Crown Boiler AWR Series Instructions For Field Conversion page 3

5) Install the new pilot assembly. If a new main burner with a pilot bracket was provided in the kit, discard the old main
burner and mount the pilot on the new main burner.
6) Install the main burners.
7) Install the new gas valve provided with the kit. Reconnect the pilot line and the gas supply. For CWD boilers, reinstall the
burner tray in the boiler. Reconnect all wiring.
8) Purge the gas supply line up to the boiler and check for leaks in accordance with the National Fuel Gas Code (ANS
Z223.1) or the requirements of the authority having jurisdiction.
9) Replace any covers or panels removed during the conversion.
10) Make sure that the boiler and system are filled with water.
11) Verify that vent system is complete and free of obstructions before attempting to fire boiler. Make sure that the silicone
cure time called for in the vent assembly instructions has passed before firing boiler.
12) Adjust thermostat to the highest setting.
13) Start the boiler using the lighting instructions on the boiler or in the installation manual's "Start-up and Check-out"
section.
14) 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.
15) Observe pilot burner flame and verify that it matches the illustration shown in the installation manual's "Start-up and
Check-out" section.
16) Inspect the main burner flame and verify that it matches the illustration shown in the installation manual's "Start-up and
Check-out" section. The flame should be stable and mostly blue. No yellow tipping should be present; however, intermittent
flecks of yellow and orange in the flame are normal.
17) 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.
18) Check the manifold pressure and adjust if necessary. To do this, use the following procedure:
Failure to follow the following procedure exactly could result in over-firing of the boiler and
death or injury due to carbon monoxide poisoning.
a) Connect a manometer to the inlet pressure tap on the gas valve. For the location of this tap, see the gas valve detail
illustration in the installation manual's "Start-up and Check-out" section.
b) Check the line pressure with all gas appliances on and off. Verify that the inlet pressure is within the limits shown in
Table 2 regardless of what combination of appliances is firing. If the inlet pressure falls outside of these limits, find and
correct the cause of the problem before proceeding further.
c) On CWD boilers, disconnect the silicone regulator tube from the hose barb on the gas valve (See Figure 45 in the CWD
installation manual).
d) Connect a manometer to the manifold (outlet) pressure tap on the gas valve. For the location of this tap, see the gas
valve detail illustration in the installation manual's "Start-up and Check-out" section.
e) Read the manifold pressure. Refer to Table 2 for the appropriate setting.
f) If a manifold pressure adjustment is needed, make the adjustment by turning the regulator screw clockwise to raise
the pressure and counter-clockwise to reduce the pressure. If a manifold pressure adjustment is made, recheck the inlet
pressure to be certain that it is still within acceptable limits. Replace the cover screw on the regulator.
g) On CWD boilers, reconnect the silicone regulator tube disconnected in Step (c)
WARNING
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