Crown Boiler CWI103, Installation Instructions Manual

Page 1: ...ause 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 Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com D E S I G N E D...

Page 2: ......

Page 3: ...llation 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 boi...

Page 4: ...CWI series boilers are low pressure cast iron gas fired hot water boilers designed for use in closed hot water heating systems These boilers are Category I draft diverter equipped appliances which must be vented by natural draft using a lined masonry or listed metal chimney system An adequate supply of air for combustion ventilation and dilution of flue gases must be available in the boiler room T...

Page 5: ...76 9 276 230 83 2 4 00 5 25 32 1 4 30 40 7 16 8 21 0 CWI311 10 310 252 81 4 4 00 5 25 35 1 2 30 45 7 16 8 23 2 CWI346 11 345 281 81 4 4 00 5 25 38 3 4 30 45 7 16 9 25 4 CWI380 12 379 309 81 4 4 00 5 25 42 30 45 7 16 9 27 6 DIMENSIONS in AFUE WATER VOL 75 100 219 TANKLESS HTR RATING 125 150 175 AHRI NET RATING 244 269 CWI311 CWI380 NOT AVAILABLE FOR USE WITH LP GAS BASIC BOILER MODEL NUMBER OF SECT...

Page 6: ...or LP The CWI311 CWI346 and CWI380 may only be used with natural gas 5 Boilers installed at altitudes above 2000 ft may require different burners and main burner orifice than those at sea level Make sure that the boiler is configured for use at the correct altitude 6 If this boiler was received as a knockdown boiler follow the instructions in Appendix A to assemble the boiler IV Locating the Boile...

Page 7: ...lution Provisions for combustion ventilation and flue gas dilution air for gas utilization equipment vented by natural draft must be made in accordance with local building codes or in absence of such codes in accordance with sections 5 3 3 and 5 3 4 Air for Combustion and Ventilation of the National Fuel Gas Code NFPA 54 ANSI Z223 1 To ensure an adequate supply of combustion ventilation and flue g...

Page 8: ...and one near the ceiling The top edge of the upper opening must be within 12 of the ceiling and the bottom edge of the lower opening must be within 12 of the floor Figure 3 Each opening must have a free area of 1 square inch per 1000 BTU hr input of all gas burning appliances in the boiler room The minimum opening dimension is 3 inches Minimum opening free area is 100 square inches per opening If ...

Page 9: ...7 7 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 ...

Page 10: ...8 8 FIGURE 6 ALL AIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM FIGURE 7 ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM ...

Page 11: ...ined masonry chimney See the National Fuel Gas Code for information on when exterior chimneys may be used An exterior masonry chimney may be used if it is lined with B vent or a listed chimney lining system 5 This boiler may be vented using a listed power venter The power venter must be in sized and installed in accordance with the power venter manufacturer s instructions the terms of the power ve...

Page 12: ...ected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused opening in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe...

Page 13: ...11 11 FIGURE 8 CWI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS FIGURE 9 VENT DAMPER INSTALLATION DETAILS ...

Page 14: ...controls Install a manual shut off valve outside the jacket and ground joint union as shown The boiler and its gas connection must be leak tested before placing the boiler in operation When doing this the boiler and its individual shut off must be disconnected from the rest of the system during any pressure testing of that system at pressures in excess of 1 2 psi When pressure testing the gas syst...

Page 15: ...ator Required Although the circulator is shipped on the boiler return it can be installed on the boiler supply If the circulator is moved to the supply it should be positioned just downstream of the expansion tank as shown in Figure 11 3 Expansion Tank Required If this boiler is replacing an existing boiler with no other changes in the system the old expansion tank can generally be reused If the e...

Page 16: ...e Systems The piping shown in Figure 13 will minimize the amount of time that the boiler operates with return temperatures below 120 F on these systems A bypass is installed as shown to divert some supply water directly into the return water The bypass pipe should be the same size as the supply The two throttling valves shown are adjusted so that the return temperature rises above 120 F during the...

Page 17: ...15 15 FIGURE 12 INDIRECT WATER HEATER BOILER SIDE PIPING FIGURE 11 STANDARD BOILER PIPING ...

Page 18: ...ing for a gravity hot water boiler The circulator 1 1 2 x 2 bushings and 1 1 2 piping are removed and the system piping is run directly to the 2 supply and return tappings on the boiler If isolation valves are installed they should be gate valves or full port ball valves If it is desired to convert the gravity system to forced hot water the factory supplied circulator and piping are used as is A g...

Page 19: ...17 17 FIGURE 15 BOILER PIPING WITH CHILLER FIGURE 14 ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER ...

Page 20: ...range of approximately 110 to 130F Follow the manufacturer s instructions for installing this valve Usually a heat trap will be required between the coil and the hot connection on the mixing valve 2 Flow Restrictor Recommended If water is drawn from the tankless coil at a rate in excess of the rating in Table 1 the temperature of the hot water may be too low to be of use The use of a flow restrict...

Page 21: ... boiler Install unions anywhere in the tankless heater piping that will facilitate removal of the heater 7 Backflow Preventer Required in Massachusetts If required by local codes install a backflow preventer in the cold water connection to the tankless coil just upstream of the piping shown in Figure 17 Install in accordance with local codes and the backflow preventer s installation instructions A...

Page 22: ... direct sunlight cold spots outside walls walls adjacent to unheated areas locations subject to drafts Provide Class II circuit between thermostat and boiler Connect thermostat wire leads to terminals T and TV inside aquastat relay 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 C...

