Crown Boiler CWD220, CWD083, CWD110, CWD193, CWD245 User Manual

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CWD Series

Gas-Fired Direct Vent Hot Water Boilers INSTALLATION INSTRUCTIONS

These instructions must be afﬁ xed on or adjacent to the boiler

Models:

• CWD060

• CWD083

• CWD110

• CWD138

• CWD165

• CWD193

• CWD220

• CWD245

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualiﬁ ed installer, service agency or the gas supplier. Read these instructions carefully before installing.

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TABLE OF CONTENTS

I Product Description 1

II Speciﬁ cations 1 III Before Installing 2 IV Locating the Boiler 2

V Air for Combustion and Ventilation 4 VI Venting 9

Vent System Design 9 Vent System Assembly 22

VII Gas Piping 32

VIII System Piping 33

IX Wiring 38

CB502 Control System 38 R8285 Control system 44

X Start-up and Checkout 48 XI Service and Maintenance 52

XII Troubleshooting 57

XIII Parts 65

Appendix A:Special Requirements for Side-Wall Vented Appliances in the Commonwealth of Massachusetts

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I Product Description

The CWD series boiler is a cast iron gas ﬁ red boiler designed for use in forced hot water heating systems. It is is a low pressure boiler intended for use in closed heating systems with water temperatures under 240F. This boiler may be vented either vertically or horizontally with combustion air supplied from either outdoors or (under certain conditions) indoors. It is ideal for use in installations where a reliable source of clean indoor combustion air cannot be guaranteed.

II Speciﬁ cations

FIGURE 1: GENERAL CONFIGURATION

TABLE 1: SPECIFICATIONS

MODEL SECTIONS

CWD060 3 60 51 44 85.1 16-1/8 3 2.0 CWD083 4 82.5 71 62 85.1 19-3/4 3 2.6 CWD110 5 110 94 82 85.2 23-3/8 3 3.1 CWD138 6 137.5 118 103 85.2 27 3 3.6

CWD165 7 165 142 123 85.2 30-5/8 3 OR 4 4.2 CWD193 8 192.5 165 143 85.2 34-1/8 3 OR 4 4.7 CWD220 9 220 189 164 85.2 37-3/4 3 OR 4 5.2

CWD245 10 245 211 183 85.3 41-3/8 3 OR 4 5.8

INPUT (MBH)

DOE HTG.

CAPY (MBH)

I=B=R NET

RATING (MBH)

AFUE

(%)

FIG 1

DIM. “A” (in.)

VENT

DIA. (in.)

WATER

CONTENT

(Gal.)

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III Before Installing

1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and 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.

• 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).

2) Read Section VI to verify that the maximum combustion air and exhaust pipe lengths will not be exceeded in the planned installation. Also verify that the vent terminal can be located in accordance with Section VI.

3) Make sure that the boiler is correctly sized:

• For heating systems employing convection radiation (baseboard or radiators), use an industry accepted sizing method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics Institute in Berkely Heights, NJ.

• For new radiant heating systems, refer to the radiant tubing manufacturer’s boiler sizing guidelines.

• For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE Heating Capacity required for the Mega-Stor or the net rating required for the heating system, whichever results in the larger boiler.

• For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s instructions for boiler output requirements.

4) Make sure that the boiler received is conﬁ gured for the correct gas (natural or LP).

5) This boiler is not designed for use with return temperatures under 120F for a sustained period of time. Some systems, such as those having large water contents, may require a return water bypass or other special provisions to protect the boiler against low return temperatures. Failure to provide such provisions if needed could result in severe corrosion damage to the boiler. For more information on when low water temperatures protection is required, and appropriate protection, see Part VIII.

6) For installations at altitudes above 2000ft, special oriﬁ ce and pressure switches are required. Make sure that the boiler is conﬁ gured for use at the correct altitude.

NOTICE

This product must be installed by a licensed plumber or gas ﬁ tter when installed within the Commonwealth of Massachusetts.

See Appendix A for additional important information about installing this product within the Commonwealth of Massachusetts.

IV Locating the Boiler

1) Boiler clearances are shown in Figure 2. Figure 2a shows clearances from the boiler when outdoor combustion air is used. Figure 2b shows clearances from the boiler when combustion air is obtained from the boiler room. These minimum clearances apply to all types of combustible construction as well as noncombustible walls, ceilings and doors. At least 24” must be provided for servicing at the front of the boiler. This front clearance may be provided through a door, such as a closet door. Boiler will be much easier to service if at least 12” is provided from the sides and rear of the boiler to walls.

2) Clearances from venting to combustible material depends upon the type of venting, whether the vent pipe is enclosed, and whether the venting is vertical or horizontal. See Table 2 for vent clearance information.

3) Boiler may be installed on a non-carpeted combustible surface.

4) The relief valve must not be moved from the location shown in Figure 1.

5) When combustion air is obtained from the boiler room, a 10” clearance is required from the side of the boiler having the air inlet collar to combustible or non-combustible obstruction (Figure 2b).

6) The boiler should be located so as to minimize the length of the vent system.

7) Do not install this boiler in a location where gasoline or other ﬂ ammable vapors or liquids will be stored or used. Do not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop. When indoor combustion air is used, do not install in a location where sources of hydrocarbons will be stored or used. Some common sources of hydrocarbons include bleaches, fabric softeners, paints, cleaners, refrigerants, and cat boxes. Traces of these substances can be drawn into the boiler causing severe corrosion damage to the boiler and /or objectionable odors.

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FIGURE 2a: CLEARANCES WHEN BOILER IS DIRECT VENTED (OUTDOOR COMBUSTION AIR IS USED)

FIGURE 2b: CLEARANCES WHEN COMBUSTION AIR IS OBTAINED FROM BOILER ROOM

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TABLE 2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION

TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE

MINIMUM CLEARANCE

TO COMBUSTIBLE

MATERIAL

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

PROTECH FASNSEAL W2

METAL-FAB CORR/GUARD

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

Z-FLEX Z-VENT III

METAL-FAB CORR/GUARD

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

Z-FLEX Z-VENT III

METAL-FAB CORR/GUARD

PROTECH FASNSEAL W2 VERTICAL OR HORIZONTAL ENCLOSED ON ALL FOUR SIDES 3”

HEAT FAB SAF-T VENT SC VERTICAL OR HORIZONTAL

“B” VENT CHASE USED AS PART OF

CROWN COAXIAL VENT SYSTEM*

VERTICAL OR HORIZONTAL

HORIZONTAL OR VERTICAL

WITH OFFSETS

VERTICAL WITH NO OFFSETS ENCLOSED ON ALL FOUR SIDES

VERTICAL

AT LEAST ONE SIDE OPEN,

COMBUSTIBLE MATERIAL ON A

MAXIMUM OF THREE SIDES

ENCLOSED ON ALL FOUR SIDES

UNENCLOSED OR ENCLOSED ON

ALL SIDES

PER “B” VENT MANFACTUER’S

INSTRUCTIONS

1”

8”

6”

0”

REFER TO “B” VENT MANUFACTURER’S

INSTRUCTIONS

* “B” Vent is used as a chase to carry combustion air in this system - never attempt to vent a CWD boiler using “B” vent

V Air for Combustion and Ventilation

Sufﬁ cient fresh air must be supplied for both combustion and ventilation. In general, combustion air is obtained in one of

two ways:

• Direct Vent Installations – Combustion air is piped directly to the boiler inlet collar from the outdoors. This is also sometimes called a “sealed combustion” installation.

• Direct Exhaust Installations – Combustion air is obtained from the boiler room. In some cases, openings or duct work may be run from the outdoors to the boiler room, however the ducting is not connected directly to the boiler.

Air for ventilation is required to keep various boiler components from overheating and is always obtained from indoors. To

ensure an adequate combustion and ventilation air supply, perform the following steps:

Step 1: Determine whether the boiler is to be installed in a building of unusually tight construction

A good deﬁ nition of “unusually tight construction” is construction having all of the following features:

• Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed.

• Weather stripping has been added on openable windows and doors.

• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and ﬂ oors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other openings.

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Step 2: Determine whether the boiler is to be installed in a conﬁ ned space

A conﬁ ned space is deﬁ ned by the National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr

input of all appliances installed in that space. To determine whether the boiler room is a conﬁ ned space:

1) Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest 1000 BTU/ hr.

2) Find the volume of the room in cubic feet. The volume of the room in cubic feet is:

Length (ft) x width (ft) x ceiling height (ft)

In calculating the volume of the boiler room, consider the volume of adjoining spaces only if no doors are installed between

them. If doors are installed between the boiler room and an adjoining space, do not consider the volume of the adjoining space, even if the door is normally left open.

3) Divide the volume of the boiler room by the input in thousands of BTU/hr. If the result is less than 50, the boiler room is a conﬁ ned space.

Example:

A CWD245 and a water heater are to be installed in a room measuring 6ft – 3 in x 7ft with an 8 ft ceiling. The water heater

has an input of 30000 BTU/hr:

Total input in thousands of BTU/hr = (245000 BTU/hr + 30000 BTU/hr) / 1000 = 275 Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft 350/275 = 1.27. Since 1.27 is less than 50, the boiler room is a conﬁ ned space.

Step 3: Decide whether the boiler will be direct vented or direct exhausted

The boiler must be direct vented (combustion air piped directly to the boiler) if:

• The boiler is to be installed in a laundry room

• The building in which the boiler is installed has an indoor pool.

• The boiler is located in an area having any of the contaminants described in Section IV.

It is also strongly recommended that combustion air be piped from outside when the boiler is installed in a building of

unusually tight construction.

Step 4: If the boiler is Direct Vented, Provide Air as Follows (If Indoor Combustion Air is used,

Skip to Step 5):

1) Combustion air piping must not exceed the maximum lengths called for in Section VI.

2) Although combustion air is obtained directly from outdoors, openings may be required into the boiler room to allow for adequate equipment ventilation. The following guidelines apply regardless of whether or not the building is of unusually tight construction:

Unconﬁ ned Space– Natural inﬁ ltration into the boiler room will provide adequate air for ventilation without additional

openings into boiler room.

Conﬁ ned Space – Provide two openings into the boiler room, one near the ﬂ oor and one near the ceiling. The top edge of

the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the ﬂ oor (Fig 3). The minimum opening dimension is 3 inches.

• If the CWD boiler is the only gas-burning appliance in the boiler room, these openings must each have a free area of 100 square inches.

• If other gas-burning appliances are in the boiler room, size the openings in accordance with the appliance manufacturer’s instructions or the National Fuel Gas Code. Minimum opening free area is 100 square inches regardless of opening requirements for other appliances.

• If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per 1000 BTU/hr of total appliance input, install a pair of identical openings into a third room. Connect additional rooms with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input.

• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used, they must be no ﬁ ner than ¼” (4 x 4) mesh.

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Step 5: If Indoor Combustion Air is Used, Provide Air as Follows:

1) Buildings of other than unusually tight construction: Unconﬁ ned Space– Natural inﬁ ltration into the boiler room will normally provide adequate air for combustion and

ventilation without additional louvers or openings into boiler room.

Conﬁ ned Space – Provide two openings into the boiler room, one near the ﬂ oor and one near the ceiling. The top edge of

the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the ﬂ oor (Fig 3).

• Each opening must have a free area of 1 square inch per 1000 BTU/hr input of all gas burning appliances in the boiler room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per opening.

• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used, they must be no ﬁ ner than ¼” (4 x 4) mesh.

2) Buildings of unusually tight construction: If at all possible, direct vent the boiler. Where the boiler must be installed in unusually tight construction and cannot be

direct vented, openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl space, which communicates directly with the outdoors. Two openings are required. The top edge of the upper opening must be within 12 inches of the ceiling. The bottom edge of the lower opening must be within 12 inches of the ﬂ oor. Size openings and ducts as follows:

• Vertical ducts or openings directly outdoors (Fig 4, Fig 5, Fig 6) – Each opening must have a free cross sectional area of 1 square inch per 4000 BTU/hr of the total input of all gas-ﬁ red appliances in the boiler room but not less than 100 square inches. Minimum opening size is 3 inches.

• Openings to outdoors via horizontal ducts (Fig 7) - Each opening must have a free cross sectional area of 1 square inch per 2000 BTU/hr of the total input of all gas ﬁ red appliances in the boiler room but not less than 100 square inches. Minimum opening size is 3 inches.

• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used, they must be no ﬁ ner than ¼” (4 x 4) mesh.

FIGURE 3: BOILER INSTALLED IN A CONFINED SPACE - VENTILATION OR COMBUSTION / VENTILATION AIR FROM INSIDE

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FIGURE 4: ALL AIR FROM OUTSIDE USING VENTILATED CRAWL SPACE AND ATTIC

FIGURE 5: ALL AIR FROM OUTSIDE USING VENTILATED ATTIC

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FIGURE 6: ALL AIR FROM OUTSIDE USING OPENINGS INTO BOILER ROOM

FIGURE 7: ALL AIR FROM OUTSIDE USING HORIZONTAL DUCTS INTO BOILER ROOM

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VI Venting

WARNING

Failure to vent this boiler in accordance with these instructions could result in unreliable boiler operation, severe damage to the boiler or property, or unsafe operation:

* Do not attampt to vent this boiler with galvanized, PVC, or any other vent system not listed in Table 4. * Do not attempt to mix components from different approved vent systems. * Do not install a barometric damper or drafthood on this boiler. * Do not attempt to use the vent system for this boiler with any other appliance. * Moisture and ice may form on the surfaces around the vent termination. To prevent deterioration, surfaces should be in good repair (sealed, painted, etc.)

A. Vent System Design

There are three basic ways to vent the CWD boiler:

• Horizontal (“side wall”) Venting - Vent system exits the building through an outside wall. Combustion air is either

obtained through a separate pipe from outside (a “direct vent” installation) or obtained from the boiler room (a “direct exhaust” installation).

• Vertical Non-Coaxial Venting - Vent system exits the building through a roof. Combustion air is either obtained

through a separate pipe from outside (a “direct vent” installation) or obtained from the boiler room (a “direct exhaust” installation).

• Vertical Coaxial Venting - Vent system exits the building through a roof. A portion of the vent system is coaxial, meaning

that it consists of a “pipe within a pipe”. Flue gasses exit the building through the inner pipe and combustion air is drawn through the space between the two pipes.

