Crown Boiler AWI095 User Manual

CROWN

Boiler Co

AWI & TWI Series

Gas-Fired Natural Draft Hot Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

Models:

• AWI037

WARNING: Improper installa-

tion, adjustment, alteration,

• AWI061

• AWI095

• AWI128

• AWI162

• AWI195

• AWI229

• AWI262

• AWI295

• TWI061

• TWI095

• TWI128

• TWI162

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.

CROWN

Boiler Co

Manufacturer of Hydronic Heatings Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

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

Table of Contents

I. Product Description .................................................. 1

VIII. System Piping ............................................. 12

IX. Wiring ......................................................... 16

II. Specifications ............................................................ 1

III. Before Installing ......................................................... 4

IV. Locating the Boiler ...................................................... 4

V. Air for Combustion & Ventilation .............................. 5

VI. Venting ....................................................................... 8

VII. Gas Piping ................................................................ 11

Start-Up & Checkout .................................. 21

XI. Service & Maintenance............................... 27

XII. Troubleshooting ......................................... 29

XIII. Parts ............................................................ 34

I Product Description

The AWI series boiler is a cast iron gas fired water boiler designed for use in closed forced circulation heating systems.

This boiler is a Category I draft diverter equipped appliance, which must be vented by 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 propane gas.

II Specifications

FIGURE1A: STANDARDCONFIGURATION(SEEPAGE3FORLETTERDIMENSIONS)

FIGURE1B:“LEFTPIPED”CONFIGURATION

FIGURE1C:“TOPPIPED”(T-AWIORT-TWI) CONFIGURATION

TABLE1:SPECIFICATIONS

RATINGS - NATURAL AND LP GASES*

DIMENSIONS (INCHES)

BASIC

BOILER

MODEL

DOE

HEATING

CAPACITY

I=B=R NET

RATING,

WATER

INPUT

AFUE

NUMBER

"A"

"B"

"C"

"D"

"E"

"F"

SECTIONS

MBH

AWI037S

AWI037E

80.0

82.3

10-1/2

11-3/4

7-1/4

5-7/8

7-1/2

9-1/8

10-3/4

12-3/8

3-5/8 3-7/8

AWI061S

AWI061E

80.0

82.6

3-5/8

4-1/8

4-5/8

5-1/8

5-5/8

1-7/8

AWI095S

AWI095E

80.1

82.3

27-7/8

AWI128S

AWI128E

80.2

82.0

128

162

195

229

262

295

105

132

159

186

212

238

18-1/4

21-1/2

24-3/4

AWI162S

AWI162E

80.3

81.7

115

138

162

184

207

AWI195S

AWI195E

80.4

81.4

AWI229S

AWI229E

80.4

81.2

29-7/8

AWI262S

AWI262E

80.5

80.9

31-1/4

34-1/2

15-5/8

17-1/4

AWI295S

AWI295E

80.7

80.6

RATINGS - NATURAL GAS ONLY

DIMENSIONS (INCHES)

BASIC

BOILER

MODEL

NUMBER

SECTIONS

DOE

HEATING

CAPACITY

I=B=R NET

RATING,

WATER

INPUT

AFUE

"A"

"B"

"C"

"D"

"E"

"F"

MBH

TWI061E

TWI095E

TWI128E

83.0 11-3/4

83.0 15

5-7/8

7-1/2

3-5/8

4-1/8

1-7/8

27-7/8

128

162

106

134

83.0 18-1/4

83.0 21-1/2

9-1/8

4-5/8

1-7/8

TWI162E

Notes:

117

10-3/4

Suffix E = Intermittent Ignition, Suffix S = Standing Pilot

Add Suffix N for Natural Gas or Suffix L for Propane Gas to basic AWI Boiler Model shown (Example: AWI295EN, AWI229SL)

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

National Fuel Gas Code, ANSI Z223.1-latest edition.

Where required by the authority having jurisdiction, this installation must conform to the Standard for Controls

and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1)-latest edition.

2) Make sure that a properly sized chimney is available which is in good condition. Consult the authority having jurisdiction,

Part VI of this manual, and the National Fuel Gas Code for additional information on venting requirements.

3) Make sure that the boiler is correctly sized:

•

For heating systems employing convection radiation (baseboard or radiators) use an industry accepted sizing

method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics Institute

in Berkeley Heights NJ.

•

For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.

For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE Heating

Capacity required for the Mega-Stor or the 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 burners and main burner orifice. Make sure that

the boiler is configured for use at the correct altitude.

IV Locating the Boiler

1) Clearances:

•

Observe the minimum clearances shown below. These clearances apply to all combustible construction, as well as

noncombustible walls, ceilings and doors. Also see Figure 2.

Front – 18”

Left Side – 6”

Right Side – 6”

Rear – 6”

Top – 18”

•

A 24” service clearance from the jacket is recommended on the left, right, and front of the boiler. These clearances

may be reduced to those shown in Figure 2, however servicing the boiler will become increasingly difficult as these

service clearances are reduced.

If the right side 24” service clearance is reduced, adequate clearance must be maintained to easily read both the

gauge and the limit control. Alternatively, access to the gauge and limit may be provided using a door

2) The boiler must be installed on a hard level surface. This surface may be combustible.

3) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or used. Do not

install this boiler in an area where large amounts of airborne dust will be present, such as a workshop.

FIGURE2:CLEARANCEFROMBOILERTOALLTYPESOFCOMBUSTIBLECONSTRUCTIONAND

NONCOMBUSTIBLE CEILINGS, WALLS AND DOORS

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 Ventilation

Sufficient fresh air must be supplied for combustion, ventilation and flue gas dilution. Provisions for combustion, ventilation

and flue gas dilution air for gas utilization equipment vented by natural draft must be made in accordance with local building

codes or, in absence of such codes, in accordance with sections 5.3.3 and 5.3.4 (“Air for Combustion and Ventilation”) of the

National Fuel Gas Code, NFPA 54/ANSI Z 223.1.

To ensure an adequate supply of combustion, ventilation and flue gas dilution air supply, start by determining whether the boiler

is to be installed in a building of unusually tight construction. A building of unusually tight construction is defined by 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

floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and

at other openings.

For Buildings of Other than Unusually Tight Construction

1) Determine whether the boiler is to be installed in a confined space - A confined space is defined by the National Fuel Gas

Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To determine

whether the boiler room is a confined space:

a. Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest

1000 BTU/hr.

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 consider the volume

of the adjoining space, even if the door is normally left open.

c. Divide the volume of the boiler room by the input in thousands of BTU/hr. If the result is less than 50, the boiler

room is a confined space.

Example:

An AWI162EN and a water heater are to be installed in a room measuring 6 ft - 3 in x 7 ft with an 8 ft ceiling.

