Crown Boiler TWZ065 Installation Instructions Manual
Twz series oil-fired hot water boilers
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Also See for TWZ065:
- Installation supplement manual (16 pages) ,
- Installation instructions manual (52 pages)
Table of Contents
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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
•
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 Boiler TWZ065
Summary of Contents for Crown Boiler 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 I. Product Description .............. 2 VIII. Tankless Heater Piping........16 II. Specifications ................ 2 IX. Fuel Line Piping ........... 17 III. Before Installing ..............3 X. Wiring ............20 IV. Locating the Boiler ............... 4 XI. Start-up and Checkout ........23 V. -
Page 5: 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 6: Locating The Boiler
3) Make sure that the boiler is correctly sized: • For heating systems employing convection radiation (baseboard or radiators) use an industry accepted sizing method such as the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI). •... - Page 7 FIGurE 2: clEarancEs FIGurE 3: InstallatIOn OVEr a cOMBustIBlE FlOOr...
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Page 8: 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 9 FIGurE 4: 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 10 FIGurE 5: all aIr FrOM OutDOOrs, VEntIlatED craWl sPacE anD attIc FIGurE 6: all aIr FrOM OutDOOrs, VIa VEntIlatED attIc...
- Page 11 FIGurE 7: all aIr FrOM OutDOOrs, usInG OPEnInGs IntO BOIlEr rOOM FIGurE 8: all aIr FrOM OutDOOrs, usInG HOrIZOntal Ducts IntO BOIlEr rOOM...
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Page 12: 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 13 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 14: System Piping Connections
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 15 1) Relief valve (Required) - Mount the relief valve on the top left side of the boiler as shown in Figure 10 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 16: Piping For Special Situations
FIGurE 11: InDIrEct WatEr HEatEr BOIlEr sIDE PIPInG FIGurE 12: 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 11 shows typical indirect water heater piping. Boiler piping is the same as for any two- zone system. - Page 17 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 13 illustrates the use of a heat exchanger to connect the TWZ boiler to this type of system.
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Page 18: Tankless Heater Piping
VIII tanKlEss HEatEr PIPInG If the TWZ is installed with an optional tankless heater, pipe the heater as shown in Figure 14. 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 19: Fuel Line Piping
FIGurE 14: 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 20 FIGurE 15: 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 15.
- Page 21 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”...
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Page 22: Wiring
FIGurE 18: 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 AUTHORITY, WITH THE NATIONAL ELECTRIC CODE (ANSI/NFPA 70). single Zone Wiring 1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt con- nections are made inside the L7248 or L7224 aquastat relay as follows (also see Fig. - Page 23 Wiring Variations 1) Multiple Circulator Zones – Figure 20 shows wiring for two or more circulator zones using Honeywell R845As. One R845A is required for each circulator zone. Circulator terminals “C1” and “C2” on the L7248 are not used. A DPST Honeywell RA832A may be substituted in place of the R845A using the “X”...
- Page 24 FIGurE 20: WIrInG DIaGraM, cIrculatOr ZOnE WIrInG usInG HOnEYWEll r845a’s (FactOrY BOIlEr WIrInG nOt sHOWn - sEE FIGurE 19) FIGurE 21: WIrInG DIaGraM, ZOnE WIrInG usInG HOnEYWEll V8043F ZOnE ValVEs (FactOrY BOIlEr WIrInG nOt sHOWn - sEE FIGurE 19)
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Page 25: Start-Up And Checkout
XI start-up and checkout Use the following procedure for initial start-up of the boiler: WARNING • 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. • SAFE RELIABLE OPERATION OF THIS BOILER REQUIRES THAT THE BURNER BE CHECKED AND ADJUSTED BY A QUALIFIED OIL SERVICEMAN USING COMBUSTION TEST INSTRUMENTS. - Page 26 23) Check for clean cutoff of the burner. Air in the oil line between fuel pump and nozzle will compress, while burner is running, and expand, when burner shuts off, causing oil line pressure to drop and nozzle drip after burner stops. Cycle burner on and off 5 to 10 times to purge air completely.
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Page 27: Service & Maintenance
taBlE 3b: 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 1.00/60A 1.25/60B 1.00/60B... - Page 28 f) Thoroughly brush boiler flueways from the top and diagonally between casting pin rows. Be careful when brushing the rear passage not to damage the rear target wall insulation. g) Vacuum soot and debris from combustion chamber. h) Check condition of rear target wall insulation, combustion chamber liner, and burner door insulation; replace if required. i) Check burner head for signs of deterioration.
- Page 29 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 30: Parts
XIII 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. 2700135 2700135 2700135... - Page 32 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 290224 290224 290225...
- Page 34 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com PN: 980270 Rev 9 TWZ - 04/12...