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TWZ Series
Oil-Fired Hot Water Boilers
InstallatIOn InstructIOns
These instructions must be affixed on or adjacent to the boiler
Models:
tWZ065
•
tWZ075
•
tWZ100
•
tWZ090
•
tWZ125
•
tWZ150
•
tWZ120
•
tWZ175
•
tWZ200
•
D
E S I G N E D
Warning: Improper instal-
lation, 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 oil supplier. Read these
instructions carefully before
installing.
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
L
T O
E A D
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Table of Contents
Related Manuals for Crown TWZ065
Summary of Contents for Crown TWZ065
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Page 1: Installation Instructions
E S I G N E D E A D TWZ Series Oil-Fired Hot Water Boilers InstallatIOn InstructIOns These instructions must be affixed on or adjacent to the boiler Models: tWZ065 • tWZ075 Warning: Improper instal- • lation, adjustment, alteration, tWZ100 •... - Page 3 WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings unless alarms or other safeguards are in place to printed in this manual and posted on the boiler. prevent such damage INSPECT THE BOILER, BURNER AND DO NOT BLOCK AIR FLOW into or around the CONTROLS ANNUALLY.
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Page 4: Table Of Contents
table of contents Product Description ................3 Specifications ..................3 III. Before Installing ..................4 Locating the Boiler ................5 Air for Combustion & Ventilation ............7 Venting ....................11 VII. System Piping ..................13 VIII. Tankless Heater Piping ................17 Fuel Line Piping .................. -
Page 5: Product Description
Number of Input Capacity I=B=R Net Water Dimensions (inches) Boiler Model Sections (Gal/hr) (Btu/hr) Rating (Btu/hr) AFUE (%) Content (Gal) "A" "B" "C" TWZ065 0.65 80000 70000 86.1 16.0 17-3/8 8 5/16 TWZ075 0.75 91000 79000 85.8 16.0 17-3/8 8 5/16 TWZ100 1.00... -
Page 6: Before Installing
Crown Boiler Company recommends the use of a chimney to vent the TWZ series boilers. If a power venter must be used, it is the responsibility of the installer and power vent manufacturer to “engineer” the power vent system. crOWn BOIlEr cOMPanY WIll assuME nO rEsPOnsIBIlItY FOr DaMaGE tO sIDInG, Etc. -
Page 7: Locating The Boiler
IV locating the Boiler WARNING FAILURE TO OBSERVE THE FOLLOWING LOCATION REQUIREMENTS COULD RESULT IN PROPERTY DAMAGE, A FIRE, EXPLOSION OR CARBON MONOXIDE (CO) HAZARD. 1) Clearances: • Observe the minimum clearances shown below. Except as noted, these clearances apply to all combustible con- struction, as well as noncombustible walls, ceilings and doors. - Page 8 FIGurE 4.1: InstallatIOn OVEr a cOMBustIBlE FlOOr...
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Page 9: Air For Combustion & Ventilation
V air for combustion and Ventilation WARNING • INSUFFICIENT COMBUSTION AIR SUPPLY MAY RESULT IN THE PRODUCTION AND RELEASE OF SOOT OR DEADLY CARBON MONOXIDE (CO) INTO THE HOME WHICH CAN CAUSE PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH. • THIS BOILER IS NOT DESIGNED FOR USE IN A SPACE THAT IS DEPRESSURIZED RELATIVE TO THE OUTDOORS. OPERATING THIS BOILER IN A DEPRESSURIZED SPACE MAY CAUSE PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH. - Page 10 FIGurE 5.0: BOIlEr InstallED In cOnFInED sPacE, all aIr FrOM InsIDE 2) Unconfined Space - Natural infiltration into the boiler room will normally provide adequate air for combustion and venti- lation 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”...
- Page 11 FIGurE 5.1: all aIr FrOM OutDOOrs, VEntIlatED craWl sPacE anD attIc FIGurE 5.2: all aIr FrOM OutDOOrs, VIa VEntIlatED attIc...
