D E S I G N E D T O L E A D FWZ Series Oil-Fired Hot Water Boilers Installation Instructions These instructions must be affixed on or adjacent to the boiler 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 information, consult a qualified installer, service agency or the oil supplier.
WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings printed in this manual and posted on the boiler. unless alarms or other safeguards are in place to prevent such damage 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. DO NOT BLOCK AIR FLOW into or around the boiler. Insufficient air may cause the boiler to produce carbon monoxide or start a fire.
Table of Contents I. Product Description ............................................................................... 3 II. Specifications ......................................................................................... 3 III. Before Installing .................................................................................... 5 IV. Field Assembly ...................................................................................... 6 V. Locating the Boiler ............................
I Product Description The FWZ 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. II Specifications TABLE 2.0: GENERAL SPECIFICATIONS DIMENSIONS BOILER MODEL ‘A’ ‘B’ WATER CONTENT (GAL) 7.70 7.70 11.08 14.46 17.
4 FRONT VIEW 3 20 4 " TOP VIEW 1 31 2 " 3 48" RELIEF VALVE 'B' MIN. FRONT SERVICE CLEARANCE (FLUEWAY CLEANING) AQUASTAT RELAY * Circulator Supplied Loose - May Be Installed On Supply Or Return. FIGURE 2.3: GENERAL CONFIGURATION * 19" BURNER SWING DOOR CLEARANCE (FULLY OPEN) BECKETT AFG BURNER FLAME OBSERVATION PORT BURNER SWING DOOR TEMP/PRESSURE GAUGE 1-1/2" FPT SUPPLY PIPING CONNECTION SPANNER BAR RIGHT VIEW 'A' * *NOTE: DRAIN VALVE SMOKEBOX COLLAR 'C' DIA.
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. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the latest edition of Installation of Oil Burning Equipment (ANSI/NFPA31).
IV Field Assembly This boiler is shipped in two pieces: a) The crated boiler itself with the following loose parts either packed in the combustion chamber or glued to the skid: • Barometric Draft Regulator (if supplied) • Circulator (if supplied) • Relief valve • Pipe Fittings b) The burner carton consisting of the following items: • Oil Burner assembly • 2nd Pass baffles (FWZ080 only) WARNING Installation of burners on the FWZ other than those provided by Crown, and marked for use with this boiler, may r
V Locating the Boiler WARNING 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 construction, as well as noncombustible walls, ceilings and doors. Also see Figure 5.0.
1) Do not install this boiler directly on a combustible floor. Where it is desired to install an FWZ on a non-carpeted combustible floor, install the boiler on a base constructed as shown in Figure 5.1 2) If listed Type L vent is used, follow vent pipe manufacturer recommendations for minimum clearances. 3) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or used.
A. 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 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.
FIGURE 6.0: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE FIGURE 6.
FIGURE 6.2: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC FIGURE 6.
FIGURE 6.
VII Venting 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 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. • Do not de-rate the appliance.
10) Vent connector must be inserted flush with inside face of the chimney liner and the space between vent connector and chimney sealed tight. A thimble permanently cemented in place can be used to facilitate removal of vent connector for cleaning. 11) Install the barometric draft regulator supplied with this boiler in accordance with the regulator manufacturer’s instructions. No other draft regulator shall be used. Mount the barometric draft regulator in the side connection of a tee (not supplied).
VIII System Piping 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 135°f can cause severe boiler or chimney damage. • Do not operate this boiler at a flow rate less than the minimum shown in Table 8.0, Column (a).
expansion tank can generally be reused. If the expansion tank must be replaced, consult the expansion tank manufacturer’s literature for proper sizing. 5) Fill Valve (Required) - Either a manual or automatic fill valve may be used. The ideal location for the fill is at the expansion tank. 6) 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.
FIGURE 8.1: INSTALLATION OF FACTORY SUPPLIED PIPING FIGURE 8.
Certain types of heating systems have additional requirements. Some of the more common variations follow: 1) Indirect Water Heaters - Figure 8.3 shows typical indirect water heater piping. Boiler piping is the same as for any two zone system. Figure 8.3 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.
FIGURE 8.4: BYPASS PIPING FIGURE 8.
IX Fuel Line Piping 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.
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 a continuous run of copper tubing having a minimum wall thickness of 0.032”. 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.
FIGURE 9.2: TWO-PIPE GRAVITY FEED SYSTEM (NOT RECOMMENDED) FIGURE 9.
X Wiring WARNING • All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70). Disconnect electrical power to the boiler and heating system before servicing. Positively assure that no voltage is present. Lock electrical boxes to prevent someone from inadvertently restoring power before the heating system is safe to operate. Never defeat or jump out safety devices.
3) Adding a Second Circulator Zone - The L7248 provided with this boiler can be used to control a second heating or DHW circulator zone. If this is done, make the following 120VAC connections in addition to those described above (also see Figure 10.0): • • Connect a 120VAC heating or DHW thermostat for the second zone between L1 and ZR. Connect the circulator for the second zone between ZC and L2.
