Pennco 3KW0.60 User Manual
Model No.
3KW0.60
3KW0.75
3KW1.00
KEYSTONE SERIES II
OIL-FIRED
CAST IRON HOT WATER BOILER
INSTALL ATION, OPER ATION
4KW.90
4KW1.25
4KW1.50
5KW1.20
5KW1.75
5KW2.00
& MAINTENANCE MANUAL
An ISO 9001-2008 Certified Company
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
P/N# 240009460, Rev. B [08/2014]
TABLE OF CONTENTS
Introduction ................................................................................................................................ 3
Boiler Ratings And Capacities ........................................................................................................ 4
Safe Installation And Operation ..................................................................................................... 5
Before You Start .......................................................................................................................... 6
Installation Requirements ............................................................................................................. 7
Fresh Air For Combustion.............................................................................................................. 8
System Piping ........................................................................................................................... 10
Antifreeze In The System .......................................................................................................... 15
Chimney And Chimney Connections ............................................................................................. 15
Electrical Connections ................................................................................................................ 17
Equipment And Accessories ........................................................................................................ 18
Filling The Boiler ...................................................................................................................... 20
Operating The Boiler ................................................................................................................. 21
Checking And Adjusting Controls ................................................................................................. 22
Maintenance ............................................................................................................................. 24
Oil Boiler / Burner Cleaning Instructions ...................................................................................... 25
Oil Burner Maintenance And Cleaning ........................................................................................... 26
Service Hints ............................................................................................................................ 27
Electrical Wiring ........................................................................................................................ 28
Sequence Of Operation............................................................................................................... 30
Beckett Oil Burner, Nozzle, And Air Setting .................................................................................... 31
These instructions
must be afxed on or
adjacent to the boiler.
OIL FIRED BOILERS
These boilers are low pressure, sectional cast iron boilers constructed
and hydrostatically tested for a maximum working pressure of 50 psi in
accordance with A.S.M.E. (American Society of Mechanical Engineers)
Section IV Standards for cast iron heating boilers.
WARNING
!
Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.
Save this manual
for reference.
2
INTRODUCTION
Boiler is a natural draft oil red hot water boiler comprised
of cast iron sections. Boiler is available with 3, 4, or 5 cast
iron sections. Sections are held together by cast iron push
nipples.
Figure 1 - Dimensions
Boiler is capable of ring #2 fuel oil from 0.60 gph
up to 2.00 gph. All packaged boilers include, limit,
temperature and pressure gauge, safety relief valve,
drain valve, ue brush, and an extra boiler tapping for
expansion tank or air elimination.
BOILER RATINGS AND CAPACITIES
OIL-FIRED HOT WATER BOILERS
RATINGS & CAPACITIES
BOILER
MODEL
3KW0.60 • 3 0.60 84 74 64 8”x8”x15’ 86.1* 17 3/4 6 9 3/4
3KW0.75 3 0.75 105 92 80 8”x8”x15’ 85.6* 17 3/4 6 9 3/4
3KW1.00 • 3 1.00 140 120 104 8”x8”x15’ 84.4 17 3/4 6 9 3/4
4KW.90 • 4 0.90 126 111 97 8”x8”x15’ 86.0* 21 6 11 3/8
4KW1.25 • 4 1.25 175 153 133 8”x8”x15’ 85.9* 21 6 11 3/8
4KW1.50 4 1.50 210 181 157 8”x8”x15’ 85.1* 21 6 11 3/8
5KW1.20 • 5 1.20 168 147 128 8”x8”x15’ 86.1* 24 1/4 6 13
5KW1.75 5 1.75 245 210 183 8”x8”x15’ 85.0* 24 1/4 6 13
5KW2.00 • 5 2.00 280 239 208 8”x8”x20’ 84.0 24 1/4 6 13
• These ring rates available only with alternate ring rate kits.
** MBH = 1,000 Btu Per Hour BTU = British Thermal Unit
*** Heating capacity based on 13% CO2 with 0.02” W.C. draft over re, and #1 smoke or less. Testing was done
in accordance with D.O.E. (Department Of Energy) test procedure.
† GPH = Gallons Per Hour Of Oil At 140,000 Btu Per Gallon
†† A.F.U.E. = Annual fuel utilization efciency based upon D.O.E. Test procedure.
* As Energy Star Partner, manufacturer has determined this product meets Energy Star guidelines for energy
efciency.
Net AHRI Water Ratings based on piping allowance of 1.15. Consult manufacturer before selecting a boiler for
installations having unusual piping and pickup requirements, such as intermittent system operation, extensive
piping systems, etc.
No.
of
Sections
Firing
Rate
†GPH
Input
**MBH
***
Heating
Capacity
**MBH
AHRI
Rating
**MBH
3
Net
Minimum
Chimney
Size/Height
A.F.U.E.
