Page 2 - TABLE OF CONTENTS; Appendix A:Special Requirements for
2 TABLE OF CONTENTS I Product Description 1 II Specifi cations 1 III Before Installing 2 IV Locating the Boiler 2 V Air for Combustion and Ventilation 4 VI Venting 9 Vent System Design 9 Vent System Assembly 22 VII Gas Piping 32 VIII System Piping 33 IX Wiring 38 CB502 Control System 38 R8285 Contro...
Page 3 - TABLE 1: SPECIFICATIONS; FIGURE 1: GENERAL CONFIGURATION
1 1 I Product 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 horizont...
Page 4 - III Before Installing; National; IV Locating the Boiler; NOTICE
2 2 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 authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance wi...
Page 6 - TABLE 2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION; V Air for Combustion and Ventilation; sometimes called a “sealed combustion” installation.
4 4 TABLE 2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MINIMUM CLEARANCE TO COMBUSTIBLE MATERIAL HEAT FAB SAF-T VENT PROTECH FASNSEAL PROTECH FASNSEAL W2 METAL-FAB CORR/GUARD VERTICAL OR HORIZONTAL AT LEAST ONE SIDE OPEN, COMBUSTIBLE MATERIAL ...
Page 8 - Step 5: If Indoor Combustion Air is Used, Provide Air as Follows:; ) Buildings of other than unusually tight construction:
6 6 Step 5: If Indoor Combustion Air is Used, Provide Air as Follows: 1) Buildings of other than unusually tight construction: Unconfi ned Space– Natural infi ltration into the boiler room will normally provide adequate air for combustion and ventilation without additional louvers or openings into b...
Page 9 - FIGURE 5: ALL AIR FROM OUTSIDE USING VENTILATED ATTIC
7 7 FIGURE 4: ALL AIR FROM OUTSIDE USING VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTSIDE USING VENTILATED ATTIC
Page 10 - FIGURE 6: ALL AIR FROM OUTSIDE USING OPENINGS INTO BOILER ROOM
8 8 FIGURE 6: ALL AIR FROM OUTSIDE USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTSIDE USING HORIZONTAL DUCTS INTO BOILER ROOM
Page 11 - VI Venting; WARNING; There are three basic ways to vent the CWD boiler:; Vertical Non-Coaxial Venting; In addition, observe the following guidelines:
9 9 VI Venting WARNING Failure to vent this boiler in accordance with these instructions could result in unreliable boiler operation, severe damage to the boiler or property, or unsafe operation: * Do not attampt to vent this boiler with galvanized, PVC, or any other vent system not listed in Table ...
Page 12 - TABLE 3a: SUMMARY OF HORIZONTAL VENTING OPTIONS
10 10 TABLE 3a: SUMMARY OF HORIZONTAL VENTING OPTIONS VENT OPTION # 1 2 3 4 5 CLASSIFICATION USED IN THIS MANUAL HORIZONTAL DIRECT VENT HORIZONTAL DIRECT VENT (RESERVED FOR FUTURE USE) HORIZONTAL DIRECT EXHAUST HORIZONTAL DIRECT EXHAUST ILLUSTRATED IN FIGURE 8a OR 8b 8a OR 8b 9 9 VENT PIPE STRUCTURE...
Page 16 - TABLE 3b: SUMMARY OF VERTICAL VENTING OPTIONS; openings must be at least 12”.
14 14 TABLE 3b: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # 6 7 8 9 10 CLASSIFICATION USED IN THIS MANUAL VERTICAL DIRECT VENT VERTICAL DIRECT VENT (RESERVED FOR FUTURE USE) VERTICAL DIRECT EXHAUST VERTICAL DIRECT EXHAUST ILLUSTRATED IN FIGURE 10 10 11 11 VENT PIPE STRUCTUREPENETRATION ROOF RO...
Page 18 - TABLE 3c : SUMMARY OF VERTICAL COAXIAL VENTING OPTIONS
16 16 TABLE 3c : SUMMARY OF VERTICAL COAXIAL VENTING OPTIONS VENT OPTION # 11 12 13 CLASSIFICATION USED IN THIS MANUAL VERTICAL COAXIAL DIRECT VENT VERTICAL COAXIAL DIRECT VENT VERTICAL COAXIAL DIRECT VENT VENT PIPE STRUCTUREPENETRATION ROOF ROOF ROOF AIR INTAKE PIPE STRUCTURE PENETRATION ROOF ROOF ...
