Crown Boiler FWZ Series User manual

FWZ Series
Oil-Fired Hot Water Boilers
INSTALLATION INSTRUCTIONS
These instructions must be axed on or adjacent to the boiler
DESIGNED TO LEAD
9802605 Rev A, 06-18
Crown Boiler Company
P.O. Box 14818
3633 I Street
Philadelphia, PA 19134
www.crownboiler.com
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage,
injury, or loss of life. For assistance or additional information, consult a qualied installer, service
agency or the gas supplier. This boiler requires a special venting system. Read these instructions
carefully before installing.
Models:
• FWZ060
• FWZ080
• FWZ081
• FWZ100
• FWZ130
• FWZ160
Equipped with Hydrolevel
3250-Plus Control System

1
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels,
or to important information concerning product life.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
DANGER
This boiler is designed for use with #2 fuel oil meeting the specications of ASTM D-396. Attempts to burn
other liquid fuels, or to convert this boiler for use with gaseous fuels, could result in reliability problems,
extensive property damage, or loss of life.
NOTICE
This boiler has a limited warranty, a copy of which is included with this boiler.
The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in
accordance with these instructions.
Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation
during storage. Surface rust is normal and does not a󰀨ect the performance or longevity of a boiler.
All boilers must be installed in accordance with National, State and Local Plumbing, Heating and
Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may dier
from this instruction manual. Authorities having jurisdiction should be consulted before installations
are made.
In all cases, reference should be made to the following Standards:
USA BOILERS
A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil
Burning Equipment”, for recommended installation practices.
B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and
Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls
and safety devices.
D. All wiring on boilers installed in the USA shall be made in accordance with the National
Electrical Code and/or Local Regulations.
CANADIAN BOILERS
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil
Burning Equipment", for recommended Installation Practices.
B. All wiring on boilers installed in Canada shall be made in accordance with the Canadian
Electrical Code and/or Local Regulations.
IMPORTANT INFORMATION - READ CAREFULLY

2
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.
Read and understand all instructions, including all those contained in component manufacturers manuals
which are provided with the boiler before installing, starting-up, operating, maintaining or servicing this
boiler. Keep this manual and literature in legible condition and posted near boiler for reference by owner
and service technician.
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable
installer or service agency.
All heating systems should be designed by competent contractors and only persons knowledgeable in
the layout and installation of hydronic heating systems should attempt installation of any boiler.
Installation is not complete unless a pressure relief valve is installed as shown in Figure 8.1 located in
Section VIII, “System Piping” of this manual.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when the installation is completed.
This boiler is suitable for installation on combustible ooring. Do not install boiler on carpeting.
Do not tamper with or alter the boiler or controls.
Inspect ueways at least once a year - preferably at the start of the heating season. The inside of the
combustion chamber, the vent system and boiler ueways should be cleaned if soot or scale has accumulated.
When cleaning this boiler, take precaution to avoid damage to burner swing door insulation. If damaged,
or if there is evidence of previous damage, burner swing door insulation must be replaced immediately.
Oil Burner and Controls must be checked at least once a year or as may be necessitated.
Do not operate boiler with jumpered or absent controls or safety devices.
Do not operate boiler if any control, switch, component, or device has been subject to water.
Boiler construction materials, products of combustion and the fuel contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and
other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing
or working nearby the appliance.
This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
DANGER
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other appliance.

3
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 e󰀩cient,
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, 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.
Insu󰀩cient air may cause the boiler to produce
carbon monoxide or start a re.
KEEP FLAMMABLE LIQUIDS AWAY from the boiler,
including paint, solvents, and gasoline. The boiler
may ignite the vapors from the liquids causing
explosion or re.
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.
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 rst 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 gauge when making this
judgment.
USE PROPER PERSONAL PROTECTION
EQUIPMENT when servicing or working near the
boiler. Materials of construction, ue 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.
WARNINGS FOR THE HOMEOWNER
WARNINGS FOR THE INSTALLER

