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D ESIGNED T O L EAD
TWZ Series
Oil-Fired Hot Water Boilers
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Models:
• TWZ065
WARNING: Improper installation,
adjustment, alteration, service or
• TWZ075
maintenance can cause property
• TWZ100
damage, injury, or loss of life.
For assistance or additional
• TWZ090
information, consult a qualified
• TWZ125
installer, service agency or the
oil supplier. Read these instruc-
• TWZ150
tions carefully before i
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Table of Contents I. Product Description.............................................................1 VIII. Tankless Heater Piping ................................ 15 II. Specifications....................................................................... 1 IX. Fuel Line Piping ...........................................16 III. Before Installing................................................................... 2 X. Wiring ..........................................................19 IV. Locati
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TABLE 1a: GENERAL SPECIFICATIONS Burner DOE Heating Number of Input Capacity I=B=R Net Approx. Water Dimensions (inches) Boiler Model Sections (Gal/hr) (Btu/hr) Rating (Btu/hr) AFUE (%) Content (Gal) "A" "B" "C" TWZ065 3 0.65 80000 70000 86.1 16.0 16 1/2 8 5/16 6 TWZ075 3 0.75 91000 79000 85.8 16.0 16 1/2 8 5/16 6 TWZ100 3 1.00 120000 104000 84.3 16.0 16 1/2 8 5/16 6 TWZ090 4 0.90 111000 97000 86.0 20.0 21 1/2 10 13/16 7 TWZ125 4 1.25 152000 132000 84.9 20.0 21 1/2 10 13/16 7 TWZ150 4 1.50 179
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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. • For systems including a Crown Mega-Stor indirect water heater, size the boiler to have either the DOE
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18* 6 6 24 6 FR ONT VIEW SIDE VIEW * CLEARANCE FROM SINGLE WALL CONNECT OR TO COMBUSTIBLE CONST RU CT I ON FIGURE 2: CLEARANCES Sheet Metal (24 GA or T hicker) 4“ MIN. Combustible Surface Openings Aligned T o Permit Free Air Circulation Hollow Masonry Blocks FIGURE 3: INSTALLATION OVER A COMBUSTIBLE FLOOR 4 5 0.47"
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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). To ensure an adequate supply of air for combustion, ventilation and flue gas dilution, start by determining whether the boiler is to be installed in a buildi
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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. The bottom edge of the lower opening must be within 1
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FIGURE 5: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC FIGURE 6: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC 7 8
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FIGURE 7: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM FIGURE 8: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 8 9
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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 applicab
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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. 8) The vertical section of vent pipe coming off the boiler should be as tall as possible, while still maintaining the proper clearance from the horizontal vent connector to combustibles
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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. • DO NOT USE TOXIC ADDITIVES, SUC
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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. A less ideal, but acceptable, location for most residential circulators is in the return (if this is done, be sure that adequate clearance exi
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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 two- zone system. Figure 11 shows circulator zoning, which is usually preferred for indirect water heaters. Size the circulator and indir
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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. The heat exchanger will permit the transfer of heat from the boiler water to the low temperature system while holding the sys
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VIII TANKLESS HEATER PIPING If the TWZ is installed with an optional tankless heater, pipe the heater as shown in Figure 14. The components in this system and their functions are as follows: 1) Mixing Valve (Required) - During the heating season, the water exiting the tankless heater may be 180 degrees or more. The mixing valve blends hot water leaving the tankless heater with cold water so as to maintain the hot water supplied to the fixtures at a fixed temperature. This saves energy, increases
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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. Depending on the location of the fuel oil storage tank in relation to an oil burner, there are four types of oil piping systems
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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. A two-pipe lift system is the
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FIGURE 17: TWO-PIPE GRAVITY FEED SYSTEM FIGURE 18: TWO-PIPE LIFT SYSTEM 18 19
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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. 19): • Hot (“black”) - Terminal “L1” • Neutral (“white”) - Terminal “L2” • Gr
