Crown Boiler KSZ125 manual

1 KSZ Series Oil-Fired Steam Boilers INST ALLA TION 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 CROWN Boiler Co T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacture[...]

2 T able of Contents I. Product Description .............................................................. 1 II. Specifications ........................................................................ 1 III. Before Installing ................................................................... 2 IV . Locating the Boiler .............................[...]

3 TABLE 1a: GENERAL SPECIFICATIONS 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.[...]

4 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 [...]

5 FIGURE 2: CLEARANCES 0. 47" Sh e e t M e t a l ( 2 4 G A o r T hic k e r ) H ol l ow M a s on r y B l oc k s O p e n ing s Alig n e d T o P er mi t F r e e A i r Ci r c u l a ti on 4“ MI N . C ombu s ti bl e S u r f ac e FIGURE 3: INSTALLATION OVER A COMBUSTIBLE FLOOR 4 6* 6 18 * * 6 24 * L H S IDE C L E AR ANC E 2 4 “ F O R FL O AT T Y [...]

6 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 al[...]

7 FIGURE 4: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE 6 FIGURE 5: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC[...]

8 7 FIGURE 6: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC FIGURE 7: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM[...]

9 FIGURE 8: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM 8[...]

10 FIGURE 9: TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS VI V enting 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.[...]

11 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 ve[...]

12 FIGURE 10: STEAM BOILER PIPING FOR GRAVITY RETURN CAUTION • INSTALL BOILER SO THAT ALL ELECTRICAL COMPONENTS ARE PROTECTED FROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERATION AND SERVICE. • OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. [...]

13 2) One-pipe steam systems require air vents on each radiator, as well as at the end of each main. For the system to work properly, these vents must be properly installed, sized, and be in good condition. Inspect and replace any defective vents. If there are no vents at the ends of the mains, install them. 3) Do not attempt to manifold multiple K[...]

14 VIII INDIRECT & T ANKLESS W A TER HEA TER PIPING INDIRECT WATER HEATER PIPING All KSZ series boilers are equipped with tappings to permit the connection of a Crown Mega-Stor, or other indirect water heater. In this type of system, hot boiler water is drawn from below the water line and passed through the heat exchanger in the indirect water [...]

15 IMPORTANT • Some indirect water heaters may not be suitable for use with a steam boiler. Consult the water heater manufacturer’s guidelines before installing it in this type of system. • Boiler water temperatures and flow rates in this type of system may be considerably lower than those upon which the water heater manufacturer’s ratings [...]

16 15 5) Globe or Ball Valve (Recommended) - Used to adjust the flow through the entire tankless heater 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 facilitat[...]

17 IX Fuel Line Piping Fuel line piping design, materials and constructions must be in accordance with local building codes, requirements of the local authority having jurisdiction, and the latest edition of Installation of Oil-Burning Equipment (ANSI/NFPA 31). Refer also to the instruction manuals provided with the burner and oil pump. Depending o[...]

18 17 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 limit in NFPA-31. This type of system should b[...]

19 18 Once the type of system has been selected, observe the following: 1) Fuel line piping must be airtight. Do not use compression type fittings for tubing connections in fuel line piping. Use only listed flare type fittings. Cast iron threaded fittings shall not be used for wrought iron or steel piping connections. 2) Piping shall be substantial[...]

20 X W iring WARNING All wiring and grounding must be done in accordance with the authoity having jurisdiction or, in the absence of such authority, with the National Electric Code (ANSI/NFPA70). 1) 120 V olt W iring - Provide the boiler with its own 15A branch circuit with fused disconnect. How the 120 volt connections are made depends upon the ty[...]

21 FIGURE 17: INDIRECT WATER HEATER FIELD WIRING 20 Feeder Wiring for Boilers Equipped with Hydr olevel CG450 Low W ater Cut-offs 1) Using Hydrolevel VXT-120 feeder - Do not alter factory boiler wiring. Connect VXT-120 to CG450 as follows: • Connect the BLACK lead on the feeder to terminal A on the CG450. • Connect the WHITE lead on the feeder [...]

22 FIGURE 18a: WIRING MCDONNELL & MILLER 101A-120 OR HYDROLEVEL VXT -120 FEEDER T O BOILER EQUIPPED WITH #67 L.W .C.O. FIGURE 18b: WIRING MCDONNELL & MILLER WF2-U-120 FEEDER 21[...]

23 FIGURE 19: WIRING (MCDONNELL & MILLER #67 LWCO) FIGURE 20: WIRING (HYDROLEVEL CG450 LWCO) 22 L1 I N TE R R U P TE D INT E R M IT TE N T BURNER M O T O R LI M I T VA L VE L2 NO T E : B U R N E R W IR IN G S H OW N I S F OR B E CK E T T AF G B UR NE R S . C O N SU LT BURNER IN ST RUC T I O N M A NU AL F O R O T HE R B U R NE R S CA D CE L L 24[...]

24 XI Start-up and Checkout WARNING • NEVER ATTEMPT TO FILL A HOT EMPTY BOILER. • MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE, AND OTHER FLAMMABLE VAPORS AND LIQUIDS. • SAFE RELIABLE OPERATION OF THIS BOILER REQUIRES THAT THE BURNER BE CHECKED AND ADJUSTED BY A QUALIFIED OIL SERVICEMAN USIN[...]

25 24) Verify primary control operation and safety features according to procedure outlined in the instructions furnished with control. 25) Check pressure limit control operation. Jump thermostat terminals and allow burner to run until boiler pressure exceeds cut-in pressure plus the differential. The burner should shut down. 26) Check low water cu[...]

26 TABLE 3b: CARLIN BURNER CONFIGURATION AND SETUP DATA TABLE 3a: BECKETT BURNER CONFIGURATION AND SETUP DATA 25 KSZ065 KSZ075 KSZ100 KSZ090 KS Z125 KSZ150 KSZ120 KSZ175 K SZ200 BUR N ER M O DEL EZ-1HP EZ-1HP EZ-1HP EZ-1HP EZ-1HP EZ-1HP EZ-1HP EZ-2HP STANDARD DEL. HAGO HA GO DEL. DEL . HAGO HAGO DEL . NOZZLE 0.55/7 0B 0.60/6 0ES 0.8 5/60 B 0.75/60A[...]

27 26 TABLE 3c: RIELLO BURNER CONFIGURATION AND SETUP DATA XII Service and Maintenance The following procedure should be performed on a weekly basis: For boilers equipped with a #67 low water cut-off, blow down the low water cut-off following the instructions on the yellow sticker adjacent to the low water cut-off. During this blow down, the low wa[...]

28 27 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 wing nuts and remove canopy retaining carriage bolts, lift off the canopy and ceramic fiber sealing strips. e) Unplug the burner, disconnec[...]

29 IMPORTANT • 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. 3) Inspect the vent system: [...]

30 29 Important Product Safety Information Refractory Ceramic Fiber Product Warning : The Parts list designates parts that contain refractory ceramic fibers (RCF). RFC has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RFC changes into crystalline silica, a known carc[...]

31 30 Installation Notes And Service Log[...]

32 31 65 75 100 90 125 150 120 175 200 1 COMPLETE HEAT EXCHANGER ASSY. 1 ea. 2800135 2800135 2800135 2800145 2800145 2800145 2800155 2800155 2800155 * FRONT SECTION 275051 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. * REAR SECTION 275062 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. * INTERMEDIATE SECTION 275055 1 ea. 1 ea. 1 ea. [...]

33 32[...]

34 33 6 5 7 5 100 9 0 125 15 0 12 0 17 5 20 0 40 LEFT SIDE JACK E T P AN E L 1 ea. 270233 270233 270233 270234 270234 270234 270235 270235 270235 41 RIGHT SIDE JAC K ET P A NE L 1 ea. 2702235 2702235 2702235 2702245 27 02245 2702245 2702255 2702255 2702255 * REA R JAC KE T PANE L 270220 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. 43 TOP J[...]

35 34[...]

36 T el: (215) 535-8900 • Fax: (215) 535-9736 • www .crownboiler .com Manufacturer of Hydronic Heating Products P .O. Box 14818 3633 I. Street Philadelphia, P A 19134 CROWN Boiler Co Rev 9- 20-10[...]