4
Table of Contents
I. Product Description ............................................................................... 5
II. Specications ......................................................................................... 5
III. Before Installing .................................................................................... 7
IV. Field Assembly ...................................................................................... 8
V. Locating the Boiler ................................................................................ 11
VI. Air for Combustion & Ventilation ......................................................... 12
VII. Venting ................................................................................................... 16
VIII. System Piping ........................................................................................ 19
IX. Fuel Line Piping .................................................................................... 24
X. Wiring .................................................................................................... 27
XI. Start-Up & Checkout ............................................................................. 31
XII. Operation ............................................................................................... 35
XIII. Service & Maintenance .......................................................................... 41
XIV. Troubleshooting ..................................................................................... 44
XV. Parts ....................................................................................................... 49
WARNING
This boiler must be properly vented. The chimney must be inspected for any obstructions and cleaned
prior to each heating season. A clean and unobstructed chimney ue is necessary to produce the minimum
draft required to safely evacuate noxious fumes that could cause personal injury or loss of life. Evidence
of loose debris and or condensate induced stains at the base of the chimney ue, connector or smokepipe
joints may be signs of condensing ue gases. Flue gas condensate is corrosive, which requires special
consideration and must be addressed immediately. Refer to Section VII, "Venting" in this manual for
more details.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start without
service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in
cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent
damage if the boiler is inoperative.
This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil
containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.
wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All ammable debris, rags, paper,
wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of
re hazards.
All boilers equipped with burner swing door have a potential hazard which, if ignored, can cause severe
property damage, personal injury or loss of life. Before opening swing door, unplug burner power cord
from receptacle located in lower right corner of jacket front panel and turn o󰀨 service switch to boiler
to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing door
fasteners completely when service is completed.

5
I Product Description
The FWZ series boiler is a cast iron oil-red 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 ue gases must be available in the boiler room.
II Specications
TABLE 2.0: GENERAL SPECIFICATIONS
MODEL
DIMENSIONS WATER
CONTENT
(GAL)
HEAT TRANSFER
SURFACE AREA
(SQ FT)
SHIPPING
WEIGHT
(LBS)
‘A’ ‘B’ ‘C’
FWZ060 16-1/4” 24” 5” 7.70 13.29 430
FWZ080 16-1/4” 24” 5” 7.70 13.29 430
FWZ081 22-1/4” 24” 6” 11.08 20.29 545
FWZ100 22-1/4” 24” 6” 11.08 20.29 545
FWZ130 28-1/4” 30” 6” 14.46 27.29 658
FWZ160 34-1/4” 36” 7” 17.84 34.29 771
Maximum working pressure, Water - 50psi
TABLE 2.1: RATING DATA
FWZ Series
AHRI Ratings Other Specications
MODEL*
BURNER
INPUT HEATING
CAPACITY
(MBH)
NET AHRI
RATING*
(MBH)
AFUE
(%)
MINIMUM CHIMNEY
REQUIREMENTS
GPH MBH ROUND
IN. DIA.
SQUARE.
TILE SIZE
HEIGHT
FT.
FWZ060 0.60 84 73 63 86.0 6 8 X 8 15
FWZ080 0.80 112 97 84 86.3 6 8 X 8 15
FWZ081 0.80 112 99 86 87.0 6 8 X 8 15
FWZ100 1.00 140 123 107 87.0 6 8 X 8 15
FWZ130 1.30 182 160 139 87.0 7 8 X 8 15
FWZ160 1.60 222 197 171 87.0 7 8 X 8 15
Burner Capacity Rating, GPH is based on #2 fuel oil with a Gross Heating Value equal to 140,000 BTU/Gal.
* Net Ratings are based on piping and pick-up allowances of 1.15

6
'C' DIA.
COLLAR
12" MIN.
REAR
SERVICE
CLEARANCE
'B' MIN.
FRONT SERVICE
CLEARANCE
(FLUEWAY CLEANING)
19"
BURNER SWING
DOOR CLEARANCE
(FULLY OPEN)
21 3
8"
SPANNER BAR
'A'
COMBINATION
LIMIT/LWCO
TOP VIEW
ARRANGEMENT.
RIGHT VIEWFRONT VIEW REAR VIEW
*NOTE: THIS DIMENSION INCREASES AND
IS CONTROLLED BY SMOKEPIPE
*
FLAME
OBSERVATION
GAUGE
PORT
TEMP/PRESSURE
BURNER
RELIEF
LINE
FLOOR
BURNER
BECKETT AFG
VALVE
SWING
DOOR
1-1/2" FPT
SUPPLY PIPING
CONNECTION
3"
4
20
31 1
2"
SMOKEBOX
CLEAN OUT
COVER
DRAIN VALVE
PIPING
COLLAR
1-1/2"
RETURN
CIRCULATOR
* Circulator Supplied Loose - May Be Installed On Supply Or Return.
FIGURE 2.3: GENERAL CONFIGURATION *