- Page 12 FIGurE 5.3: all aIr FrOM OutDOOrs, usInG OPEnInGs IntO BOIlEr rOOM FIGurE 5.4: all aIr FrOM OutDOOrs, usInG HOrIZOntal Ducts IntO BOIlEr rOOM...
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Page 13: Venting
VI Venting WARNING • IMPROPER VENTING MAY RESULT IN PROPERTY DAMAGE AND/OR THE RELEASE OF FLUE GASES, WHICH CONTAIN DEADLY CARBON MONOXIDE (CO), INTO THE HOME, WHICH CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. • INSPECT EXISTING CHIMNEY BEFORE INSTALLING BOILER. FAILURE TO CLEAN OR REPLACE DAMAGED PIPE OR TILE LINING WILL CAUSE PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH. Vent installation must be in accordance with local building codes, or the local authority having jurisdiction. - Page 14 Crown Boiler Company recommends the use of a chimney to vent the TWZ series boilers. If a power venter must be used, it is the responsibility of the installer and power vent manufacturer to “engineer” the power vent system. crOWn BOIlEr cOMPanY WIll assuME nO rEsPOnsIBIlItY FOr DaMaGE tO sIDInG, Etc.
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Page 15: System Piping
VII system Piping WARNING • INSTALL BOILER SO THAT THE ELECTRICAL COMPONENTS ARE PROTECTED FROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERATION AND SERVICE (CIRCULATOR REPLACEMENT, ETC.). • OPERATION OF THIS BOILER WITH CONTINUOUS RETURN TEMPERATURES BELOW 120°F CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. • OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. - Page 16 1) Relief valve (Required) - Mount the relief valve on the top left side of the boiler as shown in Figure 7.1 using the 3/4” nipple provided. The relief valve shipped with the boiler is set to open at 30 psi. This valve may be replaced with one having a pressure up to the “Maximum Allowable Working Pressure”...
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Page 17: Piping For Special Situations
FIGurE 7.2: InDIrEct WatEr HEatEr BOIlEr sIDE PIPInG FIGurE 7.3: BOIlEr BYPass PIPInG Piping for special situations Certain types of heating systems have additional requirements. Some of the more common variations follow: 1) Indirect Water Heaters - Figure 7.2 shows typical indirect water heater piping. Boiler piping is the same as for any two- zone system. - Page 18 3) Low Temperature Systems - Some systems, such as radiant tubing systems, require the system water temperature to be limited to a value below the temperature of the water leaving the TWZ. These systems also typically have return temperatures well below the 120°F minimum. Figure 7.4 illustrates the use of a heat exchanger to connect the TWZ boiler to this type of system.
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Page 19: Tankless Heater Piping
VIII tankless Heater Piping If the TWZ is installed with an optional tankless heater, pipe the heater as shown in Figure 8.1. The components in this system and their functions are as follows: 1) Mixing Valve (Required) - During the heating season, the water exiting the tankless heater may be 180 degrees or more. The mixing valve blends hot water leaving the tankless heater with cold water so as to maintain the hot water supplied to the fixtures at a fixed temperature. -
Page 20: Fuel Line Piping
FIGurE 8.1: tanKlEss HEatEr PIPInG IX Fuel line Piping WARNING • UNDER NO CIRCUMSTANCES CAN COPPER WITH SWEAT STYLE CONNECTORS BE USED. • DO NOT USE COMPRESSION FITTINGS. • OIL PIPING MUST BE ABSOLUTELY AIRTIGHT OR LEAKS OR LOSS OF PRIME MAY RESULT. • SOME JURISDICTIONS REQUIRE THE USE OF A FUSIBLE SHUTOFF VALVE AT THE TANK AND/OR THE BURNER. IN ADDITION, SOME JURISDICTIONS REQUIRE THE USE OF A FUSIBLE ELECTRICAL INTERLOCK WITH THE BURNER CIRCUIT. CHECK YOUR LOCAL CODES FOR SPECIAL REQUIREMENTS. - Page 21 FIGurE 9.1: OnE-PIPE GraVItY sYstEM Depending on the location of the fuel oil storage tank in relation to an oil burner, there are four types of oil piping systems generally being used: a) ONE-PIPE GRAVITY SYSTEM - used when a fuel oil storage tank is positioned above an oil burner fuel pump. See Figure 9.1.
