Crown Boiler TWZ090 manual

1 TWZ Series Oil-Fired Hot W ater Boilers INST ALLA TION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models: • TWZ065 • TWZ075 • TWZ100 • TWZ090 • TWZ125 • TWZ150 • TWZ120 • TWZ175 • TWZ200 WARNING : Improper installation, adjustment, alteration, service or maintenance can cause property damage, in[...]

2 T able of Contents I. Product Description ............................................................. 1 II. Specifications ....................................................................... 1 III. Before Installing ................................................................... 2 IV . Locating the Boiler ...............................[...]

3 TABLE 1a: GENERAL SPECIFICATIONS Notes: 1 . Net Ratings are based on piping and pick-up allowances of 1.15. 2 . Burner Capacity Rating, GPH is based on #2 oil with a Gross Heating Value equal to 140000 BTU/Gal. 3 . Maximum Working Pressure, Water - 50 PSI. 4. Tankless Heater Ratings based on I=W=H test standard. III Before Installing 1 ) Safe, re[...]

4 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 Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics Institute in Berkeley Heights, NJ. • For new radiant heating systems refer to the rad[...]

5 FIGURE 2: CLEARANCES 0. 47" Sh e e t M e t a l ( 2 4 G A o r T hic k e r ) H ol l ow M a s on r y B l oc k s O p e n in g s Alig n e d T o P er m i t F r ee A ir Ci r c ul a ti o n 4“ MI N . C ombu s t i bl e S u r f ac e FIGURE 3: INSTALLATION OVER A COMBUSTIBLE FLOOR 4 6 6 18 * 6 24 * C L EA RA N C E FRO M SI N G L E WA LL C O N N EC T O[...]

6 V Air for Combustion and V entilation Sufficient fresh air must be supplied for combustion and ventilation. Provisions for combustion and ventilation air for oil burning equipment must be made in accordance with Section 1.5, Air for Combustion and Ventilation, in the latest edition of Installation of Oil Burning Equipment (ANSI/NFPA 31). To ensur[...]

7 FIGURE 4: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE used, they must be no finer than ¼” (4 x 4) mesh. For Buildings of Unusually Tight Construction: 1 ) Openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl space, which communicates directly with the outdoors. 2) Two [...]

8 FIGURE 5: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 6: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC 7[...]

9 FIGURE 7: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 8: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 8[...]

10 FIGURE 9: TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS VI V enting Vent installation must be in accordance with local building codes, or the local authority having jurisdiction. Typical vent installation is illustrated by Figure 9. The components of vent installation are the vent connector (breeching), barometric draft regulator, and chimney.[...]

11 6 ) Prior to boiler installation, inspect chimney for obstructions or other defects and correct as required. Clean chimney as necessary. 7 ) Vent pipe should slope upward from boiler not less than one inch in four feet. No portion of vent pipe should run downward or have sags. Vent pipe must be securely supported. 8 ) The vertical section of ven[...]

12 FIGURE 10: STANDARD BOILER PIPING CAUTION • INSTALL BOILER SO THAT ALL 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 DAM[...]

13 2) Circulator (Required) - Figure 10 shows the ideal location of the circulator which is in the supply piping immediately downstream of the expansion tank. A less ideal, but acceptable, location for most residential circulators is in the return (if this is done, be sure that adequate clearance exists to open the door. 3) Expansion Tank (Required[...]

14 FIGURE 12: BOILER BYPASS PIPING FIGURE 11: INDIRECT WATER HEATER BOILER SIDE 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- zon[...]

15 FIGURE 13: ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER 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 1[...]

16 2) Flow Restrictor (Recommended) - If water is drawn from the tankless coil at a rate in excess of the rating in Table 1b, the temperature of the hot water may be too low to be of use. The use of a flow restrictor will prevent this problem by limiting the rate at which water can pass through the tankless heater. If a restrictor is used, select o[...]

17 FIGURE 14: TANKLESS HEATER PIPING IX Fuel Line Piping Fuel line piping design, materials and construction must be in accordance with local building codes, requirements of the local authority having jurisdiction, and, the latest edition of Installation of Oil-Burning Equipment (ANSI/NFPA 31). Refer also to the instruction manuals provided with th[...]

