Crown AWI128 User Manual
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause property
damage, injury, or loss of life.
For assistance or additional
information, consult a qualified
installer, service agency or the
gas supplier. Read these instructions carefully before installing.
D
ESIGNED TO
L
EAD
AWI & TWI Series
Gas-Fired Natural Draft Hot Water Boilers
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Models:
• AWI037
• AWI061
• AWI095
• AWI128
• AWI162
• AWI195
• AWI229
• AWI262
• AWI295
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
7HO)D[ZZZFURZQERLOHUFRP
• TWI061
• TWI095
• TWI128
• TWI162
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Table of Contents
I. Product Description .................................................. 1
II. Specifications ............................................................ 1
III. Before Installing ........................................................ 4
IV. Locating the Boiler .................................................... 4
V. Air for Combustion & Ventilation............................. 5
VI. Venting ...................................................................... 8
VII. Gas Piping............................................................... 11
VIII. System Piping ............................................. 12
IX. Wiring......................................................... 16
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
FIGURE 1A: STANDARD CONFIGURATION (SEE PAGE 3 FOR LETTER DIMENSIONS)
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FIGURE 1B: “LEFT PIPED” CONFIGURATION
FIGURE 1C: “TOP PIPED” (T-AWI OR T-TWI) CONFIGURATION
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TABLE 1: SPECIFICATIONS
RATINGS - NATURAL AND LP GASES* DIMENSIONS (INCHES)
BASIC
BOILER
MODEL
AWI037S
AWI037E
AWI061S
AWI061E
AWI095S
AWI095E
AWI128S
AWI128E
AWI162S
AWI162E
AWI195S
AWI195E
AWI229S
AWI229E
AWI262S
AWI262E
DOE
NUMBER
OF
SECTIONS
237 30 26
361 50 43
495 78 68
5 128 105 91
6 162 132 115
7 195 159 138
8 229 186 162
9 262 212 184
INPUT
MBH MBH MBH %
HEATING
CAPACITY
I= B= R N E T
RA TING,
WATER
AFUE
80.0
82.3
80.0
82.6
80.1
82.3
80.2
82.0
80.3
81.7
80.4
81.4
80.4
81.2
80.5
80.9
"A" "B" "C" "D" "E" "F"
10-1/2
11-3/4 5-7/8 4 3-5/8 1-7/8
27-7/8
15 7-1/2 5 4-1/8 1-7/8
18-1/4 9-1/8 6 4-5/8 1-7/8
21-1/2 10-3/4 6 4-5/8 1-7/8
24-3/4
28 14 7 5-1/8 1-7/8
29-7/8
31-1/4 15-5/8 8 5-5/8 1-7/8
7-1/4 4 3-5/8 3-7/8
12-3/8 7 5-1/8 1-7/8
AWI295S
AWI295E
BASIC
BOILER
MODEL
TWI061E 3 61 51 44 83.0 1 1-3/4
TWI095E 4 95 79 69 83.0 15 7-1/2 5 4-1/8 1-7/8
TWI128E 5 128 106 92 83.0 18-1/4 9-1/8 6 4-5/8 1-7/8
TWI162E 6 162 134 117 83.0 21-1/2 10-3/4 6 4-5/8 1-7/8
Notes:
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)
10 295 238 207
RATIN G S - N ATURAL GAS O N LY DIMENSI O NS ( INC HES )
NUMBER
OF
SECTIONS
INPUT
MBH MBH MBH %
DOE
HEATING
CAPACITY
I= B= R N E T
RA TING,
WATER
80.7
80.6
AFUE
34-1/2 17-1/4 8 5-5/8 1-7/8
"A" "B" "C" "D" "E" "F"
5-7/8 4 3-5/8 1-7/8
27-7/8
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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 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 instructions
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.
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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, 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.
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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 BTU/hr. If the result is less than 50, the boiler
room is a
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 ft
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).
confined space.
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• 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”.
FIGURE 3: BOILER INSTALLED IN CONFINED SPACE,
ALL AIR FROM INSIDE
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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, 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.
FIGURE 4: ALL AIR FROM OUTDOORS,
VENTILATED CRAWL SPACE AND ATTIC
FIGURE 5: ALL AIR FROM OUTDOORS,
VIA VENTILATED ATTIC
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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,
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.
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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 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 be 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.
7) Do not connect the boiler into a chimney flue serving an open fireplace or other solid fuel appliance.
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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 than 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.
RIGHT SIDE VIEW
FIGURE 9: VENT DAMPER INSTALLATION DETAILS
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
connected to the common venting system are not in operation.
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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 fireplace
dampers.
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
the National Fuel Gas Code, ANSI Z223.1.
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.
FIGURE 10: GAS CONNECTION TO BOILER
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*
* State of Massachusetts Requires
Manual Shut-off Valve to be “T” Handle
Type
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