CWL Series - LE Edition
Models CWL, NCWL, CWLDV
Installation
Operation
Maintenance
Manual
www.thermodynamicsboiler.com
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
Product Features
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ASME Coded Boiler Registered 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 with a Lifetime Limited Warranty
Available as Direct Vent and Rear Vent Models
CWL-LE
NCWL
CWL-DV
Contents
Service Policy
2
Homeowner Information
3
Read This First
4
Model Specifications
5
Installation
6
Operation
13
Maintenance
16
Trouble Shooting
17
Parts List
24
Preliminary Settings
25
Wiring Diagrams
27
Burner Service Records
Inside Back Cover
Service Policy
Congratulations on the purchase of your boiler. At Thermo-Dynamics Boiler
Company we pride ourselves on the design and construction of our product. Our
intent is to furnish you with a high quality appliance that will provide you and your
family with years of trouble free service.
In order to maintain peak performance of your boiler, it is recommended that
the burner/boiler be serviced annually, preferably prior to the onset of the winter
heating season. Servicing of your appliance must be performed by a qualified heating technician. You should utilize a qualified heating technician familiar with your
installation to manage your heater and perform periodic maintenance. Proper care
and maintenance of your boiler will allow you to enjoy the benefits of your new purchase 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, Thermo-Dynamics will provide you with responsive and
unparalleled service. We realize the importance that our product means to you and
your family and our goal is to get your heater up and running as quickly as possible.
Thank you for purchasing the Thermo-Dynamics boiler. Again, it is our intent
to provide you with a high quality trouble free product that will be part of your family for many years to come. Please consider Thermo-Dynamics Boiler Company in
the future for all of your home heating needs.
2
HOMEOWNER INFORMATION
Heating Contractor:
Address:
Phone No.:
A) General
Installation and service is to be done only by a certified and qualified technician.
Never burn garbage or refuse in your boiler or leave combustible material around it. Do not allow the fuel
tank to run out of oil. The fuel tank should be kept full during the summer, or periods of non-use, to prevent condensation of moisture on the inside of the tank.
B) Combustion Air Supply
The burner requires an ample amount of clean combustion air to burn efficiently. If ample supply is not
available erratic, noisy combustion will result. Under these conditions fuel odors may occur. The installation 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 prior to the heating season. The tune-up is to be
done by a qualified technician following procedures listed under Maintenance in this manual
E) If Boiler Doesn’t Start:
1) Check if there is fuel in the tank.
2) Is thermostat setting above room temperature.
3) Is service switch in the “on” position.
Should there be a problem with operation of the boiler, call a qualified service technician. Do not
tamper with the unit or controls.
3
Read This First
1.
Installer must be a trained, experienced technician and should read all instructions before
installation.
2.
Inspect the boiler, jacket and all components to be sure damage has not occurred in shipment. If
damage is evident, do not install the boiler. Contact your distributor immediately. A claim must be
filed with the freight carrier that transported the boiler from the factory to the distributor.
3.
Disconnect power supply before connecting wiring.
4.
Refer to local codes for oil burning equipment, for recommended installation practice. You will
need to be familiar with NFPA International Standard 31, “Standard for the Installation of Oil
Burning Equipment”.
5.
A complete heat loss calculation is necessary to choose the proper size unit to install. The boiler
should be sized to within 25% of the actual heat loss of the structure. Over sizing will result in
short cycling and inefficient operation.
6.
When moving the boiler, do not push against the jacket or burner. Damage will result.
7.
If the boiler is vented to a chimney, be certain the chimney is clean and free of obstructions. The
chimney must be masonry with tile lining or metal insulated with a stainless steel surface. 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 and state
codes.
9.
Conduct a thorough checkout when installation is complete. Check for indications of leaks and
make sure that no material is left adjacent to the boiler.
10.
The use of low sulfur No. 2 heating oil is highly recommended.
11. Modification, substitution or elimination of factory equipped, supplied or specified components
may result in property damage, personal injury or the loss of life.
12.
The following definitions apply to potential hazards noted in this manual.
DANGER: Indicates a hazardous situation which if not avoided will result in death or serious injury.
WARNING: Indicates a hazardous situation which if not avoided could result in death or serious
injury.
CAUTION: Indicates a hazardous situation which if not avoided, may result in a minor injury. It may
also warn against unsafe practices that may result in minor injury or damage to equipment.
NOTICE: Indicates that special attention to information is required. Not related to personal injury or
property damage.
4
Model Specifications
HEATING CAPACITY
CWL 85
CWL 100
CWL 110
101,000
118,000
127,000
IBR NET RATING
88,000
103,000
110,000
INPUT
119,000
140,000
154,000
FIRING RATE
CHIMNEY SIZE
OVER FIRE PRESSURE W.C.
.85
1.00
1.10
8 x 8 x 15
8 x 8 x 15
8 x 8 x 15
0-+.05
0-+.08
0-+.10
WATER CONTENT
15 GAL.
15 GAL.
15 GAL.
COIL CAPACITY
5 GAL.
5 GAL.
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
3-1/2
3-1/2
3-1/2
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
H. WASHOUT (ALT. RETURN HEIGHT)
I. JACKET DEPTH (INCL. FLANGE)
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
*Specifications apply to CWL-LE, NCWL and CWL-DV except when using REAR FLUE KIT, jacket height increases by
4-1/4 inches
Figure 1 - Model Dimensions
“0” Clearance Sides and Back
Approved for combustible Floors
5
Installation
I GENERAL
This hot water steel boiler is a high quality oil fired heating units. The installation of the boiler shall be
in accordance with state and local regulations. Refer to local Installation Codes for Oil Burning
Equipment, for recommended installation practice.
