Crown Boiler KSZ065 • KSZ075 • KSZ100 KSZ090 Installation Instructions Manual
  1. Manuals
  2. Brands
  3. Crown Boiler Manuals
  4. Boiler
  5. KSZ065 KSZ075 KSZ100 KSZ090
  6. Installation instructions manual

Crown Boiler KSZ065 • KSZ075 • KSZ100 KSZ090 Installation Instructions Manual

Ksz series oil-fired steam boilers
Hide thumbs Also See for KSZ065 • KSZ075 • KSZ100 KSZ090:
Table of Contents

Advertisement

Quick Links

KSZ Series
Oil-Fired Steam Boilers

InStallatIOn InStructIOnS

These instructions must be affixed on or adjacent to the boiler
Models:
KSZ065
•
KSZ075
•
KSZ100
•
KSZ090
•
KSZ125
•
KSZ150
•
KSZ120
•
KSZ175
•
KSZ200
•
D
E S I G N E D
Warning: Improper instal-
lation, adjustment, alteration,
service or maintenance can
cause property damage, injury,
or loss of life. For assistance or
additional information, consult a
qualified installer, service agency
or the oil supplier. Read these
instructions carefully before
installing.
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
L
T O
E A D

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the KSZ065 • KSZ075 • KSZ100 KSZ090 and is the answer not in the manual?

Questions and answers

Related Manuals for Crown Boiler KSZ065 • KSZ075 • KSZ100 KSZ090

Summary of Contents for Crown Boiler KSZ065 • KSZ075 • KSZ100 KSZ090

  • Page 1: Installation Instructions

    E S I G N E D E A D KSZ Series Oil-Fired Steam Boilers InStallatIOn InStructIOnS These instructions must be affixed on or adjacent to the boiler Models: KSZ065 • Warning: Improper instal- KSZ075 • lation, adjustment, alteration, service or maintenance can KSZ100 •...
  • Page 3 WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings unless alarms or other safeguards are in place to printed in this manual and posted on the boiler. prevent such damage INSPECT THE BOILER, BURNER AND DO NOT BLOCK AIR FLOW into or around the CONTROLS ANNUALLY.

  • Page 4: Table Of Contents

    table of contents I. Product Description .............. 2 VIII. Indirect Water Heater & Tankless Coil II. Specifications ................ 2 Piping ............14 III. Before Installing ..............3 IX. Fuel Line Piping ........... 17 IV. Locating the Boiler ............... 4 X. Wiring ............20 V.

  • Page 5: Before Installing

    Crown Boiler Company recommends the use of a chimney to vent the KSZ 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...

  • Page 6: Locating The Boiler

    3) Make sure that the boiler is correctly sized. Use an industry accepted sizing method such as the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI). 4) 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.
  • Page 7 FIGurE 2: clEarancES FIGurE 3: InStallatIOn OVEr a cOMBuStIBlE FlOOr...

  • Page 8: Air For Combustion & Ventilation

    V air for combustion and Ventilation WARNING • INSUFFICIENT COMBUSTION AIR SUPPLY MAY RESULT IN THE PRODUCTION AND RELEASE OF SOOT OR DEADLY CARBON MONOXIDE (CO) INTO THE HOME WHICH CAN CAUSE PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH. • THIS BOILER IS NOT DESIGNED FOR USE IN A SPACE THAT IS DEPRESSURIZED RELATIVE TO THE OUTDOORS. OPERATING THIS BOILER IN A DEPRESSURIZED SPACE MAY CAUSE PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH.
  • Page 9 FIGurE 4: BOIlEr InStallED In cOnFInED SPacE, all aIr FrOM InSIDE 2) Unconfined Space - Natural infiltration into the boiler room will normally provide adequate air for combustion and venti- lation without additional louvers or openings into boiler room. 3) 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”...
  • Page 10 FIGurE 5: all aIr FrOM OutDOOrS, VEntIlatED craWl SPacE anD attIc FIGurE 6: all aIr FrOM OutDOOrS, VIa VEntIlatED attIc...
  • Page 11 FIGurE 7: all aIr FrOM OutDOOrS, uSInG OPEnInGS IntO BOIlEr rOOM FIGurE 8: all aIr FrOM OutDOOrS, uSInG HOrIZOntal DuctS IntO BOIlEr rOOM...