The water heater has an input of 30000 BTU/hr:

Total input in thousands of BTU/hr = (162000 BTU/hr + 30000 BTU/hr)/1000 = 192

Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft³

350/192 = 1.82. Since 1.82 is less than 50, the boiler room is a confined space.

2) Unconfined Space - Natural infiltration into the boiler room will normally provide adequate air for combustion and

ventilation without additional louvers 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 room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per

opening.

•

If the total volume of both the boiler room and the room to which the openings 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 of all rooms is at least 50 cubic feet per 1000 BTU/hr of input.

•

The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens

are used, they must be no finer than ¼” (4 x 4) mesh.

If providing openings into adjacent rooms is undesirable, combustion and ventilation air can be brought into the

boiler room from outdoors. See the instructions under “For Buildings of Unusually Tight Construction”.

FIGURE3:BOILERINSTALLEDINCONFINEDSPACE,

ALL AIR FROM INSIDE

ForBuildingsofUnusuallyTightConstruction

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 lower opening must be within 12 inches of the floor.

3) Size openings and ducts as follows:

•

Vertical ducts or openings directly outdoors (Figure 4, Figure 5, and Figure 6) - Each opening must have 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 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 not less than 100

square inches. Minimum opening size is 3 inches.

The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens

are used, they must be no finer than ¼” (4 x 4) mesh.

FIGURE4: ALLAIRFROMOUTDOORS,

VENTILATED CRAWL SPACE AND ATTIC

FIGURE5: ALLAIRFROMOUTDOORS,

VIA VENTILATED ATTIC

FIGURE6:ALLAIRFROMOUTDOORS,USING

OPENINGSINTOBOILERROOM

FIGURE7:ALLAIRFROMOUTDOORS,USING

HORIZONTAL DUCTS INTO BOILER ROOM

VI Venting

Vent installation must be in accordance with local building codes, or the local authority having jurisdiction, or Chapters 7 and

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 chimney. The AWI and TWI series boilers are equipped with a draft diverter 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 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 Appliances (NFPA 211) and lined with a clay liner or other listed lining

system. Do not vent an AWI or TWI series boiler into an unlined chimney.

FIGURE8: TYPICALVENTSYSTEM

INSTALLATION AND COMPONENTS

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

wall pipe for vent connectors in attics.

•

Other Vent Connectors Permitted by the National Fuel Gas Code.

3) Chimney and Vent Connector Sizing - Size the chimney and vent connector in accordance with Chapter 10 of the National

Fuel Gas Code.

4) Exterior Chimneys - An exterior chimney has one or more sides exposed to the outdoors below the roof line. There are two

conditions under which an exterior chimney may be used:

•

In some very restrictive cases, the AWI and TWI series boilers may be vented into an exterior ceramic 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 terms of the power venter listing, and applicable codes. The boiler must

be electrically interlocked with the power venter to prevent boiler operation if the power venter fails to operate. Before

deciding to use a power venter, make certain that the flue gas exiting the power venter will not damage adjacent

construction or other structures. Also make certain that the power venter terminal will not be subjected to winds which

could effect 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) 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 vent pipe should

run downward or have sags. Vent pipe must be securely supported.

10) The vertical section of vent pipe coming off the boiler should be as tall as possible, while still maintaining the proper

clearance from the horizontal vent connector to combustibles and the proper pitch called for in (9) above.

11) Vent pipe should be installed above the bottom of the chimney to prevent blockage.

12) Vent pipe must be inserted flush with inside face of the chimney liner and the space between vent pipe and chimney

sealed tight.

13) Do not install the vent damper in any portion of the vent system which is used by appliances other the boiler being

installed.

14) Vent damper installation is mandatory on all AWI/TWI boiler models due to federally mandated efficiency regulations.

Install vent damper (see Figure 9) as follows:

a) Open vent damper carton and remove installation instructions. Read the instructions thoroughly before proceeding.

Verify that vent damper is same size as draft diverter 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 ¾” 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 with the damper.

Mount the vent damper on the flue collar without modification to either and secure with sheet metal screws. Make

sure screws do not interfere with damper blade operation. Vent damper blade position indicator must be visible to

users.

c) The damper wire harness is shipped wired into the boiler limit control. Plug the loose end of this harness into the

damper and secure the flexible conduit to the damper using a connector nut provided.

Provide adequate clearance to combustible construction and servicing.

d) Install vent connector pipe and vent fittings from vent damper outlet to chimney or gas vent. Secure with sheet

metal screws and support as required.

RIGHTSIDEVIEW

FIGURE9: VENTDAMPERINSTALLATIONDETAILS

Removing an Existing Boiler from a Common Chimney

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 following steps shall be followed with each

appliance remaining connected to the common venting system placed in operation, while the other appliances remaining

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 practical, close all building doors and windows and all doors between the space in which all the appliances

remaining connected to the common venting system are located and other spaces of the building. Turn on clothes

dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range

hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close

fireplacedampers.

d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so the appliance

will operate continuously.

e) Test for spillage at the draft hood relief opening after five (5) minutes of main burner operation. Use the flame of a

match or candle, or smoke from a cigarette, cigar, or pipe.

f) After it has been determined that each appliance remaining connected to the common venting system properly vents

when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and 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 of

theNationalFuelGasCode, ANSIZ223.1.

VII Gas Piping

Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at a line

pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing,

consult the utility or Part 2 of the National Fuel Gas Code.

Figure 10 shows typical gas piping connection to the AWI/TWI boiler. A sediment trap must be installed upstream of all

gas controls. Install a manual shut-off valve outside the jacket and ground joint union as shown.

The boiler and its gas connection must be leak tested before placing the boiler in operation. When doing this, the boiler

and its individual shut-off must be disconnected from the rest of the system during any pressure testing of that system at

pressures in excess of 1/2 psi. When pressure testing the gas system at pressures of 1/2 psi or less, isolate the boiler from the

gas supply system by closing its individual manual shut-off valve.

* State of Massachusetts Requires Manual

Shut-off Valve to be “T” Handle Type

FIGURE10: GASCONNECTIONTOBOILER

VIII System Piping

CAUTION

•

INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED

FROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERATION AND

SERVICE (CIRCULATOR REPLACEMENT, ETC.).

•

OPERATION OF THIS BOILER WITH CONTINUOUS RETURN TEMPERATURES BELOW 120°F

CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.

OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF

DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.

DO NOT USE TOXIC ADDITIVES, SUCH AS AUTOMOTIVE ANTIFREEZE, IN A HYDRONIC

SYSTEM.

StandardPiping

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 as follows:

1) Relief valve (Required) - Mount the relief valve on the right side of the boiler as shown in Figure 1 using the 3/4 nipples

and elbow provided. The relief valve shipped with the boiler is set to open at 30 psi. This valve may be replaced with

one having a pressure 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 the discharge of the relief valve to a location where water or steam will not create a hazard or cause property

damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the relief valve

discharge is not piped to a drain it must terminate at least 6 inches above the floor. Do not run relief valve discharge

piping through an area that is prone to freezing. The termination of the relief valve discharge piping must be in an area

where it is not likely to become plugged by debris.

