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

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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 Series - LE Edition

www.thermodynamicsboiler.com

Models CWL, NCWL, CWLDV

Summary of Contents for CWL

Page 1: ...o 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 Series LE Edition www thermodynamicsboiler com Models CWL NCWL CWLDV ...

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Page 3: ...ered with National Board Factory Mounted Wired Burner and Controls Fully Insulated Heat Exchanger with Powder Coated Cabinet Packaged with Standard Five Gallon per Minute Tankless Coil Domestic Hot Water NCWL Model Available Without Tankless Coil Equipped with Triple Aquastat Circulator and Temperature Altitude Gauge Provided With Additional Nozzles to Achieve a Variety of Heat Inputs Provided wit...

Page 4: ...nd 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 Therm...

Page 5: ...el odors may occur The instal lation and use of venting fans anywhere in the house or a vented dryer will greatly increase the need for outside air C Area Around Boiler The area around the boiler must be kept clean and free of any combustible materials particularly oily rags or papers The boiler must be accessible for service D Annual Tune Up The boiler should be serviced once a year ideally just ...

Page 6: ...face The chimney must be properly sized Draft requirements are essential for safe and proper operation of the boiler 8 If the boiler is connected to a venting device make sure that it is listed by a recognized testing service Follow the venting device manufacturer s installation instructions Verify that the venting device installation complies with the recommendations of the manufacturer and local...

Page 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 INCL FLANGE 22 22 22 DEPTH FRONT TO REAR W BURNER 30 3 4 30 3 4 30 3 4 HYDRONIC SUPPLY 1 1 4 1 1 4 1 1 4 HYDRONIC RETURN SIZE 1 1 4 1 1 4 1 1 4 WASHOUT ALT RETURN 1 1 4 2 1 1 4 2 1 1 4 2 AFUE RATING W DAMPER 86 0 84 9 84 1 AFUE RATING W O DAMPER 84 3 83 2 82 1...

Page 8: ...zed A complete heat loss cal culation of the structure is necessary to choose the proper size unit to install The boiler should be sized to within 25 of the actual calculated heat loss of the structure Over sizing will result in short cycling and inefficient operation IV BOILER LOCATION A Boiler to be installed in a level position with clearances in accordance with NFPA 31 Table 10 6 1 STANDARD CL...

Page 9: ...d in a full basement infiltration is normally adequate to provide air for combustion 2 In buildings of tight construction when the basement windows are weather stripped one open ing to a well ventilated attic or with the outdoors should be provided The opening should have a mini mum free area of 1 square inch per 1 000 Btu per hour of total input for all appliances in the enclosure C Special Condi...

Page 10: ...ef Valve as noted in Section 2a Trim Assembly VIII BOILER PIPING This style of boiler is equipped with a built in Air Scoop System Figure 2 This feature allows quiet air free operation of your hot water system by assuring the removal of noisy air pockets The supply line or Riser tapping in the top of the boiler extends approximately 1 below the top or waterline of the boiler thus allowing only air...

Page 11: ...washer may be obtained by piping as shown The nuts that secure the tankless coil flange should be tightened before the boiler is filled with water after initial firing and every year during annual maintenance Deterioration due to coil gasket leaks shall void warranty Venting Refer to Section VI BOILER PIPING Relief Valve discharge and drain valve piping should be piped to a safe place of discharge...

Page 12: ... with the cadmium sulfide flame detector the control will automatically control the oil heating system The primary control will stop the oil burner within a predetermined number of seconds if the fuel fails to ignite or if the flame goes out during operation The oil burner will remain off until the reset button on the relay has been pushed THE RESET MUST NEVER BE PRESSED MORE THAN ONCE DUR ING A S...

Page 13: ...atisfied thermostat setting is reached or until boiler water temperature reaches high limit control temperature setting If the high limit control temperature setting is reached the burner shuts off the circulating pump continues to operate until the room heating requirements are satisfied If the thermostat continues to call for heat after the boiler water temperature has dropped below the temperat...

Page 14: ...ufacturers instructions Set the draft to negative 02 to 04 inches W C in the stack C Roof Clearances The flue gas exit of the venting system should be at least 3 feet above the highest point where it passes through the roof and at least 2 feet higher than any portion of a building with 10 feet of the venting sys tem D Chimney Connectors The horizontal length of a chimney connector should not excee...

Page 15: ...ough water until the entire system has been purged and desired pressure is obtained C Check to make sure the oil storage tank is filled with No 2 heating oil D Make sure all manual shut off valves in the fuel system are open E Set operating controls at 180 F F Set limit switch at 200 F G Install a pressure gauge in the 1 8 gauge port or nozzle port of the fuel pump Do not take read ings at the ble...

Page 16: ...O2 probe or the smoke tester probe down into a fire tube You can also take flue gas sampling from the sight fitting sampling port above the burner If using the sampling port do not insert the probe into the combustion area too far Insert probe approximately 1 2 to 1 Excessive insertion may cause false readings Combustion readings should not be taken through the draft regulator or through a samplin...

Page 17: ... serviceman if the burner fails to operate automatically III BURNER SERVICING A Burner Components If a replacement part is necessary use only the part specified on the burner parts list in this manual Specify the part number and description when ordering See included burner literature B Nozzles Use only the correct nozzle specified on the Installer Serviceman decal located on front boiler jacket B...

