Page 2 - domestic hot water generation.
2 Table of Contents I. Product Description .................................................. 1 II. Specifications ............................................................. 2III. Before Installing ......................................................... 3IV. Locating the Boiler ...................
Page 3 - TABLE 1: CWI SPECIFICATIONS; II Specifications; FIGURE 1: CWI BOILERS - GENERAL CONFIGURATION
3 TABLE 1: CWI SPECIFICATIONS 2 II Specifications FIGURE 1: CWI BOILERS - GENERAL CONFIGURATION 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 28 40 7/16 5 10.0 CWI138 5 138 115 81.6 ...
Page 4 - III Before Installing; National Fuel Gas Code; IV Locating the Boiler; Warning
4 3 III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordancewith this manual and the requirements of the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must ...
Page 5 - V Air for Combustion and Ventilation
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...
Page 6 - For Buildings of Other than Unusually Tight Construction; National Fuel; For Buildings of Unusually Tight Construction
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...
Page 9 - VI Venting
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...
Page 10 - screws and support as required.; Removing an Existing Boiler from a Common Chimney; will operate continuously.
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...
Page 12 - VII Gas Piping
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...
Page 13 - VIII System Piping; Standard Piping; Installation of Residential Hydronic Systems; CAUTION
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...
Page 14 - and refill the entire system.; Piping for Special Situations; damage to a cast iron boiler such as the CWI. Some examples include:
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...
Page 16 - FIGURE 13: BOILER BYPASS 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 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...
Page 18 - IX TANKLESS HEATER PIPING; FIGURE 16: GRAVITY PIPING
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...
Page 19 - WARNING; A mixing valve does not eliminate the risk of scalding.
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...
Page 20 - IX Wiring; Single Zone Wiring; Ground (“green” or bare) - Ground screw on case of L8148E or L8124E; FIGURE 18: WIRING DIAGRAM, STANDING PILOT LESS TANKLESS HEATER
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...
Page 21 - FIGURE 20: WIRING DIAGRAM, STANDING PILOT WITH TANKLESS HEATER
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...
Page 22 - Wiring Variations
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...
Page 24 - CWI Control System – Sequence of Operation; (Refer to Figures 18 - 21 for ladder and connection diagrams); Sequence of Operation, Standing Pilot, Less Tankless Heater; across the combination gas control (“gas valve”) terminals “TH” and “TR”.; Sequence of Operation, Standing Pilot, With Tankless Heater; vent damper and the damper will open.
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...
Page 26 - XI Start-up and Checkout; Use the following procedure for initial start-up of the boiler:; NOTE
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 ...
Page 28 - FIGURE 26a: MAIN BURNER FLAME - 1” BURNERS
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...
Page 30 - LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL
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...
Page 31 - LIGHTING INSTRUCTIONS; TO TURN OFF GAS TO APPLIANCE; LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW
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...
Page 35 - XI Service and Maintenance; Make sure that the vent system is free of obstructions.
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...
Page 36 - Partially plugged flue passages
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...
Page 37 - XIII Troubleshooting; TV
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...
Page 38 - : Read page 36 before attempting to use this chart
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 ...
Page 39 - END
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...
Page 42 - Standing Pilot Ignition System Troubleshooting Chart; Caution; : Read page 36 before
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 ...
Page 43 - Intermittent Ignition System Troubleshooting Chart
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...
Page 44 - XIV PARTS; representative or the factory at:
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 ...
Page 50 - punctures due to mishandling.; B. Base Assembly Preparation; tion manual for additional information on placement.; C. Heat Exchanger and Flue Collector Installation; Appendix A: Knockdown Boiler Assembly Instructions; D. Jacket Installation
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 ...
Page 52 - g) Rating Plate - Located on the upper left of the right side panel; D. Gas Valve Installation; of the union located on the gas manifold.; E. Control and Trim Installation; (Refer to Figure A3 for Tapping Locations)
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...
Page 53 - FIGURE A2: JACKET INSTALLATION
Page 54 - F. Electrical Wiring Connections; (Also refer to wiring diagrams in Part X of the installation manual); G. Complete Installation
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”....
Page 56 - Manufacturer of Hydronic Heating Products
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
