Thermo Dynamics CWL GS Installation, Operation & Maintenance Manual Download Page 1

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www.thermodynamicsboiler.com

Installation

Operation

Maintenance

Manual

Thermo-Dynamics Boiler Company

ROUTE 61 • P.O. BOX 325 • SCHUYLKILL HAVEN, PA 17972

TEL (570) 385-0731 • FAX (570) 385-5304

WEB www.thermodynamicsboiler.com • EMAIL [email protected]

CWL-GS Series

Models CWL GS, CWL GS DV, NCWL GS, NCWL GS DV

Gas Fired Packaged Boiler

Summary of Contents for CWL GS

Page 1: ...ual Thermo Dynamics Boiler Company ROUTE 61 P O BOX 325 SCHUYLKILL HAVEN PA 17972 TEL 570 385 0731 FAX 570 385 5304 WEB www thermodynamicsboiler com EMAIL sales thermodynamicsboiler com CWL GS Series Models CWL GS CWL GS DV NCWL GS NCWL GS DV Gas Fired Packaged Boiler ...

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Page 3: ... under water 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 device is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 If the gas control knob is not in the OFF position turn the knob clockwise to OFF 6 Wait five 5 minutes to clear out ...

Page 4: ... Exchanger with Powder Coated Cabinet Packaged with Standard Five Gallon per Minute Tankless Coil For Domestic Hot Water CWL Models Only NCWL Model Available Without Tankless Coil Equipped with Triple Aquastat Circulator and Temperature Altitude Gauge CWL Models Only Equipped with Cold Start Aquastat Circulator and Temperature Altitude Gauge NCWL Models Only Additional Orifices Provided Lifetime L...

Page 5: ...and maintenance of your boiler will allow you to enjoy the benefits of your new pur chase as well as extend its long useful life In the event that your serviceman encounters difficulty with the boiler he she shall contact the distributor from which the product was purchased The distributor in turn will contact the Thermo Dynamics sales representative for your area By adhering to this protocol Ther...

Page 6: ...as Code ANSI Z223 1 Available from the American Gas Association Pleasant Valley Road Cleveland Ohio 44134 l When required by the authority having jurisdiction the installation must conform to the American Society of Mechanical Engineers Safety Code for Control and Safety Devices for Automatically Fired Boilers No CSD 1 l This Instruction Manual shall be kept near the boiler for future reference WA...

Page 7: ...n arrival Concealed damage claims should be filed immediately against the carrier by the consignee The carrier is responsible for taking prompt action on all claims III SIZING A complete heat loss calculation of the structure is necessary to choose the proper size unit Oversizing will result in short cycling and inefficient operation In order to insure proper sizing of the unit domestic hot water ...

Page 8: ...l 5 Gal A Jacket Height 29 1 2 29 1 2 29 1 2 B Jacket Width 21 21 21 C Coil Supply Height 22 22 22 D Supply Height Hydronic 27 1 2 27 1 2 27 1 2 E Burner Height 7 7 8 7 7 8 7 7 8 F Hydronic Return Height 15 1 2 15 1 2 15 1 2 G Flue Pipe Dia 5 5 5 H Washout Alt Return Height 3 1 2 3 1 2 3 1 2 I Jacket Depth Inc Flange 22 22 22 Depth Front to Rear w Burner 34 1 2 34 1 2 34 1 2 Hydronic Supply Size 1...

Page 9: ...iances in the enclosure and should terminate below the burner level Boilers installed in a confined area or closet must have two ventilation openings in the closet door Each opening should have a free area of not less than 1 square inch per 1 000 Btu of the total input for all appliances in the enclosure One opening located near the top of the enclosure and one near the bottom B Basement 1 Where a...

Page 10: ...o processor based control with electronic ignition and a combustion blower relay The controller uses full time flame sensing to continually monitor flame quality with a minimum current of 0 7 microamps In addition the controller is set for a 34 second pre purge In the event of a flame failure the control shall try for ignition 3 times before going into lockout Recovery from lockout requires a manu...