7
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). Installations in Canada comply with the requirements
of CSA B139-04 – Installation Code for Oil-burning Equipment.
• 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 (ANSI/ASME CSD-1).
2) Make sure that a properly sized chimney is available which is in good condition. Consult the authority having jurisdiction,
Part VI of this manual, and ANSI/NFPA31 for additional information on venting requirements.
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 Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI).
• For new radiant heating systems refer to the radiant tubing manufacturer’s boiler sizing guidelines.
• For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the Heating Capacity re-
quired for the Mega-Stor or the I=B=R Net Rating required for the heating system, whichever results in the larger boiler.
• 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 dierent burner conguration from that at sea level.
Consult the local Crown representative for more information.
CAUTION
As with all oil-fired appliances, “Power Venting” this boiler creates a number of potential
problems, especially when this is done through a side wall. These include, but are not
necessarily limited to:
• Accelerated rate of soot buildup on the oil burner cad-cell, burner head, and/or in the
boiler itself.
• Odor complaints
• Severe damage to the side of the structure in the event that the boiler operates at a high
smoke level.
These problems can occur for many reasons, some of which are out of the control of both the
installer and the appliance manufacturer. The use of a chimney to vent this boiler is therefore
recommended. If a power venter must be used, it is the responsibility of the installer and power
venter 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.

8
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
• Baes in some cases (see Table 4.1)
• Refractory blanket in some cases (see Table 4.1)
It is recommended that the boiler be moved to its nal location before the items in the burner carton are installed. To complete
eld assembly:
WARNING
Installation of burners on the FWZ other than those provided by Crown, and marked for use
with this boiler, may result in unreliable operation, property damage, personal injury, or loss of
life.
1) Make sure that the burner carton supplied is the correct one for the boiler. The crate tag on the boiler lists the Crown part
numbers for the burner cartons that may be used with it.
2) Remove the burner mounting bolts and washers from the front door. Make sure that the burner gasket is in place and undam-
aged and mount the burner to the door.
3) Plug the burner cord into the receptacle on the lower right front corner of the boiler as shown in Figure 4.0
4) Install the barometric draft regulator, and other piping/trim, as described in the Venting and Piping sections of this manual.
5) Dierent bae arrangements are used based on the boiler size and choice of burner. In some cases these baf-
es are included in the boiler and in other cases they are provided in the burner carton. In addition, some mod-
els use a refractory blanket which is shipped in the burner carton and which must be installed in the combustion
c h a m b e r . F i n a l l y , i n s o m e c a s e s b u r n e r s a r e s u p p l i e d w i t h i n s u l a t i o n w r a p p e d a r o u n d t h e i n s e r t e d b u r n e r t u b e .
Table 4.3 summarizes the use of baes, blankets, and burner tube insulation.
6) Attach the model-specic rating plate for the specic boiler model that is provided in the burner box to the left of the
permanent rating plate already on the boiler (Figure 4.0). Note that some burner boxes may contain rating plates for both
water and steam models; be sure to select the appropriate FWZ series rating plate. Before applying the rating plate clean the
area where it is to be applied with a clean, dry lint free cloth.
CAUTION
Fuel oil used with this boiler must conform to ASTM D396. The ASTM D396 standard sets a
5% limit on biodiesel concentration, requires that the biodiesel feedstock comply with ASTM
D6751, and also specifies the procedure that must be used to blend the biodiesel feedstock
with the #2 fuel oil. Attempts to use biodiesel blends not meeting all ASTM D396 requirements
may result in unreliable operation or severe property damage.

