Crown Boiler AWR Series Installation Instructions Manual
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Crown Boiler AWR Series Installation Instructions Manual

Gas-fired natural draft hot water boilers
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AWR Series
Gas-Fired Natural Draft Hot Water Boilers
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Models:
AWR038B
•
AWR070B
•
AWR105B
•
AWR140B
•
AWR175B
•
AWR210B
•
AWR245B
•
AWR280B
•
Models Equipped with
Honeywell S9361A and
Hydrolevel IDL 1200
LWCO (5.1)
9807815 Rev 0, 04-21
D
E S I G N E D
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
L
T O
E A D
Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, injury, or loss of life. For assistance
or additional information, consult a qualified
installer, service agency or the gas supplier.
This boiler requires a special venting system.
Read these instructions carefully before
installing.
1
!
WARNING
9902339

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  • Page 1 E S I G N E D E A D AWR Series Gas-Fired Natural Draft Hot Water Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models: WARNING Improper installation, adjustment, alteration, AWR038B • service or maintenance can cause property AWR070B •...
  • Page 2 The Massachusetts Board of Plumbers and Gas Fitters has approved these boilers. See the Massachusetts Board of Plumbers and Gas Fitters website for the latest Approval Code or ask your local Sales Representative. The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas fitter. The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life.
  • Page 3 WARNING Asphyxiation Hazard. Fire Hazard. Explosion Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. • Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service.

  • Page 4: Table Of Contents

    Table of Contents Product Description ................5 Specifications ..................5 III. Pre-Installation ..................6 Locating the Boiler ................8 Air for Combustion & Ventilation ............10 Venting ....................14 VII. System Piping ..................17 VIII. Gas Piping ..................... 22 Wiring ....................24 Start-Up &...

  • Page 5: Product Description

    I Product Description The AWR 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 drafthood equipped appliance, which must be vented by natural draft using a lined masonry or listed metal chimney system.

  • Page 6: Pre-Installation

    III Pre-Installation WARNING • Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death. • Assure that Front Air Dam (Figure 3.1) is in place and undamaged. A damaged front air dam will negatively affect the performance of this boiler, which can cause serious property damage, personal injury or death.
  • Page 7 5) Make sure that the boiler received is configured for the correct gas (natural or LP). DANGER • Do not attempt to operate a natural gas boiler on LP, or an LP boiler on natural gas without first converting it using a kit provided by the factory. •...

  • Page 8: Locating The Boiler

    IV Locating the Boiler WARNING Failure to observe the following location requirements could result in a fire, explosion or Carbon Monoxide (CO) hazard. 1) Clearances: • Observe minimum clearances shown below to avoid potential fire hazard. Except as noted, these clearances apply to all combustible construction as well as noncombustible walls, ceilings and doors.
  • Page 9 FIGURE 4.1: 38-210MBH MINIMUM CLEARANCE FROM BOILER TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS, WALLS AND DOORS (CLOSET) FIGURE 4.2: 245-280MBH MINIMUM CLEARANCE FROM BOILER TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS AND WALLS (ALCOVE)

  • Page 10: Air For Combustion & Ventilation

    V Air for Combustion and Ventilation WARNING • This boiler is not designed for use in a space that is depressurized relative to the outdoors. Operating this boiler in a depressurized space may cause severe personal injury or death. • INSUFFICIENT COMBUSTION AIR SUPPLY may result in the production and release of deadly Carbon Monoxide (CO) into the home.
  • Page 11 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. •...
  • Page 12 FIGURE 5.2: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC 6” FIGURE 5.3: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC Using the Outdoor Combustion Air Method 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.
  • Page 13 • 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 motorized louvers are installed in the openings to the outdoors, they must be interlocked to prevent operation of the fuel burning appliances in the boiler room unless the louvers are open.

  • Page 14: Venting

    VI Venting WARNING • Improper venting may result in property damage and/or the release of flue gases, which contain deadly Carbon Monoxide (CO), into the home, which can cause severe personal injury or death. • Do not use plastic venting materials (such as CPVC, PVC and RADEL) to vent this boiler. •...
  • Page 15 4) Exterior Chimneys - An exterior chimney has one or more sides exposed to the outdoors below the roof line. The National Fuel Gas Code prescribes two conditions under which an exterior chimney may be used: • In some very restrictive cases, this boiler may be vented into an exterior ceramic lined masonry chimney. See the National Fuel Gas Code for information on when exterior chimneys may be used.
  • Page 16 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.

  • Page 17: System Piping

    VII System Piping Standard Piping WARNING • Failure to properly pipe boiler may result in improper operation and damage to boiler or building. • 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.).
  • Page 18 FIGURE 7.1: STANDARD RELIEF VALVE POSITION FIGURE 7.2: ALTERNATE RELIEF VALVE POSITION FIGURE 7.3: STANDARD BOILER PIPING 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.
  • Page 19 10) Drain Valve - The drain valve is shipped in the boiler parts bag. Install it in the 3/4” tapping on the left side of the boiler as shown in Figure 2.1. Alternatively the drain valve can also be located in an installer supplied tee at the return connection.
  • Page 20 FIGURE 7.4: INDIRECT WATER HEATER BOILER SIDE PIPING FIGURE 7.5: BOILER BYPASS PIPING...
  • Page 21 FIGURE 7.6: ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER FIGURE 7.7: BOILER PIPING WITH CHILLER...

