Crown Boiler TWB Series Installation Instructions Manual
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Crown Boiler TWB Series Installation Instructions Manual

Oil-fired hot water boilers
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TWB Series
Oil-Fired Hot Water Boilers
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Improper installation, 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 fuel supplier. Read these instructions carefully before installing, operating, or
servicing this boiler. Keep boiler and any provided component instructions in legible condition and
posted near boiler for reference by owner and service technician.
Models:
Equipped with Hydrolevel
TWB065
•
3250-Plus Control System
TWB075
•
TWB100
•
TWB125
•
TWB150
•
TWB175
•
TWB200
•
980270B Rev 0, 11-20
D
E S I G N E D
L
T O
WARNING
9902339
Crown Boiler Company
P.O. Box 14818
3633 I Street
Philadelphia, PA 19134
www.crownboiler.com
E A D

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February 4, 2025

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Summary of Contents for Crown Boiler TWB Series

  • Page 1 E S I G N E D E A D TWB Series Oil-Fired Hot Water Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life.
  • Page 3 IMPORTANT INFORMATION - READ CAREFULLY All boilers must be installed in accordance with National, State and Local Plumbing, Heating and All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ Electrical Codes and the regulations of the serving utilities.
  • Page 4 DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and understand all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting-up, operating, maintaining or servicing this boiler.
  • Page 5 WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings printed DO NOT BLOCK AIR FLOW into or around the boiler. in this manual and posted on the boiler. Insufficient air may cause the boiler to produce carbon monoxide or start a fire. INSPECT THE BOILER, BURNER AND CONTROLS ANNUALLY.
  • Page 6 WARNINGS FOR THE INSTALLER READ THIS ENTIRE MANUAL before attempting INSTALL ALL GUARDS, cover plates, and installation, start-up, or service. Improper enclosures before operating the boiler. installation, adjustment, alteration, service, or SIZE THE BOILER PROPERLY relative to the design maintenance may cause serious property damage, heat load or, if using domestic hot water priority, personal injury, or death.

  • Page 7: Table Of Contents

    Table of Contents Product Description ................6 Specifications ..................6 III. Before Installing ..................7 Field Assembly ..................8 Locating the Boiler ................11 Air for Combustion & Ventilation ............12 VII. Venting ....................17 VIII. System Piping ..................19 Tankless Heater Piping ................

  • Page 8: Product Description

    I Product Description The TWB series boiler is a cast iron oil-fired water boiler designed for use in closed forced circulation heating systems. This boiler must be vented by natural draft into a lined masonry or metal chimney, or Type L vent. An adequate supply of air for combustion, ventilation and dilution of flue gases must be available in the boiler room.

  • Page 9: Before Installing

    TABLE 2.2: OPTIONAL TANKLESS HEATER RATINGS Rating Boiler Model (GPM) TWB065 2.75 TWB075 3.00 TWB100 3.25 3.75 TWB125 TWB150 4.00 TWB175 4.25 TWB200 4.75 Tankless heater ratings based on 40F inlet water, 140F outlet water, and 190F boiler water. Ratings are also based on 5 minute intermittent draws with 10 minutes between draws.

  • Page 10: Field Assembly

    If a power venter must be used, it is the responsibility of the installer and power venter manufacturer to “engineer” the power vent system. CROWN BOILER COMPANY WILL ASSUME NO RESPONSIBILITY FOR DAMAGE TO SIDING, ETC. FROM A POWER VENTED OIL- FIRED BOILER.
  • Page 11 3) Plug the burner cord into the connector located inside the junction box on the front of the boiler. Secure the cover plate that is on the burner cord to the junction box. This plate has keyhole slots that allow it to be mounted/unmounted for servicing without removing the junction box screws.
  • Page 12 FIGURE 4.1: FIELD INSTALLATION OF FLUE BAFFLES...

  • Page 13: Locating The Boiler

    V 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 14: Air For Combustion & Ventilation

    FIGURE 5.1: INSTALLATION OVER A COMBUSTIBLE FLOOR VI 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.
  • Page 15 For Buildings of Other than Unusually Tight Construction 1) Determine whether the boiler is to be installed in a confined space - A confined space is defined as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To determine whether the boiler room is a confined space: Total the input of all appliances in the boiler room in thousands of BTU/hr.
  • Page 16 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 17 FIGURE 6.2: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC FIGURE 6.3: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM...
  • Page 18 FIGURE 6.4: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM...

