS ORIFICE (#42 DRILL SIZE) 950298 3 ea. 44 NAT GAS ORIFICE (#44 DRILL SIZE) 95[...]

47 46[...]

48 47 69 103 138 172 207 241 276 310 3 45 379 75 LEFT SIDE JACKET PANEL 1 ea. 850301 850301 850301 850301 8503012 8503012 8503012 8503015 8503015 8503015 76 RIGHT SIDE JACKET PANEL 1 ea. 850300 850300 850300 850300 8503002 8503002 8503002 8503005 8503005 8503005 77 REAR JACKET PANEL 1 ea. 850303 850304 850305 850306 850307 850308 850309 850310 8503[...]

49 48[...]

50 A. Before Installing 1 ) Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs or punctures due to mishandling. 2 ) Do not use the heat exchanger if there is any damage to it. 3 ) Inspect the joints between the sections for openings. Reseal any openings with high temperature silicone se[...]

51 50 FIGURE A1: BASE, HEA T EXCHANGER, FLUE COLLECTOR ASSEMBL Y[...]

52 side panel installed in the previous step and secure with three #10 sheet metal screws. 5 ) Install the left side panel in the same manner as the right side. 6 ) Attach the front corners of the diverter panel to the side jacket panels using #10 sheet metal screws. 7 ) Install the horizontal (angle) jacket clips in the front edge of the side jack[...]

53 52 FIGURE A2: JACKET INST ALLA TION[...]

54 F . Electrical W iring 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 V ent Switch - Locate the two wires marked “8”. Connect these wires to the terminals on [...]

55 54 FIGURE A3: T APPING LOCA TIONS (SEE TEXT FOR T APPING USES)[...]

56 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134[...]