For each of the above three basic methods, there are several variations, resulting in a total of 13 options for venting

the CWD boiler. A description of each of these venting options is listed in Tables 3a - 3c. For clarity, these vent options are numbered from 1 to 13 in Table 3. One of the vent option columns in Table 3 must match the planned vent and air intake system exactly. In addition, observe the following guidelines:

1) Approved vent systems - Use only one of the approved vent systems shown in Table 4. These systems are made of a special stainless steel alloy (AL29-4C) for protection against corrosive ﬂ ue gas condensate. They are also designed to provide a gas tight seal at all joints and seams so that ﬂ ue gas does not enter the building. Each approved vent system has unique method for installation - do not attempt to mix components from different vent systems. The only exceptions are:

• Heat Fab Saf-T Vent SC may be combined with Saf-T Vent EZ Seal.

• Protech FasNSeal W2 may be combined with Protech FasNSeal.

See the vent installation section of this manual for information on how this can be done. Heat Fab Saf-T Vent SC is a double wall vent system which can be used in two ways on CWD installations. In vertical

coaxial vent systems (Vent Options 12 and 13), the space between the inner and outer pipes is used as a conduit to bring combustion air to the boiler. In Horizontal (Vent Options 1 to 5) and Vertical (Option 6 to 10) vent systems, Saf-T Vent SC can be used to obtain a 0” clearance to combustible construction. When this is done, the space between the inner and outer pipes is used for ventilation, but boiler combustion air comes from elsewhere.

Protech FasNSeal W2 is also a double wall vent system. In some cases, it can used to obtain closer clearances to

combustible construction than are possible using Protech FasNSeal (see Table 2). The space between the inner and outer pipes on FasNSeal W2 cannot be used as a combustion air conduit.

The Crown Vertical coaxial vent system (Vent Option 11) is similar to that constructed using Heat Fab Saf-T Vent SC

except it is constructed by running one of the 3” single wall vent systems shown in Table 4 inside 5” type “B” vent. The space between the 3” vent and the “B” vent forms a conduit to bring combustion air to the boiler. The advantage of this system is that it can be constructed using any of the vent systems shown in Table 4 except for Heat Fab Saf-T Vent SC and Protech FasNSeal W2. No turns are permitted in the coaxial section of this system.

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TABLE 3a: SUMMARY OF HORIZONTAL VENTING OPTIONS

VENT OPTION # 12345

CLASSIFICATION USED IN THIS MANUAL

ILLUSTRATED IN FIGURE 8a OR 8b 8a OR 8b 9 9

HORIZONTAL DIRECT VENT

(RESERVED

FOR FUTURE

USE)

HORIZONTAL

DIRECT

EXHAUST

HORIZONTAL

DIRECT

EXHAUST

VENT PIPE STRUCTURE PENETRATION

AIR INTAKE PIPE STRUCTURE PENETRATION

VENT PIPE SIZE 3” 4” 3” 4” AIR INTAKE PIPE SIZE 4” 4” N.A. N.A.

CWD060 - CWD138 55 FT CWD165 35 FT CWD193 25 FT CWD220 15 FT

PIPE LENGTH

MAXIMUM VENT

MAXIMUM

INTAKE PIPE

EXHAUST TERMINAL

AIR INTAKE TERMINAL

VENT MATERIAL APPROVED VENT SYSTEM SHOWN IN TABLE 4 AIR INTAKE MATERIAL GALVANIZED OR PVC N.A. N.A.

CWD245 N.R. CWD060 - CWD138 60 FT 60 FT N.A. N.A.

CWD165 40 FT 60 FT N.A. N.A. CWD193 30 FT 60 FT N.A. N.A. CWD220 20 FT 60 FT N.A. N.A.

LENGTH

CWD245 N.R.

WALL WALL WALL WALL

WALL WALL N.A. N.A.

55 FT 55 FT 55 FT 55 FT 35 FT 55 FT 55 FT 25 FT 55 FT 55 FT 15 FT 55 FT

55FT 10 FT 55 FT

60 FT N.A. N.A.

3” 90 ELBOW,

TEE, OR CROWN

COAXIAL

TERMINAL

#50-003

4” 90 ELBOW

OR CROWN

COAXIAL

TERMINAL

#50-003

4” 90 ELBOW,

TEE, OR CROWN

COAXIAL

TERMINAL

#50-004

4” 90 ELBOW

OR CROWN

COAXIAL

TERMINAL

#50-004

3” 90 ELBOW

OR TEE

N.A. N.A.

4” 90 ELBOW

OR TEE

“N.R” - Not recommended “N.A.” - Not applicable

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FIGURE 8a: HORIZONTAL DIRECT VENTING USING SEPARATE TERMINALS (VENT OPTIONS 1-2)

FIGURE 8b: HORIZONTAL DIRECT VENTING USING COAXIAL TERMINAL (VENT OPTIONS 1-2)

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FIGURE 9: HORIZONTAL DIRECT EXHAUST VENT SYSTEM (VENT OPTIONS 4,5)

2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected, the vent pipe size, and the boiler size. See Table 3 for the maximum vent length. In addition to the maximum length of piping shown in Table 3, the following ﬁ ttings may also be used:

• Horizontal Vent Systems: One 90 deg. elbow

• Vertical Vent Systems: Two 90 deg. elbows

• Vertical Coaxial Vent Systems: Two 90 deg. elbows

• Air Intake Systems: Two 90 deg. elbows

If additional elbows are desired, the maximum allowable vent length must be reduced by the amount shown in Table 5 for

each additional elbow used. Note: Termination ﬁ ttings do not need to be counted when counting additional elbows.

Example:

A 3” vent system is planned for a horizontal direct vented CWD165 which has the following components: 2 ft vertical pipe

1 90 elbow 5 ft horizontal pipe 1 90 elbow 3 ft horizontal pipe 1 45 elbow 4 ft horizontal pipe 1 termination elbow

The Vent Option #1 column in Table 3a describes a horizontal direct vent system using 3” vent pipe. From this column, we

see that a CWD165 may vent length of up to 35ft. The ﬁ rst 90 elbow and the termination elbow are not considered. From Table 5, the equivalent length of the 3” 45 elbow is 4ft and the equivalent length of the 3” 90 degree elbow is 5.5ft. The maximum allowable run of straight pipe on this system is therefore:

35ft – 4 ft – 5.5ft = 25.5ft Since the planned installation has only 14 ft of straight pipe, the planned vent length is acceptable.

3) Minimum Vent / Exhaust Pipe Length - Minimum vent length is 2ft. Minimum air inlet length is 0ft.

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3) Permitted Terminals for Horizontal Venting (Vent Options 1 - 5) - Table 3a shows permitted types of terminals for both the

vent and air inlet systems. On horizontal direct vent systems using 4” air inlet pipe (Vent Options 1 and 2), the following Crown co-axial terminals may be used. These terminals have the advantage of requiring only one wall penetration. Part numbers for the Crown coaxial terminals are as follows:

• 3” Vent - 50-003

• 4” Vent - 50-004

When separate vent and air intake terminals are used, or when the boiler uses indoor combustion air, the vent terminal

is either a tee or an elbow supplied by the vent system manufacturer and equipped with a rodent screen. Vent system manufacturer’s part numbers for these ﬁ ttings are shown in Table 4. In some cases, the elbows and tees shown in Table 4 require separate adaptors and/or rodent screens. When this is the case, vent manufacturer part numbers for these additional parts are shown in Table 4 along with the termination ﬁ tting.

When Heat Fab Saf-T Vent SC is used, the Heat Fab 5300CI or 5400CI ﬁ tting is used between the last piece of Saf-T

Vent CI and the terminal. These ﬁ ttings physically adapt from the CI pipe to the terminal and also provide ventilation openings which must remain open for the Saf-T Vent CI to maintain its clearance rating.

Except when the Crown 50-003 or 50-004 coaxial terminals are used, the air intake ﬁ tting on a horizontal direct vent

system (Options 1 - 2) is always a 90 degree elbow with a rodent screen. This elbow is made out of the same material as the rest of the air inlet system (either galvanized or PVC) and is installed as shown in Figure 8a.

4) Horizontal vent terminal location - Observe the following limitations on the vent terminal location (also see Fig 15a - d):

• Direct exhaust installations (installations using indoor combustion air) - Exhaust terminal must be at least 4 feet below or 4 feet horizontally from any window, door, or gravity air inlet into the building.

• Direct vent installations – Exhaust elbow or coaxial terminal must be at least 1 foot from any door, window, or gravity inlet into the building.

• Direct vent installations using termination elbows – Maintain the correct clearance and orientation between the inlet and exhaust elbows. The elbows must be at the same level and their center lines must be between 12 and 36 inches apart.

• The bottom of the exhaust elbow, tee, or coaxial terminal must be at least 12” above the normal snow line. In no case should it be less than 12” above grade level.

• The bottom of the exhaust elbow, tee, or coaxial terminal must be at least 7 feet above a public walkway.

• The bottom of the exhaust elbow, tee, or coaxial terminal must be at least 3 feet above any forced air inlet located within 10 feet.

• A clearance of at least 4 feet horizontally or 4 feet vertically must be maintained between the exhaust terminal and gas meters, electric meters, regulators, and relief equipment.

• Do not locate the terminal under decks or similar structures.

• Top of exhaust elbow, tee, or coaxial terminal must be at least 4 feet below eves, sofﬁ ts, or overhangs. Overhang may not exceed 3 feet (Figure 15d).

• Terminal must be at least 3 feet from an inside corner.

• Under certain conditions, water in the ﬂ ue gas may condense on the structure in areas around the terminal. If these areas are made of materials subject to damage by ﬂ ue gas condensate, they should be protected.

• If possible, install the terminal on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if the terminal is subjected to winds in excess of 40 mph.

• The noise level in the vicinity of the terminal is approximately 65 dB (roughly the level of a normal conversation). Avoid positioning the terminal in areas where this might be objectionable.

5) Horizontal air intake terminal location - Horizontal air intake terminal must be at least 12” above the normal snow line.

6) Permitted Terminals for Vertical Venting (Vent Options 6 - 10) - Terminals used on these systems are caps. Vent manufacturer part numbers for these caps are shown in Table 4. When Heat Fab Saf-T Vent SC is used, the 5300CI or 5400CI ﬁ tting is used between the highest piece of Saf-T Vent CI and the cap. These ﬁ ttings physically adapt from the CI pipe to the cap and also provide ventilation openings which must remain open for the Saf-T Vent CI to maintain its clearance rating.

Vertical direct vent systems (Vent Options 6 - 8) can have combustion air obtained from either a vertical or horizontal air

intake system. When combustion air is obtained from the roof, the air inlet terminal consists of a 180 degree elbow (or two 90 degree elbows) with a rodent screen as shown in Figure 10. When combustion air is obtained through a horizontal vent system, the air inlet termination is a 90 degree elbow with a rodent screen as shown in Figure 8a.

7) Permitted terminals for Vertical Coaxial Venting (Options 11 - 13) - When the Crown vertical coaxial vent kit is used (Vent Option 11), a cap compatible with the vent system is used (Figure 12, Table 4). The concentric air intake hood supplied in the Crown kit is the air inlet terminal (Figure 12).

When vertical coaxial venting is done using Heat Fab Saf-T Vent SC (Options 12, 13), the vent terminal is a SC03VT or

SC04VT terminal installed with a 5300CI or 5400CI adaptor. The openings in this adaptor are used for combustion air.

Page 16

TABLE 3b: SUMMARY OF VERTICAL VENTING OPTIONS

VENT OPTION # 678910

CLASSIFICATION USED IN THIS MANUAL

ILLUSTRATED IN FIGURE 10 10 11 11

VERTICAL

DIRECT VENT

VERTICAL

DIRECT VENT

(RESERVED

FOR FUTURE

USE)

VERTICAL

DIRECT

EXHAUST

VERTICAL

DIRECT

EXHAUST

VENT PIPE STRUCTURE PENETRATION

AIR INTAKE PIPE STRUCTURE PENETRATION

VENT PIPE SIZE 3” 4” 3” 4” AIR INTAKE PIPE SIZE 4” 4” N.A. N.A.

CWD060 - CWD138 47 FT CWD165 27 FT CWD193 17 FT CWD220 N.R.

PIPE LENGTH

MAXIMUM VENT

MAXIMUM

INTAKE PIPE

EXHAUST TERMINAL BY VENT SYSTEM MANUFACTURER. SAME DIAMETER AS VENT SYSTEM. SEE TABLE 4. AIR INTAKE TERMINAL

(ROOF PENETRATION) AIR INTAKE TERMINAL

(WALL PENETRATION) VENT MATERIAL APPROVED VENT SYSTEM SHOWN IN TABLE 4 AIR INTAKE MATERIAL GALVANIZED OR PVC N.A. N.A.

“N.R” - Not recommended “N.A.” - Not applicable

CWD245 N.R. CWD060 - CWD138 52 FT 50 FT N.A. N.A.

CWD165 32 FT 50 FT N.A. N.A. CWD193 22 FT 50 FT N.A. N.A. CWD220 N.R. 50 FT N.A. N.A.

LENGTH

CWD245 N.R.

ROOF ROOF ROOF ROOF

ROOF OR WALL ROOF OR WALL N.A. N.A.

47 FT 47 FT 47 FT 47 FT 27 FT 47 FT 47 FT 17 FT 47 FT 47 FT N.R. 47 FT 47 FT N.R. 47 FT

50 FT N.A. N.A.

4” 180 ELBOW 4” 180 ELBOW N.A. N.A.

4” 90 ELBOW 4” 90 ELBOW N.A. N.A.

8) Vertical Vent Terminal Locations (Vent Options 6 - 13) - Observe the following limitations on the location of all vertical vent terminals (see Figs. 10, 11, 12, 13):

• The lowest discharge opening on the cap must be at least 2 feet above any object located within 10 feet.

• If outside air is used for combustion (Options 6-7, 11-13), the vertical distance between vent and air inlet terminal openings must be at least 12”.

• The bottom of the air inlet terminal must be at least 12” above the normal snow accumulation that can be expected on the roof.

9) Terminal offsets - Horizontal elbow or tee terminals may be offset by as much as 5 ft as shown in Figure 14. This sometimes helps maintain the 12” minimum clearance required above the snow line. The extra two elbows and the section of vertical pipe on the outside of the building must be counted when checking that the maximum vent / intake pipe length is not exceeded. On horizontal direct vent systems, both terminals must be offset by the same amount so that their relationship to one another is the same as shown in Figure 8a. When this offset is used, the horizontal section of vent pipe must be pitched away from the outside so that condensate cannot collect in the lower offset elbow.

10) Wall thimbles – Wall thimbles are required where the vent pipe passes through combustible walls with less than the required clearance shown in Table 2 or as required by local codes. Vent manufacturer’s wall thimble part numbers are shown in Table 4.

