Crown Boiler AWR038 Installation Instructions Manual Download Page 1

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Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

www.crownboiler.com

WARNING

: Improper installation,

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:

•

AWR038

•

AWR070

•

AWR105

•

AWR140

•

AWR175

•

AWR210

•

AWR245

•

AWR280

AWR Series

Gas-Fired Natural Draft Hot Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

E S I G N E D T O

E A D

Equipped with Honeywell

S9361A Control System

9902339

Summary of Contents for AWR038

Page 1: ...ssistance or additional information consult a qualified installer service agency or the gas supplier Read these instructions carefully before installing Models AWR038 AWR070 AWR105 AWR140 AWR175 AWR21...

Page 2: ......

Page 3: ...ation start up or service Improper installation adjustment alteration service or maintenance may cause serious property damage personal injury or death DO NOT DISCONNECT PIPE FITTINGS on the boiler or...

Page 4: ...ns 3 III Before Installing 4 IV Locating the Boiler 4 V Air for Combustion Ventilation 6 VI Venting 10 VII Gas Piping 13 VIII System Piping 14 IX Wiring 19 X Start Up Checkout 24 XI Operation 28 XII S...

Page 5: ...d before selecting a boiler for installations having unusual piping and pickup requirements such as intermittent system opera tion extensive piping systems etc Add Suffix N for Natural Gas or Suffix L...

Page 6: ...to have either the Heating Capacity required for the Mega Stor or the I B R Net Rating required for the heating system whichever results in the larger boiler For systems that incorporate other indirec...

Page 7: ...FROM BOILER TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS WALLS AND DOORS CLOSET FIGURE 4 2 AWR245 280 MINIMUM CLEARANCE FROM BOILER TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND...

Page 8: ...ion air is drawn into the boiler room from other parts of the building and from the outdoors through natural infiltration cracks under doors etc This method can not be used in all cases see discussion...

Page 9: ...nings connect is less than 50 cubic feet per 1000 BTU hr of total appliance input install a pair of identical openings into a third room Connect additional rooms with openings until the total volume o...

Page 10: ...8ft high If two openings are installed into this basement that each have a free area of 135in2 the combined volume of the boiler room and basement will be 350ft3 6400ft3 6750ft3 and 6750 135 50ft3 per...

Page 11: ...ave a 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 Minimum opening size is 3 inches Openings to outdoors via horizontal...

Page 12: ...nto the boiler do not attempt to install an external draft hood 1 Acceptable Chimneys The following chimneys may be used to vent AWR series boilers Listed Type B or L gas vent Install in accordance wi...

Page 13: ...will not be subjected to winds which could affect power venter operation 6 Do not connect the vent of this appliance into any portion of a mechanical vent system operating under positive pressure 7 D...

Page 14: ...imney In some cases when an existing boiler is removed from a common chimney the common venting system may be too large for the remaining appliances At the time of removal of an existing boiler the fo...

Page 15: ...n venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 10 of the National Fuel Gas Code ANSI Z223 1 VII Gas Piping Gas piping to the boiler...

Page 16: ...up to the Maximum Allowable Working Pressure shown on the rating plate If the valve is replaced the replacement must have a relief capacity in excess of the DOE heating capacity for the boiler Pipe th...

Page 17: ...f 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 betw...

Page 18: ...rs If necessary the supply and return may be connected to the left side of the boiler by moving the 1 1 4 plug and the relief valve fittings from the tappings in the left side of the boiler to the cor...

Page 19: ...17 FIGURE 8 5 BOILER BYPASS PIPING FIGURE 8 6 ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER...

Page 20: ...valve and variable speed injection Circulatoring systems 5 Systems containing oxygen Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a cast iron boiler such a...

Page 21: ...or greater A service switch is recommended and is required by many local codes Locate this switch in accor dance with local codes or in the absence of any in a location where it can be safely accesse...

Page 22: ...Note When Option Plug 1 is not used the factory supplied jumper plug shown in Figure 9 1 must be installed for boiler to operate d Option Plug 2 Used to connect Crown optional touch screen display or...

Page 23: ...21 FIGURE 9 0 LINE VOLTAGE FIELD CONNECTIONS FIGURE 9 1 LOW VOLTAGE FIELD CONNECTIONS...

Page 24: ...22 FIGURE 9 2 INTERNAL CONNECTIONS DIAGRAM...

Page 25: ...23 FIGURE 9 3 LADDER DIAGRAM...

Page 26: ...rain will be filled with air Even if the gas line has been completely purged of air it may take several tries for ignition before a flame is established Once a flame has been established for the first...

Page 27: ...ion above on this label 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...

Page 28: ...elight 18 After the boiler has operated for approximately 30 minutes check the boiler and heating system piping for leaks Repair any leaks found at once 19 Inspect the vent system for flue gas leaks a...

