Crown KSZ175 User Manual
KSZ Series
D ESIGNED TO L EAD
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com
Oil-Fired Steam Boilers
INSTALLATION INSTRUCTIONS
These instructions must be afxed on or adjacent to the boiler
Models:
• KSZ065
• KSZ075
• KSZ100
• KSZ090
• KSZ125
• KSZ150
• KSZ120
• KSZ175
• KSZ200
WARNING: Improper installation, adjustment, alteration,
service or maintenance can
cause property damage, injury,
or loss of life. For assistance or
additional information, consult a
qualied installer, service agency
or the oil supplier. Read these
instructions carefully before
installing.
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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 property 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.
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 the
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 or 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.
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Table of Contents
I. Product Description .............................................................. 2
II. Specications ........................................................................ 2
III. Before Installing .................................................................... 3
IV. Locating the Boiler ............................................................... 4
V. Air for Combustion & Ventilation ......................................... 6
VI. Venting ................................................................................ 10
VII. System Piping Connections ................................................ 12
VIII. Indirect Water Heater & Tankless Coil
Piping ........................................................... 14
IX. Fuel Line Piping ........................................... 17
X. Wiring ........................................................... 20
XI. Start-up and Checkout .................................. 24
XII. Service & Maintenance ................................ 27
XIII. Parts .............................................................. 32
I Product Description
The KSZ series boiler is a cast iron oil-red low pressure 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 Type L vent. An adequate supply of air for
combustion, ventilation and dilution of ue gases must be available in the boiler room. This boiler has connections for use
with an indirect domestic water heater.
The KSZ series boilers are not designed for use in process or other “open” steam systems.
II Specications
FIGURE 1: GENERAL CONFIGURATION
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TABLE 1a: GENERAL SPECIFICATIONS
"A" "B" "C"
KSZ065 3 0.65 79000 85.1 59000 246 17-3/8 8-5/16 6
KSZ075 3 0.75 90000 84.5 68000 283 17-3/8 8-5/16 6
KSZ100 3 1.00 119000 83.5 89000 370 17-3/8 8-5/16 6
KSZ090 4 0.90 110000 85.0 83000 346 22-3/8 10-13/16 7
KSZ125 4 1.25 149000 84.2 112000 467 22-3/8 10-13/16 7
KSZ150 4 1.50 177000 83.1 133000 554 22-3/8 10-13/16 7
KSZ120 5 1.20 147000 85.4 110000 458 27-3/8 13-5/16 8
KSZ175 5 1.75 207000 83.1 155000 646 27-3/8 13-5/16 8
KSZ200 5 2.00 235000 82.9 176000 733 27-3/8 13-5/16 8
I=B=R Net
Rating (Sq. ft)AFUE (%)
I=B=R Net
Rating (Btu/hr)
Dimensions (inches)
Boiler Model
Number of
Sections
Burner
Input
(Gal/hr)
DOE Heating
Capacity
(Btu/hr)
MODEL RATING (gpm)
KSZ065 2.25
KSZ075 2.25
KSZ100 2.50
KSZ090 2.50
KSZ125 2.75
KSZ150 3.00
KSZ120 2.75
KSZ175 3.25
KSZ200 3.50
TABLE 1b: TANKLESS HEATER RATINGS
Notes:
1. Net Ratings are based on piping and pick-up allowances of 1.333.
2. Burner Capacity Rating, GPH is based on #2 oil with a Gross Heating
Value equal to 140000 BTU/Gal.
3. Maximum Working Pressure, Steam -15 PSI.
4. Tankless heater 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.
III Before Installing
1) 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.
• In the 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).
• 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 (ANSI/ASME CSD-1).
2) Make sure that a properly sized chimney is available which is in good condition. Consult the authority having
jurisdiction, Part VI of this manual, and ANSI/NFPA31 for additional information on venting requirements.
Power (“Side Wall”) Venting - Important Note
Two problems arise when any oil-red appliance is power vented:
1. There is sometimes an accelerated rate of soot buildup on the oil burner cad-cell, spinner etc.
2. 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 many reasons, some of which are out of the control of both the installer and appliance
Crown Boiler Company recommends the use of a chimney to vent the KSZ series boilers. If a power venter must be used, it
manufacturer.
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
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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 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 conguration from that at sea level.
Consult the local Crown representative for more information.
IV Locating the Boiler
WARNING
FAILURE TO OBSERVE THE FOLLOWING LOCATION REQUIREMENTS COULD RESULT
IN PROPERTY 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 con-
struction, as well as noncombustible walls, ceilings and doors. Also see Figure 2.
Front – 24”
Left Side – 6” (24” for Boilers Equipped with Float Type Low Water Cut-offs)
Right Side – 6” (24” for Boilers Equipped with Tankless Heaters)
Rear – 6” (24” for boilers connected to indirect water heaters)
Top – 6”
Single Wall Chimney Connector (to combustible construction) - 18”
• A 24” service clearance from the jacket is recommended from the top of the boiler. This clearance may be
reduced to that shown above; however, servicing the boiler will become increasingly difcult as this clearance
is reduced.
