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CROWN
Boiler Co
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.
For assistance or additional
• KSZ090
information, consult a qualified
• KSZ125
installer, service agency or the
oil supplier. Read these instruc-
• KSZ150
tions carefully before installin
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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. Locati
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TABLE 1a: GENERAL SPECIFICATIONS Burner DOE Heating Number of Input Capacity I=B=R Net I=B=R Net Dimensions (inches) Boiler Model Sections (Gal/hr) (Btu/hr) Rating (Btu/hr) Rating (Sq. ft) "A" "B" "C" KSZ065 3 0.65 78000 56000 233 16 1/2 8 5/16 6 KSZ075 3 0.75 90000 68000 283 16 1/2 8 5/16 6 KSZ100 3 1.00 119000 89000 370 16 1/2 8 5/16 6 KSZ090 4 0.90 108000 81000 338 21 1/2 10 13/16 7 KSZ125 4 1.25 149000 112000 467 21 1/2 10 13/16 7 KSZ150 4 1.50 177000 133000 554 21 1/2 10 13/16 7 KSZ120 5 1
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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. Consult the local Crown representative for more information. IV Locating the Boiler
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18** 6* 6 24 6 FR ONT VIEW SIDE VIEW * LH SIDE CLEARANCE 24“ FOR FLOAT TYPE LWCO EQUIPPED BOILERS ** CLEARANCE FROM SINGLE WALL CONNECTOR T O COMBUSTIBLE CONSTRUCT ION FIGURE 2: CLEARANCES Sheet Metal (24 GA or T hicker) 4“ MIN. Combustible Surface Openings Aligned T o Permit Free Air Circulation Hollow Masonry Blocks FIGURE 3: INSTALLATION OVER A COMBUSTIBLE FLOOR 4 5 0.47"
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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: 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
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FIGURE 4: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE FIGURE 5: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC 6 7
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FIGURE 6: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC FIGURE 7: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM 7 8
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FIGURE 8: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 8 9
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VI Venting Vent installation must be in accordance with local building codes, or the local authority having jurisdiction. Typical vent installation is illustrated by Figure 9. The components of vent installation are the vent connector (breeching), barometric draft regulator, and chimney. 1) Acceptable Chimneys - The following chimneys may be used to vent a KSZ series boiler: • Listed Type L vent - Install in accordance with the manufacturer’s instructions, the terms of its listing, and applicab
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6) Prior to boiler installation, inspect chimney for obstructions or other defects and correct as required. Clean chimney as necessary. 7) Vent pipe should slope upward from the boiler not less than one inch in four feet. No portion of vent pipe should run downward or have sags. Vent pipe must be securely supported. 8) The vertical section of vent pipe coming off the boiler should be as tall as possible, while still maintaining the proper clearance from the horizontal vent connector to combustib
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VII System Piping CAUTION • INSTALL BOILER SO THAT ALL ELECTRICAL COMPONENTS ARE PROTECTED FROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERATION AND SERVICE. • 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. Additional information on steam system design may be found in Installation Guide for Re
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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 KSZ boilers with gravity returns. 4) For installations with condensate or boiler feed pumps, follow the pump manufacturer’s piping instructions. Such syst
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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. This section describes boiler-side piping only. Refer to the indirect water heater instruction manual for domestic water piping. The components in th
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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. This may result in substantially longer water heater recovery times. TANKLESS HEATER PIPING KSZ Series boilers equipped with tankless heaters are s
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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. FIGURE 12b: TANKLESS HEATER PIPING 15 16
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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-PIP
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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. 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. d) TWO-PIPE LIFT SYSTEM - used when a fuel o
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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 for wrought iron or steel piping connections. 2) Piping shall be substantially supported and protected against physical damage and corrosion where required. 3) Refer to supplied oil pump instruction manual for proper connecti
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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. For boilers equipped with Hydrolevel CG450 - 120 Volt connections are made inside the CG450: • Connect
