This conversion kit shall be installed by a qualied service agency in accordance
with the manufacturer’s instructions and all applicable codes and requirements
of the authority having jurisdiction. If the information in these instructions is not
followed exactly, a re, an explosion or production of carbon monoxide may result
causing property damage, personal injury, or loss of life. The qualied service
agency is responsible for proper installation of this kit. The installation is not
proper and complete until the operation of the converted appliance is checked as
specied in the manufacturer’s instructions supplied with the kit.
WARNING
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In addition to these instructions, this kit consists of the following items which are factory congured for the fuel to which
the boiler is being converted:
1) Gas Valve
2) Pilot Assembly
3) Main Burner Orice
4) Fuel Conversion Label
5) A copy of the installation manual for the boiler being converted
In addition, some conversion kits also include a main burner with a pilot bracket. This burner is provided when the new
pilot assembly is mounted at a dierent angle than the original pilot. Refer to the “Parts” section of the enclosed boiler installation manual for an illustrated list of all burner and gas train components.
A complete list of the specic parts in each kit is shown in Table 1.
WARNING
Some intermittent ignition-equipped natural gas boilers manufactured before 2005 were supplied with a Honeywell S8600F ignition module. This module is not suitable for use with LP
gas. If the boiler being converted to LP gas is equipped with a Honeywell S8600F, this module must be replaced. Consult Crown Technical Support for the appropriate replacement.
CAUTION
The gas supply shall be shut o prior to disconnecting the electrical power, before proceeding with the conversion.
CAUTION
Orice sizes shown in Tables 1c and 1d are for use at the altitudes indicated in these tables.
Consult the factory for the correct orice size if the boiler is to be installed at a dierent
altitude.
Conversion procedure:
1) Turn o all electrical power to the appliance.
2) Turn o the gas supply upstream of the boiler.
3) Remove the gas valve, main burners, main burner orice, and pilot assembly originally provided with the boiler. On CWD
series boilers, removal of the burners, orice, and pilot assembly is most easily done by rst removing the entire burner tray
from the boiler. To remove the CWD burner tray:
a) Disconnect the gas supply line from the gas valve
b) Unplug the electrical connections at the gas valve and the ignition cable from the ignition module.
c) Remove the Intake Cover (key #39 in the installation manual parts list).
d) Remove the three 10-32 screws holding the Manifold Gasket Plate (key #58) in place. Remove the four 5/16-18 nuts and
washers securing the burner tray in place (keys 8, 9).
e) Remove the burner tray from the boiler.
4) Install the new main burner orices in the manifold. Before doing so, verify that the marking on each orice matches that
specied for the kit in Table 1. This marking is stamped on either a wrench at or the side of the orice in front of the wrench
ats.
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5) Install the new pilot assembly. If a new main burner with a pilot bracket was provided in the kit, discard the old main
burner and mount the pilot on the new main burner.
6) Install the main burners.
7) Install the new gas valve provided with the kit. Reconnect the pilot line and the gas supply. For CWD boilers, reinstall the
burner tray in the boiler. Reconnect all wiring.
8) Purge the gas supply line up to the boiler and check for leaks in accordance with the National Fuel Gas Code (ANS
Z223.1) or the requirements of the authority having jurisdiction.
9) Replace any covers or panels removed during the conversion.
10) Make sure that the boiler and system are lled with water.
11) Verify that vent system is complete and free of obstructions before attempting to re boiler. Make sure that the silicone
cure time called for in the vent assembly instructions has passed before ring boiler.
12) Adjust thermostat to the highest setting.
13) Start the boiler using the lighting instructions on the boiler or in the installation manual’s “Start-up and Check-out”
section.
14) Upon initial start-up, the gas train will be lled with air. Even if the gas line has been completely purged of air, it may
take several tries for ignition before a ame is established. Once a ame has been established for the rst time, subsequent
calls for burner operation should result in a ame on the rst try.
15) Observe pilot burner ame and verify that it matches the illustration shown in the installation manual’s “Start-up and
Check-out” section.
16) Inspect the main burner ame and verify that it matches the illustration shown in the installation manual’s “Start-up and
Check-out” section. The ame should be stable and mostly blue. No yellow tipping should be present; however, intermittent
ecks of yellow and orange in the ame are normal.
17) Check entire gas train for leaks using soap and water or other approved leak detection method while boiler is ring. Fix
any leaks found immediately.
18) 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-ring of the boiler and
death or injury due to carbon monoxide poisoning.
a) Connect a manometer to the inlet pressure tap on the gas valve. For the location of this tap, see the gas valve detail
illustration in the installation manual’s “Start-up and Check-out” section.
b) Check the line pressure with all gas appliances on and o. Verify that the inlet pressure is within the limits shown in
Table 2 regardless of what combination of appliances is ring. If the inlet pressure falls outside of these limits, nd and
correct the cause of the problem before proceeding further.
c) On CWD boilers, disconnect the silicone regulator tube from the hose barb on the gas valve (See Figure 45 in the CWD
installation manual).
d) Connect a manometer to the manifold (outlet) pressure tap on the gas valve. For the location of this tap, see the gas
valve detail illustration in the installation manual’s “Start-up and Check-out” section.
e) Read the manifold pressure. Refer to Table 2 for the appropriate setting.
f) If a manifold pressure adjustment is needed, make the adjustment by turning the regulator screw clockwise to raise
the pressure and counter-clockwise to reduce the pressure. If a manifold pressure adjustment is made, recheck the inlet
pressure to be certain that it is still within acceptable limits. Replace the cover screw on the regulator.
g) On CWD boilers, reconnect the silicone regulator tube disconnected in Step (c)
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10) Use a combustion analyzer to check the CO level in the boiler ue gases. On AWR, AWI, BSI and CWI boilers, sample
the ue gases directly over the heat exchanger (Figure 3). On BWF and CWD series boilers, sample the ue gases by inserting the probe into the vent terminal. The CO level in the ue gases should be less than 50PPM. Possible causes of elevated
CO include, but are not limited to:
• Incorrect manifold pressure
• Incorrect orice size for the fuel type and altitude
• Crooked or out-of-round main burner orice (never attempt to drill orice for these boilers in the eld).
• Partially plugged ue passages
• Foreign material in burner ports or venturis
• Leak in the seal between the ue collector and heat exchanger
• Inadequate combustion air supply
Do not leave the boiler in operation with a CO level in excess of 50PPM - consult the factory if the cause of the elevated
CO level cannot be identied and corrected.
11) Apply the “Boiler Conversion Label” to a conspicuous surface immediately adjacent to the boiler’s rating plate. Fill in the
date of the conversion and the name and address of the company making the conversion with a permanent marker.
12) Refer to the “Start-up and Checkout” section of the boiler installation manual and perform any checks not already completed.
WARNING
Failure to check the CO level in the ue gases or leaving the boiler in operation with an excessive CO level in the ue gases could result in injury or death from carbon monoxide poison-
ing.
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Table 1a: Conversions from NATURAL to LP Gas, Altitudes less than 2000 ft
Kit PNModelsBasic Burner TypeIgnition TypeAltitude (x1000ft)Gas ValvePilot AssyMain Pilot BurnerPNQtySize
300103AWI061S1"Standing Pilot
300107AWI195S1"Standing Pilot