Crown Boiler KSZ Series Installation Instructions Manual Download Page 38

Page: 38 / 40

100

125

150

120

175

200

REVERSIBLE SIDE JACKET PANEL

2 ea.

270523

270524

270525

HEATER SIDE JACKET PANEL

1 ea.

270533

270534

270535

REAR JACKET PANEL

290220

1 ea.

SPLIT REAR TOP JACKET PANEL

1 ea.

290543

290544

290545

FRONT JACKET PANEL

290510

1 ea.

SPLIT FRONT TOP JACKET PANEL

290215

1 ea.

#10 X 1/2" SHEET METAL SCREW

90-212

15 ea.

5/16-18 X 1/2 PAN HEAD SCREW

900420

8 ea.

3/4" LONG WELL (WITH COIL)

35-1020

1 ea.

LOW LIMIT (L4006A2015) (WITH COIL)

35-3510

1 ea.

JUNCTION BOX

96-001

1 ea.

TWIST RECEPTICAL

96-010

1 ea.

TWIST RECEPTICAL UTILITY BOX COVER

96-019

1 ea.

PRESSURE GAUGE

95-070

1 ea.

CG450 PROBE LOW WATER CUT-OFF

450450

1 ea.

#67 LOW WATER CUT-OFF (OPTIONAL)

400677

1 ea.

GLASS SET

950078

1 ea.

PRESSURE LIMIT CONTROL (PA404A)

35-5020

1 ea.

STRAIGHT BRASS PIGTAIL

95-060

1 ea.

BECKETT BURNER ASSY. (NOTE #1)

1 ea.

130511

130512

130513

130514

130515

130516

130517

130518

130519

CARLIN BURNER ASSY. (NOTE #1)

1 ea.

130521

130522

130523

130524

130525

130526

130527

130528

RIELLO BURNER ASSY. (NOTE #1)

1 ea.

130532

130533

130535

130536

130538

130539

5/16-18 X 1 HEX HD SCW (BURNER MOUNT)

900410

3 ea.

5/16 FLAT WASHER (BURNER MOUNT)

900102

3 ea.

3/4" POP SAFETY VALVE (15 psi)

95-079

1 ea.

3/4" BOILER DRAIN

95-041

1 ea.

* NOT PICTURED

NOTE #1: PART NUMBERS PROVIDED ARE FOR FULLY CONFIGURED BURNERS AND INCLUDE NOZZLES, BURNER CORD

ASSEMBLIES, AND (WHERE APPLICABLE) LOW FIRING RATE BAFFLES.

KEY #

DESCRIPTION

QTY. OR CROWN

P.N.

QUANTITY PER BOILER OR CROWN P.N.

THE FOLLOWING BURNERS HAVE TWIST LOCK PLUGS

Summary of Contents for KSZ Series

Page 1: ...G 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 gas supplier This boiler requires a special venting system Read these instructions carefully before installing 980280 Rev F 03 18 Crown Boiler Company P O Box 14818 3633 I Street Philadelph...

Page 2: ...2 ...

Page 3: ...oes not affect the performance or longevity of a boiler All boilers must be installed in accordance with National State and Local Plumbing Heating and Electrical Codes and the regulations of the serving utilities These Codes and Regulations may differ from this instruction manual Authorities having jurisdiction should be consulted before installations are made In all cases reference should be made...

Page 4: ...the 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 installation on combustible flooring See Figure 3 for means of installing boiler over a combustible floor Do not install boiler on carpeting Do not tamper with or alter the boiler or controls Inspect fl...

Page 5: ...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 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 ...

Page 6: ...signs of condensing flue gases Flue gas condensate is corrosive which requires special consideration and must be addressed immediately Refer to Section VII Venting for more details This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air This boiler is supplied with controls which may cause the boiler to shut down and ...

Page 7: ...ft 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 ...

Page 8: ...h is in good condition Consult the authority having jurisdiction Part VI of this manual and ANSI NFPA31 for additional information on venting requirements 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 200...

Page 9: ...he boiler itself Odor complaints Severe damage to the side of the structure in the event that the boiler operates at a high smoke level These problems can occur for many reasons some of which are out of the control of both the installer and the appliance manufacturer The use of a chimney to vent this boiler is therefore recommended If a power venter must be used it is the responsibility of the ins...

Page 10: ...ent 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 com bustible 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...

Page 11: ...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 i...

Page 12: ...pening 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 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 up...

Page 13: ...11 FIGURE 6 ALLAIR FROM OUTDOORS VIA VENTILATED ATTIC FIGURE 5 ALLAIR FROM OUTDOORS VENTILATED CRAWL SPACE AND ATTIC ...

Page 14: ...12 FIGURE 8 ALLAIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM FIGURE 7 ALLAIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM ...

Page 15: ...ry 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 FIGURE 9 TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS WARNING Improper venting may result in property damage ...

Page 16: ...le 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 us...

Page 17: ... occur Short cycling on low water Boiler or system Flooding Hammering Failure to heat one or more radiators VII System Piping WARNING Install boiler so that the electrical components are protected from water dripping spraying rain etc During appliance operation and service circulator replacement etc Operation of this boiler in a system having significant amounts of dissolved oxygen can cause sever...

Page 18: ...acturer s piping instructions Such systems generally do not 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 supply is from a well make sure that a strainer is installed in the well system Piping Installation 1 Remove parts bag from boiler crate 2 In...

Page 19: ...etween 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 17 in Part X 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 wa...

Page 20: ...e the heater as shown in Figure 12b The components in this system and their functions are as follows 1 Tempering Valve Required During the heating season the water exiting the tankless heater may be 180 degrees or more The mixing valve blends hot water leaving the tankless heater with cold water so as to maintain the hot water supplied to the fixtures at a fixed temperature This saves energy incre...

Page 21: ... 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 ...

Page 22: ...tion line is not completely airtight A two pipe lift system is therefore recommended over a one pipe lift system 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 limi...

Page 23: ... the pump manufacturers s instructions Do not install this bypass plug on one pipe systems as pump seal damage will result 5 Do not use check valves especially on gravity feed systems 6 Do not use Teflon tape for threaded connections Use a listed non hardening thread sealant instead 7 Attach required piping between burner fuel pump and fuel oil storage tank Install one fuel shut off valve near the...

Page 24: ...22 FIGURE 15 TWO PIPE GRAVITY FEED SYSTEM FIGURE 16 TWO PIPE LIFT SYSTEM ...

Page 25: ... 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 harness from this control to the T and T thermostat terminals on the burner primary control so that they are in parallel with the space heating thermostat Indirect Water Heater Wiring Figure 17 shows field wiring for an indirect water heate...

Page 26: ...he CG450 2 Using McDonnell Miller WF2 U 120 feeder Do not alter factory boiler wiring Connect WF2 U 120 to CG450A as follows Connect terminal 1 on the feeder to terminal A on the CG450 Connect terminal 2 on the feeder to terminal 2 on the CG450 Connect terminal 3 on the feeder to terminal 1 on the CG450 Feeder Wiring for Boilers Equipped with McDonnell Miller Low Water Cut offs Figures 18a and 18b...

Page 27: ...25 FIGURE 18a WIRING MCDONNELL MILLER 101A 120 OR HYDROLEVEL VXT 120 FEEDER TO BOILER EQUIPPED WITH 67 L W C O FIGURE 18b WIRING MCDONNELL MILLER WF2 U 120 FEEDER TO BOILER EQUIPPED WITH 67 L W C O ...

Page 28: ...HERMOSTAT L4006A LIMIT CONTROL TANKLESS EQUIPPED BOILERS ONLY L1 INTERRUPTED INTERMITTENT BURNER MOTOR LIMIT VALVE L2 NOTE BURNER WIRING SHOWN IS FOR BECKETT AFG BURNERS CONSULT BURNER INSTRUCTION MANUAL FOR OTHER BURNERS CAD CELL 24 VOLT THERMOSTAT L4006A LIMIT CONTROL TANKLESS EQUIPPED BOILERS ONLY FIGURE 19 WIRING MCDONNELL MILLER 67 LWCO FIGURE 20 WIRING HYDROLEVEL CG450 LWCO ...

Page 29: ... 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 oil pressure matches that shown in Table 3 for the burner supplied Adjust pressure if required 16 Check the vacuum at the inlet of the fuel pump Make sure that the vacuum does not exceed the fuel pump manufacturer s limit consult the pump ...

Page 30: ...rain water from boiler until about one inch of water is visible in gauge glass c Run a hose or temporary piping 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 compound Remove safety valve and refill the boiler with prepared solution through funnel R...

Page 31: ...e FLUE CO2 MIN 11 0 11 0 11 0 11 0 11 0 11 0 11 0 11 0 11 0 MAX 12 5 12 5 12 5 12 5 12 5 12 5 12 5 12 5 12 5 1 1 1 1 0 02 0 02 0 02 0 02 0 02 1 1 1 1 1 NONE NONE NONE NONE NONE 0 02 0 02 0 02 0 02 KSZ120 LOW FIRING RATE BAFFLE BECKETT 3708 BECKETT 3708 BOILER MODEL NONE KSZ175 KSZ200 NONE STATIC PLATE KSZ065 KSZ075 KSZ100 KSZ090 KSZ125 KSZ150 TABLE 3b CARLIN BURNER CONFIGURATION AND SETUP DATA BUR...

Page 32: ...mporarily 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 valve to a location where hot water and steam can be safely discharged b Make sure that this valve is closed and that the water level is at the normal water line c If a king valve is present in the steam main takeoff close it Alternatively temporarily replace enough of the v...

Page 33: ...l oil piping and fittings for kinks and leaks Repair any found 7 Inspect the system piping tankless coil and tankless coil cover gaskets and boiler plugs for water leaks Repair any leaks found immediately 4 Clean the boiler flue passages as follows a Remove vent connector and piping b Remove barometric draft regulator c Remove top jacket panel to gain access to boiler flue collector d Unscrew four...

Page 34: ... Clean the boiler even if there are no significant soot deposits Failure to remove all sulfur and ash deposits annually can cause severe corrosion damage When cleaning the rear flue passage be careful not to push the brush too far beyond the bottom of the pins Doing so may damage the target wall TANKLESS HEATER MAINTENANCE During the warm months make sure that the water level in the boiler is 23 1...

Page 35: ...ng 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 from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not classif...

Page 36: ...HX HEAD CAP SCREW 900415 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 2 ea 15 SWING DOOR 290020 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 16 SWING DOOR INSULATION 270021 1 ea 1 ea 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 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 1 ea 1 ea 19 1 2 x 1 SEALING ST...

Page 37: ...35 ...

Page 38: ...ea 46 PRESSURE GAUGE 95 070 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 47 CG450 PROBE LOW WATER CUT OFF 450450 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 67 LOW WATER CUT OFF OPTIONAL 400677 1 ea 1 ea 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 1 ea 1 ea 49 PRESSURE LIMIT CONTROL PA404A 35 5020 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 1 ea 50 STRAIG...

Page 39: ...37 ...

Page 40: ...38 Manufacturer of Hydronic Heating Products P O Box 14818 3633 I Street Philadelphia PA 19134 www crownboiler com ...

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