Crown Boiler TWZ090, TWZ100, TWZ075, TWZ065, TWZ200 User Manual
...
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause property
damage, injury , or loss of life.
For assistance or additional
information, consult a qualified
installer , service agency or the
oil supplier. Read these instructions carefully before installing.
D
ESIGNED TO
L
EAD
TWZ Series
Oil-Fired Hot Water Boilers
INST ALLA TION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Models:
• TWZ065
• TWZ075
• TWZ100
• TWZ090
• TWZ125
• TWZ150
• TWZ120
• TWZ175
• TWZ200
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
7HO)D[ZZZFURZQERLOHUFRP
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Table of Contents
I. Product Description ............................................................. 1
II. Specifications ....................................................................... 1
III. Before Installing...................................................................2
IV. Locating the Boiler............................................................... 3
V. Air for Combustion & Ventilation........................................ 5
VI. V enting .................................................................................. 9
VII. System Piping Connections ............................................... 11
VIII. T ankless Heater Piping ................................15
IX. Fuel Line Piping...........................................16
X. Wiring .......................................................... 19
XI. Start-up and Checkout..................................21
XII. Service & Maintenance................................24
XIII. Parts .............................................................27
I Product Description
The TWZ series boiler is a cast iron oil-fired water boiler designed for use in closed forced circulation heating systems.
This boiler must be vented by natural draft into a lined masonry or metal chimney, or Type L vent. An adequate supply of air
for combustion, ventilation and dilution of flue gases must be available in the boiler room. An optional tankless heater is
available to generate domestic hot water.
II Specifications
SUPPLY PIPE
LOCATION
FIGURE 1: GENERAL CONFIGURATION *
*Notes: 1. Tankless Coil Opening Not Present On Less-Coil Boilers.
2. Circulator Supplied Loose - May Be Installed On Supply Or Return.
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TABLE 1a: GENERAL SPECIFICATIONS
g
(
)
g (
)
A
)
A
(
(
)
(
)
Burner
Number of
Boiler Model
TWZ065 3 0.65 80000 70000 86.1 16.0 16 1/2 8 5/16 6
TWZ075 3 0.75 91000 79000 85.8 16.0 16 1/2 8 5/16 6
TWZ100 3 1.00 120000 104000 84.3 16.0 1 6 1/2 8 5/16 6
TWZ090 4 0.90 111000 97000 86.0 20.0 21 1/2 10 13/16 7
TWZ125 4 1.25 152000 132000 84.9 20.0 2 1 1/2 10 13/16 7
TWZ150 4 1.50 179000 156000 83.8 20.0 2 1 1/2 10 13/16 7
TWZ120 5 1.20 147000 128000 86.0 24.0 2 6 1/2 13 5/16 8
TWZ175 5 1.75 210000 183000 83.5 24.0 2 6 1/2 13 5/16 8
TWZ200 5 2.00 238000 207000 83.3 24.0 2 6 1/2 13 5/16 8
Sections
Input
Gal/hr
DOE Heating
Capacity
Btu/hr
I=B=R Net
Ratin
Btu/hr
FUE (%
pprox. Water
Content
Gal)
Dimensions (inches)
"A" "B" "C"
TABLE 1b: OPTIONAL TANKLESS HEATER RATINGS
Boiler Model
TWZ065
TWZ075
TWZ100
TWZ090
TWZ125
TWZ150
TWZ120
TWZ175
TWZ200
Tankless Heater Ratin
Gal/min
2.75
3.00
3.25
3.25
3.75
4.00
3.50
4.25
4.75
Notes:
1. Net Ratings are based on piping and pick-up allowances of 1.15.
2. Burner Capacity Rating, GPH is based on #2 oil with a Gross
Heating Value equal to 140000 BTU/Gal.
3. Maximum Working Pressure, Water - 50 PSI.
4. Tankless Heater Ratings based on I=W=H test standard.
III Before Installing
1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict
accordance with this manual and the requirements of the authority having jurisdiction.
• In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the latest
edition of Installation of Oil Burning Equipment (ANSI/NFPA31).
• Where required by the authority having jurisdiction, this installation must conform to the latest edition of Standard for
Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1).
2) Make sure that a properly sized chimney is available which is in good condition. Consult the authority having
jurisdiction, Part VI of this manual, and ANSI/NFPA31 for additional information on venting requirements.
Power (“Side Wall”) Venting - Important Note
Two problems arise when any oil-fired appliance is power vented:
1. There is sometimes an accelerated rate of soot buildup on the oil burner cad-cell, spinner etc.
2. There is a potential for severe damage to the side of the structure in the event that the boiler operates at a high smoke
level. This can happen for many reasons, some of which are out of the control of both the installer and appliance
manufacturer.
Crown Boiler Company recommends the use of a chimney to vent the TWZ series boilers. If a power venter must be used,
it is the responsibility of the installer and power vent manufacturer to “engineer” the power vent system. CROWN
BOILER COMPANY WILL ASSUME NO RESPONSIBILITY FOR DAMAGE TO SIDING, ETC. FROM A POWER
VENTED OIL-FIRED BOILER. THIS APPLIES REGARDLESS OF THE CAUSE OF THE SOOTING.
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3) Make sure that the boiler is correctly sized:
• For heating systems employing convection radiation (baseboard or radiators) use an industry accepted sizing
method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics
Institute in Berkeley Heights, NJ.
• For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.
• For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE
Heating Capacity required for the Mega-Stor or the net rating required for the heating system, whichever
results in the larger boiler.
• For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s
instructions for boiler output requirements.
4) In some cases, boilers installed at altitudes above 2000ft may require a different burner configuration from that at sea
level. Consult the local Crown representative for more information.
IV Locating the Boiler
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 2.
Front – 24”
Left Side – 6”
Right Side – 6”
Rear – 6”
Top – 6”
Single Wall Chimney Connector (to combustible construction) - 18”
• A 24” service clearance from the jacket is recommended from the top of the boiler. This clearance may be
reduced to that shown above; however, servicing the boiler will become increasingly difficult as this clearance
is reduced.
2) If listed Type L vent is used, follow vent pipe manufacturer recommendations for minimum clearances.
3) Do not install this boiler directly on a combustible surface. Where it is desired to install the TWZ over a non-carpeted
combustible surface, install the boiler on the base shown in Figure 3.
4) Do not install this boiler in a location where gasoline or other flammable 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.
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18*
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FRONT VIEW SIDE VIEW
* CLEARANCE FROM SINGLE WALL C ONNECT OR TO COMBUSTIBLE CONSTRUC TION
FIGURE 2: CLEARANCES
6
24
6
Sh ee t Me ta l (2 4 GA o r Thicker)
0.47"
4“ MI N.
Openings Aligned To Permit Free Air Circulation
Hollow Masonry Blocks
FIGURE 3: INSTALLATION OVER A COMBUSTIBLE FLOOR
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Combustible Surface
V Air for Combustion and Ventilation
Sufficient fresh air must be supplied for combustion and ventilation. Provisions for combustion and ventilation air for oil
burning equipment must be made in accordance with Section 1.5, Air for Combustion and Ventilation, in the latest edition
of Installation of Oil Burning Equipment (ANSI/NFPA 31).
To ensure an adequate supply of air for combustion, ventilation and flue gas dilution, start by determining whether the
boiler is to be installed in a building of unusually tight construction. A building of unusually tight construction is defined as
having all of the following features:
• Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm
or less with openings gasketed and sealed
• Weather stripping has been added on openable windows and doors
• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and
floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and
at other openings.
For Buildings of Other than Unusually Tight Construction
1) Determine whether the boiler is to be installed in a confined space - A confined space is defined as having a volume
less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To determine whether the boiler
room is a confined space:
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 confined space.
Example:
A TWZ090 and a water heater are to be installed in a room measuring 6 ft - 3 in x 7 ft with an 8 ft ceiling. The
water heater has an input of 30000 BTU/hr:
Input of TWZ090 = 0.90 Gal/hr x 140000 BTU/Gal = 126000 BTU/hr
Total input in thousands of BTU/hr = (126000 BTU/hr + 30000 BTU/hr)/1000 = 156
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft
350/156 = 2.24. Since 2.24 is less than 50, the boiler room is a confined space.
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2) Unconfined Space - Natural infiltration into the boiler room will normally provide adequate air for combustion and
ventilation without additional louvers or openings into boiler room.
3) Confined Space - Provide two openings into the boiler room, one near the floor and one near the ceiling. The top edge
of the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the
floor (Figure 4).
• Each opening must have a free area of 1 square inch per 1000 BTU/hr input of all fuel burning appliances in the
boiler room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per
opening.
• If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per
1000 BTU/hr of total appliance input, install a pair of identical openings into a third room. Connect additional
rooms with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input.
• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are
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FIGURE 4: BOILER INSTALLED IN CONFINED SPACE,
ALL AIR FROM INSIDE
used, they must be no finer than ¼” (4 x 4) mesh.
For Buildings of Unusually Tight Construction:
1) Openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl
space, which communicates directly with the outdoors.
2) Two 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 floor.
3) Size openings and ducts as follows:
• Vertical ducts or openings directly outdoors (Figure 5, Figure 6, and Figure 7) - Each opening must have a free
cross sectional area of 1 square inch per 4000 BTU/hr of the total input of all fuel fired appliances in the boiler
room but not less than 100 square inches. Minimum opening size is 3 inches.
• Openings to outdoors via horizontal ducts (Figure 8) - Each opening must have a free cross sectional area of 1
square inch per 2000 BTU/hr of the total input of all fuel fired appliances in the boiler room but not less than
100 square inches. Minimum opening size is 3 inches.
• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens
are used, they must be no finer than ¼” (4 x 4) mesh.
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FIGURE 5: ALL AIR FROM OUTDOORS,
VENTILATED CRAWL SPACE AND ATTIC
FIGURE 6: ALL AIR FROM OUTDOORS,
VIA VENTILATED ATTIC
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FIGURE 7: ALL AIR FROM OUTDOORS, USING
OPENINGS INTO BOILER ROOM
FIGURE 8: ALL AIR FROM OUTDOORS, USING
HORIZONTAL DUCTS INTO BOILER ROOM
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VI Venting
Vent installation must be in accordance with local building codes, or the local authority having jurisdiction.
Typical vent installation is illustrated by Figure 9. The components of vent installation are the vent connector (breeching),
barometric draft regulator, and chimney.
1 ) Acceptable Chimneys - The following chimneys may be used to vent a TWZ 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.
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.
Do not vent a TWZ series boiler into an unlined chimney.
FIGURE 9: TYPICAL VENT SYSTEM
INSTALLATION AND COMPONENTS
3 ) Chimney and Vent Connector Sizing - See Table 2 for minimum vent connector and chimney sizing. The vent connector
size must not be smaller than boiler flue collar diameter. Where two or more appliances vent into a common vent, the
cross-sectional area of the common vent should at least equal the area of largest vent plus 50% of the area in the additional
vents.
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 flue serving an open fireplace or other solid fuel appliance.
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