Crown Boiler AWI195 User Manual

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  
AWI095  
AWI128  
AWI162  
AWI195  
AWI229  
AWI262  
AWI295  
TWI061  
TWI095  
TWI128  
TWI162  
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.  
CROWN  
Boiler Co  
Manufacturer of Hydronic Heatings Products  
P.O. Box 14818 3633 I. Street  
Philadelphia, PA 19134  
Table of Contents  
I. Product Description .................................................. 1  
VIII. System Piping ............................................. 12  
IX. Wiring ......................................................... 16  
II. Specifications ............................................................ 1  
III. Before Installing ......................................................... 4  
IV. Locating the Boiler ...................................................... 4  
V. Air for Combustion & Ventilation .............................. 5  
VI. Venting ....................................................................... 8  
VII. Gas Piping ................................................................ 11  
X.  
Start-Up & Checkout .................................. 21  
XI. Service & Maintenance............................... 27  
XII. Troubleshooting ......................................... 29  
XIII. Parts ............................................................ 34  
I Product Description  
The AWI 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 draft diverter equipped appliance, which must be vented by natural draft using a lined masonry  
or listed metal chimney system. An adequate supply of air for combustion, ventilation and dilution of flue gases must be  
available in the boiler room.  
The TWI series boiler is identical to corresponding sized AWI boiler except for the addition of baffles in the flue passages  
to obtain higher AFUEs. The TWI is not available with a standing pilot or for use with propane gas.  
II Specifications  
FIGURE1A: STANDARDCONFIGURATION(SEEPAGE3FORLETTERDIMENSIONS)  
1
FIGURE1B:LEFTPIPEDCONFIGURATION  
FIGURE1C:TOPPIPED(T-AWIORT-TWI) CONFIGURATION  
2
TABLE1:SPECIFICATIONS  
RATINGS - NATURAL AND LP GASES*  
DIMENSIONS (INCHES)  
BASIC  
BOILER  
MODEL  
DOE  
HEATING  
CAPACITY  
I=B=R NET  
RATING,  
WATER  
INPUT  
AFUE  
%
NUMBER  
OF  
"A"  
"B"  
"C"  
"D"  
"E"  
"F"  
SECTIONS  
MBH  
37  
MBH  
30  
MBH  
26  
AWI037S  
AWI037E  
80.0  
82.3  
2
3
10-1/2  
11-3/4  
15  
7-1/4  
5-7/8  
7-1/2  
9-1/8  
10-3/4  
12-3/8  
14  
4
4
5
6
6
7
7
8
8
3-5/8 3-7/8  
AWI061S  
AWI061E  
80.0  
82.6  
61  
95  
50  
43  
68  
3-5/8  
4-1/8  
4-5/8  
4-5/8  
5-1/8  
5-1/8  
5-5/8  
5-5/8  
1-7/8  
1-7/8  
1-7/8  
1-7/8  
1-7/8  
1-7/8  
1-7/8  
1-7/8  
AWI095S  
AWI095E  
80.1  
82.3  
27-7/8  
4
78  
AWI128S  
AWI128E  
80.2  
82.0  
5
128  
162  
195  
229  
262  
295  
105  
132  
159  
186  
212  
238  
91  
18-1/4  
21-1/2  
24-3/4  
28  
AWI162S  
AWI162E  
80.3  
81.7  
6
115  
138  
162  
184  
207  
AWI195S  
AWI195E  
80.4  
81.4  
7
AWI229S  
AWI229E  
80.4  
81.2  
8
29-7/8  
AWI262S  
AWI262E  
80.5  
80.9  
9
31-1/4  
34-1/2  
15-5/8  
17-1/4  
AWI295S  
AWI295E  
80.7  
80.6  
10  
RATINGS - NATURAL GAS ONLY  
DIMENSIONS (INCHES)  
BASIC  
BOILER  
MODEL  
NUMBER  
OF  
SECTIONS  
DOE  
HEATING  
CAPACITY  
I=B=R NET  
RATING,  
WATER  
INPUT  
AFUE  
%
"A"  
"B"  
"C"  
"D"  
"E"  
"F"  
MBH  
61  
MBH  
51  
MBH  
44  
TWI061E  
TWI095E  
TWI128E  
3
4
83.0 11-3/4  
83.0 15  
5-7/8  
7-1/2  
4
5
3-5/8  
4-1/8  
1-7/8  
1-7/8  
95  
79  
69  
27-7/8  
5
6
128  
162  
106  
134  
92  
83.0 18-1/4  
83.0 21-1/2  
9-1/8  
6
6
4-5/8  
4-5/8  
1-7/8  
1-7/8  
TWI162E  
Notes:  
117  
10-3/4  
Suffix E = Intermittent Ignition, Suffix S = Standing Pilot  
Add Suffix N for Natural Gas or Suffix L for Propane Gas to basic AWI Boiler Model shown (Example: AWI295EN, AWI229SL)  
3
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 Controls  
and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1)-latest edition.  
2) Make sure that a properly sized chimney is available which is in good condition. Consult the authority having jurisdiction,  
Part VI of this manual, and the National Fuel Gas Code for additional information on venting requirements.  
3) Make sure that the boiler is correctly sized:  
For heating systems employing convection radiation (baseboard or radiators) use an industry accepted sizing  
method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics Institute  
in Berkeley Heights NJ.  
For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.  
For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE Heating  
Capacity required for the Mega-Stor or the net rating required for the heating system, whichever results in the  
larger boiler.  
For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s instruc-  
tions for boiler output requirements.  
4) Make sure that the boiler received is configured for the correct gas (natural or LP).  
5) Boilers built for installations at altitudes above 2000 ft. require different burners and main burner orifice. Make sure that  
the boiler is configured for use at the correct altitude.  
IV Locating the Boiler  
1) Clearances:  
Observe the minimum clearances shown below. These clearances apply to all combustible construction, as well as  
noncombustible walls, ceilings and doors. Also see Figure 2.  
Front – 18”  
Left Side – 6”  
Right Side – 6”  
Rear – 6”  
Top – 18”  
A 24” service clearance from the jacket is recommended on the left, right, and front of the boiler. These clearances  
may be reduced to those shown in Figure 2, however servicing the boiler will become increasingly difficult as these  
service clearances are reduced.  
If the right side 24” service clearance is reduced, adequate clearance must be maintained to easily read both the  
gauge and the limit control. Alternatively, access to the gauge and limit may be provided using a door  
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 flammable vapors or liquids will be stored or used. Do not  
install this boiler in an area where large amounts of airborne dust will be present, such as a workshop.  
4
FIGURE2:CLEARANCEFROMBOILERTOALLTYPESOFCOMBUSTIBLECONSTRUCTIONAND  
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, ventilation  
and flue gas dilution air for gas utilization equipment vented by natural draft must be made in accordance with local building  
codes or, in absence of such codes, in accordance with sections 5.3.3 and 5.3.4 (“Air for Combustion and Ventilation”) of the  
National Fuel Gas Code, NFPA 54/ANSI Z 223.1.  
To ensure an adequate supply of combustion, ventilation and flue gas dilution air supply, start by determining whether the boiler  
is to be installed in a building of unusually tight construction. A building of unusually tight construction is defined by the  
National Fuel Gas Code as having all of the following features:  
Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm  
or less with openings gasketed and sealed  
Weather stripping has been added on openable windows and doors  
Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and  
floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and  
at other openings.  
For Buildings of Other than Unusually Tight Construction  
1) Determine whether the boiler is to be installed in a confined space - A confined space is defined by the National Fuel Gas  
Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To determine  
whether the boiler room is a confined space:  
a. Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest  
1000 BTU/hr.  
5
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 BTU/hr. If the result is less than 50, the boiler  
room is a confined space.  
