PENNCO KEYSTONE STEAM II Technical Document

KEYSTONE STEAM II
OIL-FIRED CAST IRON BOILER
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
P/N 1305030, Rev. 1.0 [08/04]
An ISO 9001-2000 Certified Company
PENNCO BOILERS
85 Middle Rd.
Dunkirk, NY 14048
Ph: [phone]
Fax: [phone]
www.ecrinternational.com
MODEL NUMBERS:
KSB0365, KSB3100,
KSB4125, KSB4150,
KSB5175, KSB5200,
KSB6225, KSB7275

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INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
P/N# 1305030, Rev. 1.0 [08/04] • Printed in USA • Made In USA
TABLE OF CONTENTS
Safety Symbols and Warnings.............................2
Ratings, Data, and Dimensions ...........................3
Installation Procedure ..........................................4
Ventilation and Combustion Air............................5
Connecting Supply and Return Piping Steam......7
Venting System Inspection and Installation .........8
Oil Tank and Piping..............................................8
Electrical Wiring ...................................................9
Thermostat Operation ..........................................9
Normal Sequence of Operation .........................11
Operating Instructions........................................11
Maintenance Procedures ...................................14
Replacement Parts List......................................15
Service Checklist................................................20
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
SAFETY SYMBOLS & WARNINGS
The following defined symbols are used throughout
this manual to notify the reader of potential hazards
of varying risk levels.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or
serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, COULD result in death
or serious injury.
CAUTION
Indicates a potential hazardous situation
which, if not avoided, MAY result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
IMPORTANT: Read the following instructions
COMPLETELY before installing!!
WARNING
1. Keep boiler area clear and free from com-
bustible materials, gasoline and other flam-
mable vapors and liquids.
2. DO NOT obstruct air openings to the boiler
room.
3. Modification, substitution or elimination of
factory equipped, supplied or specified com-
ponents may result in property damage, per-
sonal injury or the loss of life.
4.TOTHEOWNER-Installationandserviceof
this boiler must be performed by a qualified
installer.
5.TOTHEINSTALLER -Leaveallinstructions
with the boiler for future reference.
6. When this product is installed in the Com-
monwealth of Massachusetts the installation
must be performed by a Licensed Plumber or
Licensed Gas Fitter.
WARNING
Allinstallations of boilers andventingshould
be done only by a qualified expert and in
accordance with the appropriate Pennco
manual. Installing or venting a boiler or any
other gas appliance with improper methods
or materials may result in serious injury or
death due to fire or to asphyxiation from
poisonous gases such as carbon monoxide
which is odorless and invisible.
Tested For 15 LBS.
ASME
Working Pressure

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RATINGS, DATA, AND DIMENSIONS
STANDARDEQUIPMENT:Cratedboiler,flushjacket,oil burner,targetwall/liner,ASMEreliefvalve,steam
water level gauge, steam pressure gauge, steam pressure control, mechanical low water cut-off, drain
valve,wiringharness,burnerelectricdisconnect,plastic cover, 2" supply tapping, 1½" return tapping, skim
port, and primary control. (NOTE: For tankless heater units, add tankless hot water coil, and 4006 limit
control.)
TANKLESS WATER HEATER CAPACITIES
To Water
Line
To
LWCO
Line
KSB0365 0.65 L-24 Available on request 11 8
KSB3100 1.00 L-24 4.5 11 8
KSB4125 1.25 L-24 4.5 13 9
KSB4150 1.50 L-24 4.5 13 9
KSB5175 1.75 L-24 5.0 15 10
KSB5200 2.00 L-24 5.0 15 10
KSB6225 2.25 L-24 5.0 17 11
KSB7275 2.75 L-24 5.0 19 12
Boiler Water
Boiler
Model
Number
Firing
Rate
G.P.H.
Tankless
Heater
Number
TanklessHeater
Capacity
Intermittent Draw
G.P.M.
DIMENSIONS (See FIG. A)
Length of
Flush Jacket
Front of Jacket
to Center Line of
Flue Outlet
Flue Outlet
Diameter
-A- -B- -C-
KSB-3S 16.375" 6.5" 6.0"
KSB-4S 20.25" 8.5" 6.0"
KSB-5S 23.875" 10.25" 7.0"
KSB-6S 27.5" 8.3125" 8.0"
KSB-7S 31.125" 8.3125" 8.0"
Boiler
No.
G.P.H. MBH(4) Steam
MBH Sq. Ft. Steam Water MBH Round Square
KSB0365 0.65 91 78 59 246 68 6 8x8x15 140 .60 80B 84
KSB3100 1.00 140 116 87 363 101 6 8x8x15 140 .85 80B 81.5
KSB4125 1.25 175 145 109 454 126 7 8x8x15 140 1.10 80B 82.5
KSB4150 1.50 210 170 128 533 148 7 8x8x15 140 1.25 80B 81
KSB5175 1.75 245 202 152 633 176 8 8x8x15 140 1.50 80B H 83
KSB5200 2.00 280 227 170 708 197 8 8x8x15 140 1.75 70B H 82
KSB6225 2.25 315 251 188 783 218.3 8 8x12x15 140 2.00 45B -
KSB7275 2.75 385 307 230 958 267.1 8 8x12x15 140 2.25 45B -
8. The MEAnumber for the AFG BeckettBurner used in the KSB series is 213-83-E.
Boiler
Model
Number(1)
I=B=R Oil Burner
Input(2) D.O.E.
Heating
Capacity
MBH(4)
I=B=R Net Ratings(3)(4) Min. Natural Draft
Chimney Size Pump
Pressure
PSI
Nozzle
Furnished
140PSIG(5)
A.F.U.E.
Rating
4.For altitudes above 2,000 ft. ratings maybe reduced atthe rate of 4% forevery1,000 ft. above sea level.
5.Nozzle sizes with an H designation are Hago brand,all others are Delevan.
6.The electrical service is 120 Volts,15 Amps,60 Hz.
7. The MEAnumber for the KSB series is 182-86E.
NOTES:
1.Add suffix"T"to denote boiler with tankless heater.
2.I=B=R burnercapacityis based on an oil heating value of140,000 Btu/gal.and with 13% CO2.
3.Net ratings based on 170°Ftemperature in radiators and include 33% allowance for normal piping and pick-up load.Consultmanufacturer
for unusual piping and pick-up temperatures.
FIG. A

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INSTALLATION PROCEDURE
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause injury or
property damage.
Allinstallationsmustconformtothe requirements of
the authority having jurisdiction. Such applicable
requirements take precedence over the general
instructions of this manual.
Where required by the authority having jurisdiction,
theinstallationmustconformtotheAmericanSociety
of Mechanical Engineers Safety Code for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME No. CSD-1.
Locateboilerinfrontoffinalpositionbeforeremoving
crate.Providealevel solid base as near chimneyas
possible and centrally located with respect to the
heat distribution system as practical.
WARNING
Boiler may not be installed on combustible
flooring!!
Allow 24 inches in the front, top and right hand side
for servicing and cleaning, or removing tankless
water heating coil.
Itisrecommendedthat24inchesbeallowedinback
of boiler for convenience when skimming hole is
used.
When installed in a utility room, the door should be
wide enough to allow the largest boiler part to enter,
or to permit replacement of another appliance such
as a water heater.
The boiler shall be installed such that the oil ignition
system components are protected from water
(dripping, spraying, rain etc.) during appliance
operation and service.
FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORSONLY-Theboilermustnotbeinstalledon
carpeting or vinyl flooring. Minimum clearances to
combustible construction are:
TOP ........................................24 IN.
FRONT...................................24 IN.
FLUE CONNECTOR................9 IN.
REAR .....................................24 IN.
LEFT SIDE ...............................6 IN.
RIGHT SIDE............................24IN.
NOTE: Clearance for access should exceed fire
protection clearance.
MINIMUM CLEARANCES TO COMBUSTIBLE
CONSTRUCTION (AS SEEN FROM ABOVE)
6" 24"
24"
BOILER
24"

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VENTILATION AND COMBUSTION AIR
WARNING
Air openings to combustion area must not be obstructed. By following the instructions below,
adequate combustion air can be maintained.
COMBUSTION AIR REQUIREMENTS
(MinimumOpening Requirement)
Outside Inside
Combustion
Air 1 Sq.
In./5000
BTU/Hour
(Step 4)
Combustion Air
1 Sq. In./1000
BTU/Hour (Min.
100 Sq. In.)
(Fig. 1)
Vertical
Ducts 1 Sq.
In./4000
BTU/Hour
(Fig. 2 & 3)
Horizontal
Ducts 1 Sq.
In./2000
BTU/Hour
(Fig. 4)
91,000 19 100 23 46
140,000 28 140 35 70
175,000 35 175 44 88
210,000 42 210 53 106
245,000 49 245 61 122
280,000 56 280 61 140
* A space whose volume is not less than 50 cubic feet per 1000 BTU/Hour of all
appliances installed in that space (cubic feet of space = height x width x length)
** A space whose volume is less than 50 cubic feet per 1000 BTU/Hour of all
appliances installed in that space (cubic feet of space = height x width x length)
BTU/Hr
Input
Unconfined Area* Confined Area**
Outside Combustion Air
1. Ventilation of boiler room must be adequate
enough to provide sufficient air to properly support
combustion and venting.
2.When theboileris locatedinan unconfinedspace
in a building of conventional construction frame,
masonryormetal,infiltrationnormallyisadequateto
provideairforcombustionandventilation.However,
in any building which has been altered to conserve
energy or to minimize infiltration, the boiler area
shouldbeconsideredasaconfinedspace.Ifthereis
anydoubt,installairsupplyprovisionsforcombustion
andventilationinaccordancewithsection5.3,Airfor
Combustion and Ventilation, of the NFPA 54 1988
code,therecommendationsthatfollow,orapplicable
provisions of the local building codes.
3. When the boiler is installed in an unconfined
space, in a building of unusually tight construction,
air for combustion and room ventilation must be
obtained from outdoors or from spaces freely
communicating with the outdoors. A permanent
opening or openings having a total free area of not
less than 1 square inch per 5,000 BTU per hour of
total input rating of all appliances shall be provided.
Ducts may be used to convey make-up air from the
outdoors and shall have the same cross-sectional
area 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
permanentopenings,onestarting12inches
from the top and one 12 inches from the
bottomoftheenclosedspace.Eachopening
shallhaveaminimumfreeareaof1square
inch per 1,000 BTU per hour of the total
inputratingofallappliancesintheenclosed
space,butmustnotbelessthan100square
inches. These openings must freely
communicatewiththeinteriorareashaving
adequate infiltration from the outside.
(Figure 1)
5. When the boiler is installed in a confined space
andallairisprovidedfromtheoutdoors,theconfined
spaceshallbeprovidedwithtwopermanentopenings,
one commencing within 12 inches from the top and
one commencing 12 inches from the bottom of the
enclosure.Theopeningsshallcommunicatedirectly,
or by ducts, with the outdoors or spaces (crawl or
attic) that freely communicate with the outdoors.
One of the following methods must be used to
provideadequateairforventilationandcombustion.
A.Whendirectlycommunicatingwiththeoutdoors,
each opening shall have a minimum free area of
1 square inch per 4,000 BTU per hour of total
input rating of all equipment in the enclosure.
(Figure 2)
FIGURE 1

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B. When communicating with the outdoors by
means of vertical ducts, each opening shall have
aminimumfreearea1squareinchper4,000BTU
perhouroftotalinputratingofallappliancesinthe
enclosed space. (Figure 3)
FIGURE 2
FIGURE 3
FIGURE 4
C.Ifhorizontalductsareused,eachopeningshall
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 4)
D.Whenductsareused,theyshallbeofthesame
cross sectional area as the free area of the area
of the openings to which they connect. The
minimumdimensionofrectangularairductsshall
not be less than 3 inches.
6. In calculating free area using louvers, grills or
screens for the above, consideration shall be given
to their blocking effect. Screens used shall not be
smaller than 1/4 inch mesh. If the free area through
adesign of louver orgrillis known, it should beused
in calculating the size opening required to provide
thefree area specified. If thedesignand free area is
notknown,itmaybeassumedthatwoodlouverswill
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.

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CONNECTING SUPPLY AND RETURN PIPING
1. Suggested piping for steam heating system can
beseeninFigure5.Actualpipingmayvarybasedon
system design and local conditions.
2. For further piping information refer to the I=B=R
installation piping guide.
FIGURE 5
3. See Figure 6 for typical piping for domestic hot
water heater.
4. See Figures 7 and 8 for the suggested piping for
a modular steam boiler.
SUGGESTED PIPING FOR MODULAR STEAM
BOILERS - PUMPED RETURN
FIGURE 7
PIPING FOR BUILT-IN
DOMESTIC HOT WATER HEATER
FIGURE 6
SUGGESTED PIPING FOR MODULAR STEAM
BOILERS - GRAVITY RETURN
FIGURE 8