II FREIGHT CLAIMS
All units must be inspected for damage upon arrival. Concealed damage claims should be filed immediately against the carrier by the consignor. The carrier is responsible for taking prompt action on all claims.
III SIZING
Replacement boilers should not be sized from the firing rate of the old boiler; a DOE sponsored study
indicated 65% of the heating units in U.S. homes are substantially oversized. A complete heat loss calculation 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 CLEARANCES
Front 0" (leave 12" to access burner/control)
Sides 0"
Rear 0"
Chimney Connector 18"
Top 0" (leave 18" for cleaning)
Floor: Approved for installation on combustible flooring
B) Reduced clearance installations shall comply with NFPA 31 Table 10.6.2.
C) To move the unit, push against the flue box or skids. Pushing or pulling the jacket or burner
will result in damage.
D) Be sure to level the unit by inserting shims under the elevated base.
E) CWL Series - LE rear flue kit with built-in draft regulator.
6
V. AIR FOR COMBUSTION AND VENTILATION - CHIMNEY VENT APPLICATIONS
The unit must be installed where provisions exist for combustion and ventilation air. Ordinarily, provisions may be furnished by the following methods.
A) Utility Room or Closet
In buildings of tight construction, including most modern homes, you should provide an opening, connecting to a well ventilated attic, crawl space or directly with the outdoors. The opening should have a
minimum free area of 1 square inch per 1,000 Btu per hour of total input for all appliances in the enclosure and should terminate below the burner level. Boilers installed in confined areas or closets must have
two ventilation openings in the closet door. Each opening should have a free area of not less than 1 square
inch per 1000 Btu (140 square inch per US gph) of the total input for all appliances in the enclosure. One
opening located near the top of enclosure and one near the bottom.
B. Basement
1. When a boiler is installed 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 opening to a well ventilated attic or with the outdoors should be provided. The opening should have a minimum free area of 1 square inch per 1,000 Btu per hour of total input for all appliances in the enclosure.
C. Special Conditions
When a boiler is located in an area where exhaust fans, kitchen ventilation systems, clothes dryers, or fireplaces may create conditions of unsatisfactory combustion or venting, special provisions
should be made for additional air for combustion, as specified by local authority.
VI. AIR FOR COMBUSTION AND VENTILATION - DIRECT VENT APPLICATIONS
A) VENTING SYSTEM
CAUTION: EXTERNAL VENT SURFACES ARE HOT.
NOTE: USE ONLY THE ETL LISTED VENTING SYSTEM COMPONENTS SUPPLIED WITH
THE TV-175 DIRECT VENT KIT.
SURFACE DISCOLORATION OF THE BUILDING MAY OCCUR DUE TO IMPROPER BOILER/BURNER ADJUSTMENT. THERMO DYNAMICS BOILER COMPANY WILL NOT ACCEPT
ANY LIABILITY FOR SUCH DISCOLORATION.
Install TV-175 Direct Vent Kit in accordance with installation instructions provided with the kit.
7
VII JACKET AND TRIM ASSEMBLY
A. Knock Down Boiler
1. Jacket Assembly - Unpack the jacket parts being careful not to damage the finish. Piping and accessories are installed after the jacket is in place. Assemble the jacket as shown in Figure 5.
2. Trim Assembly
a. Install the safety relief valve in the 3/4" tapping in the top of the boiler. The relief valve should be
piped to a safe place of discharge.
b. Install the limit control in the 3/4" fitting provided in the tankless coil plate.
c. Install the altitude/temperature gauge in the 1/4" fitting provided in the coil plate.
B. Packaged Boiler
Controls and burner are installed and prewired at the factory. Install Relief 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 free
water to enter the supply to the heating system. The air trapped in
the top of the boiler is then purged through a 3/4" vent tapping to be
released with an (1) automatic float vent (2) a manual vent or (3)
piped into a conventional type expansion tank.
Relief valve discharges and drain valve piping should be piped to a safe
place of discharge. All plugs and water connections should be checked
for leaks upon installation and annually.
8
FIGURE 2
BUILT-IN AIR SCOOP
IX TANKLESS WATER HEATING PIPING
The tankless heater may be connected as shown in Figure 3. A mixing valve (not supplied) may be used
to reduce the water temperature at kitchen or bathroom taps. High temperature water for a dishwasher
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.
CWL Boiler Piping
Figure 3
9
X BURNER AND CONTROLS
A) Burner Installations
Packaged boilers are shipped with the burner installed and prewired. Boilers that are shipped knockeddown must be field assembled. Follow the procedures listed below to install and connect the burner.
1. Remove the burner parts and instructions from the carton.
2. Referring to specifications at the back of the manual, check to see that the burner model and size match
the boiler model.
3. Make sure the correct nozzle is in place and is tightly sealed.
4. Check the electrode position and set the air intake as indicated in the burner manual.
5. The burner is installed with a mounting flange. The end of the burner air tube should be 1/4" from the
inside surface of the front wall of the combustion chamber.
6. Make the electrical connections as shown in the wiring diagram in this manual and in the control manufacturers installation manual. All wiring must be done in accordance with the local electrical code.
