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Table of Contents
aWr Series
gas-Fired natural Draft Hot Water Boilers
inStallation inStructionS
These instructions must be affixed on or adjacent to the boiler
Models:
aWr038
•
aWr070
•
aWr105
•
aWr140
•
aWr175
•
aWr210
•
aWr245
•
aWr280
•
Equipped with Honeywell
S9361a control System
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
Warning: 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. Read these
instructions carefully before
installing.
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Table of Contents
Related Manuals for Crown Boiler AWR070
Summary of Contents for Crown Boiler AWR070
- Page 1 These instructions must be affixed on or adjacent to the boiler Models: Warning: Improper installation, adjustment, alteration, service or aWr038 • maintenance can cause property aWr070 damage, injury, or loss of life. • For assistance or additional aWr105 • information, consult a qualified...
- Page 3 WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings unless alarms or other safeguards are in place to printed in this manual and posted on the boiler. prevent such damage INSPECT THE BOILER ANNUALLY. To keep your DO NOT BLOCK AIR FLOW into or around the boiler safe and efficient, have a service technician boiler.
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Page 4: Table Of Contents
Table of Contents Product Description ................3 Specifications ..................3 III. Before Installing ..................4 Locating the Boiler ................4 Air for Combustion & Ventilation ............6 Venting ....................10 VII. Gas Piping ....................13 VIII. System Piping ..................14 Wiring .................... -
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: Before Installing
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. - Page 7 FIGURE 4.1: AWR038-210 MINIMUM CLEARANCE FROM BOILER TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS, WALLS AND DOORS (CLOSET) FIGURE 4.2: AWR245-280 MINIMUM CLEARANCE FROM BOILER TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS AND WALLS (ALCOVE)
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Page 8: Air For Combustion & Ventilation
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 flamable vapors or liquids will be stored or used. 4) Do not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop. 5) The boiler should be located as close to the chimney as possible. - Page 9 rooms together. Repeat for any other connected rooms which do not have doors. Do not add the volume of two rooms separated by a door even if that door is “always left open”. 3) Divide the volume obtained in Step 2 by the input calculated in Step 1. 4) If the result is at least 50 ft per 1000BTU/hr, and neither of the conditions described in (6) below are met, normal infil- tration should provide adequate fresh air into the boiler room.
- Page 10 350÷135 = 2.59. Since 2.59 is less than 50, there will be an inadequate fresh air supply in the boiler room un- less openings are installed between the boiler room and at least one adjacent room. It turns out that the boiler room in this example is adjacent to a full basement which is 20ft x 45ft x 8ft high.
- Page 11 FIGURE 5.4: OUTDOOR COMBUSTION AIR METHOD: USING OPENINGS INTO BOILER ROOM FIGURE 5.5: OUTDOOR COMBUSTION AIR METHOD: USING HORIZONTAL DUCTS INTO BOILER ROOM 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.
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Page 12: Venting
• 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. Mechanical Combustion Air Supply A mechanical system may be used to bring all combustion air to the boiler which meets all of the following requirements: 1) The system must be manufactured specifically for this purpose. - Page 13 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, the AWR series boilers may be vented into an exterior ceramic lined masonry chimney.
- Page 14 14) Vent damper installation is mandatory on all AWR series boilers. Install vent damper (see Figure 6.2) 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 (Figure 2.1). Unpack vent damper carefully. Do not force closed damper blade.
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Page 15: Gas Piping
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. -
Page 16: System Piping
VIII System Piping WARNING • 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. •... - Page 17 FIGURE 8.1: STANDARD RELIEF VALVE POSITION FIGURE 8.2: ALTERNATE RELIEF VALVE POSITION FIGURE 8.3: STANDARD BOILER PIPING 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. 6) Low Water Cut-Off (Required in some situations) - A low water cutoff (LWCO) is required when the boiler is installed above radiation.
- Page 18 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 FIGURE 8.5: BOILER BYPASS PIPING FIGURE 8.6: ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER...
- Page 20 4) 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 AWR. 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 AWR boiler to this type of system.
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Page 21: 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). • DISCONNECT ELECTRICAL POWER TO THE BOILER AND HEATING SYSTEM BEFORE SERVICING. - Page 22 • Do not attempt to use EnviraCOM connections for any purpose not explicitly permitted by Crown Boiler Company. Attempting to do so may result in unreliable operation and/or damage to controls. •...
- Page 23 FIGURE 9.0: LINE VOLTAGE FIELD CONNECTIONS FIGURE 9.1: LOW VOLTAGE FIELD CONNECTIONS...
- Page 24 FIGURE 9.2: INTERNAL CONNECTIONS DIAGRAM...
