Crown Boiler FSZ080 User manual

FSZ Series
Oil-Fired Steam Boilers
INSTALLATION INSTRUCTIONS
These instructions must be afxed on or adjacent to the boiler
Models:
• FSZ080
• FSZ100
• FSZ130
• FSZ160
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause property
damage, injury, or loss of life.
For assistance or additional
information, consult a qualied
installer, service agency or the oil
supplier. Read these instructions
carefully before installing.
DESIGNED TO LEAD
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
www.crownboiler.com

1
FOLLOW ALL INSTRUCTIONS and warnings
printed in this manual and posted on the boiler.
INSPECT THE BOILER, BURNER AND
CONTROLS ANNUALLY. To keep your boiler safe
and efficient, have a service technician follow the
Service checklist near the end of this manual.
IF YOU ARE NOT QUALIFIED to install or service
boilers, do not install or service this one.
THE BOILER MAY LEAK WATER at the end of
its useful life. Be sure to protect walls, carpets,
and valuables from water that could leak from the
boiler.
PROTECT YOUR HOME IN FREEZING
WEATHER. A power outage, safety lockout, or
component failure will prevent your boiler from
lighting. In winter, your pipes may freeze and
cause extensive property damage. Do not leave
the heating system unattended 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 carbon monoxide or start a fire.
KEEP FLAMMABLE LIQUIDS AWAY from the
boiler, including paint, solvents, and gasoline.
The boiler may ignite the vapors from the liquids
causing explosion or fire.
KEEP CHILDREN AND PETS away from hot
surfaces of the boiler, boiler piping, and vent pipe.
CARBON MONOXIDE (CO) is an odorless, deadly
gas that may be introduced into your home by
any malfunctioning fuel-burning product or vent
system failure. Consider installing CO alarms near
bedrooms in all levels of the building to warn you
and your family of potential CO exposure.
READ THIS ENTIRE MANUAL before attempting
installation, start-up, or 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 and pressure gage when
making this judgment.
USE PROPER PERSONAL PROTECTION
EQUIPMENT when servicing or working near the
boiler. Materials of construction, flue products, and
fuel contain alumina, silica, heavy metals, carbon
monoxide, nitrogen oxides, and/or other toxic or
harmful substances that can are hazardous to
health and life and that are known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
INSTALL ALL GUARDS, cover plates, and
enclosures before operating the boiler.
SIZE THE BOILER PROPERLY relative to the
design heat load or, if using domestic hot water
priority, the peak hot water load, whichever
is larger. A grossly oversized boiler will cycle
excessively and this will lead to premature failure
of the boiler and its components. Our warranty
does not apply to damage from excessive cycling.
ADHERE TO ALL LOCAL CODE
REQUIREMENTS. Contact your local code
inspector prior to installation. In the absence of
a local code, adhere to the latest editions of the
Installation of Oil Burning Equipment ANSI/NFPA
31 in the USA or CAN/CSA B139, Installation Code
for Oil Burning Equipment in Canada.
ALL WIRING must comply with the National
Electrical Code ANSI/NFPA 70 (in the USA) or the
Canadian Electrical Code CSA C22.1 (in Canada)
and any local regulations.
WARNINGS FOR THE HOMEOWNER
WARNINGS FOR THE INSTALLER

2
Table of Contents
I. Product Description ............................................................................... 3
II. Specications ......................................................................................... 3
III. Before Installing .................................................................................... 5
IV. Field Assembly ...................................................................................... 6
V. Locating 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. Service & Maintenance .......................................................................... 34
XIV. Troubleshooting ..................................................................................... 38
XV. Parts ....................................................................................................... 40
Appendix A. Installation of Optional Gravity Return Piping Kit .................... 46

3
I Product Description
The FSZ series boiler is a cast iron oil-red 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 ue gases must be available in the boiler room. This boiler has connections for use with an indirect
domestic water heater.
The FSZ series boilers are not designed for use in process or other “open” steam systems.
TABLE 2.1: GENERAL SPECIFICATIONS
BOILER
MODEL
DIMENSIONS WATER CONTENT (TO NORMAL
WATER LINE) (GALLONS) HEAT TRANSFER
SURFACE AREA
(SQ FT)
SHIPPING
WEIGHT
(LBS)
‘A’ ‘B’ ‘C’ WITH TANKLESS
HEATER NON-HEATER
FSZ080 22-1/4” 24” 6” 15.3 14.9 20.29 607
FSZ100 22-1/4” 24” 6” 15.3 14.9 20.29 607
FSZ130 28-1/4” 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 CHIMNEY
REQUIREMENTS AFUE
%
GPH MBH STEAM
MBH
STEAM
SQ. FT.
ROUND
IN. DIA.
RECTANGLE
IN. X IN.
HEIGHT
FT.
FSZ080 0.80 112 97 73 303 6 8 X 8 15 85.7
FSZ100 1.00 140 122 92 381 6 8 X 8 15 86.0
FSZ130 1.30 182 158 119 494 7 8 X 8 15 86.0
FSZ160 1.60 224 195 146 610 7 8 X 8 15 85.9
Burner Capacity Rating, GPH is based on #2 fuel oil with a Gross Heating Value equal to 140,000 BTU/Gal.
AHRI Net Ratings are based on piping and pick-up allowances of 1.333.
TABLE 2.3: TANKLESS HEATER RATINGS
BOILER MODEL HEATER RATING (GPM) PRESSURE DROP THRU HEATER (PSI)
FSZ080 3.00 22.0
FSZ100 3.25 24.3
FSZ130 3.50 26.5
FSZ160 4.00 31.0
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.
II Specications

4
'B' MIN.
FRONT SERVICE
CLEARANCE
(FLUEWAY CLEANING)
* 12" MIN
REAR
SERVICE
CLEARANCE
'C' DIA
COLLAR
31 1/8"
21 3/8"
19"
BURNER SWING
DOOR CLEARANCE
(FULLY OPEN)
FLOOR
LINE
SPANNER BAR
TEMPERATURE
CONTROL
FOR HEATER
'A'
TRANSFORMER
/RELAY
OUT
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 VIEWFRONT VIEW
ARRANGEMENT. * NOTE: THIS DIMENSION INCREASES AND IS CONTROLLED BY SMOKEPIPE
REAR VIEW
PRESSURE LIMIT
WATER CUT-OFF
PORT
BECKETT AFG
OBSERVATION
BURNER
GAUGE
N.W.L.
PROBE LOW
GLASS
STEAM
PRESSURE GAUGE
FLAME
WATER
BURNER
SWING
DOOR
38 1/2"
22 1/2"
FIGURE 2.3: GENERAL CONFIGURATION

5
Power (“Side Wall”) Venting - Important Note
Two problems arise when any oil-fired appliance is power vented:
• There is sometimes an accelerated rate of soot buildup on the oil burner cad-cell, spinner etc.
• 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 FSZ 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.
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). Installations in Canada comply with the requirements
of CSA B139-04 – Installation Code for Oil-burning Equipment.
• 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 VII of this manual, and ANSI/NFPA31 for additional information on venting requirements.
3) Make sure that the boiler is correctly sized. Do this by totalling the surface area of all radiators in the system (in sq. feet). To
this, add any other space heating (not DHW) loads. Select a boiler having a net rating just larger than this total heating load.
Note: 1 sq. ft of radiation is equal to 240 BTU/hr.
4) In some cases, boilers installed at altitudes above 2000ft may require a different burner conguration from that at sea level.
Consult the local Crown representative for more information.

6
IV Field Assembly
This boiler is shipped in two pieces:
a) The crated boiler itself
b) The burner carton consisting of the following items:
• Oil Burner assembly
• Barometric Draft Regulator (if supplied)
• Safety valve
• Drain valve
• Pipe ttings
WARNING
Installation of burners on the FSZ other than those provided by Crown, and marked for use with this
boiler, may result in unreliable operation, property damage, personal injury, or loss of life.
It is recommended that the boiler be moved to its nal location before the items in the burner carton are installed. To complete
eld assembly:
1) Make sure that the burner carton supplied 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 and washers from the front door. Make sure that the burner gasket is in place and undam-
aged and mount the burner to the door as shown in Figure 4.0.
3) Plug the burner cord into the receptacle on the lower right front corner of the boiler.
4) The FSZ100 uses a pair of second pass bafes which are included in the burner carton and which must be installed in the
eld. Install these as shown in Figure 4.0. All bafes are factory installed on other models.
5) Install the barometric draft regulator, and other piping/trim, as described in the Venting and Piping sections of this manual.
FIGURE 4.0: BOILER FIELD ASSEMBLY

7
V Locating the Boiler
FIGURE 5.0: CLEARANCES
WARNING
Failure to observe the following location requirements could result in property damage, a fire,
explosion or carbon monoxide (CO) hazard.
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 5.0.
Front - 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 is recommended above the top of the boiler, as well as on the side to which the burner swing
door opens (the left side as the boiler is shipped). See also dimension ‘B’ in Table 2.0 for recommended service clear-
ances to the front of the boiler. These clearances may be reduced to those shown above; however, servicing the boiler
will become increasingly difcult as these clearances are reduced.

8
VI Air for Combustion and Ventilation
Sufcient 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 the Standard for the Installation of Oil Burning Equipment (ANSI/NFPA
31).
To ensure an adequate supply of air for combustion, ventilation and ue gas dilution, start by determining whether adequate
combustion and ventilation air can be obtained through natural inltration (air leaking into the building through cracks around
windows, doors, etc). Examples of construction features which could prevent adequate natural inltration include:
• Walls and ceilings exposed to outside atmosphere having a continuous water vapor retarder with a rating of 1 perm or
less with openings gasketed and sealed
• Weather stripping 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 oors,
between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and at other
openings.
• Large exhaust fans
In this manual, buildings where natural inltration will not provide adequate air for combustion, and ventilation are referred to
as “buildings of unusually tight constuction”. If in doubt, assume that the building in which the boiler is installed is of unusually
tight construction.
1) Do not install this boiler directly on a combustible oor. Where it is desired to install an FSZ on a non-carpeted combustible
oor, install the boiler on a base constructed as shown in Figure 5.1
2) If listed Type L vent is used, follow vent pipe manufacturer recommendations for minimum clearances.
3) Do not install this boiler in a location where gasoline or other ammable 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.
FIGURE 5.1: INSTALLATION OVER A COMBUSTIBLE FLOOR

9
A. For Buildings of Other than Unusually Tight Construction
1) Determine whether the boiler is to be installed in a conned space - A conned space is dened 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
conned 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 conned space.
Example:
An FSZ080 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 FSZ080 = 0.80 Gal/hr x 140000 BTU/Gal = 112000BTU/hr
Total input in thousands of BTU/hr = (112000 BTU/hr + 30000 BTU/hr)/1000 = 142
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3
350/142 = 2.46. Since 2.46 is less than 50, the boiler room is a conned space.
2) Unconned Space - Natural inltration into the boiler room will normally provide adequate air for combustion and ventila-
tion without additional louvers or openings into boiler room.
3) Conned Space - Provide two openings into the boiler room, one near the oor 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 oor
(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 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 ner than ¼” (4 x 4) mesh.
B. 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 oor.
3) Size openings and ducts as follows:
• Vertical ducts or openings directly outdoors (Figure 6.1, Figure 6.2, and Figure 6.3) - Each opening must have a free
cross sectional area of 1 square inch per 4000 BTU/hr of the total input of all fuel red 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 6.4) - Each opening must have a free cross sectional area of 1 square
inch per 2000 BTU/hr of the total input of all fuel red 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 ner than ¼” (4 x 4) mesh.

10
FIGURE 6.0: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE
FIGURE 6.1: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC

11
FIGURE 6.2: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC
FIGURE 6.3: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM

12
FIGURE 6.4: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM

13
VII Venting
The vent installation must be in accordance with local building codes, or the local authority having jurisdiction. Contact your
local re and building ofcials on specic requirements for restrictions and the installation of fuel oil burning equipment. In
the absence of other applicable codes, the vent system installation must meet the requirements of NFPA 31 – Standard for the
Installation of Oil-Burning Equipment and NFPA 211 - Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning
Appliances. Vent systems in Canada must comply with CSA B139-04 – Installation Code for Oil-burning Equipment.
A typical vent system is illustrated in Figure 7.0. The components of the vent installation are the vent connector (breeching),
barometric draft regulator, and chimney.
1) Acceptable Chimneys - The following chimneys may be used to vent a FSZ 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. Do not vent a FSZ series boiler into an unlined chimney.
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.
3) Chimney and Vent Connector Sizing - See Table 7.1 for minimum vent connector and chimney sizing. The vent connector
size must not be smaller than boiler ue collar diameter.
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 ue serving an open replace or other solid fuel appliance.
6) Prior to boiler installation, an existing chimney must be inspected by a qualied person in accordance with the requirements
of Chapter 11 of NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances. This inspection is
intended to identify safety problems with the chimney such as obstructions, a missing or damaged liner, or leak points. Clean
chimney as necessary and correct any other chimney defects before installing the boiler.
7) Vent connector must slope upward from boiler not less than one inch in four feet. No portion of vent pipe should run
downward or have sags. Vent connector must be securely supported.
8) The vertical section of vent connector 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 connector must be installed above the bottom of the chimney to minimize risk of blockage.
WARNING
• Improper venting may result in property damage and/or the release of flue gases, which
contain deadly carbon monoxide (CO), into the home, which can cause severe personal
injury or death.
• Inspect existing chimney before installing boiler. Failure to clean or replace damaged pipe
or tile lining will cause property damage, severe personal injury or death.
• Do not de-rate the appliance. Failure to fire the unit at it’s designed input may cause
excessive condensation upon the interior walls of the chimney. In addition, the lower input
may not create enough draft to adequately evacuate the products of combustion.

14
10) Vent connector must be inserted ush with inside face of the chimney liner and the space between vent connector and
chimney sealed tight. A thimble permanently cemented in place can be used to facilitate removal of vent connector for
cleaning.
11) Install the barometric draft regulator supplied with this boiler in accordance with the regulator manufacturer’s instructions.
No other draft 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 well as the barometric draft regulator. Use at least three screws at each joint.
FIGURE 7.0: TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS
TABLE 7.1: MINIMUM RECOMMENDED BREECHING AND CHIMNEY SIZE
BOILER
MODEL
MINIMUM
BREECHING
DIA. (INCHES)
MINIMUM CHIMNEY REQUIREMENTS
ROUND I.D.
(IN.)
SQUARE. TILE
SIZE (NOMINAL) HEIGHT (FT.)
FSZ080 6 6 8 X 8 15
FSZ100 6 6 8 X 8 15
FSZ130 6 7 8 X 8 15
FSZ160 7 7 8 X 8 15

15
VIII 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 severe heat exchanger corrosion damage.
• Do not use toxic additives, such as automotive antifreeze, in a hydronic system.
• Pipe safety valve discharge to a safe location. The safety valve may discharge steam or
scalding hot water.
• Do not install a valve in the safety valve discharge line.
• Do not move safety valve from factory location.
• Do not plug safety valve discharge. Blocking the safety valve may result in boiler
explosion.
Figure 8.1 shows recommended near boiler piping for most common types of gravity return steam systems. Additional
information on steam system design may be found in the I=B=R Guide RHH published by the Air-Conditioning, Heating and
Refrigeration Institute (AHRI).
One of the primary purposes of this near boiler piping is to separate tiny water droplets from the steam exiting the boiler
so that “dry” steam is sent to the system. If the near boiler piping is not correct, wet steam will enter the system and the
following problems may occur:
• Short cycling on low water
• Boiler or system Flooding
• Hammering
• 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 be working. If two or more steam mains must be connected to the boiler, connect
a separate take-off for each main into the header between the riser(s) and equalizer. Also note the following points:
1) A size reduction must be made to connect the header to the equalizer. This reduction must be made in the vertical
equalizer line. Do not make this size reduction in the horizontal header.
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 FSZ boilers with gravity returns.
4) For installations with condensate or boiler feed pumps, follow the pump manufacturer’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 ll 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.
7) The “drop header” arrangement shown as “Alternate Piping Method” in Fig 8.1 is useful when there is limited vertical
clearance above the boiler.

16
FIGURE 8.1: STEAM BOILER PIPING FOR GRAVITY RETURN

17
FIGURE 8.2: NEAR BOILER PIPING MISTAKES
Piping Installation
1) Remove parts bag from boiler crate.
2) Install safety valve as shown in Figure 8.1 into the 3/4” tapping “F” on rear of the boiler (spindle must be in vertical
position).
3) Pipe the discharge of the safety relief valve to a location where water or steam will 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 terminate at least 6 inches above the oor. The termination of the safety valve discharge piping
must be in an area where it is not likely to become plugged by debris or subjected to freezing.
4) Install drain valve provided into the return piping. See Figure 8.1.
5) Connect system supply and return to boiler. See Figure 8.1.

18
FIGURE 8.3: PURPOSE OF TAPPINGS AND BOSSES
TABLE 8.4 PURPOSE OF TAPPINGS
Tapping Location Size (NPT) Steam Boiler
Less Heater With Heater
A 1/4” Pressure Gauge
B1/4” Pressure Limit
C 3/4” Probe LWCO
D 1/2” Water Gauge Glass
E 2” Supply (Front & Rear Tappings)
F3/4” Safety Valve
G 1-1/2” Condensate Return (Reduced to 1-1/4”
on FSZ080,100 & 130)
H 1-1/4” Optional Front Return (Plugged)
J1-1/2” Surface Blowoff (Plugged)
K 1” Indirect Water Heater Supply (Plugged)
L1/2” Indirect Water Heater Limit (Plugged)
R 1/2” L4006 Operating
Control Plugged