Example:  
An AWI162EN and a water heater are to be installed in a room measuring 6 ft - 3 in x 7 ft with an 8 ft ceiling.  
The water heater has an input of 30000 BTU/hr:  
Total input in thousands of BTU/hr = (162000 BTU/hr + 30000 BTU/hr)/1000 = 192  
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3  
350/192 = 1.82. Since 1.82 is less than 50, the boiler room is a confined space.  
2) Unconfined Space - Natural infiltration into the boiler room will normally provide adequate air for combustion and  
ventilation without additional louvers or openings into boiler room.  
3) Confined Space - Provide two openings into the boiler room, one near the floor and one near the ceiling. The top edge of  
the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the floor  
(Figure 3).  
Each opening must have a free area of 1 square inch per 1000 BTU/hr input of all gas burning appliances in the  
boiler room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per  
opening.  
If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet  
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.  
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 providing openings into adjacent rooms is undesirable, combustion and ventilation air can be brought into the  
boiler room from outdoors. See the instructions under “For Buildings of Unusually Tight Construction”.  
FIGURE3:BOILERINSTALLEDINCONFINEDSPACE,  
ALL AIR FROM INSIDE  
6
ForBuildingsofUnusuallyTightConstruction  
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, Figure 5, and Figure 6) - Each opening must have a free  
cross sectional area of 1 square inch per 4000 BTU/hr of the total input of all gas-fired appliances in the boiler  
room but not less than 100 square inches. Minimum opening size is 3 inches.  
Openings to outdoors via horizontal ducts (Figure 7) - Each opening must have a free cross sectional area of 1  
square inch per 2000 BTU/hr of the total input of all gas fired appliances in the boiler room but not less than 100  
square inches. Minimum opening size is 3 inches.  
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.  
FIGURE4: ALLAIRFROMOUTDOORS,  
VENTILATED CRAWL SPACE AND ATTIC  
FIGURE5: ALLAIRFROMOUTDOORS,  
VIA VENTILATED ATTIC  
7
FIGURE6:ALLAIRFROMOUTDOORS,USING  
OPENINGSINTOBOILERROOM  
FIGURE7:ALLAIRFROMOUTDOORS,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. The AWI and TWI series boilers are equipped with a draft diverter which is built into the boiler;  
do not attempt to install an external draft hood.  
1) Acceptable Chimneys - The following chimneys may be used to vent AWI or TWI series boilers:  
Listed Type B or L gas vent - Install in accordance with the manufacturer’s instructions, the terms of its listing,  
and applicable codes.  
Masonry Chimney - The masonry chimney must be constructed in accordance with the Standard for Chimneys,  
Fireplaces, Vents, and Solid Fuel Burning Appliances (NFPA 211) and lined with a clay liner or other listed lining  
system. Do not vent an AWI or TWI series boiler into an unlined chimney.  
8
FIGURE8: TYPICALVENTSYSTEM  
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.  
3) Chimney and Vent Connector Sizing - Size the chimney and vent connector in accordance with Chapter 10 of the National  
Fuel Gas Code.  
4) Exterior Chimneys - An exterior chimney has one or more sides exposed to the outdoors below the roof line. There are two  
conditions under which an exterior chimney may be used:  
In some very restrictive cases, the AWI and TWI series boilers may be vented into an exterior ceramic lined masonry  
chimney. See Chapter 10 of the National Fuel Gas Code for information on when exterior chimneys may be used.  
An exterior masonry chimney may be used if it is lined with B vent or a listed chimney lining system.  
5) This boiler may vented using a listed power venter. The power venter must be in sized and installed in accordance with  
the power venter manufacturer’s instructions, the terms of the power venter listing, and applicable codes. The boiler must  
be electrically interlocked with the power venter to prevent boiler operation if the power venter fails to operate. Before  
deciding to use a power venter, make certain that the flue gas exiting the power venter will not damage adjacent  
construction or other structures. Also make certain that the power venter terminal will not be subjected to winds which  
could effect power venter operation.  
6) Do not connect the vent of this appliance into any portion of a mechanical vent system operating under positive  
pressure.  
9
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 tall as possible, while still maintaining the proper  
clearance from the horizontal vent connector to combustibles and the proper pitch called for in (9) above.  
11) Vent pipe should be installed above the bottom of the chimney to prevent blockage.  
12) Vent pipe must be inserted flush with inside face of the chimney liner and the space between vent pipe and chimney  
sealed tight.  
13) Do not install the vent damper in any portion of the vent system which is used by appliances other the boiler being  
installed.  
14) Vent damper installation is mandatory on all AWI/TWI boiler models due to federally mandated efficiency regulations.  
Install vent damper (see Figure 9) 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. See Figure 1. Unpack vent damper carefully. Do not  
force closed damper blade. Forcing vent damper closed may result in damaged gear train and void warranty.  
b) Vent damper is factory shipped having approximately ¾” diameter hole in the vent damper blade, which must be  
left open for boilers equipped with standing pilot, and should be plugged on boilers with EI control system, using  
the plug supplied with the damper.  
Mount the vent damper on the flue collar without modification to either and secure with sheet metal screws. Make  
sure screws do not interfere with damper blade operation. Vent damper blade position indicator must be visible to  
users.  
c) The damper wire harness is shipped wired into the boiler limit control. Plug the loose end of this harness into the  
damper and secure the flexible conduit to the damper using a connector nut provided.  
Provide adequate clearance to combustible construction and servicing.  
d) Install vent connector pipe and vent fittings from vent damper outlet to chimney or gas vent. Secure with sheet  
metal screws and support as required.  
RIGHTSIDEVIEW  
FIGURE9: VENTDAMPERINSTALLATIONDETAILS  
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  
10  
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 located and other spaces of the building. Turn on clothes  
dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range  
hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close  
fireplacedampers.  
d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so the appliance  
will operate continuously.  
e) Test for spillage at the draft hood relief opening after five (5) minutes of main burner operation. Use the flame of a  
match or candle, or smoke from a cigarette, cigar, or pipe.  
f) 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. When resizing any portion of the common venting system, the common  
venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 10 of  
theNationalFuelGasCode, ANSIZ223.1.  
VII Gas Piping  
Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at a line  
pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing,  
consult the utility or Part 2 of the National Fuel Gas Code.  
Figure 10 shows typical gas piping connection to the AWI/TWI boiler. A sediment trap must be installed upstream of all  
gas controls. Install a manual shut-off valve outside the jacket and ground joint union as shown.  
The boiler and its gas connection must be leak tested before placing the boiler in operation. When doing this, the boiler  
and its individual shut-off must be disconnected from the rest of the system during any pressure testing of that system at  
pressures in excess of 1/2 psi. When pressure testing the gas system at pressures of 1/2 psi or less, isolate the boiler from the  
gas supply system by closing its individual manual shut-off valve.  
*
* State of Massachusetts Requires Manual  
Shut-off Valve to be “T” Handle Type  
FIGURE10: GASCONNECTIONTOBOILER  
11  
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 ADDITIVES, SUCH AS AUTOMOTIVE ANTIFREEZE, IN A HYDRONIC  
SYSTEM.  
StandardPiping  
Figure 11 shows typical boiler system connections on a single zone system. Additional information on hydronic system  
design may be found in Installation of Residential Hydronic Systems (Pub. #200) published by the Hydronics Institute in  
Berkeley Heights, NJ. The components in this system and their purposes are as follows:  
1) Relief valve (Required) - Mount the relief valve on the right side of the boiler as shown in Figure 1 using the 3/4 nipples  
and elbow provided. The relief valve shipped with the boiler is set to open at 30 psi. This valve may be replaced with  
one having a pressure up to the “Maximum Allowable Working Pressure” shown on the rating plate If the valve is  
replaced, the replacement must have a relief capacity in excess of the DOE heating capacity for the boiler.  