18 FIGURE 16: ONE-PIPE LIFT SYSTEM b) ONE-PIPE LIFT SYSTEM (not recommended) - Used when a fuel oil storage tank is located below an oil burner fuel pump. See Figure 16. The vertical distance from bottom of the tank to center line of the pump (Dimension ‘H’) must not exceed that shown in the pump manufacturer’s instructions. Although all oil [...]

19 FIGURE 17: TWO-PIPE GRAVITY FEED SYSTEM FIGURE 18: TWO-PIPE LIFT SYSTEM 18[...]

20 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/NFPA70). Single Zone Wiring 1) 120 V olt W iring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt connections ar[...]

21 FIGURE 19: WIRING DIAGRAM, SINGLE HEATING ZONE ONLY FIGURE 20: WIRING DIAGRAM, CIRCULATOR ZONE WIRING USING HONEYWELL R845A’s (FACTORY BOILER WIRING NOT SHOWN - SEE FIGURE 19) 20 L1 I N T ERRUPT ED I N TER M I TTE N T BURN ER M O T O R LI M I T VA L V E L2 H O N EYWE LL L8 1 4 8 O R L8 1 2 4 AQ U AS T AT RE LAY NOT E : 1 ) BURNER WI RI N G SHO[...]

22 XI S tart-up and Checkout Use the following procedure for initial start-up of the boiler: 1) Ensure that the boiler and entire heating system are filled with water. 2) Check all new piping for leaks and purge heating system piping sections that are air bound. 3) Verify that the vent system is complete and free of obstructions prior to start-up o[...]

23 6) Check initial settings of oil burner air band and air shutter, head setting etc., and readjust if needed. See Table 3 for setup and combustion data pertaining to a particular boiler/ burner combination. 7) Attach plastic hose to oil pump vent fitting and provide a container to catch oil during oil pump bleeding procedure. 8) Install 0-200 PSI[...]

24 TABLE 3a: BECKETT BURNER CONFIGURATION AND SETUP DATA 23 TABLE 3b: CARLIN BURNER CONFIGURATION AND SETUP DATA TW Z0 6 5 TW Z0 7 5 TW Z1 0 0 TW Z 0 9 0 TW Z1 2 5 TW Z1 5 0 TW Z1 2 0 TW Z1 7 5 TW Z2 0 0 B U R N E R M O D E L E Z - 1 H PE Z - 1 H PE Z - 1 H PE Z - 1 H PE Z - 1 H PE Z - 1 H PE Z - 1 H PE Z - 2 H P S T A NDA R D DE L. HA G O HA GO DE[...]

25 XII Service and Maintenance The following procedure should be performed on an annual basis: 1) Turn off electrical power and oil supply to the boiler. 2) Clean the boiler as follows: a) Remove vent connector and piping. b) Remove barometric draft regulator. c) Remove top jacket panel to gain access to boiler flue collector. d) Unscrew four wing [...]

26 CAUTION WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPONENTS. REPAIR ANY LEAKS FOUND IMMEDIATELY. IMPORTANT • CLEAN THE BOILER EVEN IF THERE ARE NO SIGNIFICANT SOOT DEPOSITS. FAILURE TO REMOVE ALL SULFUR AND ASH DEPOSITS ANNUALLY CAN CAUSE SEVERE CORROSION DAMAGE. • WHEN CLEANING THE REAR FLUE PASSAGE, BE CA[...]

27 26 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 carc[...]

28 27 65 75 100 90 125 150 120 175 200 1 COMPLETE HEAT EXCHANGER ASSY. 1 ea. 270013 270013 270013 270014 270014 270014 270015 270015 270015 * FRONT SECTION 275050 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. * REAR SECTION 275060 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. * INTERMEDIATE SECTION 275055 1 ea. 1 ea. 1 ea. 2 ea. 2 e[...]

29 28[...]

30 29 65 75 100 90 125 150 120 175 200 40 LEFT SIDE JACKET PANEL 1 ea. 270233 270233 270233 270234 270234 270234 270235 270235 270235 41 RIGHT SIDE JACKET PANEL 1 ea. 270223 270223 270223 270224 270224 270224 270225 270225 270225 * REAR JACKET PANEL 270220 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 43 TOP JACKET PANEL 1 ea. 270243 270243[...]

31 30[...]

32 Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 7 HO)D[ZZZ FURZQERLOHU FRP PN980270 Rev 6 09/10[...]