FIGURE 10.
FIGURE 10.
XI Start-up and Checkout 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.
FIGURE 11.0: FLUE DRAFT TAPPING 15) Make sure that the oil pressure matches that shown in Table 11.1 for the burner supplied. Adjust pressure if required. 16) 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). 17) After chimney has warmed-up for at least 5 minutes, adjust barometric draft regulator to obtain a draft at the 1/4” tapping shown in Figure 11.
WARNING Attempts to use burners or burner configurations other than those shown in Table 11.1 could result in reliability problems, property damage, personal injury or loss of life TABLE 11.1a: BECKETT BURNER CONFIGURATION AND SETUP DATA BOILER MODEL BURNER MODEL AIR TUBE COMBO HEAD TYPE STATIC PLATE LOW FIRING RATE BAFFLE INSERTION LENGTH PITCH ANGLE STANDARD NOZZLE PUMP PRESSURE (psi) HEAD SETTING STARTING: SHUTTER SETTING BAND SETTING DRAFT IN FLUE (in w.c.) MAX SMOKE (Bacharach Scale) FLUE CO2 (%) MIN.
XII Operation A. General Information This boiler uses a proprietary version of the Honeywell L7248L Aquastat® to regulate water temperature and to manage demands from up to two circulator zones. Crown offers several options that can be used with this control and which are mounted in a console on top of the boiler. These include a touch screen display, low water cut-off kits, and an outdoor reset control.
FIGURE 12.1: BOILER CONTROL MENU STATUS MODE: =Current Status (Table 12.2) Press and Hold I, ↑, and ↓ for at least 3 sec to enter ADJUSTMENT MODE Press I to enter OPERATING MODE = High Limit Setting = Current Boiler Temp.
Status # TABLE 12.2: STATUS CODES Meaning Description 1 Standby 8 Burner Demand No call for heat or DHW OR Call for heat present , but boiler is in thermal purge (See PP on page 35) OR Call for heat/DHW present but boiler temperature is above set point (SP) setting. The burner is running OR The burner is off due to an open limit (such as an external high limit or LWCO) OR The burner is being prevented from firing its primary control.
TABLE 12.5: ADJUSTMENT MODE PARAMETERS Factory Status # Description Setting Permissible Range High Limit Set point 180F 140-240F HL High Limit Differential 15F 10-30F HdF ZC ZC and ZR Terminal Function dh dh (DHW) OR Zr (2nd Heating Zone) OR ELL (“External Low Limit” NOT RECOMMENDED) Or PP Circulator overrun 0 min 0-10 minutes Thermal Purge time 2 min 2-20 minutes St Thermal Purge Start Temp 140F 140-180F Pt DHW Priority ON ON or OFF F-C Temperature Units F F or C bAc Exit Adj.
HdF (High limit differential) - If the boiler shuts off on high limit, the water temperature must fall by an amount equal to the differential during the same call for heat before the burner will again start. For example, with HL=180 and HdF=15, the burner will shut off if the water temperature exceeds 180F and stay off until the temperature falls to 165F (180 - 15).
Or (Circulator Overrun) - Determines how long the Heating Circulator will operate after the call for heat ends. In some cases, this can help reduce energy consumption by sending heat stored in the boiler out into the system. At the same time, caution should be exercised before setting this value to something other than zero. Before doing so, verify that the system will permit flow (e.g. flow is not completely cut-off by closed zone valves) and that the overrun will not cause overheating problems.
XIII 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 severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Disconnect the burner plug from the receptacle in the front jacket.
WARNING The boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions.
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 substances become airborne and, if inhaled, may be hazardous to your health.
XIV Trouble Shooting A. Combustion 1) Nozzles - The selection of the nozzle supplied with the FWZ boiler is the result of extensive testing to obtain the best flame shape and efficient combustion. Other brands of the same spray angle and pattern may be used but may not perform at the expected level of CO2 and smoke. Nozzles are delicate and should be protected from dirt and abuse. Nozzles are massproduced and can vary from sample to sample.
B. Control System The following pages contain trouble 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 miswired electrical connections.
TABLE 14.1 - FAULTS WITHOUT ERROR CODE PRESENT Displayed Codes Problem Possible Cause Burner and Circulator Off • • • • Thermostat/s not calling for heat Loose connection in thermostat, zone valve end switch, or zone panel wiring. Thermostat, zone valve, or zone panel miswired Defective thermostat, zone valve, or zone panel StA 1 hr On Burner Off Circulator On Boiler Warm • • Boiler off on high limit (normal operation) Boiler off on thermal purge (normal operation - See Table 12.
Notes 42
Notes 43
XV Parts KEY # DESCRIPTION QTY.
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KEY # DESCRIPTION QTY.
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KEY # DESCRIPTION QTY.
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Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.
