Crown Boiler KSZ065 Installation Instructions Manual

Crown Boiler KSZ065 Installation Instructions Manual

Ksz series oil-fired steam boilers

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KSZ Series
Oil-Fired Steam Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler
Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com
Models:
KSZ065
KSZ075
KSZ100
KSZ090
KSZ125
KSZ150
KSZ120
KSZ175
KSZ200
CROWN
Boiler Co
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
1
WARNING: Improper installation,
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 instruc-
tions carefully before installing.

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Summary of Contents for Crown Boiler KSZ065

  • Page 1: Installation Instructions

    KSZ Series Oil-Fired Steam Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models: KSZ065 • WARNING: Improper installation, adjustment, alteration, service or KSZ075 • maintenance can cause property KSZ100 • damage, injury, or loss of life.
  • Page 2: Table Of Contents

    Table of Contents I. Product Description .............. 1 VIII. Indirect Water Heater & Tankless Coil II. Specifications ................ 1 Piping ............13 III. Before Installing ..............2 IX. Fuel Line Piping ........... 16 IV. Locating the Boiler ..............3 X. Wiring ............19 V.
  • Page 3: Before Installing

    This can happen for many reasons, some of which are out of the control of both the installer and appliance manufacturer. Crown Boiler Company recommends the use of a chimney to vent the KSZ series boilers. If a power venter must be used, it is the responsibility of the installer and power vent manufacturer to “engineer”...
  • Page 4: Locating The Boiler

    3) Make sure that the boiler is correctly sized. Use an industry accepted sizing method such as the I=B=R Installation Guide for Residential Hydronic Heating Systems and I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics Institute in Berkeley Heights, NJ. 4) In some cases, boilers installed at altitudes above 2000ft may require a different burner configuration from that at sea level.
  • Page 5 18** FRONT VIEW SIDE VIEW * LH SIDE CLEARANCE 24“ FOR FLOAT TYPE LWCO EQUIPPED BOILERS ** CLEARANCE FROM SINGLE WALL CONNECTOR TO COMBUSTIBLE CONSTRUCTION FIGURE 2: CLEARANCES Sheet Metal (24 GA or Thicker) 4“ MIN. Combustible Surface Openings Aligned To Permit Free Air Circulation Hollow Masonry Blocks FIGURE 3: INSTALLATION OVER A COMBUSTIBLE FLOOR...
  • Page 6 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 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: Total the input of all appliances in the boiler room in thousands of BTU/hr.
  • Page 7 FIGURE 4: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE FIGURE 5: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC...
  • Page 8 FIGURE 6: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC FIGURE 7: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM...
  • Page 9 FIGURE 8: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM...
  • Page 10: Venting

    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 KSZ series boiler: •...
  • Page 11 This can happen for many reasons, some of which are out of the control of both the installer and appliance manufacturer. Crown Boiler Company recommends the use of a chimney to vent the KSZ series boilers. If a power venter must be used, it is the responsibility of the installer and power vent manufacturer to “engineer”...
  • Page 12: System Piping Connections

    VII System Piping CAUTION • INSTALL BOILER SO THAT ALL ELECTRICAL COMPONENTS ARE PROTECTED FROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERATION AND SERVICE. • OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. Figure 10 shows recommended near boiler Piping for most common types of gravity return steam systems.
  • Page 13: Piping Installation

    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.
  • Page 14: 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 15: 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 16 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 17: Fuel Line Piping

    IX Fuel Line Piping 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). 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 the oil burner, there are four types of oil piping systems generally being used: a) ONE-PIPE GRAVITY SYSTEM - used when a fuel oil storage tank is positioned above an oil burner fuel pump.
  • Page 18 c) TWO-PIPE GRAVITY SYSTEM (not recommended) - Used when a fuel oil storage tank is located above an oil burner fuel pump. See Figure 15. 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.
  • Page 19 3” - 4” above suction line depth within the storage tank. Refer to the pump manufacturer’s instructions for tube sizing information. 8) All systems require an oil filter. On KSZ065 and KSZ075 boilers, the use of a Garber cartridge type filter is recommended.
  • Page 20: Wiring

    X Wiring WARNING All wiring and grounding must be done in accordance with the authoity having jurisdiction or, in the absence of such authority, with the National Electric Code (ANSI/NFPA70). 1) 120 Volt Wiring - Provide the boiler with its own 15A branch circuit with fused disconnect. How the 120 volt connections are made depends upon the type of low water cut-off supplied with the boiler.
  • Page 21 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 22 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 23 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 24: 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.
  • Page 25 24) Verify primary control operation and safety features according to procedure outlined in the instructions furnished with control. 25) 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. 26) Check low water cut-off operation.
  • Page 26 TABLE 3a: BECKETT BURNER CONFIGURATION AND SETUP DATA KSZ065 KSZ075 KSZ100 KSZ090 KSZ125 KSZ150 KSZ120 KSZ175 KSZ200 BURNER MODEL AIR TUBE COMBO. 70MB 70MB 70MB 70MB 70MD 70MD 70MD 70MD 70ML HEAD TYPE STATIC PLATE 3 3/8 3 3/8 3 3/8...
  • Page 27: Service & Maintenance

    TABLE 3c: RIELLO BURNER CONFIGURATION AND SETUP DATA KSZ150 KSZ120 KSZ175 KSZ200 KSZ065 KSZ075 KSZ100 KSZ090 KSZ125 BURNER MODEL 40F5 40F5 40F5 40F10 40F10 40F10 STANDARD DEL. HAGO NOZZLE 0.60/60A 0.85/60W 1.00/60A 1.25/60B 1.35/45B 1.65/45B PUMP PRESS (psi) TURBULATOR SHUTTER SETTING 2.60...
  • Page 28 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 29 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 30: Parts

    QTY. OR QUANTITY PER BOILER OR CROWN P.N. KEY # DESCRIPTION CROWN P.N. COMPLETE HEAT EXCHANGER ASSY. 1 ea. 2800135 2800135 2800135 2800145 2800145 2800145 2800155 2800155 2800155 FRONT SECTION 275051 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea.
  • Page 32 QTY. OR QUANTITY PER BOILER OR CROWN P.N. KEY # DESCRIPTION CROWN P.N. LEFT SIDE JACKET PANEL 1 ea. 270233 270233 270233 270234 270234 270234 270235 270235 270235 RIGHT SIDE JACKET PANEL 1 ea. 2702235 2702235 2702235 2702245 2702245 2702245 2702255 2702255 2702255 REAR JACKET PANEL 270220 1 ea.
  • Page 34 CROWN Boiler Co Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 Tel: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com Rev 2 - 05-03...

This manual is also suitable for:

Ksz075Ksz090Ksz125Ksz150Ksz120Ksz175 ... Show all

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