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D E S I G N E D T O L E A D
CWI Series
Gas-Fired Natural Draft Water Boilers
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Models:
WARNING: Improper installation,
adjustment, alteration, service or
• CWI069 • CWI207
maintenance can cause property
• CWI103 • CWI241
damage, injury, or loss of life. For
assistance or additional informa-
• CWI138 • CWI276
tion, consult a qualified installer,
• CWI172 • CWI310
service agency or the gas
supplier. Read
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Table of Contents I. Product Description .................................................. 1 II. Specifications ............................................................. 2 III. Before Installing ......................................................... 3 IV. Locating the Boiler ...................................................... 3 V . Air for Combustion & Ventilation .............................. 4 VI. Venting ....................................................................
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II Specifications FIGURE 1: CWI BOILERS - GENERAL CONFIGURA TION TABLE 1: CWI SPECIFICATIONS NATURAL OR LP GAS * BASIC NUMBER HEATING I=B=R NET AFUE (%) TANKLESS WATER BOILER OF INPUT CAPACITY RATING STNDG. INT. HTR. RATING DIMENSIONS (in.) VOL. MODEL SECTIONS (MBH) (MBH) (MBH) PILOT PILOT (Gal/min) "A" "B" "C" "D" (Gal) 50 CWI069 3 69 57 81.0 83.1 12 3/4 28 40 7/16 4 7.8 CWI103 4 103 86 75 81.3 83.1 2.50 16 28 40 7/16 5 10.0 100 CWI138 5 138 115 81.6 83.1 3.00 19 1/4 28 40 7/16 6 12.2 CWI17
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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 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 Co
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“X” (RH CLEARANCE) ALL SIZES LESS TANKLESS HEATER - 18“ CWI103 - CWI241 WITH TANKLESS HTR. - 18“ CWI276 - CWI379 WITH TANKLESS HTR. - 21“ CWI207 - CWI379 WITH HIGH CAPY. TANKLESS HTR. - 24“ “X” FIGURE 2: CWI BOILERS - CLEARANCES TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS, WALLS, AND DOORS. • If the right side 24” service clearance is reduced, adequate clearance must be maintained to easily read and access the controls. Alternatively, access may be provided using a door
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• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and floors, 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 confined space - A confined space is defined by the National Fuel Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr
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FIGURE 3: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC 7 6
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FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 8 7
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• 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 finer 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
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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 CWI310-CWI379. 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 damp
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FIGURE 8: CWI BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS FIGURE 9: VENT DAMPER INSTALLATION DETAILS 11 10
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VII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire 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 an
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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 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
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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 float 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
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FIGURE 11: STANDARD BOILER PIPING FIGURE 12: INDIRECT WATER HEATER BOILER SIDE PIPING 15 14
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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 flow 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 fo
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FIGURE 14: ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER FIGURE 15: BOILER PIPING WITH CHILLER 17 16
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FIGURE 16: GRAVITY PIPING IX TANKLESS HEATER PIPING If the CWI is installed with an optional 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 fixtures at a fixed temperature. T
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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 prot
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IX Wiring 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). Single Zone Wiring 1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt connections are made inside the L8148E or L8124E aquastat relay as follows (also see Figures 18-21): • Hot (“black”) - Terminal “L1” • Neutral (“white”) - Ter
