Crown Boiler AWR User's Information Manual

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PN 980425 REV O

USERS’ INFORMATION MANUAL

TO THE BOILER OWNER:

READ THIS MANUAL IMMEDIATELY AFTER THIS BOILER IS

PLACED IN SERVICE AND RETAIN IT FOR FUTURE REFERENCE.

GAS WATER BOILERS: AWR, CWI, BWF, CWD, BWC

GAS STEAM BOILER: BSI SERIES

-Do not store gasoline or other flammable va

pors and liquids in the vicinity of this or any

other appliance.

-What to do if you smell gas:

· Do not try to light any appliance

· Do not touch any electrical 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.

· If you cannot reach your gas supplier,

call the fire department.

-Installation and service must be performed

by a qualified installer, service agency, or the

gas supplier.

WARNING:

If the information in this

manual is not followed exactly, a fire or ex

plosion may result causing property damage,

personal injury or loss of life.

- Ne pas entreposer ni utiliser d’essence ni

d’autres vapeurs ou liquides inflammables

dans le voisinage de cet appareil ou de tout

autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE

ODEUR DE GAZ:

· Ne pas tenter d’allumer d’appareils.

· Ne touchez à aucun interrupteur. Ne pas

vous servir des téléphones dans le bâti

ment où vous vous trouvez.

· Appelez immédiatement votre

fournisseur de gaz depuis un voisin.

Suivez les instructions du fournisseur.

· Si vous ne pouvez rejoindre le

fournisseur de gaz, appelez le service des

incendies.

L’installation et I’entretien doivent être as

suréx

par un installateur ou un service d’entretien

AVERTISSEMENT

. Assurez-vous de bien

suivre les instructions données dans cette

notice pour réduire au minimum le risque

d’incendie ou d’explosion ou pour éviter

tout dommage matériel, toute blessure ou la

E S I G N E D T O

E A D

DANGER

THERE ARE NO USER SERVICABLE PARTS ON THIS BOILER. ATTEMPTS TO

SERVICE THIS BOILER BY SOMEONE OTHER THAN A QUALIFIED GAS SER-

VICE TECHNICIAN COULD VOID THE WARRANTY, CAUSE PROPERTY

DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

•

Do not use this boiler if any part has been under water. Immediately call a qualified service technician

to inspect the boiler and to replace any part of the control system and any gas control which has been

under water.

•

Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical

supply to the pump. Instead shut off the gas supply at a location external to the appliance/En cas de

surchauffe ou si l’admission de gaz ne peut étre coupée, ne pas couper ni débrancher l’alimentation

électrique de la pompe. Fermer plutot le robinet d’admission de gaz à l’extérieur de l’appareil.

•

This boiler may have parts containing refractory ceramic fibers (RCF). See the safety information on

page 11 if this boiler must be serviced or repaired.

CAUTION

Like all central heating appliances, this boiler is equipped with safety devices, which could cause it to shutdown,

requiring service to restore normal operation. Where such a shutdown could result in damage from low temperatures

(such as frozen pipes), do not leave the heating system unattended during cold weather unless alarms or other safe

guards are in place to prevent damage.

1) This manual covers the proper care and use of the following boilers:

•

AWR “Aruba IV” series gas water boiler

•

CWI “Cayman” series gas water boiler

•

BWF “Bali” series fan assisted water boiler

•

CWD “Cabo2” series gas direct vent water boiler

•

BWC “Bimini” series gas condensing direct vent water boiler

•

BSI “Bermuda” series gas steam boiler

Most of the information in this manual applies to all of the above boilers. Information that is unique to a par

ticular series is clearly marked with the series to which it applies.

2) Instructions to safely light and shut down this boiler are shown on pages 5 - 7, as well as on a label af

fixed to the boiler.

WARNING

•

In the event that the flame rollout switch opens, the cause of the flame rollout must be diagnosed and cor

rected by a qualified gas service technician before the boiler is restarted.

•

In the event that the ignition system on a CWD or BWC does not permit the boiler to fire, there is either

a problem with the igntion system, an occurrence of flame rollout, or a problem with the vent system.

Call a qualified gas service technician to diagnose and correct the problem.

•

A “tripped” rollout switch must be replaced by an identical switch having the same temperature setting.

Figure 2: Blocked Vent Switch

Figure 1: Flame Rollout Switch

3) All boilers except the CWD and BWC boilers are equipped with a flame rollout switch (Figure 1). This

switch will shut the burners down in the event that flames exit the burner compartment through the front

opening. The CWD and BWC use an electronic means built into the ignition system to extinguish the

burner/s in the event that flames exit the combustion chamber. If the boiler fails to fire, call a qualified

heating service agency to diagnose and correct the problem.

4) The AWR, CWI and BSI boilers are equipped with a blocked vent shut-off switch (Figure 2). This switch

will shut the boiler down in the event that there is an excessive blockage in the vent system. This switch

has a reset button, which must be pressed before the boiler can be restarted.

