Crown Boiler CWI241 User Manual

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CWI Series  
Gas-Fired Natural Draft Water Boilers  
INSTALLATION INSTRUCTIONS  
These instructions must be affixed on or adjacent to the boiler  
Models:  
WARNING: Improper installation,  
adjustment, alteration, service or  
maintenance can cause property  
damage, injury, or loss of life. For  
assistance or additional informa-  
tion, consult a qualified installer,  
service agency or the gas  
CWI207  
CWI241  
CWI276  
CWI310  
CWI345  
CWI379  
CWI069  
CWI103  
CWI138  
CWI172  
supplier. Read these instructions  
carefully before installing.  
Manufacturer of Hydronic Heating Products  
P.O. Box 14818 3633 I. Street  
Philadelphia, PA 19134  
II Specifications  
FIGURE1:CWIBOILERS-GENERALCONFIGURATION  
TABLE 1: CWI SPECIFICATIONS  
NATURAL OR LP GAS *  
BASIC  
BOILER  
MODEL  
NUMBER  
OF  
SECTIONS  
HEATING I=B=R NET  
TANKLESS  
HTR. RATING  
(Gal/min)  
WATER  
VOL.  
(Gal)  
AFUE (%)  
STNDG. INT.  
PILOT PILOT  
INPUT  
(MBH)  
CAPACITY  
(MBH)  
RATING  
(MBH)  
DIMENSIONS (in.)  
"A"  
12 3/4 28  
16 28  
"B"  
"C"  
"D"  
4
50  
CWI069  
CWI103  
CWI138  
CWI172  
CWI207  
CWI241  
CWI276  
CWI310  
CWI345  
CWI379  
3
4
69  
57  
81.0  
81.3  
81.6  
81.8  
82.1  
81.1  
81.4  
83.1  
83.1  
83.1  
83.2  
83.2  
83.2  
83.2  
40 7/16  
7.8  
75  
103  
138  
172  
207  
241  
276  
310  
345  
379  
86  
2.50  
3.00  
40 7/16  
40 7/16  
40 7/16  
40 7/16  
40 7/16  
40 7/16  
45 7/16  
45 7/16  
45 7/16  
5
6
6
7
7
8
8
9
9
10.0  
12.2  
14.4  
16.6  
18.8  
21.0  
23.2  
25.4  
27.6  
100  
125  
150  
175  
200  
225  
251  
275  
5
115  
144  
173  
202  
232  
259  
288  
316  
19 1/4 28  
22 1/2 28  
25 3/4 30  
6
3.50  
7
3.75/4.50  
8
3.75/4.75*** 29  
30  
9
4.00/5.25*** 32 1/4 30  
4.00/5.25*** 35 1/2 30  
4.00/5.25*** 38 3/4 30  
83.5**  
10  
11  
12  
83.5**  
83.5**  
4.00/5.25*** 42  
30  
* CWI345 AND CWI379 NOT AVAILABLE FOR USE WITH LP GAS  
** COMBUSTION EFFICIENCY  
*** RATING WITH OPTIONAL "HIGH CAPACITY" TANKLESS HEATER  
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 requirements of the authority having jurisdiction.  
In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the  
National Fuel Gas Code, ANSI Z223.1-latest edition.  
Where required by the authority having jurisdiction, this installation must conform to the Standard for Controls and  
Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1)-latest edition.  
Warning  
This Product Must be Installed ByALicensed Plumber Or Gas Fitter when Installed Within The  
Commonwealth Of Massachusetts  
If This Boiler is Equipped With a Tankless Heater, Tankless Heater Piping Must be Installed by a  
Licensed Plumber When Boiler is Installed Within the Commonwealth of Massachusetts  
2) Make sure that a properly sized chimney is available which is in good condition. Consult the authority having jurisdiction,  
Part VI of this manual, and the National Fuel Gas Code for additional information on venting requirements.  
3) Make sure that the boiler is correctly sized. Use an industry accepted sizing method such as the I=B=R Installation  
Guide for Residential Hydronic Heating Systems (Pub. #200) and I=B=R Heat Loss Calculation Guide (Pub. #H21 or  
#H22) published by the Hydronics Institute in Berkeley Heights NJ.  
4) Make sure that the boiler received is configured for the correct gas (natural or LP). The CWI345 and CWI379 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 Boiler  
1) Clearances:  
Observe the minimum clearances shown below. These clearances apply to all combustible construction, as well as  
noncombustible walls, ceilings and doors. Also see Figure 2.  
Front – 18”  
Right Side:  
All Sizes without Tankless Heaters – 18”  
CWI103 - CWI207 with Tankless Heater - 18”  
CWI241 - CWI379 with Standard Tankless Heater - 21”  
CWI241- CWI379 with High Capacity Tankless Heater - 24”  
Left Side – 6”  
Rear – 6”  
Top – 17”  
A 24” service clearance from the jacket is recommended on the left, right, and front of the boiler. These clearances  
may be reduced to those shown in Figure 2, however servicing the boiler will become increasingly difficult as these  
service clearances are reduced.  
3
“X” (RH CLEARANCE)  
ALL SIZES LESS TANKLESS HEATER - 18“  
CWI103 - CWI241 WITH TANKLESS HTR. - 18“  
CWI276 - CWI379 WITH TANKLESS HTR. - 21“  
CWI207 - CWI379 WITH HIGH CAPY. TANKLESS HTR. - 24“  
“X”  
FIGURE2:CWI BOILERS-CLEARANCESTOALL  
TYPESOFCOMBUSTIBLECONSTRUCTIONAND  
NONCOMBUSTIBLECEILINGS,WALLS,ANDDOORS.  
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 directly over a non-carpeted combustible floor.  
3) The boiler must be installed on a hard level surface.  
4) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or used. Do not  
install this boiler in an area where large amounts of airborne dust will be present, such as a workshop.  
5) The boiler should be located as close to the chimney as possible.  
6) Do not install this boiler directly on a surface that may get wet. Raise the boiler on a pad.  
V Air for Combustion and Ventilation  
Sufficient fresh air must be supplied for combustion, ventilation and flue gas dilution. 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 gas dilution air supply, start by determining whether the  
boiler is to be installed in a building of unusually tight construction. A good definition of a building of unusually tight  
construction is one which has all of the following features:  
Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or  
less with openings gasketed and sealed  
Weather stripping has been added on openable windows and doors  
4
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.  
ForBuildingsofOtherthanUnusuallyTightConstruction  
1) Determine whether the boiler is to be installed in a confined space - A confined space is defined by the National Fuel  
Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To  
determine whether the boiler room is a confined space:  
a. Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest 1000  
BTU/hr.  
b. Find the volume of the room in cubic feet. The volume of the room in cubic feet is:  
Length (ft) x width (ft) x ceiling height (ft)  
In calculating the volume of the boiler room, consider the volume of adjoining spaces only if no doors are installed  
between them. If doors are installed between the boiler room and an adjoining space, do not consider the volume of the  
adjoining space, even if the door is normally left open.  
c. Divide the volume of the boiler room by the input in thousands of BTU/hr. If the result is less than 50, the boiler room is a  
confined space.  
Example:  
A CWI172EN and a water heater are to be installed in a room measuring 6 ft - 3 in x 7 ft with an 8 ft ceiling. The water  
heater has an input of 30000 BTU/hr:  
TotalinputinthousandsofBTU/hr=(172000BTU/hr+30000BTU/hr)/1000=202  
Volumeofroom=6.25ftx7ftx8ft=350ft3  
350/202 = 1.73. Since 1.73 is less than 50, the boiler room is a confined space.  
2) Unconfined Space - Natural infiltration into the boiler room will normally provide adequate air for combustion and  
ventilation without additional louvers or openings into boiler room.  
3) Confined Space - Provide two openings into the boiler room, one near the floor 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(Figure3).  
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 the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per 1000  
BTU/hr of total appliance input, install a pair of identical openings into a third room. Connect additional rooms with  
openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input.  
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.  
If providing openings into adjacent rooms is undesirable, combustion and ventilation air can be brought into the boiler  
room from outdoors. See the instructions under “For Buildings of Unusually Tight Construction”.  
ForBuildingsofUnusuallyTightConstruction  
1) Openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl  
space, which communicates directly with the outdoors.  
2) Two openings are required. The top edge of the upper opening must be within 12 inches of the ceiling. The bottom edge  
of the lower opening must be within 12 inches of the floor.  
3) Size openings and ducts as follows:  
Vertical ducts or openings directly outdoors (Figure 4, Figure 5, and Figure 6) - Each opening must have a free cross  
sectional area of 1 square inch per 4000 BTU/hr of the total input of all gas-fired appliances in the boiler room but not less  
than 100 square inches. Minimum opening size is 3 inches.  
Openings to outdoors via horizontal ducts (Figure 7) - Each opening must have a free cross sectional area of 1 square  
inch per 2000 BTU/hr of the total input of all gas fired appliances in the boiler room but not less than 100 square inches.  
Minimum opening size is 3 inches.  
5
FIGURE3:BOILERINSTALLEDINCONFINEDSPACE,  
ALL AIR FROM INSIDE  
FIGURE4: ALLAIRFROMOUTDOORS,  
VENTILATED CRAWL SPACE AND ATTIC  
FIGURE5: ALLAIRFROMOUTDOORS,  
VIA VENTILATED ATTIC  
6
FIGURE6:ALLAIRFROMOUTDOORS,USING  
OPENINGSINTOBOILERROOM  
FIGURE7:ALLAIRFROMOUTDOORS,USING  
HORIZONTAL DUCTS INTO BOILER ROOM  
7
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 National  
Fuel Gas Code, NFPA54/ANSIZ223.1.  
A typical vent installation is illustrated by Figure 8. The components of vent installation are the vent damper, vent connector  
and chimney.  
1) Acceptable Chimneys - The following chimneys may be used to vent CWI series boilers:  
Listed Type B or L gas vent - Install in accordance with the manufacturer’s instructions, the terms of its listing, and  
applicable codes.  
Masonry Chimney - The masonry chimney must be constructed in accordance with the Standard for Chimneys,  
Fireplaces, Vents, and Solid Fuel Burning Appliances (NFPA 211) and lined with a clay liner or other listed lining  
system. Do not vent a CWI series boiler into an unlined chimney.  
2) Acceptable Vent Connectors - The following may be used for vent connectors:  
Listed type B or L Gas Vent  
Single Wall Galvanized Pipe - Use 0.018” (26 gauge or heavier). The size and location of the chimney may not permit  
the use of a single wall connector in some cases. See the National Fuel Gas Code. Do not use single wall pipe for  
vent connectors in attics.  
Other Vent Connectors Permitted by the National Fuel Gas Code.  
3) Chimney and Vent Connector Sizing - Size the chimney and vent connector in accordance with the National Fuel Gas  
Code.  