Pipe the discharge of the relief valve to a location where water or steam will not create a hazard or cause property  
damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the relief valve  
discharge is not piped to a drain it must terminate at least 6 inches above the floor. Do not run relief valve discharge  
piping through an area that is prone to freezing. The termination of the relief valve discharge piping must be in an area  
where it is not likely to become plugged by debris.  
DANGER  
PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION.  
DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE.  
DO NOT MOVE RELIEF VALVE FROM FACTORY LOCATION.  
DO NOT PLUG RELIEF VALVE DISCHARGE.  
2) Circulator (Required) - Although the circulator is shipped on the boiler return, it can be installed on the boiler supply. If  
the circulator is moved to the supply it should be positioned just downstream of the expansion tank as shown in Figure  
11.  
3) Expansion Tank (Required) - If this boiler is replacing an existing boiler with no other changes in the system, the old  
expansion tank can generally be reused. If the expansion tank must be replaced, consult the expansion tank  
manufacturer’s literature for proper sizing.  
4) Fill Valve (Required) - Either a manual or automatic fill valve may be used. The ideal location for the fill is at the  
expansion tank.  
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.  
12  
FIGURE11: STANDARDBOILERPIPING  
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 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. Do not attempt to wire a 24-volt low water cutoff  
into the boiler factory wiring.  
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. Wire the control to break the 120  
VAC electrical supply to the boiler.  
8) Flow Control Valve (Required under some conditions) - The flow control valve prevents flow through the system unless  
the circulator is operating. A flow control valve may be necessary on converted gravity systems to prevent gravity  
circulation. Flow control valves are also used to prevent “ghost flows” in circulator zone systems through zones that are  
not calling for heat.  
9) Isolation Valves (Optional) - Isolation valves are useful if the boiler must be drained, as they will eliminate having to  
drain and refill the entire system.  
10) Drain Valve - The drain valve is shipped in the boiler parts bag. Install it in the tee under the circulator as shown in  
Figure 1.  
Piping for Special Situations  
Certain types of heating systems have additional requirements. Some of the more common variations follow:  
1) Indirect Water Heaters - Figure 12 shows typical indirect water heater piping. Boiler piping is the same as for any two-  
zone system. Figure 12 shows circulator zoning, which is usually preferred for indirect water heaters. Size the  
circulator and indirect water heater piping to obtain the boiler water flow through the indirect water heater called for by  
the indirect water heater manufacturer.  
13  
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 for the two throttling valves shown. If the circulator is mounted on the supply, the bypass must be on the  
discharge side of the circulator.  
3) 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 AWI or TWI. 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 AWI or TWI boiler to this type of system. The heat  
exchanger will permit the transfer of heat from the boiler water to the low temperature system while holding the system  
supply and boiler return temperatures within their limits. For this system to work properly the heat exchanger must be  
properly sized and the correct flow rates are required on either side of the heat exchanger. Consult the heat exchanger  
manufacturer for sizing information. The water in the boiler is completely isolated from the water in the system. This  
means that separate fill and expansion tanks are required for the heating system loop.  
There are several other ways to connect low temperature systems to the non-condensing boilers like the AWI or TWI  
such as four way mixing valve and variable speed injection pumping systems.  
4) Systems containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage  
to a cast iron boiler such as the AWI or TWI. Some examples include:  
Radiant systems that employ tubing without an oxygen barrier.  
Systems with routine additions of fresh water.  
Systems which are open to the atmosphere.  
If the boiler is to be used in such a system, it must be separated from the oxygenated water being heated with a heat  
exchanger as shown in Figure 14.  
Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature  
requirements. All components on the oxygenated side of the heat exchanger, such as the pump and expansion tank,  
must be designed for use in oxygenated water.  
FIGURE12: INDIRECTWATERHEATER  
BOILER SIDE PIPING  
14  
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  
FIGURE14: ISOLATIONOFBOILERFROMSYSTEM  
WITH A HEAT EXCHANGER  
15  
FIGURE15: BOILERPIPINGWITHCHILLER  
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 “L1”  
Neutral (“white”) - Terminal “L2”  
Ground (“green” or bare) - Ground screw on case of L8148E  
2) Thermostat Wiring - Follow thermostat manufacturer instructions. To insure proper thermostat operation, avoid  
installation in areas of poor air circulation, hot spots (near any heat source or in direct sunlight), cold spots (outside  
walls, walls adjacent to unheated areas, locations subject to drafts). Provide Class II circuit between thermostat and  
boiler. Connect thermostat wire leads to terminals T and TV inside L8148E aquastat relay.  
16  
2
FIGURE16: WIRINGDIAGRAM,CONTINUOUSIGNITION  
(STANDING PILOT) SYSTEM  
2
FIGURE17: WIRINGDIAGRAM,INTERMITTENTIGNITION  
(EI) SYSTEM  
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. When this relay is energized,  
electrical continuity is created between terminals 3 and 4, energizing the circulator for that zone. At the same time, electri-  
cal continuity is created between terminals 5 and 6 on the R845A, creating a current path from terminal “T” to “TV” on the  
L8148E. Assuming that the supply water temperature is below the high limit setting, the normal ignition sequence will be  
initiated.  
2) Multiple Zones using Zone Valves – Figure 19 shows wiring for multiple zones using Honeywell V8043F zone valves. This  
wiring diagram may be used for other 24-volt zone valves as long as they are equipped with end switches. Do not attempt to  
use the transformer on the L8148E to power the zone valves; use a separate transformer. Up to five V8043Fs may be  
powered by one 48VA transformer, such as the Honeywell AT87A.  
A call for heat from a given thermostat will result in the application of 24 volts across the TH and TR terminals on the  
corresponding zone valve, energizing the zone valve motor. The zone valve opens and the end switch contacts are then  
made. The end switches are connected in parallel with each other and to the “T” and “TV” thermostat connections so that  
any zone valve that opens will also start the circulator and fire the boiler (assuming the high limit is not open). Zone valve  
terminal TH/TR has no internal connection on the zone valve; it is merely a “binding post” used to connect two or more  
wires.  
FIGURE18:CIRCULATORZONEWIRINGUSINGHONEYWELLR845As  
(FACTORY BOILER WIRING NOT SHOWN - SEE FIGURE 16 OR 17)  
18  
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.  
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.  
3) Assuming that the high limit is made, current will flow to pin terminal #2 (orange) at the vent damper and the damper will  
open.  
4) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin #3 (red) at the damper. This  
pin is connected through the damper harness to terminal “B1” on the L8148E. At this point in the operating sequence, 24  
volts is present across “B1” and “B2”.  
5) Under normal conditions, the flame roll-out switch and blocked vent switch are made. Voltage will therefore immediately  
appear across the combination gas control (“gas valve”) terminals “TH” and “TR”.  
6) When the boiler is first placed into operation, the pilot must be lit. The pilot heats a thermocouple which generates a small  
amount of electricity sufficient to hold open the safety shut-off valve in the combination gas control. The circuit connecting  
the thermocouple and the safety shut-off valve is self contained and completely independent of all other wiring on the boiler.  
This safety shut-off valve is upstream of the 24 volt valves in the gas control which open in response to a call for heat. If the  
pilot is not lit, the safety shut-off valve will remain closed and gas will not reach the 24 volt valves.  
7) Assuming that the pilot is established and proven by the thermocouple, the application of 24 volts across the combination  
gas valve terminals energizes the redundant 24 volt solenoid valves in the combination gas control, resulting in gas flow  
through the control and burner operation.  
19  
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.  
3) Assuming that the high limit is made, current will flow to pin terminal #2 (orange) at the vent damper and the damper will  
open.  
