Crown Boiler CWI069 User Manual

1D E S I G N E D T O L E A DTel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.comManufacturer of Hydronic Heating Pro

109sealed tight.13) Do not install the vent damper in any portion of the vent system which is used by appliances other than the boiler beinginstalled.

1110 FIGURE 8: CWI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS FIGURE 9: VENT DAMPER INSTALLATION DETAILS

1211*VII Gas PipingGas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at a line pressurebet

1312VIII System PipingStandard PipingFigure 11 shows typical boiler system connections on a single zone system. Additional information on hydronic sy

146) Low Water Cut-Off (Required in some situations) - A low water cutoff is required when the boiler is installed aboveradiation. In addition, some

1514 FIGURE 12: INDIRECT WATER HEATER BOILER SIDE PIPING FIGURE 11: STANDARD BOILER PIPING

165) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler and chiller in parallel as shown inFigure 15. Use i

17 FIGURE 15: BOILER PIPING WITH CHILLER FIGURE 14: ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER16

1817IX TANKLESS HEATER PIPINGIf the CWI is installed with an optional tankless heater, pipe the heater as shown in Figure 17. The components in thissy

19183) Pressure Relief Valve (Required) - Limits the pressure in the tankless heater and piping. Use an ASME constructed valvedesigned for domestic wa

2Table of ContentsI. Product Description ... 1II. Specifications ...

20IX WiringSingle Zone Wiring1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 vol

2120 FIGURE 19: WIRING DIAGRAM, INTERMITTENT IGNITION (EI) SYSTEM LESS TANKLESS HEATER FIGURE 20: WIRING DIAGRAM, STANDING PILOT WITH TANKLESS H

2221 FIGURE 21: WIRING DIAGRAM, INTERMITTENT IGNITION (EI) SYSTEM WITH TANKLESS HEATERWiring Variations1) Multiple Circulator Zones – Figure 22 sh

2322FIGURE 23: ZONE WIRING USING HONEYWELL V8043F ZONE VALVES(FACTORY WIRING NOT SHOWN - SEE FIGURES 18 - 21)FIGURE 22: CIRCULATOR ZONE WIRING USING

2423CWI Control System – Sequence of Operation(Refer to Figures 18 - 21 for ladder and connection diagrams)Sequence of Operation, Standing Pilot, Less

2524Sequence of Operation, Intermittent Ignition, Less Tankless Heater1) When the boiler is energized, 24 volts is immediately applied to terminals

26XI Start-up and CheckoutUse the following procedure for initial start-up of the boiler:1) Make sure that the boiler and system are filled with wate

27WARNING• NEVER USE A FLAME TO CHECK FOR GAS LEAKS.• MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBL

282715) Check the manifold pressure and adjust if necessary. To do this, use the following procedure:a) Connect a manometer to the inlet pressure tap

292816) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. For standing pilot boilermodels, pilot burne

3TABLE 1: CWI SPECIFICATIONS2II SpecificationsFIGURE 1: CWI BOILERS - GENERAL CONFIGURATIONINPUT(MBH) (MBH)(Gal/min)"A" "B" "

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

3130A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly.B. BEFORE LIG

3231A. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.B. BEF

3332A. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.B. BEF

34 FIGURE 28a: GAS VALVE DETAIL - HONEYWELL VR8204 AND VR8304 (INTERMITTENT IGNITION) FIGURE 27a: GAS VALVE DETAIL - HONEYWELL VR8200 OR VR830

3534XI Service and MaintenanceThe following routine maintenance should be performed on an annual basis:1) Turn off electrical power and gas supply to

36Heat Exchanger Cleaning Procedure1) Turn off electrical power and gas supply to the boiler.2) Disconnect the damper and vent connector from the boil

3736XIII TroubleshootingThe following pages contain troubleshooting charts for use in diagnosing control problems. To use these charts, go tothe box

38Troubleshooting Chart for CWI Boilers Without Tankless HeatersCaution: Read page 36 before attempting to use this chart37Boiler Equipped With Dampe

3938Main burners light?24 volts across B1 &B2 ?Ref er to standing pilot or intermittent ignition troubleshooting chart (page 41 or 42).*Def ective

43III Before Installing1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance

4039Troubleshooting Chart for CWI Boilers Equipped with Tankless Heaters and DampersCaution: Read page 36 before attempting to use this chartNo call f

4140120 volts across terminals at circulator?Do bur ner sshut dow n before gage temp exceeds high limit setting +15F?Circulator start?120 volts at C1&

42Standing Pilot Ignition System Troubleshooting ChartPilot lit?Main burners light?YTurn control on gas valve to PILOT. Depress red button and light

4342Does spark stop when pilot lights?24 volts across terminals 2&3 at S8600?Spark across ignitor/sensor gap?YCan you hear sparking?*Faulty S8600

4443XIV PARTS The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area Crownrepresent

4544

464569 103 138 172 207 241 276310 345 37942 1" BURNER LESS PILOT BRACKET 150501 2 ea. 4 ea. 6 ea. 8 ea. 11 ea. 13 ea. 15 ea. 17 ea. 20 ea. 22 ea.

4746

484769 103 138 172 207 241 276310 345 37975 LEFT SIDE JACKET PANEL 1 ea. 850301 850301 850301 850301 8503012 8503012 8503012 8503015 8503015 850301576

4948

54• If the right side 24” service clearance is reduced, adequate clearance must be maintained to easily read and access thecontrols. Alternatively, ac

50A. Before Installing1) Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs orpunctures

5150FIGURE A1: BASE, HEAT EXCHANGER, FLUE COLLECTOR ASSEMBLY

52side 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 righ

5352FIGURE A2: JACKET INSTALLATION

54F. Electrical Wiring Connections(Also refer to wiring diagrams in Part X of the installation manual)1) A pre-wired limit control (L8148E or L8124E)

5554FIGURE A3: TAPPING LOCATIONS (SEE TEXT FOR TAPPING USES)

56Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.comManufacturer of Hydronic Heating ProductsP.O. Box 14818 3633 I. StreetPhiladelph

6• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates andfloors, between wall-ceiling joints

76 FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILAT

8 FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL D

98• 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 t