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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-1”BURNERS
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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