4) Once the vent damper is fully open, an end switch inside the damper will make, energizing pin #3 (red) at the damper. This  
pin is connected through the damper harness to terminal “B1” on the L8148E. At this point in the operating sequence, 24  
volts is present across “B1” and “B2”.  
5) Under normal conditions, the flame roll-out switch and blocked vent switch are made. Voltage will therefore immediately  
appear across the “24V” and “24V (GND)” terminals on the ignition module.  
6) Upon application of voltage across the “24V” and “24V (GND)” terminals, the ignition module will start an ignition spark  
at the pilot and apply 24 volts across the pilot valve (terminals “PV” and “MV/PV”).  
7) Once the pilot is established, the pilot flame will act as a diode, converting the AC current at the electrode to a half wave  
DC current at the pilot’s ground strap. This DC current flows through the boiler to the “GND (BURNER)” connection on  
the ignition module. For the ignition module to recognize that a pilot flame is present, the DC current flowing into this  
terminal must be in excess of approximately 1.0 uA.  
8) Once the ignition module detects the presence of a pilot flame, voltage is applied across the main valve (terminals “MV”  
and “MV/PV”), opening the valve and establishing main flame.  
9) The way in which the ignition module handles failure to establish pilot or the loss of an already established pilot depends  
upon the exact ignition module supplied with the boiler. For more information on module operation, consult the ignition  
module instructions supplied with the boiler or the local Crown representative.  
Safety Control Operation - Standing Pilot and Intermittent Ignition  
High Limit - Interrupts main burner operation when the supply water temperature exceeds set point. Maximum allowable  
temperature is 250°F. If the high limit opens, the vent damper will close if the damper switch is in the “automatic” position.  
The circulator will continue to operate as long as there is a call for heat, regardless of the status of the high limit. Burner  
operation automatically resumes when the supply water temperature falls below set point.  
Blocked Vent (“Spill”) Switch - Automatically interrupts main burner operation in the event that flue gas spills from the draft  
diverter opening. This switch is equipped with a reset button which must be pressed to restore normal burner operation. An  
open blocked vent switch is indicative of a problem with the vent system. If the blocked vent switch opens, the cause of the  
venting problem must be found and corrected by a qualified gas service technician before the blocked vent switch is reset.  
Flame Roll-out Switch - Automatically interrupts boiler operation when flames or excessive heat are present in vestibule. The  
flame roll-out switch is a single use device which must be replaced by a identical switch in order to restore normal operation. An  
open flame roll-out switch is usually indicative of a plugged heat exchanger. The cause of the flame roll-out must be found and  
corrected by a qualified gas service technician, and the switch replaced with an identical one, before the boiler is returned to  
operation.  
20  
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. See Part 4 of the National Fuel Gas  
Code for additional information on testing and purging gas lines.  
WARNING  
NEVER USE A FLAME TO CHECK FOR GAS LEAKS.  
MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE  
MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND LIQUIDS.  
3) Verify that vent system is complete and free of obstructions before attempting to fire boiler.  
4) Inspect all wiring for loose or uninsulated connections.  
5) Make sure the main burners are seated properly in the rear of burner tray and on orifices.  
6) Adjust thermostat to the highest setting.  
7) Start the boiler using the lighting instructions for boilers with standing pilot (page 24) or operating instructions for boilers  
withintermittentignition(page25).  
8) Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take  
several tries for ignition before a flame is established. Once a flame has been established for the first time, subsequent  
calls for burner operation should result in a flame on the first try.  
9) Observe pilot burner flame:  
See Figure 20 for standing pilot. Pilot burner should produce single steady medium blue flame covering around 3/8”  
to ½” of thermocouple tip.  
See Figure 21 for intermittent ignition. Pilot burner produces three flames. The center one should be a steady medium  
blue flame covering around 3/8” to ½” of spark electrode/flame rod.  
10) Make sure vent damper is in open position when main burners are firing.  
11) Inspect the main burner flames visible through the observation port in burner access panel. The flame should be stable  
and mostly blue (see Figure 22 or 23). No yellow tipping should be present; however, intermittent flecks of yellow and  
orange in the flame are normal.  
12) Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is firing.  
Fix any leaks found immediately.  
21  
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.  
15) Check the manifold pressure and adjust if necessary. To do this, use the following procedure:  
WARNING  
FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER-  
FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD.  
a) Connect a manometer to the line pressure tap on the gas valve (see Figures 24 and 25).  
b) Check the line pressure with all gas appliances on and off. The line pressure at the boiler must be within the following  
limits regardless of what combination of appliances is firing:  
Line Press (inches w.c.)  
NaturalGas  
5.0  
LPGas  
11.0  
Min.  
Max.  
14.0  
13.0  
If the line pressure falls outside of these limits, find and correct the cause of the problem before proceeding further.  
c) Connect a manometer to the manifold (outlet) pressure tap on the gas valve (see Figures 24 and 25).  
d) Read the manifold pressure. It should be set at:  
Natural Gas  
3.5  
LP Gas  
10.0  
Manifold Press. (inches w.c.)  
e) If a manifold pressure adjustment is needed, make the adjustment by turning the regulator (see Figures 24 and 25)  
screw clockwise to raise the pressure and counter clockwise to reduce the pressure. If a manifold pressure  
adjustment is made, recheck the line pressure to be certain that it is still within acceptable limits. Replace the  
cover screw on the regulator.  
16) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. Circulator should stop  
running. For standing pilot boiler models, pilot burner should remain lit but the main burners should stop firing. For  
intermittent ignition boiler models both pilot burner and main burners should stop firing. Raise the thermostat back to the  
highest setting. Circulator should restart. The main burners( for standing pilot boiler models) or pilot burner and main  
burners (for intermittent ignition boiler models) should relight.  
17) Verify high limit operation. Allow the boiler water temperature to increase to hi limit setting. Circulator should  
continue running. For standing pilot boiler models, pilot burner should remain lit but the main burners should stop firing.  
For intermittent ignition boiler models both pilot burner and main burners should stop firing.  
18) Allow the boiler water temperature to drop below high limit setting.  
19) The main burners (for standing pilot boiler models) or pilot burner and main burners (for intermittent ignition boiler  
models) should relight.  
22  
20) After the boiler has operated for approximately 30 minutes, check the boiler and heating system piping for leaks.  
Repair any leaks found at once.  
21) Inspect the vent system for flue gas leaks. Repair any leaks found before leaving the boiler in operation.  
FIGURE20: STANDINGPILOT  
BURNER FLAME  
FIGURE21: INTERMITTENTIGNITION  
PILOTBURNERFLAME  
FIGURE23:MAINBURNERFLAME-50mm  
(“HIGHALTITUDE”)BURNERS  
FIGURE22: MAINBURNERFLAME-1BURNERS  
23  
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.  
A. This appliance has a pilot which must be  
lighted by hand. When lighting the pilot, follow  
these instructions exactly.  
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. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
B. BEFORE LIGHTING smell all around the  
appliance area for gas. Be sure to smell next  
to the floor because some gas is heavier than  
air and will settle on the floor.  
WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
LIGHTING INSTRUCTIONS  
1. STOP! Read the safety information above on  
8. Turn Knob on gas control counterclockwise  
to “PILOT”.  
this label.  
2. Set the thermostat to lowest setting.  
3. Turn off all electric power to the appliance.  
4. Remove front access panel.  
9. Push down and hold the red reset button while  
you light pilot burner with a match.  
After about one minute, release reset button.  
Pilot should remain lit. If it goes out, turn gas  
control knob clockwise  
repeat steps 5-9.  
to OFF. To relight,  
5. Rotate the gas control knob clockwise  
to OFF.  