Page 18: ... or scale can be removed from the cham ber through the burner opening IV OIL BURNER A Thoroughly brush clean the burner fan blades Only with clean fan blades is proper combustion air delivery possible B Clean nozzle assembly and all air handling parts C Check spacing and condition of the ignition electrodes D Nozzles should be inspected every year for plugged distributor slots or plugged orifices ...

Page 19: ...sistance across cad cell Primary Check for line voltage between Control the black and white leads No voltage indicates no power to the control Check for line voltage between orange and white leads No voltage indicates a faulty control Burner Check for voltage at the black and white leads to the burner motor Voltage indicates power to motor and a fault in the burner Open cad cell wires Dirty cell f...

Page 20: ...Pump worn low pressure Motor overloads Coupling worn or broken Pump discharge pressure set too low No spark or weak spark Line voltage below 120V Carboned and shorted electrodes Eroded electrode tips Incorrect electrode settings Cracked porcelain insulators Plugged orifice or distributor Plugged nozzle strainer Poor spray pattern Incorrect nozzle installed Air shutter open too far Air band open to...

Page 21: ...d cell Replace primary control Clean out heat exchanger Call utility company Replace motor Replace blower or pump SOURCE PROCEDURE CAUSES REMEDY TROUBLE BURNER FIRES BUT THEN FAILS ON SAFETY Circulator Check to see if operating control is working properly Thermostat Check thermostat settings and calibration FlowValve Check to see if flow valve is operating properly Circulator does not stop running...

Page 22: ...ply valve closed Restriction in oil line Plugged fuel filter Plugged pump strainer Cold oil Too much combustion air Pump discharge pressure incorrectly set Coupling worn or broken Pump worn low pressure motor overloads Incorrect draft setting Leak in flue system Weak fluid Plugged orifice or distributor Plugged nozzle strainer Poor spray pattern Replace nozzle with specified nozzle Reduce draft se...

Page 23: ...ustment Air leak in fuel system Compression fittings Water in oil tank Pump discharge pressure incorrectly set Coupling worn or broken Pump worn low pressure motor overloads Plugged orifice or distributor Plugged nozzle strainer Poor spray pattern Plugged heat exchanger Install vent cap Increase draft setting Reduce draft settings install second draft regulator if necessary Move draft regulator to...

Page 24: ...ective Operating control defective Circulator too small Circulator defective Insufficient voltage Settings too low Bad location due to heat build up Out of calibration Flow valve not opening fully Radiators airbound Radiators inadequate Boiler too small Piping inadequate Insufficient heat transfer Insufficient pump pressure Wrong nozzle installed Nozzle underfiring due to defective nozzle Replace ...

Page 25: ...ith integral draft regulator combustion testing can be taken through the fire port above the burner Insert your probe approximately 1 2 to 1 or through a 1 4 hole in the top of the flue box Locate hole in front right fire tube see illustration on page 4 Stack temperature can be taken through a drilled hole in the flue box To minimize air dilution hold draft regulator in a closed position See page ...

Page 26: ...Dan Foss Single Stage Fuel Pump 8 675300 Suntech Single Stage Fuel Pump 9 675310 Suntech Two Stage Fuel Pump 10 535030 007 Circulator Pump 11 522000 Aquastat Control L8124C With 205 F Mechanical Stop 12 575020 Relief Valve 3 4 Female 13 559560 Altitude Gauge 1 4 x 2 1 2 Round 14 481005 Coil Gasket TDR 15 530245 55 Coil TDR with Gasket Cartoned 16 229151 Blank Coil Plate with 1 8 and 3 4 Tapping 17...

Page 27: ...__ _________________________ _________________________ _________________________ _________________________ _________________________ Preliminary Settings 25 INSTALLER SERVICEMAN Model Number CWL 85 CWL 100 CWL 110 Burner Type Riello Riello Riello Burner Model F 5 F 5 F 5 Nozzle Type 65 60W 75 60W 85 60W Pump Pressure PSI 180 180 180 Head Pin Position 0 0 0 0 0 0 Air Band N A N A N A Air Shutter 2 ...

Page 28: ...0 11 5 Smoke Reading ZERO ZERO ZERO AFII 100 DIRECT VENT SERIES CWL 85 HAGO B CWL 100 HAGO B CWL 110 HAGO ES NOTICE Above settings are approximate Final adjustments to be made with proper test equipment Be sure all oil lines are air free and the use of flare fittings is recommended See installation service manual for detailed information _________________________ _________________________ ________...

Page 29: ...ELECTRICAL DIAGRAMS FOR CWL SERIES BOILERS 27 ...

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Page 31: ...ter Yes No 10 Replaced Nozzle Yes No 11 Clean Pump Filter Yes No 12 Inspect Coil Gasket 13 Check for Leaks plugs fittings 14 Brush Clean Flue Tube Passages 15 Vacuum Chamber Flue Tubes 16 Clean Blower Wheel 17 Check Set Electrodes See pump pressure according to the installer serviceman labels starting on page 24 BURNER SERVICE SET UP RECORDS ...

Page 32: ...TDB 080 P N 595831 MET 4088 12 10 500 ...

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