Crown CWI241 - Manuals

5 4 • If the right side 24” service clearance is reduced, adequate clearance must be maintained to easily read and access thecontrols. Alternatively, access may be provided using a door. The right side clearances shown for boilers equippedwith tankless heaters allow for removal of the tankless heate...

6 • Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates andfloors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and atother openings. For Buildings of Other than Unusually Tight Con...

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 Venting Vent installation must be in accordance with local building codes, or the local authority having jurisdiction, or the...

10 9 sealed tight.13) Do not install the vent damper in any portion of the vent system which is used by appliances other than the boiler beinginstalled.14) Vent damper installation is mandatory on all CWI boiler models except the CWI310-CWI379. Install vent damper (seeFigure 9) as follows: a) Open v...

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 theutility or Chapter 2 of the Nat...

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

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 lowwater cutoff have a manual reset function. The low water cuto...

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 in 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 refr...

18 17 IX TANKLESS HEATER PIPING If the CWI is installed with an optional tankless heater, pipe the heater as shown in Figure 17. The components in thissystem and their functions are as follows: 1) Mixing Valve (Required) - During the heating season, the water exiting the tankless heater may be 180 d...

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...

20 IX Wiring Single Zone Wiring 1) 120 Volt Wiring - 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”) - Terminal “L1” • Neutral (“whit...

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 ALL BOILERS EXCEPT CWI310 - CWI379. WHEN DAMPER IS NOT USDAMPER HARNESS IS REPLACED WITH JUMPER PLUG. TH TR + R...

22 21 FIGURE 21: WIRING DIAGRAM, INTERMITTENT IGNITION (EI) SYSTEM WITH TANKLESS HEATER Wiring Variations 1) Multiple Circulator Zones – Figure 22 shows wiring for two or more circulator zones using Honeywell R845As. One R845A isrequired for each circulator zone. Circulator terminals “C1” and “C2” o...

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 energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damper. Ass...

26 XI Start-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 ...

28 27 15) 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 w...

30 A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. 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...

31 30 A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. 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...

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 boiler2) Inspect the flue passages for signs of blockage. If there is any carbon in the combustion chamber or the flue passages,clean the heat...

36 Heat Exchanger Cleaning Procedure 1) Turn 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 blo...

37 36 XIII Troubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems. To use these charts, go tothe box marked “Start” at the top of the chart on page 37 or 39 and follow the appropriate path though the chart until abox with a list of possible causes i...

38 Troubleshooting Chart for CWI Boilers Without Tankless HeatersCaution : Read page 36 before attempting to use this chart 37 Boiler Equipped With Damper? Thermostat calls f or heat Circulator start? 120 volts at L1 & L2 ? 120 volts at C1 & C2 ? N N * Pow er of f * Blow n f us e or tripped ...

39 38 Main burners light? 24 v olts across B1 & B2 ? Ref er to standing pilot or intermittent ignition troubleshooting chart (page 41 or 42). * Def ectiv e damper * Def ectiv e L8148E * Def ectiv e damper harness * Loos e damper harness connec tion * Obstruction in path of damper blade 24 v olts...

42 Standing Pilot Ignition System Troubleshooting Chart Pilot lit? Main burners light? Y Turn control on gas valve to PILOT . Depress red button and light pilot. Hold button for at least one minute. Does pilot light? N * Pilot tubing blocked, kinked or leaking * Pilot orifice blocked * Gas line not ...

43 42 Does spark stop when pilot lights? 24 volts across terminals 2&3 at S8600? Spark across ignitor/sensor gap? Y Can you hear sparking? * Faulty S8600 module * Break in spark cable insulation * Break in pilot porcelain * Incorrect pilot spark gap * Loose connection in spark cable * Loose grou...

44 43 XIV PARTS The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area Crown representative or the factory at: Crown Boiler Co.Customer ServiceP.O. Box 14818Philadelphia PA. 19134www.crownboiler.com For boilers installed at elevations ...

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 ...

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) ja...

54 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”....

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