Crown TWZ Installation Instructions
Contents
1. HONEYWELL L7284 OR L7224 AQUASTAT RELAY JuMPERO CIRCULATOR HONEYWELL BURNER R71848 MU LUN ENNET JUNCTION BOX PROTECTORELAY CONTROL IN J BOX Ou JUMPER O INTERRUPTED IGNTOR O INTERMITTENT TRANSFORMER BURNER MOTOR 0 LIMIT BURNER MOTOR O VALVE O4 ee Ou CAD CELL OIL BK BLACK WH WHITE SOLENOID OR ORANGE NOTE 1 BURNER WIRING SHOWN IS FOR BECKETT c UNE VOLTAGE 115V FIELD INSTALLED AFG BURNERS CONSULT BURNER INSTRUCTION MANUAL FOR OTHER BURNERS 2 17224 HAS TWO TERMINALS MARKED ZC AND ZR LOW VOLTAGE 24V FIELD INSTALLED WHICH ARE NOT USED LINE VOLTAGE 115V FACTORY INSTALLED FIGURE 19 WIRING DIAGRAM SINGLE HEATING ZONE ONLY 21 ZONE 1 ZONE 2 THERMOSTAT THERMOSTAT oo Jr ni 6 4 94 a ID TERMINALS AND 17248 17224 wb NOTE 1 TERMINALS C1 AND C2 NOT USED ON L7248 OR L7224 LIMIT CONTROL FUSED DISCONNECT 120 60 1 POWER 2 GROUND WIRING NOT SHOWN GROUND SUPPLY NELITRAL IN ACCORDANCE WITH APPLICABLE CODES 120 VAC FIELD WIRING 24 VAC FIELD WIRING ZONE 1 ZONE 42 CIRCULATOR CIRCULATOR2. TABLE 1a GENERAL SPECIFICATIONS Burner DOE Heating Approx Number of Input Capacity I B R Net Water Dimensions inches Boiler Model Sections Gal hr Btu hr Rating Btu hr AFUE Content Ga B 2065 3 065 8000 7000 861 160 1738 8 se 6 TWzors 3 0 75 91000 7900 858 160 1738 8 se 6 wzo 3 100 120000 104000 843 160 173 e se 6 4 990 111000 97000 860 200 2238 101346 7 TWwziz0 5 120 147000 128000 860 240 27 318 13 56 8 TWwzt5 5 i75 21200 184000 851 240 27 38 13 546 8 TWwzz00 s 200 241000 210000 847 240 2736 13 sme 8 3 3 3 5 5 TABLE 1b OPTIONAL TANKLESS HEATER RATINGS Tankless Heater Rating Boiler Model Gal min Notes 1 Net Ratings are based on piping and pick up allowances of 1 15 3 2 Burner Capacity Rating is based on 2 oil with a Gross 3 3 4 3 TWZ100 Heating Value equal to 140000 BTU Gal 00 25 TWZ090 25 3 Maximum Working Pressure Water 50 PSI 15 00 50 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 TWZ125 2975 4 Tankless Heater Ratings based on I W H test standard e In the absence of an authority having jurisdiction insta
3. 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 K FRONT VIBA JDE VIEW LH SBDECLEARANC E24 FOR FLOAT TYPE LACO EQUIPPED BOILERS CLEARANC EFRO M SINGLE WALL CONNECTOR TO C OMBUSTIELE C O NSTRUC TION FIGURE 2 CLEARANCES sheet Metal 24 GA or Tic ker Combustible Surface Openings Aligned To Permit Free Air Circ ulation Hollow Masonry Blacks FIGURE 3 INSTALLATION OVER A COMBUSTIBLE FLOOR V Air for Combustion and Ventilation Ay warnine e INSUFFICIENT COMBUSTION AIR SUPPLY MAY RESULT IN THE PRODUCTION AND RELEASE OF SOOT OR DEADLY CARBON MONOXIDE CO INTO THE HOME WHICH CAN CAUSE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH THIS BOILER IS NOT DESIGNED FOR USE IN A SPACE THAT IS DEPRESSURIZED RELATIVE TO THE OUTDO
4. aw CROW N DESIGNED TO LEAD TWZ Series Oil Fired Hot Water Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models AUD ean CERTIFIED TWZ065 www ahridirectory org TWZ075 WARNING Improper instal lation adjustment alteration TWZI100 service or maintenance can e TWZ090 cause property damage injury or loss of life For assistance or TWZI125 additional information consult a TWZ150 qualified installer service agency or the oil supplier Read these e TWZI120 instructions carefully before TWZ175 installing TWZ200 9 lt gt OW cs ILER N Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings printed in this manual and posted on the boiler INSPECT THE BOILER BURNER AND CONTROLS ANNUALLY To keep your boiler safe and efficient have a service technician follow the Service checklist near the end of this manual IF YOU ARE NOT QUALIFIED to install or service boilers do not install or service this one THE BOILER MAY LEAK WATER at the end of its useful life Be sure to protect walls carpets and valuables from water that could leak from the boiler PROTECT YOUR HOME IN FREEZING WEATHER A power outage safety lockout or component failure will prevent your boiler from lighting In winter
5. D d v m gt A m d 2 gt F4 m 290215 1 ea 1 1 ea 90 212 15 ea 15 ea 15 ea 4 35 1006 1 ea 1 ea 1 ea 48 1 2 SHORT WELL LESS COIL 35 1005 1 ea 1 ea 1 ea 49 AQUASTAT L7224A1008 WITH COIL 3503305 1 ea 1 ea 1 ea 49 AQUASTAT L7248C1048 LESS COIL 3503020 1 ea 1 ea 1 ea JUNCTION BOX 96 001 1 ea 1 ea 40 43 44 45 46 47 8 N TWIST RECEPTICAL 96 010 1 ea 1 ea pd THE FOLLOWING BURNERS HAVE TWIST LOCK PLUGS Loe 1 THE FOLLOWING BURNERS HAVE QUICK CONNECT PLUGS FOR MAKING CONNECTION INSIDE JUNCTION BOX ee T 21 2 NOT PICTURED 51 54 55 55 6 5 130511 130521 130512 130522 130532 130513 130523 130533 o g 61 70 71 1 ea 1 ea 1 ea NOTE 1 PART NUMBERS PROVIDED ARE FOR FULLY CONFIGURED BURNERS AND INCLUDE NOZZLES BURNER CORD ASSEMBLIES AND WHERE APPLICABLE LOW FIRING RATE BAFFLES 30 MODELS ON SOME CEPTACLE FOR TWIST PLUG R gt H 2 gt n T Im z I a H lt fon 3 2 z 31 9 say OW cs ILER Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com PN 980270 Rev 9 TWZ 04 12