DANGER

•

PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION.

DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE.

DO NOT MOVE RELIEF VALVE FROM FACTORY LOCATION.

DO NOT PLUG RELIEF VALVE DISCHARGE.

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. If the expansion tank must be replaced, consult the expansion tank

manufacturer’s literature for proper sizing.

4) Fill Valve (Required) - Either a manual or automatic fill valve may be used. The ideal location for the fill is at the

expansion tank.

5) Automatic Air Vent (Required) - At least one automatic air vent is required. Manual vents will usually be required in

other parts of the system to remove air during initial fill.

FIGURE11: STANDARDBOILERPIPING

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

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 between it and the boiler.

Use a low water cutoff that breaks the 120 VAC supply to the boiler. Do not attempt to wire a 24-volt low water cutoff

into the boiler factory wiring.

7) Manual Reset High Limit (Required by some codes) - This control is required by ASME CSD-1 and some other codes.

Install the high limit in the boiler supply piping just beyond the boiler with no intervening valves. Set the manual reset

high limit as far above the operating limit setting as possible, but not over 240°F. Wire the control to break the 120

VAC electrical supply 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 Valves (Optional) - Isolation valves are useful if the boiler must be drained, as they will eliminate having to

drain and refill the entire system.

10) Drain Valve - The drain valve is shipped in the boiler parts bag. Install it in the tee under the circulator as shown in

Figure 1.

Piping for Special Situations

Certain types of heating systems have additional requirements. Some of the more common variations follow:

1) Indirect Water Heaters - Figure 12 shows typical indirect water heater piping. Boiler piping is the same as for any two-

zone system. Figure 12 shows circulator zoning, which is usually preferred for indirect water heaters. Size the

circulator and indirect water heater piping to obtain the boiler water flow through the indirect water heater called for by

the indirect water heater manufacturer.

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 shown are

adjusted so that the return temperature rises above 120°F during the first few minutes of operation. A three-way valve can

be substituted for the two throttling valves shown. If the circulator is mounted on the supply, the bypass must be on the

discharge side of the circulator.

3) Low Temperature Systems - Some systems, such as radiant tubing systems, require the system water temperature to be

limited to a value below the temperature of the water leaving the AWI or TWI. These systems also typically have return

temperatures well below the 120°F minimum.

Figure 14 illustrates the use of a heat exchanger to connect the AWI or TWI boiler to this type of system. The heat

exchanger will permit the transfer of heat from the boiler water to the low temperature system while holding the system

supply and boiler return temperatures within 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.

There are several other ways to connect low temperature systems to the non-condensing boilers like the AWI or TWI

such as four way mixing valve and variable speed injection pumping systems.

4) Systems containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage

to a cast iron boiler such as the AWI or TWI. Some examples include:

•

Radiant systems that employ tubing without an oxygen barrier.

Systems with routine additions of fresh water.

Systems which are open to the atmosphere.

If the boiler is to be used in such a system, it must be separated from the oxygenated water being heated with a heat

exchanger as shown in Figure 14.

Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature

requirements. All components on the oxygenated side of the heat exchanger, such as the pump and expansion tank,

must be designed for use in oxygenated water.

FIGURE12: INDIRECTWATERHEATER

BOILER SIDE PIPING

5) Piping with a Chiller - If the boiler is used in conjunction with a chiller, 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.

FIGURE 13: BOILER BYPASS PIPING

FIGURE14: ISOLATIONOFBOILERFROMSYSTEM

WITH A HEAT EXCHANGER

FIGURE15: BOILERPIPINGWITHCHILLER

IX Wiring

WARNING

All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of

such requirements, with the National Electrical Code (ANSI/NFPA 70)

Single Zone Wiring

1) 120 Volt Wiring - 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”) - Terminal “L1”

Neutral (“white”) - Terminal “L2”

Ground (“green” or bare) - Ground screw on case of L8148E

2) Thermostat Wiring - Follow thermostat manufacturer instructions. 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.

FIGURE16: WIRINGDIAGRAM,CONTINUOUSIGNITION

(STANDING PILOT) SYSTEM

FIGURE17: WIRINGDIAGRAM,INTERMITTENTIGNITION

(EI) SYSTEM

Wiring Variations

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” terminals in place of the “5” and “6”

terminals on a R845A.

A call for heat from any thermostat will energize the DPST relay in that zone’s R845A. When this relay is energized,

electrical continuity is created between terminals 3 and 4, energizing the circulator for that zone. At the same time, electri-

cal continuity is created between terminals 5 and 6 on the R845A, creating a current path from terminal “T” to “TV” on the

L8148E. Assuming that the supply water temperature is below the high limit setting, the normal ignition sequence will be

initiated.

2) Multiple Zones using Zone 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

A call for heat from a given thermostat will result in the application of 24 volts across the TH and TR terminals on the

corresponding zone valve, energizing the zone valve motor. The zone valve opens and the end switch contacts are then

made. The end switches are connected in parallel with each other and to the “T” and “TV” thermostat connections so that

any zone valve that opens will also start the circulator and fire the boiler (assuming the high limit is not open). Zone valve

terminal TH/TR has no internal connection on the zone valve; it is merely a “binding post” used to connect two or more

wires.

FIGURE18:CIRCULATORZONEWIRINGUSINGHONEYWELLR845As

(FACTORY BOILER WIRING NOT SHOWN - SEE FIGURE 16 OR 17)

FIGURE 19: ZONE WIRING USING HONEYWELL V8043F ZONE VALVES

(FACTORY WIRING NOT SHOWN - SEE FIGURE 16 OR 17)

AWI/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 energized, 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 energizes relay coil 1R (the relay on the L8148E), causing contacts 1R1 and 1R2 to

make. Contact 1R1 starts the circulator. Contact 1R2 sends power to the high limit.

3) Assuming that the high limit is made, current will flow to pin terminal #2 (orange) at the vent damper and the damper will

open.

4) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin #3 (red) at the damper. This

pin is connected through the damper harness to terminal “B1” on the L8148E. At this point in the operating sequence, 24

volts is present across “B1” and “B2”.

5) Under normal 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 gas control. The circuit connecting

the thermocouple and the safety shut-off valve is self contained and completely independent of all other wiring on the boiler.

This safety shut-off valve is upstream of the 24 volt valves in the gas control which open in response to a call for heat. If the

pilot is not lit, the safety shut-off valve will remain closed and gas will not reach the 24 volt valves.

7) Assuming that the pilot is established and proven by the thermocouple, the application of 24 volts across the combination

gas valve terminals energizes the redundant 24 volt solenoid valves in the combination gas control, resulting in gas flow

through the control and burner operation.