Page 20 - TABLE 4: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS
18 18 TABLE 4: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS MANUFACTURER VENT SYSTEM SIZE CONDENSATE TRAP WALL THIMBLES HORIZONTAL TERMINATION VERTICAL TERMINATION HEAT FAB SAF-T VENT EZ SEAL 3 9321 (NOTE 3) 7393GC 7393GCS 5391CI ELBOW: 7314TERMTEE: 7390TEE 5300CI 4 9421 (NOTE 3) 7493GC 74...
Page 21 - NEVER COMMON VENT A CWD BOILER WITH OTHER APPLIANCES
19 19 12) Vertical 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 t...
Page 22 - FIGURE 14: HORIZONTAL TERMINAL OFFSETS
20 20 FIGURE 15a: LOCATION OF DIRECT VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 14: HORIZONTAL TERMINAL OFFSETS
Page 23 - FIGURE 15d: POSITIONING VENT TERMINAL UNDER OVERHANGS
21 21 FIGURE 15b: LOCATION OF DIRECT EXHAUST TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 15c: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS FIGURE 15d: POSITIONING VENT TERMINAL UNDER OVERHANGS
Page 24 - FIGURE 16: USE OF CONDENSATE TRAPS; CAUTION
22 22 FIGURE 16: USE OF CONDENSATE TRAPS C. Vent / Intake System Assembly 1) General Assembly Notes: a) Where the use of “silicone” is called for in the following instructions, use GE RTV 106 for the vent collar and coaxial terminal. Air inlet piping sections are sealed with any general-purpose sili...
Page 25 - ORIFICE; FIGURE 17: INSTALLATION OF FAN OUTLET ORIFICE; NOTE; the location of the round opening on the wall.
23 23 TABLE 6: FAN OUTLET ORIFICE BOILER MODEL ORIFICE PART # CWD060 620133 CWD083 650136 CWD110 620135 CWD138 620136 CWD165 620137 CWD193 620138 CWD220 620139 CWD245 650138 FIGURE 17: INSTALLATION OF FAN OUTLET ORIFICE 3) Optional Coaxial Terminal Installation – If the optional coaxial terminal is ...
Page 27 - FIGURE 19: CORR/GUARD CONNECTION TO VENT COLLAR
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 s...
Page 28 - FIGURE 20: Z-VENT III CONNECTION TO VENT COLLAR
26 26 5) Assembly of Z-Flex Z-Vent 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 ...
Page 29 - the female ends of the pipe which seal the joints.; FIGURE 21: SAF-T VENT EZSEAL CONNECTION TO VENT COLLAR
27 27 6) Assembly of Heat Fab Saf-T Vent EZ Seal: a) Saf-T Vent General Notes: These instructions cover the installation of Saf-T Vent EZ Seal. Saf-T Vent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. • In general, Saf-T Vent pipe sections may no...
Page 30 - FIGURE 22: FASNSEAL CONNECTION TO VENT COLLAR
28 28 manufacturer’s instructions before operating the boiler. 7) Assembly of Heat Fab Saf-T Vent SC - On CWD Boiler installations where Saf-T Vent SC is used, some Saf-T Vent EZ Seal (single wall pipe) will always be required between the boiler and the Saf-T Vent SC. Install this pipe as described ...
Page 34 - VII Gas Piping; National Fuel Gas Code; FIGURE 25: GAS CONNECTION TO BOILER
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 Ga...
Page 35 - VIII System Piping; design may be found in; DANGER; parts of the system to remove air during initial fi ll.; Do not attempt to connect a 24-volt low water
33 33 VIII System Piping CAUTION • 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 120F can cau...
Page 36 - and refi ll the entire system.; B. Piping for Special Situations; to a cast iron boiler such as the CWD. Some examples include:
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 preven...
Page 39 - FIGURE 30: CHILLER PIPING
Page 40 - IX Wiring; transformer on the right side of the vestibule:; Ensure that the priority switch is “off” when it is not to be used.
38 38 IX Wiring The CWD Series boiler is offered 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 ...
