Crown Boiler Cayman Installation guide

Brand: Crown Boiler

Model: Cayman

Category: Fireplaces

Type: Installation guide

CWI Series

Gas-Fired Natural Draft Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be afxed on or adjacent to the boiler

WARNING: Improper installation,

adjustment, alteration, service or

maintenance can cause property

damage, injury, or loss of life. For

assistance or additional informa-

tion, consult a qualied installer,

service agency or the gas

supplier. Read these instructions

carefully before installing.

Models:

• CWI103

• CWI138

• CWI172

• CWI207

• CWI241

• CWI276

• CWI311

• CWI346

• CWI380

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

www.crownboiler.com

D ESIGNED TO L EAD

9902339

FOLLOW ALL INSTRUCTIONS and warnings

printed in this manual and posted on the boiler.

INSPECT THE BOILER ANNUALLY. To keep your

boiler safe and efficient, have a service technician

follow the Service checklist near the end of this

manual.

IF YOU ARE NOT QUALIFIED to install or service

boilers, do not install or service this one.

THE BOILER MAY LEAK WATER at the end of

its useful life. Be sure to protect walls, carpets,

and valuables from water that could leak from the

boiler.

PROTECT YOUR HOME IN FREEZING

WEATHER. A power outage, safety lockout, or

component failure will prevent your boiler from

lighting. In winter, your pipes may freeze and

cause extensive property damage. Do not leave

the heating system unattended during cold weather

unless alarms or other safeguards are in place to

prevent such damage

DO NOT BLOCK AIR FLOW into or around the

boiler. Insufficient air may cause the boiler to

produce carbon monoxide or start a fire.

KEEP FLAMMABLE LIQUIDS AWAY from the

boiler, including paint, solvents, and gasoline.

The boiler may ignite the vapors from the liquids

causing explosion or fire.

KEEP CHILDREN AND PETS away from hot

surfaces of the boiler, boiler piping, and vent pipe.

CARBON MONOXIDE (CO) is an odorless, deadly

gas that may be introduced into your home by

any malfunctioning fuel-burning product or vent

system failure. Consider installing CO alarms near

bedrooms in all levels of the building to warn you

and your family of potential CO exposure.

READ THIS ENTIRE MANUAL before attempting

installation, start-up, or service. Improper

installation, adjustment, alteration, service, or

maintenance may cause serious property damage,

personal injury, or death.

DO NOT DISCONNECT PIPE FITTINGS on the

boiler or in the heating system without first verifying

that the system is cool and free of pressure and

that your clothing will protect you from a release

of hot water or steam. Do not rely solely on the

boiler’s temperature and pressure gage when

making this judgment.

USE PROPER PERSONAL PROTECTION

EQUIPMENT when servicing or working near the

boiler. Materials of construction, flue products, and

fuel contain alumina, silica, heavy metals, carbon

monoxide, nitrogen oxides, and/or other toxic or

harmful substances that can are hazardous to

health and life and that are known to the State of

California to cause cancer, birth defects, and other

reproductive harm.

INSTALL ALL GUARDS, cover plates, and

enclosures before operating the boiler.

SIZE THE BOILER PROPERLY relative to the

design heat load or, if using domestic hot water

priority, the peak hot water load, whichever

is larger. A grossly oversized boiler will cycle

excessively and this will lead to premature failure

of the boiler and its components. Our warranty

does not apply to damage from excessive cycling.

ADHERE TO ALL LOCAL CODE

REQUIREMENTS. Contact your local code

inspector prior to installation. In the absence of

a local code, adhere to the National Fuel Gas

Code ANSI Z223.1/NFPA 54 or CAN/CSA B149.1,

Natural Gas and Propane Installation Code.

ALL WIRING must comply with the National

ElectrIcal Code ANSI/NFPA 70 (in the USA) or the

Canadian Electrical Code CSA C22.1 (in Canada)

and any local regulations.