4) Exterior Chimneys - An exterior chimney has one or more sides exposed to the outdoors below the roof line. There are two  
conditions under which an exterior chimney may be used:  
In some very restrictive cases, CWI series boilers may be vented into an exterior ceramic lined 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 venter listing, and applicable codes. The boiler must  
be electrically interlocked with the power venter to prevent boiler operation if the power venter fails to operate. Before  
deciding to use a power venter, make certain that the flue gas exiting the power venter will not damage adjacent  
construction or other structures. Also make certain that the power venter terminal will not be subjected to winds which  
could effect power venter operation.  
6) Do not connect the vent of this appliance into any portion of a mechanical vent system operating under positive  
pressure.  
7) Do not connect the boiler into a chimney flue serving an open fireplace or other solid fuel appliance.  
8) Prior to boiler installation, inspect chimney for obstructions or other defects and correct as required. Clean chimney as  
necessary.  
9) Vent pipe should slope upward from draft diverter not less than one inch in four feet. No portion of vent pipe should run  
downward or have sags. Vent pipe must be securely supported.  
10) The vertical section of vent pipe coming off the boiler should be as tall as possible, while still maintaining the proper  
clearance from the horizontal vent connector to combustibles and the proper pitch called for in (9) above.  
11) Vent pipe should be installed above the bottom of the chimney to prevent blockage.  
12) Vent pipe must be inserted flush with inside face of the chimney liner and the space between vent pipe and chimney  
8
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 being  
installed.  
14) 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 instructions. Read the instructions thoroughly before proceeding.  
Verify that vent damper is same size as draft diverter outlet. See Figure 1. Unpack vent damper carefully. Do not force  
closed damper blade. Forcing vent damper closed may result in damaged gear train and void warranty.  
b) Vent damper is factory shipped having approximately ¾” diameter hole in the vent damper blade, which must be left  
open for boilers equipped with standing pilot, and should be plugged on boilers with an intermittent pilot, using the  
plug supplied with the damper.  
Mount the vent damper on the flue collar without modification to either and secure with sheet metal screws. Make  
sure screws do not interfere with damper blade operation. Vent damper blade position indicator must be visible to  
users.  
c) The damper wire harness is shipped wired into the boiler junction box. Plug the loose end of this harness into the  
damper and secure the flexible conduit to the damper using a connector nut provided.  
d) Install vent connector pipe and vent fittings from vent damper outlet to chimney or gas vent. Secure with sheet metal  
screws and support as required.  
RemovinganExistingBoilerfromaCommonChimney  
In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large for  
the remaining appliances. At the time of removal of an existing boiler the following steps shall be followed with each appliance  
remaining connected 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 condition.  
c) Insofar as practical, close all building doors and windows and all doors between the space in which all the appliances  
remaining connected to the common venting system are located and other spaces of the building. Turn on clothes  
dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range  
hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close  
fireplacedampers.  
d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so the appliance  
will operate continuously.  
e) Test for spillage at the draft hood relief opening after five (5) minutes of main burner operation. Use the flame of a  
match or candle, or smoke from a cigarette, cigar, or pipe.  
f) After it has been determined that each appliance remaining connected to the common venting system properly vents  
when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning  
appliances to their previous condition of use.  
g) Any improper operation of the common venting system should be corrected so the installation conforms with the  
National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the common venting  
system should be resized to approach the minimum size as determined using the appropriate tables in the National Fuel  
GasCode,ANSIZ223.1.  
9
FIGURE8: CWI BOILERTYPICALVENTSYSTEM  
INSTALLATION AND COMPONENTS  
FIGURE 9: VENTDAMPERINSTALLATIONDETAILS  
10  
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 piping connection to the CWI boiler. A sediment trap must be installed upstream of all gas  
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 system at pressures of 1/2 psi or less, isolate the boiler from the  
gas supply system by closing its individual manual shut-off valve.  
*
* State of Massachusetts Requires Manual  
Shut-off Valve to be “T” Handle Type  
FIGURE10: GASCONNECTIONTOBOILER  
11  
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 120°F CAN  
CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.  
OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED  
OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.  
DO NOT USE TOXIC ADDITIVES, SUCH AS AUTOMOTIVE ANTIFREEZE, IN A HYDRONIC SYSTEM.  
StandardPiping  
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 are as follows:  
1) Relief valve (Required) - Mount the relief valve on the right side of the boiler as shown in Figure 1 using the 3/4 nipples  
and elbow provided. The relief valve shipped with the boiler is set to open at 30 psi. This valve may be replaced with one  
having a pressure up to the “MAWP, WATER” shown on the rating plate. If the valve is replaced, the replacement must  
have a relief capacity in excess of the DOE heating capacity for the boiler.  
Pipe the discharge of the relief valve to a location where water or steam will not create a hazard or cause property damage if  
the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the relief valve discharge is not  
piped to a drain it must terminate at least 6 inches above the floor. Do not run relief valve discharge piping through an area  
that is prone to freezing. The termination of the relief valve discharge piping must be in an area where it is not likely to  
become plugged by debris.  
DANGER  
PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION.  
DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE.  
DO NOT MOVE RELIEF VALVE FROM FACTORY LOCATION.  
DO NOT PLUG RELIEF VALVE DISCHARGE.  
2) Circulator (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 expansion tank must be replaced, consult the expansion tank  
manufacturer’s literature for proper sizing.  
4) Fill Valve (Required) - Either a manual or automatic fill valve may be used. The ideal location for the fill is at the expansion  
tank.  
5) Automatic Air Vent (Required) - At least one automatic air vent is required. Manual vents will usually be required in other  
parts of the system to remove air during initial fill.  
12  
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 designed  
for use in a hot-water system. The low water cutoff should be piped into the boiler supply just above the boiler with no  
intervening valves between it and the boiler.  
Use a low water cutoff that breaks the 120 VAC supply to the boiler. Do not attempt to wire a 24-volt low water cutoff into  
the boiler factory wiring.  
7) Manual Reset High Limit (Required by some codes) - This control is required by ASME CSD-1 and some other codes.  
Install the high limit in the boiler supply piping just beyond the boiler with no intervening valves. Set the manual reset  
high limit as far above the operating limit setting as possible, but not over 240°F. Wire the control to break the 120 VAC  
electrical supply to the boiler.  
8) Flow Control Valve (Required under some conditions) - The flow control valve prevents flow through the system unless  
the circulator is operating. A flow control valve may be necessary on converted gravity systems to prevent gravity  
circulation. Flow control valves are also used to prevent “ghost flows” in circulator zone systems through zones that are  
not calling for heat.  
9) Isolation Valves (Optional) - Isolation valves are useful if the boiler must be drained, as they will eliminate having to drain  
and refill the entire system.  
10) Drain Valve - The drain valve is shipped in the boiler parts bag. Install it in the tee under the circulator as shown in Figure  
1.  
PipingforSpecialSituations  
Certain types of heating systems have additional requirements. Some of the more common variations follow:  
1) Indirect Water Heaters - Figure 12 shows typical indirect water heater piping. Boiler piping is the same as for any two-zone  
system. Figure 12 shows circulator zoning, which is usually preferred for indirect water heaters. Size the circulator and  
indirect water heater piping to obtain the boiler water flow through the indirect water heater called for by the indirect water  
heatermanufacturer.  
2) Large Water Volume 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 first few minutes of operation. A three-way valve can  
be substituted for the two throttling valves shown. If the circulator is mounted on the supply, the bypass must be on the  
discharge side of the circulator.  
3) Low Temperature Systems - Some systems, such as radiant tubing systems, require the system water temperature to be  
limited to a value below the temperature of the water leaving the CWI. These systems also typically have return  
temperatureswellbelowthe120°Fminimum.  
Figure 14 illustrates the use of a heat exchanger to connect the CWI boiler to this type of system. The heat exchanger will  
permit the transfer of heat from the boiler water to the low temperature system while holding the system supply and boiler  
return temperatures within their limits. For this system to work properly the heat exchanger must be properly sized and the  
correct flow rates are required on either side of the heat exchanger. Consult the heat exchanger manufacturer for sizing  
information. The water in the boiler is completely isolated from the water in the system. This means that separate fill and  
expansion tanks are required for the heating system loop.  
There are several other ways to connect low temperature systems to non-condensing boilers like the CWI, such as four  
way mixing valve and variable speed injection pumping systems.  
4) Systems containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion  
damage to a cast iron boiler such as the CWI. Some examples include:  
Radiant systems that employ tubing without an oxygen barrier.  
Systems with routine additions of fresh water.  
Systems which are open to the atmosphere.  
If the boiler is to be used in such a system, it must be separated from the oxygenated water being heated with a heat  
exchanger as shown in Figure 14.  
Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature requirements.  
All components on the oxygenated side of the heat exchanger, such as the pump and expansion tank, must be designed for  
use in oxygenated water.  
13  
FIGURE11: STANDARDBOILERPIPING  
FIGURE12: INDIRECTWATERHEATER  
BOILERSIDEPIPING  
14  
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 refrigerated air passes, use flow control valves  
in the boiler piping or other automatic means to prevent gravity circulation during the cooling cycle.  
7) Gravity Hot Water Systems - The CWI is suitable for installation in a gravity hot water system. Figure 16 shows piping 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 gravity hot water system is a “large water volume system” (see (2) above) and should be piped with a bypass as shown  
in Figure 13. Many gravity hot water systems have balancing orifice installed in the radiators. These orifice may need to be  
removed to obtain proper heat distribution when the system is converted to forced hot water.  
FIGURE13: BOILERBYPASSPIPING  
15  
FIGURE14: ISOLATIONOFBOILERFROMSYSTEMWITHAHEATEXCHANGER  
FIGURE15: BOILERPIPINGWITHCHILLER  
16  
FIGURE16: GRAVITYPIPING  
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 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 water leaving the tankless heater with cold water so as to maintain the hot water supplied to  
the fixtures at a fixed temperature. This saves energy, increases the amount of usable hot water available to the  
homeowner, and reduces the risk of scalding.  
Install a mixing valve with a setting 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 restrictor will prevent this problem by limiting  
the rate at which water can pass through the tankless heater. If a restrictor is used, select one having a rating in GPM  
approximately equal to the rating shown in Table 1. If possible, locate this restrictor at least 3 feet from the tankless heater  
inlet so that it is not subjected to excessive temperatures when no water is flowing through the coil.  
17  
WARNING  
A mixing valve does not eliminate the risk of scalding.  
Set the mixing valve and boiler low limit adjustments as low as possible.  
Feel water before showering or bathing.  
If anti-scald or anti-chill protection is required, use devices specifically designed for such service. Install and  
maintain these devices in accordance with the manufacturer’s instructions. Do not use the mixing valve as a  
substitute for pressure balancing valves or other devices required by plumbing codes to protect against  
scalding.  
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 tankless coil. Pipe the  
discharge to a safe location using piping the same size as the discharge connection on the valve. In Massachusetts,  
terminate the relief valve discharge pipe 12” above the floor.  
4) Hose Bib Valves (Recommended) - These valves permit the coil to be periodically “backflushed” to remove sediment.  
5) Globe or Ball Valve (Recommended) - Used to adjust the flow through the entire tankless heater system if needed.  