9
WARNING
• Do not omit the blanket when called for in the table above.
• Do not add any extra baffles beyond those prescribed for the model/burner combination
shown in Table 4.1.
Doing either of these things could cause accelerated chimney deterioration due to
condensation or inadequate draft resulting in severe property damage, personal injury or
death.
FIGURE 4.0: RATING PLATE LOCATION
TABLE 4.1: BASIC BOILER CONFIGURATIONS
Model Boiler
Part No. Burner
Burner
Carton
Part #
Blanket
Burner
Tube
Insulation
2nd Pass
Bae
(410009)
2nd Pass
Bae
(410008)
3rd Pass
Bae
(410007)
FWZ060 FWZ0021Beckett241060B No No No No Yes
FWZ080 FWZ0021Beckett241080B No No Yes 3No Yes
FWZ081 FWZ0031Beckett 41081B Yes 3No No No Yes3
FWZ081 FWZ0031Riello 41081R Yes 3Yes No No Yes 3
FWZ081 FWZ0031Carlin 41081C Yes 3Yes No No Yes 3
FWZ100 FWZ0031Beckett 41100B No No No Yes 3No
FWZ100 FWZ0031Riello 41100R No No No Yes 3No
FWZ100 FWZ0031Carlin 41100C Ye s3Ye s No Yes3Ye s3
FWZ130 FWZ0041Beckett 41130B No No No Yes No
FWZ130 FWZ0041Riello 41130R No No No Ye s No
FWZ130 FWZ0041Carlin 41130C Ye s3Ye s No Yes Yes 3
FWZ160 FWZ0051Beckett 41160B No No No Ye s No
FWZ160 FWZ0051Riello 41160R No No No Ye s No
FWZ160 FWZ0051Carlin 41160C Ye s3Ye s No Yes Yes 3
1 Boiler PN may contain additional characters after those shown to designate other options
2 FWZ060 and FWZ080 not available with Carlin or Riello Burner.
3 Included in burner box.
Figure 4.2 identies the type and location of baes. When used, lay the refractory blanket in the combustion chamber with
the 19-1/2” side oriented as shown in Figure 4.2. Line the front edge of the blanket up with the edge of the combustion chamber.
The blanket should run the entire length of the chamber. No adhesive is required to hold the blanket in place.
When required, burner tube insulation is applied at the factory and secured in place with masking tape. This tape is only needed
to hold the insulation in place while the burner is being installed through the door. After installation, the tape will harmlessly burn
away and the insulation will be secured by the door refractory.

10
FIGURE 4.2: BAFFLE AND BLANKET INSTALLATION

11
V Locating the Boiler
FIGURE 5.0: CLEARANCES
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.
Front - 24” (from front Jacket surface)
Left Side – 6”
Right Side – 6”
Rear – 12”
Top – 6”
Single Wall Chimney Connector (to combustible construction) - 18”
• A 24” service clearance is recommended above the top of the boiler, as well as on the side to which the burner swing
door opens (the left side as the boiler is shipped). See also dimension ‘B’ in Table 2.0 for recommended service clear-
ances to the front of the boiler. These clearances may be reduced to those shown above; however, servicing the boiler
will become increasingly dicult as these clearances are reduced.

12
VI Air for Combustion and Ventilation
Sucient 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 the Standard for the Installation of Oil Burning Equipment (ANSI/NFPA
31).
To ensure an adequate supply of air for combustion, ventilation and ue gas dilution, start by determining whether adequate
combustion and ventilation air can be obtained through natural inltration (air leaking into the building through cracks around
windows, doors, etc). Examples of construction features which could prevent adequate natural inltration include:
• Walls and ceilings exposed to outside atmosphere having a continuous water vapor retarder with a rating of 1 perm or
less with openings gasketed and sealed
• Weather stripping added on openable windows and doors
• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and oors,
between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other
openings.
• Large exhaust fans
In this manual, buildings where natural inltration will not provide adequate air for combustion, and ventilation are referred to
as “buildings of unusually tight constuction”. If in doubt, assume that the building in which the boiler is installed is of unusually
tight construction.
1) Do not install this boiler directly on a combustible oor. Where it is desired to install an FWZ on a non-carpeted combustible
oor, 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 ammable 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.
FIGURE 5.1: INSTALLATION OVER A COMBUSTIBLE FLOOR