WARNINGS FOR THE HOMEOWNER

WARNINGS FOR THE INSTALLER

Table of Contents

I. Product Description .................................................... 2

II. Specications ............................................................. 3

III. BeforeInstalling ......................................................... 4

IV. LocatingtheBoiler ..................................................... 4

V. AirforCombustion&Ventilation .............................. 5

VI. Venting ....................................................................... 9

VII.GasPiping..................................................................12

VIII.SystemPiping..........................................................13

IX.TanklessHeaterPiping..............................................18

X.Wiring........................................................................20

XI.Start-Up&Checkout.................................................24

XII.Service&Maintenance.............................................30

XIII.Troubleshooting........................................................33

XIV.Parts...........................................................................40

AppendixA:KnockdownBoilerAssembly.......................46

I Product Description

 TheCWIseriesboilersarelowpressurecastirongasredhotwaterboilersdesignedforuseinclosedhotwaterheating

systems.TheseboilersareCategoryIdraftdiverterequippedappliances,whichmustbeventedbynaturaldraftusingalined

masonryorlistedmetalchimneysystem.Anadequatesupplyofairforcombustion,ventilationanddilutionofuegases

mustbeavailableintheboilerroom.

 TheCWImaybeusedonforcedorgravityhotwaterheatingsystems.CWI103-CWI279includeatanklessheaterfor

domestichotwatergeneration.ThistanklessheaterisoptionalequipmentonCWI311-CWI380

TABLE 1: CWI SPECIFICATIONS

II Specications

FIGURE1:CWIBOILERS-GENERALCONFIGURATION

INPUT

(MBH) (MBH) (Gal/min

)

"A" "B" "C" "D" (Gal)

CWI103 4 103 86 83.1 2.50 16 28 407/16 5 10.0

CWI138 5 138 115 83.1 3.00 191/4 28 407/16 6 12.2

CWI172 6 172 144 83.2 3.50 221/2 28 407/16 6 14.4

CWI207 7 207 173 83.2 3.75/4.50 253/4 30 407/16 7 16.6

CWI241 8 241 201 83.2

3.75/4.75

29 30 407/16 7 18.8

CWI276 9 276 230 83.2

4.00/5.25

321/4 30 407/16 8 21.0

CWI311 10 310 252

81.4

4.00/5.25

351/2 30 457/16 8 23.2

CWI346 11 345 281

81.4

4.00/5.25

383/4 30 457/16 9 25.4

CWI380 12 379 309

81.4

4.00/5.25

42 30 457/16 9 27.6

AHRINETRATINGSSHOWNAREBASEDONAPIPINGANDPICK-UPALLOWANCEOF1.15

THERMALEFFICIENCY

RATINGWITHOPTIONAL"HIGHCAPACITY"TANKLESSHEATER

200

TANKLESSHEATERRATINGSBASEDON40FINLETWATER,140FOUTLETWATERAND190FBOILERWATER.

RATINGSAREALSOBASEDON5MINUTEINTERMITTENTDRAWSWITH10MINUTESBETWEENDRAWS.

AHRINET

RATING

244

269

CWI311-CWI380NOTAVAILABLEFORUSEWITHLPGAS

BASIC

BOILER

MODEL

NUMBER

SECTIONS (MBH)

NATURALORLPGAS

HEATING

CAPACITY DIMENSIONS(in.)

AFUE

(%)

WATER

VOL.

100

219

TANKLESS

HTR.RATING

125

150

175

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requirementsof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-latestedition.

• 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)-latestedition.

2) Makesurethataproperlysizedchimneyisavailablewhichisingoodcondition.Consulttheauthorityhaving

jurisdiction,PartVIofthismanual,andtheNational Fuel Gas Codeforadditionalinformationonventingrequirements.

3) Makesurethattheboileriscorrectlysized.UseanindustryacceptedsizingmethodsuchastheI=B=R Installation

Guide for Residential Hydronic Heating Systems (Pub. #200) and I=B=R Heat Loss Calculation Guide(Pub.#H21or#H22)

publishedbytheHydronicsInstituteinBerkeleyHeightsNJ.

4) Makesurethattheboilerreceivedisconguredforthecorrectgas(naturalorLP).TheCWI311,CWI346andCWI380

mayonlybeusedwithnaturalgas.

5) Boilersinstalledataltitudesabove2000ft.mayrequiredifferentburnersandmainburneroricethanthoseatsealevel.

Makesurethattheboilerisconguredforuseatthecorrectaltitude.

