Crown Boiler TWZ Series Page 1 Installation Instructions Manual Download

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TWZ Series

Oil-Fired Hot Water Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

Models:

•

TWZ065

•

TWZ075

•

TWZ100

•

TWZ090

•

TWZ125

•

TWZ150

•

TWZ120

•

TWZ175

•

TWZ200

E S I G N E D T O

E A D

Equipped with Hydrolevel

3250-Plus Control System

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.

9802705 Rev 0, 03-18

Crown Boiler Company

P.O. Box 14818

3633 I Street

Philadelphia, PA 19134

www.crownboiler.com

Summary of Contents for TWZ Series

Page 1: ...lus Control System WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or loss of life For assistance or additional information consult a qualif...

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: ...least once a year preferably at the start of the heating season The inside of the combustionchamber theventsystemandboilerfluewaysshouldbecleanedifsootorscalehasaccumulated When cleaning this boiler t...

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: ...isions 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 pos...

Page 7: ...ENERAL CONFIGURATION GAL HR MBH MBH Gal 1 25 1 50 1 20 1 75 2 00 BURNER INPUT TWZ175 TWZ200 B C 0 65 0 75 1 00 0 90 84 0 86 0 TWZ120 241 TWZ065 TWZ075 TWZ100 TWZ090 TWZ125 TWZ150 212 A 86 1 85 8 84 3...

Page 8: ...irect water heater size the boiler to have either the Heating Capacity required for the Mega Stor or the I B R Net Rating required for the heating system whichever results in the larger boiler For sys...

Page 9: ...e minimum clearances shown below Except as noted these clearances apply to all combustible con struction as well as noncombustible walls ceilings and doors Also see Figure 4 0 Front 24 Left Side 6 Rig...

Page 10: ...8 FIGURE 4 1 INSTALLATION OVER A COMBUSTIBLE FLOOR FIGURE 4 0 CLEARANCES...

Page 11: ...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 o...

Page 12: ...ing takes into account the blocking effect of mesh grills and louvers Where screens are used they must be no finer than 4 x 4 mesh For Buildings of Unusually Tight Construction 1 Openings must be inst...

Page 13: ...11 FIGURE 5 1 ALLAIR FROM OUTDOORS VENTILATED CRAWL SPACE AND ATTIC FIGURE 5 2 ALLAIR FROM OUTDOORS VIA VENTILATED ATTIC...

Page 14: ...12 FIGURE 5 3 ALLAIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM FIGURE 5 4 ALLAIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM...

Page 15: ...y 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...

Page 16: ...ill maintaining the proper clearance from the horizontal vent connector to combustibles and the proper pitch called for in 7 above 9 Vent pipe should be installed above the bottom of the chimney to pr...

Page 17: ...appliance operation and service circulator replacement etc Operation of this boiler with continuous return temperatures below 120 f can cause severe heat exchanger corrosion damage Operation of this b...

Page 18: ...Required Either a manual or automatic fill valve may be used The ideal location for the fill is at the expansion tank 5 Automatic Air Vent Required At least one automatic air vent is required Manual v...

Page 19: ...irect water heater piping to obtain the boiler water flow through the indirect water heater called for by the indirect water heater manufacturer 2 Large Water Volume Systems The piping shown in Figure...

Page 20: ...red for the heating system loop There are several other ways to connect low temperature systems to the non condensing boilers like the TWZ such as four way mixing valves and variable speed injection p...

Page 21: ...he boiler Install unions anywhere in the tankless heater piping that will facilitate removal of the heater VIII Tankless Heater Piping If the TWZ is installed with an optional tankless heater pipe the...

Page 22: ...139 04 for installation in Canada Refer also to the instruction manuals provided with the burner and oil pump WARNING Under no circumstances can copper with sweat style connectors be used Do not use c...

Page 23: ...rted to a one pipe gravity system as doing so will result in lower inlet line flow and longer filter life d TWO PIPE LIFT SYSTEM used when a fuel oil storage tank is located below an oil burner fuel p...

Page 24: ...continuous run 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 All...

Page 25: ...ed 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 lim...

Page 26: ...se 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 dir...

Page 27: ...25 FIGURE 10 0 CONNECTIONS DIAGRAM BOILERS WITH OR LESS TANKLESS HEATER...

Page 28: ...26 FIGURE 10 1 CONNECTIONS DIAGRAM FOR BURNER PRIMARY CONTROLS Carlin 40200 Beckett 7505 Riello 530SE...

Page 29: ...ort immediately or after prepurge timing has expired if a burner is so equipped Refer to burner instructions for more details 15 Immediately upon firing the boiler check the smoke level If the smoke l...

Page 30: ...tem for leaks Repair any leaks found at once 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 ro...

Page 31: ...1 0 11 0 11 0 MAX 12 5 12 5 12 5 12 5 12 5 12 5 12 5 12 5 TWZ125 TWZ150 TWZ120 TWZ175 TWZ200 0 02 0 02 0 02 0 02 BOILER MODEL TWZ065 TWZ075 TWZ100 TWZ090 1 1 1 0 02 0 02 0 02 0 02 1 1 1 1 1 TABLE 11 0...

Page 32: ...iler water temperature during a call for space heat based on thermostat cycling patterns For additional information see Part B of this section FIGURE 12 0 HYDROSTAT 3250 PLUS CONTROL COMPONENT LAYOUT...

Page 33: ...uel 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 hou...

Page 34: ...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 35: ...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 36: ...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 37: ...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 38: ...ps as needed All vent piping joints must be flue gas leak free and secured with sheet metal screws 3 Inspect the vent system a Make sure that the vent system is free of obstructions and soot b Make su...

Page 39: ...he well using pipe sealing compound Teflon tape is not recommended 11 Fire the boiler and check it out using the procedure outlined in Start up and Checkout This must include checking the burner adjus...

Page 40: ...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 41: ...into the building resulting 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...

Page 42: ...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 43: ...th the clip contacting the well 2 Remove well and examine for excessive residue build up Clean and re install Boiler will not maintain low limit temperature Check for overlapping high temperature sett...

Page 44: ...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 45: ...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 46: ...0025 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 11 REFRACTORY BLANKET 1 ea 275003 275003 275003 275004 275004 275004 275005 275005 275005 13 BURNER SWING DOOR HINGE 290035 2 ea 2 ea 2 ea 2 ea 2 ea 2...

Page 47: ...45...

Page 48: ...96 002 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 56 TRIDICATOR GAUGE 95 069 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 60 BECKETT BURNER ASSY NOTE 1 1 ea 130511 130512 130513 130514 130515 13051...

Page 49: ...47...

Page 50: ...48 SERVICE RECORD DATE SERVICE PERFORMED...

Page 51: ...49 Notes...

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

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Crown Boiler TWZ Series, Installation Instructions Manual

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