BWF, CWD, BWC Series boilers –

These boilers are equipped with a safety feature which will shut

down the burners in the event that there is a blockage in the vent system. In the event that the boiler fails

to function, and the boiler is vented through an outside wall accessible from the ground, inspect the vent

terminal on the outside wall for a blockage such as a bee’s nest or ice. If a blockage is found, the burners

should ignite approximately 30 seconds after the blockage is removed. If no blockage is found, or if the

terminal is inaccessible from the ground, the problem must be diagnosed and corrected by a qualified gas

service technician.

Maintenance

1) Safe reliable operation of this boiler depends upon proper periodic maintenance.

2) The following should be done on a

continuous basis

•

Keep the area around the boiler free of objects, which are flammable or which could obstruct the

flow of air into and around the boiler.

WARNING

A shutdown of the burners due to the blocked vent switch is an indication that there is a problem with the vent system,

such as a blockage. The blocked vent switch should only be reset after a qualified gas service technician has diagnosed

and corrected the venting problem that caused the blocked vent switch to open.

•

Do not store or use sources of hydrocarbons such as bleaches, fabric softeners, paints, cleaners,

refrigerants, and cat boxes near the boiler. Traces of these chemicals can be drawn into the boiler,

causing severe corrosion damage to the boiler and/or objectionable odors.

•

Do not expose the boiler to large amounts of dust such as that generated by dry wall construction or

woodworking.

3) A qualified gas service technician should perform the maintenance procedure shown in the installation

manual on an

annual basis

4) The owner should visually inspect the venting system on a

monthly basis

. If any of the following condi

tions are found, the boiler should be shut down and a qualified gas service technician called to correct the

problem before the boiler is placed back in service:

•

Loose joints, corrosion or other deterioration

•

Condensate leakage

•

Sags in horizontal runs of vent pipe

WARNING

Carbon (“soot”) in or near the burner compartment area is an indication of a potential carbon monoxide hazard. If

carbon is found, the boiler should be shut down immediately and inspected by a qualified gas service technician.

The

cause of the sooting should be found and corrected before the boiler is restarted.

5) The owner should also perform a

monthly

visual inspection of the boiler and the surrounding system

piping. To do this, remove the boiler jacket door. If any of the following are found, a qualified gas ser

vice technician should be consulted immediately:

•

Deterioration of the visible controls, wiring, and sheet metal components

•

Heating system water Leaks

•

Carbon (“soot”) in or near the burner compartment area

•

(BWC Boilers Only) - Make sure that the condensate drain system is unobstructed and leak

tight.

6) BSI Series Boilers Only – Steam boilers require the following maintenance:

•

Some steam boilers are equipped with a float type low water cut-off (Figure 3). This control

must be “blown down” on a

weekly basis, or more often if needed

. To do this, follow the

instructions on the label adjacent to the low water cut-off.

•

It will occasionally be necessary to add water to the boiler. In most cases this will be true even

if the boiler is equipped with an automatic water feeder (most automatic water feeders maintain

the water level at the minimum point required to assure boiler operation). On a

monthly basis

turn the boiler off and wait at least 10 minutes for any water in the system to return to the boiler.

Add water to the boiler until the water level in the glass is approximately 6” (about 3/4 of the

way) from the bottom of the glass.

CAUTION - BWC BOILERS

The BWC has a heat exchanger made from a special aluminum alloy which can be severely damaged by frequent addi

tions of water or by the addition of boiler water additives which are not designed for use with aluminum boilers. If it is

nessasary to add water to the boiler, have a service technican check the system for leaks. Do not add any chemicals to

the boiler not listed in the BWC installation manual. Warranty is void if the service and maintenance procedure shown

in the BWC installation manual is not followed.

CAUTION

•

Failure to regularly blow down the float type low water cut-off can result in severe damage to boiler.

•

If it is necessary to either manually or automatically add water to the boiler more than once a month, a qualified

gas service technician should inspect the system for leaks or defective vents. Frequent additions of fresh water

could result in severe damage to boiler.

Lighting Instructions

Lighting instructions for all boilers appear on the following pages. These instructions are listed by the model of the

gas valve used. The table below references the boiler model to the gas valve used and the page on which the appropri

ate lighting instructions may be found.

Figure 3: Float Type Low Water Cut-off

Boiler Model

Ignition System

Gas Valve *

AWR038E - AWR280E

CWI103E - CWI346E

BSI069E - BSI346E

BWF069E - BWF229E

CWD060 - CWD245

CWI-380E

BSI-380E

* Gas valve numbers are to reference lighting instructions only. Do not use this chart as a

replacement parts list.

BWC070-BWC425

Direct Spark

Honeywell VK8115 or

Dungs GB-WND

Lighting

Instructions on

Page:

Honeywell VR8204 or

VR8304

Intermittent Pilot

Robertshaw

7000DERHC

7) Auxilary Controls – Many boilers are installed with equipment not supplied with the boiler, but which is criti

cal for safe, reliable operation of the boiler. Some examples of this type of equipment include:

•

Zone Controls

•

Boiler Feed Pumps

•

Draft Inducers and Power Venters

•

Motorized Combustion Air Louvers

Make sure that this equipment is maintained in accordance with its manufacturer’s instructions.

LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEYWELL

VR8204 AND VR8304 SERIES GAS VALVES (INTERMITTENT PILOT)

A. This appliance is equipped with an ignition

device which automatically lights the pilot.
Do

try to light the pilot by hand.

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.

not

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.

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.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition

device which automatically lights the pilot.

try to light the pilot by hand.

not

5. Remove front access panel.

6. Rotate the gas control knob clockwise

to OFF.

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.

8. Rotate the gas control knob counter clockwise

to “ON”.

9. Replace front access panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the

instructions “To Turn Off Gas To Appliance” and
call your service technician or gas supplier.

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if

service is to be performed.

3. Push in gas control knob slightly and turn

clockwise

to “OFF”. Do not Force.

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life.

TO TURN OFF GAS TO APPLIANCE

FOR YOUR SAFETY READ BEFORE OPERATING

GAS OUTLET

GAS CONTROL KNOB
(SHOWN IN “ON” POSITION)

GAS INLET

GAS VALVE - TOP VIEW

LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH ROBERT-

SHAW 7000DERHC SERIES GAS VALVES (INTERMITTENT PILOT)

A. This appliance is equipped with an ignition

device which automatically lights the pilot.
Do

try to light the pilot by hand.

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

not

If you cannot reach your gas supplier, call
the fire department.

C. Use only your hand to push in or turn the gas

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.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition

device which automatically lights the pilot.

try to light the pilot by hand.

not

5. Remove front access panel.

6. Rotate the gas control knob clockwise

to OFF.

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.

8. Rotate the gas control knob counter clockwise

to “ON”.

9. Replace front access panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the

instructions “To Turn Off Gas To Appliance” and
call your service technician or gas supplier.

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if

service is to be performed.

3. Push in gas control knob slightly and turn

clockwise

to “OFF”. Do not Force.

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life.

TO TURN OFF GAS TO APPLIANCE

FOR YOUR SAFETY READ BEFORE LIGHTING

GAS

INLET

GAS CONTROL KNOB

SHOWN IN "OFF" POSITION

POSITION

INDICATOR

OFF

•

•
•

10.

FOR YOUR SAFETY READ BEFORE LIGHTING

This appliance does not have a pilot. It is

equipped with an ignition device which

automatically lights the burner. Do not try

to light the burner by hand.

Do not touch any electric switch; do

not use any phone in your building.

If you cannot reach your gas supplier, call the

fire department.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

WARNING: If you do not follow these instructions exactly, a fire or explosion may

result causing property damage, personal injury or loss of life.

Immediately call your gas supplier

from a neighbor's phone. Follow the

gas supplier's instructions.

Use only your hand to 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.

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

BEFORE OPERATING 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.

STOP! Read the safety information above on

this label.

Set the thermostat to the lowest setting.

Turn off all electric power to the appliance.

This appliance is equipped with an ignition

device which automatically lights the burner.

Do not try to light the burner by hand.

TO TURN OFF GAS TO THE APPLIANCE

Smell for gas in the boiler enclosure. If you smell gas,

STOP! Follow "B" in the safety information above. If

you don't smell gas, go to the next step.

Turn on all electric power to the appliance.

Set the thermostat to the desired setting.

The first digit of the control display panel will

show a series of numbers that indicate the boiler

control sequence. The number 3 or 4 means the

burner is firing. The number 0 means there is no

call for heat from the thermostat or the domestic

water heater.

Turn off all electric power to the appliance if

service is to be performed.

Set the thermostat to the lowest setting.

Turn the external boiler manual gas valve T-

handle counterclockwise to open gas supply.

↶

Turn the external boiler manual gas valve T-

handle clockwise to close the gas supply.

↷

If the appliance will not operate, follow the

instructions "To Turn Off Gas To Appliance" below

and call your service technician or gas supplier.

LIGHTING INSTRUCTIONS FOR BOILERS EQUIPPED WITH HONEY-

WELL VK8115 OR DUNGS GB-WND SERIES GAS VALVES

(DIRECT SPARK)

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning

This boiler may include parts that contain refractory ceramic fibers (RCF).

RCF has been classified as a possible human carcinogen. When exposed to

temperatures about 1805°F, such as during direct flame contact, RCF changes

into crystalline silica, a known carcinogen. When disturbed as a result of

servicing or repair, these substances become airborne and, if inhaled, may be

hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures

Do not remove or replace RCF parts or attempt any service or repair work

involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH)

approved respirator

2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection

•  Take steps to assure adequate ventilation.
•  Wash all exposed body areas gently with soap and water after contact.
•  Wash work clothes separately from other laundry and rinse washing

machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF

and crystalline silica are not classified as hazardous wastes in the United

States and Canada.

First Aid Procedures

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing

difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

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