• A 24” service clearance is required on the left side of KSZ series boilers equipped with oat type low water cut-
offs. This is to facilitate low water cut-off maintenance.
2) If listed Type L vent is used, follow vent pipe manufacturer recommendations for minimum clearances.
3) Do not install this boiler directly on a combustible surface. Where it is desired to install the KSZ over a non-carpeted combustible surface, install the boiler on the base shown in Figure 3.
4) Do not install this boiler in a location where gasoline or other ammable 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.
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FIGURE 2: CLEARANCES
FIGURE 3: INSTALLATION OVER A COMBUSTIBLE FLOOR
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V Air for Combustion and Ventilation
WARNING
• INSUFFICIENTCOMBUSTIONAIRSUPPLYMAYRESULTINTHEPRODUCTIONAND
RELEASE OF SOOT OR DEADLY CARBON MONOXIDE (CO) INTO THE HOME WHICH CAN
CAUSE PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH.
• THISBOILERISNOTDESIGNEDFORUSEINASPACETHATISDEPRESSURIZED
RELATIVE TO THE OUTDOORS. OPERATING THIS BOILER IN A DEPRESSURIZED SPACE
MAY CAUSE PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH.
Sufcient fresh air must be supplied for combustion and ventilation. Provisions for combustion and ventilation air for oil
burning equipment must be made in accordance with Section 1.5, Air for Combustion and Ventilation, in the latest edition of
Installation of Oil Burning Equipment (ANSI/NFPA 31).
To ensure an adequate supply of air for combustion, ventilation and ue gas dilution, start by determining whether the
boiler is to be installed in a building of unusually tight construction. A building of unusually tight construction can be dened
as having one of the following features:
• Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or
less with openings gasketed and sealed.
• Weather stripping has been added on openable windows and doors.
• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and
oors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and
at other openings.
For Buildings of Other than Unusually Tight Construction
1) Determine whether the boiler is to be installed in a conned space - A conned space is dened 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
conned 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. 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 conned space.
Example:
A KSZ090 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 KSZ090 = 0.90 Gal/hr x 140000 BTU/Gal = 126000 BTU/hr
Total input in thousands of BTU/hr = (126000 BTU/hr + 30000 BTU/hr)/1000 = 156
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft
350/156 = 2.24. Since 2.24 is less than 50, the boiler room is a conned space.
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FIGURE 4: BOILER INSTALLED IN CONFINED SPACE,
ALL AIR FROM INSIDE
2) Unconned Space - Natural inltration into the boiler room will normally provide adequate air for combustion and venti-
lation without additional louvers or openings into boiler room.
3) Conned Space - Provide two openings into the boiler room, one near the oor 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 oor
(Figure 4).
• Each opening must have a free area of 1 square inch 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.
• If the 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 are
used, they must be no ner than ¼” (4 x 4) mesh.
For Buildings of Unusually Tight Construction:
1) Openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl
space, which communicates directly with the outdoors.
2) Two openings are required. The top edge of the upper opening must be within 12 inches of the ceiling. The bottom
edge of the lower opening must be within 12 inches of the oor.
3) Size openings and ducts as follows:
• Vertical ducts or openings directly outdoors (Figure 5, Figure 6, and Figure 7) - Each opening must have a free
cross sectional area of 1 square inch per 4000 BTU/hr of the total input of all fuel red appliances in the boiler
room but not less than 100 square inches. Minimum opening size is 3 inches.
• Openings to outdoors via horizontal ducts (Figure 8) - Each opening must have a free cross sectional area of 1
square inch per 2000 BTU/hr of the total input of all fuel red 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
are used, they must be no ner than ¼” (4 x 4) mesh.
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FIGURE 5: ALL AIR FROM OUTDOORS, VENTILATED
CRAWL SPACE AND ATTIC
FIGURE 6: ALL AIR FROM OUTDOORS,
VIA VENTILATED ATTIC
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FIGURE 7: ALL AIR FROM OUTDOORS, USING
OPENINGS INTO BOILER ROOM
FIGURE 8: ALL AIR FROM OUTDOORS, USING
HORIZONTAL DUCTS INTO BOILER ROOM
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VI Venting
WARNING
• IMPROPERVENTINGMAYRESULTINPROPERTYDAMAGEAND/ORTHERELEASEOF
FLUE GASES, WHICH CONTAIN DEADLY CARBON MONOXIDE (CO), INTO THE HOME,
WHICH CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.
• INSPECTEXISTINGCHIMNEYBEFOREINSTALLINGBOILER.FAILURETOCLEANOR
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.
Typical vent installation is illustrated by Figure 9. The components of vent installation are the vent connector (breeching),
barometric draft regulator, and chimney.
FIGURE 9: TYPICAL VENT SYSTEM
INSTALLATION AND COMPONENTS
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 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 KSZ series boiler into an unlined chimney.
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