††
Dimensions (Inches)
A B C
BOILER RATINGS AND CAPACITIES
These low pressure oil red hot water boilers are
constructed and hydrostatically tested for maximum
working pressure of 50 psig (pounds per square inch)
in accordance with the latest revision of the A.S.M.E.
(American Society of Mechanical Engineers) Boiler and
Pressure Vessel Code Section IV Standards for heating
boilers.
Heating Capacity indicates amount of heat available after
subtracting losses up the stack. Most of this remaining
heat is available to heat water. A small portion is heat from
the jacket and boiler surface and it is assumed that this
heat stays in the structure. Net AHRI Rating represents
portion of remaining heat that can be applied to heat
radiation or terminal units (i.e. nned tube baseboard,
cast iron radiators, radiant oor, etc.). Difference between
Heating Capacity and Net AHRI Rating, called piping and
pickup allowance, establishes reserve for heating volume
of water in the system and off-setting heat losses from
system piping. Net AHRI Rating of the boiler selected
should be greater than or equal to calculated peak heating
load (heat loss) for building or area(s) served by the
boiler and associated hot water heating systems. Consult
manufacturer before selecting boiler for installations having
unusual piping and pickup requirements.
Boilers with same number of sections are identical to each
other except for their ring rate. Firing rate is determined
by nozzle size in oil burner. For example: Models
3KW0.60Z, 3KW0.75Z and 3KW1.00Z are the same boiler,
except for ring rate of oil burner.
These boilers operate on #2 Heating Oil. Alternate ring
rate kits are available for 3 section, 4 section and 5 section
boilers.
4
SAFE INSTALLATION AND OPERATION
Boiler installation shall be completed by qualied agency.
Become familiar with symbols identifying
potential hazards.
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
!
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
!
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
NOTICE
Used to address practices not related to personal
injury.
1.
Failure to follow rules for safe operation and
instructions can cause a malfunction of the boiler and
result in death, serious bodily injury, and/or property
damage.
2.
Check your local codes and utility requirements before
installation. Installation must be in accordance with
their directives, or follow NFPA 31 Installation of Oil
Burning Equipment, latest revision.
3.
Before servicing, allow boiler to cool. Shut off any
electricity and oil to boiler when working on it.
4.
Inspect oil line and connections for leaks.
5.
Verify oil burner nozzle is the size required. Over-ring
will result in early failure of boiler sections. This will
cause dangerous operation.
6.
Never vent this boiler into enclosed space. Always vent
to outside. Never vent to another room or inside a
building.
7.
Verify there is adequate air supply for complete
combustion.
8.
Follow regular service and maintenance schedule for
efcient, safe and reliable operation.
9.
Keep boiler area clean and free of combustible
material, gasoline and other ammable vapors and
liquids.
10.
Oil burners are not do-it-yourself items. Boiler must be
installed and serviced by qualied professionals using
combustion test instruments.
!
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
11.
Be aware when piping safety relief valve if system
pressure exceeds safe limit of 30 pounds per square
inch, safety relief valve will automatically lift open.
Lifting of safety relief valve can discharge large
quantities of steam and hot water, which may damage
surroundings. Before installing safety relief valve read
manufacturer’s instructions and maintenance section of
manual on safety relief valves.
12.
Installation and sizing of the expansion tank must
consider heating systems total water volume,
temperature, boiler initial ll pressure, and system
arrangement. Improperly installed and sized expansion
tank may result in frequent lifting of safety relief
valve or other heating system problems. For proper
installation, sizing, and maintenance of expansion tank
follow guidelines established by boiler manufacturer
and expansion tank manufacturer.
13.
Expansion tank performance and life expectancy can be
hindered by overlling the boiler. Boiler manufacturer
recommends initial ll pressure of 10-12 psig. For
higher ll pressures expansion tank’s air charge will
need to be increased to match ll pressure. Consult
manufacturer’s guidelines for sizing and selection.
14.
Purging heating system of air and gases when
rst placing boiler into service is critical for proper
circulation and quiet performance. Once air and gases
are purged, for boiler installations using oat type
vents, air vents should be closed for normal operation.
If air is heard or noticed by loss of heat, purge system
and open vents for short period of time.
NOTICE
This boiler has been designed for residential
installations. If used for commercial applications,
all jurisdictional requirements must be met. This
may require wiring and/or piping modications.
Manufacturer is not responsible for any changes to
the original design.
DO NOT USE GASOLINE CRANKCASE DRAININGS
OR ANY OIL CONTAINING GASOLINE.
5
BEFORE YOU START
BEFORE YOU START
BOILER LOCATION
Complete following prior to installing boiler.