11) Condensate Traps and Pitch of Horizontal piping – All horizontal vent piping must be pitched ¼” per foot so that any condensate which forms in this piping will run towards either the outdoors or into a condensate trap. Vent manufacturer’s part numbers for suitable condensate traps are shown in Table 4.

All vertical vent systems must include at least one condensate trap as shown in Figures 10-13. This will collect any

condensate that forms in the vent system as well as any rain water that gets around the vent cap.

The maximum allowable vertical run directly off of the boiler without a condensate trap is 7.5 ft (Figure 16). Install a

condensate trap in longer vertical runs so that condensate which might form in this ﬁ rst vertical section will not run into the boiler fan.

Page 17

FIGURE 10: VERTICAL NON-COAXIAL DIRECT VENT SYSTEM (VENT OPTIONS 6, 7)

FIGURE 11: VERTICAL DIRECT EXHAUST SYSTEM (VENT OPTIONS 9, 10)

Page 18

TABLE 3c : SUMMARY OF VERTICAL COAXIAL VENTING OPTIONS

VENT OPTION # 11 12 13

CLASSIFICATION USED IN THIS MANUAL

VENT PIPE STRUCTURE PENETRATION

AIR INTAKE PIPE STRUCTURE PENETRATION

VENT PIPE SIZE 3” 3” 4” AIR INTAKE PIPE SIZE

(NON-COAXIAL SECTION)

AIR INTAKE PIPE SIZE

(COAXIAL SECTION)

CWD060 - CWD138 47 FT CWD165 27 FT 27 FT

CWD193 N.R. N.R. CWD220 N.R. N.R.

PIPE LENGTH

MAXIMUM VENT

MAXIMUM LENGTH COAXIAL SECTION

MAXIMUM

INTAKE PIPE

EXHAUST TERMINAL

AIR INTAKE TERMINAL

ADAPTOR FROM NON-COAXIAL TO COAXIAL SECTIONS

VENT MATERIAL (NON-COAXIAL SECTION)

VENT MATERIAL (COAXIAL SECTION)

AIR INTAKE MATERIAL (NON-COAXIAL SECTION)

AIR INTAKE MATERIAL (COAXIAL SECTION)

“N.R” - Not recommended “N.A.” - Not applicable

CWD245 N.R. N.R.

CWD060 - CWD138 52 FT 50 FT 50 FT CWD165 32 FT 32 FT CWD193 N.R. N.R.

LENGTH

CWD220 N.R. N.R. CWD245 N.R. N.R.

DIRECT VENT

30 FT OR AS

LIMITED BY MAX

VENT LENGTH,

WHICHEVER IS

TURER. SAME DIAMETER AS

VENT SYSTEM.

SEE TABLE 4.

SUPPLIED WITH CROWN #500005

COAXIAL VENT

TEE + SUPPORT SUPPLIED WITH CROWN #500005

COAXIAL VENT

VENT SYSTEM

VERTICAL

COAXIAL

ROOF ROOF ROOF

4” 4” 4”

5”

LESS

BY VENT

SYSTEM

MANUFAC-

KIT

5” “B” VENT

KIT

APPROVED

SHOWN IN

TABLE 4

APPROVED

SHOWN IN

TABLE 4

5” TYPE “B”

VENT

VERTICAL

COAXIAL

DIRECT VENT

5” 7”

47 FT 47 FT

AS LIMITED

BY MAX VENT

LENGTH

HEAT FAB

#SC03RC

HEAT FAB

#SC03VT

HEAT FAB

#SC03TAD4

HEAT FAB

SAF-T VENT

HEAT FAB

SAF-T VENT SC

GALVANIZED OR PVC

HEAT FAB

SAF-T VENT SC

VERTICAL

COAXIAL

DIRECT VENT

CONSULT

FACTORY

CONSULT FACTORY

CONSULT

FACTORY

HEAT FAB

#SC04RC

HEAT FAB

#SC04VT

HEAT FAB

#SC04TAD4

HEAT FAB

SAF-T VENT

HEAT FAB

SAF-T VENT SC

HEAT FAB

SAF-T VENT SC

Page 19

FIGURE 12: VERTICAL COAXIAL DIRECT VENT USING CROWN #500005 VENT KIT (VENT OPTION 11)

FIGURE 13: VERTICAL COAXIAL DIRECT VENT USING HEAT FAB SAF-T VENT SC (VENT OPTIONS 12, 13)

Page 20

TABLE 4: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS

MANUFACTURER VENT SYSTEM SIZE

SAF-T VENT

EZ SEAL

HEAT FAB

SAF-T VENT SC

FASNSEAL

PROTECH SYSTEMS

INC.

FASNSEAL W2

SVE

Z-FLEX

METAL-FAB CORR/GUARD

SERIES III

(“Z-VENT III”)

3 FSHDT3 FSWT3

3 SVEDWCF03 2SVSWTEF03

4 SVEDWCF04 2SVSWTEF04

3 CGSWDS(3”) CGSWWPK(3”)

4 CGSWDS(4”) CGSWWPK(4”)

CONDENSATE

TRAP

9321

(NOTE 3)

9421

(NOTE 3)

SC03DRN

(NOTE 3)

SC04DRN

(NOTE 3)

FSHDT4

OR FSCD4

(NOTE 4)

W2-T3

+W2-DF3

W2-T4

+ W2-DF4

WALL

THIMBLES

7393GC

7393GCS

5391CI

7493GC

7493GCS

5491CI

SC03FS

SC03FSA

SC04FS

SC04FSA

FSWT4

W2-WT3

W2-WT4

HORIZONTAL

TERMINATION

ELBOW: 7314TERM TEE: 7390TEE 5300CI

ELBOW: 7414TERM TEE: 7490TEE

ELBOW (NOTE 5): SC03HT + 7314TERM TEE (NOTE 5): SC03HT + 7390TEE

ELBOW (NOTE 5): SC04HT + 7414TERM TEE (NOTE 5): SC04HT + 7490TEE

ELBOW: FSELB9003 + FSBS3 TEE: FSTT3

ELBOW: FSELB9004 + FSBS4 TEE: FSTT4

ELBOW: FSA-SWDW3 + FSELB9003 + FSBS3 TEE: FSA-SWDW3 + FSTT3

ELBOW: FSA-DWSW4 + FSELB9004 + FSBS4 TEE: FSA-SWDW4 + FSTT4

ELBOW: 2SVSTEX0390 TEE: 2SVSTTF03

ELBOW: 2SVEEWCF0490 + 2SVSTPF TEE: 2SVSTTF04

ELBOW: CGSW90LTM(3”) TEE: CGSWTTM(3”)

ELBOW: CGSW90LTM(4”) TEE: CGSWTTM(4”)

VERTICAL

TERMINATION

5400CI

5300CI + SC03VT

(NOTE 6)

5400CI

+ SC04VT

(NOTE 6)

FSRC3

FSRC4

W2-RC3

W2-RC4

2SVSRCF03

2SVSRCF04

CGSWC(3”)

CGSWC(4”)

NOTES:

1) See vent system manufacturer’s literature for other part numbers that are required such as straight pipe, elbows, ﬁ restops and vent supports.

2) In addition to terminals shown, Crown coaxial terminals may be used in some cases. See Table 3 for applications and Crown part numbers.

3) All Heat Fab condensate traps shown may be installed in vertical or horizontal run.

4) Protech FSCD4 condensate trap may be installed in a vertical or horizontal run. All other Protech traps must be installed in a horizontal run only.

5) Heat Fab Saf-T Vent SC may not be used for horizontal coaxial venting - a separate air inlet pipe must be provided for horizontal direct vent systems. SC03HT or SC04HT adapters are used to adapt from SC pipe to terminal. Use of SC pipe in horizontal systems does allow for reduced clearances to combustibles in some applications. See Table 2.

6) Heat Fab SC03VT or SC04VT adapters are required on any vertical vent system using Saf-T Vent SC even when combustion air is obtained through a separate pipe or from the boiler room.

7) Metal-Fab CGSWDS condensate traps may only be installed in a horizontal run.

Page 21

12) Vertical and horizontal sections of piping must be properly supported. See vent system manufacturer’s instructions for more information.

13) Non-coaxial vent piping must be accessible for periodic inspection.

14) Fire stops and wall thimbles – Use ﬁ re stops where required by code or by the vent system manufacturer. Consult vent system manufacturer’s literature for information on suitable ﬁ re stops.

15) Supports - Vertical and horizontal sections of vent pipe must be properly supported. See the Vent System assembly section of this manual for more information.

B. Removing an Existing Boiler From a Common Chimney

Read this only if the CWD boiler is replacing an existing boiler that is being removed from a common chimney. This

section does not apply to the installation of a CWD boiler.

In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too

large for the remaining appliances. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

(a) Seal any unused openings in the common venting system. (b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction,

leakage, corrosion and other deﬁ ciencies which could cause an unsafe condition.

(c) Insofar as practical, close all building doors and windows and all doors between the space in which all the appliances

remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close ﬁ replace dampers.

(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so the appliance will

operate continuously.

(e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the ﬂ ame of a match or

candle, or smoke from a cigarette, cigar, or pipe.

(f) After it has been determined that each appliance remaining connected to the common venting system properly vents when

tested as outlined above, return doors, windows, exhaust fans, ﬁ replace dampers and any other gas-burning appliances to their previous condition of use.

(g) Any improper operation of the common venting system should be corrected so the installation conforms with the National

Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1.

NEVER COMMON VENT A CWD BOILER WITH OTHER APPLIANCES

TABLE 5a: VENT FITTING EQUIVALENT LENGTH

VENT FITTING EQUIVALENT

LENGTH (ft)

3” 90 ELBOW 5.5 3” 45 ELBOW 4.0

HEAT FAB SC03E90 (3” COAXIAL 90 ELBOW)

HEAT FAB SC03E45 (3” COAXIAL 45 ELBOW)

4” 90 ELBOW 8.0 4” 45 ELBOW 4.5 HEAT FAB SC04E90

(4” COAXIAL 90 ELBOW) HEAT FAB SC04E45

(4” COAXIAL 45 ELBOW

5.5

4.0

8.0

4.5

WARNING

TABLE 5b: AIR INTAKE FITTING EQUIVALENT LENGTH

INTAKE FITTING EQUIVALENT

LENGTH (ft)

4” 90 ELBOW 8.0 4” 45 ELBOW 4.5

HEAT FAB SC03E90 (3” COAXIAL 90 ELBOW)

HEAT FAB SC03E45 (3” COAXIAL 45 ELBOW)

HEAT FAB SC04E90 (4” COAXIAL 90 ELBOW)

HEAT FAB SC04E45 (4” COAXIAL 45 ELBOW)

CONSULT CROWN

Page 22

FIGURE 14: HORIZONTAL TERMINAL OFFSETS

FIGURE 15a: LOCATION OF DIRECT VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE

Page 23

FIGURE 15b: LOCATION OF DIRECT EXHAUST TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE

FIGURE 15c: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS

FIGURE 15d: POSITIONING VENT TERMINAL UNDER OVERHANGS

Page 24

FIGURE 16: USE OF CONDENSATE TRAPS

C. Vent / Intake System Assembly

1) General Assembly Notes: a) Where the use of “silicone” is called for in the following instructions, use GE RTV 106 for the vent collar and coaxial

terminal. Air inlet piping sections are sealed with any general-purpose silicone sealant such as GE RTV102. PVC air inlet

piping sections are connected with PVC cement. b) Longitudinal welded seams should not be placed at the bottom of horizontal sections of exhaust pipe. c) Do not drill holes in vent pipe. d) Do not attempt to mix vent components of different vent system manufacturers. e) In some cases, there are differences between the vent system installation instructions in this manual and those in the

vent system manufacturer’s manual. Where such differences exist, this manual takes precedence over the vent system

manufacturer’s manual.

CAUTION

Vent systems made by Heat Fab, Protech, and Z-Flex rely on gaskets for proper sealing. When these vent systems are used, take the following precautions:

• Make sure that gasket is in position and undamaged in the female end of the pipe.

• Make sure that both the male and female pipes are free of damage prior to assembly.

• Only cut vent pipe as permitted by the vent manufacturer in accordance with their instructions. When pipe is cut, cut end must be square and carefully deburred prior to assembly.

2) Vent Collar Installation – The vent collar is shipped loose in the accessory bag along with two collar gaskets, the outlet oriﬁ ce, and four 10-32 mounting screws. Verify that the 6 digit part number model number marked on the outlet exhaust oriﬁ ce matches that shown in Table 6. Mount the collar and oriﬁ ce as shown in Figure 17. If desired, the ﬁ rst piece of exhaust pipe can be connected to the collar before mounting the collar on the boiler.

Page 25

TABLE 6: FAN OUTLET ORIFICE

BOILER MODEL

CWD060 620133 CWD083 650136 CWD110 620135 CWD138 620136 CWD165 620137 CWD193 620138 CWD220 620139 CWD245 650138

ORIFICE

PART #

FIGURE 17: INSTALLATION OF FAN OUTLET ORIFICE

3) Optional Coaxial Terminal Installation – If the optional coaxial terminal is used, it should be installed in the wall before vent assembly is started. Install the terminal in accordance with the following procedure (Figures 18a & 18b):

NOTE

• Coaxial portion of inside terminal section may be installed in direct contact with combustible construction.

• Maximum wall thickness through which this terminal can be installed is 10”

a) Position the wall face plate on the outside wall in the desired terminal location. Verify that this location will permit the

terminal, and connected venting, to clear any obstructions on the inside of the wall with the appropriate clearances. Mark

the location of the round opening on the wall. b) For 3” terminals, cut a 5 ¼” Diameter hole through the wall at this location. For 4” terminals, cut a 7 1/4” opening. c) Attach the mounting plate to the outside wall with suitable fasteners. d) Attach the intake terminal to the straight coaxial section. To do this, clean the male and female ends of the inner pipes

with an alcohol pad. Lubricate the gasket in the female end of the straight section with a package of the silicone lubricant

provided and then push the intake terminal ﬁ rmly onto the straight section until the intake terminal makes contact with

the bead on the straight section. Secure the two ﬁ ttings together with the self-drilling screws provided. Use a low torque

setting to install these screws so as not to strip out the holes. e) Pass the assembled intake terminal and straight section through the wall from the outside. Bend the four Tabs in the wall

face plate towards the outside when doing this. Do not attach the pipe to the plate yet. f) Adjust the position of the terminal in the wall so that the edge of the intake skirt is 2-3” from the wall plate (Figure 18b).

