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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
WARNING: Improper installation,
adjustment, alteration, service or
• CWD083
maintenance can cause property
• CWD110
damage, injury, or loss of life. For
assistance or additional information,
• CWD138
consult a qualifi ed installer, service
• CWD165
agency or the gas supplier. Read
these instructions carefully before
• CWD193
i
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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 XIITroubleshooting 57 XIII Parts 65 Appendix A:Special Requirements for 74 Side-Wall Vented Appliances in the Commonwealth of Massach
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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 guara
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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 Dev
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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 3 3
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TABLE 2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION MINIMUM CLEARANCE TO COMBUSTIBLE TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MATERIAL HEAT FAB SAF-T VENT AT LEAST ONE SIDE OPEN, PROTECH FASNSEAL VERTICAL OR 1” COMBUSTIBLE MATERIAL ON A PROTECH FASNSEAL W2 HORIZONTAL MAXIMUM OF THREE SIDES METAL-FAB CORR/GUARD HEAT FAB SAF-T VENT PROTECH FASNSEAL HORIZONTAL OR VERTICAL 8” ENCLOSED ON ALL FOUR SIDES Z-FLEX Z-VENT III WITH OFFSETS METAL-FAB CORR/GUARD HEAT FAB SAF-T VENT PROTEC
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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 ro
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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
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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 7 7
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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 8 8
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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 wit
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TABLE 3a: SUMMARY OF HORIZONTAL VENTING OPTIONS VENT OPTION # 12345 (RESERVED HORIZONTAL HORIZONTAL CLASSIFICATION USED IN THIS HORIZONTAL HORIZONTAL FOR FUTURE DIRECT DIRECT MANUAL DIRECT VENT DIRECT VENT USE) EXHAUST EXHAUST ILLUSTRATED IN FIGURE 8a OR 8b 8a OR 8b 9 9 VENT PIPE STRUCTURE WALL WALL WALL WALL PENETRATION AIR INTAKE PIPE STRUCTURE WALL WALL N.A. N.A. PENETRATION VENT PIPE SIZE 3” 4” 3” 4” AIR INTAKE PIPE SIZE 4” 4” N.A. N.A. CWD060 - CWD138 55 FT 55 FT 55 FT 55 FT CWD165 35 F
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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) 11 11
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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
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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 ven
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TABLE 3b: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # 6789 10 (RESERVED VERTICAL VERTICAL CLASSIFICATION USED IN THIS VERTICAL VERTICAL FOR FUTURE DIRECT DIRECT MANUAL DIRECT VENT DIRECT VENT USE) EXHAUST EXHAUST ILLUSTRATED IN FIGURE 10 10 11 11 VENT PIPE STRUCTURE ROOF ROOF ROOF ROOF PENETRATION AIR INTAKE PIPE STRUCTURE ROOF OR WALL ROOF OR WALL N.A. N.A. PENETRATION VENT PIPE SIZE 3” 4” 3” 4” AIR INTAKE PIPE SIZE 4” 4” N.A. N.A. CWD060 - CWD138 47 FT 47 FT 47 FT 47 FT CWD165 27 FT 4
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FIGURE 10: VERTICAL NON-COAXIAL DIRECT VENT SYSTEM (VENT OPTIONS 6, 7) FIGURE 11: VERTICAL DIRECT EXHAUST SYSTEM (VENT OPTIONS 9, 10) 15 15
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TABLE 3c : SUMMARY OF VERTICAL COAXIAL VENTING OPTIONS VENT OPTION # 11 12 13 VERTICAL VERTICAL VERTICAL CLASSIFICATION USED IN THIS COAXIAL COAXIAL COAXIAL MANUAL DIRECT VENT DIRECT VENT DIRECT VENT VENT PIPE STRUCTURE ROOF ROOF ROOF PENETRATION AIR INTAKE PIPE STRUCTURE ROOF ROOF ROOF PENETRATION VENT PIPE SIZE 3” 3” 4” AIR INTAKE PIPE SIZE 4” 4” 4” (NON-COAXIAL SECTION) AIR INTAKE PIPE SIZE 5” 5” 7” (COAXIAL SECTION) CWD060 - CWD138 47 FT 47 FT 47 FT CWD165 27 FT 27 FT CWD193 N.R. N.R
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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) 17 17
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TABLE 4: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS CONDENSATE WALL HORIZONTAL VERTICAL MANUFACTURER VENT SYSTEM SIZE TRAP THIMBLES TERMINATION TERMINATION 7393GC ELBOW: 7314TERM 9321 3 7393GCS TEE: 7390TEE 5300CI (NOTE 3) SAF-T VENT 5391CI EZ SEAL 7493GC 9421 ELBOW: 7414TERM 4 7493GCS 5400CI (NOTE 3) TEE: 7490TEE 5491CI HEAT FAB ELBOW (NOTE 5): 5300CI + SC03VT SC03DRN SC03FS SC03HT + 7314TERM 3 (NOTE 6) (NOTE 3) SC03FSA TEE (NOTE 5): SC03HT + 7390TEE SAF-T VENT SC ELBOW (NOTE 5):