Page 11: ... circulator continuing to operate until the room heating requirements are satisfied If the thermostat continues to call for heat after the boiler temperature falls below the high limit setting the burner will restart The boiler water temperature is normally maintained at 180 F around the tankless coil by the operat ing control so that an abundance of hot water is available If the boiler water temp...

Page 12: ...E A FLAME FOR CHECKING GAS LEAKS The boiler and its individual shut off valve must be disconnected from the gas supply piping during any pressure testing of that piping at test pressures in excess of 0 5 PSIG or 14 inches water column The boiler must be isolated from the gas supply piping by closing its individual manual shut off valve during pressure testing of the gas supply piping system at tes...

Page 13: ... the foot toward the unit C Roof Clearances The chimney flue should extend at least 3 ft above the highest point at which the chimney comes in contact with the roof and no less than 2 ft above the highest roof surface or structure within 10 ft hori zontally of the chimney DIRECT VENT MODELS Install the TV 175 Combination Vent Hood by cutting a 7 1 16 by 7 1 16 opening through an exteri or wall Ens...

Page 14: ...10 ...

Page 15: ... Field connections should be protected with a 15 amp fuse Install a separate fuse disconnect switch near the unit so power can be shut off for servicing Thermostat should be located centrally within the zone to be heated Zone valves should be installed on return lines and wired per manufacturer s specifications 11 L7224A C L7248A C L OIL ELECTRONIC AQUASTAT CONTROLLERS Fig 6 L7224A C multizone sys...

Page 16: ...ulator 3 Manometer Reads in W C 4 Stack Thermometer B Adjustment to Gas Pressure Regulator The manifold pressure should be set to 120 140 160 Nat Gas LP Nat Gas LP Nat Gas LP 3 5 2 3 3 5 2 3 3 5 2 3 To adjust gas pressure turn the adjusting screw of the gas pressure regulator out counterclockwise to decrease the pressure Turn in clockwise to increase the pressure Refer to control specification she...

Page 17: ...manual HEAD AND AIR ADJUSTMENT When to adjust the Air The air shutter is a mechanical shutter Do NOT over crank the air shutter You must use an analyzer to measure the CO2 Carbon Dioxide General rule if the CO2 is too low then close the air shutter If the CO2 is too high then open the air shutter Note Do NOT set the CO2 higher than 9 8 for Natural Gas or 11 5 for LP Gas If the CO Carbon Monoxide i...

Page 18: ...actory insulation of the chamber floor Properly seal flue box gasketing and bolts III GAS BURNER A Thoroughly brush clean the air intake screen of the burner to ensure proper air delivery B Properly seal the burner flange bolts IV LUBRICATION The blower motor is equipped with sealed bearings and therefore does not require lubrication V GASKETS Tighten nuts on water coil to prevent any gasket leaks...

Page 19: ...e of any combustible materials particularly oily rags and papers The boiler should be accessible for ease of service If burner is shut down for extend ed period of time shut off manual fuel supply valve Brush clean flue passages and vacuum clean unit Inspect for leaks at gaskets and fittings Follow starting procedures to restart SERVICE INFORMATION To avoid unnecessary expense and inconvenience th...

Page 20: ...OMETER GAS PRESSURE INSTALLED TURN GAS VALVE SET POINT HEAT EXCHANGER CHECK HEAT EXCHANGER HEAT EXCHANGER FOULED CLEAN HEAT EXCHANGER SURFACES FOR SOOT AND FOULING TROUBLE INSUFFICIENT DOMESTIC HOT WATER SOURCE PROCEDURE CAUSES REMEDY OPERATING CONTROL CHECK OPERATING CONTROL SETTING TO LOW SET OPERATING CONTROL TO SETTING 180 F COIL HEAT INSPECT COILS FOR FOULED FLOW RESTRICTION REMOVE RESTRICTIO...

Page 21: ...VERALL DIAMETER OF THE GAS LINE ORIFICE DISCONNECT GAS LINE AND IMPROPERLY SIZED ORIFICE REPLACE WITH ORIFICE INSPECT ORIFICE SPECIFIED IN MANUAL NO ORIFICE INSTALLED HEAT EXCHANGER TAKE DRAFT READING OVER THE PLUGGED HEAT EXCHANGER CLEAN OUT HEAT EXCHANGER RESTRICTIONS FIRE AND AT THE FLUE BOX THE DIFFERENCE SHOULD NOT EXCEED 04W C BURNER MOTOR BURNER MOTOR TRIPS ON LINE VOLTAGE BELOW 102V CALL U...

