CWI Series
Gas-Fired Natural Draft Water Boilers INSTALLATION INSTRUCTIONS
Models
These instructions must be affixed on or adjacent to the boiler
I Product Description
Table of Contents
II Specifications
FIGURE 1 CWI BOILERS - GENERALCONFIGURATION
TABLE 1 CWI SPECIFICATIONS
IV Locating the Boiler
III Before Installing
V Air for Combustion and Ventilation
For Buildings of Other than Unusually Tight Construction
ForBuildingsofUnusuallyTightConstruction
Example
FIGURE3BOILERINSTALLEDINCONFINEDSPACE, ALL AIR FROM INSIDE
FIGURE 4 ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC
FIGURE 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
FIGURE 9 VENT DAMPER INSTALLATION DETAILS
FIGURE8 CWI BOILERTYPICALVENTSYSTEM INSTALLATION AND COMPONENTS
VII Gas Piping
VIII System Piping
StandardPiping
DANGER
Piping for Special Situations
1413
BOILERSIDEPIPING
FIGURE 11 STANDARD BOILER PIPING FIGURE 12 INDIRECT WATER HEATER
FIGURE13 BOILERBYPASSPIPING
FIGURE15 BOILERPIPINGWITHCHILLER
FIGURE14 ISOLATIONOFBOILERFROMSYSTEMWITHAHEATEXCHANGER
IX TANKLESS HEATER PIPING
A mixing valve does not eliminate the risk of scalding
Feel water before showering or bathing
FIGURE 17TANKLESSHEATERPIPING
SingleZoneWiring
IX Wiring
FIGURE 20 WIRING DIAGRAM, STANDING PILOT WITH TANKLESS HEATER
Wiring Variations
FACTORY BOILER WIRING NOT SHOWN - SEE FIGURES 18
FIGURE 22 CIRCULATOR ZONEWIRING USING HONEYWELLR845As
FIGURE23ZONEWIRINGUSINGHONEYWELLV8043FZONEVALVES
FACTORYWIRING NOT SHOWN - SEE FIGURES 18
CWI Control System - Sequence of Operation
Sequence of Operation, Standing Pilot, Less Tankless Heater
Sequence of Operation, Standing Pilot, With Tankless Heater
Sequence of Operation, Intermittent Ignition, With Tankless Heater
Sequence of Operation, Intermittent Ignition, Less Tankless Heater
Safety Control Operation - Standing Pilot and Intermittent Ignition
XI Start-up and Checkout
FIGURE 24 STANDING PILOT BURNER FLAME
2726
Page
Page
LIGHTING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING
TO TURN OFF GAS TO APPLIANCE
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL
LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERTSHAW
FOR YOUR SAFETY READ BEFORE LIGHTING
7000ERHC SERIES GAS VALVES STANDING PILOT
LIGHTING INSTRUCTIONS
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE LIGHTING
TO TURN OFF GAS TO APPLIANCE
VR8204 AND VR8304 SERIES GAS VALVES INTERMITTENT PILOT
FOR YOUR SAFETY READ BEFORE LIGHTING
7000DERHC SERIES GAS VALVES INTERMITTENT PILOT
OPERATING INSTRUCTIONS
TO TURN OFF GAS TO APPLIANCE
FIGURE 28b GASVALVEDETAIL-ROBERTSHAW 7000DERHC INTERMITTENT IGNITION
FIGURE 27a GASVALVEDETAIL-HONEYWELLVR8200ORVR8300STANDINGPILOT
XI Service and Maintenance
Heat Exchanger Cleaning Procedure
XIII Troubleshooting
C1&C2?
START
National Fuel Gas Code
5&6 on
START
L2 ?
National Fuel Gas Code
C1&C2?
T&TV?
C2 and
Caution Read page 36 before attempting to use this chart
Standing Pilot Ignition System Troubleshooting Chart
Intermittent Ignition System Troubleshooting Chart
Caution Read page 36 before attempting to use this chart
START
XIV PARTS
Page
1/4 Pilot Tubing Used with Robertshaw Valves
These Valves Piped in Series to Provide Redundent Shut-off
KEY #
40mm BURNERS ONLY
Page
KEY #
Page
A. Before Installing
Appendix A Knockdown Boiler Assembly Instructions
B. BaseAssembly Preparation
C. Heat Exchanger and Flue Collector Installation
FIGUREA1 BASE, HEAT EXCHANGER, FLUE COLLECTORASSEMBLY
E. Control and Trim Installation
D. Gas Valve Installation
FIGURE A2 JACKET INSTALLATION
G. Complete Installation
F. Electrical Wiring Connections
FIGURE A3 TAPPING LOCATIONS SEE TEXT FOR TAPPING USES
P.O. Box
Manufacturer of Hydronic Heating Products
3633 I. Street
Philadelphia
