Crown Boiler CWD110, CWD083, CWD220, CWD060, CWD165, CWD138, CWD193 Heat Exchanger Cleaning Procedure

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Heat Exchanger Cleaning Procedure

WARNING

Soot deposits in the flue passages are a sign that the boiler may be operating at high carbon monoxide (co) levels. After cleaning the boiler of soot deposits, check the CO level in the flue gas to insure that the boiler is operating properly.

If it is necessary to check CO, use a combustion analyzer, or other instrument which is designed to measure CO in flue gas. A CO “sniffer” designed for testing CO levels in ambient air cannot be used to check boiler combustion. Take a flue gas sample by inserting a sample probe through the vent terminal. Do not take a sample until the boiler has been firing for at least five minutes.

A normal CO reading for an CWD series boiler is less than 50ppm (0.005%). A reading of more than 100ppm (0.01%) is indicative of a combustion problem.

Some causes of excessive CO include:

•Incorrectly sized or drilled burner orifice

•Partially plugged flue passages

•Improper manifold pressure

•Partial blockage of vent or intake system

•Foreign material in burner venturis or burner ports

•Missing regulator cover or disconnected regulator reference tube

•Damaged fan impeller or housing

•Damaged or missing fan gasket

•Leak in seal between flue collector and heat exchanger

•Distorted or missing combustion chamber floor

•Damaged base

•Flue gas leak in the concentric section of the coaxial terminal

1)Turn off electrical power and gas supply to the boiler.

2)Remove the burner tray. To do this:

a)Remove the intake cover.

b)Remove the four Allen head screws holding the elbow flange onto the gas valve.

c)Remove the three 10-32 screws holding the manifold gasket plate to the intake box.

d)Remove the four 5-16 nuts holding the burner tray in the boiler.

e)Carefully remove the burner assembly being careful not to damage the firedoor insulation or the manifold gasket.

3)Disconnect the vent system from the boiler by removing the four 10-32 screws holding the vent collar in place.

4)Remove the top jacket panel. If possible, remove the rear and left side jacket panels.

5)Unplug the fan and remove the fan cover plate.

6)Disconnect the pressure switch hoses.

7)Loosen the two ¼-20 nuts and washers in the flue collector lugs. Slide the flue collector lugs off of each flue collector flange.

8)Score the silicone seal around the flue collector with a utility knife or similar tool.

9)Pry the flue collector off of the heat exchanger, being careful not to damage the flue collector or fan.

10 Remove the stainless steel flue baffle from each flue passage.

11)Clean the flue passageways using a stiff bristle brush. Be certain that all foreign material is removed from the gaps between the pins.

12)Clean the bottom surfaces of the heat exchanger.

13)Put a light in the combustion chamber and look through the flue passages from the top to verify that they have been thoroughly cleaned.

14)Replace the flue baffles.

15)Apply a heavy (1/4”) bead of silicone with a temperature rating of at least 400F around the perimeter of the heat exchanger.

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Contents CWD Series Table of Contents II Specifications Product DescriptionIV Locating the Boiler III Before InstallingClearances When Combustion AIR is Obtained from Boiler Room Clearances from Vent Piping to Combustible Construction Air for Combustion and VentilationPage If Indoor Combustion Air is Used, Provide Air as Follows ALL AIR from Outside Using Ventilated Crawl Space and Attic ALL AIR from Outside Using Openings Into Boiler Room Vent System Design VI VentingSummary of Horizontal Venting Options Page Horizontal Direct Exhaust Vent System Vent Options 4,5 Page Summary of Vertical Venting Options Vertical NON-COAXIAL Direct Vent System Vent Options 6 Summary of Vertical Coaxial Venting Options Page Permissible Vent Systems and Principle Vent Components Vent Fitting Removing an Existing Boiler From a Common ChimneyAIR Intake Fitting Horizontal Terminal Offsets Positioning Vent Terminal Under Overhangs USE of Condensate Traps Vent / Intake System AssemblyFAN Outlet Orifice Crown Coaxial Terminal Exploded View CORR/GUARD Connection to Vent Collar Vent III Connection to Vent Collar SAF-T Vent Ezseal Connection to Vent Collar Fasnseal Connection to Vent Collar FSA-SWDW3 Page Condensate TRAP/DRAIN Detail GAS Connection to Boiler VII Gas PipingStandard Piping Viii System PipingPiping for Special Situations Basic Piping Bypass Piping Chiller Piping CB502 System Single Zone Wiring IX WiringCB502 Control System Single Zone Field Wiring CB502 Control System Sequence of Operation CB502 System Wiring VariationsCB502 Control System Field Wiring for TWO Circulator Zones CB502 Control System Internal Ladder Diagram CB502 Control System Internal Connection Diagram R8285 Control System Wiring Variations R8285 Control System Single Zone WiringR8285 Control System Sequence of Operation R8285 Control System Single Zone Field Wiring R8285 Control System Zone Valve Field Wiring R8285 Control System Internal Connection Diagram Start-up and Checkout For Your Safety Read Before Operating Pilot Burner Flame GAS Valve XI Service and Maintenance Heat Exchanger Cleaning Procedure Service Notes Pressure Switch Settings Measuring Pressure Across Pressure Switch XII Troubleshooting PWR DHW Limit 24V GND on ign. module? Thermostat calls for heat Circulator Pilot Main Start Xiii Parts BLOCK, BASE, Flue Collector Components Page Burner Tray Components Page Jacket Components Page Common Controls & Trim Page Page Page Crown

CWD193, CWD165, CWD245, CWD220, CWD110 specifications

Crown Boiler Company is well-known for its commitment to quality and performance in the heating industry. Among its extensive range of products, the Crown Boiler CWD series stands out for its reliability and efficiency. This series includes models CWD060, CWD083, CWD110, CWD138, and CWD220, each designed to meet diverse heating needs in residential and commercial applications.

One of the main features of the CWD series is its durable construction. Made with high-quality materials, these boilers are built to withstand the test of time. The cast iron heat exchanger delivers exceptional heat retention and efficiency, ensuring optimal performance even in demanding conditions. Additionally, the CWD models are equipped with a reliable standing pilot ignition system, which enhances user safety and operational reliability.

Another important characteristic of the Crown CWD series is its versatility in fuel options. These boilers can operate on either natural gas or propane, providing flexibility to homeowners and businesses depending on their preferred energy source. The ability to easily switch fuels makes these units adaptable to various heating applications, maximizing convenience for users.

Efficiency is a cornerstone of the Crown Boiler CWD series. With an AFUE rating of up to 85%, these boilers deliver substantial cost savings over the heating season. Their efficient operation not only lowers energy bills but also contributes to a reduced environmental impact, which is increasingly important in today’s energy-conscious world.

Crown’s innovative design features also include a low water cut-off and a built-in draft hood. The low water cut-off ensures safe operation by preventing the boiler from running dry, while the draft hood allows for optimal venting capabilities, minimizing the risk of dangerous flue gas build-up.

Maintenance is straightforward with the CWD series, thanks to its easy-access design. Routine service and inspections can be performed with minimal disruption, ensuring that the units maintain peak performance over their lifespan.

The Crown Boiler CWD060, CWD083, CWD110, CWD138, and CWD220 models exemplify the brand’s dedication to delivering high-quality heating solutions. With their impressive efficiency ratings, durable construction, versatile fuel options, and user-friendly features, these boilers represent a smart investment for anyone looking to enhance heating reliability and comfort in their space.
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