  • Page 12: Venting

    VI 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. Vent installation must be in accordance with local building codes, or the local authority having jurisdiction.
  • Page 13 Crown Boiler Company recommends the use of a chimney to vent the KSZ 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...

  • Page 14: System Piping Connections

    VII 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 IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. • DO NOT USE TOXIC ADDITIVES IN THIS 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.

  • Page 15: Piping Installation

    • Boiler or system Flooding • Hammering • Failure to heat one or more radiators Avoid the common piping mistakes shown in Figure 11. This applies even if the existing boiler has one of the piping mistakes shown in Figure 11 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.

  • Page 16: Indirect Water Heater & Tankless Coil Piping

    VIII InDIrEct & tanKlESS WatEr HEatEr PIPInG InDIrEct WatEr HEatEr PIPInG All KSZ series boilers are equipped with tappings to permit the connection of a Crown Mega-Stor, or other indirect water heater. In this type of system, hot boiler water is drawn from below the water line and passed through the heat exchanger in the indirect water heater.

  • Page 17: Tankless Heater Piping

    IMPOrtant • Some indirect water heaters may 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.
  • Page 18 5) Globe or Ball Valve (Recommended) - Used to adjust the flow through the entire tankless heater system if needed. 6) Unions (Required) - Tankless heaters may require periodic gasket replacement or other maintenance which requires removal of the heater from the boiler. Install unions anywhere in the tankless heater piping that will facilitate removal of the heater.

  • Page 19: Fuel Line Piping

    IX Fuel line Piping WARNING • UNDER NO CIRCUMSTANCES CAN COPPER wITH SwEAT STYLE CONNECTORS BE USED. • DO NOT USE COMPRESSION FITTINGS. • OIL PIPING MUST BE ABSOLUTELY AIRTIGHT OR LEAKS OR LOSS OF PRIME MAY 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 BURNER CIRCUIT. CHECK YOUR LOCAL CODES FOR SPECIAL REQUIREMENTS. Fuel line piping design, materials and constructions 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).
  • Page 20 d) TWO-PIPE LIFT SYSTEM - used when a fuel oil storage tank is located below an oil burner fuel pump suction port. 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.
  • Page 21 FIGurE 15: tWO-PIPE GraVItY FEED SYStEM FIGurE 16: tWO-PIPE lIFt SYStEM...

  • Page 22: Wiring

    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/NFPA 70). 1) 120 Volt Wiring - Provide the boiler with its own 15A branch circuit with fused disconnect. How the 120 volt connec- tions are made depends upon the type of low water cut-off supplied with the boiler.
  • Page 23 FIGurE 17: InDIrEct WatEr HEatEr FIElD WIrInG 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. •...
  • Page 24 FIGurE 18a: WIrInG McDOnnEll & MIllEr 101a-120 Or HYDrOlEVEl VXt-120 FEEDEr tO BOIlEr EQuIPPED WItH #67 l.W.c.O. FIGurE 18b: WIrInG McDOnnEll & MIllEr WF2-u-120 FEEDEr...
  • Page 25 L4006A LIMIT CONTROL (TANKLESS-EQUIPPED BOILERS ONLY) INTERRUPTED 24 VOLT THERMOSTAT INTERMITTENT BURNER MOTOR LIMIT VALVE CELL NOTE: BURNER WIRING SHOWN IS FOR BECKETT AFG BURNERS. CONSULT BURNER INSTRUCTION MANUAL FOR OTHER BURNERS FIGurE 19: WIrInG (McDOnnEll & MIllEr #67 lWcO) L4006A LIMIT CONTROL (TANKLESS-EQUIPPED BOILERS ONLY) INTERRUPTED...