7. For units installed in Maine, New Jersey and New York, a low-water cutoff is required on all hot water
boilers. See the low water cutoff manufacturers installation manual for wiring instructions.
B) Oil Primary Control - Chimney Vent (Non Post Purge Control)
The oil primary control with the solid state flame sensing circuit provides automatic, non-recycling control of oil burners. When used 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 DURING A SINGLE FLAME FAILURE.
C) Oil Primary Control - Direct Vent (Post Purge Control)
The oil primary control with the solid state flame sensing circuit provides interrupted ignition. Used in
conjunction with a cadmium sulfide flame detector, the control will automatically control the oil burner.
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 DURING A SINGLE FLAME FAILURE.
Post-purge is provided to ensure that the boiler fires at maximum efficiency and dependability throughout the heating season.
Post-purge of the oil burner is controlled through the electronic circuitry supplied. Post-purge timing is
variable. The factory set post-purge timing is at approximately one minute. It is recommended that it be
left at this setting. In no case should the post purge timing be reduced to less than 1 minute.
Length of Vent Kit
0 - 10 Feet
10.1 - 15 Feet
15.1 - 20 Feet
Minimum Post Purge Time
1 Minute
1 Minute
2 Minutes
10
Times are approximate and should be considered minimum settings for the length of intake pipe installed.
The length of post-purge may be increased on those units using the Beckett AFII or Riello BF-5 oil burners to any value up to its maximum setting if field conditions require a longer purge cycle.
The length of post-purge on the Carlin burner is not adjustable. The post purge timing on the Carlin burner is 90 seconds.
D) Aquastat Relay
This control is installed in the 3/4" fitting next to the domestic coil. These immersion type controls are
used with forced hydronic heating systems which include domestic water service. This model provides
high and low limits for maintaining minimum boiler water temperature and circulator controls. This control can also be used for multi-zone control by using a separate circulator and an R845 relay for each
zone. See the control manufacturers installation manual for proper wiring of this unit. The primary control is factory wired to the aquastat relay. These controls, working as a system, will prevent the circulator operation if the water temperature is below a predetermined low level. Likewise, if the water level
reaches a predetermined high limit, the burner will automatically shut off.
CAUTION: The aquasat relay high limit set point is factory set at 180°F. Do not raise the high limit set
point over 200°F.
XI SEQUENCE OF OPERATION
Forced Circulation Hot Water System with Tankless Heater
When room temperature falls below thermostat setting, the thermostat calls for heat starting the
circulating pump. The burner and pump continue to operate until room heating requirements are satisfied
(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 temperature setting of the high limit
control the oil burner will start again, while the circulating pump will continue to run.
The boiler water temperature is normally maintained at 180°F around the tankless coil by the
operating control so that an abundance of hot water is available. If the boiler water temperature should
fall below the operating control setting (180°F), the oil burner will be started again by that control (and
the circulating pump will be prevented from operating) until the operating control setting is satisfied.
A cadmium sulfide flame scanner (cad cell) is provided with the oil burner. The cad cell will stop
the oil burner within a predetermined number of seconds if the fuel fails to ignite or if the flame extinguishes during operation. The oil burner will remain off until the red reset button on the relay has been
pushed. (Reset must never be pressed more than once during a single flame failure.)
XII FUEL SYSTEM
A) Fuel Units
NOTE: Pump pressure 140 PSI for Beckett and Carlin, and 150 PSI for Riello.
1. Burners are commonly fitted with a single stage fuel unit. A single stage unit may be connected with
a supply line only, when the fuel supply is level with or above the burner. When the burner is above the
oil level, a return line should be provided between the fuel unit and the tank. A “by-pass” plug in the fuel
unit is then required. The return line automatically purges air from fuel units and returns it to the tank.
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2. Two stage fuel unit. If the height difference between the burner and the fuel supply level exceeds 10
ft., a two stage unit should be used, and a return line should be installed.
B) Tubing
Use continuous heavy walled copper tubing with flare fittings only. Locate fittings in accessible locations. If possible, tubing should be installed under the floor. Running tubing against boiler casings or
across ceiling or floor joints should be avoided.
C) In-Line Oil Filter
The oil filter should be of a generous capacity. It should be located inside the building between the tank
shut off valve and the burner. A shut off valve and the oil filter should be located as close to the burner
as possible for ease of servicing.
D) Oil Shut Off Valve
Install manual oil shut off valves at the burner and near the tank on the supply line. Both valves should
be easily accessible.
XIII FLUE SYSTEM - CHIMNEY VENT APPLICATIONS
A) General
AN OIL FIRED UNIT SHALL BE CONNECTED TO A FLUE HAVING SUFFICIENT DRAFT AT
ALL TIMES TO ASSURE PROPER OPERATION.
B) Draft
The draft regulator should be installed in accordance with the manufacturers 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 system.
D) Chimney Connectors
The horizontal length of a chimney connector should not exceed 10 feet unless a draft booster is used.
The connector should be pitched upward at least 1/4 inch to the foot. Use only high quality lock seam
smoke pipe. Each joint should be securely fastened with sheet metal screws. Chimney connectors should
be positioned to the shortest possible run of smoke pipe to the chimney.
E) Vent Cap
Install a U.L. listed vent cap where the possibility of down drafts exist.
F) Boiler Venting
This boiler must be vented into a properly sized chimney, or into an Underwriters Laboratories Inc. listed venting device which is capable of maintaining the specified draft requirements.
As indicated in this manual, chimney sizes, draft requirements and other additional service and installation requirements are essential for safe and proper operation of the boiler.
Only a trained experienced serviceman should attempt the installation or service of any boiler and or
venting device.
12
All venting installations must comply with the recommendations of the venting manufacturer and
with all state and local codes.
XIV WIRING
All internal electrical wiring is completed at the factory on packaged boilers. All external wiring must
conform with the National Electric Code and local codes. Refer to wiring diagrams in the burner manufacturer’s installation manual and the control manufacturers installation manual for all field wiring.
A) Field connections should be protected with a 15 amp fuse.
B) Install the room thermostat on an inside wall away from cold drafts, windows, or heat from fireplaces,
appliances, or sunlight. Connect the thermostat leads to the “TT” terminals on the circulator control.
XV WARRANTY
The limited warranty is not applicable unless these installation instructions are followed.
Operation
I START UP
A. Make sure service switch to boiler is off.
B. Make sure boiler has been filled with enough 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 readings at the bleed valve port. The pressure should be set per Installer/Serviceman Label.
H. Adjust the burner air band and air shutter in accordance with Installer/serviceman Label.
I. Push the safety reset button on the primary control and release. Adjust the thermostat to call for
heat. Turn the service switch to the on position. Bleed the fuel unit. If burner fails to start, refer to the
trouble shooting guide in this manual.
J. With the burner running, bleed the fuel unit again until all air is eliminated from lines. Close and
tighten the bleed port.
K. Check all lines and plugs for oil leaks and eliminate.
II START UP ADJUSTMENTS
A)
1.
2.
3.
Equipment Required
CO2 analyzer
Draft gauge.
Fuel pressure gauge.
4. Stack thermometer.
5. Smoke tester.
13
B) Burner Adjustments
Allow the burner to operate steadily for at least 15 minutes. Check the burner settings according to the
installer/serviceman labels starting on page 24, and make the following adjustments:
When servicing this appliance or any forced draft unit, it is important to properly seal the gasketed
areas around the flue collector and burner mounting flange. Check to be sure that the sampling port
above the burner has had the port plug installed after servicing.
NOTE: A Draft regulator is an integral part of the flue collector located behind the front jacket panel.
Units shipped from the factory without the draft regulator installed, but shipped with a blank plate will
have the draft regulator packed in the miscellaneous parts box.
The CWL-Series is a forced draft boiler and requires a positive pressure over the fire. If chimney draft causes the overfire draft to become negative, the draft regulator must be installed. The overfire draft must not be less than +.005 (positive).
Combustion Analysis of Boiler with Rear Vent Kit
When a rear flue unit with a draft regulator is used, flue gas sampling must either be taken by
inserting the CO2 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 sampling hole
in the breaching on Rear Flue units. The gases become diluted as a result of room air being brought in
through the built-in draft regulator and are inaccurate.
Figure 4 - Test Location for Boiler with Rear Vent Kit
Sample Location
1 NOTE: INTEGRAL PART OF FLUE COLLECTOR LOCATED
BEHIND JACKET PANEL.
1. Sampling Hole - punch 1/4" hole in the flue between the flue box and the draft regulator. All test readings should be taken from this point.
2. In The Stack Draft - Take a draft reading from the flue pipe sampling hole. Adjust the barometric draft
regulator to -.02" in the stack. In tall chimneys a second draft regulator may be required in the flue pipe
to regulate draft under high draft conditions.
3. Overfire Draft - Take a draft reading from the draft port located to the left of the burner. Compare the
readings with those according to the installer/serviceman labels for starting on page 24. Reinstall the
draft port plug after all readings have been taken.
14
4. Pump Pressure - Adjust the pump discharge pressure per value on serviceman label.
5. Combustion Air - Reduce the air supply to allow just sufficient air for clean combustion. This is
accomplished by loosening the lock screws on the air shutter, and closing the air shutter until a trace of
smoke is recorded. Take a CO2 sample. Open the air shutter lowering CO2 about 1-1/2% to 2%. A zero
smoke reading should result. If this adjustment cannot be obtained, refer to the trouble shooting section
in this manual.
C) Instructing the Homeowner
The care and operation of the boiler should be explained to the homeowner, including care of the burner, how to adjust the thermostat, necessity of air supply to the burner, and the simple checks to make
before calling the 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.
Be extremely careful not to touch the nozzle orifice to avoid scratches or dirt which may cause leaks or
effect the oil spray pattern.
C) Electrode Settings
The electrode setting is critical for proper ignition of the fuel. Check to be sure electrode settings comply with the specifications.
D) Fan and Blower Housing
The fan and blower housing should be kept clean from lint and dirt. If the boiler is located near an unvented dryer, special care must be taken so that lint does not block air passages in the burner and proper combustion air is provided.
15
Maintenance
I VENT SYSTEM
ESCAPING GASES ARE DANGEROUS. THE ENTIRE FLUE AND VENTING SYSTEM SHOULD
BE INSPECTED AT LEAST ONCE A YEAR BY A QUALIFIED SERVICEMAN.
II OIL FILTER
The oil filter cartridge should be replaced annually.
III CLEANING
The tubular portions of the heat exchanger should be examined annually for scale and soot accumulation.
