Crown Boiler CWD060 Specifications

Manufacturer of Hydronic Heating ProductsP.O. Box 14818 3633 I. StreetPhiladelphia, PA 19134Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.cro

88FIGURE 6: ALL AIR FROM OUTSIDE USING OPENINGS INTO BOILER ROOMFIGURE 7: ALL AIR FROM OUTSIDE USING HORIZONTAL DUCTS INTO BOILER ROOM

99VI VentingWARNINGFailure to vent this boiler in accordance with these instructions could result in unreliable boiler operation, severe damage to th

1010TABLE 3a: SUMMARY OF HORIZONTAL VENTING OPTIONS VENT OPTION # 12345CLASSIFICATION USED IN THIS MANUALHORIZONTAL DIRECT VENTHORIZONTAL DIRECT VENT(

1111FIGURE 8a: HORIZONTAL DIRECT VENTING USING SEPARATE TERMINALS (VENT OPTIONS 1-2)FIGURE 8b: HORIZONTAL DIRECT VENTING USING COAXIAL TERMINAL (VENT

1212FIGURE 9: HORIZONTAL DIRECT EXHAUST VENT SYSTEM (VENT OPTIONS 4,5) 2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air i

13133) Permitted Terminals for Horizontal Venting (Vent Options 1 - 5) - Table 3a shows permitted types of terminals for both the vent and air inle

1414TABLE 3b: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # 678910CLASSIFICATION USED IN THIS MANUALVERTICALDIRECT VENTVERTICAL DIRECT VENT(RESERV

1515FIGURE 10: VERTICAL NON-COAXIAL DIRECT VENT SYSTEM (VENT OPTIONS 6, 7)FIGURE 11: VERTICAL DIRECT EXHAUST SYSTEM (VENT OPTIONS 9, 10)

1616TABLE 3c : SUMMARY OF VERTICAL COAXIAL VENTING OPTIONS VENT OPTION # 11 12 13CLASSIFICATION USED IN THIS MANUALVERTICAL COAXIALDIRECT VENTVERTICAL

1717FIGURE 12: VERTICAL COAXIAL DIRECT VENT USING CROWN #500005 VENT KIT (VENT OPTION 11)FIGURE 13: VERTICAL COAXIAL DIRECT VENT USING HEAT FAB SAF-

2TABLE OF CONTENTSI Product Description 1II Specifi cations 1III Before Installing 2IV Locating the Boiler 2V Air for Combustion and Ventilation 4VI Ve

1818TABLE 4: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTSMANUFACTURER VENT SYSTEM SIZECONDENSATE TRAPWALL THIMBLESHORIZONTAL TERMINATIONVERT

1919 12) Vertical and horizontal sections of piping must be properly supported. See vent system manufacturer’s instructions for more information.

2020FIGURE 15a: LOCATION OF DIRECT VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADEFIGURE 14: HORIZONTAL TERMINAL OFFSETS

2121FIGURE 15b: LOCATION OF DIRECT EXHAUST TERMINAL RELATIVE TO WINDOWS, DOORS, GRADEFIGURE 15c: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FO

2222FIGURE 16: USE OF CONDENSATE TRAPSC. Vent / Intake System Assembly 1) General Assembly Notes:a) Where the use of “silicone” is called for in the f

2323TABLE 6: FAN OUTLET ORIFICEBOILER MODELORIFICEPART #CWD060 620133CWD083 650136CWD110 620135CWD138 620136CWD165 620137CWD193 620138CWD220 620139CWD

2424FIGURE 18a: CROWN COAXIAL TERMINAL EXPLODED VIEWFIGURE 18b: CROWN COAXIAL TERMINAL ASSEMBLY

2525 j) Attach the intake tee to the end of the straight section protruding from the inside wall. Use the procedure described in (d) to clean

2626 5) Assembly of Z-Flex Z-Vent III:a) General Notes:• Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24

2727 6) Assembly of Heat Fab Saf-T Vent EZ Seal:a) Saf-T Vent General Notes: These instructions cover the installation of Saf-T Vent EZ Seal. Saf-

11I Product DescriptionThe CWD series boiler is a cast iron gas fi red boiler designed for use in forced hot water heating systems. It is is a low pre

2828manufacturer’s instructions before operating the boiler.7) Assembly of Heat Fab Saf-T Vent SC - On CWD Boiler installations where Saf-T Vent SC

29298) Assembly of Protech FasNSeal a) FasNSeal General Notes:• Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting oth

303011) Assembly of Vertical Coaxial Vent System Using Crown #500005 Coaxial Vent Kit (Vent Option #11)a) Start by installing the “B” vent piping. Ins

3131FIGURE 23: INSTALLATION OF VENT SUPPORT PROVIDED IN CROWN #500005 VERT. COAXIAL VENT KITFIGURE 24: CONDENSATE TRAP/DRAIN DETAIL

3232VII Gas PipingGas piping to the boiler must be sized to deliver adequate gas for the boiler to fi re at the nameplate input at a line pressure betw

3333VIII System PipingCAUTION• Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc)

34348) Flow control valve (Required under some conditions) – The fl ow control valve prevents fl ow through the system unless the circulator is operat

3535FIGURE 26: BASIC PIPINGFIGURE 27: INDIRECT WATER HEATER BOILER-SIDE PIPING

3636FIGURE 28: BYPASS PIPINGFIGURE 29: ISOLATION OF BOILER FROM SYSTEM WITH HEAT EXCHANGER

3737FIGURE 30: CHILLER PIPING

22III Before Installing1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordan

3838IX Wiring The CWD Series boiler is offered with two different types of control systems:• CB502 Control System