6) Unions (Required) - Tankless heaters may require periodic gasket replacement or other maintenance which requires  
removal of the heater from the 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 18. Install in accordance with local codes and  
the backflow preventer’s installation instructions. Also install a potable water expansion tank on the outlet side of the  
backflow preventer (between the backflow preventer and the piping shown in Figure 18).  
FIGURE 17:TANKLESSHEATERPIPING  
18  
IX Wiring  
WARNING  
All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such  
requirements,withtheNationalElectricalCode(ANSI/NFPA70).  
SingleZoneWiring  
1) 120 Volt Wiring - The boiler should be provided with its own 15Abranch 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 (“white”) - Terminal “L2”  
Ground (“green” or bare) - Ground screw on case of L8148E or L8124E  
2) Thermostat Wiring - Follow thermostat manufacturer instructions. To insure proper thermostat operation, avoid installation  
in areas of poor air circulation, hot spots (near any heat source or in 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 L8148E aquastat relay.  
(NOTE 2)  
2
N
L
V8295A  
GAS VALVE  
(CWI310-379 ONLY)  
V8295A  
(CWI310-379 ONLY)  
L
N
2. VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI310 - CWI379. WHEN DAMPER  
IS NOT USED, DAMPER HARNESS IS REPLACED WITH JUMPER PLUG  
FIGURE18: WIRINGDIAGRAM, STANDINGPILOTLESSTANKLESSHEATER  
19  
(NOTE 2)  
2
HONEYWELL  
VR8204/VR8304  
SERIES GAS VALVES  
(CWI069 - 345)  
ROBERTSHAW  
7000DERHC  
GAS VALVE  
+
TH  
TR  
(CWI379)  
2. VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI310 - CWI379. WHEN DAMPER IS NOT US  
DAMPER HARNESS IS REPLACED WITH JUMPER PLUG.  
FIGURE19: WIRINGDIAGRAM,INTERMITTENTIGNITION (EI)SYSTEMLESSTANKLESSHEATER  
(NOTE 2)  
HONEYWELL  
L8124E  
HIGH LIMIT  
2
LOW  
LIMIT  
N
L
LESS VENT  
DAMPER  
V8295A  
GAS VALVE  
V8295A  
(CWI310-379 ONLY)  
(CWI310-379 ONLY)  
L
N
2. VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI310 - CWI379. WHEN DAMPER IS  
NOT USED, DAMPER HARNESS IS OMITTED AND TERMINAL B1 IS WIRED DIRECTLY TO FRS.  
AS SHOWN IN LADDER DIAGRAM  
FIGURE20: WIRINGDIAGRAM, STANDINGPILOTWITHTANKLESSHEATER  
20  
(NOTE 2)  
HONEYWELL  
L8124E  
HIGH LIMIT  
2
MAIN VALVE  
PILOT VALVE  
LOW  
LIMIT  
LESS VENT  
DAMPER  
HO NEYW ELL  
VR82 04/VR83 04  
SERIES G AS VALVES  
(CWI06 9  
-
345)  
R O BER TSH AW  
70 00DERHC  
G AS VALVE  
(CWI37 9)  
+
TH  
TR  
2. VENT DAMPER REQUIRED ON ALL BOILERS EXCEPT CWI310 - CWI379. WHEN DAMPER IS  
NOT USED, DAMPER HARNESS IS OMITTED AND TERMINAL B1 IS WIRED DIRECTLY TO FRS.  
AS SHOWN IN LADDER DIAGRAM  
FIGURE21: WIRINGDIAGRAM, INTERMITTENTIGNITION (EI)SYSTEMWITHTANKLESSHEATER  
WiringVariations  
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.ADPST Honeywell  
RA832A may be substituted in place of the R845A using the “X” and “X” terminals in place of the “5” and “6” terminals on a  
R845A.  
Acall for heat from any thermostat will energize the DPST relay in that zone’s R845A. When this relay is energized, electrical  
continuity is created between terminals 3 and 4, energizing the circulator for that zone. At the same time, electrical continuity 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 initiated.  
2) Multiple Zones using Zone Valves – Figure 23 shows wiring for multiple zones using Honeywell V8043F zone valves. This  
wiring diagram may be used for other 24-volt zone valves as long as they are equipped with end switches. Do not attempt to  
use the transformer on the limit control to power the zone valves; use a separate transformer. Up to five V8043Fs may be  
powered by one 48VAtransformer, such as the HoneywellAT87A.  
A call for heat from a given thermostat will result in the application of 24 volts across the TH and TR terminals on the  
corresponding zone valve, energizing the zone valve motor. The zone valve opens and the end switch contacts are then made.  
The end switches are connected in parallel with each other and to the “T” and “TV” thermostat connections so that any zone  
valve that opens will also start the circulator and fire the boiler (assuming the high limit is not open). Zone valve terminal TH/  
TR has no internal connection on the zone valve; it is merely a “binding post” used to connect two or more wires.  
21  
FIGURE 22: CIRCULATOR ZONEWIRING USINGHONEYWELLR845As  
(FACTORYBOILER WIRING NOT SHOWN - SEE FIGURES 18 - 21)  
FIGURE23:ZONEWIRINGUSINGHONEYWELLV8043FZONEVALVES  
(FACTORYWIRING NOTSHOWN - SEE FIGURES 18 - 21)  
22  
CWI Control System – Sequence of Operation  
(Refer to Figures 18 - 21 for ladder and connection diagrams)  
SequenceofOperation,StandingPilot,LessTanklessHeater  
1) When the boiler is energized, 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 heat from the thermostat energizes relay coil 1R (the relay on the L8148E), causing contacts 1R1 and 1R2 to make.  
Contact 1R1 starts the circulator. Contact 1R2 sends power to the high limit.  
3) Assuming that the high limit is made, current will flow to pin terminal #2 (orange) at the vent damper and the damper will open.  
4) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin #3 (red) at the damper. This pin  
is connected through the damper harness to terminal “B1” on the L8148E. At this point in the operating sequence, 24 volts is  
present across “B1” and “B2”.  
5) Under normal conditions, the flame roll-out switch and blocked vent switch are made. Voltage will therefore immediately appear  
across the combination gas control (“gas valve”) terminals “TH” and “TR”.  
6) When the boiler is first placed into operation, the pilot must be lit. The pilot heats a thermocouple which generates a small  
amount of electricity sufficient to hold open the safety shut-off valve in the combination gas control. The circuit connecting  
the thermocouple and the safety shut-off valve is self contained and completely independent of all other wiring on the boiler.  
This safety shut-off valve is upstream of the 24 volt valves in the gas control which open in response to a call for heat. If the  
pilot is not lit, the safety shut-off valve will remain closed and gas will not reach the 24 volt valves.  
7) Assuming that the pilot is established and proven by the thermocouple, the application of 24 volts across the combination gas  
valve terminals energizes the redundant 24 volt solenoid valves in the combination gas control, resulting in gas flow through  
the control and burner operation.  
Sequence of Operation, Standing Pilot, With Tankless Heater  
1) When the boiler is energized, 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) If the boiler water 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 will therefore not operate if the boiler water temperature is  
too low to generate domestic hot water.  
3) Assuming that the high limit is made, current will flow to terminal “B1” on the L8124E and then to terminal “2” (orange) at the  
vent damper and the damper will open.  
4) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin #3 (red) at the damper. The red  
wire from this pin runs to the flame rollout switch.  
5) Under normal conditions, the flame roll-out switch and blocked vent switch are made. Voltage will therefore immediately appear  
across the combination gas control (“gas valve”) terminals “TH” and “TR”.  
6) When the boiler is first placed into operation, the pilot must be lit. The pilot heats a thermocouple which generates a small  
amount of electricity sufficient to hold open the safety shut-off valve in the combination gas control. The circuit connecting  
the thermocouple and the safety shut-off valve is self contained and completely independent of all other wiring on the boiler.  
This safety shut-off valve is upstream of the 24 volt valves in the gas control which open in response to a call for heat. If the  
pilot is not lit, the safety shut-off valve will remain closed and gas will not reach the 24 volt valves.  
7) Assuming that the pilot is established and proven by the thermocouple, the application of 24 volts across the combination gas  
valve terminals energizes the redundant 24 volt solenoid valves in the combination gas control, resulting in gas flow through  
the control and burner operation.  
8) The boiler will fire until the boiler water temperature is approximately equal to the low limit setting. Once the water temperature  
reaches this point, “R” and “B” open and “R” and “W” make. At this point, a call for heat will energize 1R, making contacts  
1R1 and 1R2. Contacts 1R1 energize the circulator. Contacts 1R2 switch current from the “hot” side of the transformer second-  
ary to the high limit switch. If the high limit is made, current flows to terminal “B1” and the ignition sequence is then the same  
as it is for a call for burner operation from the low limit (see (3) above).  
23  
SequenceofOperation,IntermittentIgnition,LessTanklessHeater  
1) When the boiler is energized, 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 heat from the thermostat energizes relay coil 1R (the relay on the L8148E), causing contacts 1R1 and 1R2 to make.  
Contact 1R1 starts the circulator. Contact 1R2 sends power to the high limit.  
3) Assuming that the high limit is made, current will flow to pin terminal #2 (orange) at the vent damper and the damper will open.  
4) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin #3 (red) at the damper. This pin  
is connected through the damper harness to terminal “B1” on the L8148E. At this point in the operating sequence, 24 volts is  
present across “B1” and “B2”.  
5) Under normal conditions, the flame roll-out switch and blocked vent switch are made. Voltage will therefore immediately appear  
across the “24V” and “24V (GND)” terminals on the ignition module.  
6) Upon application of voltage across the “24V” and “24V (GND)” terminals, the ignition module will start an ignition spark at the  
pilot and apply 24 volts across the pilot valve (terminals “PV” and “MV/PV”).  
7) Once the pilot is established, the pilot flame will act as a diode, converting the AC current at the electrode to a half wave DC  
current at the pilot’s ground strap. This DC current flows through the boiler to the “GND (BURNER)” connection on the  
ignition module. For the ignition module to recognize that a pilot flame is present, the DC current flowing into this terminal  
must be in excess of approximately 1.0 uA.  
8) Once the ignition module detects the presence of a pilot flame, voltage is applied across the main valve (terminals “MV” and  
“MV/PV”), opening the valve and establishing main flame.  
9) The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot depends  
upon the exact ignition module supplied with the boiler. For more information on module operation, consult the ignition  
module instructions supplied with the boiler or the local Crown representative.  
Sequence of Operation, Intermittent Ignition, With Tankless Heater  
1) When the boiler is energized, 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) If the boiler water 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 will therefore not operate if the boiler water temperature is  
too low to generate domestic hot water.  
3) Assuming that the high limit is made, current will flow to terminal “B1” on the L8124E and then to terminal “2” (orange) at the  
vent damper and the damper will open.  
4) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin #3 (red) at the damper. The red  
wire from this pin runs to the flame rollout switch.  
5) Under normal conditions, the flame roll-out switch and blocked vent switch are made. Voltage will therefore immediately appear  
across the “24V” and “24V (GND)” terminals on the ignition module.  