6) Ifthisboilerwasreceivedasaknockdownboiler,followtheinstructionsinAppendixAtoassembletheboiler.

IV Locating the Boiler

1) Clearances:

• Observetheminimumclearancesshownbelow.Theseclearancesapplytoallcombustibleconstruction,aswellas

noncombustiblewalls,ceilingsanddoors.AlsoseeFigure2.

Front–18”  

RightSide:

CWI311-CWI380withoutTanklessHeaters–18”

CWI103-CWI207withTanklessHeater-18”

CWI241-CWI380withStandardTanklessHeater-21”

CWI241-CWI380withHighCapacityTanklessHeater-24” 

LeftSide–6” 

Rear–6”  

Top–17”

WARNING

FAILURE TO OBSERVE THE FOLLOWING LOCATION REQUIREMENTS COULD RESULT

IN A FIRE, EXPLOSION OR CARBON MONOXIDE (CO) HAZARD.

Warning

This Product Must be Installed By A Licensed Plumber Or Gas Fitter when Installed Within The

Commonwealth Of Massachusetts

If This Boiler is Equipped With a Tankless Heater, Tankless Heater Piping Must be Installed by a

Licensed Plumber When Boiler is Installed Within the Commonwealth of Massachusetts

• A24”serviceclearancefromthejacketisrecommendedontheleft,right,andfrontoftheboiler.Theseclearances

maybereducedtothoseshowninFigure2,howeverservicingtheboilerwillbecomeincreasinglydifcultasthese

serviceclearancesarereduced.

• Iftherightside24”serviceclearanceisreduced,adequateclearancemustbemaintainedtoeasilyreadandac-

cessthecontrols.Alternatively,accessmaybeprovidedusingadoor.Therightsideclearancesshownforboilers

equippedwithtanklessheatersallowforremovalofthetanklessheater.

2) Thisboilermaybeinstalleddirectlyoveranon-carpetedcombustibleoor.

3) Theboilermustbeinstalledonahardlevelsurface.

4) Donotinstallthisboilerinalocationwheregasolineorother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.

5) Theboilershouldbelocatedasclosetothechimneyaspossible.

6) Donotinstallthisboilerdirectlyonasurfacethatmaygetwet.Raisetheboileronapad.

V Air for Combustion and Ventilation

WARNING

• INSUFFICIENT COMBUSTION AIR SUPPLY MAY RESULT IN THE PRODUCTION AND

RELEASE OF DEADLY CARBON MONOXIDE (CO) INTO THE HOME WHCH CAN CAUSE

SEVERE PERSONAL INJURY OR DEATH.

• THIS BOILER IS NOT DESIGNED FOR USE IN A SPACE THAT IS DEPRESSURIZED

RELATIVE TO THE OUTDOORS. OPERATING THIS BOILER IN A DEPRESSURIZED SPACE

MAY CAUSE SEVERE PERSONAL INJURY OR DEATH.

FIGURE2:CWIBOILERS-CLEARANCESTOALL

TYPESOFCOMBUSTIBLECONSTRUCTIONAND

NONCOMBUSTIBLECEILINGS,WALLS,AND

DOORS.

“X”

“X” (RH CLEARANCE)

ALL SIZES LESS TANKLESS HEATER - 18“

CWI103 - CWI241 WITH TANKLESS HTR. - 18“

CWI276 - CWI380 WITH TANKLESS HTR. - 21“

CWI207 - CWI380 WITH HIGH CAPY. TANKLESS HTR. - 24“

Sufcientfreshairmustbesuppliedforcombustion,ventilationanduegasdilution.Provisionsforcombustion,ventilation

anduegasdilutionairforgasutilizationequipmentventedbynaturaldraftmustbemadeinaccordancewithlocalbuilding

codesor,inabsenceofsuchcodes,inaccordancewithsections5.3.3and5.3.4(“AirforCombustionandVentilation”)ofthe

National Fuel Gas Code,NFPA54/ANSIZ223.1.

Toensureanadequatesupplyofcombustion,ventilationanduegasdilutionairsupply,startbydeterminingwhether

theboileristobeinstalledinabuildingofunusuallytightconstruction.Agooddenitionofabuildingofunusuallytight

constructionisonewhichhas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

oors,betweenwall-ceilingjoints,betweenwallpanels,atpenetrationsforplumbing,electrical,andgaslines,and

atotheropenings.