Page 23: ...ontinuity is created between terminals 5 and 6 on the R845A creating a current path from terminal T to TV on the limit control Assuming that the supply water temperature is below the high limit setting the normal ignition sequence will be initi ated 2 Multiple Zones using Zone Valves Figure 21 shows wiring for multiple zones using Honeywell V8043F zone valves This wiring diagram may be used for ot...

Page 24: ... FIGURE 21 ZONE WIRING USING HONEYWELL V8043F ZONE VALVES FACTORY WIRING NOT SHOWN SEE FIGURES 18 19 FIGURE 20 CIRCULATOR ZONE WIRING USING HONEYWELL R845As FACTORY BOILER WIRING NOT SHOWN SEE FIGURES 18 19 ...

Page 25: ...r temperature is less than the low limit setting minus the differential setting terminals R and B in the L8124E are made through the low limit switch The low limit switching action is SPDT with R being common R and W are therefore open whenever R and B are made This means that while R and B are made relay coil R1 is deenergized regardless of whether or not there is a call for heat The circulator w...

Page 26: ...ER PERFORMANCE CRITERIA WERE MET WITH THE GAS MANIFOLD AND CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS SPECIFIED IN Z21 13 Safety Control Operation Standing Pilot and Intermittent Ignition High Limit Interrupts main burner operation when the supply water temperature exceeds set point Maximum allowable tem perature is 250 F If the high limit opens the vent damper wil...

Page 27: ...s should stop firing 14 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 24a and 24b 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 combination of appliances is firing Inlet Pres...

Page 28: ...e lowest setting Both pilot burner and main burners should stop firing Raise the thermostat back to the highest setting The pilot burner and main burners should relight 16 Verify high limit operation Allow the boiler water temperature to increase to hi limit setting The burners should shut down and the circulator continue running Both the pilot burner and main burners should stop firing 17 Allow t...

Page 29: ...27 27 FIGURE 24a GAS VALVE DETAIL HONEYWELL VR8204 AND VR8304 FIGURE 24b GAS VALVE DETAIL ROBERTSHAW 7000DERHC ...

Page 30: ...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 fo...

Page 31: ...TING 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...

Page 32: ...tion Replace pilot assembly if dete rioration is found 6 Inspect the combustion chamber insulation for deterioration 7 Inspect the ignition cable insulation for cracks or other deterioration If deterioration is found replace cable 8 Reinstall burners being careful to put the pilot main burner in its original location 9 Inspect all boiler wiring for loose connections or deterioration 10 Inspect the...

Page 33: ...put the pilot main burner in its original location 16 Replace the blocked vent switch 17 Reconnect the damper and vent system WARNING SOOT 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...

Page 34: ...32 32 Notes ...

Page 35: ...r is defective or there is an obstruction in the path of the damper blade If no voltage is present there is either a loose connection in the damper harness or the limit control L8148E or L8124E is defective 6 If the charts indicate that the L8148E or L8124E is defective do the following before replacing it Check for 24 volts across TV and Z If no voltage is present the transformer in the L8148E or...

Page 36: ... 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 volts across 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...

Page 37: ...equate 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 B2 and 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 T terminal on aquastat Does boiler shut...

Page 38: ...re on rollout switch and B2 Y Refer to ignition system troubleshooting chart page 38 START Defective damper Defective damper harness Loose damper harness connection Obstruction in path of damper blade 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 accordance with Parts 7 and 10 of N...

Page 39: ... circulator shut down at end of call for heat END Pull wire off of T terminal on aquastat Does boiler shut down T stat or zone 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 not bottomed out in well Seized or defective circulator Bad electrical ...

Page 40: ... Low gas pressure at gas valve inlet Defective ignition module Main burner lights N Y 24VAC across terminals MV MV PV on module Y N N Defective ignition module 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 ...

Page 41: ...39 39 Notes ...

Page 42: ...0 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 ft 12 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 SHE...

Page 43: ...41 41 ...

Page 44: ...6 3501136 48 PILOT TUBING 1 ea 90 042 90 042 90 043 90 043 90 043 900041 900041 900041 49 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...

Page 45: ...43 43 ...

Page 46: ...AMPER 1 ea 96 031 96 032 96 032 96 033 96 033 96 035 96 035 96 036 96 036 89 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 TRID...

Page 47: ...45 45 ...

Page 48: ...er gasket 2 Once the heat exchanger has been placed on the base inspect the gasket for proper seal Repair or replace gasket if necessary 3 Secure the heat exchanger with 5 16 lock nuts with nylon inserts and washers from the hardware bag 4 Loosen nuts on tie rods until they are finger tight 5 Fiber gasket strips are used to seal the flue collector to the heat exchanger this is the same material us...

Page 49: ...47 47 FIGURE A1 BASE HEAT EXCHANGER FLUE COLLECTOR ASSEMBLY ...

Page 50: ...he upper left of the right side panel 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 Ins...

Page 51: ...49 49 FIGURE A2 JACKET INSTALLATION ...

Page 52: ...T 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...

Page 53: ...51 51 FIGURE A3 TAPPING LOCATIONS SEE TEXT FOR TAPPING USES ...

Page 54: ...52 52 Notes ...

Page 55: ...53 53 Notes ...

Page 56: ...P N 980434 11 14 Rev 2 Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com ...