6) Upon application of voltage across the “24V” and “24V (GND)” terminals, the ignition module will start an ignition spark at the  
pilot and apply 24 volts across the pilot valve (terminals “PV” and “MV/PV”).  
7) Once the pilot is established, the pilot flame will act as a diode, converting the AC current at the electrode to a half wave DC  
current at the pilot’s ground strap. This DC current flows through the boiler to the “GND (BURNER)” connection on the  
ignition module. For the ignition module to recognize that a pilot flame is present, the DC current flowing into this terminal  
must be in excess of approximately 1.0 uA.  
8) Once the ignition module detects the presence of a pilot flame, voltage is applied across the main valve (terminals “MV” and  
“MV/PV”), opening the valve and establishing main flame.  
9) The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot depends  
upon the exact ignition module supplied with the boiler. For more information on module operation, consult the ignition  
module instructions supplied with the boiler or the local Crown representative.  
10) The boiler will fire until the boiler water temperature is approximately equal to the low limit setting. Once the water temperature  
reaches this point, “R” and “B” open and “R” and “W” make. At this point, a call for heat from the thermostat will energize 1R,  
making contacts 1R1 and 1R2. Contacts 1R1 energize the circulator. Contacts 1R2 switch current from the “hot” side of the  
transformer secondary to the high limit switch. If the high limit is made, current flows to terminal “B1” and the ignition  
sequence is then the same as it is for a call for burner operation from the low limit (see (3) above).  
24  
Safety Control Operation - Standing Pilot and Intermittent Ignition  
High Limit - Interrupts main burner operation when the supply water temperature exceeds set point. Maximum allowable tempera-  
ture is 250°F. If the high limit opens, the vent damper will close if the damper switch is in the “automatic” position. The circulator  
will continue to operate as long as there is a call for heat, regardless of the status of the high limit (if the boiler is equipped with a  
tankless coil, the low limit switch will prevent the circulator from operating if the boiler water temperature is too low). Burner  
operation automatically resumes when the supply water temperature falls below set point.  
Blocked Vent (“Spill”) Switch - Automatically interrupts main burner operation in the event that flue gas spills from the draft  
diverter opening. This switch is equipped with a reset button which must be pressed to restore normal burner operation. An open  
blocked vent switch is indicative of a problem with the vent system. If the blocked vent switch opens, the cause of the venting  
problem must be found and corrected by a qualified gas service technician before the blocked vent switch is reset.  
Flame Roll-out Switch - Automatically interrupts boiler operation when flames or excessive heat are present in vestibule. The flame  
roll-out switch is a single use device which must be replaced by an identical switch in order to restore normal operation. An open  
flame roll-out switch is usually indicative of a plugged heat exchanger. The cause of the flame roll-out must be found and  
corrected by a qualified gas service technician, and the switch replaced with an identical one, before the boiler is returned to  
operation.  
XI Start-up and Checkout  
NOTE  
SAFE LIGHTING AND OTHER 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.  
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.  
3) Verify that vent system is complete and free of obstructions before attempting to fire boiler.  
4) Inspect all wiring for loose or uninsulated connections.  
5) Make sure the main burners are seated properly in the rear of burner tray and on orifices.  
6) Adjust thermostat to the highest setting.  
7) Start the boiler using the appropriate lighting instructions for the gas valve on the boiler on pages 29-32.  
8) Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take  
several tries for ignition before a flame is established. Once a flame has been established for the first time, subsequent  
calls for burner operation should result in a flame on the first try.  
9) Observe pilot burner flame:  
See Figure 24 for standing pilot. Pilot burner should produce single steady medium blue flame covering around 3/8”  
to ½” of thermocouple tip.  
See Figure 25 for intermittent ignition. Pilot burner produces three flames. The center one should be a steady medium  
blue flame covering around 3/8” to ½” of spark electrode/flame rod.  
25  
FIGURE 24: STANDINGPILOT  
BURNER FLAME  
FIGURE 25: INTERMITTENTIGNITION  
PILOT BURNER FLAME  
10) Make sure vent damper is in open position when main burners are firing.  
11) Inspect the main burner flames visible through the observation port in burner access panel. The flame should be stable  
and mostly blue (see Figure 26). No yellow tipping should be present; however, intermittent flecks of yellow and orange in  
theflamearenormal.  
12) Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is firing. Fix  
any leaks found immediately.  
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.  
13) Run gas valve safety shutdown test:  
For standing pilot boiler models, disconnect the thermocouple from gas valve. Both pilot burner and main  
burners should stop firing.  
For intermittent ignition boiler models, with main burners firing, disconnect ignition cable from ignition module.  
Both pilot burner and main burners should stop firing.  
26  
FIGURE26b:MAINBURNERFLAME-40mm  
(“HIGHALTITUDE”)BURNERS  
FIGURE26a: MAINBURNERFLAME-1BURNERS  
WARNING  
FAILURETOFOLLOWTHEFOLLOWINGPROCEDUREEXACTLYCOULDRESULTINOVER-FIRING  
OF THE BOILER AND A CARBON MONOXIDE HAZARD.  
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 within the  
following limits regardless of what combination of appliances is firing:  
Inlet Press (inches w.c.)  
NaturalGas  
5.0  
LPGas  
11.0  
Min.  
Max.  
14.0  
13.0  
If the inlet pressure falls outside of these limits, find and correct the cause of the problem before proceeding further.  
c) Connect a manometer to the manifold (outlet) pressure tap on the gas valve (see Figures 27 and 28).  
d) Read the manifold pressure. It should be set at:  
NaturalGas  
3.5  
LPGas  
10.0  
Manifold Press. (inches w.c.)  
e) If a manifold pressure adjustment is needed, make the adjustment by turning the pressure regulator (see Figures 27  
and 28) screw clockwise to raise the pressure and counter clockwise to reduce the pressure. If a manifold pressure  
adjustment is made, recheck the line pressure to be certain that it is still within acceptable limits. Replace the cover  
screw on the regulator.  
27  
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 setting. The main burners (for standing  
pilot boiler models) or pilot burner and main burners (for intermittent ignition boiler models) should relight.  
17) 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. For standing pilot boiler models, pilot burner should remain lit but the main burners  
should stop firing. For intermittent ignition boiler models, both the pilot burner and main burners should stop firing.  
18) Allow the boiler water temperature to drop below high limit setting.  
19) The main burners (for standing pilot boiler models) or pilot burner and main burners (for intermittent ignition boiler  
models) should relight.  
20) After the boiler has operated for approximately 30 minutes, check the boiler and heating system piping for leaks. Repair any  
leaks found at once.  
21) Inspect the vent system for flue gas leaks. Repair any leaks found before leaving the boiler in operation.  
28  
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL  
VR8200 AND VR8300 SERIES GAS VALVES (STANDING PILOT)  
FOR YOUR SAFETY READ BEFORE OPERATING  
WARNING: If you do not follow these instructions exactly, a fire or explosion  
may result causing property damage, personal injury or loss of life.  
A. This appliance has a pilot which must be  
lighted by hand. When lighting the pilot, follow  
these instructions exactly.  
If you cannot reach your gas supplier, call  
the fire department.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
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 IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
LIGHTING INSTRUCTIONS  
1. STOP! Read the safety information above on  
8. Turn Knob on gas control counterclockwise  
to “PILOT”.  
this label.  
2. Set the thermostat to lowest setting.  
3. Turn off all electric power to the appliance.  
4. Remove front access panel.  
9. Push down and hold the red reset button while  
you light pilot burner with a match.  
After about one minute, release reset button.  
Pilot should remain lit. If it goes out, turn gas  
control knob clockwise  
repeat steps 5-9.  
to OFF. To relight,  
5. Rotate the gas control knob clockwise  
to OFF.  
If button does not pop up when released, stop  
and immediately call your service technician  
or gas supplier.  
RESET BUTTON  
If the pilot will not stay lit after several tries,  
turn the gas control knob to “OFF” and call  
your service technician or gas supplier.  
GAS INLET  
GAS OUTLET  
10. After pilot remains lit when red reset button is  
released, turn gas control knob counterclockwise  
to ON.  
GAS CONTROL KNOB  
(SHOWN IN “ON” POSITION)  
GAS VALVE - TOP VIEW  
6. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas,  
go to the next step.  
11. Replace front access panel.  
12. Turn on all electric power to the appliance.  
13. Set thermostat to desired setting.  
7. Find pilot - follow metal pilot  
tube from gas control to  
PILOT  
BURNER  
THERMO-  
COUPLE  
pilot burner.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
29  
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW  
7000ERHC SERIES GAS VALVES (STANDING PILOT)  
FOR YOUR SAFETY READ BEFORE LIGHTING  
WARNING: If you do not follow these instructions exactly, a fire or explosion  
may result causing property damage, personal injury or loss of life.  
A. This appliance has a pilot which must be  
lighted by hand. When lighting the pilot, follow  
these instructions exactly.  
If you cannot reach your gas supplier, call  
the fire department.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
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 IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
LIGHTING INSTRUCTIONS  
1. STOP! Read the safety information above on  
8. Turn Knob on gas control counterclockwise  
to “PILOT”.  
this label.  
2. Set the thermostat to lowest setting.  
3. Turn off all electric power to the appliance.  
4. Remove front access panel.  
9. Push down and hold the Knob while  
you light pilot burner with a match.  
After about one minute, release reset button.  
Pilot should remain lit. If it goes out, turn gas  
control knob clockwise  
to OFF. To relight,  
5. Rotate the gas control knob clockwise  
to OFF.  
repeat steps 5-9.  
If button does not pop up when released, stop  
and immediately call your service technician  
or gas supplier.  
POSITION  
INDICATOR  
If the pilot will not stay lit after several tries,  
turn the gas control knob to “OFF” and call  
your service technician or gas supplier.  
PILOT  
O F  
F
O N  
GAS  
INLET  
10. After pilot remains lit when red reset button is  
released, turn gas control knob counterclockwise  
to ON.  
GAS CONTROL KNOB  
SHOWN IN "OFF" POSITION  
6. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas,  
go to the next step.  
11. Replace front access panel.  
12. Turn on all electric power to the appliance.  
13. Set thermostat to desired setting.  
7. Find pilot - follow metal pilot  
tube from gas control to  
PILOT  
BURNER  
THERMO-  
COUPLE  
pilot burner.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
30  
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL  
VR8204 AND VR8304 SERIES GAS VALVES (INTERMITTENT PILOT)  
FOR YOUR SAFETY READ BEFORE LIGHTING  
WARNING: If you do not follow these instructions exactly, a fire or explosion  
may result causing property damage, personal injury or loss of life.  
A. This appliance is equipped with an ignition  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
If you cannot reach your gas supplier, call  
the fire department.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
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 IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information above on  
this label.  
5. Remove front access panel.  
6. Rotate the gas control knob clockwise  
to OFF.  
2. Set the thermostat to lowest setting.  
7. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas  
go to the next step.  
3. Turn off all electric power to the appliance.  
4. This appliance is equipped with an ignition  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
8. Rotate the gas control knob counter clockwise  
to “ON”.  
