Crown Boiler FWZ Series, FWZ060, FWZ100, FWZ081, FWZ130 Installation Instructions Manual

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Page 1

D ESIGNED TO L EAD

FWZ Series

Oil-Fired Hot Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be axed on or adjacent to the boiler

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 gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

Models:

• FWZ060

• FWZ080

• FWZ081

• FWZ100

• FWZ130

• FWZ160

9802605 Rev A, 06-18

Equipped with Hydrolevel

3250-Plus Control System

Crown Boiler Company P.O. Box 14818 3633 I Street Philadelphia, PA 19134 www.crownboiler.com

Page 2

Page 3

IMPORTANT INFORMATION - READ CAREFULLY

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 dier

from this instruction manual. Authorities having jurisdiction should be consulted before installations are made. In all cases, reference should be made to the following Standards:

USA BOILERS A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for recommended installation practices. B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Venting requirements. C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls and safety devices. D. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or Local Regulations.

CANADIAN BOILERS A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning Equipment", for recommended Installation Practices. B. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or Local Regulations.

The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

CAUTION

NOTICE

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

DANGER

This boiler is designed for use with #2 fuel oil meeting the specications of ASTM D-396. Attempts to burn

other liquid fuels, or to convert this boiler for use with gaseous fuels, could result in reliability problems, extensive property damage, or loss of life.

This boiler has a limited warranty, a copy of which is included with this boiler. The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in

accordance with these instructions.

Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation

during storage. Surface rust is normal and does not a󰀨ect the performance or longevity of a boiler.

NOTICE

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DANGER

DO NOT store or use gasoline or other ammable 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. Keep this manual and literature in legible condition and posted near boiler for reference by owner and service technician.

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.

Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable installer or service agency.

All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler.

Installation is not complete unless a pressure relief valve is installed as shown in Figure 8.1 located in Section VIII, “System Piping” of this manual.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is completed.

This boiler is suitable for installation on combustible ooring. Do not install boiler on carpeting.

Do not tamper with or alter the boiler or controls.

Inspect ueways at least once a year - preferably at the start of the heating season. The inside of the combustion chamber, the vent system and boiler ueways should be cleaned if soot or scale has accumulated.

When cleaning this boiler, take precaution to avoid damage to burner swing door insulation. If damaged, or if there is evidence of previous damage, burner swing door insulation must be replaced immediately.

Oil Burner and Controls must be checked at least once a year or as may be necessitated.

Do not operate boiler with jumpered or absent controls or safety devices.

Do not operate boiler if any control, switch, component, or device has been subject to water.

Boiler construction materials, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance.

This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt

to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch any components unless they are cool.

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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 e󰀩cient, 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

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 rst 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 gauge when making this judgment.

USE PROPER PERSONAL PROTECTION

EQUIPMENT when servicing or working near the boiler. Materials of construction, ue 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.

or other safeguards are in place to prevent such damage

DO NOT BLOCK AIR FLOW into or around the boiler.

Insu󰀩cient air may cause the boiler to produce carbon monoxide or start a re.

KEEP FLAMMABLE LIQUIDS AWAY from the boiler,

including paint, solvents, and gasoline. The boiler may ignite the vapors from the liquids causing

explosion or re.

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.

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.

Page 6

WARNING

This boiler must be properly vented. The chimney must be inspected for any obstructions and cleaned

prior to each heating season. A clean and unobstructed chimney ue is necessary to produce the minimum

draft required to safely evacuate noxious fumes that could cause personal injury or loss of life. Evidence

of loose debris and or condensate induced stains at the base of the chimney ue, connector or smokepipe joints may be signs of condensing ue gases. Flue gas condensate is corrosive, which requires special

consideration and must be addressed immediately. Refer to Section VII, "Venting" in this manual for more details.

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.

This boiler is supplied with controls which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil

containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e. wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All ammable debris, rags, paper,

wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of

re hazards.

All boilers equipped with burner swing door have a potential hazard which, if ignored, can cause severe property damage, personal injury or loss of life. Before opening swing door, unplug burner power cord

from receptacle located in lower right corner of jacket front panel and turn o󰀨 service switch to boiler to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing door

fasteners completely when service is completed.

Table of Contents

I. Product Description ............................................................................... 5

II. Specications ......................................................................................... 5

III. Before Installing .................................................................................... 7

IV. Field Assembly ...................................................................................... 8

V. Locating the Boiler ................................................................................ 11

VI. Air for Combustion & Ventilation ......................................................... 12

VII. Venting ................................................................................................... 16

VIII. System Piping ........................................................................................ 19

IX. Fuel Line Piping .................................................................................... 24

X. Wiring .................................................................................................... 27

XI. Start-Up & Checkout ............................................................................. 31

XII. Operation ............................................................................................... 35

XIII. Service & Maintenance .......................................................................... 41

XIV. Troubleshooting ..................................................................................... 44

XV. Parts ....................................................................................................... 49

Page 7

I Product Description

The FWZ 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.

II Specications

TABLE 2.0: GENERAL SPECIFICATIONS

DIMENSIONS WATER

MODEL

FWZ060 16-1/4” 24” 5” 7.70 13.29 430

FWZ080 16-1/4” 24” 5” 7.70 13.29 430

FWZ081 22-1/4” 24” 6” 11.08 20.29 545

FWZ100 22-1/4” 24” 6” 11.08 20.29 545

FWZ130 28-1/4” 30” 6” 14.46 27.29 658

FWZ160 34-1/4” 36” 7” 17.84 34.29 771

‘A’ ‘B’ ‘C’

CONTENT

(GAL)

HEAT TRANSFER

SURFACE AREA

(SQ FT)

SHIPPING

WEIGHT

(LBS)

Maximum working pressure, Water - 50psi

TABLE 2.1: RATING DATA

FWZ Series

AHRI Ratings

BURNER

INPUT

MODEL*

GPH MBH

FWZ060 0.60 84 73 63 86.0 6 8 X 8 15

FWZ080 0.80 112 97 84 86.3 6 8 X 8 15

FWZ081 0.80 112 99 86 87.0 6 8 X 8 15

FWZ100 1.00 140 123 107 87.0 6 8 X 8 15

FWZ130 1.30 182 160 139 87.0 7 8 X 8 15

FWZ160 1.60 222 197 171 87.0 7 8 X 8 15

Burner Capacity Rating, GPH is based on #2 fuel oil with a Gross Heating Value equal to 140,000 BTU/Gal. * Net Ratings are based on piping and pick-up allowances of 1.15

HEATING

CAPACITY

(MBH)

NET AHRI

RATING*

(MBH)

AFUE

(%)

Other Specications

MINIMUM CHIMNEY

REQUIREMENTS

ROUND IN. DIA.

SQUARE.

TILE SIZE

HEIGHT

FT.

Page 8

BURNER SWING

DOOR CLEARANCE

(FULLY OPEN)

NOTE: THIS DIMENSION INCREASES AND

OBSERVATION

TEMP/PRESSURE

BURNER

BECKETT AFG

SUPPLY PIPING

CONNECTION

IS CONTROLLED BY SMOKEPIPE

ARRANGEMENT.

CIRCULATOR

LINE

FLOOR

1-1/2"

RETURN

PIPING

REAR

12" MIN.

SERVICE

'A'

COMBINATION

RELIEF

VALVE

COVER

CLEAN OUT

'C' DIA.

COLLAR

CLEARANCE

SMOKEBOX

COLLAR

DRAIN VALVE

SPANNER BAR

RIGHT VIEWFRONT VIEW REAR VIEW

LIMIT/LWCO

'B' MIN.

CLEARANCE

FRONT SERVICE

(FLUEWAY CLEANING)

TOP VIEW

1-1/2" FPT

GAUGE

BURNER

SWING

DOOR

PORT

FLAME

19"

* Circulator Supplied Loose - May Be Installed On Supply Or Return.

FIGURE 2.3: GENERAL CONFIGURATION *

Page 9

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). Installations in Canada comply with the requirements of CSA B139-04 – Installation Code for Oil-burning Equipment.

• 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.

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 re-

quired 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 dierent burner conguration from that at sea level. Consult the local Crown representative for more information.

CAUTION

As with all oil-fired appliances, “Power Venting” this boiler creates a number of potential problems, especially when this is done through a side wall. These include, but are not necessarily limited to:

• Accelerated rate of soot buildup on the oil burner cad-cell, burner head, and/or in the boiler itself.

• Odor complaints

• Severe damage to the side of the structure in the event that the boiler operates at a high smoke level.

These problems can occur for many reasons, some of which are out of the control of both the installer and the appliance manufacturer. The use of a chimney to vent this boiler is therefore recommended. 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 OILFIRED BOILER. THIS APPLIES REGARDLESS OF THE CAUSE OF THE SOOTING.

Page 10

CAUTION

Fuel oil used with this boiler must conform to ASTM D396. The ASTM D396 standard sets a 5% limit on biodiesel concentration, requires that the biodiesel feedstock comply with ASTM D6751, and also specifies the procedure that must be used to blend the biodiesel feedstock with the #2 fuel oil. Attempts to use biodiesel blends not meeting all ASTM D396 requirements may result in unreliable operation or severe property damage.

IV Field Assembly

This boiler is shipped in two pieces:

a) The crated boiler itself with the following loose parts either packed in the combustion chamber or glued to the skid:

• Barometric Draft Regulator (if supplied)

• Circulator (if supplied)

• Relief valve

• Pipe Fittings

b) The burner carton consisting of the following items:

• Oil Burner assembly

• Baes in some cases (see Table 4.1)

• Refractory blanket in some cases (see Table 4.1)

It is recommended that the boiler be moved to its nal location before the items in the burner carton are installed. To complete eld assembly:

WARNING

Installation of burners on the FWZ other than those provided by Crown, and marked for use with this boiler, may result in unreliable operation, property damage, personal injury, or loss of life.

1) Make sure that the burner carton supplied is the correct one for the boiler. The crate tag on the boiler lists the Crown part numbers for the burner cartons that may be used with it.

2) Remove the burner mounting bolts and washers from the front door. Make sure that the burner gasket is in place and undamaged and mount the burner to the door.

3) Plug the burner cord into the receptacle on the lower right front corner of the boiler as shown in Figure 4.0

4) Install the barometric draft regulator, and other piping/trim, as described in the Venting and Piping sections of this manual.

5) Dierent bae arrangements are used based on the boiler size and choice of burner. In some cases these bafes are included in the boiler and in other cases they are provided in the burner carton. In addition, some models use a refractory blanket which is shipped in the burner carton and which must be installed in the combustion c h a m b e r. F i n a l l y, i n s o m e c a s e s b u r n e r s a r e s u p p l i e d w i t h i n s u l a t i o n w r a p p e d a r o u n d t h e i n s e r t e d b u r n e r t u b e . Table 4.3 summarizes the use of baes, blankets, and burner tube insulation.

6) Attach the model-specic rating plate for the specic boiler model that is provided in the burner box to the left of the permanent rating plate already on the boiler (Figure 4.0). Note that some burner boxes may contain rating plates for both water and steam models; be sure to select the appropriate FWZ series rating plate. Before applying the rating plate clean the area where it is to be applied with a clean, dry lint free cloth.

Page 11

FIGURE 4.0: RATING PLATE LOCATION

TABLE 4.1: BASIC BOILER CONFIGURATIONS

Model

Boiler

Part No.

FWZ060 FWZ002

FWZ080 FWZ002

FWZ081 FWZ003

FWZ100 FWZ003

FWZ130 FWZ004

FWZ160 FWZ005

Burner

Beckett

Beckett 41081B Yes

Riello 41081R Ye s

Carlin 41081C Yes

Beckett 41100B No No No Yes

Riello 41100R No No No Ye s

Carlin 41100C Yes

Beckett 41130B No No No Ye s No

Riello 41130R No No No Ye s No

Carlin 41130C Yes

Beckett 41160B No No No Ye s No

Riello 41160R No No No Ye s No

Carlin 41160C Yes

Burner

Carton

Blanket

Part #

41060B No No No No Yes

41080B No No Yes

1 Boiler PN may contain additional characters after those shown to designate other options

2 FWZ060 and FWZ080 not available with Carlin or Riello Burner.

3 Included in burner box.

Burner

Insulation

Tube

2nd Pass

Bae

(410009)

2nd Pass

Bae

(410008)

No Yes

3rd Pass

Bae

(410007)

No No No Ye s

Yes No No Yes

Yes No Yes

Yes No Yes Yes

Yes

Figure 4.2 identies the type and location of baes. When used, lay the refractory blanket in the combustion chamber with the 19-1/2” side oriented as shown in Figure 4.2. Line the front edge of the blanket up with the edge of the combustion chamber.

The blanket should run the entire length of the chamber. No adhesive is required to hold the blanket in place.

When required, burner tube insulation is applied at the factory and secured in place with masking tape. This tape is only needed to hold the insulation in place while the burner is being installed through the door. After installation, the tape will harmlessly burn away and the insulation will be secured by the door refractory.

• Do not omit the blanket when called for in the table above.

• Do not add any extra baffles beyond those prescribed for the model/burner combination shown in Table 4.1.

Doing either of these things could cause accelerated chimney deterioration due to condensation or inadequate draft resulting in severe property damage, personal injury or death.

WARNING

Page 12

FIGURE 4.2: BAFFLE AND BLANKET INSTALLATION

Page 13

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 construction, as well as noncombustible walls, ceilings and doors. Also see Figure 5.0.

Front - 24” (from front Jacket surface) Left Side – 6” Right Side – 6” Rear – 12” Top – 6” Single Wall Chimney Connector (to combustible construction) - 18”

• A 24” service clearance is recommended above the top of the boiler, as well as on the side to which the burner swing door opens (the left side as the boiler is shipped). See also dimension ‘B’ in Table 2.0 for recommended service clearances to the front of the boiler. These clearances may be reduced to those shown above; however, servicing the boiler will become increasingly dicult as these clearances are reduced.

FIGURE 5.0: CLEARANCES

Page 14

1) Do not install this boiler directly on a combustible oor. Where it is desired to install an FWZ on a non-carpeted combustible oor, install the boiler on a base constructed as shown in Figure 5.1

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

3) 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 5.1: INSTALLATION OVER A COMBUSTIBLE FLOOR

VI Air for Combustion and Ventilation

Su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 the Standard for the 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 adequate combustion and ventilation air can be obtained through natural inltration (air leaking into the building through cracks around windows, doors, etc). Examples of construction features which could prevent adequate natural inltration include:

• Walls and ceilings exposed to outside atmosphere having a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed

• Weather stripping 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.

• Large exhaust fans

In this manual, buildings where natural inltration will not provide adequate air for combustion, and ventilation are referred to as “buildings of unusually tight constuction”. If in doubt, assume that the building in which the boiler is installed is of unusually tight construction.

Page 15

A. 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: An FWZ080 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 FWZ080 = 0.80 Gal/hr x 140000 BTU/Gal = 112000BTU/hr Total input in thousands of BTU/hr = (112000 BTU/hr + 30000 BTU/hr)/1000 = 142 Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft

350/142 = 2.46. Since 2.46 is less than 50, the boiler room is a conned space.

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 6.0).

• 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 eect of mesh, grills, and louvers. Where screens are

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

B. 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 6.1, Figure 6.2, and Figure 6.3) - 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 6.4) - 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 eect of mesh, grills, and louvers. Where screens are

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

Page 16

FIGURE 6.0: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE

FIGURE 6.1: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC

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

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, 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.

• Do not de-rate the appliance. Failure to fire the unit at it’s designed input may cause excessive condensation upon the interior walls of the chimney. In addition, the lower input may not create enough draft to adequately evacuate the products of combustion.

• Do not omit the blanket when called for in the table above.

• Do not add any extra baffles beyond those prescribed for the model/burner combination shown in Table 4.1.

Doing either of these things could cause accelerated chimney deterioration due to condensation or inadequate draft resulting in severe property damage, personal injury or death.

Page 19

The vent installation must be in accordance with local building codes, or the local authority having jurisdiction. Contact your local re and building ocials on specic requirements for restrictions and the installation of fuel oil burning equipment. In the absence of other applicable codes, the vent system installation must meet the requirements of NFPA 31 – Standard for the

Installation of Oil-Burning Equipment and NFPA 211 - Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances. Vent systems in Canada must comply with CSA B139-04 – Installation Code for Oil-burning Equipment.

A typical vent system is illustrated in Figure 7.0. The components of the vent installation are the vent connector (breeching), barometric draft regulator, and chimney.

1) Acceptable Chimneys - The following chimneys may be used to vent a FWZ series boiler:

• Listed Type L vent - Install in accordance with the manufacturer’s instructions, the terms of its listing, and applicable codes.

• Masonry Chimney - The masonry chimney must be constructed in accordance with the latest edition of Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances (NFPA 211) and lined with a clay liner or other listed

lining system. Do not vent a FWZ series boiler into an unlined chimney.

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. The vent connector size must not be smaller than boiler ue collar diameter.

4) Do not vent this appliance into any portion of a mechanical vent system operating under positive pressure.

5) Do not connect the boiler into a chimney ue serving an open replace or other solid fuel appliance.

6) Prior to boiler installation, an existing chimney must be inspected by a qualied person in accordance with the requirements of Chapter 11 of NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances. This inspection is intended to identify safety problems with the chimney such as obstructions, a missing or damaged liner, or leak points. Clean chimney as necessary and correct any other chimney defects before installing the boiler.

7) Vent connector must slope upward from boiler not less than one inch in four feet. No portion of vent pipe should run downward or have sags. Vent connector must be securely supported.

8) The vertical section of vent connector coming o the boiler should be as tall as possible, while still maintaining the proper clearance from the horizontal vent connector to combustibles and the proper pitch called for in (7) above.

9) Vent connector must be installed above the bottom of the chimney to minimize risk of blockage.

10) Vent connector must be inserted ush with inside face of the chimney liner and the space between vent connector and chimney sealed tight. A thimble permanently cemented in place can be used to facilitate removal of vent connector for cleaning.

