Crown Boiler KSZ200, KSZ065, KSZ120, KSZ125, KSZ100 User Manual

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CROWN

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 instructions carefully before installing.

Boiler Co

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

CROWN

Boiler Co

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

T el: (215) 535-8900 • Fax: (215) 535-9736 • www.crownboiler.com

Table of Contents

I. Product Description .............................................................. 1

II. Specifications........................................................................ 1

III. Before Installing ................................................................... 2

IV. Locating the Boiler................................................................ 3

V. Air for Combustion & Ventilation......................................... 3

VI. V enting.................................................................................. 9

VII. System Piping Connections ................................................ 11

VIII. Indirect Water Heater & Tankless Coil

Piping ...........................................................13

IX. Fuel Line Piping...........................................16

X. Wiring .......................................................... 19

XI. Start-up and Checkout.................................. 23

XII. Service & Maintenance................................26

XIII. Parts .............................................................31

I Product Description

The KSZ series boiler is a cast iron oil-fired 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 flue 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 Specifications

FIGURE 1: GENERAL CONFIGURATION

TABLE 1a: GENERAL SPECIFICATIONS

Burner

Number of

Boiler Model

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 1.20 144000 108000 450 26 1/2 13 5/16 8 KSZ175 5 1.75 207000 155000 646 26 1/2 13 5/16 8 KSZ200 5 2.00 235000 176000 733 26 1/2 13 5/16 8

Sections

Input

(Gal/hr)

DO E Heating

Capacity

(Btu/hr)

I=B=R Net

Rating (Btu/hr)

Notes:

I=B= R Net

Rating (Sq. ft)

Dime nsion s (inches )

"A" "B" "C"

TABLE 1b: TANKLESS HEATER RATINGS

1. Net Ratings are based on piping and pick-up allowances of 1.333.

MODEL RATING (gpm)

KSZ065 2.25 KSZ075 2.25 KSZ100 2.50 KSZ090 2.50 KSZ125 2.75

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.

KSZ150 3.00 KSZ120 2.75 KSZ175 3.25 KSZ200 3.50

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-fired 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 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” 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.

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

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 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 T ankless 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 difficult as this clearance is reduced.

• A 24” service clearance is required on the left side of KSZ series boilers equipped with float type low water cut-

offs. This is to facilitate low water cut-of f maintenance.

2) If listed T ype 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 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.

V 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 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 flue 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 is defined as having all 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

floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other openings.

18**

FRONT VIEW SIDE VIEW

* LH SIDE CLEARANCE 24“ FOR FLOAT TYPE LWCO EQUIPPED BO ILERS * * C LEARANCE F ROM SINGLE WALL C ONNEC TOR TO COMBUSTIBL E CONSTRU CTION

FIGURE 2: CLEARANCES

Sh eet Me t a l ( 24 GA o r Thicker)

0.47"

4“ MI N.

Openings A ligned To Permit Free Air Circulation

Hollow Masonry Blocks

FIGURE 3: INSTALLATION OVER A COMBUSTIBLE FLOOR

Combustible Surface

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. 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: 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 confined space.

2) Unconfined Space - Natural infiltration into the boiler room will normally provide adequate air for combustion and ventilation 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” of the ceiling and the bottom edge of the lower opening must be within 12” of the floor (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 finer 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 floor.

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 fired 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 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

are used, they must be no finer than ¼” (4 x 4) mesh.

FIGURE 4: BOILER INSTALLED IN CONFINED SPACE,

ALL AIR FROM INSIDE

FIGURE 5: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC

FIGURE 6: ALL AIR FROM OUTDOORS,

VIA VENTILATED ATTIC

FIGURE 7: ALL AIR FROM OUTDOORS, USING

OPENINGS INTO BOILER ROOM

FIGURE 8: ALL AIR FROM OUTDOORS, USING

HORIZONTAL DUCTS INTO BOILER ROOM

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 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.

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.

Do not vent a KSZ series boiler into an unlined chimney.

FIGURE 9: TYPICAL VENT SYSTEM

INSTALLATION AND COMPONENTS

3) Chimney and Vent Connector Sizing - See Table 2 for minimum vent connector and chimney sizing. The vent connector size must not be smaller than the boiler flue collar diameter. Where two or more appliances vent into a common vent, the cross-sectional area of the common vent should at least equal the area of largest vent plus 50% of the area in the additional vents.

4) Do not vent this appliance into any portion of a mechanical vent system operating under positive pressure.

5) Do not connect the boiler into a chimney flue serving an open fireplace or other solid fuel appliance.

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 combustibles and the proper pitch called for in (7) above.

9) Vent pipe should be installed above the bottom of the chimney to prevent blockage.

10) Vent pipe must be inserted flush with inside face of the chimney liner and the space between vent pipe and chimney sealed tight. A thimble permanently cemented in place can be used to facilitate removal of chimney connector for cleaning.

11) Install the barometric draft regulator in accordance with the regulator manufacturer’s instructions.

12) Secure all joints in the vent connector system with sheet metal screws. This includes the joint between the vent connector and the boiler collar, as well as the barometric draft regulator. Use at least three screws at each joint.

TABLE 2: MINIMUM RECOMMENDED BREECHING AND

CHIMNEY SIZE

Boiler Model

Min Breeching Dia. (inches)

Min. Recommended Chimney Size and Height

Round I.D. (in) Rectangular I.D. (in) Height (ft) KSZ065 6 6 8 x 8 15 KSZ075 6 6 8 x 8 15 KSZ100 6 6 8 x 8 15 KSZ090 7 7 8 x 8 15 KSZ125 7 7 8 x 8 15 KSZ150 7 7 8 x 8 15 KSZ120 8 8 8 x 8 15 KSZ175 8 8 8 x 8 15 KSZ200 8 8 8 x 8 15

Power (“Side Wall”) Venting - Important Note

Two problems arise when any oil-fired appliance is power vented:

1. There is sometimes an accelerated rate of soot buildup on the oil burner cad-cell, spinner etc.

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.

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Crown Boiler KSZ200, KSZ065, KSZ120, KSZ125, KSZ100 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual