D E S I G N E D T O L E A D 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 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.
Table of Contents I. Product Description ............................................................. 1 II. Specifications ....................................................................... 1 III. Before Installing ................................................................... 2 IV. Locating the Boiler ............................................................... 3 V. Air for Combustion & Ventilation ........................................ 5 VI. Venting ........................................
TABLE 1a: GENERAL SPECIFICATIONS Boiler Model TWZ065 TWZ075 TWZ100 TWZ090 TWZ125 TWZ150 TWZ120 TWZ175 TWZ200 Number of Sections 3 3 3 4 4 4 5 5 5 Burner Input (Gal/hr) 0.65 0.75 1.00 0.90 1.25 1.50 1.20 1.75 2.00 DOE Heating Capacity (Btu/hr) 80000 91000 120000 111000 152000 179000 147000 210000 238000 Approx. Water I=B=R Net Rating (Btu/hr) AFUE (%) Content (Gal) 70000 86.1 16.0 79000 85.8 16.0 104000 84.3 16.0 97000 86.0 20.0 132000 84.9 20.0 156000 83.8 20.0 128000 86.0 24.0 183000 83.5 24.
3) Make sure that the boiler is correctly sized: • • • • For heating systems employing convection radiation (baseboard or radiators) use an industry accepted sizing method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics Institute in Berkeley Heights, NJ. For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.
18* 6 6 24 FRONTVIEW 6 SIDE VIEW * CLEARANCE FROM SINGLE WALL CONNECTOR TO COMBUSTIBLE CONSTRUCTION FIGURE 2: CLEARANCES 0.47" Sheet Metal (24 GA or Thicker) 4“ MIN.
V Air for Combustion and Ventilation 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).
FIGURE 4: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE used, they must be no finer than ¼” (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 must be within 12 inches of the ceiling.
FIGURE 5: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 6: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC 87
FIGURE 7: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 8: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 98
VI Venting 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. 1) Acceptable Chimneys - The following chimneys may be used to vent a TWZ series boiler: • Listed Type L vent - Install in accordance with the manufacturer’s instructions, the terms of its listing, and applicable codes.
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 securely supported.
VII System Piping CAUTION • INSTALL BOILER SO THAT ALL 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.
DANGER • • • • PIPE RELIEF VALVE TO A SAFE LOCATION DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE DO NOT MOVE RELIEF VALVE FROM FACTORY SPECIFIED LOCATION DO NOT PLUG RELIEF VALVE DISCHARGE 2) Circulator (Required) - Figure 10 shows the ideal location of the circulator which is in the supply piping immediately downstream of the expansion tank.
FIGURE 11: INDIRECT WATER HEATER BOILER SIDE PIPING 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 twozone system. Figure 11 shows circulator zoning, which is usually preferred for indirect water heaters.
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 120°F minimum. Figure 13 illustrates the use of a heat exchanger to connect the TWZ boiler to this type of system.
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.
FIGURE 14: TANKLESS HEATER PIPING IX Fuel Line Piping Fuel line piping design, materials and construction must be in accordance with local building codes, requirements of the local authority having jurisdiction, and, the latest edition of Installation of Oil-Burning Equipment (ANSI/NFPA 31). Refer also to the instruction manuals provided with the burner and oil pump.
b) 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.
FIGURE 17: TWO-PIPE GRAVITY FEED SYSTEM FIGURE 18: TWO-PIPE LIFT SYSTEM 18 19
X Wiring WARNING 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/NFPA70). Single Zone Wiring 1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt connections are made inside the L8148 or L8124 aquastat relay as follows (also see Fig.
HONEYWELL L8148 OR L8124 AQUASTAT RELAY L1 INTERRUPTED INTERMITTENT BURNER MOTOR LIMIT VALVE L2 CAD CELL NOTE: 1) BURNER WIRING SHOWN IS FOR BECKETT AFG BURNERS. CONSULT BURNER INSTRUCTION MANUAL FOR OTHER BURNERS 2) AQUASTAT PICTURED IS L8148. TERMINAL 3 AND JUMPER FROM L1 TO 3 ARE NOT PRESENT ON L8124. L8124 HAS TWO TERMINALS, MARKED ZC AND ZR, WHICH ARE NOT USED.
FIGURE 21: WIRING DIAGRAM, ZONE WIRING USING HONEYWELL V8043F ZONE VALVES (FACTORY BOILER WIRING NOT SHOWN - SEE FIGURE 19) 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.
6) Check initial settings of oil burner air band and air shutter, head setting etc., and readjust if 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.
TABLE 3a: BECKETT BURNER CONFIGURATION AND SETUP DATA TWZ065 KSZ065 BURNER MODEL AFG AIR TUBE COMBO. 70MMAQ HEAD TYPE L1 STATIC PLATE 3 3/8 LOW FIRING RATE BECKETT #3708 BAFFLE INSERTION LENGTH 2 1/4 PITCH ANGLE 2 STANDARD HAGO NOZZLE 0.55/60B DEL. ALTERNATE NOZZLE 0.55/60W PUMP PRESS (psi) 140 HEAD SETTING NA STARTING: SHUTTER SETTING 1 BAND SETTING 1 DRAFT OVER FIRE -0.02 (in w.c.) MAX. SMOKE #1 (bacharach scale) FLUE CO2 (%) MIN. 11.0 MAX 12.
TABLE 3c: RIELLO BURNER CONFIGURATION AND SETUP DATA TWZ065 BURNER MODEL STANDARD NOZZLE PUMP PRESS (psi) TURBULATOR AIR SHUTTER SETTING DRAFT OVER FIRE (in w.c.) MAX. SMOKE (bacharach scale) FLUE CO2 (%) MIN. MAX TWZ075 TWZ100 TWZ090 40F5 40F5 DEL DEL 0.60/60A 0.85/60W 150 150 0 2 TWZ125 TWZ150 TWZ120 TWZ175 TWZ200 40F5 DEL. 1.00/60A 150 4 40F10 DEL 1.25/60B 150 1 40F10 HAGO 1.35/45B 150 1.5 40F10 DEL 1.65/45B 150 2 2.60 2.85 4 3 3 3.8 -0.02 -0.02 -0.02 -0.02 -0.02 -0.
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.
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.
65 270013 1 ea. 1 ea. 1 ea. 2 ea. 2 ea. 2 ea. 2 ea. 1 ea. 2 ea. 10 ea. 4 ea. 1 ea. 1 ea. 75 270013 1 ea. 1 ea. 1 ea. 2 ea. 2 ea. 2 ea. 2 ea. 1 ea. 2 ea. 10 ea. 4 ea. 1 ea. 1 ea. QUANTITY PER BOILER OR CROWN P.N. 100 90 125 150 120 270013 270014 270014 270014 270015 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 2 ea. 2 ea. 2 ea. 3 ea. 2 ea. 3 ea. 3 ea. 3 ea. 4 ea. 2 ea. 3 ea. 3 ea. 3 ea. 4 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 2 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.
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KEY # 40 41 * DESCRIPTION LEFT SIDE JACKET PANEL RIGHT SIDE JACKET PANEL REAR JACKET PANEL QUANTITY PER BOILER OR CROWN P.N. QTY. OR CROWN P.N. 65 75 100 90 125 150 120 175 200 1 ea. 270233 270233 270233 270234 270234 270234 270235 270235 270235 270225 1 ea. 270223 270223 270223 270224 270224 270224 270225 270225 270220 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 270243 270243 270243 270244 270244 270244 270245 270245 270245 1 ea.
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Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I.
