Freeport 2 Steam Installation Manual
Contents
1. CROWN DESIGNED TO L EAD FSZ Series Oil Fired Steam Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models rrr man nu CERTIFIED 4 FSZ080 www ahridirectorv org WARNING Improper installation e FSZ100 adjustment alteration service or e FSZ130 maintenance can cause propertv damage injurv or loss of life e FSZ160 For assistance or additional information consult a qualified installer service agencv the oil supplier Read these instructions carefully before installing gt O Manufacturer of Heating Products P O Box 14818 3633 1 Street Philadelphia PA 19134 www crownboiler com A WARNINGS FOR THE HOMEOWNER 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 p2. i 5 IV Field Assembly d 6 M Locating the 7 VL Air for Combustion Ventilation 8 VIL ET 13 System 15 IX Indirect amp Tankless Water Heater Piping 2 19 X Fuel Line Piping ERREUR 22 XIs 00 Motte tenen 25 Start Up amp Checkout 30 Service Maintenance 34 XIV Troubleshooting i ij 38 QE JUD ERUIT 40 Appendix A Installation of Optional Gravity Return Piping Kit 46 I Product Description The FSZ series boiler is a cast iron oil fired steam boiler designed for use in closed heating systems This boiler must be vented by natural draft into a lined masonry or metal chimney or L vent An adequate supply of air for combustion ventilation and dilution of flue gases must be available in the boiler room This boiler has connections for use with an indirect domestic water heater The FSZ series boilers are not designed for use in process or other steam systems II Specifications TABLE 2 1 G
3. JO 401 440 NIMVL 38 OL NIVW 14818 NIVA NUNLIA ALIAVED 40 40014 JO 9 Ol 393VH9SIQ 3818 INTI 82 NVHL 5531 ION 38 Ol NIVW AlddNS JO 14109 0135 LSM OLNI SNIVW 40 4180 437108 LNIOd H9IH WO4 NMOQ 38075 NIVW AlddNS 15 ALIAVAD DNIdId WVALS 18 HINDI C TM N AILVM WWYON 0758 2 38 15 NOILOSNNOO CYOSLYVH JO 331 NO O3ON3WWOO3H ATONOYLS SH3SIH OML 3ONVWHOJN3d 1638 N04 3101 CXVW 8 2 TE INII Ol 081114 537109 0103 Xu ZN lt ZN lt I 2 2 091754 0 1284 001284 080284 8215 3dld WNWINIW WALSAS 304 Q3QN3WWOO33 118 1 01140 88814 5 QNOJAS 16 WRONG Take Off WRONG Between Risers Header Bullheaded Into Take Off And Equalizer WRONG Take Off Bullheaded Into Two Mains FIGURE 8 2 NEAR BOILER PIPING MISTAKES Piping Installation 1 Remove parts bag from boiler crate 2 Install safetv valve as shown in Figure 8 1 into the 3 4 tapping on rear of the boiler spindle must be in vertical position 3 Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property damage if the
4. x 5 Nipple 19 1 1 2 x 3 4 x 1 1 2 Tee 20 1 1 2 x 4 Nipple 21 1 1 2 Union 22 1 1 2 x 8 Nipple 23 3 4 Plug 4 5 ES io m i 18 228721 20 ESTEE 2 DRAIN OR 63 Notes eA dii sa CE NN Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com PN 980265 FSZ Rev 3 07 13
5. 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 confined space Example 52080 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 FSZ080 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 f 350 142 2 46 Since 2 46 is less than 50 the boiler room is a confined space Unconfined Space Natural infiltration into the boiler room will normally provide adequate air for combustion and ventila tion without additional louvers or openings into boiler room Confined Space Provide two openings into the boiler room one near the floor 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 floor Figure 6 0 Each opening must have a free area of 1 square i
6. 4 LG CAP SCREWS W 3 5 16 FIGURE 4 0 BOILER FIELD ASSEMBLY FEAT WASHERS V Locating the Boiler A WARNING Failure to observe the following location requirements could result in propertv 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 18 is required for tankless heater service Rear 12 Top 6 Single Wall Chimney Connector to combustible construction 18 e A24 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 difficult as these clearances are reduced FRONT VIEW RIGHT SIDE VIEW 006006606060 Q2 Q2 52 lt gt 2 x 5 gt 57 gt OO 2522 5550509 gt 5559 25 55505 XN 555255 ENEN lt lt S CKO 525050500 CX Q2 o D 27 18 CLEAR
7. be done follows Turn off the burner b Drain water from boiler until about one inch of water is visible in gauge glass c Runa hose or temporary piping from the boiler drain valve to a location where hot water can be safely discharged Drain approximately five gallons of water from the boiler and mix in an appropriate amount of an approved boil out compound Remove safety valve and refill the boiler with prepared solution through funnel Replace safety valve d Run a hose or temporary piping from the 1 1 2 skimmer tap on the upper rear section to a location where hot water can be safely discharged e Start the burner Run boiler for several hours boiling the water without generating steam pressure Open the water feed valve sufficiently to allow a slight overflow of water through the skimmer tapping drain line Continue boiling until water coming out 1s clear f Turn off the burner Drain hot water from boiler through boiler drain valve to a location where hot water can be safely discharged Refill the boiler to normal water line level If water in the gauge glass does not look clear repeat above boil out procedure again until water clears out g Reinstall safety valve and related piping h Conduct pH and Alkalinity test of water in the system The pH reading should be in 7 to 11 range NOTE When substantial amount of make up water is used due to lost condensate or when make up water 1s hard or corrosive water treatm
8. burner circuit Check vour local codes for special requirements 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 the Standard for the Installation of Oil Burning Equipment ANSI NFPA 31 in the United States and CSA B139 04 for installation in Canada 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 that may be encountered a ONE PIPE GRAVITY SYSTEM Used when a fuel oil storage tank 1s positioned above an oil burner fuel pump See Figure 10 0 A vertical distance from top of the tank to center line of the pump Dimension H over 8 feet will result in a pump inlet pressure in excess of the 3 psi limit in NFPA 31 b ONE PIPE LIFT SYSTEM not recommended Used when a fuel oil storage tank is located below an oil burner fuel pump See Figure 10 1 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 therefore preferred to a one pipe lift system c TWO
