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CROWN
Boiler Co
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
WARNING: Improper installa-
tion, adjustment, alteration,
AWI061
TWI061
service or maintenance can
AWI095
cause property damage, injury,
TWI095
or loss of life. For assistance or
AWI128
TWI128
additional information, consult a
AWI162
qualified installer, service
TWI162
agency or the gas supplier.
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INSIDE FRONT COVER (LEAVE BLANK) 2
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Table of Contents I. Product Description .................................................. 1 VIII. System Piping ............................................. 12 II. Specifications ............................................................ 1 IX. Wiring ......................................................... 16 III. Before Installing ......................................................... 4 X. Start-Up & Checkout .................................. 21 IV. Locating the Boiler ........
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FIGURE 1B: “LEFT PIPED” CONFIGURATION FIGURE 1C: “TOP PIPED” (T-AWI OR T-TWI) CONFIGURATION 4 2
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TABLE 1: SPECIFICATIONS RATINGS - NATURAL AND LP GASES* DIMENSIONS (INCHES) BASIC DOE I=B=R NET BOILER INPUT HEATING RATING, AFUE NUMBER MODEL CAPACITY WATER OF "" A" "" B "" C "" D "" E "F SECTIONS MH BHMH B M% B AWI037S 80.0 273036 2 10-1/2 74 -1/4 38 -5/8 3-7/ AWI037E 82.3 AWI061S 80.0 316053 4 18 1-3/4 54 -7/ 38 -5/8 1-7/ AWI061E 82.6 AWI095S 80.1 27-7/8 459878 6 12 5 75 -1/ 48 -1/8 1-7/ AWI095E 82.3 AWI128S 80.2 5815 2 11 0 9 18 8-1/4 96 -1/ 48 -5/8 1-7/ AWI128E 82.0 AWI162S 80.3 6212 6 15
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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. Where required by the authority having jurisdiction, this installation must conform to the Standard for Co
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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. Provisions for combustion, ve
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b. 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. c. Divide the volume of the boiler room by the input in thousands of BT
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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. 3) Size openings and ducts as follows: Vertical ducts or openings directly outdoors (Figure 4,
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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,
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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 b
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7) Do not connect the boiler into a chimney flue serving an open fireplace or other solid fuel appliance. 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. 10) The vertical section of vent pipe coming off the boiler should be as
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connected to the common venting system are not in operation. 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
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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. DO NOT USE TOXIC ADDI
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FIGURE 11: STANDARD BOILER PIPING 6) Low Water Cut-Off (Required in some situations) - A low water cutoff is required when the boiler is installed above 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
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2) Large Water Volume Systems - The piping shown in Figure 13 will minimize the amount of time that the boiler operates 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 f
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5) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler and chiller in parallel as shown in 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 13: BOILER BYPASS PIPING FIGURE 14: ISOLA
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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. 16 or 17): Hot (“black”) - Terminal
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2 FIGURE 16: WIRING DIAGRAM, CONTINUOUS IGNITION (STANDING PILOT) SYSTEM 2 FIGURE 17: WIRING DIAGRAM, INTERMITTENT IGNITION (EI) SYSTEM 19 17
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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. When this relay is ener