Also verify that the terminal is pitched in the same direction as the rest of the vent system. g) Attach the intake/straight section to the wall face plate using the self drilling screws provided.

h) Loosen the hose clamp on the end of the exhaust terminal. Mount the exhaust terminal onto the intake terminal with the

“V” horizontal (ﬂ ue gas openings on top and bottom) as shown in Figure 18b. Slip the hose clamp over the “ﬁ ngers” on

the intake terminal and tighten the clamp. i) Seal all exposed exterior joints, including the joint between the wall face plate and the wall and between the wall face

plate and the straight section with an exterior grade silicone sealant.

Page 26

FIGURE 18a: CROWN COAXIAL TERMINAL EXPLODED VIEW

FIGURE 18b: CROWN COAXIAL TERMINAL ASSEMBLY

Page 27

j) Attach the intake tee to the end of the straight section protruding from the inside wall. Use the procedure described in (d)

to clean and assemble these parts.

k) If the inside terminal section is not supported by the wall through which it passes, install additional supports or bracing

to support the terminal. Bracing in contact with the coaxial section of the terminal may be combustible.

4) Assembly of Metal-Fab Corr/Guard Vent System: a) Corr/Guard General Notes:

• Do not cut Corr/Guard vent components.

• Refer to Corr/Guard installation instructions for proper methods of support.

• Orient Corr/Guard components so that the males ends of all ﬁ ttings point in the direction of the boiler.

b) Start assembly of the vent system at the boiler. Remove the hose clamp shipped on the BWC vent collar. Bend the three

hose clamp tabs on this collar outward slightly.

c) Clean the exterior of the male end of the ﬁ rst piece of pipe and the inside of the vent collar on the boiler. Remove dirt,

grease, and moisture from the surfaces to be sealed. Dry surfaces or allow to dry thoroughly. d) On the male end of the pipe, apply a ¼” wide bead of silicone approximately 1/2” from the end of the pipe (Fig 7.47). e) Insert the male end of the pipe into the boiler vent collar until it bottoms out. f) Apply an additional bead of silicone over the outside of the joint and smooth out. g) Replace and tighten the clamp on the vent collar. h) Assemble remaining Corr/Guard components in accordance with the Corr/Guard installation instructions.

i) Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler. Note: To join Corr/Guard to a Crown coaxial terminal, leave the Corr/Guard gasket in place. Apply a ¼” bead of silicone

to the terminal connection about ¼” from its end. Slip the Corr/Guard female end over the terminal end so that there is an overlap of approximatley 1 ¾ inches. Apply and smooth silicone over the outside of the joint including the tabs in the female end of the Corr/Guard pipe. Tighten the terminal hose clamp to mechanically lock the pipe onto the terminal.

FIGURE 19: CORR/GUARD CONNECTION TO VENT COLLAR

Page 28

5) Assembly of Z-Flex Z-Vent III: a) General Notes:

• Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw.

File or sand the cut end smooth before assembling. Expanded ends may be cut to adapt the SVE series III to the vent collar or Crown coaxial terminal. See the following instructions.

• Support horizontal piping sections at intervals of 48” or less.

• Vertical venting systems must be supported by at least one Z-Flex ﬁ re stop. An additional vertical support is required after

any offset and as required by the Z-Vent III installation instructions.

b) Start assembly of the vent system at the boiler. Remove the hose clamp shipped on the CWD vent collar. Bend the three

hose clamp tabs on this collar outward slightly.

c) Clean the exterior of the male end of the ﬁ rst piece of pipe and the inside of the vent collar on the boiler. Remove dirt,

grease, and moisture from the surfaces to be sealed. Dry surfaces or allow to dry thoroughly.

d) On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately ½ inch from the male end

of the pipe. Apply ¼” beads of silicone along both sides of the longitudinal seam (Fig. 20). e) Insert the male end of the pipe into the boiler vent collar until it bottoms out. f) Apply an additional bead of silicone over the outside of the joint and smooth out. Also apply silicone over the seams in

the collar (Fig 20). g) Replace and tighten the clamp on the vent collar. h) The female end of each Z-Vent III component has a silicone sealing gasket. Examine all vent components to insure that

the gasket integrity has remained during shipping. Gaskets must be in the proper position or ﬂ ue gas could leak resulting

in carbon monoxide poisoning. i) Align the second piece of pipe with the ﬁ rst and push them together as far as they will go, but not less than 1 3/4”. j) Tighten gear clamp to a minimum torque of 40 in-lbs and a maximum of 50 in-lbs. k) Repeat Steps (h) – (j) for the remaining Z-Vent III components. If a termination elbow is used, use this procedure to

complete the vent system. l) If a termination elbow or tee is used, a locking band or gear clamp must be used at either side of the wall penetration to

prevent shifting of the vent system in and out of the wall. This applies to both combustible and non-combustible walls. m) To join Z-Vent III to a Crown coaxial terminal, a male end must be present at the end of the piping to be joined to the

terminal. It will therefore be necessary to cut off the expanded end of the pipe before it can be joined to the terminal.

This male end of the pipe must be inserted into the terminal connection with at least a 1” overlap. It may be necessary to

crimp the end of the vent pipe before it can be inserted into the terminal. Apply silicone to the male end of the pipe as in

(d) above, insert into the terminal, and apply an additional bead of silicone over the outside of the joint. Smooth out the

excess silicone and tighten the hose clamp on the terminal. n) Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler.

FIGURE 20: Z-VENT III CONNECTION TO VENT COLLAR

Page 29

6) Assembly of Heat Fab Saf-T Vent EZ Seal: a) Saf-T Vent General Notes: These instructions cover the installation of Saf-T Vent EZ Seal. Saf-T Vent EZ Seal piping has integral gaskets installed in

the female ends of the pipe which seal the joints.

• In general, Saf-T Vent pipe sections may not be cut. Exceptions to this are the Saf-T Vent slip connector and connections

to the boiler vent collar and Crown coaxial terminal. In these cases, use a sharp pair of aviation snips, an abrasive cut-off, or a plasma cutter. See the Saf-T Vent instructions for information on cutting the slip connector.

• Orient Saf-T Vent components so that the arrows on the piping labels are in the direction of ﬂ ue gas ﬂ ow.

• Support horizontal piping sections at intervals of 6 feet or less.

• Vertical venting systems must be supported by at least one Heat Fab support. An additional vertical support is required

after any offset.

b) Connection to Boiler – Start assembly of the vent system at the boiler. Remove the hose clamp shipped on the CWD vent

collar. Bend the three hose clamp tabs on this collar outward slightly. Cut the male “spigot” off of the ﬁ rst piece of pipe (Fig 21). If necessary, crimp the cut end of the pipe so that it can be inserted at least 1” into the collar. Clean the exterior of the male end of the ﬁ rst piece of pipe and the inside of the vent collar on the boiler with an alcohol pad. On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately ½ inch from the male end of the pipe. Also apply a ¼” bead of silicone along the ﬁ rst 2 ½” of the longitudinal weld. Insert the male end of the pipe into the boiler vent collar until it bottoms out. Apply an additional bead of silicone over the outside of the joint and smooth out (Fig 21). Apply silicone over the seams in the vent collar. Replace and tighten the clamp on the vent collar.

c) Assembly of Saf-T Vent EZ Seal Vent Components - Clean the male end of the next piece of pipe with an alcohol pad and

make sure that it is free of burrs. Check the female end of the ﬁ rst piece of pipe to make sure that the gasket is in place and is undamaged. Using a slight twisting motion, insert the male end of the second ﬁ tting into the female end of the ﬁ rst ﬁ tting, taking care not to dislodge or cut the factory gasket. In extremely arid conditions, it may be easier to assemble these ﬁ ttings if the gasket is moistened with water prior to assembly. Bend the locking tabs over the locking ring on the adjacent piece of pipe. Repeat these steps for the remaining Saf-T-Vent components. If a termination elbow is used, use this procedure to complete the exhaust system.

d) Connection of Saf-T Vent to Crown coaxial terminal - Cut the locking tabs off of the female end of the Saf-T Vent

pipe to be joined to the co-axial terminal. Apply a ¼” bead of silicone around the terminal connection about ¼” from the end. Slip the Saf-T Vent pipe over the terminal and apply a second bead of silicone over the joint. Silicone must be applied even though there is a gasket on the female end of the pipe. Smooth the excess silicone over the joint, making sure that there are no visible voids in the silicone. Tighten the terminal clamp. Allow the silicone to cure per the silicone

FIGURE 21: SAF-T VENT EZSEAL CONNECTION TO VENT COLLAR

Page 30

manufacturer’s instructions before operating the boiler.

7) Assembly of Heat Fab Saf-T Vent SC - On CWD Boiler installations where Saf-T Vent SC is used, some Saf-T Vent EZ Seal (single wall pipe) will always be required between the boiler and the Saf-T Vent SC. Install this pipe as described above. On all systems except vertical coaxial systems (Options 12, 13), the following Heat Fab adapters will be needed to adapt from Saf-T Vent EZ Seal to Saf-T Vent SC:

Vent Size Heat Fab Part Number 3” SC03ADEZ 4” SC04ADEZ

On vertical coaxial vent systems employing Saf-T Vent SC, the transition from Saf-T Vent to Saf-T Vent SC is made with

one of the following Air Intake Tees:

Vent Size Heat Fab Part Number 3” SC03TAD4 4” SC04TAD4

Assemble the Saf-T Vent EZ Seal to the boiler and the adapter as described in (6) above. Proceed as follows to assemble the

Saf-T Vent SC:

a) Clean both ends of the inner pipes to be joined with an alcohol pad. This will remove any foreign matter which may effect

the integrity of the seal. Insert the male end of the ﬁ rst piece of pipe into the adaptor. In extremely dry conditions it may be helpful to moisten the gasket with clean water prior to assembly.

b) Push the ﬁ rst Saf-T Vent SC section into the adaptor until the outer jacket has made contact with the snap ring located

inside the female end of the adaptor. When fully assembled the outer female end will overlap the male end by 1”.

c) Use the three self tapping screws provided with the vent to attach the ﬁ rst piece of pipe to the adapter. No pre drilling is

required. If using a variable torque screw gun, use the low torque setting to install the screws so as not to strip out the holes. If a hole does become stripped due to over tightening, a larger (1/2” long max.) screw or short pop rivet may be

used. d) Seal all the joints in the outer jacket with foil tape or exterior grade silicone sealant. e) Repeat steps (a - d) to assemble the remaining sections of Saf-T Vent SC. f) Support the Saf-T Vent SC as called for in Heat Fab’s installation instructions. Also make sure that ﬁ re stops are provided

as called for in Heat Fab’s instructions and local codes. g) After the Saf-T Vent SC exits the building, one of the following adaptors will be needed to install the terminal:

Vent Size Heat Fab Part Number 3” 5300CI 4” 5400CI

On vertical coaxial vent systems (Vent Options 12, 13) this adapter also acts as the combustion air intake terminal. In other

installations, the openings in this adapter provide ventilation between the inner and outer walls.

FIGURE 22: FASNSEAL CONNECTION TO VENT COLLAR

Page 31

8) Assembly of Protech FasNSeal a) FasNSeal General Notes:

• Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe.

• Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of ﬂ ue gas ﬂ ow.

• Support horizontal piping sections at intervals of 6 feet or less.

• Vertical venting systems must be supported by at least one FasNSeal support. An additional vertical support is required

after any offset.

a) Remove the hose clamp shipped on the CWD vent collar. Bend the three hose clamp tabs on this collar outward slightly.

Clean the exterior of the male end of the ﬁ rst piece of pipe and the inside of the vent collar on the boiler. Remove dirt, grease, and moisture from the surfaces to be sealed. Dry surfaces or allow to dry thoroughly. On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately 1/4 inch from the male end of the pipe. Insert the male end of the pipe into the boiler vent collar until it bottoms out. Apply an additional bead of silicone over the outside of the

joint and the seams on the vent collar and smooth out (Fig 22). Replace and tighten the clamp on the vent collar. b) All other joints in the FasNSeal venting system rely on a gasket in the female end of the pipe for a proper seal. c) Align the longitudinal seam of both pipes. Insert the male end of the second pipe into the female end of the ﬁ rst pipe until

the bead on the male end contacts the ﬂ are on the female end (Fig. 17b). d) Tighten the locking band with a nut driver. e) Repeat (c) and (d) for the remaining FasNSeal components. If a termination elbow is used, use this procedure to complete

the exhaust system. f) To join FasNSeal to a Crown coaxial terminal, remove the hose clamp from the female FasNSeal end to be joined to the

terminal. Leave the FasNSeal gasket in place. Apply a ¼” bead of silicone to the terminal connection about ¼” from its

end. Slip the FasNSeal female end over the terminal end so that there is an overlap of 1 ¾ inches. Apply and smooth

silicone over the outside of the joint including the rectangular hose clamp opening in the FasNSeal pipe. Tighten the

terminal hose clamp to mechanically lock the pipe onto the terminal. g) Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler.

9) Assembly of Protech FasNSeal W2 - On CWD Boiler installations where Protech FasNSeal W2 is used, some Protech FasNSeal (single wall pipe) will always be required between the boiler and the FasNSeal W2. Install this pipe as described above. On all systems, the following components will be needed to adapt from Protech FasNSeal to FasNSeal W2:

Vent Size Protech Part Number 3” FSA-SWDW3 4” FAS-SWDW4

Follow the joint connection instructions provided with the FasNseal W2. In vertical vent systems, terminate the vent system

with the cap called for FasNSeal W2 in Table 4. In horizontal vent systems one of the following adapters will be required between the FasNSeal W2 and the terminal:

Vent Size Protech Part Number 3” FSA-DWSW3 4” FAS-DWSW4

10) Assembly of the air intake system:

a) Assemble the air intake system using either galvanized or PVC pipe. b) If PVC piping is used, use PVC cement to assemble the PVC intake system components. c) If galvanized piping is used, use at least two sheet metal screws per joint. Seal the outside of all joints. d) A 4” galvanized smoke pipe will ﬁ t inside the inlet collar on the CWD boiler. Depending upon the exact OD of the

pipe used, it may be necessary to crimp this pipe. Secure with a single #10 sheet metal screw through the hole in the inlet collar and seal the outside of the joint with silicone. If PVC is used for the intake system, use a short piece of 4” galvanized pipe to connect the PVC to the boiler. Silicone the outside of the joint between the PVC and galvanized pipe.

e) Either PVC or galvanized pipe will ﬁ t over the combustion air connection on the Crown coaxial terminal. Secure the

pipe to the terminal with at least two #10 sheet metal screws. Seal the outside of the joint between the inlet pipe and the coaxial terminal.

f) Two 90-degree elbows may be used to make the 180-degree air intake termination elbow used on vertical direct vent

installations.