6. FIGURE 9 TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS 1 Acceptable Chimneys The following chimneys may be used to vent a TWZ series boiler e 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 Do not vent a TWZ series boiler into an unlined chimney 10 2 Acceptable Vent Connectors The following may be used for vent connectors e Listed L vent e Single Wall Galvanized Pipe Use 0 018 26 gauge or heavier 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 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 6 Prior to boiler installation inspect chimney for obstructions or other defects and correct as required Clean chimney as necessary 7 Vent pipe should slope upward from boiler not less than one inch in four feet No portion of vent pipe should run downward or have sags Vent pipe must be secur
7. L L L L V V V V V 70MMAQ 70MMAQ 70MMAQ 70MMAQ 70MDAQ 70MDAQ 70MLAQ 70MLAQ 70MLAQ 338 338 338 33 8 234 23 4 NONE NONE NONE 3 3 8 3 3 8 3 3 8 3 3 8 2 3 4 2 3 4 NONE NONE NONE OW FIRING RATE 43708 43708 NONE NONE NONE NONE NONE NONE NONE HAGO HAGO HAGO DEL HAGO HAGO HAGO HAGO HAGO 0 55 60B 0 65 60B 0 85 60B 0 75 60B 1 00 60B 1 25 60B 0 90 60B 1 35 45B 1 50 45 DEL DEL DEL HAGO DEL DEL DEL DEL DEL 0 55 60W 0 65 60W 0 85 60W 0 75 60B 1 00 60B 1 25 60B 0 90 60B 1 35 45B 1 50 45B NA NA NA o o O 3 4 1 10 5 7 10 10 8 8 1 2 2 0 0 5 6 1 4 FLUE CO2 96 MIN 11 0 11 0 11 0 11 0 11 0 11 0 11 0 11 0 11 0 12 5 12 5 12 5 12 5 12 5 12 5 12 5 12 5 12 5 24 TABLE 3b CARLIN BURNER CONFIGURATION AND SETUP DATA BOILER MODEL TWZO065 TWZ075 TWZ100 TWZ090 TWZ125 TWZ150 TWZ120 TWZ175 TWZ200 BURNER MODEL EZ AHP EZ AHP EZ 1HP 2 EZ 1HP EZ 1HP EZ 1HP EZ 2HP STANDARD DEL HAGO HAGO DEL DEL HAGO HAGO DEL NOZZLE 0 55 70B 0 60 60ES 0 85 60B 0 75 60A 1 00 60A 1 25 60B 1 00 60 1 50 60A PUMP PRESS psi HEAD BAR 0 60 0 65 0 85 1 00 0 85 1 00 1 10 1 25 0 85 1 00 STARTING BAND SETTING 0 55 0 75 0 75 1 00 1 10 1 25 1 35 1 75 MAX SMOKE 1 bacharach scale FLUE CO2 MIN 11 0 11 0 11 0 11 0 11 0 11 0 11 0 11 0 12 5 12 5 1
8. area that is prone to freezing The termination of the relief valve discharge piping must be in an area where it is not likely to become plugged by debris Circulator Required Figure 10 shows the ideal location of the circulator which is in the supply piping immediately downstream of the expansion tank A less ideal but acceptable location for most residential circulators is in the return if this is done be sure that adequate clearance exists to open the door Expansion Tank Required If this boiler 18 replacing an existing boiler with no other changes in the system the old expansion tank can generally be reused If the expansion tank must be replaced consult the expansion tank manufacturer s literature for proper sizing Fill Valve Required Either a manual or automatic fill valve may be used The ideal location for the fill is at the expansion tank Automatic Air Vent Required At least one automatic air vent is required Manual vents will usually be required in other parts of the system to remove air during initial fill 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 float type or probe type but must be designed for use in a hot water system The low water cut off
9. 1 HEAT ASSY LESS COIL OPENING TION WITH COIL OPENING TION LESS COIL OPENING TE SECTION HNIPPLE ING DOOR HINGE STANDARD TION HINGE STANDARD R INSULATION 5 16 18 X 1 1 2 HX HEAD CAP SCREW 5 46 FLAT WASHER E X HEAD CAP SCREW NSPECTION COVER 18 X 3 4 HEX HEAD CAP SCREW T WALL REPLACEMENT KIT TORY BLANKET BOOK STANDARD R SWING DOOR ALTERNATE NSPECTION COVER ALTERNATE DOOR ALTERNATE 4 2 x 1 SEALING STRIP FLUE COLLECTOR 1 4 20 x 3 CARRIAGE BOLT 1 4 20 x 3 1 2 CARRIAGE BOLT 1 4 USS FLAT WASHER 1 4 20 WING NUT OPTIONAL pozo 3 8 16 X 7 8 HX HEAD CAP SCREW 3 8 USS FLAT WASHER 90 036 SEE PAGE 26 FOR WARNING REGARDING THE HANDLING OF PARTS THAT CONTAIN REFRACTORY CERAMIC FIBERS 5 2 gt gt 212 212 2 vim imijo o ciojo m m o s 23 9 9 o alc c 2 z m m a Alu alc 519 2 z n 9 JE g gt 5 0 x T Q gt FHE 2 2 9 BE a gt 5 lt 2 mim 42 gt 2 m x m gt 4 m 2 0 gt n A m 4 gt z A e m a I m 2 A m a 1 2 3 4 5 7 10 11 12 13 15 14 20 21 22 23 24 25 30 31 33 4 28 RNATE MBL Y ASS ALT DOOR amp 29 7 T C d 2
10. TEXT FOR OPENING SIZE FIGURE 6 ALL AIR FROM OUTDOORS VIA VENTILATED ATTIC L DOUBLE WALL VENT LINED MASDNRY CHIMNEY SEE VENTING SECTION BOILER UPPER OPENING BAROMETRIC DRAFT CONTROL LOWER UPENING SEE TEXT FOR OPENING SIZE FIGURE 7 ALL AIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM TYPE L DOUBLE WALL VENT OR LINED MASONRY CHIMNEY SEE VENTING SECTION E HORIZONTAL DUCT BAROMETRIC DRAFT LOWER CONTROL DP HORIZONTAL DUET SEE TEXT FOR OPENING SIZE FIGURE 8 ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM VI Venting WARNING e 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 SEVERE PERSONAL INJURY OR DEATH INSPECT EXISTING CHIMNEY BEFORE INSTALLING BOILER FAILURE TO CLEAN OR REPLACE DAMAGED PIPE OR TILE LINING WILL CAUSE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH 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 HORIZONTAL VENT CONNECTOR SLOPE SECTIONS UPWARD NOT LESS THAN ONE INCH JN FOUR FEET CLL LLL LA BAROMETRIC DRAFT CONTROL B
