ECR KSC 4 Series KSC-3090S, Installation, Operation & Maintenance Manual

Page 1: ...LLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company PATENT 7 823 544 MODELS KSC 3090S KSC 3090ST KSC 4125S KSC 4125ST KSC 5185S KSC 5185ST KSC 6210S KSC 6210ST Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...

Page 2: ...ect plastic cover 2 supply tapping 1 return tapping skim port and primary control NOTE For tankless heater units add tankless hot water coil and low limit control DIMENSIONS Boiler No Length of Flush Jacket Front of Jacket to Center Line of Flue Outlet Flue Outlet Diameter A B C KSC 3090 16 6 6 KSC 4125 20 8 6 KSC 5185 23 10 7 KSC 6210 27 85 16 8 Boiler model number on rating plate includes suffix...

Page 3: ...85ST 1 85 259 216 162 675 8 8 x8 x15 82 0 KSC 6210S KSC 6210ST 2 10 294 247 185 771 8 8 x8 x15 82 0 NOTES 1 Burner input is based on an oil heating value of 140 000 Btu gal 2 MBH 1000 Btu per hour Btu 15 Amps 60 Hz RATINGS DATA TANKLESS WATER HEATER CAPACITIES Boiler Model Number Input Rate G P H Tankless Heater Number Tankless Heater Capacity Intermittent Draw G P M Boiler Water Content Gallons T...

Page 4: ...n and operation WARNING Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids Do not obstruct air openings to boiler room Modification substitution or elimination of factory equipped supplied or specified components could result in personal injury or the loss of life WARNING Indicates a hazardous situation which if not avoided could result in de...

Page 5: ...echanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME No CSD 1 Locate boiler in front of final position before removing crate Provide level solid base as near chimney as possible and centrally located with respect to heat distribution system as practical Allow 24 inches in front top and right hand side for servicing and cleaning or removing tankl...

Page 6: ... of the openings to which they are connected 4 When air for combustion and room ventilation is from inside buildings the confined space shall be provided with two permanent openings one starting 12 inches from the top and one 12 inches from the bottom of the enclosed space Each opening shall have a minimum free area of 1 square inch per 1 000 BTU per hour of the total input rating of all appliance...

Page 7: ...ce Figure 5 C If horizontal ducts are used each opening shall have a minimum free area 1 square inch per 2 000 BTU per hour total input rating of all appliances in the enclosed space Figure 6 D When ducts are used they shall be of the same cross sectional area as the free area of the area of the openings to which they connect The minimum dimension of rectangular air ducts shall not be less than 3 ...

Page 8: ...t plug or place any obstruction in discharge line Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing Allow complete drainage of valve and discharge line Install safety valve with spindle in vertical position Do not install shutoff valve between boiler and safety valve Support safety valve discharge piping Be short and straight as possible Terminat...

Page 9: ...9 1 Suggested piping for steam heating system can be seen in Figure 7 Actual piping may vary based on system design and local conditions Figure 7 SUPPLY AND RETURN PIPING ...

Page 10: ...ions 3 See Figures 9 and 10 for the suggested piping for a modular steam boiler PIPING FOR BUILT IN DOMESTIC HOT WATER HEATER COLD WATER IN UNTEMPERED HOT FLOW REGULATOR TEMPERING VALVE COLD WATER DOMESTIC HOT WATER T P VALVE UNTEMPERED HOT WATER TO AUTOMATIC WASHER CONTROL WATER INSTALLED BELOW CENTER LINE OF BOILER HOT CONNECTION Figure 8 SUPPLY AND RETURN PIPING DANGER Water temperatures exceed...

Page 11: ...SE WITH CONDENSATE PUMP TO RECEIVER TANK STEAM MAIN TRAP TO SYSTEM FROM RECEIVER TANK FROM RECEIVER TANK STOP VALVE TO RECEIVER TANK STOP VALVE Figure 9 RETURN 2 TO SYSTEM STOP VALVE BLOWOFF VALVE STOP VALVE CHECK VALVE OPTIONAL STEAM MAIN WATER LINE 28 Figure 10 SUGGESTED PIPING FOR MODULAR STEAM BOILERS GRAVITY RETURN SUPPLY AND RETURN PIPING ...

Page 12: ...ry or metallic chimney liner Unlined chimney will have leaks that will cause poor chimney performance no draft and could result in positive pressure in the combustion chamber Horizontal portions of venting system should not exceed 10 feet in length Horizontal lengths over 10 ft will have a negative effect on chimney performance Extend chimney at least 2 ft above any portion of building within 10 f...

Page 13: ...ings on suction line often allow air to be drawn into fuel pump making it difficult to maintain oil pressure at nozzle Do not run overhead fuel lines from tank to oil burner Fuel Pump Connections Fuel pump connections and by pass should be made according to instructions attached to fuel pump If tank is more than 20 from boiler install two stage fuel unit in place of single stage pump supplied as s...

Page 14: ...team Wiring on next page Thermostat Installation 1 Thermostat should be installed on inside wall about four feet above floor 2 NEVER install thermostat on outside wall 3 Do not install thermostat where it will be affected by drafts hot or cold pipes sunlight lighting fixtures television fireplaces or chimneys 4 Check thermostat operation by raising and lowering thermostat as required to start and ...

Page 15: ...0VA 1K1 Relay Contacts Wire Connection TR 2 Transformer 120V 24V 50VA 1K2 Relay Contacts LWCO Low Water Cut Off LGV24 Volt Gas Valve LS Limit Switch EWF Electric Water Feeder PS Pressure Switch MS Manual Switch PG Power Generator NOTE Not all components listed are used in all control systems WIRING CODE Line Voltage By Factory Low Voltage By Factory Line Voltage By Installer Low Voltage By Install...

Page 16: ... burns instantly or death by scalding Refill boiler to its normal water line Operating Instructions Start of heating season have venting system inspected Check vent pipe from boiler to chimney for signs of deterioration by rust or sagging joints Repair if necessary Remove vent pipe at base of chimney or flue and using mirror check for obstruction and verify compliance to latest revision of the NFP...

Page 17: ...trol circuit after burner adjustments have been made for satisfactory performance 2 Check electrode setting they may have been jarred out of position during transportation 3 Lubricate burner motor if necessary 4 Set room thermostat to call for heat or jump thermostat contacts on boiler control 5 Open all oil line valves 6 Turn service switch on Burner should start 7 On one pipe fuel systems only b...

Page 18: ...closed To remove soot and scale from flueways remove top jacket panel top clean out plate open burner swing door See Figure 14 OPERATING INSTRUCTIONS Opening Burner Swing Door 1 Turn off power to boiler and allow boiler to cool down 2 Disconnect power cable at factory supplied burner electrical disconnect See Figure 14 3 Loosen screws on sides of lower front jacket panel See Figure 6 Pull bottom p...

Page 19: ...e each month of the heating season Before seasonal start up it is advisable to have a qualified service agency check boiler for soot and scale in flues change oil filter and nozzle clean burner and re adjust burner input rate to maintain proper operation and high operating efficiency On steam boilers verify boiler is filled to water line as indicated in Figure 14 Gauge valves should be normally op...

Page 20: ... be restricted or blocked Periodic inspection and tightening of the tankless heater cover plate bolts will reduce the risk of leaks See parts 3 and 5 under Coil and Cover Plate Replacement Parts Electronic Low Water Cut Off Operation of the probe and control should be checked with the burner on by draining the water via the drain on the bottom of the boiler This will drain the water quickly from t...

Page 21: ...nce X Inspect Oil Line Size Leaks X Inspect Electrical Connections X Install New Filter X Room Make up Air X Electrode Setting X Proper Light Off Hot Cold X Controls and Safety Devices X Nozzle Size Angle Type Pump Pressure Vacuum Line Voltage Motor Amps Smoke Test Draft Overfire In Flue CO2 or O2 Flue Gas Temperature Measure with instruments and record results below SERVICE CHECKLIST ...

Page 22: ...NOTES ...

Page 23: ...Date Service Performed Company Name Tech Initials Company Address Phone ...

Page 24: ...PENNCO BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...