Crown Boiler FWZ Series Installation Instructions Manual Download Page 1

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FWZ Series

Oil-Fired Hot Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

E S I G N E D T O

E A D

9802605 Rev A, 06-18

Crown Boiler Company

P.O. Box 14818

3633 I Street

Philadelphia, PA 19134

www.crownboiler.com

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

carefully before installing.

Models:

•

FWZ060

•

FWZ080

•

FWZ081

•

FWZ100

•

FWZ130

•

FWZ160

Equipped with Hydrolevel

3250-Plus Control System

Summary of Contents for FWZ Series

Page 1: ...www crownboiler com WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or loss of life For assistance or additional information consult a qual...

Page 2: ......

Page 3: ...the manufacturing process as well as condensation during storage Surface rust is normal and does not affect the performance or longevity of a boiler All boilers must be installed in accordance with N...

Page 4: ...start of the heating season The inside of the combustionchamber theventsystemandboilerfluewaysshouldbecleanedifsootorscalehasaccumulated When cleaning this boiler take precaution to avoid damage to bu...

Page 5: ...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 s...

Page 6: ...ons 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 possib...

Page 7: ...1 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 Maximum working pressure Water 50psi TABLE 2 1 RATING DATA FWZ Se...

Page 8: ...W FRONT VIEW REAR VIEW NOTE THIS DIMENSION INCREASES AND IS CONTROLLED BY SMOKEPIPE FLAME OBSERVATION GAUGE PORT TEMP PRESSURE BURNER RELIEF LINE FLOOR BURNER BECKETT AFG VALVE SWING DOOR 1 1 2 FPT SU...

Page 9: ...ystems 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 whichev...

Page 10: ...d other piping trim as described in the Venting and Piping sections of this manual 5 Different baffle arrangements are used based on the boiler size and choice of burner In some cases these baf fles a...

Page 11: ...Yes3 FWZ130 FWZ0041 Beckett 41130B No No No Yes No FWZ130 FWZ0041 Riello 41130R No No No Yes No FWZ130 FWZ0041 Carlin 41130C Yes3 Yes No Yes Yes3 FWZ160 FWZ0051 Beckett 41160B No No No Yes No FWZ160...

Page 12: ...10 FIGURE 4 2 BAFFLE AND BLANKET INSTALLATION...

Page 13: ...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 t...

Page 14: ...ied 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 ot...

Page 15: ...ling and the bottom edge of the lower opening must be within 12 of the floor 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...

Page 16: ...14 FIGURE 6 0 BOILER INSTALLED IN CONFINED SPACE ALLAIR FROM INSIDE FIGURE 6 1 ALLAIR FROM OUTDOORS VENTILATED CRAWL SPACE AND ATTIC...

Page 17: ...15 FIGURE 6 2 ALLAIR FROM OUTDOORS VIA VENTILATED ATTIC FIGURE 6 3 ALLAIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM...

Page 18: ...rsonal 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...

Page 19: ...ystem operating under positive pressure 5 Do not connect the boiler into a chimney flue serving an open fireplace or other solid fuel appliance 6 Prior to boiler installation an existing chimney must...

Page 20: ...RECOMMENDED BREECHING AND CHIMNEY SIZE BOILER MODEL MINIMUM BREECHING DIA INCHES MINIMUM CHIMNEY REQUIREMENTS ROUND I D IN SQUARE TILE SIZE NOMINAL HEIGHT FT FWZ060 5 6 8 X 8 15 FWZ080 5 6 8 X 8 15 F...

Page 21: ...ief 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...

Page 22: ...o the boiler supply just above the boiler with no intervening valves between it and the boiler Use a low water cut off that breaks the 120 VAC supply to the boiler Do not attempt to wire a 24 volt low...

Page 23: ...21 FIGURE 8 1 INSTALLATION OF FACTORY SUPPLIED PIPING FIGURE 8 2 STANDARD BOILER PIPING...

Page 24: ...ses above 135 F during the first 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 flow requirement...

Page 25: ...23 FIGURE 8 4 BYPASS PIPING FIGURE 8 5 ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER...

Page 26: ...ockout 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 fro...

Page 27: ...nufacturer s instructions for tube sizing information 8 Never install manual shut off valves in the return piping of a two pipe system 9 Install a listed flexible oil line s at the burner to facilitat...

Page 28: ...26 FIGURE 9 2 TWO PIPE GRAVITY FEED SYSTEM NOT RECOMMENDED FIGURE 9 3 TWO PIPE LIFT SYSTEM...

Page 29: ...d to the 3250 Plus circulator connections or the boiler is provided with a flexible conduit whip that is to be wired to the 3250 Plus circulator connections If the circulator is not already wired to t...

Page 30: ...ce 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 wiri...

Page 31: ...29 FIGURE 10 0 WIRING CONNECTIONS DIAGRAM FOR HYDROSTAT 3250 PLUS CONTROL...

Page 32: ...30 FIGURE 10 1 CONNECTIONS WIRING DIAGRAM FOR BURNER SPECIFIC PRIMARY CONTROL...

Page 33: ...rner should fire and flame 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 Immed...

Page 34: ...air completely 23 Check thermostat operation by raising or lowering its set point as required cycling burner on and off 24 Verify primary control operation and safety features according to procedure o...

Page 35: ...E 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 1 1 1 1 1 1 FLUE CO2 MIN MAX 11 5 12 8 11 5 12 8 11 5 12 8 11 5 12 8 11 5 12 8 11 5 12 8 WARNING Attempts...

Page 36: ...989 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 SETT...

Page 37: ...on FIGURE 12 0 HYDROSTAT 3250 PLUS CONTROL COMPONENT LAYOUT IMPORTANT This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases Th...

Page 38: ...ple 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 ind...

Page 39: ...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 Manu...

Page 40: ...on the control s Thermal Targeting feature actively sets varying differentials based on system conditions This option allows for selecting a 10 20 or 30 degree fixed differential when the Economy feat...

Page 41: ...gure 12 3 TABLE 12 2 DEFAULT SETTINGS Dial Setting Feature Options Description Default Setting 1 Thermal Pre Purge Off on Purge Inactive Purge Active Off 2 Fahrenheit or Celsius F c Degrees Fahrenheit...

Page 42: ...iler temperature drops below the differential set point at which point the boiler will be allowed to fire again See Differential explanation on page 31 NOTE This LED illuminates regularly during norma...

Page 43: ...and smoke box g Clean the Combustion Chamber Use a wire or fiber bristle brush to clean the surfaces of the combustion chamber Vacuum all loose debris in the chamber h Check condition of the burner s...

Page 44: ...le 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 instructio...

Page 45: ...g 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 f...

Page 46: ...g in odor complaints 6 Dirt The use of a fuel filter 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 th...

Page 47: ...al this table and flow 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 ti...

Page 48: ...ith 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 excessiv...

Page 49: ...Temp Active LED will be on at all times when the control is powered Check for 120 VAC on terminals L1 and L2 YES Is the Red LED LOW WATER On YES NO Is the Yellow LED HI TEMP On YES The Control is Sen...

Page 50: ...echeck wiring Make sure that burner is wired to B1 Burner should never fire when red or yellow LED is lit Is either Yellow LED On The Control has Reached Target or High Limit Temperature The Control i...

Page 51: ...TS 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...

Page 52: ...50...

Page 53: ...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 NAME...

Page 54: ...0117 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...

Page 55: ...53...

Page 56: ...Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com...

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