Sequence of Operation, Intermittent Ignition

1) When the boiler is energized, 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 energizes relay coil 1R (the relay on the L8148E), causing contacts 1R1 and 1R2 to

make. Contact 1R1 starts the circulator. Contact 1R2 sends power to the high limit.

3) Assuming that the high limit is made, current will flow to pin terminal #2 (orange) at the vent damper and the damper will

open.

4) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin #3 (red) at the damper. This

pin is connected through the damper harness to terminal “B1” on the L8148E. At this point in the operating sequence, 24

volts is present across “B1” and “B2”.

5) Under normal conditions, the flame roll-out switch and blocked vent switch are made. Voltage will therefore immediately

appear across the “24V” and “24V (GND)” terminals on the ignition module.

6) Upon application of voltage across the “24V” and “24V (GND)” terminals, the ignition module will start an ignition spark

at the pilot and apply 24 volts across the pilot valve (terminals “PV” and “MV/PV”).

7) Once the pilot is established, the pilot flame will act as a diode, converting the AC current at the electrode to a half wave

DC current at the pilot’s ground strap. This DC current flows through the boiler to the “GND (BURNER)” connection on

the ignition module. For the ignition module to recognize that a pilot flame is present, the DC current flowing into this

terminal must be in excess of approximately 1.0 uA.

8) Once the ignition module detects the presence of a pilot flame, voltage is applied 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 Crown representative.

Safety Control Operation - Standing Pilot and Intermittent Ignition

High Limit - Interrupts main burner operation when the supply water temperature exceeds set point. Maximum allowable

temperature is 250°F. If the high limit opens, the vent damper will close if the damper switch is in the “automatic” position.

The circulator will continue to operate as long as there is a call for heat, regardless of the status of the high limit. Burner

operation automatically resumes when the supply water temperature falls below set point.

Blocked Vent (“Spill”) Switch - Automatically interrupts main burner operation in the event that flue gas spills from the draft

diverter opening. This switch is equipped with a reset button which must be pressed to restore normal burner operation. An

open blocked vent switch is indicative of a problem with the vent system. If the blocked vent switch opens, the cause of the

venting problem must be found and corrected by a qualified gas service technician before the blocked vent switch is reset.

Flame Roll-out Switch - Automatically interrupts boiler operation when flames or excessive heat are present in vestibule. The

flame roll-out switch is a single use device which must be replaced by a identical switch in order to restore normal operation. An

open flame roll-out switch is usually indicative of a plugged heat exchanger. The cause of the flame roll-out must be found and

corrected by a qualified gas service technician, and the switch replaced with an identical one, before the boiler is returned to

operation.

X Start-up and Checkout

NOTE

SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS MANIFOLD AND

CONTROL ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TESTS

SPECIFIED IN Z21.13.

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.

WARNING

•

NEVER USE A FLAME TO CHECK FOR GAS LEAKS.

MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE

MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND LIQUIDS.

3) Verify that vent system is complete and free of obstructions before attempting to fire boiler.

4) Inspect all wiring for loose or uninsulated connections.

5) Make sure the main burners are seated properly in the rear of burner tray and on orifices.

6) Adjust thermostat to the highest setting.

7) Start the boiler using the lighting instructions for boilers with standing pilot (page 24) or operating instructions for boilers

withintermittentignition(page25).

8) Upon initial start-up, the gas train 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 time, subsequent

calls for burner 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 ½” 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 ½” of spark electrode/flame rod.

10) Make sure vent damper is in open position when main burners are firing.

11) Inspect the main burner flames visible through the observation port in burner access panel. The flame should be stable

and mostly blue (see Figure 22 or 23). No yellow tipping should be present; however, intermittent flecks of yellow and

orange in the flame are normal.

12) Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is firing.

Fix any leaks found immediately.

13) 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 firing.

15) Check the manifold pressure and adjust if necessary. To do this, use the following procedure:

WARNING

FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER-

FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD.

a) Connect a manometer to the line pressure tap on the gas valve (see Figures 24 and 25).

b) Check the line pressure with all gas appliances on and off. The line pressure at the boiler must be within the following

limits regardless of what combination of appliances is firing:

Line Press (inches w.c.)

NaturalGas

5.0

LPGas

11.0

Min.

Max.

14.0

13.0

If the line pressure falls outside of these limits, find and correct the cause of the problem before proceeding further.

c) Connect a manometer to the manifold (outlet) pressure tap on the gas valve (see Figures 24 and 25).

d) Read the manifold pressure. It should be set at:

Natural Gas

3.5

LP Gas

10.0

Manifold Press. (inches w.c.)

e) If a manifold pressure adjustment is needed, make the adjustment by turning the regulator (see Figures 24 and 25)

screw clockwise to raise the pressure 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 remain lit but the main burners should stop firing. For

intermittent ignition boiler models both pilot burner and main burners should stop firing. Raise the thermostat back to the

highest setting. Circulator should restart. The main burners( for standing pilot boiler models) or pilot burner and main

burners (for intermittent ignition boiler models) should relight.

17) Verify high limit operation. Allow the boiler water temperature to increase to hi limit setting. Circulator should

continue running. For standing pilot boiler models, pilot burner should remain lit but the main burners should stop firing.

For intermittent ignition boiler models both pilot burner and main burners should stop firing.

18) Allow the boiler water temperature to drop below high limit setting.

19) The main burners (for standing pilot boiler models) or pilot burner and main burners (for intermittent ignition boiler

models) should relight.

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.

FIGURE20: STANDINGPILOT

BURNER FLAME

FIGURE21: INTERMITTENTIGNITION

PILOTBURNERFLAME

FIGURE23:MAINBURNERFLAME-50mm

(“HIGHALTITUDE”)BURNERS

FIGURE22: MAINBURNERFLAME-1”BURNERS

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life.

A. This appliance has a pilot which must be

lighted by hand. When lighting the pilot, follow

these instructions exactly.

If you cannot reach your gas supplier, call

the fire department.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will

not push in or turn by hand, don’t try to repair it,

call a qualified service technician. Force or

attempted repair may result in a fire or explosion.

B. BEFORE LIGHTING smell all around the

appliance area for gas. Be sure to smell next

to the floor because some gas is heavier than

air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electric switch; do not

use any phone in your building.

Immediately call your gas supplier from

a neighbor’s phone. Follow the gas

supplier’s instructions.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified service

technician to inspect the appliance and to

replace any part of the control system and any

gas control which has been under water.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above on

8. Turn Knob on gas control counterclockwise

to “PILOT”.

this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. Remove front access panel.

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

repeat steps 5-9.

to OFF. To relight,

5. Rotate the gas control knob clockwise

to OFF.

If button does not pop up when released, stop

and immediately call your service technician

or gas supplier.

