Crown Boiler FSZ080 Installation Instructions Manual Download Page 4

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table of contents

Product Description ............................................................................... 3

II. Specifications ......................................................................................... 3

III. Before Installing .................................................................................... 5

IV. Field Assembly ...................................................................................... 6

Locating the Boiler ................................................................................ 7

VI. Air for Combustion & Ventilation ......................................................... 8

VII. Venting ................................................................................................... 13

VIII. System Piping ........................................................................................ 15

IX. Indirect & Tankless Water Heater Piping ............................................... 19

Fuel Line Piping .................................................................................... 22

XI. Wiring .................................................................................................... 25

XII. Start-Up & Checkout ............................................................................. 30

XIII. Service & Maintenance .......................................................................... 34

XIV. Troubleshooting ..................................................................................... 38

XV. Parts ....................................................................................................... 40

Appendix A. Installation of Optional Gravity Return Piping Kit .................... 46

Summary of Contents for FSZ080

Page 1: ...djustment 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 R...

Page 2: ......

Page 3: ...r 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...

Page 4: ...the Boiler 7 VI Air for Combustion Ventilation 8 VII Venting 13 VIII System Piping 15 IX Indirect Tankless Water Heater Piping 19 X Fuel Line Piping 22 XI Wiring 25 XII Start Up Checkout 30 XIII Serv...

Page 5: ...8 1 4 30 6 19 7 19 3 27 29 744 FSZ160 34 1 4 36 7 24 1 23 8 34 29 881 Maximum working pressure Steam 15psi TABLE 2 2 RATING DATA BOILER MODEL BURNER INPUT HEATING CAPACITY MBH AHRI NET RATINGS MINIMUM...

Page 6: ...T COVER SMOKEBOX COLLAR SAFETY VALVE CLEAN DRAIN VALVE 2 FRONT SUPPLY 2 REAR SUPPLY 1 1 2 RETURN 4 9 16 5 11 16 11 1 4 TOP VIEW RIGHT VIEW FRONT VIEW ARRANGEMENT NOTE THIS DIMENSION INCREASES AND IS C...

Page 7: ...uthority 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...

Page 8: ...upplied is the correct one for the boiler The crate tag on the boiler lists the Crown part numbers for the Beckett and Riello burner cartons that may be used with it 2 Remove the burner mounting bolts...

Page 9: ...ont 24 from front jacket surface Left Side 6 Right Side 6 18 is required for tankless heater service Rear 12 Top 6 Single Wall Chimney Connector to combustible construction 18 A 24 service clearance i...

Page 10: ...ied 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 ot...

Page 11: ...ing and the bottom edge of the lower opening must be within 12 of the floor Figure 6 0 Each opening must have a free area of 1 square inch per 1000 BTU hr input of all fuel burning appliances in the b...

Page 12: ...10 FIGURE 6 0 BOILER INSTALLED IN CONFINED SPACE ALLAIR FROM INSIDE FIGURE 6 1 ALLAIR FROM OUTDOORS VENTILATED CRAWL SPACE AND ATTIC...

Page 13: ...11 FIGURE 6 2 ALLAIR FROM OUTDOORS VIA VENTILATED ATTIC FIGURE 6 3 ALLAIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM...

Page 14: ...12 FIGURE 6 4 ALLAIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM...

Page 15: ...iameter 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 s...

Page 16: ...regulator shall be used 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 see Figure 7 0 Detail A as w...

Page 17: ...Failure to heat one or more radiators Avoid the common piping mistakes shown in Figure 8 2 This applies even if the existing boiler has one of the piping mistakes shown in Figure 8 2 and appears to b...

Page 18: ...16 FIGURE 8 1 STEAM BOILER PIPING FOR GRAVITY RETURN...

Page 19: ...not create a hazard or cause property damage if the valve opens The end of the discharge pipe must terminate in an unthreaded pipe If the safety valve discharge is not piped to a drain it must termin...

Page 20: ...1 4 Pressure Limit C 3 4 Probe LWCO D 1 2 Water Gauge Glass E 2 Supply Front Rear Tappings F 3 4 Safety Valve G 1 1 2 Condensate Return Reduced to 1 1 4 on FSZ080 100 130 H 1 1 4 Optional Front Return...

Page 21: ...n the boiler and the circulator inlet All piping between the boiler and the circulator inlet should be 1 regardless of the size of the piping required in the rest of the system See Figure 11 2 in Part...

Page 22: ...obe or Ball Valve Recommended Used to adjust the flow through the entire tankless heater system if needed TANKLESS HEATER PIPING FSZ Series boilers equipped with tankless heaters are supplied with a H...

Page 23: ...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...

Page 24: ...roblems if the suction line is not completely airtight A two pipe lift system is therefore preferred to a one pipe lift system c TWO PIPE GRAVITY SYSTEM not recommended A vertical distance from top of...

Page 25: ...manufacturer s instructions for tube sizing information 8 Never install manual shut off valves in the return piping of a two pipe system 9 Install a listed flexible oil line s at the burner to facili...

