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FOLLOW ALL INSTRUCTIONS and warnings 
printed in this manual and posted on the boiler.

INSPECT THE BOILER ANNUALLY. To keep your 
boiler safe and efficient, have a service technician 
follow the Service checklist near the end of this 
manual.

IF YOU ARE NOT QUALIFIED to install or service 
boilers, do not install or service this one.

THE BOILER MAY LEAK WATER at the end of 
its useful life. Be sure to protect walls, carpets, 
and valuables from water that could leak from the 
boiler.

PROTECT YOUR HOME IN FREEZING 
WEATHER. A power outage, safety lockout, or 
component failure will prevent your boiler from 
lighting. In winter, your pipes may freeze and 
cause extensive property damage. Do not leave 
the heating system unattended during cold weather 

unless alarms or other safeguards are in place to 
prevent such damage

DO NOT BLOCK AIR FLOW into or around the 
boiler. Insufficient air may cause the boiler to 
produce carbon monoxide or start a fire.

KEEP FLAMMABLE LIQUIDS AWAY from the 
boiler, including paint, solvents, and gasoline. 
The boiler may ignite the vapors from the liquids 
causing explosion or fire.

KEEP CHILDREN AND PETS away from hot 
surfaces of the boiler, boiler piping, and vent pipe.

CARBON MONOXIDE (CO) is an odorless, deadly 
gas that may be introduced into your home by 
any malfunctioning fuel-burning product or vent 
system failure. Consider installing CO alarms near 
bedrooms in all levels of the building to warn you 
and your family of potential CO exposure.

READ THIS ENTIRE MANUAL before attempting 
installation, 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 in the heating system without first verifying 
that the system is cool and free of pressure and 
that your clothing will protect you from a release 
of hot water or steam. Do not rely solely on the 
boiler’s temperature and pressure gage when 
making this judgment.

USE PROPER PERSONAL PROTECTION 
EQUIPMENT when servicing or working near the 
boiler. Materials of construction, flue products, and 
fuel contain alumina, silica, heavy metals, carbon 
monoxide, nitrogen oxides, and/or other toxic or 
harmful substances that can are hazardous to 
health and life and that are known to the State of 
California to cause cancer, birth defects, and other 
reproductive harm.

INSTALL ALL GUARDS, cover plates, and 
enclosures before operating the boiler.

SIZE THE BOILER PROPERLY relative to the 
design heat load or, if using domestic hot water 
priority, the peak hot water load, whichever 
is larger. A grossly oversized boiler will cycle 
excessively and this will lead to premature failure 
of the boiler and its components. Our warranty 
does not apply to damage from excessive cycling.

ADHERE TO ALL LOCAL CODE 
REQUIREMENTS. Contact your local code 
inspector prior to installation. In the absence of 
a local code, adhere to the 

National Fuel Gas 

Code ANSI Z223.1/NFPA 54 

or 

CAN/CSA B149.1, 

Natural Gas and Propane Installation Code.

ALL WIRING must comply with the 

National 

ElectrIcal Code ANSI/NFPA 70

 (in the USA) or the 

Canadian Electrical Code CSA C22.1

 (in Canada) 

and any local regulations.

WARNINGS FOR THE HOMEOWNER

WARNINGS FOR THE INSTALLER

Содержание AWR Series

Страница 1: ...or 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 A...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 12: ...quipped with a draft hood which is built into 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 Typ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 41: ...ground Pilot is damaged 58 AC Power Frequency Error 120VAC power supply frequency is incorrect Should be 60Hz 120VAC power supply is dirty consult electrician and or Utility Boiler water temperature...

Страница 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...

Страница 43: ...41 Notes...

Страница 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...

Страница 45: ...43...

Страница 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...

Страница 47: ...45...

Страница 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...

Страница 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...

Страница 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...

Страница 51: ...Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com PN 980763 Rev 2 07 13...

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