RESET BUTTON

If the pilot will not stay lit after several tries,

turn the gas control knob to “OFF” and call

your service technician or gas supplier.

GAS INLET

GAS OUTLET

10. After pilot remains lit when red reset button is

released, turn gas control knob counterclockwise

to ON.

GAS CONTROL KNOB

(SHOWN IN “ON” POSITION)

GAS VALVE - TOP VIEW

6. Wait five (5) minutes to clear out any gas. Then

smell for gas, including near the floor. If you then

smell gas, STOP! Follow “B” in the safety inform-

ation above on this label. If you don’t smell gas,

go to the next step.

11. Replace front access panel.

12. Turn on all electric power to the appliance.

13. Set thermostat to desired setting.

7. Find pilot - follow metal pilot

tube from gas control to

PILOT

BURNER

THERMO-

COUPLE

pilot burner.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

3. Push in gas control knob slightly and turn

clockwise to “OFF”. Do not Force.

2. Turn off all electric power to the appliance if

service is to be performed.

146-80-254 Rev. 0

(Standing Pilot)

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life.

A. This appliance is equipped with an ignition

If you cannot reach your gas supplier, call

the fire department.

device which automatically lights the pilot.

Do not try to light the pilot by hand.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will

not push in or turn by hand, don’t try to repair it,

call a qualified service technician. Force or

attempted repair may result in a fire or explosion.

B. BEFORE LIGHTING smell all around the

appliance area for gas. Be sure to smell next

to the floor because some gas is heavier than

air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electric switch; do not

use any phone in your building.

Immediately call your gas supplier from

a neighbor’s phone. Follow the gas

supplier’s instructions.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified service

technician to inspect the appliance and to

replace any part of the control system and any

gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on

this label.

5. Remove front access panel.

6. Rotate the gas control knob clockwise

to OFF.

2. Set the thermostat to lowest setting.

7. Wait five (5) minutes to clear out any gas. Then

smell for gas, including near the floor. If you then

smell gas, STOP! Follow “B” in the safety inform-

ation above on this label. If you don’t smell gas

go to the next step.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition

device which automatically lights the pilot.

Do not try to light the pilot by hand.

8. Rotate the gas control knob counter clockwise

to “ON”.

GAS CONTROL KNOB

(SHOWN IN “ON” POSITION)

9. Replace front access panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

GAS INLET

GAS OUTLET

12. If the appliance will not operate, follow the

instructions “To Turn Off Gas To Appliance” and

call your service technician or gas supplier.

GAS VALVE - TOP VIEW

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

3. Push in gas control knob slightly and turn

clockwise to “OFF”. Do not Force.

2. Turn off all electric power to the appliance if

service is to be performed.

146-80-255 Rev. 0

(Electronic Ignition)

FIGURE24: GASVALVEDETAIL-STANDINGPILOT

FIGURE25: GASVALVEDETAIL-INTERMITTENTIGNITION

XI Service and Maintenance

The following routine maintenance should be performed on an annual basis:

1) Turn off 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 cleaning procedure below.

3) Remove any debris found in the combustion chamber, being careful not to disturb combustion chamber insulation.

4) Remove all burners, noting the location of the pilot main burner. If burners show signs of deterioration, they should be

replaced (some discoloration around the burner ports is normal). Clean the burners by first brushing the ports with a soft

bristle brush and then vacuuming out any debris through the venturi opening.

5) Inspect the pilot assembly:

•

Standing Pilots - Check the thermocouple for deterioration (some discoloration of the thermocouple is normal). If

any deterioration is present, replace the thermocouple. Inspect the pilot assembly for deposits and deterioration.

Clean or replace the pilot assembly as necessary.

Intermittent Pilots - Clean any deposits found on the electrode and grounding 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 burners, being careful to put the pilot main burner in its original location.

9) Inspect all boiler wiring for loose connections or deterioration.

CAUTION

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN

CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING

10) Inspect the vent system:

•

Make sure that both the vent system is free of obstructions.

Make sure that all vent system supports are intact.

Inspect joints for signs of condensate or flue gas leakage.

Inspect venting components for corrosion or other deterioration. Replace any defective vent components.

11) Inspect the boiler and hydronic system for leaks.

CAUTION

WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPO-

NENTS. REPAIR ANY LEAKS FOUND IMMEDIATELY

12) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas

piping disturbed during the inspection process for leaks.

Heat Exchanger Cleaning Procedure

1) Turn off 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 the two ¼-20 nuts and washers holding the flue collector onto the heat exchanger.

7) Remove the flue collector from the heat exchanger.

8) Carefully remove the flue collector gasket strips and set them aside

9) Clean the flue passageways using a stiff bristle brush. Be certain that all foreign material is removed from the gaps

between the pins

10) Clean the bottom surfaces of the heat exchanger

11) Put a light in the combustion chamber and look through the flue passages from the top to verify that they have been

thoroughly cleaned.

12) Replace the flue collector gasket strips. If desired, RTV-732 silicone sealant with a 500F intermittent duty temperature

rating may be substituted for this rope gasket. The flue collector must be thoroughly sealed to the heat exchanger.

13) Replace the ¼-20 nuts and washers that hold down 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) 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 necessary to check CO, use an combustion analyzer, or other instrument which is designed to measure CO in flue

gas. A CO “sniffer” designed for testing CO levels in ambient air cannot be used to check boiler combustion. Take a flue

gas sample by inserting a sample probe through the draft diverter opening and into the flue collector so that the sample is

taken in the area directly over the heat exchanger. Do not take a sample until the boiler has been firing for at least five

minutes.

A normal CO reading for an AWI or TWI series boiler is less than 50ppm (0.005%). A reading of more than 100ppm

(0.01%) is indicative of a combustion problem.

Some causes of excessive CO include:

•

Incorrectly sized main burner orifice for the altitude at which boiler is installed

Crooked or out-of-round orifice holes (never attempt to drill orifice for this boiler in the field)

Partially plugged flue passages

Improper manifold pressure

Foreign material in burner venturis or burner ports

Leak in seal between flue collector and heat exchanger

XII Troubleshooting

The following four pages contain troubleshooting charts for use in diagnosing control problems. To 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, go directly to the appropriate

troubleshooting guide for the boiler (standing pilot on page 32 or intermittent ignition on page 33). In using these charts, the

following should be kept in mind:

1) These charts are only meant to be used by a professional heating technician as an aid in diagnosing control problems.

2) Where applicable, follow all precautions outlined in the appropriate lighting instructions on page 24 or 25.

3) In general, these charts assume that there are no loose or miswired electrical connections. Before using these charts,

inspect all electrical connections on the boiler to make sure that they are tight. Also, check the wiring on the boiler

against the appropriate wiring diagram in Figure 16 or 17.