If button does not pop up when released, stop  
and immediately call your service technician  
or gas supplier.  
RESET BUTTON  
If the pilot will not stay lit after several tries,  
turn the gas control knob to “OFF” and call  
your service technician or gas supplier.  
GAS INLET  
GAS OUTLET  
10. After pilot remains lit when red reset button is  
released, turn gas control knob counterclockwise  
to ON.  
GAS CONTROL KNOB  
(SHOWN IN “ON” POSITION)  
GAS VALVE - TOP VIEW  
6. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas,  
go to the next step.  
11. Replace front access panel.  
12. Turn on all electric power to the appliance.  
13. Set thermostat to desired setting.  
7. Find pilot - follow metal pilot  
tube from gas control to  
PILOT  
BURNER  
THERMO-  
COUPLE  
pilot burner.  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
24  
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  
the fire department.  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
C. Use only your hand to push in or turn the gas  
control knob. Never use tools. If the knob will  
not push in or turn by hand, don’t try to repair it,  
call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
B. BEFORE LIGHTING smell all around the  
appliance area for gas. Be sure to smell next  
to the floor because some gas is heavier than  
air and will settle on the floor.  
WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electric switch; do not  
use any phone in your building.  
Immediately call your gas supplier from  
a neighbor’s phone. Follow the gas  
supplier’s instructions.  
D. Do not use this appliance if any part has been  
under water. Immediately call a qualified service  
technician to inspect the appliance and to  
replace any part of the control system and any  
gas control which has been under water.  
OPERATING INSTRUCTIONS  
1. STOP! Read the safety information above on  
this label.  
5. Remove front access panel.  
6. Rotate the gas control knob clockwise  
to OFF.  
2. Set the thermostat to lowest setting.  
7. Wait five (5) minutes to clear out any gas. Then  
smell for gas, including near the floor. If you then  
smell gas, STOP! Follow “B” in the safety inform-  
ation above on this label. If you don’t smell gas  
go to the next step.  
3. Turn off all electric power to the appliance.  
4. This appliance is equipped with an ignition  
device which automatically lights the pilot.  
Do not try to light the pilot by hand.  
8. Rotate the gas control knob counter clockwise  
to “ON”.  
GAS CONTROL KNOB  
(SHOWN IN “ON” POSITION)  
9. Replace front access panel.  
10. Turn on all electric power to the appliance.  
11. Set thermostat to desired setting.  
GAS INLET  
GAS OUTLET  
12. If the appliance will not operate, follow the  
instructions “To Turn Off Gas To Appliance” and  
call your service technician or gas supplier.  
GAS VALVE - TOP VIEW  
TO TURN OFF GAS TO APPLIANCE  
1. Set the thermostat to lowest setting.  
3. Push in gas control knob slightly and turn  
clockwise to “OFF”. Do not Force.  
2. Turn off all electric power to the appliance if  
service is to be performed.  
25  
FIGURE24: GASVALVEDETAIL-STANDINGPILOT  
FIGURE25: GASVALVEDETAIL-INTERMITTENTIGNITION  
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.  
4) Remove all burners, noting the location of the pilot main burner. If burners show signs of deterioration, they should be  
replaced (some discoloration around the burner ports is normal). Clean the burners by first brushing the ports with a soft  
bristle brush and then vacuuming out any debris through the venturi opening.  
5) Inspect the pilot assembly:  
Standing Pilots - Check the thermocouple for deterioration (some discoloration of the thermocouple is normal). If  
any deterioration is present, replace the thermocouple. Inspect the pilot assembly for deposits and deterioration.  
Clean or replace the pilot assembly as necessary.  
Intermittent Pilots - Clean any deposits found on the electrode and grounding strap. The ideal gap between the  
electrode and the ground strap is 1/8”. Inspect the porcelain for cracks or other deterioration. Replace pilot  
assembly if deterioration is found.  
6) Inspect the combustion chamber insulation for deterioration.  
7) (Intermittent Pilot Boilers) - Inspect the ignition cable insulation for cracks or other deterioration. If deterioration is  
found, replace cable.  
8) Reinstall burners, being careful to put the pilot main burner in its original location.  
9) Inspect all boiler wiring for loose connections or deterioration.  
CAUTION  
LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN  
CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING  
10) Inspect the vent system:  
Make sure that both the vent system is free of obstructions.  
Make sure that all vent system supports are intact.  
Inspect joints for signs of condensate or flue gas leakage.  
Inspect venting components for corrosion or other deterioration. Replace any defective vent components.  
11) Inspect the boiler and hydronic system for leaks.  
CAUTION  
WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPO-  
NENTS. REPAIR ANY LEAKS FOUND IMMEDIATELY  
12) Place the boiler back in operation using the procedure outlined in “Start-up”. Check the pilot line and any other gas  
piping disturbed during the inspection process for leaks.  
27  
Heat Exchanger Cleaning Procedure  
1) Turn off electrical power and gas supply to the boiler  
2) Disconnect the damper and vent connector from the boiler.  
3) Remove the upper front and top jacket panels. If possible, remove the rear and left side jacket panels  
4) Remove the burners.  
5) Remove the blocked vent (“spill”) switch  
6) Remove the two ¼-20 nuts and washers holding the flue collector onto the heat exchanger.  
7) Remove the flue collector from the heat exchanger.  
8) Carefully remove the flue collector gasket strips and set them aside  
9) Clean the flue passageways using a stiff bristle brush. Be certain that all foreign material is removed from the gaps  
between the pins  
10) Clean the bottom surfaces of the heat exchanger  
11) Put a light in the combustion chamber and look through the flue passages from the top to verify that they have been  
thoroughly cleaned.  
12) Replace the flue collector gasket strips. If desired, RTV-732 silicone sealant with a 500F intermittent duty temperature  
rating may be substituted for this rope gasket. The flue collector must be thoroughly sealed to the heat exchanger.  
13) Replace the ¼-20 nuts and washers that hold down the flue collector  
14) Reattach all the jacket components.  
15) Reinstall burners, being careful to put the pilot main burner in its original location.  
16) Replace the blocked vent switch.  
17) Reconnect the damper and vent system.  
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.  
If it is necessary to check CO, use an combustion analyzer, or other instrument which is designed to measure CO in flue  
gas. A CO “sniffer” designed for testing CO levels in ambient air cannot be used to check boiler combustion. Take a flue  
gas sample by inserting a sample probe through the draft diverter opening and into the flue collector so that the sample is  
taken in the area directly over the heat exchanger. Do not take a sample until the boiler has been firing for at least five  
minutes.  
A normal CO reading for an AWI or TWI series boiler is less than 50ppm (0.005%). A reading of more than 100ppm  
(0.01%) is indicative of a combustion problem.  
Some causes of excessive CO include:  
Incorrectly sized main burner orifice for the altitude at which boiler is installed  
Crooked or out-of-round orifice holes (never attempt to drill orifice for this boiler in the field)  
Partially plugged flue passages  
Improper manifold pressure  
Foreign material in burner venturis or burner ports  
Leak in seal between flue collector and heat exchanger  
28  
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). In using these charts, the  
following should be kept in mind:  
1) These charts are only meant to be used by a professional heating technician as an aid in diagnosing control problems.  
2) Where applicable, follow all precautions outlined in the appropriate lighting instructions on page 24 or 25.  
3) In general, these charts assume that there are no loose or miswired electrical connections. Before using these charts,  
inspect all electrical connections on the boiler to make sure that they are tight. Also, check the wiring on the boiler  
against the appropriate wiring diagram in Figure 16 or 17.  
4) The possible causes at the end of each branch in these charts are not listed in order of likelihood. All controls on the  
AWI and TWI are tested at least once in the manufacturing process and a defective control or component is generally  
the least likely cause. Before replacing a component, try to rule out all other possible causes.  