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11) Assembly of Vertical Coaxial Vent System Using Crown #500005 Coaxial Vent Kit (Vent Option #11) a) Start by installing the “B” vent piping. Install and assemble this piping in accordance with the “B” vent manufacturer’s

instructions. Seal the joints between sections of “B” vent with GE RTV 106 or Dow 732 RTV sealant. Consult the “B” vent manufacturer’s instructions for the clearance to combustibles (typically 1”) as well as for ﬁ re stop and support requirements.

Install a 5” “B” vent Tee on the bottom of the run of “B” vent as shown in Figure 12. Extend the run of “B” vent far

enough above the roof so that the bottom of the air intake hood will be at least one foot above the normal snow line that can be expected on the roof. Seal the roof penetration with a “B” vent roof ﬂ ashing and storm collar in accordance with the “B” vent manufacturer’s instructions.

b) Assemble the vent piping that is to be run inside the “B” vent and drop it through the “B” vent. Join and seal the vent

piping in accordance with the instructions 4, 5,6 or 8 above. Use the longest sections of vent piping possible so as to minimize the number of joints inside the “B” vent. Temporarily support the vertical section of vent pipe from underneath so that the top of the vent pipe is at the correct height (Figure 12).

c) Slip the Crown concentric air intake hood over the vent pipe and seat it on the “B” vent. Secure the concentric air intake

hood to the “B” vent with at least three sheet metal screws. Install a storm collar compatible with the vent system over the vent pipe. Secure and seal it in accordance with the vent manufacturer’s instructions. Note: this collar provides a watertight seal between the vent piping and the concentric air intake hood and also supports the vent piping. Once the storm collar is installed, remove the temporary vent support. Install a compatible rain cap on the top of the vent system (Table 4).

d) Slip the Crown vent support over the vent pipe protruding from the bottom of the “B” vent. Orient the vent support so

that it will be possible to tighten the gear clamp by reaching through the side opening in the “B” vent Tee (Figure 23). Attach the vent support to the “B” vent Tee with at least three sheet metal screws. Tighten the gear clamp. Seal all joints in between the vent support, the vent pipe, and the “B” vent.

e) Install the vent piping between the boiler and the vertical section of “B” vent already installed. Observe the clearance and

support requirements in the installation manual.

f) Install a 5 x 4 single wall reducer in the side connection of the “B” vent Tee. Install 4” galvanized or PVC piping between

this reducer and the combustion air intake on the boiler. Seal all joints in the air intake piping.

12) Condensate Traps: a) Trap should have the basic conﬁ guration shown in Figure 24. All tubing is 3/8 I.D.

b) All drain tubing must be acid resistant. c) At least the ﬁ rst 6 inches of tubing must be silicone with a 300F temperature rating. d) Pipe condensate to a drain or other suitable location. Make sure that condensate disposal method is in accordance with

local regulations. Ensure condensate is not subjected to freezing temperatures.

13) Rodent Screens: a) A rodent screen is provided with the CWD boiler. On direct exhaust boilers, this screen is installed in the air inlet collar

on the boiler and held in place with screws or RTV sealant.

b) The Crown coaxial terminal has integral inlet and exhaust rodent screens. The rodent screen supplied with the boiler is not

used when the boiler is installed with the coaxial terminal.

c) In horizontal direct vent installations using termination elbows or tees, the rodent screen provided is mounted in the air

inlet elbow. A second screen is required for the exhaust elbow. This second screen can be any one of the following items:

• A rodent screen provided by the vent system manufacturer.

• A second Crown rodent screen (Crown #60-601).

• A rodent screen made of stainless steel screen having a ½” (2 x 2) or greater mesh. d) In vertical direct vent or direct exhaust systems, no rodent screen is required on the exhaust terminal. The rodent screen

is installed either on the 180-degree inlet elbow (direct vent installations) or on the boiler inlet collar (direct exhaust installations).

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FIGURE 23: INSTALLATION OF VENT SUPPORT PROVIDED IN CROWN #500005 VERT. COAXIAL VENT KIT

FIGURE 24: CONDENSATE TRAP/DRAIN DETAIL

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VII Gas Piping

Gas piping to the boiler must be sized to deliver adequate gas for the boiler to ﬁ re at the nameplate input at a line pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or the National Fuel Gas Code.

Figure 25 shows typical gas piping connections to the CWD boiler. A sediment trap must be installed upstream of all gas controls. Install a manual shutoff valve outside the jacket and ground joint union as shown.

The boiler and its gas connection must be leak tested before placing the boiler in operation. When doing this, the boiler and its individual shut-off must be disconnected from the rest of the system during any pressure testing of that system at pressures in excess of ½ psi. When pressure testing the gas system at pressures of ½ psi or less, isolate the boiler from the gas supply system by closing its individual manual shut-off valve.

FIGURE 25: GAS CONNECTION TO BOILER

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VIII System Piping

CAUTION

• Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc) during appliance operation and service (circulator replacement, etc).

• Operation of this boiler with continuous return temperatures below 120F can cause severe heat exchanger corrosion damage.

• Operation of this boiler in a system having signiﬁ cant amounts of dissolved oxygen can cause severe heat exchanger corrosion damage.

• Do not use toxic additives, such as automotive antifreeze, in a hydronic system.

A. Standard Piping

Figure 26 shows typical boiler system connections on a single zone system. Additional information on hydronic system design may be found in Installation of Residential Hydronic Systems (Pub. #200) published by the Hydronics Institute in Berkely Heights, NJ. The components in this system and their purposes are as follows:

1) Relief valve (Required) – Install the relief valve in the 3/4” tapping on the left side of the boiler as shown in Figure 1. The

relief valve shipped with the boiler is set to open at 30 psi. This valve may be replaced with one having a setting of up to

the Maximum Allowable Working Pressure (MAWP) shown on the rating plate. If the valve is replaced, the replacement

must have a relief capacity in excess of the Minimum Relief Valve Capacity shown on the rating plate. Pipe the discharge of the 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. If the relief valve discharge is not

piped to a drain, it must terminate at least 6 inches above the ﬂ oor. Do not run relief valve discharge piping through an area

that is prone to freezing. The termination of the relief valve discharge piping must be in an area where it is not likely to

become plugged by debris.

DANGER

• Pipe relief valve discharge to a safe location.

• Do not install a valve in the relief valve discharge line.

• Do not move relief valve from factory location.

• Do not plug relief valve discharge.

2) Circulator (Required) – Although the circulator is shipped on the boiler return, it can be installed on the boiler supply. If the

circulator is moved to the supply it should be positioned just downstream of the expansion tank as shown in Figure 26.

3) Expansion Tank (Required) – If this boiler is replacing an existing boiler with no other changes in the system, the old

expansion tank can generally be reused. If the expansion tank must be replaced, consult the expansion tank manufacturer’s

literature for proper sizing.

4) Fill Valve (Required) – Either a manual or automatic ﬁ ll valve may be used. The ideal location for the ﬁ ll is at the expansion

tank.

5) Automatic Air Vent (Required) – At least one automatic air vent is required. Manual vents will usually be required in other

parts of the system to remove air during initial ﬁ ll.

6) Low Water Cut-Off (Required in some situations) – A low water cut-off is required when the boiler is installed above

radiation. In addition, some codes, such as ASME CSD-1, require low water cut-offs. Codes may also require that this low

water cut-off have a manual reset function. The low water cut-off may be a ﬂ oat type or probe type but must be designed

for use in a hot-water system. The low water cut-off should be piped into the boiler supply just above the boiler with no

intervening valve between it and the boiler. Use a low water cut-off that breaks the 120 VAC supply to the boiler. Do not attempt to connect a 24-volt low water

cut-off into the boiler factory wiring.

7) Manual Reset High Limit (Required by some codes) – This control is required by ASME CSD-1 and some other codes.

Install the high limit in the boiler supply piping just beyond the boiler with no intervening valves. Set manual reset high

limit as far above the operating limit setting as possible, but not over 240F. Wire the control to break the 120 VAC electrical

supply to the boiler.

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8) Flow control valve (Required under some conditions) – The ﬂ ow control valve prevents ﬂ ow through the system unless the circulator is operating. A ﬂ ow control valve may be necessary on converted gravity systems to prevent gravity circulation. Flow control valves are also used to prevent “ghost ﬂ ows” in circulator zone systems through zones that are not calling for heat.

9) Isolation Valves (Optional) – Isolation valves are useful if the boiler must be drained, as they will eliminate having to drain and reﬁ ll the entire system.

10) Drain Valve – The drain valve is shipped in the boiler parts bag. Install it in the location shown in Figure 1.

B. Piping for Special Situations

Certain types of heating systems have additional requirements. Some of the more common variations follow:

1) Indirect Water Heaters – Figure 27 shows typical indirect water heater piping. Boiler piping is the same as for any two-zone system. Figure 27 shows circulator zoning, which is usually preferred for indirect water heaters. Size the circulator and indirect water heater piping to obtain the boiler water ﬂ ow through the indirect water heater called for by the indirect water heater manufacturer. The standard CWD control system will operate two circulator zones. See the Wiring section of this manual.

2) Gravity and “Large Water Volume” Systems – The piping shown in Figure 28 will minimize the amount of time that the boiler operates with return temperatures below 120F on these systems. A bypass is installed as shown to divert some supply water directly into the return water. The bypass pipe should be the same size as the supply. The two throttling valves shown are adjusted so that the return temperature rises above 120F during the ﬁ rst few minutes of operation. A three-way valve can be substituted for the two throttling valves shown. If the circulator is mounted on the supply, the bypass must be on the discharge side of the circulator.

3) Low Temperature Systems – Some systems, such as radiant tubing systems, require the system water temperature to be limited to a value below the temperature of the water leaving the CWD. These systems also typically have return temperatures well below the 120F minimum.

Figure 29 illustrates the use of a heat exchanger to connect a CWD boiler to this type of system. The heat exchanger will

permit the transfer of heat from the boiler water to the low temperature system while holding the system supply and boiler return temperatures within their limits. For this system to work properly, the heat exchanger must be properly sized and the correct ﬂ ow rates are required on either side of the heat exchanger. Consult the heat exchanger manufacturer for sizing information. The water in the boiler is completely isolated from the water in the system. This means that separate ﬁ ll and expansion tanks are required for the heating system loop.

There are several other ways to connect low temperature systems to the non-condensing boilers like the CWD such as

four way mixing valve and variable speed injection pumping systems.

4) Systems containing oxygen – Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a cast iron boiler such as the CWD. Some examples include:

• Radiant systems that employ tubing without an oxygen barrier.

• Systems with routine additions of fresh water.

• Systems which are open to the atmosphere.

If the boiler is to be used in such a system, it must be separated from the oxygenated water being heated with a heat

exchanger as shown in Figure 29.

Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as ﬂ ow and temperature requirements.

All components on the oxygenated side of the heat exchanger, such as the pump and expansion tank, must be designed for use in oxygenated water.

5) Piping with a Chiller – If the boiler is used in conjunction with a chiller, pipe the boiler and chiller in parallel as shown in Figure 30. Use isolation valves to prevent chilled water from entering the boiler.

6) Air Handlers – Where the boiler is connected to air handlers through which refrigerated air passes, use ﬂ ow control valves in the boiler piping or other automatic means to prevent gravity circulation during the cooling cycle.

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FIGURE 26: BASIC PIPING

FIGURE 27: INDIRECT WATER HEATER BOILER-SIDE PIPING

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FIGURE 28: BYPASS PIPING

FIGURE 29: ISOLATION OF BOILER FROM SYSTEM WITH HEAT EXCHANGER

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FIGURE 30: CHILLER PIPING

Page 40

IX Wiring

The CWD Series boiler is offered with two different types of control systems:

• CB502 Control System - Basic operation of the boiler is controlled with a “CB502 control” (Crown part #42-502) located in the left side of the boiler vestibule. This device controls one or two circulator zones without the use of additional controls and includes LEDs to show the status of the circulators, inducer, and other boiler controls.

• R8285 Control System - Basic operation of the boiler is controlled by a Honeywell R8285 fan center. This system controls a single zone, although it can be used in a multiple zone system through the use of additional controls. No diagnostic LEDs are included in this system.

Both of these control systems use the same gas valves, ignition system components, and pressure switches. Separate wiring instructions are provided for each of these two control systems in the following two sections.

WARNING

• All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70).

• If a low water cut-off is installed, wire it to break the 120VAC supply to the boiler. Attempting to wire a 24 volt low water cut-off into the boiler, or otherwise modifying any of the 24 volt boiler wiring, will void the ANSI Z21.13 certiﬁ cation of this boiler and may cause unsafe boiler operation.

A. CB502 System - Single Zone Wiring

1) Line Voltage (120 VAC) Connections (Fig 31) – The line voltage connections are located in the junction box under the transformer on the right side of the vestibule:

• Black – Line voltage “hot”

• White – “Neutral” for boiler and circulators

• Red – “Heating” circulator “hot”

• Blue – “Indirect Water Heater” circulator “hot” (This wire is not used in single zone installations)

• Green – Ground connection

2) Maximum circulator continuous current draw = 10A

3) Low Voltage (24 VAC) Connections (Fig 31) – These connections are screw terminals located on the front edge of the relay board:

• T-T Heat 1 – “Heating” thermostat connections

• T-T DHW/H2 – “Indirect Water Heater” thermostat connections

• Heat anticipator setting for both thermostat connections is 0.03 A.

4) Priority Switch – When this switch is “on”, the “heating” circulator is turned off when a call for heat is present from “indirect water heater” zone. It is used to ensure that the entire output of the boiler is available to the indirect water heater. This switch should come from the factory in the “off” position and should be turned on only when absolutely necessary to provide adequate domestic water.

5) Auxiliary Jumpers – Two jumpers are located on the relay board as shown in Figure 32. They are present for connection and conﬁ guration of an auxiliary control. Unless instructions provided with the control call for these jumpers to be moved, they should remain as shown in Figure 32.

CAUTION

A problem with the indirect water heater zone could result in a total lack of heat and freeze damage to the building if this switch is in the priority “on” position.

• Ensure that the priority switch is “off” when it is not to be used.

• Set the priority switch “on” only when absolutely necessary.

• Do not leave the priority switch “on” when the building will be empty for an extended period of time.