4) The possible causes at the end of each branch in these charts are not listed in order of likelihood. All controls on the

AWI and TWI are tested at least once in the manufacturing process and a defective control or component is generally

the least likely cause. Before replacing a component, try to rule out all other possible causes.

5) These troubleshooting charts assume that the vent damper is closed at the beginning of the troubleshooting process.

With the 120 volts applied to the boiler and no call for heat, the damper should go to the closed position. If it does not,

do the following:

•

Confirm that 120 volts is applied to the boiler and that there is no call for heat.

Make sure that the switch on the damper is in the “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 before replacing it:

•

Check for 24 volts across TV and Z. If no voltage is present, the transformer in the L8148E is defective. It is

possible that this transformer has been destroyed by a short circuit in the boiler wiring. Before replacing the

control, carefully inspect all low voltage wiring on the boiler for places where it is touching the frame of the boiler

or wiring on the other side of the transformer.

•

If 24 volts is present across TV and Z, check for 24 volts between T and W. If no voltage is present, make sure that

the brass jumper is present between W and Z and that the screws holding this jumper in place are both tight.

If not already done, temporarily replace the thermostat across TV and T with a jumper. If the boiler fires when this

is done, there is a problem with the thermostat or zone wiring.

If 24 volts is present across T and W and the relay in the L8148E does not pull in, the relay in the L8148E is

probably defective. Inspect the coil of this relay for visible heat damage. If such damage is found, there is a good

chance that a second transformer is present in the thermostat or zone valve circuit, resulting in the application of

48 volts across the relay coil. In older buildings, this transformer may be hidden in a location far from the boiler. If

this second transformer exists, it must be found and removed before the L8148E is replaced.

7) When checking voltage across damper harness pins, be careful not to insert the meter probes into the pins. Doing so

may damage the pin, resulting in a loose connection when the harness is reconnected.

AWI/TWI Troubleshooting Chart

START

Caution: Read page 29 before attempting to use this chart

Vent

damper

open?

Thermostat

calls for heat

Circulator

start?

*Pow er of f

120 volts

at L1&L2?

24 volts

*Blow n fuse or

tripped breaker

across B and R

(limit sw itch) in

L8148E?

*Misw ired or

loose electrical

connection in

120V line

*Boiler off on

limit

120 volts

across

120 volts at

terminals at

circulator?

C1&C2?

*Def ective

high limit.

Remove t'stat or

24 volts

zone valve end

sw itch w ires from

T&TV terminals on

L8148E. Install

temporary jumper

across terminals T

and TV.

betw een pins

1&4 (blue&yellow )and

2&4 (orange&yellow ) on

damper end of damper

harness? See

*Seized or

defective

circulator

24 volts

across

T&TV?

Note 7 on page 29.

Does

circulator

run now ?

*Def ective

L8148E-see

Note 6 on page

29.

*Bad electrical

connection

betw een C1 or

C2 and

* Loose

*Obstruction in

path of damper

blade

connection

betw een

damper

harness and

L8148E

circulator

*Loose connection in t'stat or

zone valve end sw itch w iring

*Def ective

damper motor

*Defective t'stat or zone valve

end sw itch

*Def ective

damper

*Loose

connection

betw een damper

harness and

damper

harness.

*T'stat or zone system

misw ired-consult t'stat or

zone valve manufacturer's

instructions

* Def ective

L8148E

Do burners

shut dow n before

gage temp

exceeds high limit

setting +15F?

Do burner and

circulator shut

dow n at end of

call for heat?

Main

burners

light?

END

*Defective damper

24 volts

across

B1 &B2 ?

*Defective L8148E

*Def ective

L8148A

*Defective damper

harness

*Sensing bulb not

bottomed out in

w ell

*Loose damper

harness connection

*Obstruction in path

24 volts across

standing pilot gas

valve terminals or

terminals 5&6 on

S8600 module?

of damper blade

Pull w ire of f of T

terminal on

aquastat. Does

boiler shut dow n?

Refer to standing pilot or

intermittent ignition

troubleshooting chart

(page 32 or 33).

24 volts

across spill

sw itch?

*Chimney blockage

*T'stat or

*Chimney system not

zone valve

w iring calling

for heat

constructed in accordance

w ith Parts 7 and 11 of

National Fuel Gas Code.

24 volts

across

rollout

*Dow n draft

*T'stat w ires

shorted

*Inadequate combustion air

supply in boiler room

sw itch?

*Internal boiler

w iring

problem,

consult Crow n

representative

*Rollout sw itch open.

Replace w ith exact

replacement (see parts

list). Check for blocked

heat exchanger.

*Loose electrical

connection in 24

volt w iring

betw een B1 or B2

and gas valve or

module

Standing Pilot Ignition System Troubleshooting Chart

START

Caution: Read page 29 before

(24 VOLTS PRESENT ACROSS TH AND TR

ON GAS VALVE, BUT MAIN BURNERS DO

NOT LIGHT)

attempting to use this chart

Ensure knob

on gas valve is

set toON

Main

burners

light?

Does pilot

stay lit?

Pilot lit?

END

*Loose

thermocouple

connection at

Turn control on

gas valve to

PILOT. Depress

red button and

light pilot. Hold

button for at

least one

Turn control

on gas valve

to ON.

*Defective gas

valve

gas valve.

*Defective

thermocouple.

minute.

*Condensation

quenching pilot.

Disconnect

thermocouple from

gas valve. Connect a

volt meter to the

thermocouple. Light

the pilot and hold

down the red button

while reading the

voltage across the

thermocouple.

*Low line

pressure.

Does pilot

stay lit when

red button is

released?

Does pilot

light?

Line pressure

within the range

indicated on

boiler's rating

plate?

Is voltage at

least 18mV?

Consult gas

supplier.

*Pilot tubing

blocked, kinked

or leaking

*Loose or defective

thermocouple

connection at gas valve

*Defective thermocouple

*Pilot orifice

blocked

*Pilot improperly

adjusted

*Defective gas valve

*Gas line not

purged of air

*Pilot tube blocked, kinked, or

leaking

*Pilot improperly

adjusted.

*Pilot orifice partially plugged

Intermittent Ignition System Troubleshooting Chart

START

Caution: Read page 29 before

attempting to use this chart

(24 volts is present across 5 and 6 on S8600

module, but main burners do not light)

Spark

Does

Main

burner

lights?

across

ignitor/sensor

gap?

Pilot

lights?

spark stop

when pilot

lights?

END

24VAC

across

terminals 1&2

on S8600?

24 volts

across

terminals 2&3

at S8600?

*Defective

S8600 module

Can you

hear

*Defective

S8600

module

sparking?

24 volts

between MV &

MV/PV on gas

valve?

24 volts

across PV &

MV/PV at gas

valve?

*Faulty

S8600

module

*Loose connection in

ignition cable or

ground wire

*Defective EI

wiring

harness.