5) These troubleshooting charts assume that the vent damper is closed at the beginning of the troubleshooting process.  
With the 120 volts applied to the boiler and no call for heat, the damper should go to the closed position. If it does not,  
do the following:  
Confirm that 120 volts is applied to the boiler and that there is no call for heat.  
Make sure that the switch on the damper is in the “automatic” position.  
Unplug the harness from the damper and check for 24 volts across pin #1 (blue) and pin #4 (yellow).  
If voltage is present, the damper is defective or there is an obstruction in the path of the damper blade.  
If no voltage is present, there is either a loose connection in the damper harness or the L8148E is defective  
6) If the charts indicate that the L8148E is defective, do the following before replacing it:  
Check for 24 volts across TV and Z. If no voltage is present, the transformer in the L8148E is defective. It is  
possible that this transformer has been destroyed by a short circuit in the boiler wiring. Before replacing the  
control, carefully inspect all low voltage wiring on the boiler for places where it is touching the frame of the boiler  
or wiring on the other side of the transformer.  
If 24 volts is present across TV and Z, check for 24 volts between T and W. If no voltage is present, make sure that  
the brass jumper is present between W and Z and that the screws holding this jumper in place are both tight.  
If not already done, temporarily replace the thermostat across TV and T with a jumper. If the boiler fires when this  
is done, there is a problem with the thermostat or zone wiring.  
If 24 volts is present across T and W and the relay in the L8148E does not pull in, the relay in the L8148E is  
probably defective. Inspect the coil of this relay for visible heat damage. If such damage is found, there is a good  
chance that a second transformer is present in the thermostat or zone valve circuit, resulting in the application of  
48 volts across the relay coil. In older buildings, this transformer may be hidden in a location far from the boiler. If  
this second transformer exists, it must be found and removed before the L8148E is replaced.  
7) When checking voltage across damper harness pins, be careful not to insert the meter probes into the pins. Doing so  
may damage the pin, resulting in a loose connection when the harness is reconnected.  
29  
AWI/TWI Troubleshooting Chart  
START  
Caution: Read page 29 before attempting to use this chart  
Vent  
damper  
open?  
Y
Y
Thermostat  
calls for heat  
Circulator  
start?  
N
N
*Pow er of f  
N
120 volts  
at L1&L2?  
24 volts  
*Blow n fuse or  
tripped breaker  
Y
across B and R  
(limit sw itch) in  
L8148E?  
*Misw ired or  
loose electrical  
connection in  
120V line  
Y
*Boiler off on  
limit  
120 volts  
across  
Y
N
N
120 volts at  
terminals at  
circulator?  
C1&C2?  
*Def ective  
high limit.  
N
Y
Remove t'stat or  
24 volts  
zone valve end  
sw itch w ires from  
T&TV terminals on  
L8148E. Install  
temporary jumper  
across terminals T  
and TV.  
betw een pins  
1&4 (blue&yellow )and  
2&4 (orange&yellow ) on  
damper end of damper  
harness? See  
*Seized or  
defective  
circulator  
24 volts  
across  
T&TV?  
Y
N
N
Note 7 on page 29.  
Does  
circulator  
run now ?  
N
Y
*Def ective  
L8148E-see  
Note 6 on page  
29.  
*Bad electrical  
connection  
betw een C1 or  
C2 and  
* Loose  
*Obstruction in  
path of damper  
blade  
connection  
betw een  
damper  
harness and  
L8148E  
circulator  
Y
*Loose connection in t'stat or  
zone valve end sw itch w iring  
*Def ective  
damper motor  
*Defective t'stat or zone valve  
end sw itch  
*Def ective  
damper  
*Loose  
connection  
betw een damper  
harness and  
damper  
harness.  
*T'stat or zone system  
misw ired-consult t'stat or  
zone valve manufacturer's  
instructions  
* Def ective  
L8148E  
30  
Do burners  
shut dow n before  
gage temp  
exceeds high limit  
setting +15F?  
Do burner and  
circulator shut  
dow n at end of  
call for heat?  
Main  
burners  
light?  
Y
Y
Y
END  
N
N
N
*Defective damper  
24 volts  
across  
B1 &B2 ?  
N
*Defective L8148E  
*Def ective  
L8148A  
*Defective damper  
harness  
Y
*Sensing bulb not  
bottomed out in  
w ell  
*Loose damper  
harness connection  
*Obstruction in path  
24 volts across  
standing pilot gas  
valve terminals or  
terminals 5&6 on  
S8600 module?  
of damper blade  
N
Pull w ire of f of T  
terminal on  
aquastat. Does  
boiler shut dow n?  
Refer to standing pilot or  
intermittent ignition  
troubleshooting chart  
(page 32 or 33).  
Y
N
Y
24 volts  
across spill  
sw itch?  
Y
*Chimney blockage  
*T'stat or  
*Chimney system not  
zone valve  
w iring calling  
for heat  
constructed in accordance  
w ith Parts 7 and 11 of  
National Fuel Gas Code.  
N
24 volts  
across  
rollout  
*Dow n draft  
*T'stat w ires  
shorted  
*Inadequate combustion air  
supply in boiler room  
sw itch?  
Y
N
*Internal boiler  
w iring  
problem,  
consult Crow n  
representative  
*Rollout sw itch open.  
Replace w ith exact  
replacement (see parts  
list). Check for blocked  
heat exchanger.  
*Loose electrical  
connection in 24  
volt w iring  
betw een B1 or B2  
and gas valve or  
module  
31  
Standing Pilot Ignition System Troubleshooting Chart  
START  
Caution: Read page 29 before  
(24 VOLTS PRESENT ACROSS TH AND TR  
ON GAS VALVE, BUT MAIN BURNERS DO  
NOT LIGHT)  
attempting to use this chart  
Y
Ensure knob  
on gas valve is  
set toON  
Main  
burners  
light?  
Y
Y
Does pilot  
stay lit?  
Pilot lit?  
N
END  
N
N
*Loose  
thermocouple  
connection at  
Turn control on  
gas valve to  
PILOT. Depress  
red button and  
light pilot. Hold  
button for at  
least one  
Turn control  
on gas valve  
to ON.  
*Defective gas  
valve  
gas valve.  
*Defective  
thermocouple.  
minute.  
*Condensation  
quenching pilot.  
Y
Disconnect  
thermocouple from  
gas valve. Connect a  
volt meter to the  
thermocouple. Light  
the pilot and hold  
down the red button  
while reading the  
voltage across the  
thermocouple.  
*Low line  
pressure.  
Does pilot  
stay lit when  
red button is  
released?  
Y
N
Does pilot  
light?  
N
Line pressure  
within the range  
indicated on  
boiler's rating  
plate?  
N
Y
Is voltage at  
least 18mV?  
Consult gas  
supplier.  
Y
N
*Pilot tubing  
blocked, kinked  
or leaking  
*Loose or defective  
thermocouple  
connection at gas valve  
*Defective thermocouple  
*Pilot orifice  
blocked  
*Pilot improperly  
adjusted  
*Defective gas valve  
*Gas line not  
purged of air  
*Pilot tube blocked, kinked, or  
leaking  
*Pilot improperly  
adjusted.  
*Pilot orifice partially plugged  
32  
Intermittent Ignition System Troubleshooting Chart  
START  
Caution: Read page 29 before  
attempting to use this chart  
(24 volts is present across 5 and 6 on S8600  
module, but main burners do not light)  
Spark  
Does  
Main  
burner  
lights?  
Y
Y
Y
Y
across  
ignitor/sensor  
gap?  
Pilot  
lights?  
spark stop  
when pilot  
lights?  