  • Page 19: Venting

    VII 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, resulting in 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.
  • Page 20 2) Acceptable Vent Connectors - The following may be used for vent connectors: • Listed Type L vent. • Single Wall Galvanized Pipe - Use 0.018” (26 gauge) or heavier. 3) Chimney and Vent Connector Sizing - See Table 7.1 for minimum vent connector and chimney sizing. 4) Do not vent this appliance into any portion of a mechanical vent system operating under positive pressure.

  • Page 21: System Piping

    VIII 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.
  • Page 22 1) Relief valve (Required) - Mount the relief valve on the top left side of the boiler as shown in Figure 8.1 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”...
  • Page 23 FIGURE 8.2: INDIRECT WATER HEATER BOILER SIDE PIPING FIGURE 8.3: BOILER BYPASS PIPING...
  • Page 24 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 boiler. These systems also typically have return temperatures well below the 120°F minimum. Figure 8.4 illustrates the use of a heat exchanger to connect this boiler to such a system.

  • Page 25: Tankless Heater Piping

    IX Tankless Heater Piping DANGER-SCALD HAZARD The control supplied with this boiler is not intended to provide accurate control of the domestic water temperature leaving the tankless heater. An installer supplied, ASSE 1017 or ASSE 1070 certified tempering valve is therefore REQUIRED as part of this boiler’s installation.

  • Page 26: Fuel Line Piping

    FIGURE 9.1: TANKLESS HEATER PIPING X 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. •...
  • Page 27 FIGURE 10.1: 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 10.1.
  • Page 28 7) Attach required piping between burner fuel pump and fuel oil storage tank. Install one fuel shut-off valve near the storage tank and second fuel shut-off valve near the oil burner fuel pump. Use heavy wall copper tubing in a continuous run. On two-pipe systems, the return line should terminate 3”...

  • Page 29: Wiring

    FIGURE 10.4: TWO-PIPE LIFT SYSTEM XI 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 30 2) Low Voltage Connections – Low voltage field connections are located as shown in Figure 11.0 and 11.1 and are as follows: • T-T - Connect to a 24 volt heating thermostat or other “dry contacts” (such as a zone panel end switch) that close upon a call for heat.
  • Page 31 FIGURE 11.0: CONNECTIONS DIAGRAM, BOILERS WITH OR LESS TANKLESS HEATER...
  • Page 32 Riello 530SE: Beckett 7505: Carlin 40200: FIGURE 11.1: CONNECTIONS DIAGRAM FOR BURNER PRIMARY CONTROLS...

  • Page 33: Start-Up & Checkout

    XII 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 34 20) Check the CO and confirm that it is between the minimum and maximum limits shown in Table 12.0, (also see NOTICE on page 33). Adjust if necessary. 21) Verify that the smoke level still does not exceed #1 and that the draft over fire is -0.02 inch w.c. 22) Turn off the burner and remove pressure gauge.
  • Page 35 TABLE 12.0b: CARLIN BURNER CONFIGURATION AND SETUP DATA BOILER MODEL TWB065 TWB075 TWB100 TWB125 TWB150 TWB175 TWB200 BURNER MODEL EZ-1HP EZ-1HP EZ-1HP EZ-1HP EZ-1HP EZ-2HP STANDARD DEL. DEL. HAGO DEL. DEL. DEL. NOZZLE 0.55/70B 0.60/60W 0.85/60B 1.00/60A 1.25/60B 1.50/60A PUMP PRESS (psi) HEAD BAR 0.50 0.60-0.65 0.85-1.00 0.85-1.00 1.10-1.25...