*Break in

spark cable

insulation

*Defective EI

harness

*Pilot electrode

porcelain cracked

*Break in pilot

porcelain

* Low line pressure

*Pilot flame not

covering gap

between electrode

and grounding

strap

*Plugged, kinked or leaking

pilot tubing

*Incorrect pilot

spark gap

*Defective

gas valve

*Plugged pilot orifice

*Loose

connection in

spark cable

*Low gas pressure

at gas valve inlet

*Gas line not purged of air

*Defective pilot assembly

*Defective gas valve

*Loose

ground

connection

*Defective S8600

module

XIII PARTS

The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area

Crown representative or the factory at:

Crown Boiler Co.

CustomerService

P.O. Box 14818

Philadelphia Pa. 19134

www.crownboiler.com

Main burner orifice shown are for sea level configured boilers. For boilers installed at elevations above 2000 ft, consult the

local Crown representative or the factory for the correct main burner orifice.

In some cases, the following parts lists do not include Crown part numbers because they were not available at the time of

printing. Order these parts by their description, specifying the boiler model number on which they are to be used.

QTY. OR

CROWN P.N.

1 ea.

700001

700002

700003

700000

1 ea.

QUANTITY PER BOILER OR CROWN P.N.

KEY #

DESCRIPTION

262

700019

1 ea.

16 ea.

700649

700669

700689

701689

295

700020

1 ea.

18 ea.

700650

700670

700690

701690

700012

1 ea.

700013

1 ea.

128

162

195

229

COMPLETE HEAT EXCHANGER ASSY.

LEFT END SECTION

RIGHT END SECTION

INTERMEDIATE SECTION

PUSHNIPPLE

700014

1 ea.

700015

1 ea.

700016

1 ea.

700017

1 ea.

700018

1 ea.

2 ea.

3 ea.

4 ea.

5 ea.

6 ea.

2 ea.

4 ea.

6 ea.

8 ea.

10 ea.

700646

700666

700686

701686

12 ea.

700647

700667

700687

701687

14 ea.

700648

700668

700688

701688

BASE TRAY

700642

700662

700682

700643

700663

700683

701683

700644

700664

700684

701684

700645

700665

700685

701685

BASE WRAPPER

1 ea.

BURNER TRAY (1" BURNERS)

BURNER TRAY (50mm BURNERS)

BASE FRONT PANEL ASSY. (INCLUDES

INSULATION)

1 ea.

700602

700603

700604

700605

700606

700607

700608

700609

700610

BURNER ACCESS PANEL

BASE END INSULATION

BASE REAR INSULATION

BASE LEG ASSY.

1 ea.

720601

1 ea.

700622

2 ea.

720602

4 ea.

20 ea.

2.6 ft

1 ea.

2 ea.

4 ea.

700623

2 ea.

720603

4 ea.

20 ea.

3.7 ft

1 ea.

2 ea.

4 ea.

2 ea.

700123

3 ft

700624

2 ea.

720604

4 ea.

20 ea.

4.2 ft

1 ea.

2 ea.

4 ea.

3 ea.

700124

3.3 ft

2 ea.

700625

2 ea.

720605

4 ea.

20 ea.

4.8 ft

1 ea.

2 ea.

4 ea.

700125

3.5 ft

2 ea.

700626

2 ea.

720606

4 ea.

20 ea.

5.3 ft

1 ea.

2 ea.

4 ea.

5 ea.

700126

3.8 ft

2 ea.

700627

2 ea.

720607

4 ea.

21 ea.

5.9 ft

1 ea.

2 ea.

4 ea.

700628

2 ea.

720608

4 ea.

21 ea.

6.4 ft

1 ea.

2 ea.

4 ea.

700629

2 ea.

720609

4 ea.

21 ea.

7.0 ft

1 ea.

2 ea.

4 ea.

700630

2 ea.

720610

4 ea.

21 ea.

7.5 ft

1 ea.

2 ea.

4 ea.

700110

900100

900146

960122

900121

90-048

90-212

900102

900103

900101

650100

1 ea.

1/4-20 X 1/2" SELF TAPPING SCREW

1/2" x 2" SEALING STRIP

ROLLOUT SWITCH G4AM0600240C

ROLLOUT SWITCH BRACKET

#8 x 3/4" SELF TAPPING SCREW

#10 x 1/2" SHEET METAL SCREW

5/16 USS FLAT WASHER

5/16-18 LOCK NUT

5/16-18 x 1-1/4 SELF TAPPING SCREW

FLUE BAFFLE (TWI ONLY)

DRAFT DIVERTER ASSEMBLY

1/2" x 1" SEALING STRIP

1/4-20 x 3" CARRIAGE BOLT

1/4" USS FLAT WASHER

1/4-20 WING NUT

700129

4.6 ft

2 ea.

700130

4.9 ft

2 ea.

700122

2.7 ft

2 ea.

700127

4.1 ft

2 ea.

700128

4.4 ft

2 ea.

900145

900126

90-215

900125

2 ea.

BLOCKED VENT SWITCH ASSY.

(INCLUDES MOUNTING BRACKET)

960123

1 ea.

* NOT PICTURED

Base-Block-Hood

CAUTION: MAIN BURNER ORIFICE SIZES SHOWN ARE FOR BOILERS INSTALLED AT ALTITUDES

BELOW 2000 ft

QTY. OR

CROWN P.N.

150500

150501

1 ea.

950300

950301

950302

950304

950330

950336

950331

3507010

(VR8200C6008)

3507020

(VR8204C6000)

3507110

(VR8300C4134)

3507120

(VR8304P4298)

3507210

(VR8200C6040)

3507220

(VR8204C6018)

3507230

(VR8300C4548)

3507240

(VR8304P4280)

3504005

(Q327A1949)

35-4700

(Q348A1275)

35-4020

(Q327A1915)

35-4600

(Q348A1259)

1 ea.

QUANTITY PER BOILER OR CROWN P.N.

KEY #

DESCRIPTION

1 ea.

700152

1 ea.

128

1 ea.

162

1 ea.

195

1 ea.

229

1 ea.

262

1 ea.

15 ea.

700159

295

1 ea.

17 ea.

700160

1" BURNER WITH PILOT BRACKET

1" BURNER LESS PILOT BRACKET

MANIFOLD (1" BURNERS)

1 ea.

2 ea.

700153

3 ea.

4 ea.

700154

6 ea.

700155

8 ea.

700156

11 ea.

700157

13 ea.

700158

NAT GAS ORIFICE (#44 DRILL SIZE)

NAT GAS ORIFICE (#45 DRILL SIZE)

NAT GAS ORIFICE (#46 DRILL SIZE)

NAT GAS ORIFICE (#48 DRILL SIZE)

LP GAS ORIFICE (#55 DRILL SIZE)

LP GAS ORIFICE (1.25mm DRILL SIZE)

LP GAS ORIFICE (#56 DRILL SIZE)

GAS VALVE (STND. PILOT, NAT GAS)

2 ea.

