Crown Boiler AWI037 Installation Instructions Manual Download Page 1 | Manualshive

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Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com

Manufacturer of Hydronic Heatings Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

AWI & TWI Series

Gas-Fired Natural Draft Hot Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

WARNING: Improper installa-
tion, adjustment, alteration,
service or maintenance can
cause property damage, injury,
or loss of life. For assistance or
additional information, consult a
qualified installer, service
agency or the gas supplier.
Read these instructions carefully
before installing.

Models:

•

AWI037

•

AWI061

•

AWI095

•

AWI128

•

AWI162

•

AWI195

•

AWI229

•

AWI262

•

AWI295

•

TWI061

•

TWI095

•

TWI128

•

TWI162

CROWN

Boiler Co

CROWN

Boiler Co

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Summary of Contents for AWI037

Page 1: ...st be affixed on or adjacent to the boiler WARNING Improper installa tion adjustment alteration service or maintenance can cause property damage injury or loss of life For assistance or additional information consult a qualified installer service agency or the gas supplier Read these instructions carefully before installing Models AWI037 AWI061 AWI095 AWI128 AWI162 AWI195 AWI229 AWI262 AWI295 TWI0...

Page 2: ...2 INSIDE FRONT COVER LEAVE BLANK ...

Page 3: ...y natural draft using a lined masonry or listed metal chimney system An adequate supply of air for combustion ventilation and dilution of flue gases must be available in the boiler room The TWI series boiler is identical to corresponding sized AWI boiler except for the addition of baffles in the flue passages to obtain higher AFUEs The TWI is not available with a standing pilot or for use with pro...

Page 4: ...4 2 FIGURE1B LEFTPIPED CONFIGURATION FIGURE1C TOPPIPED T AWIORT TWI CONFIGURATION ...

Page 5: ... 8 5 4 8 7 1 S 2 6 1 I W A E 2 6 1 I W A 6 2 6 1 2 3 1 5 1 1 3 0 8 7 1 8 2 1 1 2 4 3 0 1 6 8 5 4 8 7 1 S 5 9 1 I W A E 5 9 1 I W A 7 5 9 1 9 5 1 8 3 1 4 0 8 4 1 8 4 3 4 2 8 7 9 2 8 3 2 1 7 8 1 5 8 7 1 S 9 2 2 I W A E 9 2 2 I W A 8 9 2 2 6 8 1 2 6 1 4 0 8 2 1 8 8 2 4 1 7 8 1 5 8 7 1 S 2 6 2 I W A E 2 6 2 I W A 9 2 6 2 2 1 2 4 8 1 5 0 8 9 0 8 4 1 1 3 8 5 5 1 8 8 5 5 8 7 1 S 5 9 2 I W A E 5 9 2 I W A...

Page 6: ...net rating required for the heating system whichever results in the larger boiler For systems that incorporate other indirect water heaters refer to the indirect water heater manufacturer s instruc tions for boiler output requirements 4 Make sure that the boiler received is configured for the correct gas natural or LP 5 Boilers built for installations at altitudes above 2000 ft require different b...

Page 7: ... the National Fuel Gas Code as having all of the following features Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed Weather stripping has been added on openable windows and doors Caulking and sealants are applied to areas such as joints around window and door frames between sole plates and flo...

Page 8: ...or openings into boiler room 3 Confined Space Provide two openings into the boiler room one near the floor and one near the ceiling The top edge of the upper opening must be within 12 of the ceiling and the bottom edge of the lower opening must be within 12 of the floor Figure 3 Each opening must have a free area of 1 square inch per 1000 BTU hr input of all gas burning appliances in the boiler ro...

Page 9: ... free cross sectional area of 1 square inch per 4000 BTU hr of the total input of all gas fired appliances in the boiler room but not less than 100 square inches Minimum opening size is 3 inches Openings to outdoors via horizontal ducts Figure 7 Each opening must have a free cross sectional area of 1 square inch per 2000 BTU hr of the total input of all gas fired appliances in the boiler room but ...

Page 10: ...o install an external draft hood 1 Acceptable Chimneys The following chimneys may be used to vent AWI or TWI series boilers Listed Type B or L gas vent Install in accordance with the manufacturer s instructions the terms of its listing and applicable codes Masonry Chimney The masonry chimney must be constructed in accordance with the Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Ap...

Page 11: ...amic lined masonry chimney See Chapter 10 of the National Fuel Gas Code for information on when exterior chimneys may be used An exterior masonry chimney may be used if it is lined with B vent or a listed chimney lining system 5 This boiler may vented using a listed power venter The power venter must be in sized and installed in accordance with the power venter manufacturer s instructions the term...

Page 12: ...er outlet See Figure 1 Unpack vent damper carefully Do not force closed damper blade Forcing vent damper closed may result in damaged gear train and void warranty b Vent damper is factory shipped having approximately diameter hole in the vent damper blade which must be left open for boilers equipped with standing pilot and should be plugged on boilers with EI control system using the plug supplied...

