Crown Boiler CWI207, CWI172, CWI345, CWI310 Standing Pilot Ignition System Troubleshooting Chart

Page 42
Standing Pilot Ignition System Troubleshooting Chart

Standing Pilot Ignition System Troubleshooting Chart

START

(24 VOLTS PRESENT ACROSS TH AND TR ON GAS VALVE, BUT MAIN BURNERS DO NOT LIGHT)

Caution: Read page 36 before

attempting to use this chart

 

 

 

 

Y

Ensure knob

 

 

 

Main

 

Y

 

 

Does pilot

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pilot lit?

 

 

 

on gas valve is

 

 

 

burners

 

 

 

 

 

 

 

 

 

 

 

 

 

END

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

stay lit?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

set to ON

 

 

 

light?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Turn control on

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Loose

gas valve to

 

 

 

 

 

 

 

Turn control

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

thermocouple

PILOT. Depress

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

connection at

red button and

 

 

 

 

 

 

 

on gas valve

 

 

*Defective gas

 

 

 

 

 

 

 

 

 

 

gas valve.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

light pilot. Hold

 

 

 

 

 

 

 

to ON.

 

 

valve

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

button for at

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Defective

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

least one

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

thermocouple.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

minute.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Condensation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

Disconnect

 

 

 

 

 

quenching pilot.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

thermocouple from

 

 

 

 

 

*Low line

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

gas valve. Connect a

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does pilot

 

 

 

 

 

 

 

 

pressure.

 

 

 

 

 

 

 

 

Y

N

 

volt meter to the

 

 

 

 

 

Does pilot

 

 

 

 

 

 

 

 

 

stay lit when

 

thermocouple. Light

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

light?

 

 

 

 

 

 

red button is

 

 

 

 

 

 

 

the pilot and hold

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

released?

 

 

 

 

 

 

down the red button

 

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

while reading the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

voltage across the

 

 

 

 

 

 

 

 

Line pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

thermocouple.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

within the range

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

indicated on

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

boiler's rating

 

 

 

 

 

 

 

 

 

 

 

Is voltage at

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

plate?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

least 18mV?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

Consult gas

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

supplier.

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Pilot tubing

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

blocked, kinked

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

or leaking

 

 

 

 

 

*Defective thermocouple

 

 

 

 

 

*Loose or defective

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

thermocouple

 

 

 

*Pilot orifice

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Pilot improperly

 

 

 

 

 

 

 

 

 

 

 

connection at gas valve

 

 

blocked

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

adjusted

 

 

 

 

 

 

 

 

 

 

 

*Defective gas valve

 

 

 

*Gas line not

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Pilot tube blocked, kinked, or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

purged of air

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

leaking

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Pilot improperly

 

 

 

 

 

*Pilot orifice partially plugged

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

adjusted.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

42

41

Image 42
Contents Models Gas-Fired Natural Draft Water Boilers INSTALLATION INSTRUCTIONSCWI Series These instructions must be affixed on or adjacent to the boilerTable of Contents I Product DescriptionII Specifications FIGURE 1 CWI BOILERS - GENERALCONFIGURATIONTABLE 1 CWI SPECIFICATIONS III Before Installing IV Locating the BoilerV Air for Combustion and Ventilation For Buildings of Other than Unusually Tight Construction ForBuildingsofUnusuallyTightConstructionExample FIGURE3BOILERINSTALLEDINCONFINEDSPACE, ALL AIR FROM INSIDE FIGURE 4 ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTICFIGURE 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 VIII System Piping StandardPipingDANGER 1413 Piping for Special SituationsFIGURE 11 STANDARD BOILER PIPING FIGURE 12 INDIRECT WATER HEATER BOILERSIDEPIPINGFIGURE13 BOILERBYPASSPIPING FIGURE14 ISOLATIONOFBOILERFROMSYSTEMWITHAHEATEXCHANGER FIGURE15 BOILERPIPINGWITHCHILLERIX TANKLESS HEATER PIPING A mixing valve does not eliminate the risk of scalding Feel water before showering or bathingFIGURE 17TANKLESSHEATERPIPING IX Wiring SingleZoneWiringFIGURE 20 WIRING DIAGRAM, STANDING PILOT WITH TANKLESS HEATER Wiring Variations FIGURE23ZONEWIRINGUSINGHONEYWELLV8043FZONEVALVES FIGURE 22 CIRCULATOR ZONEWIRING USING HONEYWELLR845AsFACTORY BOILER WIRING NOT SHOWN - SEE FIGURES 18 FACTORYWIRING NOT SHOWN - SEE FIGURES 18CWI Control System - Sequence of Operation Sequence of Operation, Standing Pilot, Less Tankless HeaterSequence 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 TO TURN OFF GAS TO APPLIANCE FOR YOUR SAFETY READ BEFORE OPERATINGLIGHTING INSTRUCTIONS LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELLFOR YOUR SAFETY READ BEFORE LIGHTING LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW7000ERHC SERIES GAS VALVES STANDING PILOT TO TURN OFF GAS TO APPLIANCE FOR YOUR SAFETY READ BEFORE LIGHTINGOPERATING INSTRUCTIONS 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 ?C1&C2? T&TV?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 These Valves Piped in Series to Provide Redundent Shut-off 1/4 Pilot Tubing Used with Robertshaw Valves40mm BURNERS ONLY Page KEY # Page B. BaseAssembly Preparation Appendix A Knockdown Boiler Assembly InstructionsA. Before Installing 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 P.O. Box 3633 I. StreetPhiladelphia