GAS CONTROL KNOB  
(SHOWN IN “ON” POSITION)  
9. Replace front access panel.  
10. Turn on all electric power to the appliance.  
11. Set thermostat to desired setting.  
GAS INLET  
GAS OUTLET  
12. If the appliance will not operate, follow the  
instructions “To Turn Off Gas To Appliance” and  
call your service technician or gas supplier.  
GAS VALVE - TOP VIEW  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
31  
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW  
7000DERHC SERIES GAS VALVES (INTERMITTENT PILOT)  
FOR YOUR SAFETY READ BEFORE LIGHTING  
WARNING: If you do not follow these instructions exactly, a fire or explosion  
may result causing property damage, personal injury or loss of life.  
A. This appliance is equipped with an ignition  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
If you cannot reach your gas supplier, call  
the fire department.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
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 IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information above on  
this label.  
5. Remove front access panel.  
6. Rotate the gas control knob clockwise  
to OFF.  
2. Set the thermostat to lowest setting.  
7. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas  
go to the next step.  
3. Turn off all electric power to the appliance.  
4. This appliance is equipped with an ignition  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
8. Rotate the gas control knob counter clockwise  
to “ON”.  
POSITION  
INDICATOR  
9. Replace front access panel.  
10. Turn on all electric power to the appliance.  
11. Set thermostat to desired setting.  
F
O F  
O N  
GAS  
INLET  
12. If the appliance will not operate, follow the  
instructions “To Turn Off Gas To Appliance” and  
call your service technician or gas supplier.  
GAS CONTROL KNOB  
SHOWNIN"OFF" POSITION  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
32  
FIGURE 27a: GASVALVEDETAIL-HONEYWELLVR8200ORVR8300(STANDINGPILOT)  
FIGURE 27b: GASVALVEDETAIL-ROBERTSHAW 7000ERHCANDHONEYWELLV8295(STANDINGPILOT)  
FIGURE 28a: GASVALVEDETAIL-HONEYWELLVR8204ANDVR8304 (INTERMITTENT IGNITION)  
FIGURE 28b: GASVALVEDETAIL-ROBERTSHAW 7000DERHC (INTERMITTENT IGNITION)  
33  
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 cleaning procedure below.  
3) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation.  
4) Remove all burners, noting the location of the pilot main burner. If burners show signs of deterioration, they should be  
replaced (some discoloration around the burner ports is normal). Clean the burners by first brushing the ports with a soft  
bristle brush and then vacuuming out any debris through the venturi opening.  
5) Inspect the pilot assembly:  
Standing Pilots - Check the thermocouple for deterioration (some discoloration of the thermocouple is normal). If any  
deterioration is present, replace the thermocouple. Inspect the pilot assembly for deposits and deterioration. Clean or  
replace the pilot assembly as necessary.  
Intermittent Pilots - Clean any deposits found on the electrode and grounding strap. The ideal gap between the  
electrode and the ground strap is 1/8”. Inspect the porcelain for cracks or other deterioration. Replace pilot assembly  
if deterioration is found.  
6) Inspect the combustion chamber insulation for deterioration.  
7) (Intermittent Pilot Boilers) - 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.  
CAUTION  
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE  
IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.  
10) Inspect the vent system:  
Make sure that the vent system is free of obstructions.  
Make sure that all vent system supports are intact.  
Inspect joints for signs of condensate or flue gas leakage.  
Inspect venting components for corrosion or other deterioration. Replace any defective vent components.  
11) Inspect the boiler and hydronic system for leaks.  
CAUTION  
WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPO-  
NENTS. REPAIR ANY LEAKS FOUND IMMEDIATELY.  
12) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas piping  
disturbed during the inspection process for leaks.  
34  
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 blocked vent (“spill”) switch.  
6) Remove the ¼-20 nuts and washers holding the flue collector onto the heat exchanger.  
7) Carefully remove the flue collector gasket strips and set them aside.  
8) Remove the flue collector from the heat exchanger.  
9) Clean the flue passageways using a stiff bristle brush. Be certain that all foreign material is removed from the gaps  
between the pins.  
10) Clean the bottom surfaces of the heat exchanger.  
11) Put a light in the combustion chamber and look through the flue passages from the top to verify that they have been  
thoroughly cleaned.  
12) Replace the flue collector gasket strips. If desired, RTV silicone sealant with a 500F intermittent duty temperature may be  
substituted for this rope gasket. The flue collector must be thoroughly sealed to the heat exchanger.  
13) Replace the ¼-20 nuts and washers that hold down the flue collector.  
14) Reattach all the jacket components.  
15) Reinstall burners, being careful to 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 CO, use a combustion analyzer, or other instrument which is designed to measure CO in flue gas.  
A CO “sniffer” designed for testing CO levels in ambient air cannot be used to check boiler combustion. Take a flue gas  
sample by inserting a sample probe through the draft diverter opening and into the flue collector so that the sample is taken  
in the area directly over the heat exchanger. Do not take a sample until the boiler has been firing for at least five minutes.  
Anormal CO reading for a CWI series boiler is less than 50ppm (0.005%).Areading of more than 100ppm (0.01%) is  
indicative of a combustion problem.  
Some causes of excessive CO include:  
Incorrectly sized main burner orifice for the altitude at which boiler is installed  
Crooked or out-of-round orifice holes (never attempt to drill orifice for this boiler in the field)  
Partially plugged flue passages  
Improper manifold pressure  
Foreign material in burner venturis or burner ports  
Leak in seal between flue collector and heat exchanger  
Inadequate supply of combustion air  
35  
XIII Troubleshooting  
The following pages contain troubleshooting charts for use in diagnosing control problems. To 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 within the ignition system, go directly to the  
appropriate troubleshooting guide for the boiler (standing pilot on page 41 or intermittent ignition on page 42). In using  
these charts, the following should be kept in mind:  
1) These charts are only meant to be used by a professional heating technician as an aid in diagnosing control  
problems.  
2) Where applicable, follow all precautions outlined in the appropriate lighting instructions on pages 29-32.  
3) In general, these charts assume that there are no loose or miswired electrical connections. Before using these  
charts, inspect all electrical connections on the boiler to make sure that they are tight. Also, check the wiring on the  
boiler against the appropriate wiring diagram in Figures 18 - 21.  
4) The possible causes at the end of each branch in these charts are not listed in order of likelihood. All controls on  
the CWI are tested at least once in the manufacturing process and a defective control or component is generally the  
least likely cause. Before replacing a component, try to rule out all other possible causes.  
5) These troubleshooting charts assume that the vent damper is closed at the beginning of the troubleshooting  
process. With the 120 volts applied to the boiler and no call for heat, the damper should go to the closed position. If  
it does not, do the following:  
Confirm that 120 volts is applied to the boiler and that there is no call for heat.  
Make sure that the switch on the damper is in the “automatic” position.  
Unplug the harness from the damper and check for 24 volts across pin #1 (blue) and pin #4 (yellow).  
If voltage is present, the damper 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 L8124E is  
defective. It is possible that this transformer has been destroyed by a short circuit in the boiler wiring. Before  
replacing the control, carefully inspect all low voltage wiring on the boiler for places where it is touching the  
frame of the boiler or wiring on the other side of the transformer.  
If 24 volts is present across TV and Z, check for 24 volts between T and W. On L8148Es, if no voltage is  
present, make sure that the brass jumper is present between W and Z and that the screws holding this jumper  
in place are both tight. If the boiler is equipped with a L8124E, voltage will only be present across T and W  
when there is a call for heat AND the boiler water temperature high enough to satisfy the low limit.  
If not already done, temporarily replace the thermostat across TV and T with a jumper. If the boiler fires when  
this is done, there is a problem with the thermostat or zone wiring.  
If 24 volts is present across T and W and the relay in the L8148E or L8124E does not pull in, the relay in this  
control is probably defective. Inspect the coil of this relay for visible heat damage. If such damage is found,  
there is a good chance that a second transformer is present in the thermostat or zone valve circuit, resulting in  
the application of 48 volts across the relay coil. In older buildings, this transformer may be hidden in a location  
far from the boiler. If this second transformer exists, it must be found and removed before the L8148E or L8124E  
is replaced.  
7) When checking voltage across damper harness pins, be careful not to insert the meter probes into the pins. Doing so  
may damage the pin, resulting in a loose connection when the harness is reconnected.  
36  
Troubleshooting Chart for CWI Boilers Without Tankless Heaters  
Caution: Read page 36 before attempting to use this chart  
START  
N
Boiler  
Equipped  
With  
Vent  
damper  
open?  
Y
Y
Y
Thermostat  
calls for heat  
Circulator  
start?  
Damper?  
N
N
*Pow er of f  
N
120 volts  
at L1&L2?  
24 volts  
*Blow n fuse or  
tripped breaker  
Y
across B and R  
(limit sw itch) in  
L8148E?  
*Misw ired or  
loose electrical  
connection in  
120V line  
Y
*Boiler off on  
limit  
120 volts  
across  
Y
N
N
120 volts at  
terminals at  
circulator?  
C1&C2?  
*Def ective  
high limit.  
N
Y
Remove t'stat or  
24 volts  
zone valve end  
sw itch w ires from  
T&TV terminals on  
L8148E. Install  
temporary jumper  
across terminals T  
and TV.  
betw een pins  
1&4 (blue&yellow )and  
2&4 (orange&yellow ) on  
damper end of damper  
harness? See  
*Seized or  
defective  
circulator  
24 volts  
across  
T&TV?  
Y
N
N
Note 7 on page 28.  
Does  
circulator  
run now ?  
N
Y
*Def ective  
L8148E-see  
Note 6 on page  
36.  
*Bad electrical  
connection  
betw eenC1 or  
C2 and  
* Loose  
*Obstruction in  
path of damper  
blade  
connection  
betw een  
damper  
harness and  
L8148E  
circulator  
Y
*Loose connection in t'stat or  
zone valve end sw itch w iring  
*Def ective  
damper motor  
*Defective t'stat or zone valve  
end sw itch  
*Def ective  
damper  
*Loose  
connection  
betw een damper  
harness and  
damper  
harness.  
*T'stat or zone system  
misw ired-consult t'stat or  
zone valve manufacturer's  
instructions  
* Def ective  
L8148E  
37  
Do burners  
shut dow n before  
gage temp  
exceeds high limit  
setting +15F?  
Do burner and  
circulator shut  
dow n at end of  
call for heat?  
Main  
burners  
light?  
Y
Y
Y
END  
N
N
N
*Defective damper  
24 volts  
across  
B1 &B2 ?  
N
*Defective L8148E  
*Def ective  
L8148A  
*Defective damper  
harness  
Y
*Sensing bulb not  
bottomed out in  
w ell  
*Loose damper  
harness connection  
*Obstruction in path  
24 volts across  
standing pilot gas  
valve terminals or  
terminals 5&6 on  
S8600 module?  
of damper blade  
N
Pull w ire of f of T  
terminal on  
aquastat. Does  
boiler shut dow n?  
Refer to standing pilot or  
intermittent ignition  
troubleshooting chart  
(page 41 or 42).  