Page 29: ...RE 10 1 PILOT BURNER FLAME FIGURE 10 2 MAIN BURNER FLAME FIGURE 10 3 GAS VALVE DETAIL TABLE 10 4 FLUE GAS COMBUSTION READING Fuel Max CO2 Min O2 Max CO PPM Natural Gas 8 5 6 0 50 PPM Propane 10 0 5 8...

Page 30: ...o see Figure 11 1 1 Status Mode This is the default mode of operation for the control In it the display alternates between StA and a number indicating the current status of the boiler A list and descr...

Page 31: ...ODE Visible when Lockout is Present Code for Error Present Table 13 0 total burner Cycles Total Run Time hrs Press I Return to Status Mode Press or Boiler in Lockout Temperature Units Reset Circulator...

Page 32: ...self AND a forced delay period has passed 14 Hard Lockout A fault has occurred which requires manual intervention before the boiler will again operate This intervention can be in the form of interrupt...

Page 33: ...used as a second heating zone see Table 11 5 this parameter will be shown as OFF and tt will be shown as ON when this zone calls for heat FLA Flame Current Flame rectification signal uA run Run Time H...

Page 34: ...t if all calls for heat end while the burners are off on high limit the burner will not restart during the next call for heat until the thermal purge requirements described below are met Or Circulator...

Page 35: ...eous calls for heat and DHW are present the heating circulator will be forced off for as long as it takes the boiler to satisfy the call for DHW This feature is sometimes useful when the boiler size i...

Page 36: ...If the blocked vent switch flame roll out switch and any external limits connected to Option Plug 1 are made 24 VAC will be applied across pin terminal 2 orange and 4 yellow at the vent damper and the...

Page 37: ...main burner operation in the event that a blocked vent causes flue gas to spill from the draft diverter opening This switch is equipped with a reset button which must be pressed to restore normal bur...

Page 38: ...its original location 9 Inspect all boiler wiring for loose connections or deterioration 10 Inspect the vent system Make sure that the vent system is free of obstructions Make sure that all vent syste...

Page 39: ...ghly sealed to the heat exchanger 13 Reattach the flue collector 14 Reattach all the jacket components 15 Reinstall burners being careful to put the pilot main burner in its original location 16 Repla...

Page 40: ...es 5 When checking voltage across at wiring connectors such as at the vent damper harness plug be careful not to insert the meter probes into the metal sockets Doing so may damage the socket resulting...

Page 41: ...swired con nections If no harness defect is found replace vent damper 57 Grounded pilot electrode Condensate or foreign material is shorting pilot electrode to ground Ignition cable insulation is dama...

Page 42: ...rode porcelain or ignition wire insulation replace pilot Pilot electrode or Ground strap damaged replace pilot If you cannot hear spark at all replace control StA 6 Spark but no pilot flame Low inlet...

Page 43: ...41 Notes...

Page 44: ...SCRIPTION QTY OR CROWN PN QUANTITY PER BOILER OR CROWN PART NUMBER 38 70 105 140 175 210 245 280 1 COMPLETE HEAT EXCHANGER ASSEMBLY 1 EA 760012 760013 760014 760015 760016 760017 760018 760019 LEFT EN...

Page 45: ...43...

Page 46: ...4 760625 760626 760627 760628 760629 13 1 2 X 2 SEALING GASKET 900146 3 9 FT 4 4 FT 4 9 FT 5 4 FT 5 9 FT 6 4 FT 7 0 FT 7 5 FT 14 BASE SIDE INSULATION 760520 2 EA 2 EA 2 EA 2 EA 2 EA 2 EA 2 EA 2 EA 15...

Page 47: ...45...

Page 48: ...FICE 1 25MM DRILL 950345 2 EA 27 LP GAS ORIFICE 1 20MM DRILL 950346 4 EA 6 EA 8 EA 10 EA 12 EA 14 EA 16 EA 28 PILOT BURNER 150760 1 E A 1 EA 1 EA 1 EA 1 E A 1 EA 1 E A 1 EA 29 PILOT ASSEMBLY NAT GAS H...

Page 49: ...ACKET PANEL 1 EA 760302 760303 760304 760305 760306 760307 760308 760309 39 VESTIBULE PANEL 1 EA 760332 760333 760334 760335 760336 760337 760338 760339 40 TOP JACKET PANEL 1 EA 760322 760323 760324 7...

Page 50: ...2 WINDOW 900723 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 54 CROWN NAMEPLATE 98 004 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 55 DOOR KNOB 90 210 2 EA 2 EA 2 EA 2 EA 2 EA 2 EA 2 EA 2 EA 3 4 RELIEF VALVE 3...

Page 51: ...Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com PN 980763 Rev 5 10 16...

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