11. WITH A HEAT EXCHANGER 15 VIII TANKLESS HEATER PIPING If the TWZ is installed with an optional tankless heater pipe the heater as shown in Figure 14 The components in this system and their functions are as follows 1 Mixing Valve Required During the heating season the water exiting the tankless heater may be 180 degrees or more The mixing valve blends hot water leaving the tankless heater with cold water so as to maintain the hot water supplied to the fixtures at a fixed temperature This saves energy increases the amount of usable hot water available to the homeowner and reduces the risk of scalding Install a mixing valve with a setting range of approximately 110 to 130F Follow the manufacturer s instructions for installing this valve Usually a heat trap will be required between the coil and the hot connection on the mixing valve Ay warnine A MIXING VALVE DOES NOT ELIMINATE THE RISK OF SCALDING SET THE MIXING VALVE AND BOILER LOW LIMIT ADJUSTMENTS AS LOW AS POSSIBLE e FEEL WATER BEFORE SHOWERING OR BATHING e IF ANTI SCALD OR ANTI CHILL PROTECTION IS REQUIRED USE DEVICES SPECIFICALLY DESIGNED FOR SUCH SERVICE INSTALL AND MAINTAIN THESE DEVICES IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS DO NOT USE THE MIXING VALVE AS A SUBSTITUTE FOR PRESSURE BALANCING VALVES OR OTHER DEVICES REQUIRED BY PLUMBING CODES TO PROTECT AGAINST SCALDING 2 Flow Restrictor Recommended If water is drawn fr
12. according to the burner manufacturer s instructions c Remove and clean fuel pump strainer d Remove any accumulations of dust hair etc from the air shutter blower wheel and other air handling parts of the burner 5 Replace the fuel oil line filter element and gaskets 6 Inspect all oil piping and fittings for kinks and leaks Repair any found 7 Inspect the hydronic piping tankless coil gasket and boiler plugs for water leaks Repair any leaks found immediately 8 Verify operation of relief valve by manually lifting lever replace relief valve immediately if valve fails to relieve 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 Ay warnine WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPONENTS REPAIR ANY LEAKS FOUND IMMEDIATELY 26 Important Product Safety Information Refractory Ceramic Fiber Product Warning The Parts list designates parts that contain refractory ceramic fibers RCF RFC has been classified as a possible human carcinogen When exposed to temperatures about 1805 F such as during direct flame contact RFC changes into crystalline silica a known carcinogen When disturbed as a result of servicing or repair these su
13. heating systems employing convection radiation baseboard or radiators use an industry accepted sizing method such as the B R Guide RHH published by the Air Conditioning Heating and Refrigeration Institute AHRI Fornew radiant heating systems refer to the radiant tubing manufacturer s boiler sizing guidelines e For systems including a Crown Mega Stor indirect 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 e 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 A warnine FAILURE TO OBSERVE THE FOLLOWING LOCATION REQUIREMENTS COULD RESULT IN PROPERTY DAMAGE A FIRE EXPLOSION OR CARBON MONOXIDE CO HAZARD 1 Clearances Observe the 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 2 Front 24 Left Side 6 Right Side 6 Rear 6 Top 6 Single Wall Chimney Connector to combustible construction 18 e A 24
14. 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 11 System Piping A warning INSTALL BOILER SO THAT THE ELECTRICAL COMPONENTS ARE PROTECTED FROM WATER DRIPPING SPRAYING RAIN ETC DURING 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 RELIEF VALVE DISCHARGE TO A SAFE LOCATION THE RELIEF VALVE MAY DISCHARGE SCALDING HOT WATER DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE DO NOT MOVE RELIEF VALVE FROM FACTORY LOCATION DO NOT PLUG RELIEF VALVE DISCHARGE BLOCKING THE RELIEF VALVE MAY RESULT IN BOILER EXPLOSION Standard Piping Figure 10 shows typical boiler system connection
15. 2 5 12 5 12 5 12 5 12 5 12 5 TABLE 3c RIELLO BURNER CONFIGURATION AND SETUP DATA BOILER MODEL TWZ065 TWZ075 TWZ100 Twzogo TWZ125 TWZ150 TWZ120 TWZ175 TWZ200 BURNER MODEL 40F5 40F5 40F5 40 10 40F10 40F10 STANDARD DEL DEL DEL DEL HAGO DEL NOZZLE 0 60 60A 0 85 60W 1 00 60A 1 25 60B 1 85 45B 1 65 45 PUMP PRESS psi 15 2 AIR 3 1 TURBULATOR a 2 2 DRAFT OVERFIRE 0 02 0 02 0 02 0 02 0 02 0 02 in w c 1 1 1 1 1 bacharach scale 11 0 12 5 FLUE CO2 96 MIN 11 0 11 0 11 0 11 0 11 0 MAX 12 5 12 5 12 5 12 5 12 5 XII Service and Maintenance The following procedure should be performed on an annual basis 1 Turn off electrical power and oil supply to the boiler 2 Clean the boiler as follows a Remove vent connector and piping b Remove barometric draft regulator c Remove top jacket panel to gain access to boiler flue collector d Unscrew four wing nuts and remove canopy retaining carriage bolts lift off the canopy and ceramic fiber sealing strips Unplug the burner disconnect the oil lines 1f the pump is hard piped and remove the two 5 16 bolts securing the burner door Open the burner swing door 25 f Thoroughly brush boiler flueways from the top and diagonally between casting pin rows careful when brushing the rear passage not to damage the rear target wall insulation g Vacuum soot and debris from combustion c
16. Do not use check valves especially on gravity feed systems 6 Do not use Teflon tape for threaded connections Use a listed non hardening thread sealant instead 18 7 Attach required piping between burner fuel pump and fuel oil storage tank Install one fuel shut off valve near the storage tank and second fuel shut off valve near the oil burner fuel pump Use heavy wall copper tubing in a 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 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 requirements of ASTM D 396 FILTER NOZZLE FIGURE 16 ONE PIPE LIFT SYSTEM SHUT OFF VALVE FOR SERVICE FILTER NOZZLE RETURN 3 4 INCHES T ABOVE INLE RETURN LINE DO NOT USE CHECK VALVES ON GRAVITY FEED SYSTEMS FIGURE 17 TWO PIPE GRAVITY FEED SYSTEM 19 FILTER NDZZLE RETURN LINE TERMINATES 3 4 INCHES INLET LINE FIGURE 18 TWO PIPE LIFT SYSTEM X Wiring Ay warnine ALL WIRING AND GROUNDING MUST BE DONE IN ACCORDANCE WITH THE AUTHORITY HAVING JURISDICTION OR IN THE ABSENCE OF SUCH AUTHORITY WITH THE NATIONAL ELECTRIC CODE ANSI NFPA 70 Single Zone Wiring 1 120 Volt Wiring The boiler sh