Remove scale and soot with a flexible, 2 inch, soft, round brush and a boiler vacuum cleaner. Be careful not to damage internal refractory insulation of the chamber floor.
Remove the oil burner to inspect the burner head. Any soot or scale can be removed from the chamber 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. If it is necessary to replace the nozzle, use only the specified nozzle to be sure that the replacement meets the spray
pattern specifications of the burner.
V GASKETS
Tighten the nuts on the water coil annually to prevent any gasket leaks. Deterioration due to coil gasket
leaks shall void the warranty.
VI WIRING
Check the electrical wiring for damage or frayed insulation..
16
Troubleshooting Guide
TROUBLE: BURNER DOES NOT START
SOURCE
PROCEDURE
CAUSES
REMEDY
Thermostat
Check Thermostat
Thermostat set too low.
Turn thermostat up.
Thermostat on “off ”or “cool.”
Switch to heat.
Open thermostat wires.
Repair or replace wires.
Loose thermostat connectors.
Tighten connection.
Faulty thermostat.
Replace thermostat.
Thermostat not level.
Level thermostat.
Check burner motor overload
switch. (If equipped)
Burner motor tripped on
overload.
Push reset button.
Check primary control safety
switch.
Primary tripped on safety.
Reset safety switch.
Check boiler disconnect switch
and main disconnect switch.
Switch open.
Close switch.
Tripped breaker or blown fuse.
Reset breaker or replace fuse.
Jump the FF terminals on
primary control, if the burner
starts, fault is in detector circuit.
Open cad cell wires.
Repair or replace wire.
Dirty cell face.
Clean or replace face.
Faulty cad cell.
Replace cad cell.
Check resistance across cad cell.
If 400-600 ohms cell is bad.
Replace cad cell.
Check for line voltage between
the black and white leads. No
voltage indicates no power to the
control.
Limit control switch open
Check limit setting.
Circuit
Overloads
Power
Cad Cell
Primary
Control
Burner
Jump terminals - if burner
starts replace control.
Open circuit between limit
control and disconnect switch.
Repair circuit.
Low line voltage or power
failure
Call utility company.
Check for line voltage between
orange and white leads. No
voltage indicates a faulty control.
Defective control.
Replace control.
Check for voltage at the black
and white leads to the burner
motor. Voltage indicates power
to motor and a fault in the
burner.
Pump seized.
Turn off power to burner.
Rotate blower by hand, check
for excessive drag. Replace
fuel unit or blower wheel.
Blower wheel binding.
Burner motor defective.
When checking burner adjustments always use instruments.
17
Replace burner motor.
TROUBLE: BURNER STARTS BUT DOES NOT ESTABLISH FLAME
SOURCE
PROCEDURE
CAUSES
REMEDY
Oil Supply
Check tank for oil.
Empty tank.
Fill tank.
Check for water in oil tank using
a dip stick coated with litmus
paste.
Water in oil tank.
Strip tank of water exceeding
2" in depth.
Listen for pump whine.
Fuel supply valve closed.
Open valve.
Open pump bleed port and start
burner. Milky oil or no oil
indicates loss of prime.
Air leak in fuel system.
Repair leak, using only flared
fittings. Do not use Teflon
tape on oil fittings.
Listen for pump whine.
Oil filter plugged.
Replace filter cartridge.
Plugged pump strainer.
Clean Strainer.
Restriction in oil line.
Repair oil line.
Pump worn - low pressure.
Motor overloads.
Replace pump.
Coupling worn or broken.
Replace coupling.
Pump discharge pressure set
too low.
No spark or weak spark.
Set pressure according to the
installer/serviceman labels
starting on page 24.
Connect transformer leads to line
voltage. Listen for spark. Check
that transformer terminals are not
arcing with buss bars. Check that
transformer is properly grounded.
Line voltage below 120V.
Replace transformer.
Remove and inspect drawer
assembly.
Carboned and shorted
electrodes.
Clean electrodes.
Eroded electrode tips.
Incorrect electrode settings.
Replace and reset
electrodes.
Cracked porcelain insulators.
Replace and reset electrodes.
Plugged orifice or distributor.
Poor spray pattern.
Replace nozzle with nozzle
according to the installer/
serviceman labels starting on
page 24.
Inspect nozzle for correct size
and specifications.
Incorrect nozzle installed.
Install correct nozzle.
See “Burner Adjustment
Instructions” in this manual.
Air shutter open too far.
Decrease air shutter setting.
Air band open too far.
Decrease air band opening.
Oil Line
and Filter
Oil Pump
Ignition
Transformer
Ignition
Electrodes
Nozzle
Install pressure gauge in port of
fuel pump. Pressure should be
according to the installer/serviceman labels starting on page 24.
Check for faulty nozzle.
Call utility company.
Plugged nozzle strainer.
Combustion
Air
Adjustments
When checking burner adjustments always use instruments.
18
TROUBLE: BURNER FIRES, BUT THEN FAILS ON SAFETY
SOURCE
PROCEDURE
CAUSES
REMEDY
Cad Cell
Check cad cell with ohmmeter. If
more than 2000 ohms, cad cell is
defective or dirty.
Faulty or dirty cad cell
Clean or replace cad cell.
Primary
Control
After burner fires, open cad cell
circuit if flame looks OK. If
burner continues to operate, fault
is in primary control.
Faulty primary control
Replace primary control.