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FIGURE 31: CB502 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING

FIGURE 32: CB502 CONTROL SYSTEM - FACTORY SWITCH / JUMPER CONFIGURATION

Page 42

B. CB502 System - Wiring Variations

1) Two Circulator Zones – Figure 33 shows wiring for two circulator zones. The second zone may be either an indirect water heater or a heating zone. No additional electrical controls are required to operate two circulator zones with a standard CWD boiler.

2) Hybrid Zone Valve/Circulator Zone System using Honeywell V8043Fs – The system shown in Figure 34 is useful when zone valves are to be used for space heating zones but not the indirect water heater zone. Two circulators are wired into the CWD boiler as shown in Figure 34. The zone valve end switches are connected in parallel and connected to the “T – T Heat” thermostat connections. A separate transformer is required to power the zone valves – do not attempt to use the transformer supplied with the boiler.

When a given heating thermostat calls, it opens the zone valve to which it is wired. When the zone valve opens, its end

switch makes, sending a call for heat to the CWD board. This starts the heating circulator and ﬁ res the boiler.

The indirect water heater thermostat is connected directly to T-T DHW/H2. Upon a call for heat, it starts the indirect

water heater circulator and ﬁ res the boiler. If the priority switch is “on”, a call from the indirect water thermostat also turns off the heating circulator. CAUTION: Do not use the factory supplied transformer to power zone valves or other loads external to the boiler.

C. CB502 Control System – Sequence of Operation

(Refer to Figures 35 and 36 for ladder and connection diagrams)

1) When no call for heat is present and 120 VAC power is supplied to the boiler, the transformer is energized. The “PWR” LED connected across the transformer secondary glows.

2) Assuming that no call for heat is present from the “DHW/H2” thermostat connections, a call for heat from the “Heat 1” thermostat will apply voltage across relay coil 1K and the “Heat” LED.

3) When the 1K relay coil is energized, contacts 1K1 make, starting the heating circulator. Contacts 1K2 also make, sending power to the high limit.

4) Assuming that the high limit is made, voltage will appear across the “Limit” LED which will illuminate, verifying that the high limit switch is closed.

5) At this point, the pressure switch should be open and continuity should be present between the COM” and “N.C.” contacts on the pressure switch. If this is the case, relay coil 3K will be energized along with the “FAN” LED. In the event that the pressure switch is stuck in “fan proven” position at the beginning of the operating sequence, the “NC” contact on the pressure switch will be open at this point and the operating sequence will not proceed further. This prevents the boiler from ﬁ ring if the pressure switch is stuck in the “fan proven” position.

6) Once relay coil 3K1 is energized, contacts 3K1 and 3K2 make. Contacts 3K1 energize the fan. Contacts 3K2 provide a “latch” for coil 3K, ensuring that coil 3K remains energized after the pressure switch “normally closed” contacts open.

7) Once the combustion fan has created an adequate pressure differential across the pressure switch, the pressure switch “NO” contacts will make. Voltage is then applied across both the “PRESS” LED and the ignition module.

8) After 30 seconds has passed, the ignition module will initiate an ignition spark and apply 24 VAC across the pilot valve (terminals “PV” and “MV/PV” on the gas valve).

9) If pilot ﬂ ame is established before the 90 second trial for ignition period has ended, the spark will stop. Voltage is then applied across the main valve (gas valve terminals “MV” and “MV/PV”) opening the valve and establishing main ﬂ ame.

10) If no pilot ﬂ ame is detected during the 90-second trial for ignition period, the pilot valve will close and the module will wait 30 seconds. It will then go through at least one more 90 second trial for ignition period, depending on the exact module supplied with the boiler.

11) A call for heat from the DHW/H2 thermostat will energize relay coil 2K and the “DHW” LED. Relay contacts 2K1 make, starting the domestic water circulator. SPDT contacts 2K2 also change position, breaking one current path to relay coil 1K and energizing the high limit. The boiler will then start following the sequence outlined in Steps (4) - (10).

12) The “priority switch “SW1” is “on” when it is open and “off” when it is closed. If the priority switch is “off”, a current path will still exist to relay coil 1K after the 2K2 N.C. contacts have opened. If the priority switch is “on” (as shown in Figure

35), relay coil 1K will be de-energized, causing contacts 1K1 and 1K2 to open. The “heat” circulator will be de-energized, but the burner will continue to ﬁ re because the 2K2 “NO” contacts are made.

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FIGURE 33: CB502 CONTROL SYSTEM - FIELD WIRING FOR TWO CIRCULATOR ZONES

FIGURE 34: CB502 CONTROL SYSTEM - FIELD WIRING FOR HYBRID CIRCULATOR/ZONE VALVE SYSTEM

Page 44

FIGURE 35: CB502 CONTROL SYSTEM - INTERNAL LADDER DIAGRAM

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FIGURE 36: CB502 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM

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D. R8285 Control System - Single Zone Wiring

1) Line Voltage (120 VAC) Connections (Fig 37) – The line voltage connections are located in the junction box under the R8285 fan center on the right side of the boiler.

• Black – Line voltage “hot”

• White – “Neutral” for boiler and circulators

• Green – Ground connection

2) The circulator is factory wired. If a different circulator is wired to the boiler, its full load current draw must not exceed 12A.

3) Connect the 24-volt thermostat to terminals “R” and “G” on the R8285 fan center. Set the heat anticipator to 0.34 Amps.

E. R8285 Control System - Wiring Variations

1) Multiple Circulator Zones – Figure 38 shows wiring for two or more circulator zones using Honeywell R845As. One fewer R845A is used than the total number of circulator zones. A DPST Honeywell RA832A may be substituted in place of the R845A using the “X” and “X” terminals in place of the “5” and “6” terminals on a R845A.

A call for heat from the “zone #1” thermostat causes the zone #1 circulator to start and the boiler to ﬁ re exactly as in a

single zone system (see “Sequence of Operation”). A call for heat from any other thermostat will energize the DPST relay in that zone’s R845A. When this relay is energized, electrical continuity is created between terminals 3 and 4, energizing the circulator for that zone. At the same time, electrical continuity is created between terminals 5 and 6 on the R845A, creating a current path from terminal “R” to “Y” on the R8285 fan center in the CWD. Assuming that the supply water temperature is below the high limit setting, the normal ignition sequence will be initiated. If this happens when there is no call from the zone #1 thermostat, the relay on the R8285A will not be energized and the zone #1 circulator will remain off.

2) Multiple Zones using Zone Valves – Figure 39 shows wiring for multiple zones using Honeywell V8043F zone valves. This wiring diagram may be used for other 24-volt zone valves as long as they are equipped with end switches. Do not attempt to use the transformer on the R8285 to power the zone valves; use a separate transformer. Up to ﬁ ve V8043Fs may be powered by one 40VA transformer, such as the Honeywell AT87A.

A call for heat from a given thermostat will result in the application of 24 volts across the TH and TR terminals on the

corresponding zone valve, energizing the zone valve motor. The zone valve opens and the end switch contacts are then made. The end switches are connected in parallel with each other and to the CWD “thermostat” connections so that any zone valve that opens will also start the circulator and ﬁ re the boiler (assuming the high limit is not open). Zone valve terminal TH/TR has no internal connection on the zone valve; it is merely a “binding post” used to connect two or more wires.

F. R8285 Control System – Sequence of Operation

(Refer to Figures 40 and 41 for ladder and connection diagrams)

1) A call for heat from the thermostat energizes relay coil 1K (the relay on the R8285), causing contacts 1K1 and 1K2 to make. Contact 1K1 starts the circulator. Contact 1K2 sends power to the high limit.

2) Assuming that the high limit is made, current will ﬂ ow through the normally closed contacts on the pressure switch to relay coil “2K” (the R8222 relay coil). Contacts 2K1 make, starting the combustion blower. Contacts 2K2 make, creating a current path in parallel with the normally closed pressure switch contacts.

3) As the combustion fan comes up to full speed, the normally closed contacts on the vacuum switch break. Power remains applied to the 2K coil, however, through the 2K2 contacts. Once the combustion fan has created adequate pressure across the pressure switch, the normally open contacts on the pressure switch will make, sending power to the ignition module.

4) After 30 seconds has passed, the ignition module will initiate an ignition spark and apply 24 VAC across the pilot valve (terminals “PV” and “MV/PV” on the gas valve).

5) If pilot ﬂ ame is established before the 90 second trial for ignition period has ended, the spark will stop. Voltage is then applied across the main valve (gas valve terminals “MV” and “MV/PV”) opening the valve and establishing main ﬂ ame.

6) If no pilot ﬂ ame is detected during the 90-second trial for ignition period, the pilot valve will close and the module will wait 30 seconds. It will then go through at least one more 90 second trial for ignition period, depending on the exact module supplied with the boiler.

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FIGURE 37: R8285 CONTROL SYSTEM - SINGLE ZONE FIELD WIRING

FIGURE 38: R8285 CONTROL SYSTEM - FIELD WIRING FOR TWO CIRCULATOR ZONES

Page 48

FIGURE 39: R8285 CONTROL SYSTEM - ZONE VALVE FIELD WIRING

FIGURE 40: R8285 CONTROL SYSTEM - INTERNAL LADDER DIAGRAM

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FIGURE 41: R8285 CONTROL SYSTEM - INTERNAL CONNECTION DIAGRAM

Page 50

X Start-up and Checkout

WARNING

• Never attempt to ﬁ ll a hot empty boiler.

• Never use a ﬂ ame to check for gas leaks.

• Make sure that the area around the boiler is clear and free from combustible materials, gasoline, and other ﬂ am- mable vapors and liquids.

• If antifreeze is used in the system, it must be a nontoxic type such as propylene glycol.

NOTE

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the

boiler when the boiler underwent the tests speciﬁ ed in Z21.13.

Use the following procedure for initial start-up of the boiler:

1) Make sure that the boiler and system are ﬁ lled with water.

2) Check all new gas piping for leaks and purge piping sections that are ﬁ lled with air. See the National Fuel Gas Code for additional information on testing and purging gas lines.

3) Verify that vent system is complete and free of obstructions before attempting to ﬁ re boiler. Make sure that the silicone cure time called for in the vent assembly instructions has passed before ﬁ ring boiler.

4) Inspect all wiring for loose or uninsulated connections.

5) Adjust thermostat to the highest setting.

6) Start the boiler using the lighting instructions on the opposite page.

7) Upon initial start-up, the gas train will be ﬁ lled with air. Even if the gas line has been completely purged of air, it may take several tries for ignition before a ﬂ ame is established. Once a ﬂ ame has been established for the ﬁ rst time, subsequent calls for burner operation should result in a ﬂ ame on the ﬁ rst try.

8) Observe pilot burner ﬂ ame. Pilot burner produces three ﬂ ames. The center one should be a steady medium blue ﬂ ame covering around 3/8” to ½” of spark electrode / ﬂ ame rod (Figure 42).

9) Inspect the main burner ﬂ ames visible through the observation port in burner access panel. The ﬂ ame should be stable and mostly blue. No yellow tipping should be present; however, intermittent ﬂ ecks of yellow and orange in the ﬂ ame are normal (Figure 43).

10) Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is ﬁ ring. Fix any leaks found immediately.

11) Run gas valve safety shutdown test. With main burners ﬁ ring, disconnect ignition cable from ignition module. Both pilot burner and main burners should stop ﬁ ring.

Page 51

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life.

A. This appliance is equipped with an ignition

device which automatically lights the pilot. Do try to light the pilot by hand.

not

B. BEFORE LIGHTING smell all around the

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance. Do not touch any electric switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the pilot. Do try to light the pilot by hand.not

If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

5. Remove front access panel.

6. Rotate the gas control knob clockwise to OFF.

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas go to the next step.

GAS CONTROL KNOB (SHOWN IN “ON” POSITION)

GAS OUTLET

GAS VALVE - TOP VIEW

GAS INLET

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

8. Rotate the gas control knob counter clockwise to “ON”.

9. Replace front access panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

3. Push in gas control knob slightly and turn clockwise to “OFF”. Do not Force.

Page 52

WARNING

Failure to follow the following procedure exactly could result in over-ﬁ ring of the boiler and a carbon monoxide hazard.

12) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a) Connect a manometer to the line pressure tap on the gas valve (see Figure 44).

b) Check the line pressure with all gas appliances on and off. The line pressure at the boiler must be within the following

limits regardless of what combination of appliances is ﬁ ring:

Line Press (inches w.c.) Natural Gas LP Gas Minimum 5.0 11.0 Maximum 14.0 13.0

If the line pressure falls outside of these limits, ﬁ nd and correct the cause of the problem before proceeding further. c) Disconnect the silicone regulator tube from the hose barb on the gas valve (Figure 45).

d) Connect a manometer to the manifold (outlet) pressure tap on the gas valve (Figure 44). e) Read the manifold pressure. It should be set at:

Natural Gas LP Gas Manifold Press. (inches w.c.) 3.5 10.0

e) If a manifold pressure adjustment is needed, make the adjustment by turning the regulator screw (see Figure 44)

clockwise to raise the pressure and counter-clockwise to reduce the pressure. If a manifold pressure adjustment is made, recheck the line pressure to be certain that it is still within acceptable limits. Replace the cover screw on the regulator.

f) Reconnect the silicone regulator tube disconnected in Step (c)

13) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. Circulator should stop

running. Raise the thermostat back to the highest setting. Circulator should restart. The pilot burner and main burners should relight.

14) Verify high limit operation. Allow the boiler water temperature to increase to high limit setting. Circulator should continue

running and pilot burner and main burners should stop ﬁ ring. When water temperature drops below the limit setting, the pilot burner and main burners should relight.

15) After the boiler has operated for approximately 30 minutes, check the boiler and heating system piping for leaks. Repair any

leaks found at once.

16) Inspect the vent system for ﬂ ue gas leaks. Repair any leaks found before leaving the boiler in operation.

FIGURE 42: PILOT BURNER FLAME

FIGURE 43: MAIN BURNER FLAME

Page 53

FIGURE 44: GAS VALVE

FIGURE 45: MEASURING MANIFOLD PRESSURE

Page 54

XI Service and Maintenance

The following routine maintenance should be performed on an annual basis:

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 ﬂ ange 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. f) Carefully remove the burner assembly being careful not to damage the ﬁ redoor insulation or the manifold gasket.

3) Inspect the ﬂ ue passages for signs of blockage. If there is any carbon in the combustion chamber or the ﬂ ue passages, clean

the heat exchanger before proceeding further. See the cleaning procedure below.

4) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation.

5) Inspect and clean the burners. Clean the burners by ﬁ rst brushing the ports with a soft bristle brush and then vacuuming out

any debris through the venturi opening. If burners show signs of deterioration, they should be replaced (some discoloration around the burner ports is normal).