17. ORS OPERATING THIS BOILER IN A DEPRESSURIZED SPACE MAY CAUSE PROPERTY DAMAGE SEVERE PERSONAL INJURY OR DEATH 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 can be defined as one having 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 e 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 b
18. QUIPMENT when servicing or working near the boiler Materials of construction flue products and fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides and or other toxic or harmful substances that can are hazardous to health and life and that are known to the State of California to cause cancer birth defects and other reproductive harm INSTALL ALL GUARDS cover plates and enclosures before operating the boiler SIZE THE BOILER PROPERLY relative to the design heat load or if using domestic hot water priority the peak hot water load whichever is larger A grossly oversized boiler will cycle excessively and this will lead to premature failure of the boiler and its components Our warranty does not apply to damage from excessive cycling ADHERE TO ALL LOCAL CODE REQUIREMENTS Contact your local code inspector prior to installation In the absence of a local code adhere to the latest editions of the Installation of Oil Burning Equipment ANSI NFPA 31 in the USA or CAN CSA B139 Installation Code for Oil Burning Equipment in Canada ALL WIRING must comply with the National Electrical Code ANSI NFPA 70 in the USA or the Canadian Electrical Code CSA C22 1 in Canada and any local regulations Table of Contents I Product Deseription 2 VIII Tankless Heater 16 II Specificatioris 5 irn erbe dee rere eris 2 IX Fuel L
19. S TAPPING AS A RETURN CONNECTION 13 SYSTEM FLOW CONTROL VALVES ISOLATION REQUIRED IN CIRC ZONE VALVE ISOLATION RELIEF VALVE PROPERLY SIZED I W H CIRC AND ZONE PIPING LOW WATER b FILL VALVE CUT DFF IF USED EXPANSIUN TANK BOILER SUPPLY CONNECTION LIMIT FROM BOILER RETURN SYSTEM CONNECTION ISOLATION ISOLATION INDIRECT WATER HEATER DRAIN OIL BURNER FIGURE 11 INDIRECT WATER HEATER BOILER SIDE PIPING SYSTEM ISOLATION THROTTLING VALVE FROM SYSTEM VALVES N ISOLATION VALVE FLOW CONTROL VALVE COLD WATER 27 LINE FILL VALVE LOW WATER NW CUT DFF QF USED L EXPANSION TANK GAUGE DIL BURNER FIGURE 12 BOILER BYPASS PIPING Piping for Special Situations Certain types of heating systems have additional requirements Some of the more common variations follow 1 Indirect Water Heaters Figure 11 shows typical indirect water heater piping Boiler piping is the same as for any two zone system Figure 11 shows circulator zoning which is usually preferred for indirect water heaters Size the circulator and indirect 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 12 will minimize the amount of time that the boiler operates with return temperatures below 120 F on these systems A bypass is i
20. TO TERMINAL L1 ON 17248 17224 TO TERMINAL L2 17248 OR 17224 FIGURE 20 WIRING DIAGRAM CIRCULATOR ZONE WIRING USING HONEYWELL R845A s FACTORY BOILER WIRING NOT SHOWN SEE FIGURE 19 lt ADDITIONAL ZONE VALVE TERMINALS T AND T UN L7248A UR L7224C ENDSWITCHES IF USED HEATING ZONE 1 HEATING ZONE 2 24 THERMOSTAT 24 VAC THERMOSTAT HONEYWELL HONEYWELL V8043F E V8043F ZONE VALVE NH ZONE VALVE 21 24 VOLT TRANSFORMER SEE TEXT FUSED DISCO 2 1 HIT i o TO TERMINAL L1 ON L7248A OR L7224C supp NEUTRAL TERMINAL L2 DN L7248A L7224C 120 VAC FIELD WIRING NOTE GROUND WIRING NOT SHOWN GROUND IN 24 VAC FIELD WIRING ACCORDANCE WITH APPLICABLE CODES FIGURE 21 WIRING DIAGRAM ZONE WIRING USING HONEYWELL V8043F ZONE VALVES FACTORY BOILER WIRING NOT SHOWN SEE FIGURE 19 22 XI Start up and Checkout Use the following procedure for initial start up of the boiler A WARNING NEVER ATTEMPT TO FILL A HOT EMPTY BOILER MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS SAFE RELIABLE OPERATION OF THIS BOILER REQUIRES THAT THE BURNER BE CHECKED AND ADJUSTED BY A QUALIFIED OIL SERVICEMAN USING COMBUSTION TEST INSTRUMENTS FAILURE TO PERFORM ALL OF THE CHECKS O
21. UTLINED IN THE FOLLOWING PROCEDURE COULD RESULT IN UNRELIABLE OPERATION DAMAGE TO THE BOILER NOT COVERED UNDER WARRANTY PROPERTY DAMAGE OR UNSAFE OPERATION 1 Ensure that the boiler and entire heating system are filled with water 2 Check all new piping for leaks and purge heating system piping sections that are air bound 3 Verify that the vent system is complete and free of obstructions prior to start up of the boiler 4 Inspect all wiring for loose or uninsulated connections proper size fuses installed etc 5 Verify that oil tank is filled with 2 fuel oil meeting ASTM D396 specifications oil piping has been tested and is air tight and shutoff valve s are closed 6 Check initial settings of oil burner air band and air shutter head setting etc and readjust 1f needed See Table 3 for setup and combustion data pertaining to a particular boiler burner combination 7 Attach plastic hose to oil pump vent fitting and provide a container to catch oil during oil pump bleeding procedure 8 Install 0 200 PSI pressure gauge into oil pump gauge port 9 Open all oil line shutoff valves 10 Open flame observation port cover on burner swing door to see flame 11 Adjust system thermostat to highest setting 12 Set boiler controls high limit low limit etc to suit individual requirements of the installation 13 Turn the line service switch to ON position 14 Crack open vent fitting on the oil pump and allow burner t