11) Install the barometric draft regulator supplied with this boiler in accordance with the regulator manufacturer’s instructions. No other draft regulator shall be used. Mount the barometric draft regulator in the side connection of a tee (not supplied).

12) Secure all joints in the vent connector system with sheet metal screws. This includes the joint between the vent connector and the boiler collar (see Figure 7.0, Detail ‘A’), as well as the barometric draft regulator. Use at least three screws at each joint.

Page 20

FIGURE 7.0: TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS

TABLE 7.1: MINIMUM RECOMMENDED BREECHING AND CHIMNEY SIZE

BOILER MODEL

FWZ060 5 6 8 X 8 15

FWZ080 5 6 8 X 8 15

FWZ081 5 6 8 X 8 15

FWZ100 6 6 8 X 8 15

FWZ130 6 7 8 X 8 15

FWZ160 7 7 8 X 8 15

MINIMUM

BREECHING

DIA. (INCHES)

MINIMUM CHIMNEY REQUIREMENTS

ROUND I.D.

(IN.)

SQUARE. TILE

SIZE (NOMINAL)

HEIGHT (FT.)

Page 21

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 135°f can cause severe boiler or chimney damage.

• Do not operate this boiler at a flow rate less than the minimum shown in Table 8.0, Column (a).

• Operation of this boiler in a system having significant amounts of dissolved oxygen can cause severe heat exchanger corrosion damage.

• Do not use toxic additives, such as automotive antifreeze, in a hydronic system.

• Pipe relief valve discharge to a safe location. The relief valve may discharge scalding hot water.

• Do not install a valve in the relief valve discharge line.

• Do not move relief valve from factory location.

• Do not plug relief valve discharge. Blocking the relief valve may result in boiler explosion.

A. Standard Piping

Figure 8.2 shows typical boiler system connections on a single zone system. Additional information on hydronic system design may be found in the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI). The components in this system and their purposes are as follows:

1) Relief valve (Required) - Mount the relief valve on the rear of the boiler as shown in Figure 8.1 using the ttings 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” shown on the rating plate. If the valve is replaced, the replacement must have a relief capacity in excess of the heating capacity for the boiler.

Pipe the discharge of the relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the relief valve discharge is not piped to a drain, it must terminate at least 6 inches above the oor. Do not run relief valve discharge piping through an area that is prone to freezing. The termination of the relief valve discharge piping must be in an area where it is not likely to become plugged by debris.

2) Return Injector Pipe - The return injector distributes water evenly throughout the heat exchanger and also helps to minimize the possibility of thermal shock. Install it in the upper-rear tapping as shown in Figure 8.1. The 2 x 1-1/2” reducing elbow can be oriented in any direction.

3) Circulator (Required) - Figure 8.2 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. The circulator/s and connected piping should be sized so that the temperature rise across the boiler is 20F. Burner operation while the ow through the boiler is less than that shown in Table 8.0, column (a) could result in problems regulating the supply temperature. If the system is zoned, the ow rate through the boiler should be greater than that shown in Table 8.0 when only the zone having the lowest ow rate is on. If this requirement cannot otherwise be met, use a bypass, or primary-secondary piping. Boiler head loss data at the minimum ow and the ow corresponding to a 20F rise are shown in Table 8.0.

4) Expansion Tank (Required) - If this boiler is replacing an existing boiler with no other changes in the system, the old expansion tank can generally be reused. If the expansion tank must be replaced, consult the expansion tank manufacturer’s literature for proper sizing.

Page 22

5) Fill Valve (Required) - Either a manual or automatic ll valve may be used. The ideal location for the ll is at the expansion tank.

6) Automatic Air Vent (Required) - At least one automatic air vent is required. Manual vents will usually be required in other parts of the system to remove air during initial ll.

7) Low Water Cut-O (Required in some situations) - A low water cut-o is required when the boiler is installed above radiation. In addition, some codes such as ASME CSD-1, require low water cut-os. Codes may also require that this low water cut-o have a manual reset function. The low water cut-o may be a oat type or probe type, but must be designed for use in a hot-water system. The low water cut-o should be piped into the boiler supply just above the boiler with no intervening valves between it and the boiler. Use a low water cut-o that breaks the 120 VAC supply to the boiler. Do not attempt to wire a 24-volt low water cut-o into the boiler factory wiring.

8) Manual Reset High Limit (Required by some codes) - This control is required by ASME CSD-1 and some other codes. Install the high limit in the boiler supply piping just beyond the boiler with no intervening valves. Set the manual reset high limit as far above the operating limit setting as possible, but not over 240°F. Wire the control to break the 120 VAC electrical supply to the boiler.

9) Flow Control Valve (Required under some conditions) - The ow control valve prevents ow through the system unless the circulator is operating. A ow control valve may be necessary on converted gravity systems to prevent gravity circulation. Flow control valves are also used to prevent “ghost ows” in circulator zone systems through zones that are not calling for

heat.

10) Isolation Valves (Optional) - Isolation valves are useful if the boiler must be drained, as they will eliminate having to drain and rell the entire system.

11) Drain Valve - The drain valve is shipped in the boiler parts bag. Install it in the bottom-rear of the boiler return as shown in Figure 8.1.

Table 8.0 Minimum Flow Rate Requirements

Minimum Flow

(Approx 35F Rise)*

Flow at 20F Rise

(a) (c) (d) (e)

Model

Min. Flow (Gal /Min)

Boiler Head

Loss (ft w.c.)

Flow

(GPM)

Boiler Head

Loss (ft w.c.) FWZ060 4.5 0.10 7.3 0.22 FWZ080 6.0 0.16 9.7 0.38 FWZ081 8.0 0.27 9.9 0.40

FWZ100 8.0 0.27 12.3 0.61 FWZ130 10.0 0.42 16.0 0.88

FWZ160 12.0 0.61 19.7 1.45

* Approximate 25°F Rise for FWZ081

Page 23

FIGURE 8.1: INSTALLATION OF FACTORY SUPPLIED PIPING

FIGURE 8.2: STANDARD BOILER PIPING

Page 24

B. Piping for Special Situations

Certain types of heating systems have additional requirements. Some of the more common variations follow:

1) Indirect Water Heaters - Figure 8.3 shows typical indirect water heater piping. Boiler piping is the same as for any two zone system. Figure 8.3 shows circulator zoning, which is usually preferred for indirect water heaters. Size the circulator and indirect water heater piping to obtain the boiler water ow through the indirect water heater called for by the indirect water

heater manufacturer.

2) Large Water Volume Systems - The piping shown in Figure 8.4 will minimize the amount of time that the boiler operates with return temperatures below 135°F on these systems. A bypass is installed as shown to divert some supply water directly into the return water. The bypass pipe should be the same size as the supply. The two throttling valves shown are adjusted so that the return temperature rises above 135°F during the rst few minutes of operation. A three-way valve can be substituted for the two throttling valves shown. A bypass can also be used to ensure that the minimum ow requirement in Table 8.0 is

met.

3) Systems Containing Oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a cast iron boiler such as the FWZ. Some examples include:

• Radiant systems that employ tubing without an oxygen barrier.

• Systems with routine additions of fresh water.

• Systems which are open to the atmosphere.

If the boiler is to be used in such a system, it must be separated from the oxygenated water being heated with a heat

exchanger as shown in Figure 8.5. Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as ow and temperature requirements. All components on the oxygenated side of the heat exchanger, such as the pump and expansion tank, must be designed for use in oxygenated water.

4) Air Handlers - Where the boiler is connected to air handlers through which refrigerated air passes, use ow control valves in the boiler piping or other automatic means to prevent gravity circulation during the cooling cycle.

FIGURE 8.3: INDIRECT WATER HEATER BOILER SIDE PIPING

Page 25

FIGURE 8.4: BYPASS PIPING

FIGURE 8.5: ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER

Page 26

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.

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 the Standard for the Installation of Oil-Burning Equipment (ANSI/NFPA

31) in the United States and CSA B139-04 for installation in Canada. Refer also to the instruction manuals provided with the burner and oil pump.

Depending on the location of the fuel oil storage tank in relation to an oil burner, there are four types of oil piping systems that may be encountered:

a) ONE-PIPE GRAVITY SYSTEM - Used when a fuel oil storage tank is positioned above an oil burner fuel pump. See

Figure 9.0. A vertical distance from top of the tank to center line of the pump (Dimension ‘H’) over 8 feet will result in a pump inlet pressure in excess of the 3-psi limit in NFPA-31.

b) ONE-PIPE LIFT SYSTEM (not recommended) - Used when a fuel oil storage tank is located below an oil burner fuel

pump. See Figure 9.1. 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 piping systems must be airtight, one-pipe lift systems are particularly susceptible to nuisance lockout problems if the suction line is not completely airtight. A two-pipe lift system is therefore preferred to a one-pipe lift system.

c) TWO-PIPE GRAVITY SYSTEM (not recommended) - A vertical distance from top of the tank to center line of the pump

(Dimension ‘H’) over 8 feet will result in a pump inlet pressure in excess of the 3-psi limit in NFPA-31. This type of system should be converted to a one-pipe gravity system, as doing so will result in lower inlet line ow and longer lter life.

d) TWO-PIPE LIFT SYSTEM - Used when a fuel oil storage tank is located below an oil burner fuel pump suction port.