A. Verify you have selected right size boiler with proper
1.
capacity. AHRI rating of boiler selected should be
greater than or equal to calculated peak heating load
2.
(heat loss) for building or area(s) served by boiler
and associated hot water heating systems. See boiler
rating and capacity table previously listed. Any heat
loss calculations used should be based on approved
methods.
3.
4.
B. Supply boiler with proper oil supply and oil piping,
sufcient fresh combustion air, and suitable electrical
supply.
C. Connect boiler to suitable venting system and piping
system adequate to distribute heating load.
D. Thermostat must be properly located and installed for
control of heating system.
5.
If there are any doubts as to requirements, check with local authorities and obtain professional help where needed.
Operating Instructions, Checks And Adjustments, And
Maintenance sections in this manual are vital to proper and
safe operation of heating system. Take time to be sure they
are all done.
Place boiler in location centralized with piping system
and as close to chimney as possible.
Boiler must be level. If necessary use metal shims
beneath boiler’s feet.
Use raised base if oor can become wet or damp.
Maintain clearances for re safety as well as
servicing. Maintain 18” clearance at a side where
passage is required for access to another side for
cleaning, servicing, inspection, or replacement
of any parts that normally may require such
attention. Boilers must be installed at least 6” from
combustible material on all sides and above. Allow at
least 24” front clearance for servicing.
Allow fresh air for combustion at front of boiler.
Allow fresh air for ventilation to front and rear of
boiler. Air passages must be free of obstructions at
all times. Ventilating and combustion air must enter
boiler room without restrictions.
!
WARNING
Fire hazard. Do not install boiler on combustible
ooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
Figure 2 - Clearances
Boiler
6”
Front
Min.
24” Min.
6”
Min.
24”
Min.
6.
Floor supporting boiler must be noncombustible and
sufciently stable. If ooring is combustible, place
boiler on 2” concrete patio blocks or 2” Cladlite
Pad™. Blocks or pad must be under entire boiler to
protect oor.
7.
Be sure installation is in accordance with the
requirements of the local authorities having
jurisdiction. Compliance with these regulations is
required. In the absence of local codes, follow NFPA
31 Installation of Oil Burning Equipment, latest
revision.
MINIMUM CLEARANCE DIMENSIONS
BOILER CLEARANCES
Unit
Top 6” 18”
Right Side 24” 24”
Left Side 6”
Base Non-combustible
Front 24”
Back 6”
All distances measured from the cabinet of the boiler.
Combustible
Clearance
Accessibility,
Cleaning, and
Servicing
Flue to
Combustible
Clearance
18”
6
Figure 3 - Boiler With Piping System
ALWAYS KEEP MANUAL FUEL SUPPLY VALVE SHUT OFF IF
BURNER IS SHUT DOWN FOR EXTENDED PERIOD OF TIME.
INSTALLATION REQUIREMENTS
7
FRESH AIR FOR COMBUSTION
!
WARNING
Asphyxiation, re hazard. Do not obstruct air
EXAMPLE 2: Boiler Located in Conned Space
A. All Air from Inside the Building: Conned space
openings to combustion area. Follow instructions
below, to maintain adequate combustion air.
NOTICE
Install outside air intake if you use replace or
kitchen or bathroom exhaust fan. These devices rob
boiler and water heater of combustion air.
Provide enough fresh air to assure proper combustion. Fire
in the boiler uses oxygen. It must have continuous supply.
Air in the house contains only enough oxygen to supply
burner for short time. Outside air must enter house to
replace air used by the burner. Study following examples 1
and 2 to determine your fresh air requirements.
EXAMPLE 1: Boiler Located in Unconned Space
If your boiler is in open area (non partitioned basement) in
conventional house, air that leaks through cracks around
doors and windows will usually be adequate to provide air
for combustion. Doors should not t tightly. Do not caulk
cracks around windows.
Unconned space is dened as space whose volume is not
less than 50 cubic feet per 1,000 Btu per hour of total input
rating of all appliances installed in that space.
shall be provided with two permanent openings
communicating directly with additional room(s) of
sufcient volume so that combined volume of all spaces
meets criteria for unconned space. Total input of all
combustion equipment installed in combined space
shall be considered in making this determination. Each
opening shall have minimum free area of one square
inch per 1,000 Btu per hour of total input rating of all
combustion equipment in conned space, but not less
than 100 square inches. One opening shall be within 12
inches of top and one within 12 inches of bottom of the
enclosure.
Example: Your boiler is rated at 100,000 Btu per hour.
Water heater is rated at 30,000 Btu per hour. Total
is 130,000 Btu per hour. You need two grilles, each
with 130 square inches of FREE opening. Metal grilles
have about 60% FREE opening. To nd louvered area
needed, multiply free opening required by 1.7 (130 x
1.7 = 221.0 sq. in. louvered area). In this example,
two grilles each having 8” x 30” (240 sq. in.) louvered
area would be used.