END  
N
N
N
N
24VAC  
across  
terminals 1&2  
on S8600?  
N
24 volts  
across  
terminals 2&3  
at S8600?  
N
Y
*Defective  
S8600 module  
Can you  
hear  
Y
*Defective  
S8600  
module  
Y
sparking?  
N
24 volts  
between MV &  
MV/PV on gas  
valve?  
24 volts  
across PV &  
MV/PV at gas  
valve?  
N
Y
*Faulty  
S8600  
module  
N
Y
*Loose connection in  
ignition cable or  
ground wire  
*Defective EI  
wiring  
harness.  
*Break in  
spark cable  
insulation  
*Defective EI  
harness  
*Pilot electrode  
porcelain cracked  
*Break in pilot  
porcelain  
* Low line pressure  
*Pilot flame not  
covering gap  
between electrode  
and grounding  
strap  
*Plugged, kinked or leaking  
pilot tubing  
*Incorrect pilot  
spark gap  
*Defective  
gas valve  
*Plugged pilot orifice  
*Loose  
connection in  
spark cable  
*Low gas pressure  
at gas valve inlet  
*Gas line not purged of air  
*Defective pilot assembly  
*Defective gas valve  
*Loose  
ground  
connection  
*Defective S8600  
module  
33  
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.  
CustomerService  
P.O. Box 14818  
Philadelphia Pa. 19134  
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.  
In some cases, the following parts lists do not include Crown part numbers because they were not available at the time of  
printing. Order these parts by their description, specifying the boiler model number on which they are to be used.  
QTY. OR  
CROWN P.N.  
1 ea.  
700001  
700002  
700003  
700000  
1 ea.  
QUANTITY PER BOILER OR CROWN P.N.  
KEY #  
DESCRIPTION  
262  
700019  
1 ea.  
1 ea.  
1 ea.  
16 ea.  
700649  
700669  
700689  
701689  
295  
700020  
1 ea.  
1 ea.  
1 ea.  
18 ea.  
700650  
700670  
700690  
701690  
37  
700012  
1 ea.  
61  
700013  
1 ea.  
1 ea.  
1 ea.  
95  
128  
162  
195  
229  
1
*
*
*
*
2
3
4
4
COMPLETE HEAT EXCHANGER ASSY.  
LEFT END SECTION  
RIGHT END SECTION  
INTERMEDIATE SECTION  
PUSHNIPPLE  
700014  
1 ea.  
700015  
1 ea.  
700016  
1 ea.  
700017  
1 ea.  
700018  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
3 ea.  
4 ea.  
5 ea.  
6 ea.  
2 ea.  
4 ea.  
6 ea.  
8 ea.  
10 ea.  
700646  
700666  
700686  
701686  
12 ea.  
700647  
700667  
700687  
701687  
14 ea.  
700648  
700668  
700688  
701688  
BASE TRAY  
700642  
700662  
700682  
700643  
700663  
700683  
701683  
700644  
700664  
700684  
701684  
700645  
700665  
700685  
701685  
BASE WRAPPER  
1 ea.  
1 ea.  
1 ea.  
BURNER TRAY (1" BURNERS)  
BURNER TRAY (50mm BURNERS)  
BASE FRONT PANEL ASSY. (INCLUDES  
INSULATION)  
5
1 ea.  
700602  
700603  
700604  
700605  
700606  
700607  
700608  
700609  
700610  
6
7
8
9
BURNER ACCESS PANEL  
BASE END INSULATION  
BASE REAR INSULATION  
BASE LEG ASSY.  
1 ea.  
720601  
1 ea.  
700622  
2 ea.  
720602  
4 ea.  
20 ea.  
2.6 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
700623  
2 ea.  
720603  
4 ea.  
20 ea.  
3.7 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
2 ea.  
700123  
3 ft  
700624  
2 ea.  
720604  
4 ea.  
20 ea.  
4.2 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
3 ea.  
700124  
3.3 ft  
2 ea.  
2 ea.  
2 ea.  
700625  
2 ea.  
720605  
4 ea.  
20 ea.  
4.8 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
4 ea.  
700125  
3.5 ft  
2 ea.  
2 ea.  
2 ea.  
700626  
2 ea.  
720606  
4 ea.  
20 ea.  
5.3 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
5 ea.  
700126  
3.8 ft  
2 ea.  
2 ea.  
2 ea.  
700627  
2 ea.  
720607  
4 ea.  
21 ea.  
5.9 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
700628  
2 ea.  
720608  
4 ea.  
21 ea.  
6.4 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
700629  
2 ea.  
720609  
4 ea.  
21 ea.  
7.0 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
700630  
2 ea.  
720610  
4 ea.  
21 ea.  
7.5 ft  
1 ea.  
1 ea.  
1 ea.  
2 ea.  
4 ea.  
4 ea.  
4 ea.  
700110  
900100  
900146  
960122  
900121  
90-048  
90-212  
900102  
900103  
900101  
650100  
1 ea.  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
1/4-20 X 1/2" SELF TAPPING SCREW  
1/2" x 2" SEALING STRIP  
ROLLOUT SWITCH G4AM0600240C  
ROLLOUT SWITCH BRACKET  
#8 x 3/4" SELF TAPPING SCREW  
#10 x 1/2" SHEET METAL SCREW  
5/16 USS FLAT WASHER  
5/16-18 LOCK NUT  
5/16-18 x 1-1/4 SELF TAPPING SCREW  
FLUE BAFFLE (TWI ONLY)  
DRAFT DIVERTER ASSEMBLY  
1/2" x 1" SEALING STRIP  
1/4-20 x 3" CARRIAGE BOLT  
1/4" USS FLAT WASHER  
1/4-20 WING NUT  
700129  
4.6 ft  
2 ea.  
2 ea.  
2 ea.  
700130  
4.9 ft  
2 ea.  
2 ea.  
2 ea.  
700122  
2.7 ft  
2 ea.  
2 ea.  
2 ea.  
700127  
4.1 ft  
2 ea.  
2 ea.  
2 ea.  
700128  
4.4 ft  
2 ea.  
2 ea.  
2 ea.  
900145  
900126  
90-215  
900125  
2 ea.  
2 ea.  
2 ea.  
BLOCKED VENT SWITCH ASSY.  
(INCLUDES MOUNTING BRACKET)  
25  
960123  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
* NOT PICTURED  
34  
Base-Block-Hood  
35  
CAUTION: MAIN BURNER ORIFICE SIZES SHOWN ARE FOR BOILERS INSTALLED AT ALTITUDES  
BELOW 2000 ft  
QTY. OR  
CROWN P.N.  
150500  
150501  
1 ea.  
950300  
950301  
950302  
950304  
950330  
950336  
950331  
3507010  
(VR8200C6008)  
3507020  
(VR8204C6000)  
3507110  
(VR8300C4134)  
3507120  
(VR8304P4298)  
3507210  
(VR8200C6040)  
3507220  
(VR8204C6018)  
3507230  
(VR8300C4548)  
3507240  
(VR8304P4280)  
3504005  
(Q327A1949)  
35-4700  
(Q348A1275)  
35-4020  
(Q327A1915)  
35-4600  
(Q348A1259)  
1 ea.  
QUANTITY PER BOILER OR CROWN P.N.  
KEY #  
DESCRIPTION  
37  
1 ea.  
1 ea.  
700152  
61  
95  
1 ea.  
128  
1 ea.  
162  
1 ea.  
195  
1 ea.  
229  
1 ea.  
262  
1 ea.  
15 ea.  
700159  
295  
1 ea.  
17 ea.  
700160  
41  
42  
43  
44  
44  
44  
44  
44  
44  
44  
45  
1" BURNER WITH PILOT BRACKET  
1" BURNER LESS PILOT BRACKET  
MANIFOLD (1" BURNERS)  
1 ea.  