See Figure 9.3. 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. The maximum permissible distance ‘H’ allowed is reduced by the number of ttings, lters and valves installed in the line.

Once the type of system has been selected, observe the following:

1) Fuel line piping must be airtight. Do not use compression type ttings for tubing connections in fuel line piping. Use only listed are type ttings. Cast iron threaded ttings shall not be used.

2) Piping shall be substantially supported and protected against physical damage and corrosion.

3) Refer to supplied oil pump instruction manual for proper connections. On one-pipe systems, ensure that the fuel pump return port plug is tightened securely.

4) Some fuel pumps, such as the Suntec A and B series, are supplied with a loose bypass plug which must be installed on twopipe systems. If such a plug is supplied, install it as shown in the pump manufacturer’s instructions. Do not install this bypass plug on one-pipe systems as pump seal damage will result.

5) Do not use check valves, especially on gravity feed systems.

6) Do not use Teon tape for threaded connections. Use a non-hardening thread sealant listed for use with #2 fuel oil .

Page 27

7) Attach required piping between burner fuel pump and fuel oil storage tank. Install one fuel shut-o valve near the storage

tank and second fuel shut-o valve near the oil burner fuel pump. Use a continuous run of copper tubing having a minimum wall thickness of 0.032”. On two-pipe systems, the return line should terminate 3” - 4” above suction line depth within the storage tank. Refer to the pump manufacturer’s instructions for tube sizing information.

8) Never install manual shut-o valves in the return piping of a two-pipe system.

9) Install a listed exible oil line/s at the burner to facilitate opening of the boiler’s swing door.

10) All systems require an oil lter. Use of a high eciency micron lter (Garber or equivalent) in addition to a conventional

lter is highly recommended, particularly on FWZ060 and FWZ080.

11) Use only #2 Fuel Oil with physical and chemical characteristics meeting the requirements of ASTM D-396.

FIGURE 9.0: ONE-PIPE GRAVITY SYSTEM

FIGURE 9.1: ONE-PIPE LIFT SYSTEM

Page 28

FIGURE 9.2: TWO-PIPE GRAVITY FEED SYSTEM (NOT RECOMMENDED)

FIGURE 9.3: TWO-PIPE LIFT SYSTEM

Page 29

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

• Disconnect electrical power to the boiler and heating system before servicing. Positively assure that no voltage is present. Lock electrical boxes to prevent someone from inadvertently restoring power before the heating system is safe to operate.

• Never defeat or jump out safety devices.

• Protect each boiler circuit with a properly sized over-current protection device.

• Make electrical connections carefully according to the boiler’s wiring diagram and instructions.

• Wire additional field supplied safety limits, such as low water cutoffs and temperature limit devices, in series with the 120V circuit used to power the boiler. Do not alter the boiler’s factory wiring when adding an additional limit device.

1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. 120VAC power connections are made inside the Hydrolevel 3250-Plus hot water boiler control as follows (also see Figures. 10.0 and 10.1):

National Electrical Code (ANSI/NFPA 70).

• Hot (“black”) - Terminal “L1”

• Neutral (“white”) - Terminal “L2”

• Ground (“green” or bare) - Ground screw on case of 3250-Plus.

The heating circulator is factory wired to the 3250-Plus circulator connections or the boiler is provided with a exible conduit “whip” that is to be wired to the 3250-Plus circulator connections. If the circulator is not already wired to the control, connect it as follows:

• Circulator “Hot” - Black wire lead from “whip” to C1

• Circulator “Neutral” - White wire lead from “whip” to C2

2) Low Voltage Connections – Low voltage eld connections are located as shown in Figure 10.0 and 10.1 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. Follow thermostat manufacturer’s instructions. To insure proper thermostat operation, avoid installation in areas of poor air circulation, hot spots (near any heat source or in direct sunlight), cold spots (outside walls, walls adjacent to unheated areas, locations subject to drafts). Provide Class II circuit between thermostat (or zone controls) and boiler.

3) Adding a Second Circulator Zone - The control provided on this boiler can be used to control a second heating or DHW circulator zone. If this is done, make the following 120VAC connections in addition to those described above (also see Figure

10.0):

• Connect a 120VAC heating or DHW thermostat for the second zone between ZC and ZR.

• Connect the DHW circulator or the second heating zone circulator between ZR and L2.

See Part XII of this manual for information on conguring the control to respond properly to the DHW or second heating zone circulator.

Page 30

NOTICE

• When making low voltage connections, make sure that no external power source is present in the thermostat circuits. If such a power source is present, it could destroy the boiler’s control. One example of an external power source that could be inadvertently connected to the low voltage connections is a transformer in old thermostat wiring.

• Do not use the transformer provided on the boiler to power external devices such as zone valves. Doing so may cause damage to the transformer.

Page 31

FIGURE 10.0: WIRING CONNECTIONS DIAGRAM FOR HYDROSTAT 3250-PLUS CONTROL

Page 32

FIGURE 10.1: CONNECTIONS WIRING DIAGRAM FOR BURNER SPECIFIC PRIMARY CONTROL

Page 33

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.

• Failure to perform all of the checks outlined in the following procedure could result in unreliable operation, damage to the boiler not covered under warranty, property damage, or unsafe operation.

• All 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. Be sure to tighten swing door fastener completely when service is completed. In addition, the burner power cord will have to be disconnected from the receptacle in the front jacket.

1) Ensure that the boiler and entire heating system are lled with water.

2) Check all new piping for leaks and purge all heating system piping of air. Clean heating system if system water is dirty.

3) Verify that the venting system is properly installed and free of obstructions prior to start-up of the boiler. Refer to Section

VII for more information.

4) Inspect all wiring for loose or uninsulated connections, proper size fuses installed, etc.

5) Verify that oil tank is lled with #2 fuel oil meeting ASTM D396 specications, oil piping has been tested and is air tight, and shuto valve(s) are closed.

6) Check initial settings of oil burner air band and air shutter, head setting etc., and readjust if needed. See Table 11.1 for setup and combustion data pertaining to a particular boiler/ burner combination.

7) Ensure that burner is tightly secured to the burner swing door creating an airtight seal.

8) Attach plastic hose to oil pump vent tting and provide a container to catch oil during oil pump bleeding procedure.

9) Install 0-200 PSI pressure gauge into oil pump gauge port.

10) Open all oil line shuto valves.

11) Adjust system thermostat to highest setting.

12) Turn the service switch to “ON” position.

13) Crack open vent tting on the oil pump and allow burner to run until a solid oil stream, free of air bubbles, ows for 15 seconds into container. As the vent tting is closed, the burner should re and ame should be visible through observation port immediately (or after prepurge timing has expired, if a burner is so equipped). Refer to burner instructions for more details.

14) Immediately upon ring the boiler, check the smoke level. If the smoke level is in excess of a #1, open the air adjustment to bring the smoke level below a #1.

15) Make sure that the oil pressure matches that shown in Table 11.1 for the burner supplied. Adjust pressure if required.

16) Check the vacuum at the inlet of the fuel pump. Make sure that the vacuum does not exceed the fuel pump manufacturer’s limit (consult the pump manufacturer’s instructions).

17) Close the ame observation cover.

Page 34

FIGURE 11.0: FLUE DRAFT TAPPING

18) After chimney has warmed-up for at least 5 minutes, adjust barometric draft regulator to obtain a draft at the 1/4” tapping shown in Figure 11.0 that is within the range shown in Table 11.1. DRAFT AT THIS LOCATION MUST NEVER BE POSITIVE.

19) Check the CO2 and conrm that it is between the minimum and maximum limits shown in Table 11.1. Adjust if necessary.

20) Verify that the smoke level still does not exceed #1 and that the draft in the breech still within the range prescribed by Table 11.1.

21) Turn o the burner and remove pressure gauge. Install and tighten gauge port plug, then restart the burner.

22) Check for clean cuto of the burner. Air in the oil line between fuel pump and nozzle will compress, while burner is running, and expand when burner shuts o, causing nozzle drip after burner stops. Cycle burner on and o 5 to 10 times to purge air completely.

23) Check thermostat operation by raising or lowering its set point as required, cycling burner on and o.

24) Verify primary control operation and safety features according to procedure outlined in the instructions furnished with

the burner.

25) Check high limit control operation. Jump thermostat terminals and allow burner to run until boiler water temperature exceeds high limit setting. The burner should shut down, and circulator continue running. Allow the temperature to drop below the control setting. The burner must restart. Boiler installation is not complete unless these checks are made and are satisfactory. Remove thermostat jumper and reconnect thermostat upon check completion.

26) After the boiler has operated for approximately 30 minutes, check the boiler and heating system for leaks. Repair any leaks found at once.

27) After the above checks have been completed, leave thermostat(s) at desired setting. Leave all instructions provided with the boiler with owner or in boiler room, displayed near boiler.

Page 35

WARNING

Attempts to use burners or burner configurations other than those shown in Table 11.1 could result in reliability problems, property damage, personal injury or loss of life.