Y
N
Y
24 volts  
across spill  
sw itch?  
Y
*Chimney blockage  
*T'stat or  
*Chimney systemnot  
zone valve  
w iring calling  
for heat  
constructed in accordance  
w ith Parts 7 and 10 of  
National Fuel Gas Code.  
N
24 volts  
across  
rollout  
*Dow n draft  
*T'stat w ires  
shorted  
*Inadequate combustion air  
supply in boiler room  
sw itch?  
Y
N
*Internal boiler  
w iring  
problem,  
consult Crow n  
representative  
*Rollout sw itch open.  
Replace w ith exact  
replacement (see parts  
list). Check for blocked  
heat exchanger.  
*Loose electrical  
connection in 24  
volt w iring  
betw eenB1 or B2  
and gas valve or  
module  
38  
Troubleshooting Chart for CWI Boilers Equipped with Tankless Heaters and Dampers  
Caution: Read page 36 before attempting to use this chart  
START  
No call for heat,  
boiler w ater  
temp. at least  
20F below low  
limit setting  
Allow boiler w ater  
temperature to  
reach low limit +  
differential setting.  
Initiate call for heat  
Vent  
damper  
open?  
Main  
burners  
light?  
Y
Y
N
N
24 volts  
across TV  
and Z?  
N
*Def ective damper  
N
24 volts across  
gray w ire on  
rollout sw itch  
and B2 ?  
24 volts  
N
*Def ective damper  
harness  
across B1 and  
TV on L8124E?  
Y
120 volts  
across L1 &  
L2?  
*Loose damper  
harness connection  
Y
Y
N
*Obstruction in path  
of damper blade  
Y
*Boiler w ater  
temp above  
low limit  
setting  
24 volts across  
standing pilot gas  
valve terminals or  
terminals 5&6 on  
S8600 module?  
* Defective  
transformer in  
L8124E  
*Def ective  
L8124E  
Y
Refer to standing  
pilot or  
intermittent  
ignition  
troubleshooting  
chart (page 41 or  
42).  
*Pow er of f  
N
*Blow n fuse or  
tripped breaker  
24 volts  
24 volts  
across spill  
sw itch?  
Y
betw een pins  
1&4 (blue&yellow )and  
2&4 (orange&yellow ) on  
damper end of damper  
harness? See  
*Misw ired or  
loose electrical  
connection in  
120V line  
N
N
*Chimney blockage  
Note 7 on page 36.  
*Chimney system not  
constructed in accordance  
w ith Parts 7 and 10 of  
National Fuel Gas Code.  
24 volts  
across  
rollout  
Y
24 volts  
across TV  
Y
N
Y
sw itch?  
& Z?  
*Dow n draf t  
*Obstruction in  
path of damper  
blade  
N
*Inadequate combustion air  
supply in boiler room  
* Loose  
connection  
betw een  
damper  
harness and  
L8124E  
*Def ective  
damper motor  
*Loose electrical  
connection in 24  
volt w iring  
betw een rollout  
sw itch orB2 and  
gas valve or  
* Def ective  
L8124E  
*Rollout sw itch open.  
Replace w ith exact  
replacement (see parts  
list). Check for blocked  
heat exchanger.  
*Loose connection  
betw een damper  
harness and  
*Def ective  
damper  
harness.  
damper  
module  
39  
Do burners  
shut dow n before  
gage temp  
exceeds high limit  
setting +15F?  
Y
Do burner and  
circulator shut  
dow n at end of  
call for heat?  
Circulator  
start?  
Y
Y
END  
Main  
burners  
light?  
N
Y
N
N
N
*Boiler w ater  
temperature  
exceeds high limit  
setting  
*Def ective  
L8124E  
*Sensing bulb not  
bottomed out in  
w ell  
* Defective  
L8124E  
N
120 volts  
across  
120 volts at  
terminals at  
circulator?  
C1&C2?  
Y
N
Y
N
Pull w ire of f of T  
terminal on  
aquastat. Does  
boiler shut dow n?  
Remove t'stat or  
zone valve end  
sw itch w ires from  
T&TV terminals on  
L8124E. Install  
temporary jumper  
across terminals T  
and TV.  
24 volts  
across  
T&TV?  
Y
Y
N
*Seized or  
defective  
circulator  
*T'stat or  
zone valve  
w iring calling  
for heat  
N
Does  
circulator  
run now ?  
*Def ective  
L8124E-see  
Note 6 on page  
36.  
*T'stat w ires  
shorted  
Y
* Boiler w ater  
temperature  
has dropped  
below low limit  
setting  
*Loose connection in t'stat or  
zone valve end sw itch w iring  
* Boiler w ater  
temperature  
has dropped  
below low limit  
setting  
*Bad electrical  
connection  
betw eenC1 or  
C2 and  
*Defective t'stat or zone  
component  
circulator  
*Internal boiler  
w iring  
*T'stat or zone system  
misw ired-consult t'stat or  
zone valve manufacturer's  
instructions  
problem,  
consult Crow n  
representative  
40  
Standing Pilot Ignition System Troubleshooting Chart  
START  
Caution: Read page 36 before  
(24 VOLTS PRESENT ACROSS TH AND TR  
ON GAS VALVE, BUT MAIN BURNERS DO  
NOT LIGHT)  
attempting to use this chart  
Y
Ensure knob  
on gas valve is  
set toON  
Main  
burners  
light?  
Y
Y
Does pilot  
stay lit?  
Pilot lit?  
N
END  
N
N
*Loose  
thermocouple  
connection at  
Turn control on  
gas valve to  
PILOT. Depress  
red button and  
light pilot. Hold  
button for at  
least one  
Turn control  
on gas valve  
to ON.  
*Defective gas  
valve  
gas valve.  
*Defective  
thermocouple.  
minute.  
*Condensation  
quenching pilot.  
Y
Disconnect  
thermocouple from  
gas valve. Connect a  
volt meter to the  
thermocouple. Light  
the pilot and hold  
down the red button  
while reading the  
voltage across the  
thermocouple.  
*Low line  
pressure.  
Does pilot  
stay lit when  
red button is  
released?  
Y
N
Does pilot  
light?  
N
Line pressure  
within the range  
indicated on  
boiler's rating  
plate?  
N
Y
Is voltage at  
least 18mV?  
Consult gas  
supplier.  
Y
N
*Pilot tubing  
blocked, kinked  
or leaking  
*Loose or defective  
thermocouple  
connection at gas valve  
*Defective thermocouple  
*Pilot orifice  
blocked  
*Pilot improperly  
adjusted  
*Defective gas valve  
*Gas line not  
purged of air  
*Pilot tube blocked, kinked, or  
leaking  
*Pilot improperly  
adjusted.  
*Pilot orifice partially plugged  
41  
Intermittent Ignition System Troubleshooting Chart  
START  
Caution: Read page 36 before  
attempting to use this chart  
(24 volts is present across 5 and 6 on S8600  
module, but main burners do not light)  
Spark  
Does  
Main  
burner  
lights?  
Y
Y
Y
Y
across  
ignitor/sensor  
gap?  
Pilot  
lights?  
spark stop  
when pilot  
lights?  
END  
N
N
N
N
24VAC  
across  
terminals 1&2  
on S8600?  
N
24 volts  
across  
terminals 2&3  
at S8600?  
N
Y
*Defective  
S8600 module  
Can you  
hear  
Y
*Defective  
S8600  
module  
Y
sparking?  
N
24 volts  
between MV &  
MV/PV on gas  
valve?  
24 volts  
across PV &  
MV/PV at gas  
valve?  
N
Y
*Faulty  
S8600  
module  
N
Y
*Loose connection in  
ignition cable or  
ground wire  
*Defective EI  
wiring  
harness.  
*Break in  
spark cable  
insulation  
*Defective EI  
harness  
*Pilot electrode  
porcelain cracked  
*Break in pilot  
porcelain  
* Low line pressure  
*Pilot flame not  
covering gap  
between electrode  
and grounding  
strap  
*Plugged, kinked or leaking  
pilot tubing  
*Incorrect pilot  
spark gap  
*Defective  
gas valve  
*Plugged pilot orifice  
*Loose  
connection in  
spark cable  
*Low gas pressure  
at gas valve inlet  
*Gas line not purged of air  
*Defective pilot assembly  
*Defective gas valve  
*Loose  
ground  
connection  
*Defective S8600  
module  
42  
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 Service  
P.O. Box 14818  
Philadelphia PA. 19134  
For boilers installed at elevations above 2000 ft, consult the local Crown representative or the factory for the correct main burner  
orifice.  
QTY. OR  
CROWN P.N.  
QUANTITY PER BOILER OR CROWN P.N.  
KEY #  
DESCRIPTION  
310  
345  
379  
69  
103  
138  
172  
207  
241  
276  
CWI HEAT EXCHANGER ASSY.  
LESS TANKLESS HEATER OPENING  
CWI HEAT EXCHANGER ASSY.  
(WITH TANKLESS HEATER OPENING)  
BSI/CWI LEFT END SECTION  
CWI RH SECTION (LESS HTR OPENING)  
CWI RH SECTION (WITH HTR OPENING)  
BSI/CWI INTERMEDIATE SECTION  
UPPER PUSHNIPPLE  
LOWER PUSHNIPPLE  
BASE TRAY  
BASE WRAPPER  
BURNER TRAY (1" BURNERS)  
BURNER TRAY (40mm BURNERS)  
BASE FRONT PANEL ASSY. (INCLUDES  
INSULATION)  
1
1
1 ea.  
1 ea.  
850013  
850014  
850015  
850016  
850017  
850018  
850019  
850020  
850021  
850022  
750013  
750014  
750015  
750016  
750017  
750018  
750019  
750020  
750021  
750022  
*
*
*
*
*
750001  
850002  
750002  
750003  
275075  
275070  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
3 ea.  
1 ea.  
1 ea.  
1 ea.  
3 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
5 ea.  
1 ea.  
1 ea.  
1 ea.  
5 ea.  
6 ea.  
1 ea.  
1 ea.  
1 ea.  
6 ea.  
7 ea.  
1 ea.  
1 ea.  
1 ea.  
7 ea.  
8 ea.  
1 ea.  
1 ea.  
1 ea.  
8 ea.  
9 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
10 ea.  
11 ea.  
11 ea.  
700652  
700672  
700692  
9 ea.  
10 ea.  
10 ea.  
700651  
700671  
700691  
*
2 ea.  
3 ea.  
4 ea.  
5 ea.  
6 ea.  
7 ea.  
8 ea.  
9 ea.  
2
3
4
4
700643  
700663  
700683  
751683  
700644  
700664  
700684  
751684  
700645  
700665  
700685  
751685  
700646  
700666  
700686  
751686  
700647  
700667  
700687  
751687  
700648  
700668  
700688  
751688  
700649  
700669  
700689  
751689  
700650  
700670  
700690  
751690  
5
1 ea.  
700603  
700604  
700605  
700606  
700607  
700608  
700609  
700610  
700611  
700612  
6
7
8
9
BURNER ACCESS PANEL  
BASE END INSULATION  
BASE REAR INSULATION  
BASE LEG ASSY.  
