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Crown Boiler FWZ060, Installation Instructions Manual, Page: 1 / 52

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1

FWZ Series

 

Oil-Fired Hot Water Boilers

 

INSTALLATION INSTRUCTIONS

     

Models:

FWZ060

FWZ080  

FWZ100

FWZ130

FWZ160

WARNING

: Improper installation, 

adjustment, alteration, service or 
maintenance can cause property 
damage, injury, or loss of life. 
For assistance or additional 
 
installer, service agency  or  the oil 
supplier. Read these instructions 
carefully before installing.

D

E S I G N E D   T O  

L

E A D

Manufacturer of Hydronic Heating Products

P.O. Box 14818  3633 I. Street

Philadelphia, PA  19134

www.crownboiler.com

Summary of Contents for FWZ060

Page 1: ...alteration service or maintenance can cause property damage injury or loss of life For assistance or additional installer service agency or the oil supplier Read these instructions carefully before i...

Page 2: ...2...

Page 3: ...r 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...

Page 4: ...2 Table of Contents 05 7 0 0 5 XV Parts 44...

Page 5: ...jk 0jk k 5 0 j 5 7C5 5 jk 0jk k 5 0 j 5 7C 55 00 jk 0jk k 5 05 0 j 7C 5 0 jk 5k k j j 0 0 7C 5 j jk k k j j 0 D E 7 5 TABLE 2 1 RATING DATA BOILER K QNKQ N YK NU q T YW YQ NK Q NU T YW N Y NKq QKZ QK...

Page 6: ...R VIEW FRONT VIEW NOTE THIS DIMENSION INCREASES AND IS CONTROLLED BY SMOKEPIPE BECKETT AFG PORT GAUGE BURNER FLOOR TEMP PRESSURE LINE RELIEF BURNER OBSERVATION FLAME DOOR SWING VALVE 1 1 2 FPT SUPPLY...

Page 7: ...the use of a chimney to vent the FWZ 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...

Page 8: ...allation 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 W D D 0W Q D D...

Page 9: ...0 CLEARANCES WARNING Failure to observe the following location requirements could result in property damage a fire explosion or carbon monoxide CO hazard W D D K E E D D E 5 0jk T W k Q k Q 0k k 7 T W...

Page 10: ...Standard for the Installation of Oil Burning Equipment T N N W F E G E D F T D D E E W K D F 7 D D D 7 D D D D E D G E D D E D D E E E E E D D F E k E D W G 7 7C G E D 0W E D W D G F D D D E D FIGURE...

Page 11: ...ater 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...

Page 12: ...5 FIGURE 6 0 BOILER INSTALLED IN CONFINED SPACE ALLAIR FROM INSIDE FIGURE 6 1 ALLAIR FROM OUTDOORS VENTILATED CRAWL SPACE AND ATTIC...

Page 13: ...11 FIGURE 6 2 ALLAIR FROM OUTDOORS VIA VENTILATED ATTIC FIGURE 6 3 ALLAIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM...

Page 14: ...12 FIGURE 6 4 ALLAIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM...

Page 15: ...ppliances D E E W D N D D W E D T W W 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 seve...

Page 16: ...E _WE D D FIGURE 7 0 TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS TABLE 7 1 MINIMUM RECOMMENDED BREECHING AND CHIMNEY SIZE BOILER K N QKK Y NU T N YK W N Y NKq QKZ QK KN Q N T N W Z QK K CK TN N W...

Page 17: ...n 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 syst...

Page 18: ...D W 7C5 5 j 5 5 5 00 7C5 5 5 5 5 7C 55 5 5 0 0 5 7C 5 5 5 5 j0 5 5 7C 5 0 5 5 j E _ W TQ F W K W TQ F W F D F W D 7 TQ F W D D F D E K E F D D F D D D D G E D D D D D D D 05 D 0j D D D W Q Y TQ F W F...

Page 19: ...FIGURE 8 1 INSTALLATION OF FACTORY SUPPLIED PIPING FIGURE 8 2 STANDARD BOILER PIPING...

Page 20: ...GURE 8 3 INDIRECT WATER HEATER BOILER SIDE PIPING F D W 7 Y D D D D E D D D D G D D D heater manufacturer 0W 7 D j D D D D D D D D D D D D G D F 5 met W 7C Q D D D D E D D D D G D F E E D jW Y 7 D E G...

Page 21: ...FIGURE 8 4 BYPASS PIPING FIGURE 8 5 ISOLATION OF BOILER FROM SYSTEM WITH A HEAT EXCHANGER...

Page 22: ...e 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 s...

Page 23: ...21 W F D D 5 5 0k D E k jk D Q _ W N D W G _ D 5W F TU F W E 7C5 5 7C5 5 W 0 D F FIGURE 9 0 ONE PIPE GRAVITY SYSTEM FIGURE 9 1 ONE PIPE LIFT SYSTEM...

Page 24: ...22 FIGURE 9 2 TWO PIPE GRAVITY FEED SYSTEM NOT RECOMMENDED FIGURE 9 3 TWO PIPE LIFT SYSTEM...

Page 25: ...eat 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 instr...