- Page 25 FIGURE 9.3: LADDER DIAGRAM...
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Page 26: 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 MONOXOIDE (CO) POISONING. WARNING • GAS LEAKS MAY RESULT IN FIRE OR EXPLOSION. •... - Page 27 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 28 13) Run gas valve safety shutdown test. With main burners firing, disconnect ignition cable from ignition module. Both pilot burner and main burners should stop firing. 14) 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 10.3).
- Page 29 FIGURE 10.2: MAIN BURNER FLAME FIGURE 10.1: PILOT BURNER FLAME FIGURE 10.3: GAS VALVE DETAIL Max. Fuel co (PPM) Natural Gas 50 PPM Propane 10.0 50 PPM TABLE 10.4: FLUE GAS COMBUSTION READING...
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Page 30: 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 31 FIGURE 11.1: BOILER CONTROL MENU STATUS MODE: =Current Status (Table 11.2) Press and Hold I, ↑, and ↓ for at least 3 Press I to enter OPERATING MODE sec to enter ADJUSTMENT MODE = Current Boiler Temp. = High Limit Setting = Limit Differential = Current Set Point = High Limit Setting =Circulator Overrun = Limit Differential =Thermal Purge Time =Call for Heat? (On/Off) =Thermal Purge Temp =DHW Priority (ON/OFF) =Call for DHW? (On/Off) Zone =Flame Signal (uA) =Use of 2 =Total Run Time (hrs) =Reset =total burner Cycles =Temperature Units =Return to Status Mode Boiler in ...
- Page 32 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 32) 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 33 TABLE 11.4: OPERATING MODE PARAMETERS Parameter # Description Meaning Boiler Temperature Current boiler water temperature measured by the control’s sensor. Current target temperature (always the same as the high limit setting unless Boiler water set point Crown outdoor reset card option is installed). Boiler will stop firing if boiler water temperature exceeds this value (Circulator/s High Limit Set point will continue to operate)
- Page 34 C. Using Adjustment Mode 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. A list of parameters which can be changed on this control are shown in Table 11.5. To enter Adjustment mode and change parameters: 1) Press and hold I, ↑, ↓...
- Page 35 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 36 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 37 utes before the ignition sequence is retried. 10) Once the ignition module detects the presence of a pilot flame, voltage is applied across the main valve (terminals MV and MV/PV on the valve), opening the valve and establishing main flame. 11) If the water temperature climbs above the high limit setting during the call for heat, the burner will shut down, and the vent damper close, while the Heating Circulator continues to operate.
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Page 38: Service & Maintenance
XII Service and Maintenance WARNING • THE BOILER CONTAINS REFRACTORY CERAMIC FIBER, A POSSIBLE HUMAN CARCINOGEN. USE A NIOSH APPROVED RESPIRATOR WHEN SERVICING HIGH-TEMPERATURE INSULATION AND GASKET MATERIALS. WASH EXPOSED SKIN GENTLY WITH SOAP AND WATER AFTER CONTACT. WASH EXPOSED CLOTHING SEPERATE FROM NORMAL LAUNDRY. - Page 39 11) Inspect the boiler and hydronic system for leaks. 12) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas pip ing disturbed during the inspection process for leaks. 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.
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Page 40: 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 41 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 42 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 43 Notes...
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Page 44: Parts
XIV 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. Customer Service 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. - Page 46 QUANTITY PER BOILER OR CROWN PART NUMBER QTY. OR DESCRIPTION CROWN PN 760662 760663 760664 760665 760666 760667 760668 760669 BASE WRAPPER 1 EA 760642 760643 760644 760645 760646 760647 760648 760649 BASE TRAY 1 EA 760682 760683 760684 760685 760686 760687 760688...
- Page 48 QUANTITY PER BOILER OR CROWN PART NUMBER QTY. OR DESCRIPTION CROWN PN GAS VALVE (NAT. GAS) ** 3507020 1 EA 1 EA 1 EA 1 EA 1 EA HONEYWELL VR8204C6000 GAS VALVE (NAT. GAS) ** 3507120 1 EA 1 EA 1 EA HONEYWELL VR8304P4298 GAS VALVE (LP GAS) **...
- Page 49 QUANTITY PER BOILER OR CROWN PART NUMBER QTY. OR DESCRIPTION CROWN PN 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA LEFT SIDE JACKET PANEL 760301 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA...
- Page 50 QUANTITY PER BOILER OR CROWN PART NUMBER QTY. OR DESCRIPTION CROWN PN 760902 JUNCTION BOX COVER PLATE 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 760901 JUNCTION BOX 1 EA 1 EA 1 EA 1 EA 1 EA...
- Page 51 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com PN 980763 Rev 2, 07/13...