9. burner on and off 25 Verify primary control operation and safety features according to procedure outlined in the instructions furnished with the burner 26 Check pressure limit control operation Jump thermostat terminals and allow burner to run until boiler pressure exceeds cut in pressure plus the differential The burner should shut down 27 Check low water cut off operation With the thermostat still jumped fire the boiler and crack the boiler drain valve so that water is slowly drained from the boiler Confirm that the burner shuts down before the water level drops below the bottom of the sight glass Do not permit the boiler to fire without water visible in the sight glass Add water to the boiler and confirm that the burner restarts Remove thermostat jumper and reconnect thermostat upon check completion 28 After the boiler has operated for approximately 30 minutes check the boiler and heating system for leaks Repair any leaks found at once 29 After the above checks have been completed leave thermostat s at desired setting Leave all instructions provided with 21 the boiler with owner or in boiler room displaved near boiler 30 After new boiler has been installed and put into continuous operation for several davs clean the boiler of oil grease sludge and other contaminants that mav have been present in existing piping This will prevent unsteadv water line and water carry over into supply main The boiler boil out should
10. present in the bottom of the boiler repeat steps b through g until all mud or scale is removed Once all mud or scale is removed replace the 1 1 4 valve and temporary blow down piping with the standard plug After all parts of the boiler are at room temperature refill the boiler to the normal water line NOTE A large accumulation of mud or scale in the bottom of the heat exchanger is usually a sign of excessive feedwater make up Such accumulations can cause severe heat exchanger damage If mud or scale accumulations are found Make sure that all vents are in working order Vents should not permit any passage of steam or water Check all steam and return piping for leaks Be aware that buried return piping can leak and go undetected during normal operation TANKLESS HEATER MAINTENANCE During the warm months make sure that the water level in the boiler is 30 to 31 1 2 inches above the surface on which the boiler is installed Failure to do this may result in inadequate hot water and or steaming when there is no call for heat Maintain the mixing valve in accordance with the valve manufacturer s instructions 34 B Fire Side Maintenance A VARNING 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 propertv damage personal injurv or loss of life if ignored Before opening swing door turn off service
11. shall be used 12 Secure all joints in the vent connector svstem 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 E Y T MNEY H FSZ080 160 NOT LESS THAN 8 X 8 X 15 VENT PIPE 26 GA MIN TE THIMBLE ALL HORIZONTAL VENT PIPE SHOULD SLOPE UPWARD NOT LESS THAN ONE INCH IN SLOPE UP FOUR FEET gt AIR GAP APPROX DRAFT REGULATOR 10 0 CLOCK 0 CLOCK POSITION POSITION DILUTION AIR SVSTEM FSZ BOILER FRONT CLEANOUT 6 O CLOCK POSITION DETAIL A DETAIL A RECOMMENDED SCREW LOCATIONS FOR CHIMNEY CONNECTORS LINE FIGURE 7 0 TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS TABLE 7 1 MINIMUM RECOMMENDED BREECHING AND CHIMNEY SIZE MINIMUM CHIMNEY REQUIREMENTS BOILER MINIMUM MODEL ROUND LD SQUARE TILE DIA INCHES IN SIZE NOMINAL 15 7 5 EA 14 VIII Svstem Piping warnine 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 in a system having significant amounts of dissolved oxygen can cause severe heat exchanger corrosion damage Do not use toxic additives such as automotive antifr
12. 30 FSZ160 so OIL BURNER ASSY BECKETT BURNER ASSY NOTE 1 42100 2 411308 411608 EA RIELLO OIL BURNER 55 NOTE 1 42100R 41130R 41160R pm or gt Temmen Ls fe EO GAUGE GLASS SET 6 CONBRACO 71 1040 sow P 3 4 NPT SAFETY VALVE 15 PSI CONBRACO 13 512 B15 Ls eee L m l 1 27 NPT X 5 NIPPLE 950025 LIR X LI 3 NPT REDUCING TEE memmewem oe NOT SHOWN 1 PART NUMBERS PROVIDED ARE FOR FULLY CONFIGURED BURNERS AND INCLUDE PRIMARY SAFETY CONTROL NOZZLES BURNER CORD ASSEMBLIES AND WHERE APPLICABLE LOW FIRING RATE BAFFLES 2 BURNER ASSEMBLIES FOR THE FSZ100 ARE PACKAGED WITH 2 SECOND PASS BAFFLES PN 410008 44 Appendix A Optional Dropped Header Gravitv Return Piping Kit The following near boiler piping kits are available from Crown for use with FSZ boilers installed in gravitv return svstems 421095 Dropped Header Gravity Return Near Boiler Piping Kit FSZ080 100 130 421096 Dropped Header Gravity Return Near Boiler Piping Kit FSZ160 These kits provide the pipe and fittings needed for the drop header piping as listed in Table A 1 for the FSZ080 FSZ100 and FSZ130 and in Table A 3 for the FSZ160 Installation of Dropped Header Gravity Return Piping Kit 1 Assemble Dropped Head
13. ANCE REQUIRED WHEN BOILER IS EQUIPPED WITH TANKLESS HEATER FIGURE 5 0 CLEARANCES 1 Donot install this boiler directly on a combustible floor Where it is desired to install an FSZ on a non carpeted combustible floor install the boiler on a base constructed as shown in Figure 5 1 2 Iflisted 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 Do not install this boiler in an area where large amounts of airborne dust will be present such as a workshop SHEET METAL 24GA OR THIC 9 COMBUST IBLE OPENINGS ALIGNED TO PERMIT FREE AIR CIRCULATION HOLLOW MASONRY BLOCKS FIGURE 5 1 INSTALLATION OVER A COMBUSTIBLE FLOOR VI 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 the Standard for the 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 adequate combustion and ventilation air can be obtained through natural infiltration air lea
14. Drain valve Pipe fittings A WARNING Installation of burners on the FSZ other than those provided bv Crown and marked for use with this boiler mav result in unreliable operation propertv damage personal injurv or loss of life It 15 recommended that the boiler be moved to its final location before the items in the burner carton are installed To complete field assembly 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 Beckett and Riello 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 as shown in Figure 4 0 3 Plug the burner cord into the receptacle on the lower right front corner of the boiler 4 The 57100 uses a pair of second pass baffles which are included in the burner carton and which must be installed in the field Install these as shown in Figure 4 0 baffles are factory installed on other models 5 Install the barometric draft regulator and other piping trim as described in the Venting and Piping sections of this manual SWING DOOR BURNER FLANGE GASKET POWER RECEPTACLE FSZ100 SECOND PASS FOR BURNER BAFFLE INSTALLATION BURNER POWER CORD BAFFLES ARE FACTORY INSTALLED ON OTHER MODELS LWCO REMOVED FOR CLARITY 3 5 16 18 X 3
15. ENERAL SPECIFICATIONS DIMENSION WATER CONTENT TO NORMAL WATER LINE GALLONS HEAT TRANSFER SHIPPING MODEL SURFACE AREA WEIGHT 52080 2214 24 e 13 49 929 67 uw e mm p mm 25 Maximum working pressure Steam 15psi TABLE 2 2 RATING DATA BURNER MINIMUM AHRI NET RATINGS BOILER INPUT HEATING ANRINETRATINGS REQUIREMENTS AFUE MODEL GEH MBH STEAM STEAM ROUND RECTANGLE HEIGHT SQ FT IN DIA IN XIN FT 7 s sxs szo mo 2 o 6 sxs so Burner Capacity Rating is based on 2 fuel oil with a Gross Heating Value equal to 140 000 BTU Gal AHRI Net Ratings are based on piping and pick up allowances of 1 333 TABLE 2 3 TANKLESS HEATER RATINGS BOILER MODEL HEATER RATING GPM PRESSURE DROP THRU HEATER PSI FSZ130 FSZ160 Ratings based on 40F inlet water 140F outlet water and 190F boiler water Ratings are also based on 5 minute intermittent draws with 10 minutes between draws avd Ava HINNVAS NOLLVNDIHNOD TVIHNAD PANO N3dO 1 4 JONVAVIID ONIMS JINANA 61 INOJ i 3ATVA Al34VS IN3W3ONV3lal v 3dld331OWS Ad GITIONINOD SI ANY S3SV383ONI NOISNAWIG 31ON AVTIOD XO833OWS 4 4 TOJ