22. bstances become airborne and if inhaled may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear 1 A National Institute for Occupational Safety and Health NIOSH approved respirator Long sleeved loose fitting clothing Gloves 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 classified as hazardous wastes in the United States and Canada First Aid Procedures e If contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficulty develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention 27 XIII Parts mU QUANTITY PER BOILER OR CROWN P N s oss Jos
23. confined Space Natural infiltration into the boiler room will normally provide adequate air for combustion and venti lation 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 used they must be no finer than 4 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 m
24. ectrical continuity is created between terminals 5 and 6 on the R845A creating a current path from terminal to on the L7248 L7224 Assuming that the supply water temperature is below the high limit setting the normal ignition sequence will be initiated 2 Multiple Zones using Zone Valves Figure 21 shows wiring for multiple zones using Honeywell V8043F zone valves This wiring diagram may be used for other 24 volt zone valves as long as they are equipped with end switches Do not attempt to use the transformer on the L7248 or L7224 to power the zone valves use a separate transformer Up to five V8043Fs may be powered by one 48VA transformer such as the Honeywell AT87A A call for heat from a given thermostat will result in the application of 24 volts across the TH and TR terminals on the corresponding zone valve energizing the zone valve motor The zone valve opens and the end switch contacts are then made The end switches are connected in parallel with each other and to the and thermostat connections so that any zone valve that opens will also start the circulator and fire the boiler assuming the high limit is not open Zone valve terminal TH TR has no internal connection on the zone valve it is merely a binding post used to connect two or more wires ITEMS SUPPLIED BY INSTALLER SERVICE FUSED DISCONNECT THERMOSTAT SWITCH SWITCH gt OS 0 11 POWER SUPPLY 12 120 60 1 euo 8
25. ely supported 8 The vertical section of vent pipe coming off the boiler should be as tall as possible while still 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 prevent blockage 10 Vent pipe must be inserted flush with inside face of the chimney liner and the space between vent pipe and chimney sealed tight A thimble permanently cemented in place can be used to facilitate removal 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 TABLE 2 MINIMUM RECOMMENDED BREECHING AND CHIMNEY SIZE Min Breeching Min Recommended Chimney Size and Height Dia inches Round I D in Rectangular 1 0 in Height ft 6 E 6 8 asm 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
26. ff causing oil line pressure to drop and nozzle drip after burner stops Cycle burner on and off 5 to 10 times to purge air completely 24 Check thermostat operation by raising or lowering its set point as required cycling burner on and off 25 Verify primary control operation and safety features according to procedure outlined in the instructions furnished with control 26 Check high limit control operation Jump thermostat terminals and allow burner to run until boiler water temperature exceeds high limit setting The burner should shut down and circulator continue running Allow the temperature to drop below the control setting The burner must restart Boiler installation is not complete unless these checks are made and are satisfactory Remove thermostat jumper and reconnect thermostat upon check completion 27 After the boiler has operated for approximately 30 minutes check the boiler and heating 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 Ay warnine ATTEMPTS TO USE BURNERS OR BURNER CONFIGURATIONS OTHER THAN THOSE SHOWN IN TABLE 3 COULD RESULT IN RELIABILITY PROBLEMS PROPERTY DAMAGE OR UNSAFE OPERATION TABLE 3a BECKETT BURNER CONFIGURATION AND SETUP DATA 2065 Twzo75 TWZ100 Twzogo TWZ125 TWZ150 TWZ120 TWZ175 TWZ200
27. hamber h Check condition of rear target wall insulation combustion chamber liner and burner door insulation replace if required 1 Check burner head for signs of deterioration Clean the head of any deposits j Close burner door reinstall 5 16 bolts reconnect fuel oil and electrical lines k Installation of boiler canopy jacket top panel barometric draft regulator 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 vent piping joints must be flue gas leak free and secured with sheet metal screws IMPORTANT CLEAN THE BOILER EVEN IF THERE ARE NO SIGNIFICANT SOOT DEPOSITS FAILURE TO REMOVE ALL SULFUR AND ASH DEPOSITS ANNUALLY CAN CAUSE SEVERE CORROSION DAMAGE WHEN CLEANING THE REAR FLUE PASSAGE BE CAREFUL NOT TO PUSH THE BRUSH TOO FAR BEYOND THE BOTTOM OF THE PINS DOING SO MAY DAMAGE THE TARGET WALL 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 Inspect joints for signs of condensate or flue gas leakage d Inspect venting components for corrosion or other deterioration Replace any defective vent system components 4 Service the oil burner a Replace oil nozzle with identical make and model see Table 3 b Inspect the electrodes Replace if they are deteriorated Make sure that the electrode position is set
28. ine Piping coe 17 Before ttes 3 X WIFE e OR en OPERE IO ERR 20 Locating the tret tein 4 XI Start up and Checkout 23 V Air for Combustion amp Ventilation sess 6 XII Service amp Maintenance 25 C SIDuDIMDIEERT 10 DT Paris eoe oU ENIM UE NIE 28 VII System Piping Connections sse 12 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 RELIEF VALVE 1i suPPLY TEMP PRESSURE GAUGE FLAME OBSERVATION AQUASTAT RELAY PORT OIL BURNER W PRIMARY CONTROL 1 RETURN DRAIN VALVE 11 SEE NOTE 2 BURNER SWING DOOR CLEARANCE OPEN 90 FRONT VIEW RIGHT SIDE VIEW NOTES 1 CIRCULATOR SUPPLIED LOOSE MAY BE INSTALLED ON SUPPLY OR RETURN 2 RETURN FITTINGS AND DRAIN VALVE SHIPPED LOOSE 3 DASHED PIPING SHOWN NOT FURNISHED WITH BOILER 4 TANKLESS COIL OPENING NOT PRESENT ON LESS COIL BOILERS FIGURE 1 GENERAL CONFIGURATION
29. llation must be in accordance with this manual and the latest edition of Installation of Oil Burning Equipment ANSI NFPA3 1 e 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 ANSUASME CSD 1 2 Make sure that a properly sized chimney is available which 15 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 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 3 Make sure that the boiler is correctly sized For
30. nstalled as shown to divert some supply water directly into the return water The bypass pipe should be the same size as the supply The two throttling valves shown are adjusted so that the return temperature rises above 120 F during the first few minutes of operation A three way valve can be substituted for the two throttling valves shown 14 3 Low Temperature Systems Some systems such as radiant tubing systems require the system water temperature to be limited to a value below the temperature of the water leaving the TWZ These systems also typically have return temperatures well below the 1209 minimum Figure 13 illustrates the use of a heat exchanger to connect the TWZ boiler to this type of system The heat exchanger will permit the transfer of heat from the boiler water to the low temperature system while holding the system supply and boiler return temperatures within their limits For this system to work properly the heat exchanger must be properly sized and the correct flow rates are required on either side of the heat exchanger Consult the heat exchanger manufacturer for sizing information The water in the boiler is completely isolated from the water in the system This means that separate fill and expansion tanks are required 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
31. nstruction manuals provided with the burner and oil pump 17 SHUT OFF VALVE FOR SERVICE FILTER DO NOT USE CHECK VALVES ON GRAVITY FEED SYSTEMS FIGURE 15 ONE PIPE GRAVITY SYSTEM Depending on the location of the fuel oil storage tank in relation to an oil burner there are four types of oil piping systems generally being used a ONE PIPE GRAVITY SYSTEM used when a fuel oil storage tank is positioned above an oil burner fuel pump See Figure 15 vertical distance from top of the tank to center line of the pump Dimension H over 8 feet will result in a pump inlet pressure in excess of the 3 psi limit in NFPA 31 ONE PIPE LIFT SYSTEM not recommended Used when a fuel oil storage tank is located below an oil burner fuel pump See Figure 16 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 Although all oil piping systems must be airtight one pipe lift systems are particularly susceptible to nuisance lockout problems if the suction line is not completely airtight A two pipe lift system is therefore recommended over a one pipe lift system TWO PIPE GRAVITY SYSTEM not recommended Used when a fuel oil storage tank 15 located above an oil burner fuel pump See Figure 17 A vertical distance from top of the tank to center line of the pump Dimension over 8 feet will result in a pump inlet pressure in excess
32. o run until a solid oil stream free of air bubbles flows for 15 seconds into container As the vent fitting 1s closed the burner 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 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 3 for the burner supplied Adjust pressure if required 17 Check the vacuum at the inlet of the fuel pump Make sure that the vacuum does not exceed the fuel pump manufacturer s limit consult the pump manufacturer s instructions 18 Close the flame observation cover 19 After chimney has warmed up to operating temperature adjust barometric draft regulator for a draft of 0 02 inch w c over the fire 20 Check the CO2 and confirm that it is between the minimum and maximum limits shown in Table 3 Adjust if necessary 21 Verify that the smoke level still does not exceed 1 and that the draft over fire is 0 02 inch w c 22 Turn off the burner and remove pressure gauge Install and tighten gauge port plug then restart the burner 23 23 Check for clean cutoff of the burner Air in the oil line between fuel pump and nozzle will compress while burner is running and expand when burner shuts o
