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Crown Boiler AWR Series - User Manual

Crown Boiler AWR Series
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Models:
AWR038B
AWR070B
AWR105B
AWR140B
AWR175B
AWR210B
AWR245B
AWR280B
AWR Series
Gas-Fired Natural Draft Hot Water Boilers
INSTALLATION INSTRUCTIONS
These instructions must be a󰀩xed on or adjacent to the boiler
D ESIGNED TO L EAD
Models Equipped with
Honeywell S9361A and
Hydrolevel IDL 1200
LWCO (5.1)
9902339
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.
This boiler requires a special venting system.
Read these instructions carefully before
installing.
!
9807815 Rev 0, 04-21
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com

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Summary

Product Description

Specifications

Pre-Installation

Inspect Shipment and Verify Equipment

Inspect shipment for damage and file claims promptly within sixty days.

Installation Authority and Standards

Install according to manual, local codes, NFPA 54, and ANSI/ASME CSD-1 standards.

Gas Configuration and Altitude

Verify gas configuration (Natural/LP) and ensure correct orifice for altitude above 2000ft.

Locating the Boiler

Required Clearances

Observe minimum clearances from combustibles and walls, including service clearances.

Installation Surface and Location Requirements

Install on a hard level surface, avoid flammable vapors, dust, carpeting, wet areas, and locate near chimney.

Air for Combustion and Ventilation

Indoor Combustion Air Method

Details on calculating and providing air for combustion via indoor infiltration.

Indoor Combustion Air Method Calculations

Steps for calculating required air volume and providing openings for indoor combustion air.

Outdoor Combustion Air Method

Requirements for supplying combustion air directly from outdoors via ducts or openings.

Mechanical Combustion Air Supply

Using a blower system to supply combustion air, including sizing and interlocking requirements.

Venting

Acceptable Chimney and Vent Connector Types

Lists approved chimney types (Type B/L, Masonry) and vent connectors (Type B/L, Single Wall).

Chimney and Vent Connector Sizing

Sizing requirements for chimneys and vent connectors according to the National Fuel Gas Code.

Exterior Chimneys and Power Venters

Guidelines for using exterior chimneys and installing listed power venters with interlocks.

Vent Damper Installation

Detailed instructions for installing the supplied vent damper, including connections and mounting.

Removing Boiler from Common Chimney

System Piping

Relief Valve Installation and Discharge

Mount relief valve correctly and pipe discharge to a safe location.

Circulator, Expansion Tank, and Fill Valve

Proper installation and sizing for circulator, expansion tank, and fill valve.

Low Water Cut-Off (LWCO) Functionality

Explains the factory-supplied LWCO and requirements for manual reset LWCOs.

High Limit, Flow Control, Isolation, and Drain Valves

Install high limit, flow control, isolation valves, and drain valve as per codes and manual.

Special Piping Situations

Guidelines for low temp systems (radiant) and systems prone to oxygen corrosion.

Gas Piping

Gas Piping Sizing and Connection

Design for adequate gas supply, connect to valve using approved methods and materials.

Gas Connection Pressure Testing

Procedures for protecting the gas control valve and leak testing the gas connection.

Wiring

Line Voltage (120 VAC) Field Connections

Details on 120VAC connections, dedicated circuits, service switches, and specific wire functions.

Low Voltage Connections

Describes low voltage connections for thermostats, limits, and the EnviraCom system.

Line Voltage Wiring Diagram

Diagram illustrating field connections for line voltage wiring.

Low Voltage Wiring Diagram

Diagram showing low voltage field connections for thermostats and controls.

Boiler Control Connections Diagram

Detailed wiring diagram for the S9361A boiler control, including all connections.

Boiler Control Ladder Diagram

Ladder diagram illustrating the control logic and wiring sequences.

Start-up and Checkout

Initial Checks and LWCO Verification

Perform initial checks, burner seating, and verify Low Water Cut-Off (LWCO) operation.