16. GURE 9 1 INDIRECT WATER HEATER BOILER SIDE PIPING 19 IMPORTANT Some indirect water heaters mav not be suitable for use with a steam boiler Consult the water heater manufacturer s guidelines before installing it in this type of system Boiler water temperatures and flow rates in this type of system may be considerably lower than those upon which the water heater manufacturer s ratings are based This may result in substantially longer water heater recovery times TANKLESS HEATER PIPING FSZ Series boilers equipped with tankless heaters are supplied with a Honeywell L4006A limit control and 1 2 NPT well These components are shipped unmounted This control is mounted in the 1 2 tapping in the center of the tankless coil Make the piping connections to the coil before installing the L4006A making sure that these connections are routed so that they will not interfere with the L4006A Pipe the heater as shown in Figure 9 2 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 the amount of usable hot water available to the homeowner and reduces the risk of scalding Install a mixing valve with a setting
17. III must also be supplied the installer A call for heat from the indirect water heater thermostat will energize the relav making both sets of contacts One set of these contacts then energizes the cir culator The other set of contacts will make the and contacts on the R8285D control firing the burner If the boiler water temperature exceeds the high limit setting of 180F the high limit will open the circuit and the burner will shut down If there is a call for space heat the heating thermostat will make R G circuit and the boiler will fire without regard to the status of the indirect water heater The low water cut off and pressure limit control will interrupt 120 volt power to the burner in the event of a low water or excessive pressure condition Feeder Wiring for Boilers Equipped with Hydrolevel CG450 Low Water Cut offs 1 Using Hydrolevel VXT 120 feeder Do not alter factory boiler wiring Connect VXT 120 to CG450 as follows Connect the BLACK lead on the feeder to terminal A on the CG450 Connect the WHITE lead on the feeder to terminal 2 on the CG450 CAUTION When making low voltage connections make sure that no external power source is present in the thermostat circuits If such a power source is present it could destroy the boiler s control One example of an external power source that could be inadvertently connected to the low voltage connections is a transf
18. ING DOOR INSULATION WITH POCKETS 1 2 DIA GASKET SWING DOOR ao 1 1 8 DIA ROPE GASKET OBSERVATION PORT 1 jsemma 3 i tie 2 HEX 2 1 HEX HD BOLT 3 8 16 X 1 3 4 BRASS SQUARE HD PIPE PLUG 1 4 NPT SMOKEBOX COLLAR 6 DIA 1 2 DIA GASKET CLEAN OUT COVER NOT SHOWN 1 40 KON 542 34 La 28 ZA ry 4 JA 9 gt SP WSS SERS gt J E MB Mb gt gt gt 8 QUANTITV PER BOILER OR CROWN PART NUMBER 420303 420304 QTY OR CROWN PN FSZ080 FSZ100 KEY DESCRIPTION 2 RECEPTACLE ENCLOSURE 410090 FRONT JACKET PANEL 420310 1 RIGHT SIDE JACKET PANEL 420303 LEFT SIDE JACKET PANEL 420313 420313 REAR JACKET PANEL TOP JACKET PANEL 5 JUNCTION BOX 420323 420323 FIBERGLASS INSULATION WRAPPER 422303 422303 POWER RECEPTACLE 960041 CROWN NAMEPLATE 98 004 10 X 1 2 SHEET METAL SCREW 900120 Un 1 5 167 18 X 1 2 PAN HEAD SCREW 900420 4 5 16 18 3 THREADED STUD 900111 5 8 O D X 2 5 32 LONG JACKET SPACER 5 16 18 ACORN NUT SHOWN 410200 9 30 31 32 33 34 35 37 40 4 42 43 44 45 46 146 95 042 42 QTV OR QUANTITV PER BOILER OR CROWN PART NUMBER DESCRIPTION CROWN PN FSZ080 FSZ100 FSZ1
19. INOD JdANLVAIHWAL AVI33 3ONV3V31O JIWJOASNVAL 3244358 NIW ONINV3TO AVM3114 JONVAVITD 3543 INOX 14405 INOX AlddN L NANL3A Z l l Div 1133034 1404 NOILVA33S8O 3WVv JjdO 102 JILVM 38O3ld JDNVD 34055344 JANSSIAA WV3lS 2 3 4 HI Before Installing 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 Inthe 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 ANSUASME CSD 1 Make sure that a properly sized chimney is available which is in good condition Consult the authority having jurisdiction Part VII of this manual and ANSI NFPA31 for additional information on venting requirements Make sure that the boiler is correctly sized Do this by totalling the surface area of all radiators in the system in sq feet To
20. LVIH SSIMINVL SS31 CSYSHLO A8 19933905109 STI LOH 1 09 021 AWYLNSN annoyg 3MDd LIWII 350553359 WVILS VvOV 7112 HONEVWELL R7284P PRIMARV CONTROL IGNITOR gt IGNITOR BURNER MOTOR gt MOTOR 2701 SOLENOID VALVE ENVIRACOM POLARIZED TERMINALS CONNECTOR T T TERMINALS BURNER DISCONNECT HARNESS BURNER J BOX T T JUMPER INTERNALLY PROGRAMMED ON R7284P CAD CELL RIELLO BURNER PRIMARY CONTROL AUX TERMINAL 120 CONSTANT POWER POLARIZED CONNECTOR RIELLO BURNER DISCONNECT HARNESS BECKETT 7505P1515 PRIMARY CONTROL IGNITOR gt IGNITOR POLARIZED BURNER MOTOR BECKETT BURNER DISCONNECT HARNESS SOLENOID VALVE T T TERMINALS BURNER J BOX JUMPER FIGURE 11 1 CONNECTIONS WIRING DIAGRAM FOR BURNER SPECIFIC PRIMARV CONTROL INDIRECT WATER HEATER THERMOSTAT HIGH LIMIT SET AT 180F 115 VAC WIRING I 24 VAC WIRING TT WIRE CONNECTION HONEYWELL FUSED DISCONNECT HOT o 7oo NELITRAL CIRCULATOR FIGURE 11 2 INDIRECT WATER HEATER FIELD WIRING 29 SPACE HEATING THERMOSTAT 30 FACTORY WIRING NOT SHUWN OR R8283D CONTROL XII Start up and Checkout A WARNING Never attempt to fill a hot emptv boiler Make s
21. NE PIPE LIFT SYSTEM 23 SHUT OFF VALVE FOR SERVICE FILTER NOZZLE RETURN 3 4 INCHES ABOVE INLET RETURN LINE DO NOT USE CHECK VALVES ON GRAVITY FEED SYSTEMS FIGURE 10 2 TWO PIPE GRAVITY FEED SYSTEM NOT RECOMMENDED FILTER NOZZLE RETURN LINE TERMINATES 3 4 INCHES ABOVE INLET LINE FIGURE 10 3 TWO PIPE LIFT SYSTEM 24 1 2 3 3 XI Wiring Ay 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 Protect each boiler circuit with a properly sized over current protection device Make electrical connections carefully according to the boiler s wiring diagram and instructions Wire additional field supplied safety limits such as low water cutoffs and temperature limit devices in series with the 120V circuit used to power the boiler Do not alter the boiler s factory wiring when adding an additional limit device 120 Volt Wiring The boiler should be provided with its own 15 branch circuit with fused disconnect 120 power con nections are made inside the junction bo
