Crown Boiler CWI Series, CWI172, CWI345, CWI310, CWI103, CWI276, CWI069, CWI241 Boilerbypasspiping

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FIGURE13: BOILERBYPASSPIPING

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

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Contents Gas-Fired Natural Draft Water Boilers INSTALLATION INSTRUCTIONS CWI SeriesModels These instructions must be affixed on or adjacent to the boilerTable of Contents I Product DescriptionFIGURE 1 CWI BOILERS - GENERALCONFIGURATION II SpecificationsTABLE 1 CWI SPECIFICATIONS III Before Installing IV Locating the BoilerV Air for Combustion and Ventilation ForBuildingsofUnusuallyTightConstruction For Buildings of Other than Unusually Tight ConstructionExample FIGURE 4 ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE3BOILERINSTALLEDINCONFINEDSPACE, ALL AIR FROM INSIDEFIGURE 5 ALL AIR FROM OUTDOORS VIA VENTILATED ATTIC FIGURE 6 ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM VI Venting Removing an Existing Boiler from a Common Chimney FIGURE8 CWI BOILERTYPICALVENTSYSTEM INSTALLATION AND COMPONENTS FIGURE 9 VENT DAMPER INSTALLATION DETAILSVII Gas Piping StandardPiping VIII System PipingDANGER 1413 Piping for Special SituationsFIGURE 11 STANDARD BOILER PIPING FIGURE 12 INDIRECT WATER HEATER BOILERSIDEPIPINGFIGURE13 BOILERBYPASSPIPING FIGURE14 ISOLATIONOFBOILERFROMSYSTEMWITHAHEATEXCHANGER FIGURE15 BOILERPIPINGWITHCHILLERIX TANKLESS HEATER PIPING Feel water before showering or bathing A mixing valve does not eliminate the risk of scaldingFIGURE 17TANKLESSHEATERPIPING IX Wiring SingleZoneWiringFIGURE 20 WIRING DIAGRAM, STANDING PILOT WITH TANKLESS HEATER Wiring Variations FIGURE 22 CIRCULATOR ZONEWIRING USING HONEYWELLR845As FACTORY BOILER WIRING NOT SHOWN - SEE FIGURES 18FIGURE23ZONEWIRINGUSINGHONEYWELLV8043FZONEVALVES FACTORYWIRING NOT SHOWN - SEE FIGURES 18Sequence of Operation, Standing Pilot, Less Tankless Heater CWI Control System - Sequence of OperationSequence of Operation, Standing Pilot, With Tankless Heater Sequence of Operation, Intermittent Ignition, Less Tankless Heater Sequence of Operation, Intermittent Ignition, With Tankless HeaterXI Start-up and Checkout Safety Control Operation - Standing Pilot and Intermittent Ignition2726 FIGURE 24 STANDING PILOT BURNER FLAMEPage Page FOR YOUR SAFETY READ BEFORE OPERATING LIGHTING INSTRUCTIONSTO TURN OFF GAS TO APPLIANCE LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELLLIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW FOR YOUR SAFETY READ BEFORE LIGHTING7000ERHC SERIES GAS VALVES STANDING PILOT FOR YOUR SAFETY READ BEFORE LIGHTING OPERATING INSTRUCTIONSTO TURN OFF GAS TO APPLIANCE VR8204 AND VR8304 SERIES GAS VALVES INTERMITTENT PILOT7000DERHC SERIES GAS VALVES INTERMITTENT PILOT FIGURE 27a GASVALVEDETAIL-HONEYWELLVR8200ORVR8300STANDINGPILOT FIGURE 28b GASVALVEDETAIL-ROBERTSHAW 7000DERHC INTERMITTENT IGNITIONXI Service and Maintenance Heat Exchanger Cleaning Procedure XIII Troubleshooting START C1&C2?5&6 on National Fuel Gas CodeSTART L2 ?T&TV? C1&C2?C2 and Standing Pilot Ignition System Troubleshooting Chart Caution Read page 36 before attempting to use this chartIntermittent Ignition System Troubleshooting Chart XIV PARTS Page 1/4 Pilot Tubing Used with Robertshaw Valves These Valves Piped in Series to Provide Redundent Shut-off40mm BURNERS ONLY Page KEY # Page Appendix A Knockdown Boiler Assembly Instructions A. Before InstallingB. BaseAssembly Preparation C. Heat Exchanger and Flue Collector InstallationFIGUREA1 BASE, HEAT EXCHANGER, FLUE COLLECTORASSEMBLY D. Gas Valve Installation E. Control and Trim InstallationFIGURE A2 JACKET INSTALLATION F. Electrical Wiring Connections G. Complete InstallationFIGURE A3 TAPPING LOCATIONS SEE TEXT FOR TAPPING USES 3633 I. Street P.O. BoxPhiladelphia