  • Page 36: Operation

    XIII Operation A. General Information This boiler uses the Hydrolevel Hydrostat® model 3250-Plus control to provide control of boiler water temperature, as well as to manage demands for up to two circulator zones. In addition, this control also provides protection against low water conditions. The 3250-Plus is used on both boilers equipped with tankless heaters and those without.
  • Page 37 B. Setting the Control NOTE: Settings can be checked using the TEST/SETTINGS button located on the top right of the control. See page 39 for details. 1) Setting the High Limit - The high limit is factory set at 190°F. To adjust, turn the HI TEMP dial A until the desired setting is displayed.
  • Page 38 NOTE: DHW Priority: During a call from an indirect water heater, the control will de-energize the circulator contacts (C1/C2) to heat only the indirect tank ensuring an adequate supply of domestic hot water. The control will re-energize the circulator when the indirect tank is satisfied or if the boiler temperature reaches 170°F. If the indirect call continues for 45 minutes, the control will override the priority function energizing the circulator to provide space heating.
  • Page 39 5) Circulator Hold Off (Enhanced Condensing Protection) - To reduce the potential for condensing, on a call for heat the control will allow the boiler to heat to 125°F prior to energizing the circulator. Once energized, the circulator will remain on for the duration of the heating call unless the boiler temperature drops below 115°F.
  • Page 40 TABLE 13.2 DEFAULT SETTINGS Dial Default Feature Options Description Setting Setting Purge Inactive Thermal Pre-Purge Purge Active Degrees Fahrenheit Fahrenheit or Celsius Degrees Celsius LWCO Manual or Auto- Automatic Reset matic Reset Manual Reset Circulator operation on TT call only Circulator Options Circulator operation on ZC/ZR call only Circulator operation on call from either...
  • Page 41 FIGURE 13.3 LED Legend and TEST/SETTINGS Button 5) ECONOMY - ACTIVE - Indicates that the thermal targeting function is active and the control will reduce boiler temperature to conserve fuel. The Economy feature is activated using the ECONOMY dial. (See “Setting the Economy Feature” on page 35 for more information).

  • Page 42: Service & Maintenance

    XIV Service and Maintenance The following procedure should be performed on an annual basis: 1) Turn off electrical power and oil supply to the boiler. Unplug burner disconnect. 2) Clean the boiler as follows: a) Remove vent connector and piping. b) Remove barometric draft regulator.
  • Page 43 4) Service the oil burner: a) Replace oil nozzle with identical make and model (see Table 12.0). b) Inspect the electrodes. Replace if they are deteriorated. Make sure that the electrode position is set according to the burner manufacturer’s instructions. c) Remove and clean fuel pump strainer.
  • Page 44 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.

  • Page 45: Troubleshooting

    XV Trouble Shooting A. Combustion 1) Nozzles - The selection of the nozzle supplied with this boiler is the result of extensive testing to obtain the best flame shape and efficient combustion. Other brands of the same spray angle and pattern may be used but may not perform at the expected level of CO and smoke.
  • Page 46 B. Control System The following pages contain a trouble shooting table and flow charts for use in diagnosing control problems. When using these materials 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 XII (Start-up and Checkout).
  • Page 47 TABLE 14.0 - DIAGNOSTIC CONDITIONS Condition Possible Cause Burner will not fire See Flow Chart 1, page 46 Burner will not shut down See Flow Chart 2, page 47 Under normal operation, boiler temperature will continue to rise after the control shuts off Temperature display exceeds the burner.
  • Page 48 Troubleshooting Flow Chart 1 – Burner Will Not Fire           The Control is The Thermal Pre-Purge feature holds off the burner until the   Does the Purging Latent control determines if the latent heat in the boiler can satisfy Display Read Heat from the the heat call.
  • Page 49 Troubleshooting Flow Chart 2 – Burner Will Not Shut Down Is the The Control is Red LED Sensing (LOW WATER) Low Water. WARNING! TURN OFF POWER TO BURNER IMMEDIATELY! CAUTION – ALWAYS ALLOW A BOILER TO FULLY COOL BEFORE ADDING WATER. Recheck wiring.

  • Page 50: Parts

    XVI 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 270015 270015 HEAT EXCH ASSY. LESS COIL OPENING 1 ea. 2700135 2700135 2700135 2700145 2700145...
  • Page 52 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 270525 270525 REAR JACKET PANEL 290220 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.
  • Page 54 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 55 Notes...
  • Page 56 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com...

This manual is also suitable for:

Twb065Twb075Twb100Twb125Twb150Twb175 ... Show all

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