22. NEY SEE VENTING SECTION IN UPPER OPENING SEE TEXT FIR OPENING SIZE BAROMETRIC DRAFT CONTROL BW LDWER OPENING FIGURE 6 3 ALL AIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM TYPE L DOUBLE WALL VENT OR LINED MASONRY CHIMNEY SEE VENTING SECTION BOILER ROOM XSEE TEXT FIR DUCT SIZE BAROMETRIC DRAFT CONTROL XHORIZONTAL DUCTS FIGURE 6 4 ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM 12 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 i 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 The vent installation must be in accordance with local building codes or the local authority having jurisdiction Contact your local fire and building officials on specific requirements for restrictions and the installation of fuel oil burning equipment In the absence of other applicable codes the vent system installation must meet t
23. PIPE GRAVITY SYSTEM not recommended A vertical distance from top of the tank to center line of the pump Dimension H over 8 feet will result in a pump inlet pressure in excess of the 3 psi limit in NFPA 31 This type of system should be converted to a one pipe gravity system as doing so will result in lower inlet line flow and longer filter life See Figure 10 2 d TWO PIPE LIFT SYSTEM Used when a fuel oil storage tank is located below an oil burner fuel pump suction port See Figure 10 3 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 The maximum permissible distance H allowed is reduced by the number of fittings filters and valves installed in the line Once the type of system has been selected observe the following 1 Fuel line piping must be airtight Do not use compression type fittings for tubing connections in fuel line piping Use only listed flare type fittings Cast iron threaded fittings shall not be used 2 Piping shall be substantially supported and protected against physical damage and corrosion 3 Refer to supplied oil pump instruction manual for proper connections On one pipe systems ensure that the fuel pump return port plug is tightened securely 4 Some fuel pumps such as the Suntec A and B series are supplied with a loose bypass plug which must be installed on two pipe systems If such a plu
24. at the oil pressure matches that shown in Table 12 1 for the burner supplied Adjust pressure if required 30 REMOVE BRASS PLUG TO CHECK FLUE DRAFT REINSTALL PLUG WHEN FINISHED FIGURE 12 0 FLUE DRAFT TAPPING REAR OF BOILER 17 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 18 Close the flame observation cover 19 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 12 0 that is within the range shown in Table 12 1 DRAFT AT THIS LOCATION MUST NEVER BE POSITIVE 20 Check the CO2 and confirm that it is between the minimum and maximum limits shown in Table 12 1 Adjust if necessary 21 Verify that the smoke level still does not exceed 1 and that the draft in the breech is still within the range prescribed by Table 12 1 22 Turn off the burner and remove pressure gauge Install and tighten gauge port plug then restart the burner 23 Check for clean cutoff of the burner Air in the oil line between fuel pump and nozzle will compress while burner is running and expand when burner shuts off causing oil line pressure to drop and nozzle drip after burner stops Cycle burner on and off 5 to 10 times to purge air completely 24 Check thermostat operation by raising or lowering its set point as required cycling
25. d 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 mass produced and can vary from sample to sample For all of those reasons a spare nozzle should be part of a serviceman s replacement parts inventory 2 Flame Shape As seen for the observation port the flame should appear straight with no sparklers rolling up toward the crown of the chamber If the flame drags to the right or left sends sparklers upward or makes wet spots on the chamber walls the nozzle should be replaced If the condition persists look for fuel leaks air leaks water or dirt in the fuel as described below 3 Fuel Leaks Any fuel leak between the pump and the nozzle will be detrimental to good combustion results Look for wet surfaces in the air tube under the ignitor and around the air inlet Any such leaks should be repaired as they may cause erratic burning of the fuel and in the extreme case may become a fire hazard 4 Air Leaks Any such leaks should be repaired as they may cause erratic burning of fuel and in extreme cases may become a fire hazard 5 Gasket Leaks If CO2 readings between 11 5 and 12 8 with a 1 smoke cannot be obtained in the breeching or if odors are observed look for leaks around the burner mounting gasket observation door and canopy gasket or in the breeching below the point where the flue gas sample is taken Air leakage into the bo
26. e 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 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 Table of Contents I Product Description pas ew la 3 HT Specifications an THE NEUES 3 HL Before Installing
27. eeze in a hydronic system Pipe safety valve discharge to a safe location The safety valve may discharge steam or scalding hot water Do not install a valve in the safety valve discharge line Do not move safety valve from factory location Do not plug safety valve discharge Blocking the safety valve may result in boiler explosion Figure 8 1 shows recommended near boiler piping for most common types of gravity return steam systems Additional information on steam system design may be found in the B R Guide RHH published by the Air Conditioning Heating and Refrigeration Institute AHRI One of the primary purposes of this near boiler piping is to separate tiny water droplets from the steam exiting the boiler so that dry steam is sent to the system If the near boiler piping is not correct wet steam will enter the system and the following problems may occur Short cycling on low water Boiler or system Flooding Hammering Failure to heat one or more radiators Avoid the common piping mistakes shown in Figure 8 2 This applies even if the existing boiler has one of the piping mistakes shown in Figure 8 2 and appears to be working If two or more steam mains must be connected to the boiler connect a separate take off for each main into the header between the riser s and equalizer Also note the following points 1 Asize reduction must be made to connect the header to the equalizer This reduction must be made i
28. ent is required Contact qualified water treatment company for recommended water treatment compounds and procedure A WARNING Attempts to use burners or burner configurations other than those shown in Table 12 1 could result in reliabilitv problems propertv damage personal injurv or loss of life 32 TABLE 12 1a BECKETT BURNER CONFIGURATION AND SETUP DATA LOW FIRING RATE BAFFLE NONE NONE NONE INSERTION LENGTH PITCH ANGLE EXC ERU EE DELAVAN DELAVAN HAGO HAGO 65 X 604 85 X 60B 1 10X60B 135X60B PUMP PRESSURE psi HEAD SETTING FIXED FIXED 00 30 STARTING SHUTTER SETTING 10 7 8 9 BAND SETTING 1 1 2 5 DRAFT IN FLUE in w c 0 to 0 02 0 to 0 02 0 to 0 02 0 to 0 02 MAX SMOKE FLUE CO 99 MIN 11 5 11 5 11 5 11 5 MAX 12 8 12 8 12 8 12 8 TABLE 12 1b RIELLO BURNER CONFIGURATION AND SETUP DATA DELAVAN DELAVAN DELAVAN 1 1 1 1 2 2 DRAFT IN FLUE in w c 0 to 0 02 0 to 0 02 0 to 0 02 MAX SMOKE Bacharach Scale FLUE CO MIN 1 5 1 5 11 5 MAX 1258 12 8 12 8 5 33 Service and Maintenance A Water Side Maintenance The following procedure should be performed on an annual basis 1 Turn off electrical power and oil supplv to the boiler 2 Inspect the low water cut off For Hydrolevel CG450 low water cut offs Remove and inspect the probe for scale and sediment buildup Clean any sediment or scale from the probe with a scouring