For Buildings of Other than Unusually Tight Construction

1) Determinewhethertheboileristobeinstalledinaconnedspace-Aconnedspaceisde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connedspace:

a. 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.

b. 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.

c. 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connedspace.

Example:

 ACWI172ENandawaterheateraretobeinstalledinaroommeasuring6ft-3inx7ftwithan8ftceiling.Thewater

heaterhasaninputof30000BTU/hr:

 TotalinputinthousandsofBTU/hr=(172000BTU/hr+30000BTU/hr)/1000=202

 Volumeofroom=6.25ftx7ftx8ft=350ft

 350/202=1.73.Since1.73islessthan50,theboilerroomisaconnedspace.

2) UnconnedSpace-Naturalinltrationintotheboilerroomwillnormallyprovideadequateairforcombustionand

ventilationwithoutadditionallouversoropeningsintoboilerroom.

3) ConnedSpace-Providetwoopeningsintotheboilerroom,onenearthe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

oor(Figure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.

• 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nerthan¼”(4x4)mesh.

• Ifprovidingopeningsintoadjacentroomsisundesirable,combustionandventilationaircanbebroughtintotheboiler

roomfromoutdoors.Seetheinstructionsunder“ForBuildingsofUnusuallyTightConstruction”.

FIGURE4:ALLAIRFROMOUTDOORS,   

VENTILATEDCRAWLSPACEANDATTIC

FIGURE5:ALLAIRFROMOUTDOORS, 

VIA VENTILATED ATTIC

FIGURE3:BOILERINSTALLEDINCONFINEDSPACE,

ALLAIRFROMINSIDE

FIGURE6:ALLAIRFROMOUTDOORS,USING

 OPENINGSINTOBOILERROOM

FIGURE7:ALLAIRFROMOUTDOORS,USING

 HORIZONTALDUCTSINTOBOILERROOM

For Buildings of Unusually Tight Construction

1) 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.

2) 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oor.

3) Sizeopeningsandductsasfollows:

• Verticalductsoropeningsdirectlyoutdoors(Figure4,Figure5,andFigure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-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(Figure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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nerthan¼”(4x4)mesh.

VI Venting

Ventinstallationmustbeinaccordancewithlocalbuildingcodes,orthelocalauthorityhavingjurisdiction,ortheNational

Fuel Gas Code,NFPA54/ANSIZ223.1.

AtypicalventinstallationisillustratedbyFigure8.Thecomponentsofventinstallationaretheventdamper,ventconnector

andchimney.

1) AcceptableChimneys-ThefollowingchimneysmaybeusedtoventCWIseriesboilers:

• ListedTypeBorLgasvent-Installinaccordancewiththemanufacturer’sinstructions,thetermsofitslisting,and

applicablecodes.

• MasonryChimney-ThemasonrychimneymustbeconstructedinaccordancewiththeStandard for Chimneys,

Fireplaces, Vents, and Solid Fuel Burning Appliances(NFPA211)andlinedwithaclaylinerorotherlistedlining

system.DonotventaCWIseriesboilerintoanunlinedchimney.

2) AcceptableVentConnectors-Thefollowingmaybeusedforventconnectors:

• ListedtypeBorLGasVent

• SingleWallGalvanizedPipe-Use0.018”(26gaugeorheavier).Thesizeandlocationofthechimneymaynot

permittheuseofasinglewallconnectorinsomecases.SeetheNational Fuel Gas Code.Donotusesinglewall

pipeforventconnectorsinattics.

• OtherVentConnectorsPermittedbytheNational Fuel Gas Code.

3) ChimneyandVentConnectorSizing-SizethechimneyandventconnectorinaccordancewiththeNational Fuel Gas

Code.

4) ExteriorChimneys-Anexteriorchimneyhasoneormoresidesexposedtotheoutdoorsbelowtheroofline.Thereare

twoconditionsunderwhichanexteriorchimneymaybeused:

WARNING

• IMPROPER VENTING MAY RESULT IN PROPERTY DAMAGE AND/OR THE RELEASE OF

FLUE GASES, WHICH CONTAIN DEADLY CARBON MONOXIDE (CO), INTO THE HOME,

WHICH CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.