13
A. For Buildings of Other than Unusually Tight Construction
1) Determine whether the boiler is to be installed in a conned space - A conned space is dened 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
conned 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 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 conned space.
Example:
An FWZ080 and a water heater are to be installed in a room measuring 6 ft - 3 in x 7 ft with an 8 ft ceiling. The
water heater has an input of 30000 BTU/hr:
Input of FWZ080 = 0.80 Gal/hr x 140000 BTU/Gal = 112000BTU/hr
Total input in thousands of BTU/hr = (112000 BTU/hr + 30000 BTU/hr)/1000 = 142
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3
350/142 = 2.46. Since 2.46 is less than 50, the boiler room is a conned space.
2) Unconned Space - Natural inltration into the boiler room will normally provide adequate air for combustion and ventila-
tion without additional louvers or openings into boiler room.
3) Conned Space - Provide two openings into the boiler room, one near the oor 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 oor
(Figure 6.0).
• 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 eect of mesh, grills, and louvers. Where screens are
used, they must be no ner than ¼” (4 x 4) mesh.
B. 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. The bottom edge of
the lower opening must be within 12 inches of the oor.
3) Size openings and ducts as follows:
• Vertical ducts or openings directly outdoors (Figure 6.1, Figure 6.2, and Figure 6.3) - Each opening must have a free
cross sectional area of 1 square inch per 4000 BTU/hr of the total input of all fuel red 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 6.4) - Each opening must have a free cross sectional area of 1 square
inch per 2000 BTU/hr of the total input of all fuel red 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 eect of mesh, grills, and louvers. Where screens are
used, they must be no ner than ¼” (4 x 4) mesh.

14
FIGURE 6.0: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE
FIGURE 6.1: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC

15
FIGURE 6.2: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC
FIGURE 6.3: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM

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FIGURE 6.4: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM
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. Failure to fire the unit at it’s designed input may cause
excessive condensation upon the interior walls of the chimney. In addition, the lower input
may not create enough draft to adequately evacuate the products of combustion.
• Do not omit the blanket when called for in the table above.
• Do not add any extra baffles beyond those prescribed for the model/burner combination
shown in Table 4.1.
Doing either of these things could cause accelerated chimney deterioration due to condensa-
tion or inadequate draft resulting in severe property damage, personal injury or death.

17
The vent installation must be in accordance with local building codes, or the local authority having jurisdiction. Contact your
local re and building ocials on specic requirements for restrictions and the installation of fuel oil burning equipment. In
the absence of other applicable codes, the vent system installation must meet the requirements of NFPA 31 – Standard for the
Installation of Oil-Burning Equipment and NFPA 211 - Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning
Appliances. Vent systems in Canada must comply with CSA B139-04 – Installation Code for Oil-burning Equipment.
A typical vent system is illustrated in Figure 7.0. The components of the vent installation are the vent connector (breeching),
barometric draft regulator, and chimney.
1) Acceptable Chimneys - The following chimneys may be used to vent a FWZ series boiler:
• 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 FWZ series boiler into an unlined chimney.
2) Acceptable Vent Connectors - The following may be used for vent connectors:
• Listed Type L vent.
• Single Wall Galvanized Pipe - Use 0.018” (26 gauge) or heavier.
3) Chimney and Vent Connector Sizing - See Table 7.1 for minimum vent connector and chimney sizing. The vent connector
size must not be smaller than boiler ue 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 ue serving an open replace or other solid fuel appliance.
6) Prior to boiler installation, an existing chimney must be inspected by a qualied person in accordance with the requirements
of Chapter 11 of NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances. This inspection is
intended to identify safety problems with the chimney such as obstructions, a missing or damaged liner, or leak points. Clean
chimney as necessary and correct any other chimney defects before installing the boiler.
7) Vent connector must slope upward from boiler not less than one inch in four feet. No portion of vent pipe should run
downward or have sags. Vent connector must be securely supported.
8) The vertical section of vent connector coming o 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 connector must be installed above the bottom of the chimney to minimize risk of blockage.
10) Vent connector must be inserted ush 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).
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 (see Figure 7.0, Detail ‘A’), as well as the barometric draft regulator. Use at least three screws at each joint.

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FIGURE 7.0: TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS
TABLE 7.1: MINIMUM RECOMMENDED BREECHING AND CHIMNEY SIZE
BOILER
MODEL
MINIMUM
BREECHING
DIA. (INCHES)
MINIMUM CHIMNEY REQUIREMENTS
ROUND I.D.
(IN.)
SQUARE. TILE
SIZE (NOMINAL) HEIGHT (FT.)
FWZ060 5 6 8 X 8 15
FWZ080 5 6 8 X 8 15
FWZ081 5 6 8 X 8 15
FWZ100 6 6 8 X 8 15
FWZ130 6 7 8 X 8 15
FWZ160 7 7 8 X 8 15