Crown TWZ175 User Manual

TWZ Series

D ESIGNED TO L EAD

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

www.crownboiler.com

Oil-Fired Hot Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be afxed 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, injury, or loss of life. For assistance or additional information, consult a

qualied installer, service agency

or the oil supplier. Read these instructions carefully before installing.

WARNINGS FOR THE HOMEOWNER

FOLLOW ALL INSTRUCTIONS and warnings printed in this manual and posted on the boiler.

INSPECT THE BOILER, BURNER AND CONTROLS ANNUALLY. To keep your boiler safe and efficient, have a service technician follow the Service checklist near the end of this manual.

IF YOU ARE NOT QUALIFIED to install or service boilers, do not install or service this one.

THE BOILER MAY LEAK WATER at the end of its useful life. Be sure to protect walls, carpets, and valuables from water that could leak from the boiler.

PROTECT YOUR HOME IN FREEZING WEATHER. A power outage, safety lockout, or component failure will prevent your boiler from lighting. In winter, your pipes may freeze and cause extensive property damage. Do not leave the heating system unattended during cold weather

unless alarms or other safeguards are in place to prevent such damage

DO NOT BLOCK AIR FLOW into or around the boiler. Insufficient air may cause the boiler to produce carbon monoxide or start a fire.

KEEP FLAMMABLE LIQUIDS AWAY from the boiler, including paint, solvents, and gasoline. The boiler may ignite the vapors from the liquids causing explosion or fire.

KEEP CHILDREN AND PETS away from hot surfaces of the boiler, boiler piping, and vent pipe.

CARBON MONOXIDE (CO) is an odorless, deadly gas that may be introduced into your home by any malfunctioning fuel-burning product or vent system failure. Consider installing CO alarms near bedrooms in all levels of the building to warn you and your family of potential CO exposure.

WARNINGS FOR THE INSTALLER

READ THIS ENTIRE MANUAL before attempting installation, start-up, or service. Improper installation, adjustment, alteration, service, or maintenance may cause serious property damage, personal injury, or death.

DO NOT DISCONNECT PIPE FITTINGS on the boiler or in the heating system without first verifying that the system is cool and free of pressure and that your clothing will protect you from a release of hot water or steam. Do not rely solely on the boiler’s temperature and pressure gage when making this judgment.

USE PROPER PERSONAL PROTECTION EQUIPMENT when servicing or working near the boiler. Materials of construction, flue products, and fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, and/or other toxic or harmful substances that can are hazardous to health and life and that are known to the State of California to cause cancer, birth defects, and other reproductive harm.

INSTALL ALL GUARDS, cover plates, and enclosures before operating the boiler.

SIZE THE BOILER PROPERLY relative to the design heat load or, if using domestic hot water priority, the peak hot water load, whichever is larger. A grossly oversized boiler will cycle excessively and this will lead to premature failure of the boiler and its components. Our warranty does not apply to damage from excessive cycling.

ADHERE TO ALL LOCAL CODE REQUIREMENTS. Contact your local code inspector prior to installation. In the absence of a local code, adhere to the latest editions of the

Installation of Oil Burning Equipment ANSI/NFPA 31 in the USA or CAN/CSA B139, Installation Code for Oil Burning Equipment in Canada.

ALL WIRING must comply with the National Electrical Code ANSI/NFPA 70 (in the USA) or the Canadian Electrical Code CSA C22.1 (in Canada)

and any local regulations.

Table of Contents

I. Product Description .............................................................. 2

II. Specications ........................................................................ 2

III. Before Installing .................................................................... 3

IV. Locating the Boiler ............................................................... 4

V. Air for Combustion & Ventilation ......................................... 6

VI. Venting ................................................................................ 10

VII. System Piping Connections ................................................ 12

VIII. Tankless Heater Piping................................... 16

IX. Fuel Line Piping ........................................... 17

X. Wiring ........................................................... 20

XI. Start-up and Checkout .................................. 23

XII. Service & Maintenance ................................ 25

XIII. Parts .............................................................. 28

I Product Description

The TWZ series boiler is a cast iron oil-red 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 ue gases must be available in the boiler room. An optional tankless heater is available to generate domestic hot water.

II Specications

FIGURE 1: GENERAL CONFIGURATION *

TABLE 1a: GENERAL SPECIFICATIONS

"A" "B" "C" TWZ065 3 0.65 80000 70000 86.1 16.0 17-3/8 8 5/16 6 TWZ075 3 0.75 91000 79000 85.8 16.0 17-3/8 8 5/16 6 TWZ100 3 1.00 120000 104000 84.3 16.0 17-3/8 8 5/16 6 TWZ090 4 0.90 111000 97000 86.0 20.0 22-3/8 10 13/16 7 TWZ125 4 1.25 152000 132000 85.1 20.0 22-3/8 10 13/16 7 TWZ150 4 1.50 179000 156000 84.0 20.0 22-3/8 10 13/16 7 TWZ120 5 1.20 147000 128000 86.0 24.0 27-3/8 13 5/16 8 TWZ175 5 1.75 212000 184000 85.1 24.0 27-3/8 13 5/16 8 TWZ200 5 2.00 241000 210000 84.7 24.0 27-3/8 13 5/16 8

I=B=R Net

Rating (Btu/hr) AFUE (%)

Approx.