• DO NOT USE PLASTIC VENTING MATERIALS (SUCH AS CPVC, PVC AND RADEL) TO VENT

THIS BOILER.

• INSPECT EXISTING CHIMNEY BEFORE INSTALLING BOILER. FAILURE TO CLEAN OR

REPLACE DAMAGED PIPE OR TILE LINING WILL CAUSE SEVERE INJURY OR DEATH.

• In some very restrictivecases,CWIseriesboilersmaybeventedintoanexteriorceramiclinedmasonrychimney.

SeetheNational Fuel Gas Codeforinformationonwhenexteriorchimneysmaybeused.

• AnexteriormasonrychimneymaybeusedifitislinedwithBventoralistedchimneyliningsystem.

5) Thisboilermaybeventedusingalistedpowerventer.Thepowerventermustbeinsizedandinstalledinaccordance

withthepowerventermanufacturer’sinstructions,thetermsofthepowerventerlisting,andapplicablecodes.Theboiler

mustbeelectricallyinterlockedwiththepowerventertopreventboileroperationifthepowerventerfailstooperate.Before

decidingtouseapowerventer,makecertainthattheuegasexitingthepowerventerwillnotdamageadjacentconstruction

orotherstructures.Alsomakecertainthatthepowerventerterminalwillnotbesubjectedtowindswhichcouldeffectpower

venteroperation.

6) Donotconnecttheventofthisapplianceintoanyportionofamechanicalventsystemoperatingunderpositivepressure.

7) Donotconnecttheboilerintoachimneyueservinganopenreplaceorothersolidfuelappliance.

8) Priortoboilerinstallation,inspectchimneyforobstructionsorotherdefectsandcorrectasrequired.Cleanchimneyas

necessary.

9)Ventpipeshouldslopeupwardfromdraftdiverternotlessthanoneinchinfourfeet.Noportionofventpipeshouldrun

downwardorhavesags.Ventpipemustbesecurelysupported.

10) Theverticalsectionofventpipecomingofftheboilershouldbeastallaspossible,whilestillmaintainingtheproper

clearancefromthehorizontalventconnectortocombustiblesandtheproperpitchcalledforin(9)above.

11) Ventpipeshouldbeinstalledabovethebottomofthechimneytopreventblockage.

12) Ventpipemustbeinsertedushwithinsidefaceofthechimneylinerandthespacebetweenventpipeandchimney

sealedtight.

13) Donotinstalltheventdamperinanyportionoftheventsystemwhichisusedbyappliancesotherthantheboilerbeing

installed.

14) VentdamperinstallationismandatoryonallCWIboilermodelsexcepttheCWI311-CWI380.Installventdamper(see

Figure9)asfollows:

a) Openventdampercartonandremoveinstallationinstructions.Readtheinstructionsthoroughlybeforeproceeding.

Verifythatventdamperissamesizeasdraftdiverteroutlet.SeeFigure1.Unpackventdampercarefully.Do not

force closed damper blade. Forcingventdamperclosedmayresultindamagedgeartrainandvoidwarranty.

b) Ventdamperisfactoryshippedhavingapproximately¾”diameterholeintheventdamperblade,whichmust be

left openforboilersequippedwithstandingpilot,andshouldbepluggedonboilerswithanintermittentpilot,using

theplugsuppliedwiththedamper.

Mounttheventdamperontheuecollarwithoutmodicationtoeitherandsecurewithsheetmetalscrews.Make

surescrewsdonotinterferewithdamperbladeoperation.Ventdamperbladepositionindicatormustbevisibleto

users.

c) Thedamperwireharnessisshippedwiredintotheboilerjunctionbox.Plugthelooseendofthisharnessintothe

damperandsecuretheexibleconduittothedamperusingaconnectornutprovided.

d) Installventconnectorpipeandventttingsfromventdamperoutlettochimneyorgasvent.Securewithsheetmetal

screwsandsupportasrequired.

Removing an Existing Boiler from a Common Chimney

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opening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de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

replacedampers.