Figure 4 - Air Openings For Boiler Located In
Conned Space (Utility Room)
8
FRESH AIR FOR COMBUSTION
3.
B. All Air from Outdoors: Conned space shall
be provided with two permanent openings,
one commencing within 12 inches of top and
another commencing within 12 inches of bottom
of enclosure. Openings shall communicate
directly, or by ducts, with outdoors or spaces
(crawl or attic) that freely communicate with
outdoors.
1.
When directly communicating with outdoors, each
opening shall have minimum free area of one
square inch per 4,000 Btu per hour of total input
rating of all equipment in the enclosure.
2.
When communicating with the outdoors through
vertical ducts, each opening shall have a minimum
free area of one square inch per 4,000 Btu per
hour of total input rating of all equipment in the
enclosure.
Figure 5 - Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In
Tightly Constructed Houses
When communicating with outdoors through
horizontal ducts, each opening shall have
minimum free area of one square inch per 2,000
Btu per hour of total input rating of all equipment
in the enclosure.
4.
When ducts are used, they shall be of same cross
sectional area as free area of openings to which
they connect. Minimum dimension of rectangular
air ducts shall be not less than three inches.
FRESH AIR DUCT CAPACITIES
THROUGH LOUVERS
Fresh Air
¼” Mesh
Screen
Wood
Louvers
Metal
Louvers
Duct Size
(Btuh)* (Btuh)* (Btuh)*
3 ½” x 12” 144,000 36,000 108,000
8” x 8” 256,000 64,000 192,000
8” x 12” 384,000 96,000 288,000
8” x 16” 512,000 128,000 384,000
*Btuh = British Thermal Units per hour based on
opening covered by ¼” mesh screen , wood louvers,
or metal louvers.
9
SYSTEM PIPING
1.
Installation of boiler for new heating system,
Install all of radiation units (panels, radiators,
baseboard, or tubing) and supply and return mains
rst. After all heating system piping and components
have been installed, make nal connection of system
piping to boiler. It is recommended to mount circulating
pump on supply side piping, such that it pumps away
from expansion tank. Refer to gures on next pages.
6.
Verify clean cold water supply is available when
connecting to pressure reducing valve. Use sand
strainer or pump strainer when water supply is from
well.
Low Design Water Temperature Systems (Below 140°
F) And Large Water Content Systems
2.
Equip hot water boiler installed above radiation
level with low water cut off device. Periodic inspection
is necessary, as is ushing of oat type devices, per low
water cut off manufacturer’s specic instructions.
3.
Packaged boiler is set up with 1¼” NPT supply
and return piping from front of boiler. Boiler supply
and return piping can be moved to rear of boiler. Boiler
should not be piped return line to front, supply line
to rear, or vice versa, will cause boiler water to short
circuit heat exchanger. Piping connections may require
additional ttings and parts.
4.
Install drain valve provided with boiler in return tee.
See gure on page 3.
5.
Install Safety Relief valve in rear section using ¾”
nipple and street elbow provided with boiler. See gure
6.
A. Install safety relief valve with spindle in vertical
position.
B. Do not install shutoff valve between boiler and
safety relief valve.
C. Install discharge piping from safety relief valve.
• Use ¾” or larger pipe.
Signicant condensation may form in this boiler and/
or venting system if boiler is operated with return
temperatures of less than 120° F.
Condensation is corrosive and can eventually cause damage
to boiler and venting system. Minimum design return water
temperature to prevent this condensation in boiler and
venting is 120°F.
Boiler used in heating system where design water
temperatures below 140°F are desired (e.g. radiant oor
heating), a 3-way or 4-way mixing valve or suitable
alternative (e.g. Bypass Piping Arrangement shown
in diagram on following page) is required to prevent
low temperature (below return 120°F) return water
from entering boiler. When using mixing valve, follow
manufacturer’s installation instructions.
Boiler connected to system having large water content
(such as former gravity system), use of Bypass Piping
Arrangement shown in diagram on following page is
suggested.
Figure 6 - Safety Relief Valve Installation
• Use pipe suitable for temperatures of 375°F
(191°C) or greater.
• Individual boiler discharge piping shall be
independent of other discharge piping.
• Size and arrange discharge piping to avoid
reducing safety relief valve relieving capacity
below minimum relief valve capacity stated on
rating plate.
• Run pipe as short and straight as possible to
location protecting user from scalding and properly
drain piping.
• Install union, if used, close to safety relief valve
outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
• Terminate pipe with plain end (not threaded).
Follow instructions
to install discharge
piping from safety
relief valve to drain.
10
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