2 ea.  
700153  
3 ea.  
4 ea.  
700154  
6 ea.  
700155  
8 ea.  
700156  
11 ea.  
700157  
13 ea.  
700158  
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 (1.25mm DRILL SIZE)  
LP GAS ORIFICE (#56 DRILL SIZE)  
GAS VALVE (STND. PILOT, NAT GAS)  
2 ea.  
2 ea.  
5 ea.  
5 ea.  
7 ea.  
7 ea.  
9 ea.  
9 ea.  
12 ea.  
12 ea.  
14 ea.  
14 ea.  
16 ea.  
16 ea.  
18 ea.  
18 ea.  
3 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
45  
45  
GAS VALVE (E.I., NAT GAS)  
GAS VALVE (STND. PILOT, NAT GAS)  
GAS VALVE (E.I., NAT GAS)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
45  
45  
GAS VALVE (STND. PILOT, LP GAS)  
GAS VALVE (E.I. PILOT, LP GAS)  
GAS VALVE (STND. PILOT, LP GAS)  
GAS VALVE (E.I., LP GAS)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
45  
45  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
45  
46  
PILOT ASSY. (STND. PILOT, NAT GAS)  
PILOT ASSY. (E.I., NAT GAS)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
46a  
46  
PILOT ASSY. (STND. PILOT, LP GAS)  
PILOT ASSY. (E.I., LP GAS)  
46a  
47  
47a  
48  
THERMOCOUPLE  
IGNITION CABLE  
PILOT TUBING  
35-1040 35-1040 35-1040 35-1040 35-1040 35-1040 35-1040 3501141 3501141  
3501136 3501136  
3501124 3501124 3501124 3501124 3501130 3501130 3501130  
1 ea.  
1 ea.  
90-042  
90-042  
90-042  
90-042  
90-043  
90-043  
90-043  
900041  
900041  
1/8 SHORT FERRULE (INCLUDED WITH  
GAS VALVE)  
49  
35-1600  
(392449)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1/8 LONG FERRULE (INCLUDED WITH  
PILOT ASSEMBLY)  
50  
51  
35-1650  
(392449-4)  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
A26 PILOT ORIFICE (STND. PILOT NAT  
GAS) - INCLUDED WITH PILOT ASSY.  
KF24 PILOT ORIFICE (E.I., NAT GAS) -  
INCLUDED WITH PILOT ASSY.  
K14 PILOT ORIFICE (STND. PILOT LP  
GAS) - INCLUDED WITH PILOT ASSY.  
K16 PILOT ORIFICE (E.I., LP GAS) -  
INCLUDED WITH PILOT ASSY.  
51a  
51  
51a  
60  
61  
62  
50mm BURNER WITH PILOT BRACKET  
50mm BURNER LESS PILOT BRACKET  
MANIFOLD (50mm BURNERS)  
150550  
150551  
1 ea.  
1 ea.  
1 ea.  
701153  
1 ea.  
2 ea.  
701154  
1 ea.  
3 ea.  
701155  
1 ea.  
4 ea.  
701156  
1 ea.  
5 ea.  
701157  
1 ea.  
6 ea.  
701158  
1 ea.  
7 ea.  
701159  
1 ea.  
8 ea.  
701160  
MAIN BURNER ORIFICE-CONSULT  
CROWN REPRESENTATIVE FOR  
CORRECT SIZE  
63  
2 ea.  
3 ea.  
4 ea.  
5 ea.  
6 ea.  
7 ea.  
8 ea.  
9 ea.  
64  
65  
66  
67  
*
ORIFICE HITCH PIN  
950370  
1 ea.  
1 ea.  
2 ea.  
700503  
700523  
2 ea.  
3 ea.  
700504  
700524  
2 ea.  
4 ea.  
700505  
700525  
2 ea.  
5 ea.  
700506  
700526  
2 ea.  
6 ea.  
700507  
700527  
3 ea.  
7 ea.  
700508  
700528  
3 ea.  
8 ea.  
700509  
700529  
3 ea.  
9 ea.  
700510  
700530  
3 ea.  
LOWER INJECTION SHIELD  
UPPER INJECTION SHIELD  
1/4-20 BRASS WING NUT  
10-32 x 3/16" SCREW  
146-95-301  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
* NOT PICTURED  
36  
1” BURNER COMPONENTS  
50mm BURNER COMPONENTS  
37  
QTY. OR  
CROWN P.N.  
1 ea.  
QUANTITY PER BOILER OR CROWN P.N.  
KEY #  
DESCRIPTION  
262  
295  
37  
61  
95  
128  
162  
195  
229  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
90  
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  
700301  
700300  
700302  
700322  
700362  
700352  
700372  
700382  
2 ea.  
2 ea.  
26 ea.  
2 ea.  
2 ea.  
96-030  
1 ea.  
700301  
700300  
700303  
700323  
700363  
700353  
700373  
700383  
2 ea.  
2 ea.  
26 ea.  
2 ea.  
2 ea.  
96-030  
1 ea.  
700301  
700300  
700304  
700324  
700364  
700354  
700374  
700384  
2 ea.  
700301  
700300  
700305  
700325  
700365  
700355  
700375  
700385  
2 ea.  
700301 7003015 7003015 7003015 7003015  
700300 7003005 7003005 7003005 7003005  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
800340  
800341  
90-212  
90-210  
90-211  
700306  
700326  
700366  
700356  
700376  
700386  
2 ea.  
700307  
700327  
700367  
700357  
700377  
700387  
2 ea.  
700308  
700328  
700368  
700358  
700378  
700388  
2 ea.  
700309  
700329  
700369  
700359  
700379  
700389  
2 ea.  
2 ea.  
27 ea.  
2 ea.  
700310  
700330  
700370  
700360  
700380  
700390  
2 ea.  
2 ea.  
27 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
26 ea.  
2 ea.  
26 ea.  
2 ea.  
27 ea.  
2 ea.  
27 ea.  
2 ea.  
27 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
2 ea.  
96-035  
1 ea.  
2 ea.  
96-035  
1 ea.  
1 ea.  
96-031  
1 ea.  
96-032  
1 ea.  
96-032  
1 ea.  
96-033  
1 ea.  
96-033  
1 ea.  
1/2" LONG WELL  
35-1006  
35-3000  
35-5000  
(S8600F1000)  
35-5050  
(S8600M1013)  
905000  
95-038  
AQUASTAT (L8148E1257)  
IGNITION MODULE (E.I. BOILERS)  
(NATURAL GAS ONLY)  
IGNITION MODULE (E.I. BOILERS)  
(NATURAL OR LP GAS)  
MODULE BRACKET (E.I. BOILERS)  
TRIDICATOR GUAGE  
3/4" RELIEF VALVE (30 psi)  
CIRCULATOR (TACO 007)  
TACO FLANGE SET  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
*
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
*
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
*
91  
92  
93  
94  
95  
96  
*
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
4 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
1 ea.  
95-040  
95-012  
95-014  
95-041  
3/4" BOILER DRAIN  
8-32 X 1/2" SELF TAPPING SCREW  
DAMPER WIRE HARNESS  
AQUASTAT - R.O. SWITCH HARNESS  
SPILL SWITCH HARNESS  
INTERMITTENT IGNITION HARNESS  
GROUND WIRE HARNESS (EI ONLY)  
90-223  
9601250  
9601200  
9601270  
9601100  
9601101  
*
*
*
*
* NOT PICTURED  
38  
Jacket/Components  
39  
CROWN  
Boiler Co  
Manufacturer of Hydronic Heatings Products  
P.O. Box 14818 3633 I. Street  
Philadelphia, PA 19134  

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