FIGURE8:CWIBOILERTYPICALVENTSYSTEM   

INSTALLATION AND COMPONENTS

FIGURE9:VENTDAMPERINSTALLATIONDETAILS

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ve(5)minutesofmainburneroperation.Usethe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,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the

NationalFuelGasCode,ANSIZ223.1.

VII Gas Piping

 Gaspipingtotheboilermustbesizedtodeliveradequategasfortheboilerto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Chapter2oftheNational Fuel Gas Code.

Figure10showstypicalgaspipingconnectiontotheCWIboiler.Asedimenttrapmustbeinstalledupstreamofallgas

controls.Installamanualshut-offvalveoutsidethejacketandgroundjointunionasshown.

FIGURE10:GASCONNECTIONTOBOILER

*StateofMassachusettsRequiresManual

Shut-offValvetobe“T”HandleType

WARNING

• SHUT OFF GAS SUPPLY BEFORE SERVICING THE BOILER.

• ALL GAS PIPING MUST BE GAS TIGHT. USE GAS RATED THREAD COMPOUND

ON ALL THREADED JOINTS TO AVOID LEAKS, WHICH MAY RESULT IN FIRE OR

EXPLOSION.

• SIZE GAS PIPING, REGULATORS, VALVES AND METERS SO AS TO PROVIDE AN

ADEQUATE GAS FLOW AND PRESSURE TO THE BOILER DURING OPERATION.

FAILURE TO DO SO MAY CAUSE POOR COMBUSTION, NOISE, INJURY OR

DEATH.

VIII System Piping

Standard Piping

 Figure11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

BerkeleyHeights,NJ.Thecomponentsinthissystemandtheirpurposesareasfollows:

1) Reliefvalve(Required)-MountthereliefvalveontherightsideoftheboilerasshowninFigure1usingthe3/4nipples

andelbowprovided.Thereliefvalveshippedwiththeboilerissettoopenat30psi.Thisvalvemaybereplacedwithone

havingapressureuptothe“MAWP,WATER”shownontheratingplate.Ifthevalveisreplaced,thereplacementmust

haveareliefcapacityinexcessoftheDOEheatingcapacityfortheboiler.

 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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.

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

11.

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.

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1/2psi.Whenpressuretestingthegassystematpressuresof1/2psiorless,isolatetheboilerfromthegassupply

systembyclosingitsindividualmanualshut-offvalve.

WARNING

• 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 120°F CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.

• OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF

DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION

DAMAGE.

• DO NOT USE TOXIC ADDITIVES, SUCH AS AUTOMOTIVE ANTIFREEZE, IN A

HYDRONIC SYSTEM.

• PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION. THE RELIEF VALVE

MAY DISCHARGE SCALDING HOT WATER.

• 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. BLOCKING THE RELIEF VALVE MAY

RESULT IN BOILER EXPLOSION.

4) FillValve(Required)-Eitheramanualorautomaticllvalvemaybeused.Theideallocationforthe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ll.

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

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

watercutoffhaveamanualresetfunction.Thelowwatercutoffmaybeaoattypeorprobetype,butmustbedesigned

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

interveningvalvesbetweenitandtheboiler.

 Usealowwatercutoffthatbreaksthe120VACsupplytotheboiler.Donotattempttowirea24-voltlowwatercutoff

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themanualreset

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

electricalsupplytotheboiler.

8) FlowControlValve(Requiredundersomeconditions)-Theowcontrolvalvepreventsowthroughthesystemunless

thecirculatorisoperating.Aowcontrolvalvemaybenecessaryonconvertedgravitysystemstopreventgravity

circulation.Flowcontrolvalvesarealsousedtoprevent“ghost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relltheentiresystem.

10) DrainValve-Thedrainvalveisshippedintheboilerpartsbag.Installitintheteeunderthecirculatorasshownin

Figure1.

Piping for Special Situations

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

1) IndirectWaterHeaters-Figure12showstypicalindirectwaterheaterpiping.Boilerpipingisthesameasforanytwo-

zonesystem.Figure12showscirculatorzoning,whichisusuallypreferredforindirectwaterheaters.Sizethecirculator

andindirectwaterheaterpipingtoobtaintheboilerwaterowthroughtheindirectwaterheatercalledforbytheindirect

waterheatermanufacturer.