TABLE 11.1a: BECKETT BURNER CONFIGURATION AND SETUP DATA

BOILER MODEL FWZ060 FWZ080 FWZ081 FWZ100 FWZ130 FWZ160

BURNER MODEL AFG AFG AFG AFG AFG AFG

AIR TUBE COMBO 70MQASN 70MMAQN 70MMAQN 70MMAQN 70MLASN 70MLASN

HEAD TYPE L2 L1 L1 L1 V1 V1

STATIC PLATE 3-3/8U 3-3/8U 3-3/8U 3-3/8U NONE 2-3/4M

LOW FIRING RATE BAFFLE

INSERTION LENGTH 2.0” 2.0” 2.0” 2.0” 2.0” 2.0”

PITCH ANGLE 0 0 0 0 0 0

STANDARD NOZZLE

PUMP PRESSURE (psi) 180 150 150 150 150 150

HEAD SETTING FIXED FIXED FIXED FIXED 0 1

STARTING: SHUTTER SETTING BAND SETTING

DRAFT IN FLUE (in w.c.) 0 to -0.02 0 to -0.02 0 to -0.02 0 to -0.02 0 to -0.02 0 to -0.02

MAX SMOKE (Bacharach Scale)

FLUE CO MIN. MAX.

(%)

BECKETT

SILVER (5880)

DELAVAN

0.50 X 45W

#1 #1 #1 #1 #1 #1

11.5

12.8

BECKETT

SILVER (5880)

DELAVAN

0.65 X 60A

11.5

12.8

BECKETT

SILVER (5880)

DELAVAN

0.65 X 60A

11.5

12.8

NONE NONE NONE

DELAVAN

0.85 X 60B

11.5

12.8

DELAVAN

1.10 X 60B

11.5

12.8

DELAVAN

1.35 X 60B

9 5

11.5

12.8

TABLE 11.1b: RIELLO BURNER CONFIGURATION AND SETUP DATA

BOILER MODEL FWZ081 FWZ100 FWZ130 FWZ160 BURNER MODEL F3 F5 F5 F5 TURBULATOR DISK 5 SLOT 9 SLOT 9 SLOT 9 SLOT COMBUSTION HEAD VSBT 10” LBT 6” SBT VSBT

STANDARD NOZZLE

DELAVAN

0.60 X 60A

DELAVAN

0.85 X 60B

DELAVAN

1.10 X 60B

DELAVAN

1.35 X 60B INSERTION LENGTH 2.5” 10” 3.5” 2.25” PUMP PRESSURE (psi) 175 145 150 145 TURBULATOR SETTING 3.0 2.0 4.0 4.0 AIR GATE SETTING 2.4 2.5 3.75 4.0 DRAFT IN FLUE (in w.c.) 0 to -0.02 0 to -0.02 0 to -0.02 0 to -0.02 MAX SMOKE

(Bacharach Scale) FLUE CO

(%)

MIN. MAX.

#1 #1 #1 #1

11.5

12.8

11.5

12.8

11.5

12.8

11.5

12.8

Page 36

TABLE 11.1c: CARLIN BURNER CONFIGURATION AND SETUP DATA

BOILER MODEL FWZ081 FWZ100 FWZ130 FWZ160

BURNER MODEL EZ1-LF EZ1-LF EZ1-LF EZ-66

BLENDER 28 HOLE NONE NONE NONE

CARLIN AIR TUBE NUMBER 50989 50989 50989 51198

STANDARD NOZZLE

DANFOSS

0.60 X 60AS

HAGO

0.75 X 60B

HAGO

1.00 X 45B

HAGO

1.35 X 45B

INSERTION LENGTH 2.62” 2.62” 2.62” 2.62”

PITCH ANGLE 1° 1° 1° 1°

PUMP PRESSURE (psi) 175 175 175 140

HEAD SETTING 2 2 3 5

STARTING AIR BAND SETTING 45% 35% 45% 60%

DRAFT IN FLUE (in w.c.) 0 to -0.02 0 to -0.02 0 to -0.02 0 to -0.02

MAX SMOKE (Bacharach Scale)

#1 #1 #1 #1

FLUE CO MIN. MAX.

(%)

11.5

12.8

11.5

12.8

11.5

12.8

11.5

12.8

Page 37

XII 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.

This boiler complies with the 2007 Energy and Independence Security Act, using an “Economy” feature, which raises or lowers the target boiler water temperature during a call for space heat based on thermostat cycling patterns. For additional information

see Part B of this section.

IMPORTANT

This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is not used for any space heating.

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

FIGURE 12.0 HYDROSTAT 3250-PLUS CONTROL COMPONENT LAYOUT

Page 38

B. Setting the Control

NOTE: Settings can be checked using the TEST/SETTINGS button located on the top right of the control. See page 33 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. (Setting range: 100°-220°F) See Figure 12.0.

2) Setting the Low Limit - The low limit is factory set to OFF and should not be adjusted.

NOTICE

For proper operation low limit setting must be at least 10F below high limit setting.

3) Setting the Economy Feature - The Economy Feature is factory set for a 1 zone heating system. To adjust, turn the ECONOMY Dial D until the number displayed equals the number of heating zones. Do not include indirect water heaters in the number of heating zones. The Economy Feature conserves fuel by analyzing thermostat activity and continually evaluating how much heat the house requires. When it is very cold outside, the heat demand is high and the control will raise the boiler’s target temperature to provide needed heat to the home. When the outside temperature is milder, the heat demand is lower. During these periods, the control will lower the boiler’s target temperature – saving fuel – while continuing to provide comfort to the house. If the heating system is unable to supply needed heat to the house, the ECONOMY Dial should be turned to a lower setting (example: In a three zone house, turn the dial to 2 or 1). Conversely, if the boiler provides adequate heat, added fuel savings can be achieved by selecting a higher setting (example: 4 or 5). If the heating and indirect water heater signals were not separated when wiring the control, the Economy Feature should be turned OFF to ensure the boiler supplies adequate temperature to heat the indirect tank. See Figure 12.0 & Table 12.1.

SETTING

OFF

4) Setting the Zone/Indirect Switch - See Figure 10.0.

TABLE 12.1 ECONOMY SETTING RECOMMENDATIONS

Disables economy function. Will allow boiler to re until hi limit temp is reached and re-re with a 10° subtractive dierential.

Provides lowest level of fuel savings. Use this setting only if the house does not stay warm at higher settings.

Recommended setting for single zone systems

Recommended setting for two zone systems

Recommended setting for three zone systems

Recommended setting for four zone systems

Recommended setting for ve zone systems

Provides highest level of fuel savings

NOTICE

IMPORTANT: When installing with an indirect water heater, the Zone/Indirect Switch must be set in the I position. When set in the I position, calls to ZC-ZR will bypass the thermal targeting feature and allow the boiler to fire to the high limit setting to heat the indirect tank. The indirect signal must be separate from all heating zone signals.

Page 39

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 satised 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.

C. Optional Features

NOTE: The Program Mode - Pro - is accessed by turning the LO TEMP dial to a position just above OFF.

1) Thermal Pre-Purge - Thermal Pre-Purge is designed to maximize boiler eciency. When activated, the control will supply

latent heat that may remain in the boiler from a previous run cycle to the heating zone that is now calling. The control monitors how quickly the boiler temperature is declining and activates the burner only when it determines that the latent heat is insucient to satisfy the call. During the purge cycle, the display will indicate Pur. This feature works with single-zone and multi-zone heating systems utilizing circulators or zone valves. No change in wiring is needed.

To activate Thermal Pre-Purge

1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as Pro

2. Turn the HI TEMP dial to select feature 1

3. Push the Test/Settings Button to turn Thermal Pre-Purge on or OFF

4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 28)

2) Degrees Fahrenheit or Celsius - The control has the ability to operate in degrees Fahrenheit or Celsius. When operating in

Celsius, a c will appear in the display next to the temperature whenever the temperature is below 100 degrees.

To change between degrees Fahrenheit and degrees Celsius

1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as Pro

2. Turn the HI TEMP dial to select feature 2

3. Push the Test/Settings Button to c for Celsius or F for Fahrenheit

1. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 28)

3) Manual Reset Low Water Cut-O - The low water cut-o operation on the HydroStat can be set to operate in automatic

(default) or manual reset mode. When in manual reset mode, the control will shut-down the burner immediately when a low water condition is detected. If the low water condition is sustained for 30 seconds, the low water light will blink, indicating that the control has locked out the burner. The control can only be reset by pushing the Test Settings button on the top of the control. The manual reset feature meets CSD-1 code requirements.

To activate Manual Reset LWCO mode

1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as Pro

2. Turn the HI TEMP dial to select feature 3

3. Push the Test/Settings Button to A for Automatic Reset Mode or b for Manual Reset Mode

4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 28)

To Test the Manual Reset Feature: Press and hold the Test/Settings button located on the top of the control for 30 seconds to simulate a low water condition. After 30 seconds, the Low Water light will blink indicating that the control is locked out. To reset the lock-out condition, press the Test/Settings button momentarily.