Water

Content (Gal)

Dimensions (inches)

Boiler Model

Number of

Sections

Burner

Input

(Gal/hr)

DOE Heating

Capacity

(Btu/hr)

TWZ065 TWZ075 TWZ100 TWZ090 TWZ125 TWZ150 TWZ120 TWZ175 TWZ200

Boiler Model

2.75

3.00

3.50

4.25

4.75

Tankless Heater Rating

(Gal/min)

3.25

3.75

4.00

TABLE 1b: OPTIONAL TANKLESS HEATER RATINGS

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, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction.

• In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the latest

edition of Installation of Oil Burning Equipment (ANSI/NFPA31).

• Where required by the authority having jurisdiction, this installation must conform to the latest edition of Standard for

Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1).

2) Make sure that a properly sized chimney is available which is in good condition. Consult the authority having jurisdiction, Part VI of this manual, and ANSI/NFPA31 for additional information on venting requirements.

Power (“Side Wall”) Venting - Important Note

Two problems arise when any oil-red appliance is power vented:

1. There is sometimes an accelerated rate of soot buildup on the oil burner cad-cell, spinner etc.

2. There is a potential for severe damage to the side of the structure in the event that the boiler operates at a high smoke

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. FROM A POWER VENTED OIL-FIRED BOILER. THIS APPLIES REGARDLESS OF THE CAUSE OF THE SOOTING.

level. This can happen for many reasons, some of which are out of the control of both the installer and appliance

manufacturer.

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).

• For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.

• For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the Heating

Capacity required for the Mega-Stor or the I=B=R Net Rating required for the heating system, whichever results

in the larger boiler.

• For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s

instructions for boiler output requirements.

4) In some cases, boilers installed at altitudes above 2000ft may require a different burner conguration from that at sea level. Consult the local Crown representative for more information.

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. Also see Figure 2.

Front – 24” Left Side – 6” Right Side – 6” Rear – 6” Top – 6” Single Wall Chimney Connector (to combustible construction) - 18”

• A 24” service clearance from the jacket is recommended from the top of the boiler. This clearance may be

reduced to that shown above; however, servicing the boiler will become increasingly difcult as this clearance is reduced.

2) If listed Type L vent is used, follow vent pipe manufacturer recommendations for minimum clearances.

3) Do not install this boiler directly on a combustible surface. Where it is desired to install the TWZ over a non-carpeted combustible surface, install the boiler on the base shown in Figure 3.

4) Do not install this boiler in a location where gasoline or other ammable vapors or liquids will be stored or used. Do not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop.

FIGURE 2: CLEARANCES

FIGURE 3: INSTALLATION OVER A COMBUSTIBLE FLOOR

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.

Sufcient 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 ensure an adequate supply of air for combustion, ventilation and ue gas dilution, start by determining whether the boiler is to be installed in a building of unusually tight construction. A building of unusually tight construction can be dened as one having the following features:

• Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or

less with openings gasketed and sealed

• Weather stripping has been added on openable windows and doors

• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and

oors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other openings.

For Buildings of Other than Unusually Tight Construction

1) Determine whether the boiler is to be installed in a conned space - A conned space is dened 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 conned space:

a. Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest

1000 BTU/hr.

b. Find the volume of the room in cubic feet. The volume of the room in cubic feet is:

Length (ft) x width (ft) x ceiling height (ft)

In calculating the volume of the boiler room, consider the volume of adjoining spaces only if no doors are installed

between them. If doors are installed between the boiler room and an adjoining space, do not consider the volume of the adjoining space, even if the door is normally left open.

c. Divide the volume of the boiler room by the input in thousands of BTU/hr. If the result is less than 50, the boiler

room is a conned space.

Example:

A TWZ090 and a water heater are to be installed in a room measuring 6 ft - 3 in x 7 ft with an 8 ft ceiling. The water heater has an input of 30000 BTU/hr:

Input of TWZ090 = 0.90 Gal/hr x 140000 BTU/Gal = 126000 BTU/hr

Total input in thousands of BTU/hr = (126000 BTU/hr + 30000 BTU/hr)/1000 = 156

Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft

350/156 = 2.24. Since 2.24 is less than 50, the boiler room is a conned space.

FIGURE 4: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE

2) Unconned Space - Natural inltration into the boiler room will normally provide adequate air for combustion and ventilation without additional louvers or openings into boiler room.

3) Conned Space - Provide two openings into the boiler room, one near the oor and one near the ceiling. The top edge of the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the oor (Figure 4).

• Each opening must have a free area of 1 square inch per 1000 BTU/hr input of all fuel burning appliances in the boiler room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per opening.

• If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per 1000 BTU/hr of total appliance input, install a pair of identical openings into a third room. Connect additional rooms with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input.

• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used, they must be no ner 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 openings are required. The top edge of the upper opening must be within 12 inches of the ceiling. The bottom edge of the lower opening must be within 12 inches of the oor.

3) Size openings and ducts as follows:

• Vertical ducts or openings directly outdoors (Figure 5, Figure 6, and Figure 7) - Each opening must have a free

cross sectional area of 1 square inch per 4000 BTU/hr of the total input of all fuel red appliances in the boiler room but not less than 100 square inches. Minimum opening size is 3 inches.

• Openings to outdoors via horizontal ducts (Figure 8) - Each opening must have a free cross sectional area of 1

square inch per 2000 BTU/hr of the total input of all fuel red appliances in the boiler room but not less than 100 square inches. Minimum opening size is 3 inches.

• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens

are used, they must be no ner than ¼” (4 x 4) mesh.

FIGURE 5: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC

FIGURE 6: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC

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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