Page 26: ...24 FIGURE 10 2 TWO PIPE GRAVITY FEED SYSTEM NOT RECOMMENDED FIGURE 10 3 TWO PIPE LIFT SYSTEM...

Page 27: ...n nections are made inside the junction box on the right side of the boiler as follows also see Figures 11 0 and 11 1 Connect Hot black to black pigtail in junction box Connect Neutral white to white...

Page 28: ...tat will energize the relay making both sets of contacts One set of these contacts then energizes the cir culator The other set of contacts will make the R and G contacts on the R8285D control firing...

Page 29: ...27 FIGURE 11 0 WIRING CONNECTIONS DIAGRAM STEAM CG450 PROBE LWCO...

Page 30: ...28 FIGURE 11 1 CONNECTIONS WIRING DIAGRAM FOR BURNER SPECIFIC PRIMARY CONTROL...

Page 31: ...29 FIGURE 11 2 INDIRECT WATER HEATER FIELD WIRING...

Page 32: ...ith 2 fuel oil meeting ASTM D396 specifications oil piping has been tested and is air tight and shutoff valve s are closed 5 Check initial settings of oil burner air band and air shutter head setting...

Page 33: ...le drip after burner stops Cycle burner on and off 5 to 10 times to purge air completely 24 Check thermostat operation by raising or lowering its set point as required cycling burner on and off 25 Ver...

Page 34: ...ng from the boiler drain valve to a location where hot water can be safely discharged Drain approximately five gallons of water from the boiler and mix in an appropriate amount of an approved boil out...

Page 35: ...8 2 9 5 DRAFT IN FLUE in w c 0 to 0 02 0 to 0 02 0 to 0 02 0 to 0 02 MAX SMOKE Bacharach Scale 1 1 1 1 FLUE CO2 MIN MAX 11 5 12 8 11 5 12 8 11 5 12 8 11 5 12 8 TABLE 12 1b RIELLO BURNER CONFIGURATION...

Page 36: ...is fired d Fire the boiler and allow it to steam until 2 5 psi is registered on the gauge e Turn off the burner and immediately fully open the 1 1 4 valve f Allow the boiler to blow down until either...

Page 37: ...ris in the bottom of the combustion chamber and smoke box g Clean the Combustion Chamber Use a wire or fiber bristle brush to clean the surfaces of the combustion chamber Vacuum all loose debris in th...

Page 38: ...Service the oil burner a Replace oil nozzle with identical make and model see Table 12 1 b Inspect the electrodes Replace if they are deteriorated Make sure that the electrode position is set accordin...

Page 39: ...g sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately f...

Page 40: ...g in odor complaints 6 Dirt The use of a fuel filter is good practice Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from th...

Page 41: ...39 Notes...

Page 42: ...LESS POCKETS 410021 1 1 1 10 SWING DOOR INSULATION WITH POCKETS 410023 1 11 1 2 DIA ROPE GASKET SWING DOOR 410024 1 1 1 1 12 1 8 DIA ROPE GASKET OBSERVATION PORT 410032 1 1 1 1 13 OBSERVATION PORT COV...

Page 43: ...41...

Page 44: ...33 REAR JACKET PANEL 420301 1 1 1 1 34 TOP JACKET PANEL 1 420323 420323 420324 420325 35 JUNCTION BOX 960155 1 1 1 1 37 FIBERGLASS INSULATION WRAPPER 1 422303 422303 422304 422305 40 POWER RECEPTACLE...

Page 45: ...43...

Page 46: ...1 3 4 NPT 90 ELBOW 95 057 1 1 1 1 62 3 4 NPT X 8 LONG NIPPLE 950008 1 1 1 1 63 3 4 NPT SAFETY VALVE 15 PSI CONBRACO 13 512 B15 95 079 1 1 1 1 64 1 1 2 NPT X 3 NIPPLE 950023 1 1 1 1 65 1 1 2 NPT CAP 95...

Page 47: ...45...

Page 48: ...the drop header piping as listed in Table A 1 for the FSZ080 FSZ100 and FSZ130 and in Table A 3 for the FSZ160 Installation of Dropped Header Gravity Return Piping Kit 1 Assemble Dropped Header Gravi...

Page 49: ...le 2 7 2 x 3 Nipple FSZ080 and FSZ100 or 2 x 9 Nipple FSZ130 1 8 2 x 4 1 2 Nipple 3 9 2 Tee 2 10 2 1 1 2 Reducing Elbow 1 11 1 1 2 x 8 Nipple 1 12 1 1 2 Union 1 13 1 1 2 x 5 1 2 Nipple 1 14 1 1 2 Wye...

Page 50: ...w 4 5 2 x 15 Nipple 2 6 2 x 7 Nipple 2 7 3 x 2 Reducing Elbow 2 8 3 x 9 Nipple 1 8A 3 x 10 Nipple 1 9 3 Union 1 10 3 x 5 Nipple 2 11 3 x 3 x 2 Tee 1 12 3 Tee 1 13 2 x 7 Nipple 1 13A 2 x 5 Nipple 1 14...

Page 51: ...Notes...

Page 52: ...PN 980265 FSZ Rev 3 07 13 Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com...

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