4) Circulator Activation Options - When in the default mode, the control activates the circulator (C1/C2 contacts) on calls to

TT. The control can be programmed to activate the circulator on calls to ZC/ZR in place of, or in addition to, calls to TT.

To change how the Circulator is activated

1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as Pro

2. Turn the HI TEMP dial to select feature 4

3. Push the Test/Settings Button to select between the following options:

A - Circulator on TT call only

b - Circulator on ZC/ZR call only

C - Circulator on both TT & ZC/ZR calls

4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 28)

Page 40

5) Circulator Hold O (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. If this occurs, the circulator will re-energize when the boiler returns to 125°F. Circulator Hold O will expire after 15 minutes.

To activate Circulator Hold O

1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as Pro

2. Turn the HI TEMP dial to select feature 5

3. Push the Test/Settings Button to turn Circulator Hold O on or OFF

4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 28)

6) Not available on this control.

7) Not available on this control.

8) Well Type - Hydrolevel Electro-Well (factory installed on boiler).

9) High Limit Dierential - When the Economy feature is on, the control’s Thermal Targeting feature actively sets varying dierentials based on system conditions. This option allows for selecting a 10, 20 or 30 degree xed dierential when the Economy feature is turned OFF. These optional dierential settings are subtractive from the HIGH LIMIT setting. Note: If the Economy feature is on, this setting will be overridden by the control’s Thermal Targeting function.

To change the High Limit Dierential

1. Turn the LO TEMP dial to access the Program Mode –indicated in the display as Pro

2. Turn the HI TEMP dial to select feature 9

3. Push the Test/Settings Button to select a high limit dierential of 10, 20, or 30

4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 28)

dEF) Restore Factory Default Settings

To restore all features to the factory default settings (see Table 12.2 for default settings)

1. Turn the LO TEMP dial to access the Program Mode – indicated in the display as Pro

2. Turn the HI TEMP dial to select feature dEF

3. Push the Test/Settings Button to Y to reset all features to the default settings.

4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 28)

Page 41

TABLE 12.2 DEFAULT SETTINGS

Dial

Setting

def

Feature Options Description

Thermal Pre-Purge

Fahrenheit or Celsius

LWCO Manual or Auto-

matic Reset

Circulator Options

Circulator Hold O

Not available on this

control

Not available on this

control

Well Type

High Limit

Dierential

Restore Factory

Defaults

Off

F c

A b

A b c

Off

A b

10 20 30

y n

Purge Inactive Purge Active

Degrees Fahrenheit Degrees Celsius

Automatic Reset Manual Reset

Circulator operation on TT call only Circulator operation on ZC/ZR call only Circulator operation on call from either

Circulator Hold O - Active Circulator Hold O - Inactive

Hydrolevel Electro-Well (supplied with boiler) Standard Immersion Well

10° Dierential 20° Dierential 30° Dierential

Restore Defaults Do Not Restore Defaults

Default

Setting

Off

D. LED Legend and TEST/SETTINGS Button (Figure 12.3)

1) TEMP - ACTIVE - Indicates that the control is powered and that the temperature function is active.

2) TEMP - HI TEMP - Illuminates when the boiler water temperature reaches the high limit setting. It will remain lit until the

water temperature falls 10°. The control prevents burner operation while this LED is on. See Dierential explanation on page

28.

3) LWCO - ACTIVE - Indicates that the low water cut-o (LWCO) function of the control is active.

4) LWCO - LOW WATER - Indicates that the boiler is in a low water condition. The control will prevent burner operation

during this condition. If the LOW WATER light is blinking, the control has been programmed to provide lock- out protection in the event a low water condition is detected (see Manual Reset Low Water Cut-O on page 30). Pressing the TEST/ SETTINGS button will reset the control.

WARNING

If the Hydrostat is found to be in a low water condition:

• Have the system checked by a qualified HVAC service technician before attempting to restore operation.

• Do not add water to the boiler until it has fully cooled.

Page 42

FIGURE 12.3 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 29 for more information).

6) ECONOMY - TARGET - When the Economy feature is active, the control continually sets target temperatures below the high limit setting to maximize fuel eciency. When the boiler water reaches the target temperature, the LED illuminates and the burner will shut down. The boiler water will continue to circulate and heat the house as long as the thermostat call continues. The LED will stay lit until the boiler temperature drops below the dierential set point at which point the boiler will be allowed to re again. See Dierential explanation on page 31. NOTE: This LED illuminates regularly during normal boiler operation.

7) TEST/SETTINGS BUTTON - To Test Low Water Cut-O: Press and hold the Test/ Settings button for 5 seconds. The display will read LCO. The red Low Water light should illuminate and the burner circuit (B1 and B2) should de-energize. NOTE: The control must be installed with a Hydrolevel Electro-Well™ for low water cut-o functionality (see page 28 for more details). To View Current Settings: Press and release the Test/Settings Button in short intervals to sequentially display the following settings:

HIGH LIMIT SETTING HL

LOW LIMIT SETTING LL

ECONOMY SETTING ECO

CURRENT TARGET TEMPERATURE ooo

The display will return to boiler temperature (default) if Test/Settings Button in not pressed for 5 seconds.

Page 43

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. Disconnect the burner plug from the receptacle in the front jacket. Be sure to tighten the swing door fastener completely when service is completed.

The following procedure should be performed on an annual basis:

1) Turn o electrical power and oil supply to the boiler.

2) Clean the boiler as follows:

a) Remove the two 3/8” bolts from either side of the swing door and open the door to access the combustion chamber.

b) Remove the two smoke box clean-out covers from the rear smoke box by removing the four 5/16” bolts. It is

not necessary to remove the vent connector from the smoke box to clean boiler however if there is heavy soot accumulation in the boiler remove the vent connector to inspect the base of the chimney for condensate or accumulation of debris.

c) Remove the baes (if installed) from the ue passages.

d) Clean the 3rd Pass - Insert a 2” dia x 42” long wire or ber bristle brush into one of the two 3rd ue passes. Using

long strokes push the brush all the way through the boiler until the brush has exited the smoke box opening. Pull the brush all the way forward until it has exited the front of the boiler. Continue this operation for the entire height of the ue way until clean. Repeat the operation for the other 3rd pass ue way.

e) Clean the 2nd Pass - Insert a 2” dia x 42” long wire or ber bristle brush into one of the two 2nd ue passes. Using

long strokes push the brush all the way through the boiler until the brush hits the back wall of the reversing chamber. Pull the brush all the way forward until it has exited the front of the boiler. Continue this operation for the entire height of the ue way until clean. Repeat the operation for the other 2nd pass ue way.

f) Vacuum to loose debris in the bottom of the combustion chamber and smoke box

g) Clean the Combustion Chamber - Use a wire or ber bristle brush to clean the surfaces of the combustion chamber.

Vacuum all loose debris in the chamber.

h) Check condition of the burner swing door insulation and rope gaskets for signs of damage; replace if required.

i) Check burner head for signs of deterioration. Clean the head of any deposits.

j) Insert baes (if originally installed) into the correct ueways.

k) Attach the smoke box clean-out covers onto the rear of the boiler using the 5/16” bolts originally removed. Verify

that the rope gasket is in good order before assembly. Replace rope gasket if necessary. Do not over tighten. The bolts should be snug but not bottomed out.

l) Close the swing door and tighten it with the 3/8” bolts originally removed. When securing the burner swing door

make sure the door is drawn-in equally on both sides by alternating the tightening method for right side to left side. Do not over tighten. The rope gasket will provide sucient seal when door is snugged into place.

m) Ensure all vent piping joints are gas tight and secured with sheet metal screws.

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.

IMPORTANT

Page 44

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. A clean and unobstructed chimney flue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efficiency.

3) Inspect the vent system:

a) Make sure that the vent system is free of obstructions and soot.

b) Make sure that all vent system supports are intact.

c) Inspect joints for signs of condensate or ue gas leakage.

d) Inspect venting components for corrosion or other deterioration. Replace any defective vent system components.

4) Service the oil burner:

a) Replace oil nozzle with identical make and model (see Table 11.1).

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.

d) Remove any accumulations of dust, hair, etc. from the air shutter, blower wheel, and other air handling parts of the

burner.

e) Replace the fuel oil line lter element and gaskets.

6) Inspect all oil piping and ttings for kinks and leaks. Repair any found.

7) Inspect the hydronic piping and boiler for water leaks. Repair any leaks found immediately.

8) Verify operation of relief valve by manually lifting lever; replace relief valve immediately if valve fails to relieve

pressure.

9) Open fuel line shut-o valve(s) and restore electrical power to the boiler.

10) Fire the boiler and check it out using the procedure outlined in “Start-up and Checkout” . This must include checking the

burner adjustments using instruments. Check for proper operation of all controls.

Water leaks can cause severe corrosion damage to the boiler or other system components. Repair any leaks found immediately.

WARNING

Page 45

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. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

Page 46

XIV Trouble Shooting

A. Combustion

1) Nozzles - The selection of the nozzle supplied with the FWZ boiler is the result of extensive testing to obtain the best ame shape and ecient combustion. Other brands of the same spray angle and pattern may be used but may not perform at the expected level of CO2 and smoke. Nozzles are delicate and should be protected from dirt and abuse. Nozzles are massproduced and can vary from sample to sample. For all of those reasons a spare nozzle should be part of a serviceman’s replacement parts inventory.

