Crown Boiler AWR Guide

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 ammable 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 re department.
-Installation and service must be performed
by a qualied installer, service agency, or the
gas supplier.
WARNING: If the information in this
manual is not followed exactly, a re 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 inammables
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
DESIGNED TO LEAD

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 qualied 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 bers (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-
xed to the boiler.
WARNING

• In the event that the ame rollout switch opens, the cause of the ame rollout must be diagnosed and cor-
rected by a qualied 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 re, there is either
a problem with the igntion system, an occurrence of ame rollout, or a problem with the vent system.
Call a qualied 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.
1

Figure 2: Blocked Vent SwitchFigure 1: Flame Rollout Switch
3) All boilers except the CWD and BWC boilers are equipped with a ame rollout switch (Figure 1). This
switch will shut the burners down in the event that ames 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 ames exit the combustion chamber. If the boiler fails to re, call a qualied
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.
5) 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 qualied 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 ammable or which could obstruct the
ow 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 qualied gas service technician has diagnosed
and corrected the venting problem that caused the blocked vent switch to open.
2

• 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 qualied 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 qualied 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 qualied 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 qualied 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 oat 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.
3
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 oat 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 qualied
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.
4
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 7
Lighting
Instructions on
Page:
Honeywell VR8204 or
VR8304 5
Intermittent Pilot
Robertshaw
7000DERHC 6
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)
5
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.
Do 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)
6
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.
Do 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
ON OFF

107
A. •
C.
B.
D.
•
•
•
1. 5.
2. 6.
3.
4. 7.
8.
9.
10.
1. 3.
2.
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)

8
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
www.crownboiler.com