33. of the 3 psi limit in NFPA 31 This type of system should be converted to a one pipe gravity system as doing so will result in lower inlet line flow and longer filter life TWO PIPE LIFT SYSTEM used when a fuel oil storage tank is located below an oil burner fuel pump suction port See Figure 18 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 allowed is reduced by the number of fittings filters and valves installed in the line b we d Once the type of system has been selected observe the following 1 Fuel line piping must be airtight Do not use compression type fittings for tubing connections in fuel line piping Use only listed flare type fittings Cast iron threaded fittings shall not be used 2 Piping shall be substantially supported and protected against physical damage and corrosion where required 3 Refer to supplied oil pump instruction manual for proper connections On one pipe systems ensure that the fuel pump return port plug is tightened securely 4 Some fuel pumps such as the Suntec A and B series are supplied with a loose bypass plug which must be installed on two pipe systems If such a plug is supplied install it as shown in the pump manufacturer s instructions Do not install this bypass plug on one pipe systems as pump seal damage will result 5
34. oiler 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 Findthe 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 a water heater are to be installed in a room measuring 6 ft 3 in x 7 ft with an 8 fi 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 fi x 8 ft 350 f 350 156 2 24 Since 2 24 is less than 50 the boiler room is a confined space 6 12 UPPER TYPE L DOUBLE WALL OPENING VENT OR LINED MASONRY CHIMNEY SEE VENTING LOWER SECTION OPENING BAROMETRIC DRAFT CONTROL 12 MAX SEE TEXT FOR OPENING SIZE FIGURE 4 BOILER INSTALLED IN CONFINED SPACE ALL AIR FROM INSIDE 2 Un
35. om the tankless coil at a rate in excess of the rating in Table 1b the temperature of the hot water may be too low to be of use The use of a flow restrictor will prevent this problem by limiting the rate at which water can pass through the tankless heater If a restrictor is used select one having a rating in GPM approximately equal to the rating shown in Table 1b If possible locate this restrictor at least 3 feet from the tankless heater inlet so that it is not subjected to excessive temperatures when no water is flowing through the coil 3 Pressure Relief Valve Required Limits the pressure in the tankless heater and piping Use an ASME constructed valve designed for domestic water service such as the Watts 3L Note that this is a pressure relief valve not a T amp P valve Select a valve with a pressure setting less than or equal to the working pressure marked on the tankless coil Pipe the discharge to a safe location using piping the same size as the discharge connection on the valve 4 Hose Bib Valves Recommended These valves permit the coil to be periodically backflushed to remove sediment 5 Globe or Ball Valve Recommended Used to adjust the flow through the entire tankless heater system if needed 6 Unions Required Tankless heaters may require periodic 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 rem
36. ould be provided with its own 15A branch circuit with fused disconnect All 120 volt con nections are made inside the L7248 or L7224 aquastat relay as follows also see Fig 19 e black Terminal L1 e Neutral white Terminal L2 Ground or bare Ground screw on case of L7248 or L7224 2 Thermostat Wiring Follow thermostat manufacturer instructions To insure proper thermostat operation avoid installa tion in areas of poor air circulation hot spots near any heat source or in direct sunlight cold spots outside walls walls adjacent to unheated areas locations subject to drafts Provide Class II circuit between thermostat and boiler Connect thermostat wire leads to terminals and inside L7248 L7224 aquastat relay 20 Wiring Variations 1 Multiple Circulator Zones Figure 20 shows wiring for two or more circulator zones using Honeywell R845As One 845 is required for each circulator zone Circulator terminals C1 and C2 on the L7248 are not used DPST Honeywell RA832A may be substituted in place of the R845A using the X and X terminals in place of the 5 and 6 terminals on a R845A A call for heat from any thermostat will energize the DPST relay in that zone s R845A When this relay is energized electrical continuity 15 created between terminals 3 and 4 energizing the circulator for that zone At the same time el
37. oval of the heater 16 TANKLESS HEATER SHOWN WITH CONTROL REMOVED LINIUNS FLOW RESTRICTOR RELIEF VALVE 3 BALL OR GLUBE VALVE i COLD WATER IN HUSE BIB VALVES FIGURE 14 TANKLESS HEATER PIPING IX Fuel Line Piping A WARNING UNDER NO CIRCUMSTANCES CAN COPPER WITH SWEAT STYLE CONNECTORS BE USED DO NOT USE COMPRESSION FITTINGS OIL PIPING MUST BE ABSOLUTELY AIRTIGHT OR LEAKS OR LOSS OF PRIME MAY RESULT SOME JURISDICTIONS REQUIRE 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 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 31 in the United States and CSA B139 04 for installation Canada Refer also to the i