3939FIGURE 31: CB502 CONTROL SYSTEM - SINGLE ZONE FIELD WIRINGFIGURE 32: CB502 CONTROL SYSTEM - FACTORY SWITCH / JUMPER CONFIGURATION

4040 B. CB502 System - Wiring Variations1) Two Circulator Zones – Figure 33 shows wiring for two circulator zones. The second zone may be either an i

4141FIGURE 33: CB502 CONTROL SYSTEM - FIELD WIRING FOR TWO CIRCULATOR ZONES FIGURE 34: CB502 CONTROL SYSTEM - FIELD WIRING FOR HYBRID CIRCULATOR/ZONE

4242FIGURE 35: CB502 CONTROL SYSTEM - INTERNAL LADDER DIAGRAM

4343FIGURE 36: CB502 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM

4444D. R8285 Control System - Single Zone Wiring 1) Line Voltage (120 VAC) Connections (Fig 37) – The line voltage connections are located in the jun

4545FIGURE 38: R8285 CONTROL SYSTEM - FIELD WIRING FOR TWO CIRCULATOR ZONESFIGURE 37: R8285 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING

4646FIGURE 39: R8285 CONTROL SYSTEM - ZONE VALVE FIELD WIRINGFIGURE 40: R8285 CONTROL SYSTEM - INTERNAL LADDER DIAGRAM

4747FIGURE 41: R8285 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM

33FIGURE 2a: CLEARANCES WHEN BOILER IS DIRECT VENTED (OUTDOOR COMBUSTION AIR IS USED) FIGURE 2b: CLEARANCES WHEN COMBUSTION AIR IS OBTAINED FROM BOILE

4848X Start-up and CheckoutUse the following procedure for initial start-up of the boiler:1) Make sure that the boiler and system are fi lled with w

4949A. This appliance is equipped with an ignitiondevice which automatically lights the pilot.Do try to light the pilot by hand.B. BEFORE LIGHTING sme

505012) Check the manifold pressure and adjust if necessary. To do this, use the following procedure:a) Connect a manometer to the line pressure tap o

5151FIGURE 44: GAS VALVEFIGURE 45: MEASURING MANIFOLD PRESSURE

5252XI Service and MaintenanceThe following routine maintenance should be performed on an annual basis:1) Turn off electrical power and gas supply to

5353 Heat Exchanger Cleaning Procedure1) Turn off electrical power and gas supply to the boiler.2) Remove the burner tray. To do this:a) Remove the

545416) Set the fl ue collector onto the block and press down so that the fl ue collector is set into the silicone applied in the previous step.17) Slid

5555TABLE 7: PRESSURE SWITCH SETTINGSALTITUDE CROWN PNMAKE SETTING* (inches w.c.)BREAK SETTING* (inches w.c.)SEA LEVEL - 5200 ft 620009 1.26 1.16ABOVE

5656FIGURE 46b: MEASURING PRESSURE ACROSS PRESSURE SWITCH

5757 XII TroubleshootingThe following pages contain troubleshooting charts for use in diagnosing control problems. If troubleshooting a CB502 contr

44TABLE 2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTIONTYPE OF VENT PIPE PIPE DIRECTION ENCLOSUREMINIMUM CLEARANCETO COMBUSTIBLE MATERIALH

5858120 volts across black and white transformer primary leads ? Call from "HEAT 1" zone"HEAT 1"Circulator start?* Power off

5959NYYCall for heat from "DHW/H2" zone"DHW/H2" circulator start?Defective CB502 boardDHW LED On?24V across "DHW/H2" T a

6060120 volts present?* Loose connection at fan plug or fan capacitor* Defective capacitor* Defective fan24 volts present across yellow transformer l

6161Wait 30 seconds (prepurge)*Loose harness*Defective CB502 board*Loose, leaking, blocked, or reversed pressure switch tubes*Leaks in flue collect

6262120 volts across black and white transformer primary leads on back of R8285 ? Thermostat calls for heatCirculator start?* Power off * Blo

6363Pilot light?24 volts between 24V and 24V (GND) on ign. module?See "Intermittent Ignition System Troubleshooting Chart" on page 64.Minim

6464Does spark stop when pilot lights?24 volts across terminals PV & MV/PV at module?Pulsing Spark across ignitor/sensor gap?Y* Module is in soft

6565XIII PARTSThe following parts may be obtained from any Crown distributor. To fi nd the closest Crown distributor, consult the area Crown representa

6666BLOCK, BASE, FLUE COLLECTOR COMPONENTSKEY DESCRIPTIONPART # OR QTY.PART # OR QTY.CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD2451 BASE 1 6

6767

55Step 2: Determine whether the boiler is to be installed in a confi ned space A confi ned space is defi ned by the National Fuel Gas Code as having a v

6868BURNER TRAY COMPONENTSKEY DESCRIPTIONPART# OR QTY.PART # OR QTY.CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD24550 FRONT FIREDOOR 1 620543

6969

7070JACKET COMPONENTSKEY DESCRIPTIONPART# OR QTYPART # OR QTYCWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD24580 VESTIBULE PANEL 1 620323 62032

7171

7272COMMON CONTROLS & TRIMKEY DESCRIPTIONPART# ORQTYPART # OR QTYCWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245* 1/8” SILICONE TUBING 14-

7373

7474Appendix A: Special Requirements For Side-Wall Vented AppliancesIn The Commonwealth of MassachusettsIMPORTANTThe Commonwealth of Massachusetts re

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

66Step 5: If Indoor Combustion Air is Used, Provide Air as Follows:1) Buildings of other than unusually tight construction: Unconfi ned Space–

77FIGURE 4: ALL AIR FROM OUTSIDE USING VENTILATED CRAWL SPACE AND ATTICFIGURE 5: ALL AIR FROM OUTSIDE USING VENTILATED ATTIC