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

AWI262, AWI095, TWI095, AWI195, AWI037 specifications

Crown Boiler is a renowned name in the heating industry, providing high-quality, efficient heating solutions that cater to various residential and commercial needs. Among its impressive lineup, the AWI and TWI series stand out for their design, technology, and performance.

The Crown Boiler AWI061 and TWI061 are part of the Hydronic Boiler range, designed to deliver efficient hot water heating. The AWI series features an advanced pressure-jet design that allows it to operate with exceptional fuel efficiency, reducing operating costs for homeowners and businesses alike. Additionally, these models come equipped with an integrated pump system that ensures a consistent supply of hot water, making them ideal for both space heating and domestic hot water applications.

Meanwhile, the AWI162 and AWI128 models are engineered for higher output, addressing larger heating needs without compromising efficiency. These models showcase a robust heat exchanger made of durable cast iron, promoting longevity and effective heat transfer. The AWI series boilers feature a modern control system that allows for precise temperature management, enhancing comfort while minimizing energy consumption.

The Crown Boiler AWI295, on the other hand, steps up with a significant heating capacity suited for commercial applications. This model is designed with advanced safety and efficiency technologies, including an intelligent control module that monitors temperature and pressure, ensuring optimal performance while preventing malfunctions. The large water volume design allows for enhanced thermal stability and consistent heating output.

A notable characteristic across these models is their ease of installation and maintenance. Crown Boiler has engineered the units with user-friendly features, including accessible components and simplified diagnostics that help technicians service the boilers swiftly. Moreover, the durability of cast iron construction ensures that these units can withstand high thermal stress while delivering reliable performance over the years.

In summary, Crown Boiler’s AWI061, TWI061, AWI162, AWI128, and AWI295 models offer a range of solutions equipped with advanced technologies and features designed for efficiency and reliability. These boilers are suitable for diverse heating needs, promising optimal comfort and convenience in both residential and commercial settings. With Crown Boiler's longstanding commitment to quality, customers can be assured of a robust heating solution backed by exceptional service.