38. s on a single zone system Additional information on hydronic system design may be found in the B R Guide RHH published by the Air Conditioning Heating and Refrigeration Institute AHRI The components in this system and their purposes are as follows SYSTEM ISOLATION VALVE pod FLOW CONTROL VALVE CIRCULATOR r AIR VENT RELIEF VALVE CDLD WATER LINE FILL OW WATER Mails LOW W CUT OFF EXPANSION IF USED r TANK GAUGE LIMIT FROM SYSTEM ISOLATION DRAIN OIL BURNER FIGURE 10 STANDARD BOILER PIPING 1 2 3 4 5 6 7 7 8 wm 9 10 Relief valve Required Mount the relief valve on the top left side of the boiler as shown in Figure 10 using the 3 4 nipple provided The relief valve shipped with the boiler is set to open at 30 psi This valve may be replaced with one having a pressure up to the Maximum Allowable Working Pressure shown on the rating plate If the valve is replaced the replacement must have a relief capacity 1n excess of the DOE heating capacity for the boiler Pipe the discharge of the relief 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 discharge is not piped to a drain it must terminate at least 6 inches above the floor Do not run relief valve discharge piping through an
39. should be piped into 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 water cut off into the boiler factory wiring Manual Reset High Limit Required by some codes This control is required by ASME CSD 1 and some other codes Install the high limit in the boiler supply piping just beyond the boiler with no intervening valves Set the manual reset high limit as far above the operating limit setting as possible but not over 240 F Wire the control to break the 120 VAC electrical supply to the boiler Flow Control Valve Required under some conditions The flow control valve prevents flow through the system unless the circulator is operating flow control valve may be necessary on converted gravity systems to prevent gravity circulation Flow control valves are also used to prevent ghost flows in circulator zone systems through zones that are not calling for heat Isolation Valves Optional Isolation valves are useful if the boiler must be drained as they will eliminate having to drain and refill the entire system Drain Valve The drain valve is shipped in the boiler parts bag Install it in the tee on the boiler return as shown in Figure 1 IMPORTANT THE 1 1 2 PLUGGED TAPPING ON THE BOTTOM REAR SECTION IS PRESENT FOR MANUFACTURING PURPOSES ONLY DO NOT ATTEMPT TO USE THI
40. 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 systems that employ tubing without an oxygen barrier Systems with routine additions of fresh water Systems which are open to the atmosphere If the boiler is to be used in such a system it must be separated from the oxygenated water being heated with a heat exchanger as shown in Figure 13 Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature requirements components on the oxygenated side of the heat exchanger such as the pump and expansion tank must be designed for use in oxygenated water 5 Air Handlers Where the boiler is connected to air handlers through which refrigerated air passes use flow control valves in the boiler piping or other automatic means to prevent gravity circulation during the cooling cycle 0 SEPARATE CIRCULATOR EXPANSION TANK TEMP PRESS 2 FILL AND AIR VENT FOR SYSTEM U FRUM SYSTEM HEAT EXCHANGER lt P ISOLATION VALVE 22 FLOW CONTROL VALVE ISOLATION 7 CIRCULATOR VALVE AIR VENT D a RELIEF oF jd WATER VALVE LINE LOW WATER Fin CUT OFF DO dF USED VALVE AS EXPANSION TANK GAUGE e LIMIT BURNER DRAIN FIGURE 13 ISOLATION OF BOILER FROM SYSTEM
41. ust 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 4 4 x 4 mesh VENTILATED ATTIC UPPER OPENING LOWER OPENING BOILER RDUM TYPE 14 DOUBLE WALL VENT OR LINED MASONRY 17 CHIMNEY CSEE VENTING 1 OH SECTIONS BAROMETRIC DRAFT CONTROL VENTILATED CRAWL SPACE SEE TEXT FOR OPENING SIZE FIGURE 5 ALL AIR FROM OUTDOORS VENTILATED CRAWL SPACE AND ATTIC VENTILATED ATTIC UPPER OPENING DUCT FROM ATTIC BOILER ROOM TYPE L DOUBLE WALL H VENT OR LINED MASONRY 1 CHIMNEY SEE VENTING k SECTION BAROMETRIC DRAFT CONTROL k
42. your pipes may freeze and cause extensive property damage Do not leave the heating system unattended during cold weather unless alarms or other safeguards are in place to prevent such damage DO NOT BLOCK AIR FLOW into or around the boiler Insufficient air may cause the boiler to produce carbon monoxide or start a fire KEEP FLAMMABLE LIQUIDS AWAY from the boiler including paint solvents and gasoline The boiler may ignite the vapors from the liquids causing explosion or fire KEEP CHILDREN AND PETS away from hot surfaces of the boiler boiler piping and vent pipe CARBON MONOXIDE CO is an odorless deadly gas that may be introduced into your home by any malfunctioning fuel burning product or vent system failure Consider installing CO alarms near bedrooms in all levels of the building to warn you and your family of potential CO exposure A WARNINGS FOR THE INSTALLER READ THIS ENTIRE MANUAL before attempting installation start up 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 and pressure gage when making this judgment USE PROPER PERSONAL PROTECTION E
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