Crown Boiler CWI379, CWI172, CWI345 D. Gas Valve Installation, E. Control and Trim Installation

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side 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 right side.

6)Attach the front corners of the diverter panel to the side jacket panels using #10 sheet metal screws.

7)Install the horizontal (angle) jacket clips in the front edge of the side jacket panels. Slide this clip through the rectangular slot that is about halfway up the front edge of the side jacket panels and secure with the 8-32 self tapping screws provided.

8)Slip the Vertical Jacket Clip through the rectangular slot that is near the bottom of the front edge of the side jacket panels. Secure with the 8-32 sheet metal screws provided.

9)Install the top jacket panel. Use #10 sheet metal screws to attach it to the rear jacket panel and the top-front corners of the side panels.

10)Install the upper-front jacket panel. Insert the flange on the top of this panel under the top panel. Run two #10 sheet metal screws into the horizontal jacket clips through the holes in the bottom of this panel.

11)Attach the door knobs to the Lower-Front Panel using 8-32 x 1/2 machine screws.

12)The labels have been applied at the factory. Verify the location of the labels according to the list below:

a)Clearance Label - Located on the top jacket panel.

b)Lighting Instructions - Located on the lower left corner of the right side panel next to the gas manifold

c)Lowest Permissible Water Level Plate - Located next to the bottom water gauge tapping.

d)Blow Down Card - Located just above the "Lowest Permissible" Water Level Plate

e)Wiring Diagram - Located on the inside of the removable door

f)"CROWN" Nameplate - Located on the top center of the outside of the removable door

g)Rating Plate - Located on the upper left of the right side panel

D.Gas Valve Installation

1)The gas valve assembly has been pre-piped with one half of a piping union and is to be connected to the other half of the union located on the gas manifold.

2)Connect the pilot tubing from the pilot burner to the gas valve pilot tapping.

3)Connect the thermocouple lead to the gas valve (standing pilot boilers only).

E. Control and Trim Installation

(Refer to Figure A3 for Tapping Locations)

1)Install the tankless heater or blank cover plate on the opening on the right side of the heat exchanger using the gasket and 3/8 bolts provided.

2)Install the high limit well in the tapping in the tankless heater or cover plate.

3)Mount the limit control (L8148E or L8124E) onto the control well. Be sure that the temperature sensing bulb is bottomed out in the well. Tighten the screw on the bottom of the control so that it is securely clamped onto the well.

4)Install a 1/2 x 1/4 bushing and the tridicator gauge into tapping “C”. Tighten with wrench applied to the square shank on the back of the gauge. Do not apply pressure on the gauge case since this may ruin the calibration of the gauge.

5)Install relief valve (spindle must be in vertical position) into tapping “H” on the boiler left side (See Figure 1 in the installation manual) using the ¾” NPT nipples and elbow supplied. Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. The safety valve discharge piping must be in an area where it is not likely to become plugged by debris or subjected to freezing.

6)Install the 1-1/2 return piping and circulator in tapping “D”. See Section VIII System Piping in the installation manual for instructions on completing the piping of this boiler.

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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