29. er Gravity Return Piping Kit for the FSZ080 FSZ100 FSZ130 as shown in Figure 2 2 Assemble Dropped Header Gravity Return Piping Kit for the FSZ160 as shown in Figure A 4 3 Tighten unions only after all piping is in the proper position Use of pipe dope or teflon tape on all threaded surfaces is A WARNING reommended Difference in piping compound and or method may effect pipe alignment 46 TABLE 1 Dropped Header Material List for FSZ080 FSZ100 and FSZ130 Boilers 2 2 3 Nipple 57080 and FSZ100 2 9 Nipple FSZ130 15 1 1 2 1 1 4 Bushing 16 1 1 4 x 22 Nipple i 19 1 1 4 x 1 1 4 x 3 4 Tee 20 1 1 4 x 7 Nipple 1 1 4 x Close Nipple 1 1 4 Union 10 11 12 13 14 diem O8 io __2 EE 121555 6 __ ISE __2 2 21 22 23 1 FIGURE 2 Dropped Header Gravity Return Diagram for FSZ080 FSZ100 and FSZ130 TABLE A 3 Dropped Header Material List for FSZ160 Boilers Fitting Description 2 x 12 Nipple 2 2 Union 2 x 6 Nipple 2 Elbow 2 x 15 Nipple 2 x 7 Nipple 3 x 2 Reducing Elbow 3 x 9 Nipple 3 x 10 Nipple 3 Union 3 x 5 Nipple 3 3 x 2 Tee 12 3 195 2 7 Nipple 2 x 5 Nipple 2 Wye 2 1 1 2 Bushing 16 1 1 2 x 20 3 4 Nipple 17 1 1 2 x 1 1 2 x 3 4 Tee 18 1 1 2
30. esigned for domestic water service such as the Watts 3L Note that this is a pressure relief valve not a T amp P valve Select a valve with a pressure setting less than or equal to the working pressure marked on the tankless coil Pipe the discharge to a safe location using piping the same size as the discharge connection on the valve 4 Hose Bib Valves Recommended These valves permit the coil to be periodically backflushed to remove sediment 5 Globe or Ball Valve Recommended Used to adjust the flow through the entire tankless heater system 1f needed 20 6 Unions Required Tankless heaters may require periodic gasket replacement or other maintenance which requires removal of the heater from the boiler Install unions anvwhere in the tankless heater piping that will facilitate removal of the heater TANKLESS HEATER SHOWN WITH CONTROL REMOVED O UNIONS oO TO FIXTURES FLOW RESTRICTOR 58 RELIEF VALVE BALL IR GLOBE VALVE COLD HOSE BIB VALVES FIGURE 9 2 TANKLESS HEATER PIPING 21 X Fuel Line Piping A WARNING Under no circumstances can copper with sweat stvle connectors be used Do not use compression fittings Oil piping must be absolutelv airtight or leaks or loss of prime mav 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
31. ff valve s are closed 5 Check initial settings of oil burner air band and air shutter head setting etc and readjust if needed See Table 12 1 for setup and combustion data pertaining to a particular boiler burner combination 6 Ensure the burner is tightly secured to the burner swing door creating an airtight seal 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 11 Adjust system thermostat to highest setting 12 Set pressure limit control to suit individual requirements of the installation For most systems the cut in pressure should be set at 0 5 psi with a 1 psi differential 13 Turn the line service switch position 14 Crack open vent fitting on the oil pump and allow burner to run until a solid oil stream free of air bubbles flows for 15 seconds into container As the vent fitting 1s closed the burner should fire and flame should be visible through observation port immediately or after prepurge timing has expired if a burner is so equipped Refer to burner instructions for more details 15 Immediately upon firing the boiler check the smoke level If the smoke level is in excess of a 1 open the air adjustment to bring the smoke level below a 1 16 Make sure th
32. g is supplied install it as shown in the pump manufacturer s instructions Do not install this bypass plug on one pipe systems as pump seal damage will result 5 Do not use check valves especially on gravity feed systems 6 Do not use Teflon tape for threaded connections Use a non hardening thread sealant listed for use with 2 fuel oil 22 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 8 Never install manual shut off valves in the return piping of a two pipe system 9 Install a listed flexible oil line s at the burner to facilitate opening of the boiler s swing door 10 All systems require an oil filter Use of a high efficiency micron filter Garber or equivalent in addition to a conventional filter is highly recommended particularly on the FSZ080 11 Use only 2 Fuel Oil with physical and chemical characteristics meeting the requirements of ASTM D 396 SHUT OFF VALVE FOR SERVICE FILTER DU NOT USE CHECK VALVES GRAVITY FEED SYSTEMS FIGURE 10 0 ONE PIPE GRAVITY SYSTEM FILTER NOZZLE FIGURE 10 1 O
33. he Boiler Even If There Are No Significant Soot Deposits Failure To Remove All Sulfur And Ash Deposits Annually Can Cause Severe Corrosion Damage 35 A 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 A clean and unobstructed chimney flue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler s efficiency 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 Inspect joints for signs of condensate or flue gas leakage d Inspect venting components for corrosion or other deterioration Replace any defective vent system components e Ensure all vent piping joints are gas tight and secured with sheet metal screws 4 Service the oil burner a Replace oil nozzle with identical make and model see Table 12 1 b Inspect the electrodes Replace if they are deteriorated Make sure that the electrode position is set according to the burner manufacturer s instructions c Remove and clean fuel pump strainer d Remove any accumulations of dus
34. he 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 FSZ 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 FSZ 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 flue 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 i
35. ia 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 fired 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 effect of mesh grills and louvers Where screens used they must be no finer than 1 2 4 x 4 mesh 12 MM 1 3 OPENING BOILER TEXT OPENING SIZE X DIER OPENING UN FIGURE 6 0 BOILER INSTALLED IN CONFINED SPACE ALLAIR FROM INSIDE VENTILATED ATTIC OPENING BOILER ROOM TEXT FOR SIZE UF OPENINGS XLUWER OPENING 4 ENTILATED CRAWL SPACE TYPE L DOUBLE WALL VENT OR LINED MASONRY CHIMNEY SEE VENTING SECTION BAROMETRIC DRAFT CONTROL TYPE L DOUBLE WALL VENT OR LINED MASONRY CHIMNEY SEE VENTING SECTION BAROMETRIC DRAFT CONTROL FIGURE 6 1 ALL AIR FROM OUTDOORS VENTILATED CRAWL SPACE AND ATTIC VENTILATED ATTIC OPENING FROM ATTIC TEXT FOR SIZE UF OPENING AND DUCT BOILER uuu TYPE L DOUBLE WALL VENT OR LINED MASONRY CHIMNEY SEE VENTING SECTION BAROMETRIC DRAFT CONTROL FIGURE 6 2 ALL AIR FROM OUTDOORS VIA VENTILATED ATTIC BOILER 12 MAX TYPE L DOUBLE WALL VENT OR LINED MASONRY CHIM
