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Crown Boiler AWI061 - page 1
1 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacturer of Hydronic Heatings Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 A WI & TWI Series Gas-Fired Natural Draf t Hot W ater Boilers INST ALLA TION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler WARNING : Improper in ...
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Crown Boiler AWI061 - page 2
2 INSIDE FRONT COVER (LEA VE BLANK) ...
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Crown Boiler AWI061 - page 3
3 T able of Contents I. Product Description .................................................. 1 II. Specifications ............................................................ 1 III. Before Installing ......................................................... 4 IV . Locating the Boiler ...................................................... 4 V . Ai ...
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Crown Boiler AWI061 - page 4
4 2 FIGURE 1B: “LEFT PIPED” CONFIGURATION FIGURE 1C: “TOP PIPED” (T-AWI OR T-TWI) CONFIGURATION ...
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Crown Boiler AWI061 - page 5
5 TABLE 1: SPECIFICATIONS Notes: Suffix E = Intermittent Ignition, Suf fix S = Standing Pilot Add Suffix N for Natural Gas or Suffix L for Propane Gas to basic A WI Boiler Model shown (Example: A WI295EN, A WI229SL) C I S A B R E L I O B L E D O M * S E S A G P L D N A L A R U T A N - S G N I T A R ) S E H C N I ( S N O I S N E M I D R E B M U N F ...
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Crown Boiler AWI061 - page 6
6 III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the Nationa ...
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Crown Boiler AWI061 - page 7
7 4 ) The boiler should be located as close to the chimney as possible. 5) Do not install this boiler over carpeting. 6) Do not install this boiler directly on a surface that may get wet. Raise the boiler on a pad. V Air for Combustion and V entilation Sufficient fresh air must be supplied for combustion, ventilation and flue gas dilution. Provisio ...
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Crown Boiler AWI061 - page 8
8 b. Find the volume of the room in cubic feet. The volume of the room in cubic feet is: Length (ft) x width (ft) x ceiling height (ft) In calculating the volume of the boiler room, consider the volume of adjoining spaces only if no doors are installed between them. If doors are installed between the boiler room and an adjoining space, do not consi ...
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Crown Boiler AWI061 - page 9
9 For Buildings of Unusually Tight Construction 1 ) Openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl space, which communicates directly with the outdoors. 2) Two openings are required. The top edge of the upper opening must be within 12 inches of the ceiling. The bottom edge of the ...
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Crown Boiler AWI061 - page 10
10 VI V enting Vent installation must be in accordance with local building codes, or the local authority having jurisdiction, or Chapters 7 an d 10 of the National Fuel Gas Code , NFPA 54/ANSI Z 223.1. Typical vent installation is illustrated by Figure 8. The components of vent installation are boiler draft diverter, vent damper, vent connector and ...
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Crown Boiler AWI061 - page 11
11 2 ) Acceptable Vent Connectors - The following may be used for vent connectors: • Listed type B or L Gas Vent • Single Wall Galvanized Pipe - Use 0.018” (26 gauge or heavier). The size and location of the chimney may not permit the use of a single wall connector in some cases. See Chapter 10 of the National Fuel Gas Code. Do not use single ...
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Crown Boiler AWI061 - page 12
12 7 ) Do not connect the boiler into a chimney flue serving an open fireplace or other solid fuel appliance. 8 ) Prior to boiler installation, inspect chimney for obstructions or other defects and correct as required. Clean chimney as necessary. 9) Vent pipe should slope upward from draft diverter not less than one inch in four feet. No portion of ...
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Crown Boiler AWI061 - page 13
13 connected to the common venting system are not in operation. a ) Seal any unused opening in the common venting system. b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. c ) Insofar as pract ...
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Crown Boiler AWI061 - page 14
14 VIII System Piping Standard Piping Figure 11 shows typical boiler system connections on a single zone system. Additional information on hydronic system design may be found in Installation of Residential Hydronic Systems (Pub. #200) published by the Hydronics Institute in Berkeley Heights, NJ. The components in this system and their purposes are ...
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Crown Boiler AWI061 - page 15
15 6) Low Water Cut-Off (Required in some situations) - A low water cutoff is required when the boiler is installed above radiation. In addition, some codes such as ASME CSD-1 require low water cutoffs. Codes may also require that this low water cutoff have a manual reset function. The low water cutoff may be a float type or probe type, but must be ...
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Crown Boiler AWI061 - page 16
16 2) Large Water Volume Systems - The piping shown in Figure 13 will minimize the amount of time that the boiler operates with return temperatures below 120°F on these systems. A bypass is installed as shown to divert some supply water directly into the return water. The bypass pipe should be the same size as the supply. The two throttling valves ...