  • Page 22: Gas Piping

    VIII Gas Piping WARNING • Shut off gas supply before servicing the boiler. • All gas piping must be gas tight. Use thread compound that is listed for gas service on all threaded joints to avoid leaks, which may result in fire or explosion. •...
  • Page 23 FIGURE 8.1: GAS CONNECTION TO BOILER...

  • Page 24: Wiring

    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). In Canada, all wiring and grounding must be done in accordance with the Canadian Electrical Code, Part 1 (CSA C22.1 - latest edition).
  • Page 25 b) DHW Thermostat - If used, connect to a 24VAC domestic hot water thermostat or 2nd space heating thermostat. c) Auxiliary Limit Jumper - Used to connect auxiliary limit device. If no such devices are installed, the factory supplied jumper shown in Figures 9.3 and 9.4 must be installed for boiler to operate. d) EnviraCOM - Used to connect an EnviraCom thermostat or other approved EnviraCom device to this boiler.
  • Page 26 FIGURE 9.3: CONNECTIONS DIAGRAM...
  • Page 27 FIGURE 9.4: LADDER DIAGRAM...

  • Page 28: Start-Up & Checkout

    X Start-up and Checkout WARNING Do not leave the boiler in service if it fails any of the following start-up checks. Doing so may result in fire, explosion, or Carbon Monoxide (CO) poisoning. WARNING • Gas leaks may result in fire or explosion. •...
  • Page 29 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 device which automatically lights the pilot.
  • Page 30 Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a) Connect a manometer to the inlet pressure tap on the gas valve (see Figure 10.2). b) Check the inlet line pressure with all gas appliances on and off. The inlet pressure at the boiler must be within the following limits regardless of what combination of appliances is firing: Inlet Press Natural Gas...
  • Page 31 Review User’s Information Manual and system operation with owner or operator. FIGURE 10.4: MAIN BURNER FLAME FIGURE 10.5: PILOT BURNER FLAME (NG ONLY) FIGURE 10.6: PILOT BURNER FLAME (LP ONLY)

  • Page 32: Operation

    XI Operation A. General Information This boiler uses a proprietary version of the Honeywell S9361A “integrated boiler control” to manage all boiler functions including flame supervision, temperature control, and Circulator operation. This control can operate one or two circulator zones without the use of additional relays.
  • Page 33 FIGURE 11.1: BOILER CONTROL MENU STATUS MODE:        =Current Status (Table 11.1)  Press and Hold I, ↑, and ↓ for at least 3  sec to enter ADJUSTMENT MODE  Press I to enter OPERATING MODE        = Current Boiler Temp.      = High Limit Setting       = Current Set Point         = Limit Differential  ...
  • Page 34 TABLE 11.2: STATUS CODES Status # Description Meaning No call for heat or DHW Standby Call for heat present , but boiler is in thermal purge (See on page 36) Call for heat/DHW present but boiler temperature is above set point (SP) setting. Damper has opened and control is briefly waiting before starting trial for ignition Prepurge (pre-purge time is 1.7s).
  • Page 35 TABLE 11.4: OPERATING MODE PARAMETERS Parameter # Description Meaning Boiler Temperature Current boiler water temperature measured by the control’s sensor. Boiler water set point Current target temperature (always the same as the high limit setting.) Boiler will stop firing if boiler water temperature exceeds this value (Circulator/s High Limit Set point will continue to operate) If high limit setting is reached, boiler water temperature will need to drop by this...
  • Page 36 A list of parameters which can be changed on this control are shown in Table 11.5. To enter Adjustment mode and change WARNING Improper adjustments to control parameters could result in unreliable boiler operation, property damage, personal injury, or loss of life. Adjustments should only be made by a qualified heating technician. parameters: 1) Press and hold I, ↑, ↓...
  • Page 37 TABLE 11.6 EXAMPLES OF THERMAL PURGE OPERATION Thermal Purge Settings Boiler Call for Temp at Example Heat Use of Start Temp Begin From DHW Zone Time (Pt) (St) Call Boiler Behavior • Heating Circulator starts 2 min. 140F immediately • Burner fires immediately •...
  • Page 38 TABLE 11.7 SUMMARY OF CIRCULATOR BEHAVIOR Thermostat Inputs Parameters Circulator Outputs Use of “DHW” 2nd Zone Priority Heating “DHW” “DHW” Zone (dh) (Pt) (Red Circ. Lead) (Blue Circ. Lead) dh=dh dh=dh dh=dh dh=dh dh=dh dh=dh Heat dh=tt2 ON or OFF Heat dh=tt2 ON or OFF...
  • Page 39 damper close, while the Heating Circulator continues to operate. The ignition sequence will restart (from Step 4) when the water temperature falls to the high limit setting (HL) minus the high limit differential (HdF). 12) A call for DHW results in a sequence of operation that is identical to that described above except for omission of the thermal purge function described in (3).