1/4-20 X 1/2" SELF TAPPING SCREW  
1/2" x 2" SEALING STRIP  
ROLLOUT SWITCH G4AM0600240C  
ROLLOUT SWITCH BRACKET  
#8 x 3/4" SELF TAPPING SCREW  
#10 x 1/2" SHEET METAL SCREW  
5/16 USS FLAT WASHER  
1 ea.  
720601  
1 ea.  
700623  
2 ea.  
720603  
4 ea.  
20 ea.  
3.7 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
850123  
3 ft  
700624  
2 ea.  
720604  
4 ea.  
20 ea.  
4.2 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
850124  
3.3 ft  
4 ea.  
4 ea.  
4 ea.  
700625  
2 ea.  
720605  
4 ea.  
700626  
2 ea.  
720606  
4 ea.  
700627  
2 ea.  
720607  
4 ea.  
21 ea.  
5.9 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
850127  
4.1 ft  
4 ea.  
4 ea.  
4 ea.  
700628  
2 ea.  
720608  
4 ea.  
21 ea.  
6.4 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
850128  
4.4 ft  
4 ea.  
4 ea.  
4 ea.  
700629  
2 ea.  
720609  
4 ea.  
21 ea.  
7.0 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
850129  
4.6 ft  
4 ea.  
4 ea.  
4 ea.  
700630  
2 ea.  
720610  
4 ea.  
21 ea.  
7.5 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
850130  
4.9 ft  
4 ea.  
4 ea.  
4 ea.  
700631  
2 ea.  
720611  
6 ea.  
25 ea.  
8.0 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
850131  
5.2 ft  
4 ea.  
4 ea.  
4 ea.  
700632  
2 ea.  
720612  
6 ea.  
25 ea.  
8.5 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
850132  
5.5 ft  
4 ea.  
4 ea.  
4 ea.  
700110  
900100  
900146  
960122  
900121  
90-048  
90-212  
900102  
900103  
900101  
1 ea.  
10  
11  
12  
13  
14  
15  
16  
17  
18  
20  
21  
22  
23  
24  
20 ea.  
4.8 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
850125  
3.5 ft  
4 ea.  
4 ea.  
4 ea.  
20 ea.  
5.3 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
850126  
3.8 ft  
4 ea.  
4 ea.  
4 ea.  
5/16-18 LOCK NUT  
5/16-18 x 1-1/4 SELF TAPPING SCREW  
DRAFT DIVERTER ASSEMBLY  
1/2" x 1" SEALING STRIP  
1/4-20 x 1-1/4" CARRIAGE BOLT  
1/4" USS FLAT WASHER  
900145  
90-201  
90-215  
900125  
4 ea.  
4 ea.  
4 ea.  
1/4-20 WING NUT  
BLOCKED VENT SWITCH ASSY.  
(INCLUDES MOUNTING BRACKET)  
HEATER OPENING COVER PLATE  
TANKLESS HEATER  
HIGH CAPY. TANKLESS HTR. (OPT.)  
TANKLESS HEATER GASKET  
3/8 USS FLAT WASHER  
25  
960123  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
26  
27  
27  
28  
29  
30  
270003  
1 ea.  
1 ea.  
270001  
90-036  
900450  
1 ea.  
750007  
1 ea.  
750007  
1 ea.  
750007  
1 ea.  
750007  
750010  
1 ea.  
6 ea.  
6 ea.  
1 ea.  
750007  
750010  
1 ea.  
6 ea.  
6 ea.  
1 ea.  
750008  
750010  
1 ea.  
6 ea.  
6 ea.  
1 ea.  
750008  
750010  
1 ea.  
6 ea.  
6 ea.  
1 ea.  
750008  
750010  
1 ea.  
6 ea.  
6 ea.  
1 ea.  
750008  
750010  
1 ea.  
6 ea.  
6 ea.  
1 ea.  
6 ea.  
6 ea.  
1 ea.  
6 ea.  
6 ea.  
1 ea.  
6 ea.  
6 ea.  
1 ea.  
6 ea.  
6 ea.  
3/8-16 X 7/8 HX HEAD CAP SCREW  
* NOT PICTURED  
43  
44  
QTY. OR  
CROWN P.N.  
QUANTITY PER BOILER OR CROWN P.N.  
KEY #  
41  
DESCRIPTION  
310  
345  
379  
69  
103  
138  
172  
207  
241  
276  
1" BURNER WITH PILOT BRACKET  
(Q350 PILOT)  
1" BURNER WITH PILOT BRACKET  
(Q327 NAT, Q348 PILOTS)  
1" BURNER WITH PILOT BRACKET  
(Q327 LP PILOT)  
150502  
150500  
150503  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
41  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
41  
42  
43  
44  
44  
44  
44  
44  
44  
44  
45  
1" BURNER LESS PILOT BRACKET  
MANIFOLD (1" BURNERS)  
150501  
1 ea.  
950298  
950300  
950303  
950304  
950329  
950330  
950336  
2 ea.  
700153  
3 ea.  
4 ea.  
700154  
6 ea.  
700155  
8 ea.  
700156  
11 ea.  
700157  
13 ea.  
700158  
15 ea.  
700159  
17 ea.  
700160  
20 ea.  
700161  
22 ea.  
700162  
NAT GAS ORIFICE (#42 DRILL SIZE)  
NAT GAS ORIFICE (#44 DRILL SIZE)  
NAT GAS ORIFICE (#47 DRILL SIZE)  
NAT GAS ORIFICE (#48 DRILL SIZE)  
LP GAS ORIFICE (#54 DRILL SIZE)  
LP GAS ORIFICE (#55 DRILL SIZE)  
LP GAS ORIFICE (#1.25mm DRILL SIZE)  
GAS VALVE (STND. PILOT, NAT GAS)  
(EXCEPT 40mm BURNERS)  
5 ea.  
5 ea.  
7 ea.  
7 ea.  
9 ea.  
9 ea.  
12 ea.  
12 ea.  
14 ea.  
14 ea.  
16 ea.  
16 ea.  
18 ea.  
18 ea.  
21 ea.  
23 ea.  
3 ea.  
3507010  
(VR8200C6008)  
3507350  
(VR8200C6032)  
3507020  
(VR8204C6000)  
3507110  
(VR8300C4134)  
3507355  
(VR8300C4183)  
3507120  
(VR8304P4298)  
3507300  
(V8295A1024)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
45  
45  
45  
45  
45  
45  
45  
45  
45  
45  
45  
45  
46  
46  
46a  
46  
46a  
GAS VALVE (STND. PILOT, NAT GAS)  
(40mm BURNERS ONLY)  
GAS VALVE (E.I., NAT GAS)  
GAS VALVE (STND. PILOT, NAT GAS)  
(EXCEPT 40mm BURNERS)  
GAS VALVE (STND. PILOT, NAT GAS)  
(40mm BURNERS ONLY)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
GAS VALVE (E.I., NAT GAS)  
1 ea.  
1 ea.  
1 ea.  
GAS VALVE (STND. PILOT, NAT GAS)**  
1 ea.  
1 ea.  
1 ea.  
GAS VALVE (STND. PILOT, NAT GAS)**  
(ROBERTSHAW 7000ERHC-S7C)  
GAS VALVE (E.I., NAT GAS)  
(ROBERTSHAW 7000DERHC)  
GAS VALVE (STND. PILOT, LP GAS)  
3507305  
3507310  
3507210  
(VR8200C6040)  
3507220  
(VR8204C6018)  
3507230  
(VR8300C4548)  
3507240  
(VR8304P4280)  
3504050  
(Q350A1644)  
3504005  
(Q327A1949)  
35-4700  
(Q348A1275)  
35-4020  
(Q327A1915)  
35-4600  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
GAS VALVE (E.I. PILOT, LP GAS)  
GAS VALVE (STND. PILOT, LP GAS)  
GAS VALVE (E.I., LP GAS)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
PILOT ASSY. (STND. PILOT, NAT GAS)  
PILOT ASSY. (STND. PILOT, NAT GAS)  
PILOT ASSY. (E.I., NAT GAS)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
PILOT ASSY. (STND. PILOT, LP GAS)  
PILOT ASSY. (E.I., LP GAS)  
(Q348A1259)  
1 ea.  
47  
47a  
48  
THERMOCOUPLE  
IGNITION CABLE  
PILOT TUBING***  
35-1040 35-1040 35-1040 35-1040 35-1040 35-1040 3501141 3501142 3501142 3501142  
3501124 3501124 3501124 3501130 3501130 3501130 3501136 3501136 3501136 3501136  
90-042  
1 ea.  
1 ea.  
90-042  
90-042  
90-043  
90-043  
90-043  
900041  
900041  
900041  
1/8 SHORT FERRULE (INCLUDED WITH  
GAS VALVE)  
49  
35-1600  
(392449)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1/8 LONG FERRULE (INCLUDED WITH  
PILOT ASSEMBLY)  
50  
51  
35-1650  
(392449-4)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
CAR12 PILOT ORIFICE (Q350 PILOT,  
NAT GAS) - INCLUDED WITH PILOT  
A26 PILOT ORIFICE (Q327 PILOT, NAT  
GAS) - INCLUDED WITH PILOT ASSY.  
KF24 PILOT ORIFICE (Q348 PILOT, NAT  
GAS) - INCLUDED WITH PILOT ASSY.  
K14 PILOT ORIFICE (Q327 PILOT, LP  
GAS) - INCLUDED WITH PILOT ASSY.  
K16 PILOT ORIFICE (Q348 PILOT LP  
GAS) - INCLUDED WITH PILOT ASSY.  
40mm BURNER WITH PILOT BRACKET  
(Q350 PILOTS)  
51  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
51a  
51  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
51a  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
60  
60  
150540  
150542  
40mm BURNER WITH PILOT BRACKET  
(Q327, Q348 PILOTS)  
1 ea.  
1 ea.  
1 ea.  
61  
62  
40mm BURNER LESS PILOT BRACKET  
MANIFOLD (40mm BURNERS)  
150541  
1 ea.  
1 ea.  
701253  
2 ea.  
701254  
3 ea.  
701255  
4 ea.  
701256  
5 ea.  
701257  
6 ea.  
701258  
7 ea.  
701259  
8 ea.  
701260  
MAIN BURNER ORIFICE-CONSULT  
CROWN REPRESENTATIVE FOR  
CORRECT SIZE  
63  
2 ea.  
3 ea.  
4 ea.  
5 ea.  
6 ea.  
7 ea.  
8 ea.  
9 ea.  
** These Valves Piped in Series to Provide Redundent Shut-off  
***1/4 Pilot Tubing Used with Robertshaw Valves  
45  
46  
QTY. OR  
CROWN P.N.  
1 ea.  
QUANTITY PER BOILER OR CROWN P.N.  
