Crown Boiler CWI276, CWI172, CWI345, CWI310, CWI103 III Before Installing, IV Locating the Boiler

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IIIBefore Installing

IIIBefore 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 By A Licensed 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.

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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