2) LargeWaterVolumeSystems-ThepipingshowninFigure13willminimizetheamountoftimethattheboileroperates

withreturntemperaturesbelow120°F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120°Fduringthe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CWI.Thesesystemsalsotypicallyhavereturn

temperatureswellbelowthe120°Fminimum.

 Figure14illustratestheuseofaheatexchangertoconnecttheCWI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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

llandexpansiontanksarerequiredfortheheatingsystemloop.

 Thereareseveralotherwaystoconnectlowtemperaturesystemstonon-condensingboilersliketheCWI,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CWI.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.

FIGURE12:INDIRECTWATERHEATER 

 BOILERSIDEPIPING

FIGURE11:STANDARDBOILERPIPING

 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14.

 Consulttheheatexchangermanufacturerforproperheatexchangersizingaswellas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15.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owcontrolvalves

intheboilerpipingorotherautomaticmeanstopreventgravitycirculationduringthecoolingcycle.

7)GravityHotWaterSystems-TheCWIissuitableforinstallationinagravityhotwatersystem.Figure16showspiping

foragravityhotwaterboiler.Thecirculator,1-1/2”x2”bushings,and1-1/2”pipingareremovedandthesystempipingis

rundirectlytothe2”supplyandreturntappingsontheboiler.Ifisolationvalvesareinstalled,theyshouldbegatevalves

or“fullport”ballvalves.

 Ifitisdesiredtoconvertthegravitysystemtoforcedhotwater,thefactorysuppliedcirculatorandpipingareusedasis.

Agravityhotwatersystemisa“largewatervolumesystem”(see(2)above)andshouldbepipedwithabypassasshown

inFigure13.Manygravityhotwatersystemshavebalancingoriceinstalledintheradiators.Theseoricemayneedto

beremovedtoobtainproperheatdistributionwhenthesystemisconvertedtoforcedhotwater.

FIGURE13:BOILERBYPASSPIPING

FIGURE15:BOILERPIPINGWITHCHILLER

FIGURE14:ISOLATIONOFBOILERFROMSYSTEMWITHAHEATEXCHANGER

IX TANKLESS HEATER PIPING

IftheCWIissuppliedwithatanklessheater,pipetheheaterasshowninFigure17.Thecomponentsinthissystemand

theirfunctionsareasfollows:

1)MixingValve(Required)-Duringtheheatingseason,thewaterexitingthetanklessheatermaybe180degreesormore.

Themixingvalveblendshotwaterleavingthetanklessheaterwithcoldwatersoastomaintainthehotwatersupplied

tothexturesataxedtemperature.Thissavesenergy,increasestheamountofusablehotwateravailabletothe

homeowner,andreducestheriskofscalding.

Installamixingvalvewithasettingrangeofapproximately110to130F.Followthemanufacturer’sinstructionsfor

installingthisvalve.Usuallya“heattrap”willberequiredbetweenthecoilandthe“hot”connectiononthemixingvalve.

FIGURE16:GRAVITYPIPING

WARNING

A MIXING VALVE DOES NOT ELIMINATE THE RISK OF SCALDING.

• SET THE MIXING VALVE AND BOILER LOW LIMIT ADJUSTMENTS AS LOW

AS POSSIBLE.

• FEEL WATER BEFORE SHOWERING OR BATHING.

• IF ANTI-SCALD OR ANTI-CHILL PROTECTION IS REQUIRED, USE DEVICES

SPECIFICALLY DESIGNED FOR SUCH SERVICE. INSTALL AND MAINTAIN

THESE DEVICES IN ACCORDANCE WITH THE MANUFACTURER’S

INSTRUCTIONS. DO NOT USE THE MIXING VALVE AS A SUBSTITUTE

FOR PRESSURE BALANCING VALVES OR OTHER DEVICES REQUIRED BY

PLUMBING CODES TO PROTECT AGAINST SCALDING.

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Crown Boiler Cayman Installation guide

Brand: Crown Boiler

Model: Cayman

Category: Fireplaces

Type: Installation guide

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Crown Boiler Cayman Installation guide

Crown Boiler Cayman Installation guide

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