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Crown TWZ065, Installation Instructions Manual

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Summary of Contents for TWZ065

Page 1: ...roper instal lation 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 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 crow...

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Page 3: ...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 first 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...

Page 4: ...Installing 4 IV Locating the Boiler 5 V Air for Combustion Ventilation 7 VI Venting 11 VII System Piping 13 VIII Tankless Heater Piping 17 IX Fuel Line Piping 18 X Wiring 21 XI Start Up Checkout 26 XII Operation 29 XIII Service Maintenance 36 XIV Troubleshooting 39 XV Parts 42 ...

Page 5: ...N TABLE 2 1 GENERAL SPECIFICATIONS A B C TWZ065 3 0 65 80000 70000 86 1 16 0 17 3 8 8 5 16 6 TWZ075 3 0 75 91000 79000 85 8 16 0 17 3 8 8 5 16 6 TWZ100 3 1 00 120000 104000 84 3 16 0 17 3 8 8 5 16 6 TWZ090 4 0 90 111000 97000 86 0 20 0 22 3 8 10 13 16 7 TWZ125 4 1 25 152000 132000 85 1 20 0 22 3 8 10 13 16 7 TWZ150 4 1 50 179000 156000 84 0 20 0 22 3 8 10 13 16 7 TWZ120 5 1 20 147000 128000 86 0 2...

Page 6: ...tems 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 Power Side Wall Venting Important Note Two problems arise when any ...

Page 7: ...fficult 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 4 1 4 Do not install this boiler in a location where gasoline or other fl...

Page 8: ...6 FIGURE 4 1 installation over a combustible floor ...

Page 9: ...o 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...

Page 10: ...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 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...

Page 11: ...9 FIGURE 5 1 ALLAIR FROM OUTDOORS VENTILATED CRAWL SPACE AND ATTIC FIGURE 5 2 ALLAIR FROM OUTDOORS VIA VENTILATED ATTIC ...

Page 12: ...10 FIGURE 5 3 ALLAIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM FIGURE 5 4 ALLAIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM ...

Page 13: ...ry 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 TWZ series boiler into an unlined chimney FIGURE 6 0 TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS WARNING IMPROPER VENTING MAY RESULT IN PROPERTY DAMAG...

Page 14: ...oval of chimney connector for cleaning 11 Install the barometric draft regulator in accordance with the regulator manufacturer s instructions 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 as well as the barometric draft regulator Use at least three screws at each joint Power Side Wall Venting Impor...

Page 15: ... 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 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 RE...

Page 16: ...vents will usually be required in other parts of the system to remove air during initial fill 6 Low Water Cut Off Required in some situations A low water cut off is required when the boiler is installed above radiation In addition some codes such as ASME CSD 1 require low water cut offs Codes may also require that this low water cut off have a manual reset function The low water cut off may be a f...

Page 17: ...direct 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 7 3 will minimize the amount of time that the boiler operates with return temperatures below 120 F on these systems A bypass is installed as shown to divert some supply water directly into the retur...

Page 18: ...ired 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 pumping systems 4 Systems containing oxygen Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a cast iron boiler such as the TWZ Some examples include Radiant s...

Page 19: ...odic gasket replacement or other maintenance which requires removal of the heater from the 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 heater as shown in Figure 8 1 The components in this system and their functions are as follows 1 Mixing Valve R...

Page 20: ...DITION 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 lo cal authority having jurisdiction and the latest edition of the Standard for the Installation of Oil Burning Equipment ANSI NFPA 3...

Page 21: ...erted 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 pump suction port See Figure 9 4 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 Distance H allo...

Page 22: ... 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 systems require an oil filter On TWZ065 and TWZ075 boilers the use of a Garber cartridge type filter is recommended 9 Use only 2 Fuel Oil with physical and chemical characteristics meeting the requi...

Page 23: ...th 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 Wiri...

Page 24: ...tside walls walls adjacent to unheated areas locations subject to drafts Provide Class II circuit between thermostat or zone controls and boiler 1 2 3 Used to connect EnviraCom thermostat or other EnviraCOM device approved by Crown for use with this boiler refer to instructions provided with EnviraCOM device 3 Adding a Second Circulator Zone The control provided on TWZ boilers can be used to contr...

Page 25: ...23 FIGURE 10 0 CONNECTIONS DIAGRAM BOILERS LESS TANKLESS HEATER COLD START CONTROL ...

Page 26: ...24 FIGURE 10 1 CONNECTIONS DIAGRAM BOILERS WITH TANKLESS HEATER WARM START CONTROL ...

Page 27: ...25 FIGURE 10 2 CONNECTIONS DIAGRAM FOR BURNER PRIMARY CONTROLS Carlin 40200 Beckett 7505 Riello 530SE ...

Page 28: ...port 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 level is in excess of a 1 open the air adjustment to bring the smoke level below a 1 16 Make sure that the oil pressure matches that shown in Table 11 0 for the burner supplied Adjust pressure if requ...

