D E S I G N E D T O L E A D 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 • AWI061 • AWI095 • AWI128 • AWI162 • AWI195 • AWI229 • AWI262 • AWI295 • TWI061 • TWI095 • TWI128 • TWI162 WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life.
Table of Contents I. Product Description .................................................. 1 II. Specifications ............................................................ 1 III. Before Installing ........................................................ 4 IV. Locating the Boiler .................................................... 4 V. Air for Combustion & Ventilation ............................. 5 VI. Venting ...................................................................... 8 VII. Gas Piping ......
FIGURE 1B: “LEFT PIPED” CONFIGURATION FIGURE 1C: “TOP PIPED” (T-AWI OR T-TWI) CONFIGURATION 42
TABLE 1: SPECIFICATIONS RATINGS - NATURAL AND LP GASES* BASIC BOILER MODEL NUMBER OF SECTIONS DIMENSIONS (INCHES) DOE HEATING CAPACITY I=B=R NET RATING, WATER AFUE MBH MBH MBH % INPUT "A" "B" "C" "D" "E" "F" AWI037S AWI037E 2 37 30 26 80.0 82.3 10-1/2 7-1/4 4 3-5/8 3-7/8 AWI061S AWI061E 3 61 50 43 80.0 82.6 11-3/4 5-7/8 4 3-5/8 1-7/8 AWI095S AWI095E 4 95 78 68 80.1 82.3 15 7-1/2 5 4-1/8 1-7/8 AWI128S AWI128E 5 128 105 91 80.2 82.
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.
FIGURE 2: CLEARANCE FROM BOILER TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND 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.
b. c. 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. Divide the volume of the boiler room by the input in thousands of BTU/hr.
For Buildings of Unusually Tight Construction 1) Openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl space, which communicates directly with the outdoors. 2) Two openings are required. The top edge of the upper opening must be within 12 inches of the ceiling. The bottom edge of the lower opening must be within 12 inches of the floor.
FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 7: ALL AIR FROM OUTDOORS, 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.
FIGURE 8: TYPICAL VENT SYSTEM 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.
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.
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.
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.
FIGURE 11: STANDARD BOILER PIPING 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.
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.
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 15: BOILER PIPING WITH CHILLER 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.
2 FIGURE 16: WIRING DIAGRAM, CONTINUOUS IGNITION (STANDING PILOT) SYSTEM 2 FIGURE 17: WIRING DIAGRAM, INTERMITTENT IGNITION (EI) SYSTEM 19 17
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.
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.
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.
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.
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. 14) Check the manifold pressure and adjust if necessary.
19) After the boiler has operated for approximately 30 minutes, check the boiler and heating system piping for leaks. Repair any leaks found at once. 20) Inspect the vent system for flue gas leaks. Repair any leaks found before leaving the boiler in operation.
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. If you cannot reach your gas supplier, call the fire department. A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. C. Use only your hand to push in or turn the gas control knob. Never use tools.
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 device which automatically lights the pilot. Do not try to light the pilot by hand. 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.
FIGURE 24: GAS VALVE DETAIL - STANDING PILOT FIGURE 25: GAS VALVE DETAIL - INTERMITTENT IGNITION 28 26
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.
Heat Exchanger Cleaning Procedure 1) 2) 3) 4) 5) 6) 7) 8) 9) Turn off electrical power and gas supply to the boiler Disconnect the damper and vent connector from the boiler. Remove the upper front and top jacket panels. If possible, remove the rear and left side jacket panels Remove the burners. Remove the blocked vent (“spill”) switch Remove the two ¼-20 nuts and washers holding the flue collector onto the heat exchanger. Remove the flue collector from the 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).
AWI/TWI Troubleshooting Chart START Caution: Read page 29 before attempting to use this chart Thermostat calls for heat Circulator start? Vent damper open? Y Y N N *Pow er off N *Blow n fuse or tripped breaker *Misw ired or loose electrical connection in 120V line 120 volts at L1&L2? 24 volts across B and R (limit sw itch) in L8148E ? Y 120 volts at C1&C2? 120 volts across terminals at circulator? Y N Remove t'stat or zone valve end sw itch w ires from T&TV terminals on L8148E.
Main burners light? Do burners shut dow n before gage temp exceeds high limit setting +15F? Y N Do burner and circulator shut dow n at end of call for heat? Y Y END N N *Defective damper 24 volts across B1 &B2 ? N *Defective L8148E *Defective damper harness Y *Loose damper harness connection 24 volts across standing pilot gas valve terminals or terminals 5&6 on S8600 module? *Defective L8148A *Sensing bulb not bottomed out in w ell *Obstruction in path of damper blade Y Refer to standing pil
Standing Pilot Ignition System Troubleshooting Chart START (24 VOLTS PRESENT ACROSS TH AND TR ON GAS VALVE, BUT MAIN BURNERS DO NOT LIGHT) Y Pilot lit? Ensure knob on gas valve is set to ON Caution: Read page 29 before attempting to use this chart Main burners light? Y Does pilot stay lit? N N Turn control on gas valve to PILOT. Depress red button and light pilot. Hold button for at least one minute. Turn control on gas valve to ON.
Intermittent Ignition System Troubleshooting Chart START (24 volts is present across 5 and 6 on S8600 module, but main burners do not light) Spark across ignitor/sensor gap? Y Pilot lights? Does spark stop when pilot lights? Y N N Main burner lights? Y Y END 24VAC across terminals 1&2 on S8600? N N Y *Defective S8600 module Y Y N N 24 volts across terminals 2&3 at S8600? Can you hear sparking? Caution: Read page 29 before attempting to use this chart *Defective S8600 module N *Fault
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. 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.
Base-Block-Hood 37 35
CAUTION: MAIN BURNER ORIFICE SIZES SHOWN ARE FOR BOILERS INSTALLED AT ALTITUDES BELOW 2000 ft KEY # DESCRIPTION 42 43 44 44 44 44 44 44 44 45 1" BURNER WITH PILOT BRACKET (Q348A, Q327A Pilots) 1" BURNER WITH PILOT BRACKET (Q350A Pilots) 1" BURNER LESS PILOT BRACKET MANIFOLD (1" BURNERS) 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.
1” BURNER COMPONENTS 50mm BURNER COMPONENTS 39 37
KEY # 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 * * * 91 92 93 94 95 96 * * * * * DESCRIPTION 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 1/2" LONG WELL AQUASTAT (L8148E1257) IGNITION MODULE (E.I. BOILERS) (NATURAL GAS ONLY) IGNITION MODULE (E.I.
Jacket/Components 41 39
Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I.