System Filling, Gas Supply, and Vent Verification

Fill system, turn on gas supply, purge lines, and verify vent system integrity.

Safety Before Lighting and Operating

Crucial safety precautions before lighting the pilot and operating the appliance.

Boiler Operating Procedure

Step-by-step instructions for lighting, operating, and turning off the boiler.

Manifold Pressure Adjustment and Flame Checks

Adjust manifold pressure and check main and pilot burner flames for proper appearance.

Safety Control and System Leak Checks

Test gas valve safety shutdown, high limit, LWCO, thermostat, external safety devices, and check for system leaks.

Operation

General Information

Overview of the Honeywell S9361A integrated boiler control and its functions.

Reading Status and Using Menu

Explains how to navigate the control's modes (Status, Operating, Error, Adjustment).

Boiler Control Menu Navigation

Flowchart detailing navigation through Status, Operating, and Adjustment modes.

Status Codes Explained

List and meaning of various status codes indicating boiler operation or faults.

Operating Mode Parameters

Definitions and meanings of parameters displayed in Operating Mode.

Adjustment Mode Parameters

Lists adjustable parameters, factory settings, and permissible ranges.

Parameter Adjustment Guidelines

Details on adjusting parameters like High Limit, Differential, Circulator Overrun, and Thermal Purge.

Thermal Purge Operation Examples

Examples illustrating thermal purge behavior based on call for heat and zone settings.

Circulator Behavior Summary

Summary of circulator output based on thermostat inputs and control parameters.

Sequence of Operation Details

Step-by-step explanation of boiler operation including vent damper and ignition sequence.

Safety Control Operation

Explains the function and operation of safety controls like Blocked Vent Switch, Flame Roll-out, and LWCO.

Service and Maintenance

Refractory Ceramic Fiber Product Safety

Safety information regarding Refractory Ceramic Fiber (RCF) components.

Precautionary Measures and First Aid

Protective gear, handling procedures for RCF materials, and first aid steps.

Routine Annual Maintenance Steps

Annual maintenance tasks including power off, inspecting flue passages, burners, pilot assembly, wiring, and vent system.

Heat Exchanger Cleaning Procedure

Detailed steps for cleaning soot deposits from the heat exchanger and flue passages.

Troubleshooting

Before Troubleshooting Guidelines

General guidelines and precautions for troubleshooting boiler control problems.

Display is Blank Troubleshooting

Identifies causes and checks for a blank display on the boiler control.

Error Codes Explained

List of error codes, their meanings, and possible causes for boiler control issues.

Faults Without Error Codes

Lists common faults indicated by control displays without specific error codes.

PARTS

Service Parts Identification

Identifies service parts with part numbers and quantities for section assemblies and clips.

Base Assembly Parts

Lists part numbers for base wrapper, tray, insulation, front panel, and other base components.

Gas Train Components

Identifies gas valves, manifolds, orifices, pilot assemblies, and tubing with part numbers.

Drafthood and Vent Components

Lists part numbers for the drafthood, gasket kit, and blocked vent switch.

Boiler Control and Transformer Parts

Identifies the integrated boiler control, transformer, LWCO, and control bracket.

Jacket and Panel Components

Lists part numbers for rear, side, vestibule, and top jacket panels, door assembly, and logo plate.

Gauges, Valves, and Vent Damper

Identifies temperature/pressure gauge, relief valve, drain valve, and vent damper with part numbers.

Wire Harness Assemblies

Lists part numbers for line voltage, low voltage, vent damper, and switch harness assemblies.

Appendix A: High Altitude Installations (US Only)

Altitude Derating Requirements

Explains derating for altitudes above 2000ft and the need for correct burner orifices.

Orifice Selection for Altitude

Guidance on selecting the correct orifice size for installation altitude.

Crown Boiler AWR Series Specifications

General IconGeneral
TypeWater Boiler
Fuel TypeNatural Gas or Propane
Heat Exchanger MaterialCast Iron
Vent TypeChimney Vent
Ignition TypeElectronic Ignition

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