Page 41 - FIGURE 31: CB502 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING
39 39 FIGURE 31: CB502 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING FIGURE 32: CB502 CONTROL SYSTEM - FACTORY SWITCH / JUMPER CONFIGURATION
Page 42 - C. CB502 Control System – Sequence of Operation; (Refer to Figures 35 and 36 for ladder and connection diagrams)
40 40 B. CB502 System - Wiring Variations 1) Two 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)...
Page 44 - FIGURE 35: CB502 CONTROL SYSTEM - INTERNAL LADDER DIAGRAM
42 42 FIGURE 35: CB502 CONTROL SYSTEM - INTERNAL LADDER DIAGRAM
Page 45 - FIGURE 36: CB502 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM
43 43 FIGURE 36: CB502 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM
Page 46 - D. R8285 Control System - Single Zone Wiring; R8285 fan center on the right side of the boiler.; E. R8285 Control System - Wiring Variations; (Refer to Figures 40 and 41 for ladder and connection diagrams)
44 44 D. R8285 Control System - Single Zone Wiring 1) Line Voltage (120 VAC) 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• Gre...
Page 47 - FIGURE 37: R8285 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING
45 45 FIGURE 38: R8285 CONTROL SYSTEM - FIELD WIRING FOR TWO CIRCULATOR ZONES FIGURE 37: R8285 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING
Page 49 - FIGURE 41: R8285 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM
47 47 FIGURE 41: R8285 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM
Page 50 - X Start-up and Checkout; mable vapors and liquids.; boiler when the boiler underwent the tests specifi ed in Z21.13.
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 infor...
Page 53 - FIGURE 45: MEASURING MANIFOLD PRESSURE
51 51 FIGURE 44: GAS VALVE FIGURE 45: MEASURING MANIFOLD PRESSURE
Page 54 - XI Service and Maintenance
52 52 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) Remove the burner tray. To do this: a) Remove the intake cover.b) Remove the four Allen head screws holding the elbow fl ange onto ...
Page 55 - Heat Exchanger Cleaning Procedure; ) Turn off electrical power and gas supply to the boiler.
53 53 Heat Exchanger Cleaning Procedure 1) Turn off electrical power and gas supply to the boiler. 2) Remove the burner tray. To 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...
Page 56 - DO NOT OVER TIGHTEN; Service Notes; ) Orifi ce Size – Sea level orifi ce sizes are:; pressure reading across the switch to drop as the boiler heats up.
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...
Page 57 - TABLE 7: PRESSURE SWITCH SETTINGS; FIGURE 46a: PRESSURE SWITCH CONNECTIONS
55 55 TABLE 7: PRESSURE SWITCH SETTINGS ALTITUDE 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
Page 58 - FIGURE 46b: MEASURING PRESSURE ACROSS PRESSURE SWITCH
56 56 FIGURE 46b: MEASURING PRESSURE ACROSS PRESSURE SWITCH
Page 59 - XII Troubleshooting
57 57 XII Troubleshooting 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 ...
Page 67 - XIII PARTS; Crown representative or the factory at:
65 65 XIII PARTS The following parts may be obtained from any Crown distributor. To fi nd 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 Main burner orifi ce shown are for...
Page 70 - BURNER TRAY COMPONENTS; KEY
68 68 BURNER TRAY COMPONENTS KEY DESCRIPTION PART# OR QTY. PART # 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 INSULATION 1 620523 620524 620525 620526 620527 620528 620529 620530 52 INSU...
Page 72 - JACKET COMPONENTS
70 70 JACKET COMPONENTS KEY DESCRIPTION PART# OR QTY PART # OR QTY CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 80 VESTIBULE PANEL 1 620323 620324 620325 620326 620327 620328 620329 620330 81 LARGE PLASTIC BUSHING 960051 1 1 1 1 1 1 1 1 82 FAN COVER PLATE 1 620302 620302 620302 60-300 60-...
Page 76 - IMPORTANT
74 74 Appendix A: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT 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 applian...
Page 78 - Manufacturer of Hydronic Heatings Products; CROWN; Boiler Co
Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com Manufacturer of Hydronic Heatings Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 CROWN Boiler Co PN 980060 CWDMANV4 04/09