  • Page 40: Service & Maintenance

    Installation, Operating & Service Manual SERIES 2E XII Service and Maintenance Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
  • Page 41 WARNING • Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. ATTENTION. Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher. Les erreurs de câblage peuvent nuire au bon fonctionnement et être dangereuses. S’assurer que l’appareil fonctionne adéquatement une fois l’entretien terminé.
  • Page 42 Heat Exchanger Cleaning Procedure 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.

  • Page 43: Troubleshooting

    XIII Troubleshooting A. Before Troubleshooting The following pages contain trouble shooting tables for use in diagnosing control problems. When using these tables the following should be kept in mind: 1) This information is only meant to be used by a professional heating technician as an aid in diagnosing boiler problems. 2) Where applicable, follow all precautions outlined in the Section X (Start-up and Checkout).
  • Page 44 TABLE 13.0 - ERROR CODES Error Code Meaning Possible Cause • Low gas pressure at gas valve inlet • Partially plugged pilot tubing or pilot orifice • Loose connection in ignition cable or ground wiring Low Flame Signal • Dirty pilot electrode/ground strap •...
  • Page 45 TABLE 13.1 - FAULTS WITHOUT ERROR CODE PRESENT Displayed Codes Problem Possible Cause • Thermostat/s not calling for heat StA 1 Burners and • Loose connection in thermostat, zone valve end switch, or zone panel wiring. tt OFF Circulator Off •...

  • Page 46: Parts

    XIV PARTS All Service Parts may be obtained through your local Crown distributor. Should you require assistance in locating a Crown distributor in your area, or have questions regarding the availability of products or service parts, please contact us at (215) 535-8900 or Fax (215) 535-9736.
  • Page 47 WARNING If base must be replaced, there is a good chance pilot assembly and pilot tubing will need to be replaced as well. Replacement pilot assemblies are shown on page 48. Also check condition of manifold and gas valve and replace if they show any signs of heat, corrosion, or water damage.
  • Page 48 Part Number [Quantity] Description 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section Gas Valve (Natural Gas), 3507020 [1] VR8204C6000 Gas Valve (Natural Gas), 109882-01 [1] VR8304P4553 Gas Valve (LP Gas), 3507220 [1] VR8204C6018 Gas Valve (LP Gas), 3507240 [1]...
  • Page 49 Part Number [Quantity] Description 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section Drafthood 760122 [1] 760123 [1] 760124 [1] 760125 [1] 760126 [1] 760127 [1] 760128 [1] 760129 [1] Drafthood Gasket Kit 6206001 [1] Blocked Vent Switch 960129 [1]...
  • Page 50 Part Number [Quantity] Key No. Description 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section Integrated Boiler Control 3505076 [1] (Honeywell S9361A2076) Transformer 106034-01 [1] (Honeywell AT140B1297) Hydrolevel IDL 1200 LWCO 450608 [1] Control Bracket 109353-01 [1] Sensor Clamp...
  • Page 51 Part Number [Quantity] Description 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section Rear Jacket Panel 760302 [1] 760303 [1] 760304 [1] 760305 [1] 760306 [1] 760307 [1] 760308 [1] 760309 [1] Rear Dischargre Chute 760342 [1] 760343 [1] 760344 [1]...
  • Page 52 Part Number [Quantity] Description 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section Temperature/Pressure Gauge 95-038 [1] 1/2” Short Electrowell 450353 [1] (Hydrolevel 48-221)* 3/4" Safety Relief Valve 95-040 [1] (30 psi) Boiler Drain Valve 95-0415 [1] Vent Damper 96-030 [1]...
  • Page 53 Part Number [Quantity] Key No. Description 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section Line Voltage Wire Harness 110012-01 [1] 110011-01 [1] Low Voltage Wire Harness 9601803 [1] Vent Damper Harness 9601850 [1] Blocked Vent Switch-Flame 9601805 [1] Rollout Switch Harness...

  • Page 54: Appendix A. Instructions For High Altitude Installations (Us Only)

    As with most gas appliances, special consideration must be given when this boiler is installed at altitudes above 2000 ft: • AWR Series boilers is not certified for installation above 2000ft in Canada. • Do not install the AWR038B at altitudes above 2000ft anywhere.
  • Page 55 Table A2: AWR Series Orifice Sizes at Various Altitudes Natural Gas Propane Nominal Altitude Orifice size Crown PN Orifice size Crown PN 0ft - Tested 1.25mm Sea Level 950303 1.20mm 950346 2000 950303 1.20mm 950346 3000 950303 1.20mm 950346 4000...
  • Page 56 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com PN 9807815 Rev 0, 04/21...

This manual is also suitable for:

Awr038bAwr070bAwr105bAwr140bAwr175bAwr210b ... Show all

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