Crown Boiler FWZ060 User manual

1
FWZ Series
Oil-Fired Hot Water Boilers
INSTALLATION INSTRUCTIONS

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

installer, service agency or the oil
supplier. Read these instructions
carefully before installing.
DESIGNED TO LEAD
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com

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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, 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.
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
EQUIPMENT 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.
WARNINGS FOR THE HOMEOWNER
WARNINGS FOR THE INSTALLER

2
Table of Contents
 
 
 
 
 


 
 
 
 
 
 
 
XV. Parts ....................................................................................................... 44


I Product Description




TABLE 2.0: GENERAL SPECIFICATIONS
BOILER

 






WEIGHT

  
      
      
      
      
      

TABLE 2.1: RATING DATA
BOILER


 






 
GPH  


TILE SIZE
HEIGHT
FT.
        
  112      
        
        
  222      



4
19"
BURNER SWING
DOOR CLEARANCE
(FULLY OPEN)
21 3
8"
COLLAR
'C' DIA.
12" MIN.
REAR
SERVICE
CLEARANCE
'B' MIN.
FRONT SERVICE
CLEARANCE
(FLUEWAY CLEANING)
RIGHT VIEW
TOP VIEW
ARRANGEMENT.
REAR VIEWFRONT VIEW
*NOTE: THIS DIMENSION INCREASES AND
IS CONTROLLED BY SMOKEPIPE
*
BECKETT AFG
PORT
GAUGE
BURNER
FLOOR
TEMP/PRESSURE
LINE
RELIEF
BURNER
OBSERVATION
FLAME
DOOR
SWING
VALVE
1-1/2" FPT
SUPPLY PIPING
CONNECTION
31 1
2"
"
4 3
20
4 3
8"
CLEAN OUT
SMOKEBOX
COLLAR
DRAIN VALVE
PIPING
COVER
1-1/2"
RETURN
CIRCULATOR
SPANNER BAR
AQUASTAT
RELAY
'A'

FIGURE 2.3: GENERAL CONFIGURATION *


Power (“Side Wall”) Venting - Important Note
Two problems arise when any oil-fired appliance is power vented:
 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 FWZ 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.
III Before Installing
 

 
 Installation of Oil Burning Equipment 
Installation Code for Oil-burning Equipment.
 Standard for
Controls and Safety Devices for Automatically Fired Boilers
 
 
 
 
such as the I=B=R 
 
 -

 

 



IV Field 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.


 

 -

 
 

 
FIGURE 4.0: BOILER FIELD ASSEMBLY


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.
 
 







 
-




VI Air for Combustion and Ventilation

Standard for the Installation of Oil Burning Equipment




 

 
 


 



 

 
 

FIGURE 5.1: INSTALLATION OVER A COMBUSTIBLE FLOOR


A. For Buildings of Other than Unusually Tight Construction
 


 

 




 
a .
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

 -

 


 

 


 

B. For Buildings of Unusually Tight Construction
 

 

 
 


 


 


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

11
FIGURE 6.2: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC
FIGURE 6.3: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM

12
FIGURE 6.4: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM


VII Venting


Standard for the
Installation of Oil-Burning EquipmentStandard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning
AppliancesInstallation Code for Oil-burning Equipment.


 
 

  Standard for
Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances
.
 
 
 
 The vent connector
.
 
 
 
Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances


 

 

 
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.

14
 


 

 

FIGURE 7.0: TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS
TABLE 7.1: MINIMUM RECOMMENDED BREECHING AND CHIMNEY SIZE
BOILER








 
    
    
    
    
    


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).
 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.
A. Standard Piping

I=B=R 

 


 





 


 
 The





 


Table 8.0 Minimum Flow Rate Requirements


 
   








    
    
    
    
    


 

 

 





 



 


heat.
 

 

B. Piping for Special Situations


FIGURE 8.1: INSTALLATION OF FACTORY SUPPLIED PIPING
FIGURE 8.2: STANDARD BOILER PIPING


FIGURE 8.3: INDIRECT WATER HEATER BOILER SIDE PIPING

 


heater manufacturer.
 




met.
 

 
 
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
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