36. iler or breeching can cause low CO readings the lower the firing rate the greater effect an air leak can have on CO readings Such leaks can also cause flue gas leakage into the building resulting in odor complaints 6 Dirt The use of a fuel filter is good practice Accidental accumulation of dirt in fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from the nozzle The smaller the firing rate the smaller the slots in the nozzle and the more prone to plugging it becomes 7 Water Water in the fuel in large amounts will stall the fuel pump Water in the fuel in smaller amounts will cause excessive wear on the pump More importantly it chills the flame and causes smoke and unburned fuel to pass through the combustion chamber and clog the flueways of the boiler 8 Cold Oil If the oil temperature near the fuel pump is 40 F or lower poor combustion or delayed ignition may result Cold oil is harder for the nozzle to atomize thus the oil droplets get larger and travel further creating a longer flame An outside fuel tank that is above grade or has fuel lines in a shallow bury is a good candidate for cold oil The best solution is to bury the tank and lines deep enough to keep the oil above 40 F Be sure to follow any state and local codes when burying fuel oil tanks and or fuel oil lines 9 Start Up Noise Delayed ignition is the cause of start up noises If it occurs recheck for electrode settings fla
37. king into the building through cracks around windows doors etc Examples of construction features which could prevent adequate natural infiltration 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 e Caulking and sealants are applied to areas such as joints around window and door frames between sole plates and floors 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 infiltration 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 1s of unusually tight construction 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 2 3 2 3 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
38. me shape air or water in the fuel lines 10 Shut Down Noise If the flame runs out of air before it runs out of fuel an after burn with noise may occur That may be the result of a faulty cut off valve in the fuel pump or it may be air trapped in the nozzle line It may take several firing cycles for that air to be fully vented through the nozzle Water in the fuel or poor flame shape can also cause shut down noises TEST PROCEDURE FOR FUEL SIDE PROBLEMS A good test for isolating fuel side problems is to disconnect the fuel system and with a 24 length of tubing fire the burner out of an auxiliary five gallon of clean fresh warm 2 fuel oil from another source If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the installation 38 Notes 39 XV Parts QTY OR QUANTITY PER BOILER OR CROWN PART NUMBER DESCRIPTION CROWN PN FSZ080 FSZ100 FSZ130 FSZ160 HEAT EXCHANGER ASSEMBLY WITH 420013 420013 420014 420015 HEATER OPENING HEAT EXCHANGER ASSEMBLY WITH NO HEATER OPENING 4200135 4200135 4200145 4200155 5 410403 410403 410404 410405 NYLON GLIDE 700111 HEX HD CAP SCREW 5 16 18 X 7 8 FLAT WASHER 5 16 EN HEX JAM NUT 5 16 18 EM AINE HINGE BRACKET a 1 HEX HD CAP SCREW 5 16 18 X 7 8 EE SWING DOOR wo SWING DOOR INSULATION LESS POCKETS am 1 SW
39. move or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear 1 A National Institute for Occupational Safety and Health NIOSH approved respirator Long sleeved loose fitting clothing Gloves Eve Protection Take steps to assure adequate ventilation Wash all exposed bodv areas gentiv with soap and water after contact Wash work clothes separatelv from other laundrv and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components bv sealing in an airtight plastic bag RCF and crvstalline silica are not classified as hazardous wastes in the United States and Canada First Aid Procedures e If contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficultv develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plentv of water Seek immediate medical attention 37 XIV Trouble Shooting A Combustion 1 Nozzles The selection of the nozzle supplied with the FSZ boiler is the result of extensive testing to obtain the best flame shape and efficient combustion Other brands of the same spray angle an
40. n the vertical equalizer line Do not make this size reduction in the horizontal header 2 One pipe steam systems require air vents on each radiator as well as at the end of each main For the system to work properly these vents must be properly installed sized and be in good condition Inspect and replace any defective vents If there are no vents at the ends of the mains install them 3 Do not attempt to manifold multiple FSZ boilers with gravity returns 4 For installations with condensate or boiler feed pumps follow the pump manufacturer s piping instructions Such systems generally do not require Hartford loops 5 Do not use a check valve in place of or in addition to a Hartford loop on a gravity return system 6 Pipe the fill connection from a clean source of cold water When the water supply is from a well make sure that a strainer is installed in the well system 7 The drop header arrangement shown as Alternate Piping Method in Fig 8 1 is useful when there is limited vertical clearance above the boiler 15 JNIdId 3ILVNHILW WALSAS 431108 9NIHSMIH O4 S3 ATVA NIVAQ 831108 OL NMOQ HOLId 1035 LIM WVILS 31441 AAQINOHS AQ 35019 SNIdId 3LVNAILW 9NIdId 934435944 NOI OS3NNOO NUNLIA GUOHLAVHI Sv SNIVW 5 IVNOILIQQV NIN 7 V LV ATIVOILYSA
41. nch 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 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 effect of mesh grills and louvers Where screens used they must be no finer than 1 2 4 x 4 mesh B For Buildings of Unusually Tight Construction 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 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 floor Size openings and ducts as follows e 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 fired appliances in the boiler room but not less than 100 square inches Minimum opening size is 3 inches Openings to outdoors v
42. nto a chimney flue serving an open fireplace or other solid fuel appliance 6 Prior to boiler installation an existing chimney must be inspected by a qualified person in accordance with the requirements of Chapter 11 of NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances This inspection 1s 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 off 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 13 10 Vent connector must be inserted flush with inside face of the chimnev liner and the space between vent connector and chimnev 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