Heat
Exchanger
Restriction
Inspect heat exchanger.
Plugged heat exchanger.
Clean out heat exchanger.
Burner
Motor
Burner motor trips on overload.
Turn off power and rotate blower
by hand to check for excessive
drag.
Line voltage below 120V
Call utility company.
Faulty motor.
Replace motor.
Pump or blower overloading
motor.
Replace blower or pump.
TROUBLE: TOO MUCH HEAT
SOURCE
PROCEDURE
CAUSES
REMEDY
Circulator
Check to see if operating control
is working properly.
Circulator does not stop
running.
Repair operating control.
Thermostat
Check thermostat settings and
calibration.
Thermostat set too high.
Reset thermostat.
Thermostat defective
Replace thermostat.
Thermostat out of calibration.
Recalibrate. Check level.
Flow valve dirty and stuck.
Clean flow valve.
Flow valve defective.
Replace flow valve.
Flow Valve
Check to see if flow valve is
operating properly.
When checking burner adjustments always use instruments.
19
TROUBLE: BURNER FIRES, BUT THEN LOSES FLAME
SOURCE
PROCEDURE
CAUSES
REMEDY
Poor Fire
Inspect flame for stability.
Unbalanced fire.
Replace nozzle with specified
nozzle.
Excessive draft.
Reduce draft setting.
Insufficient draft.
Increase draft.
Insufficient combustion air sources.
Increase combustion air sources.
Air leak in fuel system.
Repair leak - use only flare
fittings.
Water in oil tank.
Strip tank of water exceeding
2" in depth.
Fuel supply valve closed.
Open valve.
Restriction in oil line.
Clear oil line restriction.
Plugged fuel filter.
Replace filter cartridge.
Plugged pump strainer.
Clean Strainer.
Cold oil.
Use #1 heating oil.
Oil Supply
If burner loses flame prior to the
primary control locking out, fault
is in fuel system.
Combustion
Air
Reduce combustion air supply.
Too much combustion air.
Close air band and air to raise
CO2. Check with instruments.
Pump
Install pressure gauge in gauge
port of fuel pump. Pressure
should be according to installer/
serviceman labels starting on
page 24.
Pump discharge pressure
incorrectly set.
Set pressure according to
installer/serviceman labels
starting on page 24.
Coupling worn or broken.
Replace coupling.
Pump worn - low pressure
motor overloads.
Replace pump.
Excessive
Draft
Take a draft reading. Draft should
be according to installer/serviceman labels starting on page 24
in stack.
Incorrect draft setting.
Reduce setting. Install second
draft regulator if necessary.
Poor Flue
Gas Sample
Insert CO2 probe into heat
exchanger tube. If reading is
greater by 1/2% or more, sample
was being diluted near flue box.
Leak in flue system.
Sample CO2 in heat exchanger.
Testing
Method
Using a chemical absorption type
device, let instrument set after a
test before venting. If CO2
reading increases 1/2% fluid is
weak.
Weak fluid.
Replace fluid in testing device.
Nozzle
Check for faulty nozzle.
Plugged orifice or distributor.
Replace nozzle with specified
nozzle.
Seal flue system leak.
Plugged nozzle strainer.
Poor spray pattern.
When checking burner adjustments always use instruments.
20
TROUBLE: BURNER FIRES, BUT PULSATES
SOURCE
PROCEDURE
CAUSES
REMEDY
Draft
Take a draft reading. Draft should
be according to installer/serviceman labels starting on page 24,
in the stack.
Down drafts.
Install vent cap.
Insufficient draft.
Increase draft setting.
Excessive draft.
Reduce draft settings, install
second draft regulator if
necessary.
Draft
Regulator
Inspect draft regulator for correct
location on flue system.
Improper installation.
Move draft regulator to
correct location.
Combustion
Air
See Table 1.
Inspect installation for
combustion air provisions.
Improper installation.
Provide sufficient sources of air
for combustion.
Open air band wide and take
CO2 reading.
Improper adjustment.
Adjust CO2 level - start with air
band wide open. Use instrument.
Bleed pump; inspect for air leaks
or water contamination.
Air leak in fuel system.
Compression fittings.
Repair leak - use only flare
joints.
Water in oil tank.
Strip tank of water exceed 2"
in depth.
Pump discharge pressure
incorrectly set.
Set pressure according to
installer/serviceman labels
starting on page 24.
Coupling worn or broken.
Replace coupling.
Pump worn - low pressure
motor overloads.
Replace pump.
Plugged orifice or distributor.
Replace nozzle with nozzle
specified on burner housing.
Oil Supply
Pump
Pressure
Nozzle
Install pressure gauge in gauge
port of fuel pump. Pressure
should be according to installer/
serviceman labels starting on
page 24.
Check for faulty nozzle.
Plugged nozzle strainer.
Poor spray pattern.
Heat
Exchanger
Restrictions
Inspect heat exchanger.
Plugged heat exchanger.
When checking burner adjustments always use instruments.
21
Clean out heat exchanger.
TROUBLE: INSUFFICIENT HEAT
SOURCE
PROCEDURE
CAUSES
REMEDY
Circulator
Check if circulator is operational.
Coupling worn or broken.
Replace coupling.
Pump binding.
Replace pump.
Circulator motor burned out.
Replace circulator motor.
Wiring from operating control
defective.
Repair wiring.
Operating control defective.
Repair or replace operating
control.