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Crown Boiler AWI061 - page 17
17 FIGURE 13: BOILER BYPASS PIPING FIGURE 14: ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER 5) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler and chiller in parallel as shown i n Figure 15. Use isolation valves to prevent chilled water from entering the boiler. 6) Air Handlers - Where the boiler ...
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Crown Boiler AWI061 - page 18
18 IX W iring Single Zone Wiring 1) 120 V olt W iring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt connections are made inside the L8148E aquastat relay as follows (also see Fig. 16 or 17): • Hot (“black”) - T erminal “L1” • Neutral (“white”) - T erminal “L2” • Ground (“ ...
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Crown Boiler AWI061 - page 19
19 FIGURE 16: WIRING DIAGRAM, CONTINUOUS IGNITION (STANDING PILOT) SYSTEM 17 FIGURE 17: WIRING DIAGRAM, INTERMITTENT IGNITION (EI) SYSTEM 2 2 ...
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Crown Boiler AWI061 - page 20
20 Wiring V ariations 1) Multiple Circulator Zones – Figure 18 shows wiring for two or more circulator zones using Honeywell R845As. One R845A is required for each circulator zone. Circulator terminals “C1” and “C2” on the L8148E are not used. A DPST Honeywell RA832A may be substituted in place of the R845A using the “X” and “X” t ...
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Crown Boiler AWI061 - page 21
21 A WI/TWI Control System – Sequence of Operation (Refer to Figures 16 or 17 for ladder and connection diagrams) Sequence of Operation, Standing Pilot 1) When the boiler is ener gized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damper . Assuming that there is no call for heat, and that the damper ...
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Crown Boiler AWI061 - page 22
22 Sequence of Operation, Intermittent Ignition 1) When the boiler is ener gized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damper . Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will close. 2) A call for heat from the thermostat ...
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Crown Boiler AWI061 - page 23
23 X Start-up and Checkout Use the following procedure for initial start-up of the boiler: 1 ) Make sure that the boiler and system are filled with water. 2 ) Check all new gas piping for leaks and purge piping sections that are filled with air. See Part 4 of the National Fuel Gas Code for additional information on testing and purging gas lines. 3 ...
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Crown Boiler AWI061 - page 24
24 1 3 ) Run gas valve safety shutdown test: • For standing pilot boiler models, disconnect the thermocouple from gas valve. Both pilot burner and main burners should stop firing. • For intermittent ignition boiler models, with main burners firing, disconnect ignition cable from ignition module. Both pilot burner and main burners should stop fi ...
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Crown Boiler AWI061 - page 25
25 20) After the boiler has operated for approximately 30 minutes, check the boiler and heating system piping for leaks. 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. FIGURE 20: STANDING PILOT BURNER FLAME FIGURE 21: INTERMITTENT IGNITION PILOT BURNER F ...
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Crown Boiler AWI061 - page 26
26 A. This appl ianc e has a pilot wh ich must b e light ed by ha nd . When lightin g t he pilo t, f ollow these in stru ction s exactly. B. BEFO RE LI GHTIN G smel l all a ro und t he app liance ar ea for gas. Be sure to smell ne xt to t he floor bec ause so me gas is heavie r than air and w ill settle on the floo r . WHA T TO DO IF YOU SMELL GAS ...
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Crown Boiler AWI061 - page 27
27 A. Th is applian c e is equipp ed w ith an ign ition device w hich automat ic ally li ghts th e pi lot. D o t r yt ol i g h tt h ep i l o tb yh a n d . B. BE FO RE LI GHTING s mell a ll ar ound t he app liance ar ea for gas. Be sure to smel l next to t he floor bec ause so me gas is heavie r than air and w ill settle on the floor . WHA T T O DO ...
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Crown Boiler AWI061 - page 28
28 FIGURE 24: GAS VALVE DETAIL - STANDING PILOT FIGURE 25: GAS VALVE DETAIL - INTERMITTENT IGNITION 26 ...
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Crown Boiler AWI061 - page 29
29 XI Service and Maintenance The following routine maintenance should be performed on an annual basis: 1) T urn of f electrical power and gas supply to the boiler 2) Inspect the flue passages for signs of blockage. If there is any carbon in the combustion chamber or the flue passages, clean the heat exchanger before proceeding further . See the cl ...