5 ea.

7 ea.

9 ea.

12 ea.

14 ea.

16 ea.

18 ea.

3 ea.

1 ea.

GAS VALVE (E.I., NAT GAS)

GAS VALVE (STND. PILOT, NAT GAS)

GAS VALVE (E.I., NAT GAS)

1 ea.

GAS VALVE (STND. PILOT, LP GAS)

GAS VALVE (E.I. PILOT, LP GAS)

GAS VALVE (STND. PILOT, LP GAS)

GAS VALVE (E.I., LP GAS)

1 ea.

PILOT ASSY. (STND. PILOT, NAT GAS)

PILOT ASSY. (E.I., NAT GAS)

1 ea.

46a

PILOT ASSY. (STND. PILOT, LP GAS)

PILOT ASSY. (E.I., LP GAS)

46a

47a

THERMOCOUPLE

IGNITION CABLE

PILOT TUBING

35-1040 35-1040 35-1040 35-1040 35-1040 35-1040 35-1040 3501141 3501141

3501136 3501136

3501124 3501124 3501124 3501124 3501130 3501130 3501130

1 ea.

90-042

90-043

900041

1/8 SHORT FERRULE (INCLUDED WITH

GAS VALVE)

35-1600

(392449)

1 ea.

1/8 LONG FERRULE (INCLUDED WITH

PILOT ASSEMBLY)

35-1650

(392449-4)

1 ea.

A26 PILOT ORIFICE (STND. PILOT NAT

GAS) - INCLUDED WITH PILOT ASSY.

KF24 PILOT ORIFICE (E.I., NAT GAS) -

INCLUDED WITH PILOT ASSY.

K14 PILOT ORIFICE (STND. PILOT LP

GAS) - INCLUDED WITH PILOT ASSY.

K16 PILOT ORIFICE (E.I., LP GAS) -

INCLUDED WITH PILOT ASSY.

51a

50mm BURNER WITH PILOT BRACKET

50mm BURNER LESS PILOT BRACKET

MANIFOLD (50mm BURNERS)

150550

150551

1 ea.

701153

1 ea.

2 ea.

701154

1 ea.

3 ea.

701155

1 ea.

4 ea.

701156

1 ea.

5 ea.

701157

1 ea.

6 ea.

701158

1 ea.

7 ea.

701159

1 ea.

8 ea.

701160

MAIN BURNER ORIFICE-CONSULT

CROWN REPRESENTATIVE FOR

CORRECT SIZE

2 ea.

3 ea.

4 ea.

5 ea.

6 ea.

7 ea.

8 ea.

9 ea.

ORIFICE HITCH PIN

950370

1 ea.

2 ea.

700503

700523

2 ea.

3 ea.

700504

700524

2 ea.

4 ea.

700505

700525

2 ea.

5 ea.

700506

700526

2 ea.

6 ea.

700507

700527

3 ea.

7 ea.

700508

700528

3 ea.

8 ea.

700509

700529

3 ea.

9 ea.

700510

700530

3 ea.

LOWER INJECTION SHIELD

UPPER INJECTION SHIELD

1/4-20 BRASS WING NUT

10-32 x 3/16" SCREW

146-95-301

2 ea.

* NOT PICTURED

1” BURNER COMPONENTS

50mm BURNER COMPONENTS

QTY. OR

CROWN P.N.

1 ea.

QUANTITY PER BOILER OR CROWN P.N.

KEY #

DESCRIPTION

262

295

128

162

195

229

LEFT SIDE JACKET PANEL

RIGHT SIDE JACKET PANEL

REAR JACKET PANEL

TOP JACKET PANEL

LOWER FRONT PANEL

UPPER FRONT PANEL

DIVERTER PANEL

VESTIBULE PANEL

HORIZONTAL JACKET CLIP

VERTICAL JACKET CLIP

#10 X 1/2" SHEET METAL SCREW

DOOR KNOB

8-32 X 1/4" H.W.H. SCREW

VENT DAMPER

700301

700300

700302

700322

700362

700352

700372

700382

2 ea.

26 ea.

2 ea.

96-030

1 ea.

700301

700300

700303

700323

700363

700353

700373

700383

2 ea.

26 ea.

2 ea.

96-030

1 ea.

700301

700300

700304

700324

700364

700354

700374

700384

2 ea.

700301

700300

700305

700325

700365

700355

700375

700385

2 ea.

700301 7003015 7003015 7003015 7003015

700300 7003005 7003005 7003005 7003005

1 ea.

800340

800341

90-212

90-210

90-211

700306

700326

700366

700356

700376

700386

2 ea.

700307

700327

700367

700357

700377

700387

2 ea.

700308

700328

700368

700358

700378

700388

2 ea.

700309

700329

700369

700359

700379

700389

2 ea.

27 ea.

2 ea.

700310

700330

700370

700360

700380

700390

2 ea.

27 ea.

2 ea.

26 ea.

2 ea.

26 ea.

2 ea.

27 ea.

2 ea.

27 ea.

2 ea.

27 ea.

2 ea.

96-035

1 ea.

2 ea.

96-035

1 ea.

96-031

1 ea.

96-032

1 ea.

96-032

1 ea.

96-033

1 ea.

96-033

1 ea.

1/2" LONG WELL

35-1006

35-3000

35-5000

(S8600F1000)

35-5050

(S8600M1013)

905000

95-038

AQUASTAT (L8148E1257)

IGNITION MODULE (E.I. BOILERS)

(NATURAL GAS ONLY)

IGNITION MODULE (E.I. BOILERS)

(NATURAL OR LP GAS)

MODULE BRACKET (E.I. BOILERS)

TRIDICATOR GUAGE

3/4" RELIEF VALVE (30 psi)

CIRCULATOR (TACO 007)

TACO FLANGE SET

1 ea.

4 ea.

1 ea.

4 ea.

1 ea.

4 ea.

1 ea.

4 ea.

1 ea.

4 ea.

1 ea.

4 ea.

1 ea.

4 ea.

1 ea.

4 ea.

1 ea.

4 ea.

1 ea.

95-040

95-012

95-014

95-041

3/4" BOILER DRAIN

8-32 X 1/2" SELF TAPPING SCREW

DAMPER WIRE HARNESS

AQUASTAT - R.O. SWITCH HARNESS

SPILL SWITCH HARNESS

INTERMITTENT IGNITION HARNESS

GROUND WIRE HARNESS (EI ONLY)

90-223

9601250

9601200

9601270

9601100

9601101

* NOT PICTURED

Jacket/Components

CROWN

Boiler Co

Manufacturer of Hydronic Heatings Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

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

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