Page 29: ...system 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 room displayed near boiler TABLE 11 0a BECKETT BURNER CONFIGURATION AND SETUP DATA TWZ065 TWZ075 TWZ100 TWZ090 TWZ125 TWZ150 TWZ120 TWZ175 TWZ200 BURNER MODEL AFG AFG AFG AFG AFG AFG AFG AFG AFG AIR ...

Page 30: ...11 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 0c RIELLO BURNER CONFIGURATION AND SETUP DATA BURNER MODEL 40F5 40F5 40F5 40F10 40F10 40F10 STANDARD DEL DEL DEL DEL HAGO DEL NOZZLE 0 60 60A 0 85 60W 1 00 60A 1 25 60B 1 35 45B 1 65 45B PUMP PRESS ps...

Page 31: ...the 3 digit LED and three buttons shown in Figure 12 0 The L7248L and L7224A have four basic modes of operation also see Figure 12 1 1 Status Mode This is the default mode of operation for the control In it the display alternates between StA and a number indicating the current status of the boiler A list and description of these status numbers is shown in Table 12 2 2 Operating Mode Provides addit...

Page 32: ...ress or Error Detected by Aquastat Lockout Temperature Units Circulator Overrun High Limit Setting High Limit Differential Cold Start Control Only Thermal Purge Temp Thermal Purge Time DHW Priority ON OFF Use of 2 nd Zone N Error Detected by Aquastat N Y Except as shown above press I to navigate through menu Use to change parameters in Adjustment Mode Y Low Limit Setting Warm Start Control Only Lo...

Page 33: ...rature always the same as the high limit setting HL High Limit Set Point Boiler will stop firing if boiler water temperature exceeds this value Circulator s will continue to operate HdF High Limit Differential If high limit setting is reached boiler water temperature will need to drop by this amount before boiler will again fire during the same call for heat LL Low Limit Set Point Warm Strat Contr...

Page 34: ...ity ON ON or OFF F C Temperature Units F F or C bAc Exit Adjustment Mode N A N A TABLE 12 5b ADJUSTMENT MODE PARAMETERS FOR L7224A WARM START CONTROL Status Description Factory Setting Permissible Range HL High Limit Set Point 180F 140 240F LL Low Limit Set Point 110F 110 220F LdF Low Limit Differential 10F 10 25F ZC ZC and ZR Terminal Function Zr Zr Zone Request Call for Heat OR dh DHW or 2nd Hea...

Page 35: ... off on high limit the burner will not restart during the next call for heat until the thermal purge requirements described below are met On the Warm Start Boiler Control the High Limit Differential is fixed at 10F ZC ZC and ZR Terminal Functions Cold Start Boiler Control Terminals ZC and ZR can be used to control a IWH circulator or a second heating zone circulator using a 120VAC thermostat see S...

Page 36: ...g used for DHW ZC dh the burners will immediately come on upon a call for DHW as long as the water temperature is below the high limit setting Thermal purge is only invoked when a call for heat first appears and the boiler is not already firing For this reason if the boiler is already firing in response to an call for heat and a call for heat appears at the second zone the boiler will continue to ...

Page 37: ...which causes the DHW demand to be indefinite Figure 12 7 describes the behavior of both the Heating and DHW Circulators with Pt turned both ON and OFF F C Temperature Units Determines whether temperature units on the L7248L are displayed in F or C Note that this selection only applies to the temperature displayed on the LED shown in Figure 12 0 Temperature units must be selected independently on t...

Page 38: ...r and breeching piping is done in reverse order of removal Make sure canopy is sealed tight to the casting replace ceramic fiber sealing strips 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 sure that all vent system supports are intact c Inspect joint...

Page 39: ...ve pressure 9 Open fuel line shut off 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 WARNING Water leaks can cause severe corrosion damage to the boiler or other system components Repair any leak...

Page 40: ...ng 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 classif...

Page 41: ...ng 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 the nozzle The smaller the firing 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 fue...

Page 42: ...ouble shooting tables for use in diagnosing control problems When using these tables 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 these tables assume that there are no loose or miswir...

Page 43: ...ee Table 12 6 hr On Heating Circulator Off Heating Circulator is being forced off on DHW priority normal operation if Pt ON see Table 12 7 See causes for DHW Circulator off below dh On DHW Circulator Off Loose connection in circulator wiring Defective circulator Circulator is running but system problem is preventing circulation StA 8 Burner Off No LEDs illuminated on Burner Primary control Externa...

Page 44: ... ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 10 TARGET WALL REPLACEMENT KIT 270025 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 12 SWING DOOR STANDARD 270020 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 13 BURNER SWING DOOR HINGE ALTERNATE 290035 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 15 FLAME INSPECTION COVE...

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Page 46: ...1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 55 BLANK UTILITY BOX COVER 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 130516 130517 130518 130519 60 CARLIN BURNER ASSY NOTE 1 1 ea 130521 130522 130523 130524 130525 130526 130527 130528 60 RIELLO BURNER ASSY NOTE...

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Page 48: ...46 PN 980270 Rev 10 TWZ 12 12 Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com ...

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