2) Flame Shape - As seen for the observation port, the ame should appear straight with no sparklers rolling up toward the crown of the chamber. If the ame drags to the right or left, sends sparklers upward or makes wet spots on the chamber walls, the nozzle should be replaced. If the condition persists look for fuel leaks, air leaks, water or dirt in the fuel as described below.

3) Fuel Leaks - Any fuel leak between the pump and the nozzle will be detrimental to good combustion results. Look for wet surfaces in the air tube, under the ignitor and around the air inlet. Any such leaks should be repaired as they may cause erratic burning of the fuel and in the extreme case may become a re hazard.

4) Air Leaks - Any such leaks should be repaired as they may cause erratic burning of fuel and in extreme cases may become a re hazard.

5) Gasket Leaks - If CO2 readings between 11.5% and 12.8% with a #1 smoke cannot be obtained in the breeching, or if odors are observed, look for leaks around the burner mounting gasket, observation door and canopy gasket, or in the breeching below the point where the ue gas sample is taken. Air leakage into the boiler or breeching can cause low CO2 readings (the lower the ring rate, the greater eect an air leak can have on CO2 readings). Such leaks can also cause ue gas leakage into the building, resulting in odor complaints.

6) Dirt - The use of a fuel lter is good practice. Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from the nozzle. The smaller the ring rate, the smaller the slots in the nozzle and the more prone to plugging it becomes.

7) Water - Water in the fuel in large amounts will stall the fuel pump. Water in the fuel in smaller amounts will cause excessive wear on the pump. More importantly it chills the ame and causes smoke and unburned fuel to pass through the combustion chamber and clog the ueways of the boiler.

8) Cold Oil - If the oil temperature near the fuel pump is 40°F or lower, poor combustion or delayed ignition may result. Cold oil is harder for the nozzle to atomize, thus the oil droplets get larger and travel further creating a longer ame. An outside fuel tank that is above grade or has fuel lines in a shallow bury is a good candidate for cold oil. The best solution is to bury the tank and lines deep enough to keep the oil above 40°F. Be sure to follow any state and local codes when burying fuel oil tanks and/or fuel oil lines.

9) Start-Up Noise - Delayed ignition is the cause of start-up noises. If it occurs recheck for electrode settings, ame shape, air or water in the fuel lines.

10) Shut Down Noise - If the ame runs out of air before it runs out of fuel, an after burn with noise may occur. That may be the result of a faulty cut-o valve in the fuel pump, or it may be air trapped in the nozzle line. It may take several ring cycles for that air to be fully vented through the nozzle. Water in the fuel or poor ame shape can also cause shut down noises.

TEST PROCEDURE FOR FUEL SIDE PROBLEMS

A good test for isolating fuel side problems is to disconnect the fuel system and with a 24” length of tubing, fire the burner out of an auxiliary five gallon pail of clean, fresh, warm #2 fuel oil from another source. If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the installation.

Page 47

B. Control System

The following pages contain a trouble shooting table and ow 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 XI (Start-up and Checkout).

3) In general, this table and ow charts assume that there are no loose or miswired electrical connections. Before using these

tables inspect all electrical connections on the boiler to make sure that they are tight. Also, check the wiring on the boiler against the wiring diagram in Figures 10.0 and 10.1. Ensure that incoming 120 VAC power polarity is correct and that the boiler is properly grounded.

4) All controls on the boiler are tested at least once in the manufacturing process and a defective control or component is

generally the least likely cause. Before replacing a component, try to rule out all other possible causes.

Page 48

TABLE 14.0 - DIAGNOSTIC CONDITIONS

Condition Possible Cause

Burner will not re See Flow Chart 1, page 46

Burner will not shut down See Flow Chart 2, page 47

Temperature display exceeds high limit setting

No or insucient domestic hot water

Low water light (Red LED) is on or blinking

House will not get or stay warm

Circulator contacts C1 and C2 not energized on call

for heat

All LED lights and temp display are blinking

Under normal operation, boiler temperature will continue to rise after the control shuts o the burner. This condition, known as “thermal stacking”, results from hot boiler surfaces continuing to release heat into the boiler water.

For boilers equipped with a tankless coil, make sure the low limit setting on the control is set properly. NOTE: If the low limit setting is dialed fully counterclockwise, it will shut o the low temperature maintenance feature and will function as a cold start control. If installed with an indirect water heater, check that the Zone/Indirect Switch is set in the Indirect (I) position. Verify that the end switch in the relay box controlling the indirect water heater is connected to the ZC-ZR terminals. This will ensure that the domestic water calls are prioritized.

WARNING: A low water condition is a serious and potentially dangerous condition. Do not attempt to add water to a hot boiler. Allow the boiler to fully cool before adding water.

When the LOW WATER light is on, this indicates that the control is not detecting water in the boiler. When the LOW WATER light is blinking, this indicates that the control has been programmed to provide low water lock-out protection and is currently locked out (see Manual Reset Low Water Cut-O). Pressing the TEST/SETTINGS button after the low water condition is resolved will reset the lock-out condition.

1. If the light is on and the heating system is lled with water, pull the sensor out of the well and inspect it. Make sure that the metal clip is protruding enough to come in contact with the inside of the well tube. Check that the well does not have excessive build-up of heat transfer grease that may interfere with the clip contacting the well.

2. Remove well and examine for excessive residue build-up. Clean and re-install.

1. Check for air-bound radiators.

2. Check thermostat settings including heat anticipator settings (common on non-digital thermostats).

3. Check the Economy setting. The Economy feature, much like outdoor reset controls, lowers average boiler temperature and can slow or, in some cases, prevent the house from coming up to temperature. Move to a lower setting (see “Setting the Economy Feature”).

Check to see that boiler water is at or above 125°F. On a call for heat, the control will not permit the circulator to operate if the boiler water temperature is below 125°F (see “Circulator Hold O”).

If the LED lights and the temp display are blinking alternately, this indicates the control has sensed a boiler temperature of 250°F. When this occurs, the control pulses the burner relay and then shuts down and locks-out the burner. The system should be analyzed to determine the cause of the overheating condition. Check that the sensor is inserted all the way into the well so it can accurately sense the temperature of the boiler water. Check the load on the burner contacts: If the load exceeds the 7.4 Amp rating, the contacts may have welded. Correct the overloading condition and replace the control before reenergizing the system. If the load on the contacts is below the rating, check system wiring and operation as well as the control’s high limit setting. If the cause of the overheating is found and the system is deemed safe, the control can be reset by removing power from the control and then repowering while simultaneously pressing the Test/Settings button on the top of the control. If the cause of the overheating condition is not determined, the control should be replaced.

Page 49

Troubleshooting Flow Chart 1 – Burner Will Not Fire

Does the

Display Read

the

Green LED

YES

Yellow

(HI

TEMP

On?

the

LED

)

(TEMP ACTIVE)

Red LED (LOW

WATE R) On?



YES



YES



YES

The

Control is

Purging Latent

Heat

from

oiler.



The Control

Not Power



The

Control is

ensing

Low

Water.



The Control

Sensing T

emperature.

the

ed.

High

The Thermal Pre-Purge feature holds off the burner until the control determines the heat

call.



The Temp Active LED powered.

�

Check

for



CAUTION – ALW

The burner



�

Check that the system

�

Check that the sensor between



�

Check that the control

ee pages 38 and 39

The burner

high

limit

differential set-point

�

Check that the high temperature setting

the latent heat

will

on at all

120 VAC on terminals L1 and

AYS ALLOW A BOILER TO COOL BEFORE

will not

fire

until

the

filled with

its

spring clip and the copper well tube

will not

inserted fully into the well and

tightly clamped

for

additi

fire

until

the boiler water has dropped

times when the control

L2.

low

water condition

water.

onal

oubl

eshooting i

(10°

below high

is correct.

the boiler can

ADDING WATER

the

limit setting).

is satisfied.

is made.

well.

nformation.

satisfy

cont

to the

act

the

Yellow

LED

(TARG

ET)

On?

the

Thermost

(T-T) Calling

for Heat?

YES

There

120 VAC

Between B1

and B2?



YES

The Boiler has

Reached

arget

emperature.

  



YES

the

External Zone

(ZC-ZR) Calling

for Heat?

YES



The Control

is Operat

Properly.

When the ECONOMY function



demand and establishes Target boiler temperatures below the

the

limit

setting

conserve fuel. The burner



emperature drops

ifferential.

  

Low Limit Dial

Set

to OFF?

active, the control monitors heati

the automatically calculated Target Temp



 

the

 

YES



HydroStat

ing

�

supplying 120 VAC

Recheck wiring and operation

the burner

burner and other

will

not fire until the boiler

When the

low t setting HydroStat start control. The will not a call (T-T) (

ZC-ZR).

Set thermostat

�

for fire.