Page 26: ...ons is a transformer in old thermostat wiring Do not attempt to use EnviraCOM connections for any purpose not explicitly permitted by Crown Boiler Company Attempting to do so may result in unreliable...

Page 27: ...0 FIGURE 10 0 WIRING CONNECTIONS DIAGRAM FOR L7248 AQUASTAT...

Page 28: ...0 FIGURE 10 1 CONNECTIONS WIRING DIAGRAM FOR BURNER SPECIFIC PRIMARY CONTROL...

Page 29: ...sing 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...

Page 30: ...D F W _ T _ W W D E jk D 5 D D Q Y N NK KQ K POSITIVE W 2 D D W D 05W E 0 W D D E D E D E 5 00W D F E 0 W D the burner 0jW T E W D D D E D D Q 0 W 5 E Q 0 W E T W D D D E FIGURE 11 0 FLUE DRAFT TAPPI...

Page 31: ...K T D W 5 5 50 5 5 50 5 5 50 5 5 50 5 5 50 K T W K 2 TvW N 0 0 0 0 0 WARNING Attempts to use burners or burner configurations other than those shown in Table 11 1 could result in reliability problems...

Page 32: ...ion Y D 0j F D D D D D E D D E E D E D DDD D D 055 K E E k B Reading Status and Using Menu _ E D E D K D 0 5 0j T 0 W 1 E D 6W D 0 0 2 I D 0 5 7 E D EW D D 0 I D D 0 0 k D 0 0 E I 6W E D K K E UU E D...

Page 33: ...MODE Visible when Lockout is Present UU Code for Error Present Table 14 0 Press E F Return to Status Mode Press or Error Detected by Aquastat Temperature Units 2U Circulator Overrun High Limit Setting...

Page 34: ...er will keep the display on the actual reading For example pressing while reading boiler temperature as shown in Figure 12 3 will keep the display on 180 for as long as this button is held This makes...

Page 35: ...F E F K N N WARNING Improper adjustments to control parameters could result in unreliable boiler operation property damage personal injury or loss of life Adjustments should only be made by a qualifi...

Page 36: ...T W N C C D E D CQ C K T K D kW 7C D D G D TABLE 12 6 EXAMPLES OF THERMAL PURGE OPERATION K Heat From Use of Y7 C Time 3WW 6WW 1 T T N 2 min j5 5 0k 2 T T N 2 min j5 5 0k D 0 OR D j5 ZR Y7 T GKW 2 min...

Page 37: ...N Y7 F GK 2 N N N OFF Y7 F GK 2 N OFF OFF N Y7 F GK 2 OFF N N OFF Heat F U 21 or 2 N OFF OFF N Heat F U 21 or 2 OFF N N N Heat F U 21 or 2 N N 2U T W D Y D E E E D G D T G D W D C D E 33 T W E D D D...

Page 38: ...III 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 seve...

Page 39: ...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...

Page 40: ...r 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...

Page 41: ...E D E 7 G D 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...

Page 42: ...5 K 05 D jW E C If Display is Blank 05 0 D D If Control Shows UU Code j 5 E If Control Shows 6W Code but Other Problem Present If no UU T I WE j TABLE 14 0 ERROR CODES Error D D K D D K D F D D T W D...

Page 43: ...14 1 FAULTS WITHOUT ERROR CODE PRESENT 6W KU 2 GK 2 E D E D E E D E E 6W KU 2Q Burner Off 7 T W T 0 W KU 2Q Y Y Y7 T 3W N 0 W Y7 D GK 2Q Y7 D E 6W Burner Off N K on Burner K 7 D 0 0j 6W Burner Off K o...

Page 44: ...42 Notes...

Page 45: ...j Notes...

Page 46: ...2 2 2 2 7 NU Q j 5505 1 1 1 1 1 5 7 NU Q N N K K j 550 1 1 1 1 5 7 NU Q N N 7 Y K j 550 1 11 0k Q K U K 7 NU Q j 550j 1 1 1 1 1 12 k Q K U K KQ N Q j 55 0 1 1 1 1 1 KQ N Q KQ j 5500 1 1 1 1 1 14 K Y Q...

Page 47: ...j...

Page 48: ...5 0 j 5 0 j 5 j 5 j j 5 QK Q K NK j 5 5 1 1 1 1 1 j K NK 1 j 5 00 j 5 00 j 5 0 j 5 0j j 5 0 KQU N N 7Q KQ 1 j 0 50 j 0 50 j 0 5 j 0 5j j 0 5 7KQ QK K K 55j 1 1 1 1 1 Q 7N N K K 55j 1 1 1 1 1 5 0k YKK...

Page 49: ...j...

Page 50: ...k N K 550 1 1 1 1 1 jk N jk N K 5 1 1 1 1 1 jk jk QK NU NU 5 1 1 1 1 1 jk N Q N K 5j 1 1 1 1 1 0k N k N K 550 1 1 1 1 1 0 0k N Q 550 1 1 1 1 1 0k N U j 1 1 1 1 1 j 0k jk Y NU 5 1 1 1 1 1 jk N K N K 5...

Page 51: ...j...

Page 52: ...N 50 5 FWZ Q 5 Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com...

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