43. ormer in old thermostat wiring Do not use the transformer provided on the boiler to power external devices such as zone valves Doing so may cause damage to the transformer 26 OOMT 05790 WVALS WVYDVIG SNOLLOANNOD 0 II TANDIH INIIVAINO3 511 NMOHS 3dAL 3WVS 3HL HLIM O3OV d3H LSNW LI 38 LSNW AONVITdd JHL HLIM 03179915 24IM IVNID14O JHL dO dI MOTIJA 3LIHM l3 701A 39NV3O AVJI 3549 13000 40709 193NNO9 lt 01748 e 01314 ONIJIM 01414 239VLIOA JNII 2 601 JAIM G3ONVHIS WMV 3dAL ANOLOVS 39VLIOA QN3937 WV3S9VIO SNOIIOSNNOO JOMINOO Ol SS3N HVH LOANNOOS 0 3 lO93NNOOSIQ TVNIWMAL MAXIS ONDOMNS SJIN3O IDALNOD QS8288 TIJAA3NOH 1041409 1 15 900 1 TIHAA3NOH NOILONAF a YOLIANNOD 037139704 99044 JNISNIS VIZI I3 13A3710H4QAH A IAWAF QITIVISNI A OLOV4 A ZNUNA so ac 4 LYVWS HLIM 330 109 YSLVM MOT 05799 18 410 0 JNILLIS i MOlVdIOIlNV oy i 1V3H 95 48 11138 01 41311 lV3H 2 SHAHLO A8 VISOWBMJHLI Ave AI
44. pad or steel wool Consult the Hydrolevel CG450 manual for any additional maintenance information Test the low water cut off before placing the boiler back into service 3 Allow the boiler to cool to room temperature and drain the boiler Remove the 1 1 4 plug from the unused return tapping Use a flashlight to inspect the bottom row of pushnipples for accumulated scale or mud If a significant amount is present use the following procedure to clean the inside of the heat exchanger a b c d e f g h i j Temporarilv install a 1 1 4 inch or larger full port ball valve in place of the 1 1 4 plug Temporarilv pipe the outlet of this valve to a location where hot water and steam be safely discharged Make sure that this valve is closed and that the water level is at the normal water line If a king valve is present in the steam main takeoff close it Alternatively temporarily replace enough of the vents on the mains and or radiators with plugs so that 2 5 psi can be developed when the boiler is fired Fire the boiler and allow it to steam until 2 5 psi is registered on the gauge Turn off the burner and immediately fully open the 1 1 4 valve Allow the boiler to blow down until either the water runs clear or the water level reaches the bottom of the gauge glass Allow all parts of the boiler to cool to room temperature Drain the boiler completely and remove the 1 1 4 valve If significant mud or scale is still
45. range of approximately 110 to 130F Follow the manufacturer s instructions for installing this valve Usually a heat trap will be required between the coil and the hot connection on the mixing valve A WARNING A mixing valve does not eliminate the risk of scalding Setthe mixing valve and boiler low limit adjustments as low as possible e Feel water before showering bathing e lfanti scald or anti chill protection is required use devices specifically designed for such service Install and maintain these devices in accordance with the manufacturer s instructions Do not use the mixing valve as a substitute for pressure balancing valves or other devices required by plumbing codes to protect against scalding 2 Flow Restrictor Recommended If water is drawn from the tankless coil at a rate in excess of the rating in Table 2 3 the temperature of the hot water may be too low to be of use The use of a flow restrictor will prevent this problem by limiting the rate at which water can pass through the tankless heater If a restrictor is used select one having a rating in GPM approximately equal to the rating shown in Table 2 3 If possible locate this restrictor at least 3 feet from the tankless heater inlet so that it is not subjected to excessive temperatures when no water is flowing through the coil 3 Pressure Relief Valve Required Limits the pressure in the tankless heater and piping Use an ASME constructed valve d
46. roperty 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 A WARNINGS FOR THE INSTALLER 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 th
47. ses Using long strokes push the brush all the way through the boiler until the brush hits the back wall of the reversing chamber Pull the brush all the way forward until it has exited the front of the boiler Continue this operation for the entire height of the flue way until clean Repeat the operation for the other 2nd pass flue way f Vacuum to loose debris in the bottom of the combustion chamber and smoke box g Clean the Combustion Chamber Use a wire or fiber bristle brush to clean the surfaces of the combustion chamber Vacuum all loose debris in the chamber h Check condition of the burner swing door insulation and rope gaskets for signs of damage replace if required 1 Check burner head for signs of deterioration Clean the head of any deposits j Insert baffles if originally installed into the correct flueways k Attach the smoke box clean out covers onto the rear of the boiler using the 5 16 bolts originally removed Verify that the rope gasket is in good order before assembly Replace rope gasket if necessary Do not over tighten The bolts should be snug but not bottomed out Close the swing door and tighten it with the 3 8 bolts originally removed When securing the burner swing door make sure the door is drawn in equally on both sides by alternating the tightening method for right side to left side Do not over tighten The rope gasket will provide sufficient seal when door is snugged into place IMPORTANT Clean T
48. switch to boiler to prevent accidental firing of burner outside the combustion chamber Disconnect the burner plug from the receptacle in the front jacket Be sure to tighten the swing door fastener completelv when service is completed The following procedure should be performed on an annual basis Turn off electrical power and oil supply to the boiler 2 Clean the boiler as follows a Remove the two 3 8 bolts from either side of the swing door and open the door to access the combustion chamber b Remove the two smoke box clean out covers from the rear smoke box by removing the four 5 16 bolts It is not necessary to remove the vent connector from the smoke box to clean boiler however if there is heavy soot accumulation in the boiler remove the vent connector to inspect the base of the chimney for condensate or accumulation of debris c Remove the baffles if installed from the flue passages d Clean the 3rd Pass Insert a 2 dia x 42 long wire or fiber bristle brush into one of the two 3rd flue passes Using long strokes push the brush all the way through the boiler until the brush has exited the smoke box opening Pull the brush all the way forward until it has exited the front of the boiler Continue this operation for the entire height of the flue way until clean Repeat the operation for the other 3rd pass flue way e Clean the 2nd Pass Insert a 2 dia x 42 long wire or fiber bristle brush into one of the two 2nd flue pas