6) Inspect the pilot assembly. Clean any deposits found on the electrode and grounding strap. The ideal gap between the

electrode and the ground strap is 1/8”. Inspect the porcelain for cracks or other deterioration. Replace pilot assembly if deterioration is found. Inspect the ignition cable insulation for cracks or other deterioration. If deterioration is found, replace cable assembly.

7) Inspect the combustion chamber insulation for deterioration. Replace insulation if necessary.

8) Inspect all boiler wiring for loose connections or deterioration.

9) Inspect the vent system:

• Make sure that the vent system is free of obstructions.

• Make sure that all vent system supports are intact.

• Inspect joints for signs of condensate or ﬂ ue gas leakage.

• Inspect venting components for corrosion or other deterioration. Replace any defective vent components.

10) Inspect the boiler and hydronic system for leaks.

11) Place the boiler back in operation using the procedure outlined in Part X. Check the pilot line and any other gas piping

disturbed during the inspection process for leaks.

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

CAUTION

Water leaks can cause severe corrosion damage to the boiler or other system components. Repair any leaks found immediately.

Page 55

Heat Exchanger Cleaning Procedure

WARNING

Soot deposits in the ﬂ ue 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 ﬂ ue 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 ﬂ ue gas. A CO “sniffer” designed for testing CO levels in ambient air cannot be used to check boiler combustion. Take a ﬂ ue gas sample by inserting a sample probe through the vent terminal. Do not take a sample until the boiler has been ﬁ ring for at least ﬁ ve 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 oriﬁ ce

• Partially plugged ﬂ ue 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 ﬂ ue collector and heat exchanger

• Distorted or missing combustion chamber ﬂ oor

• 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 ﬂ ange 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 ﬁ redoor 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 ﬂ ue collector lugs. Slide the ﬂ ue collector lugs off of each ﬂ ue collector ﬂ ange.

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

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

10 Remove the stainless steel ﬂ ue bafﬂ e from each ﬂ ue passage.

11) Clean the ﬂ ue 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 ﬂ ue passages from the top to verify that they have been

thoroughly cleaned.

14) Replace the ﬂ ue bafﬂ es.

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

Page 56

16) Set the ﬂ ue collector onto the block and press down so that the ﬂ ue collector is set into the silicone applied in the previous step.

17) Slide the ﬂ ue collector lugs back into position and retighten the ¼-20 bolts. DO NOT OVER TIGHTEN.

18) Apply a bead of silicone around the outside of the joint between the heat exchanger and the ﬂ ue collector.

19) Reattach all the jacket components.

20) Reconnect the pressure switch tubes (see Figure 46 for correct tubing orientation).

21) Reconnect the fan.

22) Reconnect the vent system.

23) Reinstall the burner tray.

Service Notes

1) Oriﬁ ce Size – Sea level oriﬁ ce sizes are:

Natural Gas – #50 Drill Size LP Gas – Consult Factory

Consult your Crown representative for correct oriﬁ ce sizes for use at altitudes above 2000 ft. Oriﬁ ce for this boiler cannot

be drilled in the ﬁ eld.

2) Operating the Boiler with Intake Cover Removed – For inspection and troubleshooting purposes, this boiler may be started and run with the intake cover removed. When this is done, a resonance (“hum”) may be observed. This is normal and should disappear as soon as the intake cover is replaced.

WARNING

Do not leave the boiler in service with the intake cover removed.

3) Pressure Switch – This boiler is equipped with a differential pressure switch which makes when there is adequate ﬂ ue gas ﬂ ow through the boiler. This switch measures the pressure drop across an oriﬁ ce plate inside the ﬂ ue collector - the higher

the ﬂ ue gas ﬂ ow through this plate, the higher the pressure drop. The N.O. contacts on the pressure switch make, allowing the boiler to ﬁ re, when the pressure drop across the ﬂ ue collector oriﬁ ce plate switch exceeds the “make setting” shown in Table 7. Once the switch is made, the boiler will ﬁ re as long as the pressure at the switch is above the “break setting” shown in Table 7. The pressure at both pressure switch tappings is actually below atmospheric (“negative”) with the pressure at the upper ﬂ ue collector tap being the more negative of the two pressures. Figure 46a shows the pressure switch connections.

Figure 46b shows the correct method of reading the pressure across the pressure switch tappings. It is normal for the

pressure reading across the switch to drop as the boiler heats up.

4) Burner and Pilot Removal - If necessary, the pilot can be removed without removing the burner tray. To do so, remove the screws holding the main burners on each side of the pilot bracket. The main burners will then be loose enough to allow the pilot hood to slip between them.

Main burners cannot be removed without removing the burner tray from the boiler.

Page 57

TABLE 7: PRESSURE SWITCH SETTINGS

MAKE SETTING*

ALTITUDE CROWN PN

SEA LEVEL - 5200 ft 620009 1.26 1.16

ABOVE 5200 ft 620010 1.10 1.00

(inches w.c.)

*Settings shown are based on “plus tolerance” - actual setting may be lower.

BREAK SETTING*

(inches w.c.)

FIGURE 46a: PRESSURE SWITCH CONNECTIONS

Page 58

FIGURE 46b: MEASURING PRESSURE ACROSS PRESSURE SWITCH

Page 59

XII Troubleshooting

The following pages contain troubleshooting charts for use in diagnosing control problems. If troubleshooting a CB502 control system, go to the box marked “Start” at the top of the chart on page 58 and follow the appropriate path though the chart until a box with a list of possible causes is reached. If troubleshooting a R8285 control system, go to the box marked “Start” at the top of the chart on page 62 and follow the appropriate path though the chart until a box with a list of possible causes is reached.If the problem is known to be within the ignition system, go directly to the ingition system troubleshooting guide on page 64. In using these charts, the following should be kept in mind:

1) These charts are only meant to be used by a professional heating technician as an aid in diagnosing control problems.

2) Where applicable, follow all precautions outlined in the appropriate lighting instructions on page 49.

3) In general, these charts assume that there are no loose or miswired electrical connections. Before using these charts, inspect

all electrical connections on the boiler to make sure that they are tight. Also, check the wiring on the boiler against the

appropriate wiring diagrams in the Wiring section.

4) The possible causes at the end of each branch in these charts are not listed in order of likelihood. All controls on the CWD

are tested at least once in the manufacturing process and a defective control or component is generally the least likely cause.

Before replacing a component, try to rule out all other possible causes.

5) If the charts indicate that the boiler transformer is defective, it is possible that this transformer has been destroyed by a short

circuit in the boiler wiring. Before replacing the transformer, carefully inspect all low voltage wiring on the boiler for places

where it is touching the frame of the boiler or wiring on the other side of the transformer.

6) If the charts indicate that one of the relays in the CB502 board or the R8285 are defective, it is possible that a second

transformer is present in the thermostat or zone valve circuit, resulting in the application of 48 volts across the relay coil. In

older buildings, this transformer may be hidden in a location far from the boiler. If this second transformer exists, it must be

found and removed before the relay is replaced.

Page 60

START

(No call for

heat from

either zone)

120 volts across

black and white

primary leads ?

* Power off * Blown fuse or

tripped breaker * Mi s wired or loose electrical connection in 120 volt line

* Defective transformer.

24volts transformer secondary?

transformer

PWR

LED On?

*Defective transformer harness *Defective CB502

Call from "HEAT 1"

zone

120 volts across red and white circulator

leads?

* Loose connection between boiler J-box circ. * Defective circulator

* Loose connection i n t'stat or zone valve end switch wiring * Defective t'stat or zone valve end s witch * T'stat or zone system miswired-consult zone valve or t ' s tat manufacturer's instructions.

"HEAT 1"

Circulator

start?

HEAT

LED On?

24V across

"HEAT 1" T

and T

"DHW/H2"

PRIORITY"

Swit ch on?

*Defective CB 502 board *Defective "DHW/H2" relay

zone used?

"DHW

*Defective CB 502

* Defective "HEAT 1" relay on CB502 * Relay not fully seated in socket

board

TROUBLESHOOTING CHART FOR BOILERS WITH CB502 CONTROL SYSTEM (USING #42-502A BOARD) PAGE 1 OF 4

Page 61

Call for heat

from

"DHW/H2"

zone

"DHW/H2"

circulator

start?

Continued on

24V across

"DHW/H2" T

and T

Defective

CB502 board

* Loose connection i n t'stat or zone valve end switch wiring * Defective t'stat or zone valve end s witch * T'stat or zone system miswired-consult zone valve or t 'stat manufacturer's instructions.

DHW

LED On?

120 volts across

blue and white

circulator leads?

* Defective "DHW/H2" relay on CB502 * Relay not fully seated in so cke t * Loose connection i n circulator wi ring

*Loose connection between boiler J-box and ci rc

TROUBLESHOOTING CHART FOR BOILERS WITH CB502 CONTROL SYSTEM (USING #42-502A BOARD) PAGE 2 OF 4

Page 62

Continued

from previous

page

LIMIT

LED on?

Fan On?

PRESS

LED on?

YYY

* Mis sing or loose "RESET CONTROL" jumper *Mis sing or loose "CN1" jumper *Defective CB502 board

* Boiler water temp over L4080D setpoint *Defective L4080D

* Kinked or blocked vacuum switch t ubing * Defective vacuum switch

FAN

24 volts present

across yellow transformer lead and red lead on pressure

24V between

brown lead on

limit and yellow

lead on

transformer?

24 volts present

across yellow

transformer lead and

purple lead on

pressure switch?

LED on?

Unplug fan and check for 120V

across H FA N and N FAN on

CB502 board

switch?

*Loose pressure swit ch harness *Defective CB502 board

* Loose connection at fan plug or fan capacitor * Defective capacitor * Defecti ve fan

120 volts

present?

*Defective "FA N" relay *Defective CB502 board

*Tubes reversed on

pressure switch *Leak in tubes at pressure switch connection *Loose pressure switch harness connection *Defective CB502 board

Minimum

pressure at

switch called in

Table 7 present

across switch?

TROUBLESHOOTING CHART FOR BOILERS WITH CB502 CONTROL SYSTEM (USING #42-502A BOARD) PAGE 3 OF 4

Page 63

Wait 30 seconds (prepurge)

Pilot

light?

Main

burners

light?

Do burners shut

down before gauge temp

exceeds high limit

setting +15F?

24 volts

between 24V

and

24V (GND) on

ign. module?

*Loose harness *Defective CB502 board

*Loose, leaking, blocked, or rev ersed pressure switch tubes *Leaks in flue collector joints *Foreign object in fan or flue collector

* Blockage in venting system * Vent sy stem not installed in

accordance with i ns tallation manual * Ex ces sive silicone on I.D. of vent system joints

* Damaged or missing fan gasket * Defecti ve fan * Wind at horizontal v ent terminal in

excess of 40 mph *Incorrect fan outlet orifice

See "Intermitt ent Ignit ion System Troubleshooting Chart" on page 64

* Defective L4080D * Sensing bulb not bottomed

out in well

Do burner,

circulator and

fan shut down at

end of call for

heat?

Does boiler shut down when t'st at

wire is removed from

t'sat terminal

END

* T'stat or zone sy stem calling for heat

* T'stat wires shorted

* Internal boiler w iring

problem, consult Crown representative

TROUBLESHOOTING CHART FOR BOILERS WITH CB502 CONTROL SYSTEM (USING #42-502A BOARD) PAGE 4 OF 4

Page 64

START

Thermostat

calls for heat

Circulator

start?

24volts across R and C on R8285

fan center?

Induced

draft fan

start?

Unplug fan and check for 120 volts across black and white connections on female half of plug.

Wait 30 seconds (prepurge)

* Power off * Blown fuse or

tripped breaker * Mi swired or loose electrical connection in 120 volt line

* Defective transformer. Replace R8285.

120 volts across

black and white

transformer

primary leads on

back of R8285 ?

* Loose connection i n t'stat or zone valve end switch wiring * Defective t'stat or zone valve end switch * T'stat or zone system miswired-consult zone valve or t'stat manufacturer's instructions.

120 volts across

circulator

connections?

24 volts across

G and C on

R8285 fan

center?

* Loose connection at fan plug or fan capacitor * Defective capacitor * Defecti ve fan

24 volts pres ent

across yellow

and orange

connections on

R8222?

120 volts

present?

Reconnect fan

24 volts

present across

yellow and

purple leads on

R8222?

* Defective R8222 relay * Socket not fully seated on relay

* Defective relay on R8285 * Relay not fully seated in so cke t * Loose connection i n circulator wi ring

* Defective circulator

* Kinked or blocked pressure switch tubing * Defectiv e pres sure switch

* Boiler off on high limit * Defective L4080D

TROUBLESHOOTING CHART FOR BOILERS WITH R8285 CONTROL SYSTEM - PAGE 1 OF 2

Page 65

Pilot

light?

END

Main

burners

light?

Do burners shut

down before

gauge temp

exceeds high limit

setting +15F?

24 volts

between 24V

and

24V (GND) on

ign. module?

Minimum

pressure at

switch called in

Table 7 present

across switch?

See "Intermittent

Ignition System Troubleshooting Chart" on page 64.

* Defective L4080D * Sensing bulb not bot t omed

out in well

Do burner,

circulator and

fan shut down at

end of call for

heat?

Does boiler shut down when t'stat

wire is removed from

terminal R on

R8285?

*Tubes reversed on pressure switch *Leak in tubes at pressure switch connection *Loose pressure switch harness connection

* Blockage in venting system * Vent system not installed in

accordance with i nstallation manual * Ex cessive s ilicone on I.D. of vent system joints * Blockage, condensate or leakage in vacuum swit ch t ubing

* Improperly sealed flue collector * Damaged or missing fan gasket * Defecti ve fan * Wind at horizontal vent terminal in

exces s of 40 mph

* Internal boi ler w iring problem, consult Crown representative

* T'stat or zone system calling for heat * T'stat wires shorted

TROUBLESHOOTING CHART FOR BOILERS WITH R8285 CONTROL SYSTEM - PAGE 2 OF 2

Page 66

START

(24 volts is present across 24V and 24V (GND) on

Igni t ion Module, 30 second prepurge period has

passed)

IMPORTANT: ALL PILOT TROUBLESHOOTING ON THIS CHART MUST BE PERFORMED AFTER THE 30 SECOND PREPURGE HAS ENDED AND BEFORE THE END OF THE 90 SECOND TRIAL FOR IGNITION PERIOD.

Pulsing

Spark

across

ignitor/sensor

gap?