- Page 22 3” - 4” above suction line depth within the storage tank. Refer to the pump manufacturer’s instructions for tube sizing information. 8) All systems require an oil filter. On TWZ065 and TWZ075 boilers, the use of a Garber cartridge type filter is recommended.
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Page 23: Wiring
FIGurE 9.4: tWO-PIPE lIFt sYstEM X Wiring WARNING • All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70). • Disconnect electrical power to the boiler and heating system before servicing. Positively assure that no voltage is present. -
Page 24: Thermostat Wiring
• 1,2,3 - Used to connect EnviraCom thermostat, or other EnviraCOM device, approved by Crown for use with this boiler (refer to instructions provided with EnviraCOM device). 3) Adding a Second Circulator Zone - The control provided on TWZ boilers can be used to control a second heating or DHW circulator zone. - Page 25 FIGurE 10.0: cOnnEctIOns DIaGraM, BOIlErs lEss tanKlEss HEatEr, cOlD start cOntrOl...
- Page 26 FIGurE 10.1: cOnnEctIOns DIaGraM, BOIlErs WItH tanKlEss HEatEr, WarM start cOntrOl...
- Page 27 riello 530sE: Beckett 7505: carlin 40200: FIGurE 10.2: cOnnEctIOns DIaGraM FOr BurnEr PrIMarY cOntrOls...
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Page 28: Start-Up & Checkout
XI start-up and checkout Use the following procedure for initial start-up of the boiler: WARNI NG • Never attempt to fill a hot empty boiler. • Make sure that the area around the boiler is clear and free from combustible materials, gasoline, and other flammable vapors and liquids. - Page 29 ATTEMPTS TO USE BURNERS OR BURNER CONFIGURATIONS OTHER THAN THOSE SHOWN IN TABLE 3 COULD RESULT IN RELIABILITY PROBLEMS, PROPERTY DAMAGE OR UNSAFE OPERATION. taBlE 11.0a: BEcKEtt BurnEr cOnFIGuratIOn anD sEtuP Data BOILER MODEL TWZ065 TWZ075 TWZ100 TWZ090 TWZ125 TWZ150...
- Page 30 11.0b: carlIn BurnEr cOnFIGuratIOn anD sEtuP Data BOILER MODEL TWZ065 TWZ075 TWZ100 TWZ090 TWZ125 TWZ150 TWZ120 TWZ175 TWZ200 BURNER MODEL EZ-1HP EZ-1HP EZ-1HP EZ-1HP EZ-1HP EZ-1HP EZ-1HP EZ-2HP STANDARD DEL. HAGO HAGO DEL. DEL. HAGO HAGO DEL. NOZZLE 0.55/70B 0.60/60ES 0.85/60B 0.75/60A...
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Page 31: Operation
Crown offers a low water cut-off kit that may be used with this control (PN 411000). Specific information on this kit, along with installation and operating instructions, are available through Crown distributors and at www.crownboiler.com. - Page 32 FIGurE 12.1: BOIlEr cOntrOl MEnu STATUS MODE: =Current Status (Table 12.2) Press and Hold I, ↑, and ↓ for at least 3 sec to Press I to enter OPERATING MODE enter ADJUSTMENT MODE = High Limit Setting = Current Boiler Temp. ...