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Crown Boiler AWI061 - page 30
30 Heat Exchanger Cleaning Pr ocedur e 1) T urn of f electrical power and gas supply to the boiler 2) Disconnect the damper and vent connector from the boiler . 3) Remove the upper front and top jacket panels. If possible, remove the rear and left side jacket panels 4) Remove the burners. 5) Remove the blocked vent (“spill”) switch 6) Remove th ...
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Crown Boiler AWI061 - page 31
31 The following four pages contain troubleshooting charts for use in diagnosing control problems. T o use these charts, go to the box marked “Start” at the top of the chart on page 30 and follow the appropriate path though the chart until a box with a list of possible causes is reached. If the problem is known to be within the ignition system, ...
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Crown Boiler AWI061 - page 32
32 30 A WI/TWI T roubleshooting Chart Caution : Read page 29 before attempting to use this chart T her m os tat c all s f or heat C i r c ulator st a rt ? 120 v ol ts at L1 & L2 ? 120 v ol ts a t C1 & C2 ? N N * Po w e r o f f * Bl ow n f us e or tr i pped br eaker * Mi s w i r e d o r l oo se e l e ct ri ca l c onnec tion i n 120V l ine R ...
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Crown Boiler AWI061 - page 33
33 31 Ma i n bur ner s l ight? 24 v olts ac r os s B1 & B2 ? R ef e r t o s t a n d in g p ilo t o r in t e r m it t e n t ig n it io n tr oubles hoot ing c har t ( page 32 or 33) . * D ef ec tiv e dam per * D ef ec tiv e L8148E * D ef ec tiv e dam per har nes s * Loos e dam per har nes s c onnec ti on * O b st ru ct i on i n p at h of dam per ...
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Crown Boiler AWI061 - page 34
34 32 St anding Pilot Ignition System T roubleshooting Chart Pi lo t lit? Ma in burners light ? Y Tu r n c o n t ro l o n gas v al v e t o PIL O T .D e p r e s s red b ut t on and li g h t p il o t . H o ld butt on fo r at le ast o ne minu t e. Doe s pi l o t lig ht? N * Pi lot tu b ing bl oc k ed, k i nk ed or l eaki ng * Pilo t or if ice bloc ked ...
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Crown Boiler AWI061 - page 35
35 33 Doe s sp a r k sto p w he n pilot lig h ts ? 24 v olt s ac ros s te r m in a ls 2 & 3 at S 860 0? Sp ar k ac ros s ig n ito r /se n s o r ga p? Y Ca n y o u he a r sp a r kin g ? * Fau l t y S8 6 0 0 module * Br ea k i n sp a rk ca b le ins u l ation * Br ea k in p il o t porc e l ai n * Inc or re c t pi l ot sp a r k g a p * Loos e c onn ...
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Crown Boiler AWI061 - page 36
36 XIII P AR TS The following p art s may be obtained from any Crown distributor . T o find the closest Crown distributor , consult the area Crown representative or the factory at: Crown Boiler Co. Customer Service P .O. Box 14818 Philadelphia Pa. 19134 www .crownboiler .com Main burner orifice shown are for sea level configured boilers. For boiler ...
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Crown Boiler AWI061 - page 37
37 35 Base-Block-Hood ...
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Crown Boiler AWI061 - page 38
38 36 CAUTION: MAIN BURNER ORIFICE SIZES SHOWN ARE FOR BOILERS INST ALLED A T AL TITUDES BELOW 2000 ft 37 61 95 128 162 195 229 262 295 41 1" BURNER W IT H PILOT BRACKET 150500 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 42 1" BURNER LESS PILOT BRACKET 150501 1 ea. 2 ea. 4 ea. 6 ea. 8 ea. 11 ea. 13 ea. 15 ea. 17 ea. 43 MANIFOLD ...
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Crown Boiler AWI061 - page 39
39 37 50mm BURNER COMPONENTS 1” BURNER COMPONENTS ...
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Crown Boiler AWI061 - page 40
40 38 37 61 95 128 162 195 229 262 295 75 LEFT SIDE JACKET PANEL 1 ea. 700301 700301 700301 700301 700301 7003015 7003015 7003015 7003015 76 RIGHT SIDE JACKET PANEL 1 ea. 700300 700300 700300 700300 700300 7003005 7003005 7003 005 7003005 77 REAR JACKET PANEL 1 ea. 700302 700303 700304 700305 700306 70 0307 700308 700309 70 0310 78 TOP JACKET PANEL ...
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Crown Boiler AWI061 - page 41
41 39 Jacket/Components ...
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Crown Boiler AWI061 - page 42
42 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacturer of Hydronic Heatings Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 CROWN Boiler Co ...
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