Crown Boiler KSB Series Installation Instructions Manual Download Page 1

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KSB Series

Oil-Fired Steam Boilers

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

Models:

•

KSB065

•

KSB075

•

KSB100

•

KSB125

•

KSB150

•

KSB175

•

KSB200

E S I G N E D T O

E A D

980280B Rev 0, 11-20

Crown Boiler Company

P.O. Box 14818

3633 I Street

Philadelphia, PA 19134

www.crownboiler.com

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 fuel supplier. Read these instructions carefully before installing, operating, or

servicing this boiler. Keep boiler and any provided component instructions in legible condition and

posted near boiler for reference by owner and service technician.

9902339

Summary of Contents for KSB Series

Page 1: ...19134 www crownboiler com WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or loss of life For assistance or additional information consult a...

Page 2: ...2...

Page 3: ...s from this instruction manual Authorities having jurisdiction should be consulted before installations are made are made In all cases reference should be made to the following Standards In all cases...

Page 4: ...e responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is completed This boiler is not suitable for direct inst...

Page 5: ...nattended 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 car...

Page 6: ...CSA C22 1 in Canada and any local regulations WARNINGS FOR THE INSTALLER WARNING This boiler must be properly vented The chimney must be inspected for any obstructions and cleaned prior to each heatin...

Page 7: ...IV Field Assembly 8 V Locating the Boiler 11 VI Air for Combustion Ventilation 12 VII Venting 17 VIII System Piping 19 IX Indirect Tankless Water Heater Piping 21 X Fuel Line Piping 23 XI Wiring 26 X...

Page 8: ...TIONS GAL HR MBH Sq ft MBH 1 20 1 50 1 75 1 90 KSB175 KSB200 KSB150 B C BURNER INPUT 0 65 0 75 1 00 79 A 85 1 HEATING CAPACITY NET AHRI RATING STEAM AFUE 91 85 1 KSB065 KSB075 KSB100 KSB125 DIMENSIONS...

Page 9: ...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...

Page 10: ...Pipe Fittings Loose Flue Baffles KSB100 Only b The burner carton consisting of the following items Oil Burner assembly complete with cord and nozzle installed This nozzle is for the highest firing ra...

Page 11: ...the instruction manual envelope and apply it next to the rating plate TABLE 4 0 FIELD ASSEMBLY COMPONENTS BURNER1 BOILER MODEL KSB0652 KSB075 KSB100 KSB125 KSB150 KSB175 KSB200 BECKETT CROWN CARTON PA...

Page 12: ...10 FIGURE 4 1 FIELD INSTALLATION OF FLUE BAFFLES...

Page 13: ...this clearance is reduced A 24 service clearance is required on the left side of boilers equipped with float type low water cut offs This is to facilitate low water cut off maintenance 2 If listed Ty...

Page 14: ...osphere 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 ar...

Page 15: ...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...

Page 16: ...an opening takes into account the blocking effect of mesh grills and louvers Where screens are used they must be no finer than 4 x 4 mesh For Buildings of Unusually Tight Construction 1 Openings must...

Page 17: ...15 FIGURE 6 2 ALLAIR FROM OUTDOORS VIA VENTILATED ATTIC FIGURE 6 3 ALLAIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM...

Page 18: ...16 FIGURE 6 4 ALLAIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM...

Page 19: ...nry 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 lin...

Page 20: ...e 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...

Page 21: ...occur Short cycling on low water Boiler or system Flooding Hammering Failure to heat one or more radiators VIII System Piping WARNING Install boiler so that the electrical components are protected fr...

Page 22: ...require Hartford loops 5 Do not use a check valve in place of or in addition to a Hartford loop on a gravity return system 6 Pipe the fill connection from a clean source of cold water When the water...

Page 23: ...for wiring information 2 Y Strainer Install a Y strainer to prevent sediment from accumulating inside the indirect water heater 3 Check Valve Prevents gravity circulation through the indirect water he...

Page 24: ...ed to excessive temperatures when no water is flowing through the coil 3 DHW Pressure Relief Valve Required Limits the pressure in the tankless heater and piping Use an ASME constructed valve designed...

Page 25: ...fer also to the instruction manuals provided with the burner WARNING Under no circumstances can copper with sweat style connectors be used Do not use compression fittings Oil piping must be absolutely...

Page 26: ...ld 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 oil storage tank is located below an oil bu...

Page 27: ...uel pump Use heavy wall copper tubing in a continuous run On two pipe systems the return line should terminate 3 4 above suction line depth within the storage tank Refer to the pump manufacturer s ins...

Page 28: ...he National Electrical Code ANSI NFPA 70 Disconnect electrical power to the boiler and heating system before servicing Positively assure that no voltage is present Lock electrical boxes to prevent som...

Page 29: ...ring Install the L4006A with the 3 4 NPT well in the 3 4 tapping in the center of the coil plate Make sure that the sensing bulb of this control is fully bottomed out in the well Route the wire harnes...

Page 30: ...28 FIGURE 11 0 120V BOILER CONNECTIONS DIAGRAM See Figs 11 1a c for burner and low voltage thermostat wiring Beckett 7505 FIGURE 11 1a CONNECTIONS DIAGRAM FOR BECKETT BURNER PRIMARY CONTROL...

Page 31: ...29 Carlin 40200 FIGURE 11 1b CONNECTIONS DIAGRAM FOR CARLIN BURNER PRIMARY CONTROL Riello 530SE FIGURE 11 1c CONNECTIONS DIAGRAM FOR RIELLO BURNER PRIMARY CONTROL...

Page 32: ...30 FIGURE 11 2 INDIRECT WATER HEATER FIELD WIRING...

Page 33: ...s for more details 14 Immediately upon firing the boiler check the smoke level If the smoke level is in excess of a 1 open the air adjustment to bring the smoke level below a 1 15 Make sure that the o...

Page 34: ...has been installed and put into continuous operation for several days clean the boiler of oil grease sludge and other contaminants that may have been present in existing piping This will prevent unste...

Page 35: ...DRAFT OVER FIRE in w c MAX SMOKE bacharach scale FLUE CO2 MIN 11 0 11 0 11 0 11 0 11 0 11 0 11 0 MAX 12 5 13 0 13 0 13 0 13 0 12 5 13 0 0 02 0 02 0 02 1 0 02 0 02 1 1 1 1 NONE NONE NONE NONE 1 0 02 0...

Page 36: ...DEL DEL HAGO DEL NOZZLE 0 60 60A 0 85 60W 1 00 60A 1 25 60B 1 35 45B 1 65 45B PUMP PRESS psi 150 150 150 150 150 150 TURBULATOR 0 2 3 3 1 5 2 AIR SHUTTER SETTING 2 60 2 85 3 8 4 5 3 3 8 DRAFT OVER FI...

Page 37: ...or other deterioration Replace any defective vent system components a Temporarily install a 1 1 4 inch or larger full port ball valve in place of the 1 1 2 plug Temporarily pipe the outlet of this val...

Page 38: ...valve immediately if valve fails to relieve pressure 11 Open fuel line shut off valve s and restore electrical power to the boiler 12 Fire the boiler and check it out using the procedure outlined in S...

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: ...gas leakage into the building resulting in odor complaints 6 Dirt The use of a fuel filter is required Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and pro...

Page 41: ...70021 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 17 FLAME INSPECTION COVER 290022 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 18 5 16 18 X 3 4 HEX HEAD CAP SCREW 900400 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 19 1 2 x 1 SE...

Page 42: ...450 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 48 GLASS SET 950078 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 49 PRESSURE LIMIT CONTROL L404F1367 3503800 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 50 90 DEGREE BRASS PIGTAIL...

Page 43: ...41...

Page 44: ...42 Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com...

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