Page 13: ...nd any other gas burning appliances to their previous condition of use g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 10 ...

Page 14: ... 2 Circulator Required Although the circulator is shipped on the boiler return it can be installed on the boiler supply If the circulator is moved to the supply it should be positioned just downstream of the expansion tank as shown in Figure 11 3 Expansion Tank Required If this boiler is replacing an existing boiler with no other changes in the system the old expansion tank can generally be reused...

Page 15: ...upply to the boiler 8 Flow Control Valve Required under some conditions The flow control valve prevents flow through the system unless the circulator is operating A flow control valve may be necessary on converted gravity systems to prevent gravity circulation Flow control valves are also used to prevent ghost flows in circulator zone systems through zones that are not calling for heat 9 Isolation...

Page 16: ...ithin their limits For this system to work properly the heat exchanger must be properly sized and the correct flow rates are required on either side of the heat exchanger Consult the heat exchanger manufacturer for sizing information The water in the boiler is completely isolated from the water in the system This means that separate fill and expansion tanks are required for the heating system loop...

Page 17: ...ller 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 15 ...

Page 18: ...ctions To insure proper thermostat operation avoid installation in areas of poor air circulation hot spots near any heat source or in direct sunlight cold spots outside walls walls adjacent to unheated areas locations subject to drafts Provide Class II circuit between thermostat and boiler Connect thermostat wire leads to terminals T and TV inside L8148E aquastat relay FIGURE15 BOILERPIPINGWITHCHI...

Page 19: ...19 FIGURE16 WIRINGDIAGRAM CONTINUOUSIGNITION STANDING PILOT SYSTEM 17 FIGURE17 WIRINGDIAGRAM INTERMITTENTIGNITION EI SYSTEM 2 2 ...

Page 20: ... Valves Figure 19 shows wiring for multiple zones using Honeywell V8043F zone valves This wiring diagram may be used for other 24 volt zone valves as long as they are equipped with end switches Do not attempt to use the transformer on the L8148E to power the zone valves use a separate transformer Up to five V8043Fs may be powered by one 48VA transformer such as the Honeywell AT87A A call for heat ...

Page 21: ...ormal conditions the flame roll out switch and blocked vent switch are made Voltage will therefore immediately appear across the combination gas control gas valve terminals TH and TR 6 When the boiler is first placed into operation the pilot must be lit The pilot heats a thermocouple which generates a small amount of electricity sufficient to hold open the safety shut off valve in the combination ...

Page 22: ...plied across the main valve terminals MV and MV PV opening the valve and establishing main flame 9 The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot depends upon the exact ignition module supplied with the boiler For more information on module operation consult the ignition module instructions supplied with the boiler or the local C...

Page 23: ...r operation should result in a flame on the first try 9 Observe pilot burner flame See Figure 20 for standing pilot Pilot burner should produce single steady medium blue flame covering around 3 8 to of thermocouple tip See Figure 21 for intermittent ignition Pilot burner produces three flames The center one should be a steady medium blue flame covering around 3 8 to of spark electrode flame rod 10...

Page 24: ...essure and counter clockwise to reduce the pressure If a manifold pressure adjustment is made recheck the line pressure to be certain that it is still within acceptable limits Replace the cover screw on the regulator 16 Test thermostat operation while the boiler is running Turn the thermostat to the lowest setting Circulator should stop running For standing pilot boiler models pilot burner should ...

Page 25: ...eaks Repair any leaks found at once 21 Inspect the vent system for flue gas leaks Repair any leaks found before leaving the boiler in operation FIGURE20 STANDINGPILOT BURNER FLAME FIGURE21 INTERMITTENTIGNITION PILOTBURNERFLAME FIGURE22 MAINBURNERFLAME 1 BURNERS FIGURE23 MAINBURNERFLAME 50mm HIGHALTITUDE BURNERS 23 ...

Page 26: ...LOT 9 Push down and hold the red reset button while you light pilot burner with a match After about one minute release reset button Pilot should remain lit If it goes out turn gas control knob clockwise to OFF To relight repeat steps 5 9 If button does not pop up when released stop and immediately call your service technician or gas supplier If the pilot will not stay lit after several tries turn ...

Page 27: ...abel 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the pilot Do try to light the pilot by hand not 5 Remove front access panel 6 Rotate the gas control knob clockwise to OFF 7 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you then smell g...

Page 28: ...28 FIGURE24 GASVALVEDETAIL STANDINGPILOT FIGURE25 GASVALVEDETAIL INTERMITTENTIGNITION 26 ...

Page 29: ...ing strap The ideal gap between the electrode and the ground strap is 1 8 Inspect the porcelain for cracks or other deterioration Replace pilot assembly if deterioration is found 6 Inspect the combustion chamber insulation for deterioration 7 Intermittent Pilot Boilers Inspect the ignition cable insulation for cracks or other deterioration If deterioration is found replace cable 8 Reinstall burner...