  • Page 26: Start-Up And Checkout

    XI Start-up and checkout WARNING • NEVER ATTEMPT TO FILL A HOT EMPTY BOILER. • MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND LIQUIDS. • SAFE RELIABLE OPERATION OF THIS BOILER REqUIRES THAT THE BURNER BE CHECKED AND ADJUSTED BY A QUALIFIED OIL SERVICEMAN USING COMBUSTION TEST INSTRUMENTS. • FAILURE TO PERFORM ALL OF THE CHECKS OUTLINED IN THE FOLLOwING PROCEDURE COULD RESULT IN UNRELIABLE OPERATION, DAMAGE TO THE BOILER NOT COVERED UNDER WARRANTY, PROPERTY DAMAGE, OR UNSAFE OPERATION.
  • Page 27 22) 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.
  • Page 28 taBlE 3a: BEcKEtt BurnEr cOnFIGuratIOn anD SEtuP Data BOILER MODEL KSZ065 KSZ075 KSZ100 KSZ090 KSZ125 KSZ150 KSZ120 KSZ175 KSZ200 BURNER MODEL AIR TUBE COMBO. 70MMAQ 70MMAQ 70MMAQ 70MMAQ 70MDAQ 70MDAQ 70MLAQ 70MLAQ 70MLAQ HEAD TYPE STATIC PLATE 3 3/8 3 3/8 3 3/8 3 3/8 2 3/4...

  • Page 29: Service & Maintenance

    taBlE 3c: rIEllO BurnEr cOnFIGuratIOn anD SEtuP Data BOILER MODEL KSZ065 KSZ075 KSZ100 KSZ090 KSZ125 KSZ150 KSZ120 KSZ175 KSZ200 BURNER MODEL 40F5 40F5 40F5 40F10 40F10 40F10 STANDARD DEL. HAGO NOZZLE 1.35/45B 1.65/45B 0.60/60A 0.85/60W 1.00/60A 1.25/60B PUMP PRESS (psi) TURBULATOR SHUTTER SETTING 2.60...
  • Page 30 3) Allow the boiler to cool to room temperature and drain the boiler. Remove the 1-1/2” 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) Temporarily install a 1-1/4”...
  • Page 31 IMPOrtant • CLEAN THE BOILER EVEN IF THERE ARE NO SIGNIFICANT SOOT DEPOSITS. FAILURE TO REMOVE ALL SULFUR AND ASH DEPOSITS ANNUALLY CAN CAUSE SEVERE CORROSION DAMAGE. • WHEN CLEANING THE REAR FLUE PASSAGE, BE CAREFUL NOT TO PUSH THE BRUSH TOO FAR BEYOND THE BOTTOM OF THE PINS.
  • Page 32 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Parts list designates parts that contain refractory ceramic fibers (RCF). RFC has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RFC changes into crystalline silica, a known carcinogen.
  • Page 33 Installation notes and Service log...

  • Page 34: Parts

    XIII Parts QUanTiTY PEr BOiLEr Or CrOWn P.n. QTY. Or CrOWn KEY # DESCriPTiOn P.n. HEAT EXCH ASSY. WITH COIL OPENING 1 ea. 290013 290013 290013 290014 290014 290014 290015 290015 290015 HEAT EXCH ASSY. LESS COIL OPENING 1 ea. 2700135 2700135 2700135...
  • Page 36 QUanTiTY PEr BOiLEr Or CrOWn P.n. QTY. Or CrOWn KEY # DESCriPTiOn P.n. REVERSIBLE SIDE JACKET PANEL 2 ea. 270523 270523 270523 270524 270524 270524 270525 270525 270525 HEATER SIDE JACKET PANEL 1 ea. 270533 270533 270533 270534 270534 270534 270535 270535 270535...
  • Page 38 Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com 980280 Rev 4 11-11...

This manual is also suitable for:

Ksz125Ksz150Ksz120Ksz200Ksz175Ksz075 ... Show all

Table of Contents