49. t hair etc from the air shutter blower wheel and other air handling parts of the burner e Replace the fuel oil line filter element and gaskets 6 Inspect all oil piping and fittings for kinks and leaks Repair any found 7 Inspect the hydronic piping and boiler for water leaks Repair any leaks found immediately 8 Verify operation of relief valve by manually lifting lever replace relief valve immediately if valve fails to relieve pressure 9 Open fuel line shut off valve s and restore electrical power to the boiler 10 Fire the boiler and check it out using the procedure outlined in Start up and Checkout This must include checking the burner adjustments using instruments Check for proper operation of all controls A WARNING Water leaks can cause severe corrosion damage to the boiler or other system components Repair anv leaks found immediatelv 36 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 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 AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not re
50. this add any other space heating not DHW loads Select a boiler having a net rating just larger than this total heating load Note 1 sq ft of radiation is equal to 240 BTU hr In some cases boilers installed at altitudes above 2000ft may require a different burner configuration from that at sea level Consult the local Crown representative for more information A Power Side Wall Venting Important Note Two problems arise when anv 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 manv 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 FSZ 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 IV Field Assembly This boiler is shipped in two pieces The crated boiler itself b The burner carton consisting of the following items Oil Burner assembly Barometric Draft Regulator if supplied Safety valve
51. tor should be located as low and as close to the boiler as practical Do not install valves or other devices having a significant pressure drop between the boiler and the circulator inlet All piping between the boiler and the circulator inlet should be 1 regardless of the size of the piping required in the rest of the system See Figure 11 2 in Part XI for wiring information 2 Strainer Install a strainer to prevent sediment from accumulating inside the indirect water heater 3 Check Valve Prevents gravity circulation through the indirect water heater when the boiler is responding to a call for heat 4 Boiler Limit Control Use a SPST break on rise temperature limit control such as the Honeywell L4006A Do not set the limit above 180F as doing so may cause the boiler to steam when there is no for heat See Figure 11 2 for wiring information 5 Valves and Unions Install shut off valves drain valves and unions in locations that will facilitate maintenance of the system Do not install any valves between the boiler and circulator inlet 2 NPT LIMIT TAPPING L CREAR OF BOILER A _ WATER TEMPERATURE LIMIT TO INDIRECT WATER HEATER CIRCULATOR FSZ BOILER STRAINER 1 NPT LOCATE INDIRECT SUPPLV SUPPLY TAPPING K PIPING AS CLOSE TO FLOOR CREAR OF BOILER LEVEL AS PRACTICAL WATER HEATER FLOW CONTROL VALVE TO BOILER RETURN 1 172 RETURN TAPPING G REAR OF BOILER FI
52. ure 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 bv a qualified oil serviceman using combustion test instruments Failure to perform all of the checks outlined in the following procedure could result in unreliable operation damage to the boiler not covered under warrantv propertv damage or unsafe operation All boilers equipped with burner swing door have a potential hazard which can cause severe propertv damage personal injurv 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 Be sure to tighten swing door fastener completelv when service is completed In addition the burner power cord will have to be disconnected from the receptacle in the front jacket Use the following procedure for initial start up of the boiler 1 Ensure that the boiler is filled to the normal water level 2 Verifv that the vent svstem is properlv installed and free of obstructions prior to start up of the boiler Refer to Section VII for more information 3 Inspect all wiring for loose or uninsulated connections proper size fuses installed etc 4 Verify that oil tank is filled with 2 fuel oil meeting ASTM D396 specifications oil piping has been tested and is air tight and shuto
53. valve opens The end of the discharge pipe must terminate in an unthreaded pipe If the safetv valve discharge is not piped to a drain it must terminate at least 6 inches above the floor The termination of the safetv valve discharge piping must be in an area where it is not likely to become plugged by debris or subjected to freezing 4 Install drain valve provided into the return piping See Figure 8 1 5 Connect system supply and return to boiler See Figure 8 1 17 TANKLESS HEATER OR HEATER COVER PLATE FRONT VIEW REAR VIEW FIGURE 8 3 PURPOSE OF TAPPINGS AND BOSSES TABLE 8 4 PURPOSE OF TAPPINGS Steam Boiler p I Q ooo nA on FSZ080 100 amp 130 Pi __ 5 L4006 Operating 18 IX INDIRECT 4 TANKLESS WATER HEATER PIPING INDIRECT WATER HEATER PIPING FSZ series boilers are equipped with tappings to permit the connection of a Crown Mega Stor or other indirect water heater In this tvpe of svstem hot boiler water is drawn from below the water line and passed through the heat exchanger in the indirect water heater This section describes boiler side piping only Refer to the indirect water heater instruction manual for domestic water piping The components in this svstem and their functions are as follows 1 Circulator Mount the circulator as shown in Figure 9 1 The circula
54. x on the right side of the boiler as follows also see Figures 11 0 and 11 1 Connect Hot black to black pigtail in junction box Connect Neutral white to white pigtail in junction box Connect Ground green or bare to green pigtail in junction box Install R8285D Control The R8285D transformer relay control is shipped loose inside the accessory carton Connect the plug on the back of this control into the receptical inside the junction box and mount the R8285D on the junction box as shown in Figure 2 3 24 Volt Thermostat Wiring Connect to a 24 volt heating thermostat to Terminals R and G on the R8285 Figure 11 1 Follow thermostat manufacturer s instructions To insure proper thermostat operation avoid installation in areas of poor air circulation hot spots near any heat source or in direct sunlight cold spots outside walls walls adjacent to unheated areas locations subject to drafts Provide Class II circuit between thermostat or zone controls and boiler Optional Tankless Heater Wiring Route the wire harness from this control to the and thermostat terminals on the R8285D control so that they are in parallel with the space heating thermostat Figure 11 1 23 Indirect Water Heater Wiring Figure 11 2 shows field wiring for an indirect water heater Honevwell 845 or equivalent DPST relav and transformer is required The high limit described in Part V
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