Check if circulator is correct
size.
Circulator too small.
Replace with proper circulator.
Check if circulator is up to
speed; check if voltage to
circulator is sufficient.
Circulator defective.
Repair circulator.
Insufficient voltage.
Call utility company.
Check thermostat settings.
Settings too low.
Increase setting.
Check thermostat location.
Bad location due to heat build
up.
Move thermostat to a better
location.
Check thermostat calibration.
Out of calibration.
Recalibrate. Level thermostat.
Flow Valve
Check flow valve for sticking in
partially closed position.
Flow valve not opening fully.
Clean or replace flow valve.
Radiation
Check for air in radiators.
Radiators airbound.
Bleed radiators.
Check to see if radiators are
sized properly.
Radiators inadequate.
Install adequate radiation.
Boiler
Determine structure heat load.
Boiler too small.
Additional heating capacity.
Piping
Check to see if piping is sized
properly.
Piping inadequate.
Install adequate piping.
Heat
Exchanger
Check heat exchanger for soot or
scale accumulation.
Insufficient heat transfer.
Clean heat exchanger.
Burner
Check pump pressure with
pressure gauge.
Insufficient pump pressure.
Increase pressure according to
installer/serviceman labels
starting on page 24.
Nozzle
Check nozzle for size and spray
angle.
Wrong nozzle installed.
Install specified nozzle.
Check for faulty nozzle.
Nozzle underfiring due to
defective nozzle.
Replace nozzle.
Thermostat
22
TROUBLE: HIGH NET STACK TEMPERATURES
SOURCE
PROCEDURE
CAUSES
REMEDY
Nozzle
Check pump pressure with pump
gauge.
Nozzle overfiring due to high
pump pressure.
Reduce pump pressure according
to installer/serviceman labels
starting on page 30.
Heat
Exchanger
Check heat exchanger surfaces
for soot or scale fouling.
Heat exchanger fouled.
Clean heat exchanger.
Baffles
Check baffles installed.
Baffles not installed.
Install baffles.
TROUBLE: INSUFFICIENT DOMESTIC HOT WATER
SOURCE
PROCEDURE
CAUSES
REMEDY
Tankless
Coil
Analyze capacity vs. usage.
Insufficient coil capacity.
Install larger coil.
Operating
Control
Check operating control.
Setting too low.
Set operating control to 180°F.
Raise differential set point.
Heat
Exchanger
Inspect coils for fouled surfaces
and/or flow restrictions.
Flow restriction.
Remove restriction.
Fouled surfaces on heat exchanger.
Clean heat exchanger surfaces.
SERVICE SET-UP TIPS
COMBUSTION EFFICIENCY = CO2 vs. Stack Temp.
When using the rear vent flue box with 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 4)
BURNER AIR refer to page 5 concerning air for combustion, ventilation, and placement of the boiler in a utility room or
closet. This also addresses special conditions where a boiler is located in an area of operation next to exhaust fans, kitchen
ventilation systems, clothes dryers, etc...(See Section V).
Draft overfire all models 0 to +.10
Draft in stack all models - .02 Min.
CO2 readings all models 10 - 11.5%
Smoke reading all models 0
- NOTICE Above settings are approximate. Final adjustments to be made with proper test equipment. Be sure oil lines are air free
and the use of flare fittings is recommended. See installation/service manual for detailed information.
Alternate Nozzles for AFG
1 .75 - 70°B HAGO
2 .85 - 80°A DELAVAN OR .85 80°B HAGO
3 1.00 - 80°A DELAVAN OR 1.00-80°A HAGO
23
Parts List CWL Series - LE Edition
(Designate boiler and burner model numbers on all orders.)
Item No.
Part no.
Description
1
540550
Beckett AFG Burner (1501) (Direct Vent AFII - Part No. 540580)
2
542200
Carlin EZ-1 Burner (Direct Vent EZ1 - Part No. 542160)
3
541165
Riello 5F Burner (Direct Vent BF5 - Part No. 541166)
4
675400
F-3 Head (Beckett/CWL LE 85)
5
657405
F-4 Head (Beckett/CWL LE 100)
6
675410
F-6 Head (Beckett/CWL LE 110)
7
675320
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
190399
Baffles (CWL, 10 required)
18
190401
Flue Box (Top Vent)
19
199991
Flue Box (Rear Vent with Regulator)
20
337070
Gasket Material (25’ Roll)
21
337805
Cerablanket Floor Insulation
22
337800
Ceraform Floor Board 19 x 19
24
Preliminary Settings
INSTALLER/SERVICEMAN
INSTALLER/SERVICEMAN
DIRECT VENT
Model Number
Burner Type
Model Number
CWL-85DV CWL-100DV CWL-110DV
_________________________
Carlin*
Carlin*
Burner Type
Carlin*
*Requires Carlin Air Intake Adapter
ZERO
Carlin
Carlin
EZ-1PRO EZ-1PRO
EZ-1PRO
_________________________
Nozzle Type
.70 60°W .85 60°W .90 60°W
_________________________
Pump Pressure PSI _________________________
150
150
150
Head/Pin Position _________________________
.75
.85-1.00
.85-1.00
Air Band
.65
.85
.90
_________________________
Air Shutter
N/A
N/A
N/A
_________________________
Draft Over Fire
0 to + 0.10" 0 to + 0.10" 0 to + 0.10"
_________________________
Draft In Stack
-0.02"
-0.02"
-0.02"
_________________________
CO2 Reading
10-11.5% 10-11.5% 10-11.5%
_________________________
EZ-1
EZ-1
EZ-1
_________________________
Nozzle Type
.75 60B
.85 60B
1.00 60B
_________________________
Pump Pressure PSI _________________________
140
140
140
Head/Pin Position _________________________
75
75
85-100
Air Band
85
125
140
_________________________
Air Shutter
N/A
N/A
N/A
_________________________
Draft Over Fire
+0.03"
-0.04"
+0.06"
_________________________
Draft In Stack
+0.03"
+0.03"
+0.03"
_________________________
CO2 Reading
10-11.5% 10-11.5% 10-11.5%
_________________________
ZERO
Carlin
Burner Model
Burner Model
Smoke Reading
CWL-85
CWL-100
CWL-110
_________________________
Smoke Reading
ZERO
ZERO
ZERO
ZERO
Use 60° HAGO Nozzle
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.