- Page 33 taBlE 12.2: status cODEs Status # Description Meaning No call for heat or DHW Standby Call for heat present , but boiler is in thermal purge (See on page 11) Call for heat/DHW present but boiler temperature is above set point (SP) setting. The burner is running Burner Demand The burner is off due to an open limit (such as an external high limit or LWCO)
- Page 34 taBlE 12.5a: aDJustMEnt MODE ParaMEtErs FOr l7248l - cOlD start cOntrOl Factory Status # Description Setting Permissible Range High Limit Set Point 180F 140-240F High Limit Differential 10-30F dh (DHW) Zr (2nd Heating Zone) ZC and ZR Terminal Function ELL (“External Low Limit” - NOT RECOMMENDED) Circulator Overrun 0 min...
- Page 35 c. using adjustment Mode WARNING Improper adjustments to control parameters could result in unreliable boiler operation, property damage, personal injury, or loss of life. Adjustments should only be made by a qualified heating technician. A list of parameters which can be changed on this control are shown in Table 12.5. To enter Adjustment mode and change parameters: 1) Press and hold I, ↑, ↓...
- Page 36 Or (Circulator Overrun) - Determines how long the Heating Circulator will operate after the call for heat ends. In some cases, this can help reduce energy consumption by sending heat stored in the boiler out into the system. At the same time, caution should be exercised before setting this value to something other than zero.
- Page 37 St (Thermal Purge Start Temperature) - See description for Thermal Purge Time above. Pt (DHW Priority) - If this feature is turned on, and simultaneous calls for heat and DHW are present, the heating circulator will be forced off for as long as it takes the boiler to satisfy the call for DHW. This feature is sometimes useful when the boiler size is marginal for the peak DHW demand, but should be used with caution as it can result in lack of heat if the DHW call is very long, or if there is a problem with the DHW zone which causes the DHW demand to be indefinite.
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Page 38: Service & Maintenance
XIII service and Maintenance WARNING All boiler cleaning must be completed with the burner service switch turned off. Boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. - Page 39 WARNING The boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions.
- Page 40 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Parts list designates parts that contain refractory ceramic fibers (RCF). RFC has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RFC changes into crystalline silica, a known carcinogen.
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Page 41: Troubleshooting
2) Flame Shape - As seen for the observation port, the flame should appear straight with no sparklers rolling up toward the crown of the chamber. If the flame drags to the right or left, sends sparklers upward or makes wet spots on the chamber walls, the nozzle should be replaced. - Page 42 B. control system The following pages contain trouble shooting tables for use in diagnosing control problems. When using these tables the following should be kept in mind: 1) This information is only meant to be used by a professional heating technician as an aid in diagnosing boiler problems. 2) Where applicable, follow all precautions outlined in the Section XI (Start-up and Checkout).
- Page 43 taBlE 14.1 - Faults WItHOut ErrOr cODE PrEsEnt Displayed Codes Problem Possible Cause • Thermostat/s not calling for heat StA 1 Burner and • Loose connection in thermostat, zone valve end switch, or zone panel wiring. hr OFF Circulator Off •...
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Page 44: Parts
XV Parts QUanTiTY PEr BOiLEr Or CrOWn P.n. QTY. Or CrOWn KEY # DESCriPTiOn P.n. HEAT EXCH ASSY. WITH COIL OPENING 1 ea. 270013 270013 270013 270014 270014 270014 270015 270015 270015 HEAT EXCH ASSY. LESS COIL OPENING 1 ea. - Page 46 QUanTiTY PEr BOiLEr Or CrOWn P.n. QTY. Or CrOWn KEY # DESCriPTiOn P.n. REVERSIBLE SIDE JACKET PANEL (RED) 2 ea. 270523 270523 270523 270524 270524 270524 270525 270525 270525 REVERSIBLE SIDE JACKET PANEL (GRAY) 2 ea. 290223 290223 290223 290224...
- Page 48 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com PN: 980270 Rev 10 TWZ - 12/12...