* Module is in soft lockout. Reset by momentarily interupting power to boiler and wai ting for prepurge. * Break in spark cable insulation * Break in pi lot porcelain * Incorre ct pilot spark gap * Loose connection in spark cable * Loose ground connection * Defective Ignition Module

* Low inlet gas pressure * Plugged, kinked or leaking

pilot tubi ng

* Plugged pilot ori fice * Gas line not purged of air * Defective pilot assembly * Defective gas valve

Pilot

lights?

24 volts

across

terminals PV

& MV/PV at

module?

24 volts

across PV &

MV/PV at gas

valve?

* Defective EI wiring harness.

* Defective module

Does

spark stop

when pilot

lights?

* Loose connection in ignition cable or ground wire * Pilot electrode porcelain cra cke d * Pilot flame not coveri ng gap between electrode and grounding strap * Low inlet gas pressure * Defective module

Main burner lights?

24VAC

across

terminals MV

& MV/PV on

module?

24 volts between MV & MV/PV on gas

valve?

*Defective EI harness

* Defective gas valve

END

* Defective module

TROUBLESHOOTING CHART FOR IGNITION SYSTEMS USING UT 1003-626A IGNITION MODULE

Page 67

XIII PARTS

The following parts may be obtained from any Crown distributor. To ﬁ nd the closest Crown distributor, consult the area

Crown representative or the factory at:

Crown Boiler Co. Customer Service P.O. Box 14818 Philadelphia Pa. 19134 www.crownboiler.com

Main burner oriﬁ ce shown are for sea level conﬁ gured boilers. For boilers installed at elevations above 2000 ft, consult the

local Crown representative or the factory for the correct main burner oriﬁ ce.

In some cases, the following parts lists do not include Crown part numbers because they were not available at the time of

printing. Order these parts by their description, specifying the boiler model number on which they are to be used.

Page 68

BLOCK, BASE, FLUE COLLECTOR COMPONENTS

PART

KEY DESCRIPTION

1 BASE 1 620113 620114 620115 620116 620117 620118 620119 620120 2 NYLON FEET (GLIDES) 700111 44444444 3 INTAKE BOX 1 620233 620234 620235 620236 620237 620238 620239 620240

4 1/4-20 X1/2 PAN HEAD SCREW 900100 14 14 14 14 14 14 14 14 5 5/16-18 X 1 1/4 TAP BOLT 900101 22222222 6 COMPLETE CAST IRON BLOCK ASSEMBLY 1 620013 620014 620015 620016 620017 620018 620019 620020 * LEFT END SECTION 620011 11111111 * INTERMEDIATE SECTION 620006 12345678 * RIGHT END SECTION 620012 11111111 * PUSH NIPPLE 620008 4 6 8 10 12 14 16 18

5/16-18 X 1 1/2 FULLY THREADED ZINC

PLATED STUDS

8 5/16 USS FLAT WASHER 900102 14 14 14 14 14 14 14 14 9 5/16-18 S,S HEX NUT 90-010 88888888

10 5/16-18 NYLON INSERT HEX NUT 900103 22222222

3/4 X 1/4 BLACK IRON REDUCING

BUSHING

12 3/4 IN BLACK IRON PLUG 95-048 22222222 13 3/4” HIGH LIMIT WELL 14 CWD DISTRIBUTOR PIPE 1 620143 620144 820145 620146 620147 620148 620149 620150

3/8-16 X 1 1/4 ZINC PLATED HEX HEAD

CAP SCREW 16 FLUE BAFFLE 620100 23456789 17 TINNERMAN NUT 90-217 10 10 12 12 12 12 12 12 18 10-32 X 1/8 I.D.HOSE BARB 90-222 33333333 19 10-32 HEX NUT 90-219 33333333 20 REAR FIREDOOR 1 620203 620204 620205 620206 620207 620208 620209 620210 21 REAR FIREDOOR INSULATION 1 620533 620534 620535 620536 620537 620538 620539 620540 22 1 1/4 CUP HEAD PIN 900203 44666666 23 1 1/4 SELF LOCKING WASHER 900200 44666666 24 1” CERAFELT SEALING STRIP 900145 0.75 FT 1.05 FT 1.35 FT 1.65 FT 1.95 FT 2.25FT 2.55 FT 2.85 FT 25 5/16-18 X 3/4 HEX CAP SCREW 900400 44444444 26 FLUE COLLECTOR 1 620123 620124 620125 620126 620127 620128 620129 620130 27 FLUE COLLECTOR LUG 60-501 22222222 28 FAN GASKET 1 620002 620002 620002 650002 650002 650002 650002 650002 29 FAN ASSEMBLY 1 620001 620001 620001 60-001 60-001 60-001 60-001 60-001

* REPLACEMENT FAN CAPACITOR 1 620003 620003 620003 60-003 60-003 60-003 60-003 60-003 30 1/4-20 HEX NUT 90-202 44444444 31 COLLAR GASKET 60-600 22222222 32 FAN OUTLET ORIFICE 1 620133 650136 620135 620136 620137 620138 620139 650138 33 10-32 X1/2 SLOTTED ROUND SCREW 90-058 66666666 34 #10 FLAT WASHER 90-057 44444444 35 COMB CHAMBER FLOOR 1 620223 620224 620225 620226 620227 620228 620229 620230 36 DISTRIBUT0R SCREEN 1 620253 620254 620255 620256 620257 620258 620259 620260

10-32 X1/2 SLOTTED HEX WASHER SCREW,

TYPE “F”, ZINC PLATED 38 INTAKE BOX INSULATION 1 620553 620554 620555 620556 620557 620558 620559 620560 39 INTAKE COVER 1 620213 620214 620215 620216 620217 620218 620219 620220 40 INTAKE COVER GASKET 1 620613 620614 620615 620616 620617 620618 620619 620620 41 SIGHT GLASS 60-052 11111111 42 SIGHT GLASS GASKET 60-056 11111111 43 SIGHT GLASS FRAME 60-055 11111111 44 #10 X 3/4 HEX HEAD TYPE “B” SCREW 90-054 10 10 12 12 12 12 12 12 45 3 “ VENT COLLAR 60-603 11111100 45 4” VENT COLLAR 60-604 00001111

* 10.1 oz TUBE SILICONE SEALANT 90-045 11111111

# OR

QTY.

900425 44444444

950017 11111111

900452 11111111

900155 25 31 37 43 49 55 61 67

CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245

35-

1010

11111111

PART # OR QTY.

* NOT PICTURED

Page 69

Page 70

BURNER TRAY COMPONENTS

PART#

KEY DESCRIPTION

50 FRONT FIREDOOR 1 620543 620544 620545 620546 620547 620548 620549 620550 51 FRONT FIREDOOR INSULATION 1 620523 620524 620525 620526 620527 620528 620529 620530 52 INSULATION SUPPORT BRACKET 620101 22222444 53 MICA SIGHT GLASS 60-050 11111111 54 1/8 ALUMINUM POP RIVET 90-068 22222222 55 BURNER MANIFOLD 1 620153 620154 620155 620156 620157 620158 620159 620160 56 #49 ORIFICE (SEA LEVEL, NAT GAS) 950305 40000000 56 #50 ORIFICE (SEA LEVEL, NAT GAS) 950306 0 6 8 10 12 14 16 18 56 #56 ORIFICE (SEA LEVEL, LP GAS) 950331 40000000 56 #57 ORIFICE (SEA LEVEL, LP GAS) 950332 0 6 8 10 12 14 16 18 57 MANIFOLD GASKET 60-151 11111111 58 MANIFOLD GASKET PLATE 60-150 11111111 59 3/4” 90 DEGREE FLANGE 35-1055 11111111

HONEYWELL VR8204C2328 GAS VAL VE

(NAT GAS) HONEYWELL VR8304P2342 GAS VAL VE

(NAT GAS) HONEYWELL VR8204P2294 GAS VAL VE

(LP GAS) HONEYWELL VR8304P3522 GAS VAL VE

(LP GAS) 61 1/8” GAS VALVE HOSE BARB HW#394537 35-1060 11111111 62 BECKETT GAS BURNERS 150620 4 6 8 10 12 14 16 18 63 PILOT BRACKET 150625 11111111

Q3481B1131 PILOT ASSEMBLY (NAT GAS)

- INCLUDES IGNITION CABLE

Q3481B1149 PILOT ASSEMBLY (LP GAS)

- INCLUDES IGNITION CABLE 65 30” X 1/8” PILOT TUBING 90-043 11111111 66 IGNITION GROUND HARNESS 9601101 11111111

67 10-32 X 3/16 HEX HEAD PILOT SCREW

1/8 SHORT FERRULE (INCLUDED WITH

GAS VALVE) 1/8 LONG FERRULE (INCLUDED WITH

PILOT ASSY.) KF24 PILOT ORIFICE (NAT GAS) -

INCLUDED WITH PILOT ASSY. K14 PILOT ORIFICE (LP GAS) -

INCLUDED WITH PILOT ASSY.

QTY.

3507400 11111000

3507410 00000111

3507405 11111000

3507245 00000111

3504100 11111111

3504105

146-95-

35-1600

35-1650

CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245

301

11111111

PART # OR QTY.

Page 71

Page 72

JACKET COMPONENTS

PART#

KEY DESCRIPTION

80 VESTIBULE PANEL 1 620323 620324 620325 620326 620327 620328 620329 620330 81 LARGE PLASTIC BUSHING 960051 11111111 82 FAN COVER PLATE 1 620302 620302 620302 60-300 60-300 60-300 60-300 60-300 83 #10 X 1/2 SHEET METAL SCREW 90-212 31 31 32 31 34 36 36 36 84 LH JACKET PANEL 620301 11111111 85 RH JACKET PANEL 620300 11111111 86 REAR JACKET PANEL 1 620303 620304 620305 620306 620307 620308 620309 620310 87 PLASTIC BUSHING 96-050 22222222 88 CONTROL PANEL 620350 11111111 89 TOP JACKET PANEL 1 620323 620324 620325 620326 620327 620328 620329 620330 90 CWD FRONT JACKET PANEL 1 620323 620324 620325 620326 620327 620328 620329 620330 91 DOOR KNOB 90-210 22222222 92 8-32 X 1/4 MACH. SCREWS 90-211 22222222

QTY

CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245

PART # OR QTY

Page 73

Page 74

COMMON CONTROLS & TRIM

PART#

KEY DESCRIPTION

* 1/8” SILICONE TUBING 14-008 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 100 HONEYWELL L4080D LIMIT 35-3300 11111111 101 TRIDICATOR GAUGE 95-069 11111111 102 UT IGNITION MODULE 1003-626A 3503062 11111111 103 MODULE BRACKET 905000 00001111

* INTERMITTENT IGNITION HARNESS 9601100 11111111 104 4X4 JUNCTION BOX 96-055 11111111

SEA LEVEL PRESSURE SWITCH (ALL

105

SIZES) PRESSURE SWITCH (AS NEEDED ABOVE

105

5200FT)

106 #8 X1/2 SHEETMETAL SCREWS 900130 22222222

111 1 1/2 X 1 1/4 BLACK 90 DEGREE ELBOW 950200 11111111 112 ISOLATION FLANGE SET 95-061 11111111 113 TACO 007 CIRCULATOR 95-012 11111111 114 3/4” X 5” NIPPLE 95-044 11111111 115 3/4” 90 DEGREE ELBOW 95-057 11111111 116 3/4” CLOSE NIPPLE 95-105 11111111 117 3/4” ASME RELIEF V ALVE 95-040 11111111 118 3/4” X 4 1/2” NIPPLE 95-102 11111111 119 3/4” COUPLING 95-056 11111111

120 3/4” BOILER DRAIN 95-041 11111111

* CWD FAN EXTENSION HARNESS 9601630 00000011

QTY

620009 11111111

620010

CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245

PART # OR QTY

CONTROLS UNIQUE TO CB502 CONTROL SYSTEM

KEY DESCRIPTION

107 CB502A RELAY BOARD 42-502A 11111111 108 REPLACEMENT RELAY FOR CB502A 42-503 33333333 109 RESET PLUG FOR CB502A 42-504 11111111

* HIGH VOLTAGE HARNESS 1 96-1005 96-1005 96-1005 96-1005 96-1006 96-1006 96-1006 96-1006

* CWD/CB502 TRANSFORMER HARNESS 1 9601620 9601620 9601620 9601620 9601625 9601625 9601625 9601625

* CWD LOW VOLTAGE HARNESS 1 9601635 9601635 9601635 9601635 9601635 9601635 9601635 9601635

110 TRANSFORMER-AT72D1006 35-2100 11111111

QTY

CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245

PART#

PART # OR QTY

CONTROLS UNIQUE TO R8285 CONTROL SYSTEM

PART#

KEY DESCRIPTION

* CWD/R8285 HARNESS #1 1 9601600 9601600 9601600 9601600 9601605 9601605 9601605 9601605

* CWD/R8285 HARNESS #2 1 9601610 9601610 9601610 9601610 9601615 9601615 9601615 9601615

* BWF HARNESS #4 1 9601120 9601120 9601120 9601120 9601120 9601120 9601120 9601120 121 R8285D5001 FAN CENTER 3505555 11111111 122 R8222U1006 RELAY 3505556 11111111 123 R8222 MOUNTING PLATE 620102 11111111

QTY

CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245

* NOT PICTURED

PART # OR QTY

Page 75

Page 76

Appendix A: Special Requirements For Side-Wall Vented Appliances

In The Commonwealth of Massachusetts

IMPORTANT

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows:

1. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisﬁ ed:

a. If there is not already one present, on each ﬂ oor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).

b. A carbon monoxide detector shall be located in the room that houses the appliance or equipment and shall:

i. Be powered by the same electrical circuit as the appliance or equipment such that only one service switch services both the appliance and the carbon monoxide detector; ii. Have battery back-up power; iii. Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and iv. Have been approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527 CMR.

c. A product-approved vent terminal must be used, and if applicable, a product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.

d. A metal or plastic identiﬁ cation plate shall be mounted at the exterior of the building, four feet directly above the location of the vent terminal. The plate shall be of sufﬁ cient size to be easily read from a distance of eight feet away, and read “Gas Vent Directly Below”.

2. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed above four feet above grade the following requirements must be satisﬁ ed:

b. A carbon monoxide detector shall :

i. Be located in the room that houses the appliance or equipment ii. Be either hard-wired or battery powered or both; and iii. Comply with NFPA 720 (2005 Edition)

Page 77

Page 78

Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com

CROWN

Boiler Co

Manufacturer of Hydronic Heatings Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

PN 980060

CWDMANV4

04/09

Crown Boiler CWD220, CWD083, CWD110, CWD193, CWD245 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual