ECR PENNCO KSC STEAM, Installation, Operation And Maintenance Manual

Page 1: ...240007515 Rev B 08 08 MODEL NUMBERS KSC3100 KSC4100 KSC4125 KSC4150 KSC5175 KSC5200 KSC6225 KSC7275 Installation operation and maintenance MANUAL PENNCO BOILERS 85 Middle Road Dunkirk NY 14048 www dunkirk com An ISO 9001 2000 Certified Company ...

Page 2: ... Com monwealth of Massachusetts the installation must be performed by a Licensed Plumber or Licensed Gas Fitter IMPORTANT Read the following instruc tions COMPLETELY before installing TABLE OF CONTENTS Tested For 15 LBS ASME Working Pressure The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels INSTALLATION MANUAL AND OPERATI...

Page 3: ...o brand all others are Delevan 6 The electrical service is 120 Volts 15 Amps 60 Hz 7 The MEA number for this boiler series is 182 86E 8 The MEA number for the AFG Beckett Burner used in this boiler series are AF 156 77 E AFG 213 83 E AFII 85 24 92 E AFII 150 456 90 E Ratings Data And Dimensions STANDARD EQUIPMENT Crated boiler flush jacket oil burner target wall liner ASME relief valve steam water...

Page 4: ...iction the in stallation must conform to the American Society of Mechan ical 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 a level solid base as near chimney as possible and centrally located with respect to the heat distribution system as practical Boiler may not be in...

Page 5: ...he same cross sectional area of the openings to which they are connected When air for combustion and room ventilation is from 4 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 i...

Page 6: ...e assumed that wood louvers will have 20 25 free area and metal louvers and grills will have 60 75 free area Louvers and grills shall be fixed in the open position or interlocked with the boiler so that they are opened automatically during boiler operation shall be provided with two permanent openings one commencing within 12 inches from the top and one commencing 12 inches from the bottom of the ...

Page 7: ...ETURN PIPING IS LARGER INCORPORATE SIZE TO EQUAL THE RETURN PIPE SIZE FROM BOTTOM OF BOILER heater See 4 Figures 9 and 10 for the suggested piping for a modular steam boiler SUGGESTED PIPING FOR MODULAR STEAM BOILERS PUMPED RETURN CHECK VALVE BLOWOFF VALVE SOLENOID VALVE OPTIONAL F T TRAP HIGH LEVEL SPILL DO NOT USE WITH CONDENSATE PUMP TO RECEIVER TANK STEAM MAIN TRAP PUMPED RETURN TO SYSTEM FROM...

Page 8: ...e drawn into the fuel pump mak ing it difficult to maintain oil pressure at the nozzle Do not run overhead fuel lines from tank to oil burner Fuel pump connections and by pass should be made ac cording to instructions attached to the fuel pump If tank is Boiler is to be vented by natural draft and shall not be connected into any portion of a me chanical draft operating system under a posi tive pre...

Page 9: ...trical Code ANSI NFPA No 70 and or lo cal authority having jurisdiction When an external electrical source is utilized the 1 boiler when installed MUST BE electrically grounded in accordance with these requirements oil tank and piping Install a fused disconnect switch between boiler and 2 meter at a convenient location When the boiler is equipped with self energized 3 controls no outside source of...

Page 10: ...20V 24V 40VA 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 STEAM WIRING W BECKETT BURNER NOTE Not all components listed are used in all control systems WIRING CODE Line Voltage By Factory Low Voltage By Factory Line Volt...

Page 11: ...11 STEAM WIRING W RIELLO BURNER WIRING CODE Line Voltage By Factory Low Voltage By Factory Line Voltage By Installer Low Voltage By Installer ...

Page 12: ...12 STEAM WIRING W CARLIN BURNER WIRING CODE Line Voltage By Factory Low Voltage By Factory Line Voltage By Installer Low Voltage By Installer ...

Page 13: ...ance to the latest revision of the NFPA 211 The lever of the pressure relief valve Figure 14 on the boiler should be operated periodically to make sure that it is functioning properly MOUNTING BOTH SIDES LOWER FRONT JACKET PANEL PRESSURE RELIEF VALVE TOP JACKET PANEL 1 4 SLOT BURNER ELECTRICAL DISCONNECT 28 WATER ELECTRONIC LOW WATER CUT OFF INSPECTION COVER LINE SCREWS HOT The pressure relief val...

Page 14: ...ve been made for satisfactory performance RIELLO SETTINGS Boiler No Burner No Air Damper Pump Press Turb Nozzle Fur nished 3100 F 5 3 6 150 PSI 1 85 80W 4125 F 5 4 150 PSI 3 1 10 60W 4150 F 5 6 150 PSI 4 1 25 60W 5200 F 10 5 150 PSI 0 1 75 80B CARLIN SETTINGS Boiler No Burner No Air Damper Pump Press Head Bar Nozzle Fur nished 3100 EZ 1 0 85 150 PSI 85 1 00 85 70B 4125 EZ 1 1 00 1 10 150 PSI 1 10 ...

Page 15: ...al The lever of the pressure relief valve on the boiler Figure 14 should be operated periodically to make sure that it is functioning properly Refill boiler to its normal water line C Primary Control and Flame Sensor To Check Flame Failure 1 simulate by shutting off oil supply with hand valve while burner is on Sixty seconds after flame out the safety switch locks out ignition stops motor stops an...

Page 16: ...stion and ventilation air to the boiler and boiler room must not be restricted or blocked Discharge will be boiling hot water and steam WARNING The safety valve should open before the steam pressure exceeds the 15 lb reading on the gauge Figure 14 If this pressure is exceeded and the safety valve does not open it must be replaced If the safety valve leaks steam when the boiler is operating at norm...

Page 17: ...ed that a qualified service agency be employed to make an annual inspection of the boiler and heating Service Checklist Inspect Chimney and Flue Pipe X Inspect and Clean Appliance 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 Service Record Date Nozzle Pump Pressure PSI Line Voltage Motor Amp...

Page 18: ...4 00 GAUGE WATER LEVEL 1 4 240007394 BRASS SIPHON OFF CENTER LOOP 62208 1 5 14693057 TEE BRASS 1 4 1 6 240007412 PIPE BRASS 1 4 x3 1 7 240007411 ELB BRASS 1 4 90 STREET 2 8 GA 003 00 GAUGE PRESSURE STEAM 1 9 240007160 ELWCO CG450 P 2060 CYCLE GUARD 1 10 SS 001 01 PRESSURE SWITCH PA404A 1009 1 11 1263012 HARN J BOX 22 BECKETT RIELLO 1 240007185 HARN J BOX STEAM CARLIN 12 240007187 HARN BRNR STEAM B...

Page 19: ...6701 Stud 5 16 18 x 2 4 5 2252501 Support Jacket Brkt 2 6 HW07001 Stud 5 16 x 18 x 1 3 7 HW06901 Nut 5 16 18 Wislock 8 8 HW 016 02 Drain 1 9 PF 004 04 Pipe Fit Bushing 1 x 1 10 2452906 Flue Collector 3 Sec 1 2452902 Flue Collector 4 Sec 2452903 Flue Collector 5 Sec 2452907 Flue Collector 6 Sec 2452908 Flue Collector 7 Sec 11 109007327 Baffle Assy H E Rear 1 ...

Page 20: ...03 Tie Rod x 20 6 Sec HW 025 09 Tie Rod x 23 7 Sec ITEM PART NO DESCRIPTION QTY 8 100 1 5 01 22 Push Nipple 3 Sec 2 22 Push Nipple 4 Sec 3 22 Push Nipple 5 Sec 4 22 Push Nipple 6 Sec 5 22 Push Nipple 7 Sec 6 9 MS 006 00 Rope Med Density 3 Sec 13 0 Rope Med Density 4 Sec 19 5 Rope Med Density 5 Sec 26 0 Rope Med Density 6 Sec 32 5 Rope Med Density 7 Sec 39 0 10 HW 008 03 Washer ID Flat 3 11 HW 003 ...

Page 21: ...21803 21521808 21521803 Left Side Panel 4 Sec 21521804 21521804 21521809 21521804 Left Side Panel 5 Sec 21521805 21521805 21521810 21521805 Left Side Panel 6 Sec 21521806 21521806 21521811 21521806 Left Side Panel 7 Sec 21521807 21521807 21521812 21521807 Not Shown Jacket Replacement Kit 3 Sec 3001487AH 3001487C 3001487AC 3001487AD Jacket Replacement Kit 4 Sec 3001488AH 3001488C 3001488AC 3001488A...

Page 22: ...1 NOZ 2 00 45B 240007291 BRNR BECK CF375 UT2602 NOZ 2 25 60B 1050006 BRNR F5 40 SERIES RIELLO 2 PCS BN07007 BRNR F10 40 SER RIELLO 3949071 NEW BRNR OIL EZ1 3100SE STE CARLIN NEW BRNR OIL EZ1 4100SE STE CARLIN NEW BRNR OIL EZ1 4125SE STE CARLIN NEW BRNR OIL EZ1 4150SE STE CARLIN NEW BRNR OIL EZ1 5200SE STE CARLIN 2 BN08001 BURNER OIL FLANGE GASKET 3616 1 3 CD 001 01 CAD CELL FOR BOILERS W BECKETT B...

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Page 24: ...formed Company Name Tech Initials Company Address Phone For technical assistance with this product call toll free 1 800 325 5479 ECR International PO Box 4729 Utica NY 13504 4729 www ecrinternational com Service RECORD ...