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.
INSTALLER/SERVICEMAN
INSTALLER/SERVICEMAN
DIRECT VENT
Model Number
Burner Type
CWL-85
CWL-100
CWL-110
_________________________
Riello
Riello
Model Number
Riello
Burner Type
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
2.5
3.0
6.0
_________________________
Draft Over Fire
+0.02"
+0.04"
+0.06"
_________________________
Draft In Stack
-0.02"
-0.02"
-0.02"
_________________________
CO2 Reading
10-11.5% 10-11.5% 10-11.5%
_________________________
Smoke Reading
ZERO
ZERO
CWL-85DV CWL-100DV CWL-110DV
_________________________
Riello
Riello
Riello
Burner Model
BF5
BF5
BF5
_________________________
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
3.6
4.9
7.0
_________________________
Draft Over Fire
0 to +.1"
0 to +.1"
0 to +.1"
_________________________
Draft In Stack
-0.02"
-0.02"
-0.02"
_________________________
CO2 Reading
10-11.5% 10-11.5% 10-11.5%
_________________________
ZERO
Smoke Reading
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.
ZERO
ZERO
ZERO
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.
25
INSTALLER/SERVICEMAN
INSTALLER/SERVICEMAN
DIRECT VENT
Model Number
Burner Type
Burner Model
Model Number
CWL-85DV CWL-100DV CWL-110DV
_________________________
Beckett
Beckett
Burner Type
Beckett
ZERO
Smoke Reading
Beckett
Beckett
Burner Model
AFG
AFG
AFG
_________________________
Nozzle Type
.75 70B
.85 80A
1.00 80A
_________________________
_________________________
Pump Pressure PSI _________________________
140
140
140
Head/Pin Position _________________________
F-3
F-4
F-6
Air Band
3
3
5
_________________________
Air Shutter
3
4
5
_________________________
Draft Over Fire
0 to +.1"
0 to +.1"
0 to +.1"
_________________________
Draft In Stack
-0.02"
-0.02"
-0.02"
_________________________
CO2 Reading
Smoke Reading
ZERO
ZERO
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.
CWL-85
CWL-100
CWL-110
_________________________
Beckett
ZERO
AFII 100 DIRECT VENT SERIES: CWL 85 HAGO B
CWL 100 HAGO B
CWL 110 HAGO ES
INSTALLER/SERVICEMAN
Burner Type
Beckett
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.
Model Number
Beckett
AFII 100
AFII 100
AFII 100
_________________________
Nozzle Type
.75 60°B
.85 60°B 1.00-60°ES
_________________________
Pump Pressure PSI _________________________
140
140
140
Head/Pin Position _________________________
4
5
7
Air Band
N/A
N/A
N/A
_________________________
Air Shutter
4.5
5.0
7
_________________________
Draft Over Fire
0 to +.1"
0 to +.1"
0 to +.1"
_________________________
Draft In Stack
-0.02"
-0.02"
-0.02"
_________________________
CO2 Reading
10-11.5% 10-11.5% 10-11.5%
_________________________
.75 60°B
.85 60°B 1.00-60°ES
_________________________
Pump Pressure PSI _________________________
140
140
140
Head/Pin Position _________________________
4
5
Air Band
N/A
N/A
N/A
_________________________
Air Shutter
4.5
5.0
7
_________________________
Draft Over Fire
0 to +.1"
0 to +.1"
0 to +.1"
_________________________
Draft In Stack
-0.02"
-0.02"
-0.02"
_________________________
CO2 Reading
10-11.5% 10-11.5% 10-11.5%
_________________________
ZERO
Beckett
Burner Model
AFII 100
AFII 100
AFII 100
_________________________
Nozzle Type
Smoke Reading
CWL-85
CWL-100
CWL-110
_________________________
10-11.5%
10-11.5%
10-11.5%
ZERO
ZERO
ZERO
Hago nozzle can be substituted
Equipped with Oil Delay Valve on all models
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.
26
ELECTRICAL DIAGRAMS FOR CWL SERIES BOILERS
27
BURNER SERVICE SET-UP RECORDS
Initial Set Up
1
2
3
1. Date
2. Model Number
3. Firing Rate
4. Pump Pressure*
5. CO2
6. “0” Smoke
7. Gross Stack°F
8. Draft Over Fire
9. Replaced Filter 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.
4
5
TDB-080 P/N 595831
MET-4088
12/10-500