� If

less coil, set the Temperature Limit maintain t

emperature

set

will

act as a

fire unless there

from

the thermost

an external

heat. Burner should

the boiler has a t

emperature.

circuit.

limit controls.

OFF,

burner

to call

high

the

cold

zone

ank-

Low

Replace

ontrol

both the red and yellow LEDs are

there

a call

120 VAC � If

120 VAC

fire the burner, there

terminals B1 and B2.

is not

replaced.

present, the control should

off and

will be

Page 50

Troubleshooting Flow Chart 2 – Burner Will Not Shut Down

Is the

Red LED

(LOW WATER)

On?

Is either

Yellow LED

On?

Is the

Thermostat

(T-T) Calling

for Heat?

Is the

External Zone

(ZC-ZR) Calling

for Heat?

YES

The Control is

Sensing

Low Water.

The Control has

Reached Target

or High Limit Temperature.

The Control is

Operating Normally.

The Control is

Operating Normally.

WARNING!

TURN OFF POWER TO BURNER IMMEDIATELY!

CAUTION – ALWAYS ALLOW A BOILER TO FULLY COOL BEFORE ADDING WATER.

 Recheck wiring. Make sure that burner is wired to

B1. Burner should never fire when red or yellow LED is lit.

The burner will continue to fire when there is a call from the thermostat or external zone.

Is the

Low Limit Dial

Set to OFF?

YES

Is there

120 VAC between

B1 and B2?

YES

Replace Control.

 Check temperature display. When the Low Limit is

set, the HydroStat will fire the burner until the temperature reaches the Low Limit Setting.

Recheck

Wiring.

If there is no call for heat (from T-T, ZC-ZR or Low Limit), there should be 0 VAC between B1-B2.

 If there is voltage between B1-B2, the control

should be replaced.

When there is no call to fire the burner, the voltage should be 0 volts between B1 and B2.

 Make sure the burner is wired to B1.

Page 51

XV Parts

KEY # DESCRIPTION

1 HEAT EXCHANGER ASSEMBLY 1 410012 410012 410013 410013 410014 410015

2 SPANNER BAR 2 410402 410402 410403 410403 410404 410405

3 NYLON GLIDE 700111 4 4 4 4 4 4

4 HEX HD CAP SCREW 5/16-18 X 7/8” 900109 10 10 10 10 10 10

5 FLAT WASHER 5/16” 900102 13 13 13 13 13 13

6 HEX JAM NUT 5/16-18 900103 4 4 4 4 4 4

7 HINGE BRACKET 410010 1 1 1 1 1 1

8 HEX HD CAP SCREW 5/16-18 X 7/8” 900109 2 2 2 2 2 2

9 SWING DOOR 410020 1 1 1 1 1 1

10 SWING DOOR INSULATION LESS POCKETS 410021 1 1 1 1 1

10 SWING DOOR INSULATION WITH POCKETS 410023 1

11 1/2” DIA ROPE GASKET - SWING DOOR 410024 1 1 1 1 1 1

12 1/8” DIA ROPE GASKET - OBSERVATION PORT 410032 1 1 1 1 1 1

13 OBSERVATION PORT COVER 410022 1 1 1 1 1 1

14 SOCKET HD CAP SCREW 5/16”-18 X 3/4” 900108 2 2 2 2 2 2

15 HEX HD TAP BOLT 3/8”-16 X 1-3/4” 900170 2 2 2 2 2 2

16 FLAT WASHER 3/8” 90-036 2 2 2 2 2 2

17 SMOKEBOX 410006 1 1 1 1 1 1

18 BRASS SQUARE HD PIPE PLUG 1/4” NPT 950041 1 1 1 1 1 1

19 SMOKEBOX COLLAR - 5” DIA. 410025 1 1

19 SMOKEBOX COLLAR - 6” DIA. 410026 1 1 1

19 SMOKEBOX COLLAR - 7” DIA. 410027 1

20 CLEAN OUT COVER 410004 2 2 2 2 2 2

21 1/2” DIA ROPE GASKET - CLEAN OUT COVER 410005 EA EA EA EA EA EA

22 THIRD PASS BAFFLE * 410007 2 2 2 2* 2* 2*

23 SECOND PASS BAFFLE - 080 410009 2

24 SECOND PASS BAFFLE - 100/130/160 410008 2 2 2

25 REFRACTORY BLANKET * 1 NA NA 415003 415003* 415004* 415005*

* Not used in all applications - consult Table 4.1

QTY. OR CROWN

FWZ060 FWZ080 FWZ081 FWZ100 FWZ130 FWZ160

QUANTITY PER BOILER OR CROWN PART NUMBER

Page 52

Page 53

KEY # DESCRIPTION

30 FRONT JACKET PANEL 410310 1 1 1 1 1 1

31 RIGHT SIDE JACKET PANEL 1 410302 410302 410303 410303 410304 410305

32 LEFT SIDE JACKET PANEL 1 410312 410312 410313 410313 410314 410315

33 REAR JACKET PANEL 410301 1 1 1 1 1 1

34 TOP JACKET PANEL 1 410322 410322 410323 410323 410324 410325

35 FIBERGLASS INSULATION WRAPPER 1 412302 412302 412303 412303 412304 412305

36 POWER RECEPTACLE 960041 1 1 1 1 1 1

37 CROWN NAMEPLATE 98-004 1 1 1 1 1 1

38 #10 X 1/2” SHEET METAL SCREW 900120 15 15 15 15 15 15

39 5/16”-18 X 1/2” PAN HEAD SCREW 900420 4 4 4 4 4 4

40 5/16”-18 X 3” THREADED STUD 900111 2 2 2 2 2 2

41 5/8”O.D. X 2-5/32” LONG JACKET SPACER 410200 2 2 2 2 2 2

42 5/16”-18 ACORN NUT 146-95-042 2 2 2 2 2 2

43 RECEPTACLE ENCLOSURE 410090 1 1 1 1 1 1

* NOT SHOWN

QTY. OR

CROWN

FWZ060 FWZ080 FWZ081 FWZ100 FWZ130 FWZ160

QUANTITY PER BOILER OR CROWN PART NUMBER

Page 54

KEY # DESCRIPTION

50 BECKETT OIL BURNER ASSY

50 RIELLO OIL BURNER ASSY

50 CARLIN OIL BURNER ASSY

QTY. OR

CROWN PN

1 41060B 41080B 41081B 41100B 41130B 41160B

1 41060R 41081R 41100R 41130R 41160R

1 41081C 41100C 41130C 41160C

FWZ060 FWZ080 FWZ081 FWZ100 FWZ130 FWZ160

QUANTITY PER BOILER OR CROWN PART NUMBER

51 TEMPERATURE & PRESSURE GAUGE 950039 1 1 1 1 1 1

52 HYDROLEVEL 48-222 ELECTROWELL 450354 1 1 1 1 1 1

53 HYDROSTAT 3250 PLUS 450352 1 1 1 1 1 1

54 2” NPT RETURN INJECTOR PIPE 410050 1 1 1 1 1 1

55 2” X 1-1/2” NPT REDUCING ELBOW 950036 1 1 1 1 1 1

56 1-1/2” NPT X 3” NIPPLE 950023 1 1 1 1 1 1

57 1-1/4” NPT X 4” NIPPLE 95-033 1 1 1 1 1 1

58 1-1/4” X 3/4” REDUCING COUPLING 950117 1 1 1 1 1 1

59 3/4” NPT DRAIN VALVE 95-041 1 1 1 1 1 1

61 1-1/2” NPT X 8” NIPPLE 950028 1 1 1 1 1 1

62 1-1/2” NPT CROSS 950029 1 1 1 1 1 1

63 1-1/2” NPT PLUG 95-143 1 1 1 1 1 1

64 1-1/2” X 3/4” BUSHING 95-096 1 1 1 1 1 1

65 3/4” NPT X CLOSE NIPPLE 95-105 2 2 2 2 2 2

66 3/4” NPT 90° ELBOW 95-057 1 1 1 1 1 1

67 3/4” NPT RELIEF VALVE (30 PSI) 95-040 1 1 1 1 1 1

68 BURNER TUBE INSULATION 415001 SEE TABLE 4.1 FOR WHERE USED

* BAROMETRIC DRAFT CONTROL 1 130022 130022 13-020 13-020 13-020 13-018

* CIRCULATOR (TACO 007) 95-012 1 1 1 1 1 1

* 1-1/2” NPT TACO FLANGE SET 950150 1 1 1 1 1 1

* FWZ STANDARD WIRING HARNESS 9601903 1 1 1 1 1 1

* NOT SHOWN

1. PART NUMBERS PROVIDED ARE FOR FULLY CONFIGURED BURNERS AND INCLUDE PRIMARY SAFETY CONTROL, NOZZLES, BURNER CORD ASSEMBLIES AND (WHERE APPLICABLE) LOW FIRING RATE BAFFLES. SOME BURNERS ARE ALSO SUPPLIED WITH BLANKETS AND BAFFLES. SEE TABLE 4.1 FOR DETAILS.

Page 55

Page 56

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

www.crownboiler.com

Crown Boiler FWZ Series, FWZ060, FWZ100, FWZ081, FWZ130 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual