Crown Boiler KSZ065 KSZ075 KSZ100 KSZ090 User manual

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KSZ Series
Oil-Fired Steam Boilers
INSTALLATION 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
Tel: [phone] • Fax: [phone] • www.crownboiler.com
Manufacturer of Hydronic Heating Products
P.O. Box 14818 3633 I. Street
Philadelphia, PA 19134
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
oil supplier. Read these instruc-
tions carefully before installing.

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Table of Contents
I. Product Description .............................................................. 1
II. Specifications........................................................................ 1
III. Before Installing ................................................................... 2
IV. Locating the Boiler ................................................................ 3
V. Air for Combustion & Ventilation ......................................... 3
VI. Venting .................................................................................. 9
VII. System Piping Connections ................................................ 11
I Product Description
The KSZ series boiler is a cast iron oil-fired low pressure 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 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
1
VIII. Indirect Water Heater & Tankless Coil
Piping ........................................................... 1 3
IX. Fuel Line Piping ........................................... 16
X. Wiring .......................................................... 1 9
XI. Start-up and Checkout .................................. 23
XII. Service & Maintenance ................................ 26
XIII. Parts ............................................................. 29

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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. Ratings are also based on 5 minute intermittent draws with
10 minutes between draws.
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).
•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 VI of this manual, and ANSI/NFPA31 for additional information on venting requirements.
Power (“Side Wall”) Venting - Important Note
Two problems arise when any oil-fired appliance is power vented:
1. There is sometimes an accelerated rate of soot buildup on the oil burner cad-cell, spinner etc.
2. 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 KSZ 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.
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"A" "B" "C"
KSZ065 3 0.65 78000 56000 233 84.9 16 1/2 8 5/16 6
KSZ075 3 0.75 90000 68000 283 84.5 16 1/2 8 5/16 6
KSZ100 3 1.00 119000 89000 370 83.5 16 1/2 8 5/16 6
KSZ090 4 0.90 108000 81000 338 84.9 21 1/2 10 13/16 7
KSZ125 4 1.25 149000 112000 467 84.2 21 1/2 10 13/16 7
KSZ150 4 1.50 177000 133000 554 83.1 21 1/2 10 13/16 7
KSZ120 5 1.20 144000 108000 450 84.5 26 1/2 13 5/16 8
KSZ175 5 1.75 207000 155000 646 83.1 26 1/2 13 5/16 8
KSZ200 5 2.00 235000 176000 733 82.9 26 1/2 13 5/16 8
AFUE (%)
Dimensions (inches)
Boiler Model
Number of
Sections
Burner
Input
(Gal/hr)
DOE Heating
Capacity
(Btu/hr)
I=B=R Net
Rating (Sq. ft)
I=B=R Net
Rating (Btu/hr)
MODEL RATING (gpm)
KSZ065 2.25
KSZ075 2.25
KSZ100 2.50
KSZ090 2.50
KSZ125 2.75
KSZ150 3.00
KSZ120 2.75
KSZ175 3.25
KSZ200 3.50
TABLE1b:TANKLESSHEATERRATINGS

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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 may require a different burner configuration from that at sea level.
Consult the local Crown representative for more information.
IV Locating the Boiler
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 2.
Front – 24”
Left Side – 6” (24” for Boilers Equipped with Float Type Low Water Cut-offs)
Right Side – 6” (24” for Boilers Equipped with Tankless Heaters)
Rear – 6” (24” for boilers connected to indirect water heaters)
Top – 6”
Single Wall Chimney Connector (to combustible construction) - 18”
•A 24” service clearance from the jacket is recommended from the top of the boiler. This clearance may be
reduced to that shown above; however, servicing the boiler will become increasingly difficult as this clearance is
reduced.
•A 24” service clearance is required on the left side of KSZ series boilers equipped with float type low water cut-
offs. This is to facilitate low water cut-off maintenance.
2) If listed Type L vent is used, follow vent 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
combustible 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 an area where large amounts of airborne dust will be present, such as a workshop.
V Air for Combustion and Ventilation
Sufficient 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 Section 1.5, Air for Combustion and Ventilation, in the latest edition of
Installation of Oil Burning Equipment (ANSI/NFPA 31).
To ensure an adequate supply of air for combustion, ventilation and flue gas dilution, start by determining whether the boiler
is to be installed in a building of unusually tight construction. A building of unusually tight construction is defined as having
all of the following features:
•Walls and ceilings exposed to outside atmosphere 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 are applied 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
other openings.
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FIGURE 2: CLEARANCES
0.47"
Sheet Metal (24 GA or Thicker)
Hollow Masonry Blocks
Openings Aligned To Permit Free Air Circulation
4“ MIN.
Combustible Surface
FIGURE 3: INSTALLATION OVER A COMBUSTIBLE FLOOR
4
6* 6
18**
6
24
* LH SIDE CLEARANCE 24“ FOR FLOAT TYPE LWCO EQUIPPED BOILERS
** CLEARANCE FROM SINGLE WALL CONNECTOR TO COMBUSTIBLE CONSTRUCTION
FRONT VIEW SIDE VIEW

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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 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 confined space.
Example:
A KSZ090 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 KSZ090 = 0.90 Gal/hr x 140000 BTU/Gal = 126000 BTU/hr
Total input in thousands of BTU/hr = (126000 BTU/hr + 30000 BTU/hr)/1000 = 156
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3
350/156 = 2.24. Since 2.24 is less than 50, the boiler room is a confined space.
2) Unconfined Space - Natural infiltration into the boiler room will normally provide adequate air for combustion and
ventilation without additional louvers or openings into boiler room.
3) Confined Space - Provide two openings into the boiler room, one near the floor 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 floor
(Figure 4).
• 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 finer than ¼” (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 upper opening must be within 12 inches of the ceiling. The bottom
edge of the lower opening must be within 12 inches of the floor.
3) Size openings and ducts as follows:
• Vertical ducts or openings directly outdoors (Figure 5, Figure 6, and Figure 7) - Each opening must have a free
cross sectional area of 1 square inch per 4000 BTU/hr of the total input of all fuel fired 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 8) - Each opening must have a free cross sectional area of 1
square inch per 2000 BTU/hr of the total input of all fuel fired 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 finer than ¼” (4 x 4) mesh.
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FIGURE 4: BOILER INSTALLED IN CONFINED SPACE,
ALL AIR FROM INSIDE
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FIGURE 5: ALL AIR FROM OUTDOORS,
VENTILATED CRAWL SPACE AND ATTIC

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

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FIGURE 8: ALL AIR FROM OUTDOORS, USING
HORIZONTAL DUCTS INTO BOILER ROOM
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FIGURE 9: TYPICAL VENT SYSTEM
INSTALLATION AND COMPONENTS
VI Venting
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.
1) Acceptable Chimneys - The following chimneys may be used to vent a KSZ 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 KSZ 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 2 for minimum vent connector and chimney sizing. The vent connector
size must not be smaller than the boiler flue collar diameter. Where two or more appliances vent into a common vent, the
cross-sectional area of the common vent should at least equal the area of largest vent plus 50% of the area in the additional
vents.
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 solid fuel appliance.
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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 vent pipe 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 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 used to facilitate removal of chimney connector for cleaning.
11) Install the barometric draft regulator in accordance with the regulator manufacturer’s instructions.
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, as well as the barometric draft regulator. Use at least three screws at each joint.
TABLE 2: MINIMUM RECOMMENDED BREECHING AND
CHIMNEY SIZE
Power (“Side Wall”) Venting - Important Note
Two problems arise when any oil-fired appliance is power vented:
1. There is sometimes an accelerated rate of soot buildup on the oil burner cad-cell, spinner etc.
2. 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 KSZ 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.
10
Round I.D. (in) Rectangular I.D. (in) Height (ft)
KSZ065 6 6 8 x 8 15
KSZ075 6 6 8 x 8 15
KSZ100 6 6 8 x 8 15
KSZ090 7 7 8 x 8 15
KSZ125 7 7 8 x 8 15
KSZ150 7 7 8 x 8 15
KSZ120 8 8 8 x 8 15
KSZ175 8 8 8 x 8 15
KSZ200 8 8 8 x 8 15
Boiler
Model
Min Breeching
Dia.
(
inches
)
Min. Recommended Chimne
y
Size and Hei
g
ht

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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.
Figure 10 shows recommended near boiler Piping for most common types of gravity return steam systems. Additional
information on steam system design may be found in Installation Guide for Residential Hydronic Heating Systems (Pub.
#200) published by the Hydronics Institute in Berkeley Heights, NJ.
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 11. This applies even if the existing boiler has one of the piping mistakes
shown in Figure 11 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.
VII System Piping
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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 KSZ 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 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) Install safety valve (spindle must be in vertical position) into the 3/4” tapping on top of the boiler.
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 floor. 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.
5) Connect system supply and return to boiler. See Figure 10. All KSZ boilers use one supply riser and one return tapping.
DANGER
•PIPE RELIEF VALVE TO A SAFE LOCATION
•DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE
•DO NOT MOVE RELIEF VALVE FROM FACTORY SPECIFIED
LOCATION
•DO NOT PLUG RELIEF VALVE DISCHARGE
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WRONG - TAKE-OFF BULLHEADED
INTO TWO MAINS
WRONG - HEADER BULLHEADED
INTO TAKE-OFF AND EQUALIZER
FIGURE 11: COMMON NEAR-BOILER PIPING MISTAKES

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VIII INDIRECT & TANKLESS WATER HEATER 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 heater. This section describes boiler-side piping only. Refer to the indirect water heater instruction manual
for domestic water piping. The components in this system and their functions are as follows:
1) Circulator - Mount the circulator as shown in Figure 12A. The circulator should be located as low and as close to the
boiler as practical. Do not install valves, or other devices having a significant pressure drop, between 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 water heater when the boiler is responding to a call for
heat.
4) Boiler Limit Control - Use a SPST break-on-rise temperature limit control such as the Honeywell L4006A. Do not set the
limit above 180F as doing so may cause the boiler to steam when there is no call for heat. See Figure 17 for wiring
information.
5) Valves and Unions - Install shut-off valves, drain valves, and unions in locations that will facilitate maintenance of the
system. Do not install any valves between the boiler and circulator inlet.
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FIGURE 12a: INDIRECTWATERHEATER BOILER-SIDEPIPING

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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 are based. This may result in substantially longer water heater recovery times.
2) Flow Restrictor (Recommended) - If water is drawn from the tankless coil at a rate in excess of the rating in Table 1b, the
temperature of the hot water may be too low to be of use. The use of a flow restrictor will prevent this problem by limiting
the rate at which water can pass through the tankless heater. If a restrictor is used, select one having a rating in GPM
approximately equal to the rating shown in Table 1b. If possible, locate this restrictor at least 3 feet from the tankless heater
inlet so that it is not subjected to excessive temperatures when no water is flowing through the coil.
3) Pressure Relief Valve (Required) - Limits the pressure in the tankless heater and piping. Use an ASME constructed valve
designed for domestic water service, such as the Watts #3L. Note that this is a pressure relief valve, not a T&P valve.
Select a valve with a pressure setting less than or equal to the working pressure marked on the tankless coil. Pipe the
discharge to a safe location using piping the same size as the discharge connection on the valve.
4) Hose Bib Valves (Recommended) - These valves permit the coil to be periodically “backflushed” to remove sediment.
WARNING
A mixing valve does not eliminate the risk of scalding.
•Set the mixing valve and boiler low limit adjustments as low as possible.
•Feel water before showering or bathing.
•If anti-scald or anti-chill protection is required, use devices specifically designed for such service. Install and
maintain these devices in accordance with the manufacturer’s instructions. Do not use the mixing valve as a
substitute for pressure balancing valves or other devices required by plumbing codes to protect against
scalding.
TANKLESS HEATER PIPING
KSZ Series boilers equipped with tankless heaters are supplied with a Honeywell L4006A limit control and a 3/4 NPT well.
For shipping purposes, these components are shipped unmounted. This control is mounted in the 3/4 tapping in the center
of the tankless coil.
Make the piping connections to the coil before installing the L4006A. When making the “OUT” connection, make sure
that the piping is routed so that it will not interfere with the L4006A.
Pipe the heater as shown in Figure 12b. The components in this system and their functions are as follows:
1) Mixing 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, increases the amount of usable hot water available to the
homeowner, and reduces the risk of scalding.
Install a mixing valve with a setting range of approximately 110 to 130F. Follow the manufacturer’s instructions for
installing this valve. Usually a “heat trap” will be required between the coil and the “hot” connection on the mixing valve.
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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 facilitate removal of the
heater.
FIGURE 12b: TANKLESSHEATERPIPING

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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 on the location of the fuel oil storage tank in relation to the oil burner, there are four types of oil piping systems
generally being used:
a) ONE-PIPE GRAVITY SYSTEM - used when a fuel oil storage tank is positioned above an oil burner fuel pump. See
Figure 13. 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.
b) ONE-PIPE LIFT SYSTEM (not recommended) - Used when a fuel oil storage tank is located below an oil burner fuel
pump. See Figure 14. The vertical distance from bottom of the tank to center line of the pump (Dimension ‘H’) must
not exceed that shown in the pump manufacturer’s instructions. Although all oil piping systems must be airtight, one-
pipe lift systems are particularly susceptible to nuisance lockout problems if the suction line is not completely airtight.
A two-pipe lift system is therefore recommended over a one-pipe lift system.
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FIGURE 13: ONE-PIPE GRAVITY SYSTEM
FIGURE 14: ONE-PIPE LIFT SYSTEM

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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 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 burner fuel pump suction port. See
Figure 16. The vertical distance from bottom of the tank to center line of the pump (Dimension ‘H’) must not exceed that
shown in the pump manufacturer’s instructions. Distance ‘H’ allowed is reduced by number of fittings, filters and
valves installed in the line.
FIGURE 15: TWO-PIPE GRAVITY FEED SYSTEM
FIGURE 16: TWO-PIPE LIFT SYSTEM

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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 substantially supported and protected against physical damage and corrosion where required.
3) Refer to supplied oil pump instruction manual for proper connections. On one-pipe systems, ensure that the fuel pump
return port plug is tightened securely.
4) Some fuel pumps, such as the Suntec A and B series, are supplied with a loose bypass plug which must be installed on
two-pipe systems. If such a plug is supplied, install it as shown in 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 storage
tank and second fuel shut-off valve near the oil burner fuel 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 instructions for tube sizing information.
8) All systems require an oil filter. On KSZ065 and KSZ075 boilers, the use of a Garber cartridge type filter is
recommended.
9) Use only #2 Fuel Oil with physical and chemical characteristics meeting the requirements of ASTM D-396.

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X Wiring
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 Volt Wiring - Provide the boiler with its own 15A branch circuit with fused disconnect. How the 120 volt connections
are made depends upon the type of low water cut-off supplied with the boiler.
For boilers equipped with Hydrolevel CG450 - 120 Volt connections are made inside the CG450:
•Connect Hot (“black”) to terminal #1 in CG450
•Connect Neutral (“white”) to terminal #2 in CG450
•Connect Ground (“green” or bare) to green screw on case of CG450
For boilers equipped with McDonnell & Miller #67 low water cut-offs - 120 Volt connections are made inside the
junction box mounted on the low water cut-off:
• Connect Hot (“black”) to black pigtail in junction box
•Connect Neutral (“white”) to white pigtail in junction box
•Connect Ground (“green” or bare) to green screw in junction box
2) Thermostat Wiring - Follow thermostat manufacturer instructions. To insure proper thermostat operation, avoid installa-
tion in areas of poor air circulation, hot spots (near any heat source or in direct sunlight), or cold spots (outside walls,
walls adjacent to unheated areas, locations subject to drafts). Provide Class II circuit between thermostat and boiler.
Connect thermostat wire leads to terminals “T” and “T” on the burner primary control.
3) Optional Tankless Heater Wiring - 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 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 heater. AHoneywell R845A or equivalent DPST relay and transformer is
required. The high limit described in Part VIII must also be supplied by the installer. A call for heat from the indirect water
heater thermostat will energize the relay making both sets of contacts. One set of these contacts then energizes the circulator.
The other set of contacts will make the “T” and “T” contacts on the burner primary control, firing the burner. If the boiler
water temperature exceeds the high limit setting of 180F, the high limit will open the “T” - “T” circuit and the burner will shut
down.
If there is a call for space heat, the heating thermostat will make the “T”-”T” circuit and the boiler will fire without regard to
the status of the indirect water heater. The low water cut-off and pressure limit control will interrupt 120 volt power to the
burner in the event of a low water or excessive pressure condition.
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