172 207 241 276  
850301 8503012 8503012 8503012 8503015 8503015 8503015  
850300 8503002 8503002 8503002 8503005 8503005 8503005  
KEY #  
DESCRIPTION  
310  
345  
379  
69  
103  
138  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
LEFT SIDE JACKET PANEL  
RIGHT SIDE JACKET PANEL  
REAR JACKET PANEL  
TOP JACKET PANEL  
LOWER FRONT PANEL  
UPPER FRONT PANEL  
DIVERTER PANEL  
VESTIBULE PANEL  
HORIZONTAL JACKET CLIP  
VERTICAL JACKET CLIP  
#10 X 1/2" SHEET METAL SCREW  
DOOR KNOB  
8-32 X 1/4" H.W.H. SCREW  
IGNITION MODULE (E.I. BOILERS)  
(NATURAL GAS ONLY)  
IGNITION MODULE (E.I. BOILERS)  
(NATURAL OR LP GAS)  
MODULE BRACKET (E.I. BOILERS)  
VENT DAMPER  
3/4 SHORT WELL (LESS COIL BOILERS)  
3/4 LONG WELL (WITH COIL BOILERS)  
AQUASTAT (L8148E1257) LESS COIL  
AQUASTAT (L8124E1065) WITH COIL  
TRIDICATOR GAUGE  
3/4" RELIEF VALVE (30 psi)  
TACO 007 CIRCULATOR  
TACO 0010 CIRCULATOR  
1-1/2" TACO FLANGE SET  
1-1/4" TACO FLANGE SET  
3/4" BOILER DRAIN  
850301  
850300  
850303  
850323  
850363  
850353  
850373  
850383  
2 ea.  
850301  
850300  
850304  
850324  
850364  
850354  
850374  
850384  
2 ea.  
850301  
850300  
850305  
850325  
850365  
850355  
850375  
850385  
2 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
850306  
850326  
850366  
850356  
850376  
850386  
2 ea.  
850307  
850327  
850367  
850357  
850377  
850387  
2 ea.  
850308  
850328  
850368  
850358  
850378  
850388  
2 ea.  
850309  
850329  
850369  
850359  
850379  
850389  
2 ea.  
850310  
850330  
850370  
850360  
850380  
850390  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
850311  
850331  
850371  
850361  
850381  
850391  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
850312  
850332  
850372  
850362  
850382  
850392  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
800340  
800341  
90-212  
90-210  
90-211  
35-5000  
(S8600F1000)  
35-5050  
(S8600M1013)  
905000  
1 ea.  
35-1010  
35-1020  
35-3000  
3503350  
95-069  
95-040  
95-012  
95-015  
950150  
95-014  
95-041  
90-223  
2 ea.  
28 ea.  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
28 ea.  
2 ea.  
28 ea.  
2 ea.  
28 ea.  
2 ea.  
28 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
*
*
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
*
1 ea.  
96-030  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-031  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-032  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-032  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-033  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-033  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-035  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-035  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-036  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
96-036  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
88  
89  
89  
90  
90  
91  
92  
93  
93  
94  
94a  
95  
99  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
4 ea.  
1 ea.  
4 ea.  
1 ea.  
4 ea.  
8-32 X 1/2" SELF TAPPING SCREW  
CWI DAMPER HARNESS  
(WITH COIL BOILERS)  
*
9601555  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
CWI DAMPER HARNESS  
(LESS COIL BOILERS)  
*
*
*
9601550  
9601270  
9601200  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
BLOCKED VENT SWITCH HARNESS  
AQUASTAT - R.O. SWITCH HARNESS  
(LESS COIL OR LESS VENT DAMPER)  
AQUASTAT - R.O. SWITCH HARNESS  
(WITH COIL AND VENT DAMPER)  
INTERMITTENT IGNITION HARNESS  
1 ea.  
1 ea.  
*
*
9601500  
9601100  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
* NOT PICTURED  
47  
48  
Appendix A: Knockdown Boiler Assembly Instructions  
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 sealant.  
4) Keep the base in the shipping carton until it is time to perform the assembly. This keeps foreign material from  
contaminating the burners or creating other hazards. Do not use the base assembly if there are any signs of visible  
damage.  
5) Review all of the installation requirements in this installation manual.  
B. BaseAssembly Preparation  
1) The combination base-burner-manifold is shipped assembled from the factory. (The combination gas valve is  
shipped assembled and can be found in the "Base Box").  
2) Smear a thin layer of silicone in several places across the top of the base to adhere the fiber gasket strip.  
3) Install the fiber gasket strip, which was shipped in the "Base Box" (Figure A1).  
4) Place the base assembly in the location where the boiler is to be installed. Refer to Section III and IV in the installa-  
tion manual for additional information on placement.  
C. Heat Exchanger and Flue Collector Installation  
1) Position the heat exchanger above the base with the return connection located toward the front of the boiler and the  
lugs, located on each end of the boiler, centered over the studs, which are on each end of the base (Figure A1).  
Lower the heat exchanger over the studs, taking care not to disturb the studs which may push out if the heat  
exchanger comes in contact with them. Also, take care not to disturb the ceramic fiber 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 used between  
the heat exchanger and base). Install this gasketing on the top of the heat exchanger (Figure A1). A few dabs of  
silicone may be used to keep this gasketing from shifting when the flue collector is installed.  
6) Install the flue collector as shown in Figure A1. Secure with the 1/4-20 carriage bolt, nuts, and washers provided.  
7) Carefully inspect the joint between the flue collector and the heat exchanger to verify that the gasket is properly  
positioned.  
8) Install the blocked vent switch using the #8 sheet metal screw provided as shown in Figure A1  
D. Jacket Installation  
NOTE  
Before installing the jacket, make sure to plug any tappings which are not going to be used. Also make sure that no tappings  
are plugged which will be needed. See FigureA3 of this appendix, as well as Part XIII of the installation manual.  
1) Attach the diverter Panel to the vestibule panel using two #10 sheet metal screws. Install these screws in the  
outside holes.  
2) Slip this diverter/vestibule panel assembly behind the draft diverter opening in the draft diverter assembly (Figure  
A2). Attach to the diverter assembly using #10 sheet metal screws.  
3) Attach the right side panel to the base and vestibule panel using four #10 sheet metal screws.  
4) Orient the rear jacket panel so that the two notches are up. Slip the rear panel under the flange on the rear of the  
49  
FIGUREA1: BASE, HEAT EXCHANGER, FLUE COLLECTORASSEMBLY  
50  
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 jacket panels. Slide this clip through the  
rectangular slot that is about halfway up the front edge of the side jacket panels and secure with the 8-32 self  
tapping screws provided.  
8) Slip the Vertical Jacket Clip through the rectangular slot that is near the bottom of the front edge of the side jacket  
panels. Secure with the 8-32 sheet metal screws provided.  
9) Install the top jacket panel. Use #10 sheet metal screws to attach it to the rear jacket panel and the top-front corners  
of the side panels.  
10) Install the upper-front jacket panel. Insert the flange on the top of this panel under the top panel. Run two #10 sheet  
metal screws into the horizontal jacket clips through the holes in the bottom of this panel.  
11) Attach the door knobs to the Lower-Front Panel using 8-32 x 1/2 machine screws.  
12) The labels have been applied at the factory. Verify the location of the labels according to the list below:  
a) Clearance Label - Located on the top jacket panel.  
b) Lighting Instructions - Located on the lower left corner of the right side panel next to the gas manifold  
c) Lowest Permissible Water Level Plate - Located next to the bottom water gauge tapping.  
d) Blow Down Card - Located just above the "Lowest Permissible" Water Level Plate  
e) Wiring Diagram - Located on the inside of the removable door  
f) "CROWN" Nameplate - Located on the top center of the outside of the removable door  
g) Rating Plate - Located on the upper left of the right side panel  
D. GasValve 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 andTrim Installation  
(Refer to Figure A3 for Tapping Locations)  
1) Install the tankless heater or blank cover plate on the opening on the right side of the heat exchanger using the  
gasket and 3/8 bolts provided.  
2) Install the high limit well in the tapping in the tankless heater or cover plate.  
3) Mount the limit control (L8148E or L8124E) onto the control well. Be sure that the temperature sensing bulb is  
bottomed out in the well. Tighten the screw on the bottom of the control so that it is securely clamped onto the well.  
4) Install a 1/2 x 1/4 bushing and the tridicator gauge into tapping “C”. Tighten with wrench applied to the square  
shank on the back of the gauge. Do not apply pressure on the gauge case since this may ruin the calibration of the  
gauge.  
5) Install relief valve (spindle must be in vertical position) into tapping “H” on the boiler left side (See Figure 1 in the  
installation manual) using the ¾” NPT nipples and elbow supplied. Pipe the discharge of the safety relief valve to a  
location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the  
discharge pipe must terminate in an unthreaded pipe. The safety valve discharge piping must be in an area where it  
is not likely to become plugged by debris or subjected to freezing.  
6) Install the 1-1/2 return piping and circulator in tapping “D”. See Section VIII System Piping in the installation  
manual for instructions on completing the piping of this boiler.  
51  
FIGUREA2: JACKET INSTALLATION  
52  
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”. Connect these wires to the terminals on the blocked vent switch (it  
does not matter which of these wires is connected to which terminal on the blocked vent switch). Install the strain relief  
provided in the hole in the jacket through which these wires pass.  
3) Flame Roll-Out Switch:  
a) Route the wire marked “10” through the bushing located on the left jacket panel and connect it to one side of the flame  
roll-out switch.  
b) Route the wire marked “7” through the bushing located on the left jacket panel and connect it to the other side of the  
flame roll-out switch.  
4) Standing Pilot GasValve (HoneywellVR8200, VR8300 or Robertshaw Model 7000ERHC-S7C) - Connect wire “6” to the “TH”  
terminal on the gas valve. Connect wire “5” to the TR terminal on the gas valve.  
Note: Boilers equipped with the Robertshaw 7000ERHC are also equipped with a Honeywell Model V8295 gas valve to  
provide redundancy. This valve should be factory pre-wired to the 7000ERHC with one black lead connected to the “TH”  
terminal and the other black lead connected to the “TR” terminal on the 7000ERHC gas valve.  
5) Honeywell Intermittent Ignition System:  
a) Mount the S8600 series 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 S8600 module.  
c) Plug the green burner ground wire numbered “4” to terminal 4 on the S8600. Check that the ground wire has been routed  
under the burners and that the other end is attached to the pilot assembly under the lower mounting screw.  
d) Plug the red wire with the yellow trace, numbered “5”, to terminal 5 on the S8600 module.  
e) Plug the black wire with the white trace, numbered “6”, to terminal 6 on the S8600 module.  
f) Plug the orange Pilot Ignition Cable, numbered “9”, to terminal 9 on the S8600 module. Verify that this cable has been  
routed under the burners and that the other end is plugged onto the pilot assembly electrode.  
G. Complete Installation  
Follow the instructions that start on page 1 of this manual to complete boiler installation.  
53  
FIGUREA3: TAPPING LOCATIONS (SEE TEXT FOR TAPPING USES)  
54  
Manufacturer of Hydronic Heating Products  
P.O. Box 14818 3633 I. Street  
Philadelphia, PA 19134  

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