Page 22: ...R LEVELS EXCESSIVE DRAFT TAKE A DRAFT READING DRAFT INCORRECT DRAFT SETTING REDUCE DRAFT SETTING SHOULD BE O TO 02 POSITIVE INSTALL SECOND DRAFT PRESSURE OVER THE FIRE REGULATOR IF NECESSARY TROUBLE BURNER FIRES BUT THEN FAILS ON SAFETY SOURCE PROCEDURE CAUSES REMEDY FLAME CHECK CAD CELL WITH FAULTY FLAME SENSOR CLEAN OR REPLACE SENSOR OHMMETER IF MORE THAN 2000 OHMS CAD CELL IS DEFECTIVE OR DIRTY...

Page 23: ...IBRATION RECALIBRATES FLOW VALVE CHECK FLOW VALVE FOR FLOW VALVE NOT OPENING FULLY CLEAN OR REPLACE FLOW STICKING IN PARTIALLY CLOSED VALVE POSITION RADIATION CHECK RADIATORS FOR AIR RADIATORS AIR BOUND BLEED RADIATORS CHECK TO SEE IF RADIATORS ARE RADIATORS INADEQUATE INSTALL ADEQUATE RADIATION PROPERLY SIZED BOILER DETERMINE STRUCTURE HEAT BOILER TO SMALL ADDITIONAL HEATING CAPACITY LOAD REQUIRE...

Page 24: ...H POWER CHECK BOILER DISCONNECT SWITCH OPEN CLOSE SWITCH SWITCH AND MAIN DISCONNECT SWITCH TRIPPED BREAKER OR BLOWN RESET BREAKER OR REPLACE FUSE FUSE PRIMARY CONTROL CHECK FOR VOLTAGE AT THE LIMIT CONTROL SWITCH OPEN CHECK LIMIT SETTING BURNER BETWEEN THE BLACK AND WHITE WIRES JUMPER TERMINALS IF BURNER STARTS REPLACE CONTROL OPEN CIRCUIT BETWEEN LIMIT REPAIR CIRCUIT CONTROL AND DISCONNECT SWITCH...

Page 25: ...Gauge 1 4 x 2 1 2 Round 8 481005 Coil Gasket TDR 9 530247 TDR5L Coil with Gasket Cartoned 10 229151 Blank Coil Plate with 1 8 and 3 4 Tapping 11 190399 Baffles CWL 10 required 12 190401 Flue Box Top Vent 13 199991 Flue Box Rear Vent with Regulator 14 337135 Gasket Material 25 Roll 15 337799 Cerablanket Floor Insulation 14 337800 Ceraform Floor Board 19 x 19 542260 LP Orifice 15 64 542261 Natural G...

Page 26: ...ents to be made with proper test equipment See installation service manual for detailed information INSTALLER SERVICEMAN Fixed Pressure and Variable Orifice Model Number CWL GS 120 CWL GS 140 CWL GS 160 Burner Type Heat Wise Heat Wise Heat Wise Burner Model SU 2A SU 2A SU 2A Fuel LP Gas LP Gas LP Gas Orifice 15 64 1 4 19 64 Max Inlet Pressure 11 11 11 Min Inlet Pressure 4 5 4 5 4 5 Manifold Pressu...

Page 27: ...ents to be made with proper test equipment See installation service manual for detailed information INSTALLER SERVICEMAN Fixed Pressure and Variable Orifice Model Number NCWL GS 120 NCWL GS 140 NCWL GS 160 Burner Type Heat Wise Heat Wise Heat Wise Burner Model SU 2A SU 2A SU 2A Fuel LP Gas LP Gas LP Gas Orifice 15 64 1 4 19 64 Max Inlet Pressure 11 11 11 Min Inlet Pressure 4 5 4 5 4 5 Manifold Pre...

Page 28: ...P N 595830 100 2 10 MET 235 ...

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