Page 30: ... being careful to put the pilot main burner in its original location 16 Replace the blocked vent switch 17 Reconnect the damper and vent system WARNING SOOT DEPOSITS IN THE FLUE PASSAGES ARE A SIGN THAT THE BOILER MAY BE OPERATING AT HIGH CARBON MONOXIDE CO LEVELS AFTER CLEANING THE BOILER OF SOOT DEPOSITS CHECK THE CO LEVEL IN THE FLUE GAS TO INSURE THAT THE BOILER IS OPERATING PROPERLY If it is ...

Page 31: ... automatic position Unplug the harness from the damper and check for 24 volts across pin 1 blue and pin 4 yellow If voltage is present the damper is defective or there is an obstruction in the path of the damper blade If no voltage is present there is either a loose connection in the damper harness or the L8148E is defective 6 If the charts indicate that the L8148E is defective do the following be...

Page 32: ...t stat or zone valve end sw itch T stat or zone system misw ired consult t stat or zone valve manufacturer s instructions Vent damper open 24 volts across B and R limit sw itch in L8148E Boiler off on limit Defective high limit 24 volts betw een pins 1 4 blue yellow and 2 4 orange yellow on damper end of damper harness See Note 7 on page 29 Loose connection betw een damper harness and L8148E Defec...

Page 33: ...raft Inadequate combustion air supply in boiler room Y N N Y Y 24 volts across rollout sw itch Loose electrical connection in 24 volt w iring betw een B1 or B2 and gas valve or module Rollout sw itch open Replace w ith exact replacement see parts list Check for blocked heat exchanger Y N N Y N Do burner and circulator shut dow n at end of call for heat END Pull w ire off of T terminal on aquastat ...

Page 34: ...ilot orifice partially plugged Y N N Y N Turn control on gas valve to ON Y END Defective gas valve Y START 24 VOLTS PRESENT ACROSS TH AND TR ON GAS VALVE BUT MAIN BURNERS DO NOT LIGHT Ensure knob on gas valve is set toON Loose thermocouple connection at gas valve Defective thermocouple Condensation quenching pilot Low line pressure N Y N Does pilot stay lit when red button is released Disconnect t...

Page 35: ...orcelain cracked Pilot flame not covering gap between electrode and grounding strap Low gas pressure at gas valve inlet Defective S8600 module Main burner lights N Y 24VAC across terminals 1 2 on S8600 Y N N Defective S8600 module 24 volts between MV MV PV on gas valve Defective gas valve Defective EI harness END START 24 volts is present across 5 and 6 on S8600 module but main burners do not ligh...

Page 36: ...08 700609 700610 6 BURNER ACCESS PANEL 1 ea 700622 700623 700624 700625 700626 700627 700628 700629 700630 7 BASE END INSULATION 720601 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 8 BASE REAR INSULATION 1 ea 720602 720603 720604 720605 720606 720607 720608 720609 720610 9 BASE LEG ASSY 700110 4 ea 4 ea 4 ea 4 ea 4 ea 4 ea 4 ea 4 ea 4 ea 10 1 4 20 X 1 2 SELF TAPPING SCREW 900100 20 ea 20 ea 20 ea ...

Page 37: ...37 35 Base Block Hood ...

Page 38: ...0041 49 35 1600 392449 50 35 1650 392449 4 51 51a 51 51a 60 50mm BURNER WITH PILOT BRACKET 150550 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 61 50mm BURNER LESS PILOT BRACKET 150551 1 ea 2 ea 3 ea 4 ea 5 ea 6 ea 7 ea 8 ea 62 MANIFOLD 50mm BURNERS 1 ea 701153 701154 701155 701156 701157 701158 701159 701160 64 ORIFICE HITCH PIN 950370 2 ea 3 ea 4 ea 5 ea 6 ea 7 ea 8 ea 9 ea 65 LOWER INJECTION SHIELD 1...

Page 39: ...39 37 50mm BURNER COMPONENTS 1 BURNER COMPONENTS ...

Page 40: ...6 032 96 033 96 033 96 035 96 035 89 1 2 LONG WELL 35 1006 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 90 AQUASTAT L8148E1257 35 3000 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea IGNITION MODULE E I BOILERS 35 5000 NATURAL GAS ONLY S8600F1000 IGNITION MODULE E I BOILERS 35 5050 NATURAL OR LP GAS S8600M1013 MODULE BRACKET E I BOILERS 905000 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 91 TRIDICATO...

Page 41: ...41 39 Jacket Components ...

Page 42: ...42 Tel 215 535 8900 Fax 215 535 9736 www crownboiler com Manufacturer of Hydronic Heatings Products P O Box 14818 3633 I Street Philadelphia PA 19134 CROWN Boiler Co ...

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