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VENTING SYSTEM INSPECTION & INSTALLATION
WARNING
Boileristobeventedbynaturaldraftandshall
not be connected into any portion of a
mechanical draft operating system under a
positive pressure.
Inspect chimney to make certain it is constructed
according to the latest revision of the NFPA 211.
Local regulations may differ from this code and
should be checked. Where there is a conflict, the
local code will prevail.
The boiler must be installed into a chimney which
has a masonry or metallic chimney liner.
An unlined chimney will have leaks that will cause
poor chimney performance (no draft), and could
result in a positive pressure in the combustion
chamber.
Horizontalportionsoftheventingsystem should not
exceed 10 feet in length. Horizontal lengths over 10
ft. will have a negative effect on the chimney
performance.
The chimney should extend at least 2 ft. above any
portionofthebuildingwithin10ft.(Figure9) Itshould
produce a -.02 inch W.C. draft in the combustion
chamber. See "Chimney or Vent Sizes" chart for
recommended minimum and maximum chimney or
vent sizes.
Inadequate draft will cause improper combustion,
resulting in dirty flue ways and high fuel bills.
CHIMNEY OR VENT SIZES
MIN MAX MIN MAX MIN MAX
91,000 - 140,000 6 8 8x8 8x8 15 40
175,000 - 210,000 7 8 8x8 8x10 15 40
245,000 - 280,000 8 10 8x8 8x12 15 50
315,000 8 10 8x8 8x12 15 50
385,000 8 10 8x8 8x12 15 50
BTU/HR INPUT ROUND INCHES SQUARE INCHES HEIGHT (FT)
FIGURE 9
Connect flue pipe same size as boiler outlet to
chimney, sloping upward continuously toward the
chimney approximately 1/4" per foot. Bolt or screw
joints together to avoid sag.
Ifanoilfiredwaterheaterisventedintothesameflue
astheboiler,provideaseparateholeintothechimney
whenever possible. When this isn’t possible, use a
“Y”connectioninthefluepipe,usingaseparatedraft
regulator for each unit. When a chimney will not
provide adequate draft to handle the input from the
water heater and boiler simultaneously, wire the
units so that only one will operate at a time, favoring
the water heater.
OIL TANK AND PIPING
Oiltankandpipingshouldbeinstalledinaccordance
with the National Board of Fire Underwriters and
local regulations. Oil storage tank, vent, fill pipe and
caps should be as prescribed by local codes. In no
case should the vent pipe be smaller than 1-1/4"
I.P.S. The fill pipe should not be less than 2" I.P.S.
Thesuctionlinefromthetanktotheburnershouldbe
one continuous piece of tubing to prevent air enter-
ing the line. The suction line, must be 3/8" O.D.
copper tubing for runs of 50 feet or less, and 1/2"
O.D. for longer runs. An oil return line, same size as
the suction line, must be used on any installation
where the bottom of the tank is below the fuel unit of
the burner. Oil lines should be buried or otherwise
protectedfrommechanicalinjury.Flarefittingsonall
oil lines are recommended. Compression fittings on
the suction line often allow air to be drawn into the
fuelpump, making itdifficult to maintain oilpressure
at the nozzle. Do not run overhead fuel lines from
tank to oil burner.
Fuelpumpconnectionsandby-passshouldbemade
according to instructions attached to the fuel pump.

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If tank is more than 20' from the boiler, a two stage
fuel unit should be installed in place of the single
stage pump supplied as standard equipment with
the burner. Make certain the rotation and speed are
the same and the pump is suitable for the burner
horsepower rating.
FIGURE 10
TYPICAL INSTALLATION -
SINGLE PIPE OIL SYSTEM
FIGURE 11
TYPICAL INSTALLATION -
TWO PIPE OIL SYSTEM
Anoillinefilterandshut-offvalveshouldbeinstalled
inthesuctionline.Shut-offvalvesshouldbeinstalled
in both the suction and return lines at the burner for
convenience in servicing burner. Allow extra tubing
at burner so burner may be removed from boiler for
cleaning without disconnecting tubing. (Figures 10-
11) An optional flexible oil line is available.
ELECTRICAL WIRING
Electrical wiring must conform with the latest revi-
sions of the National Electrical Code, ANSI/NFPA
No. 70, and/or local authority having jurisdiction.
1. When an external electrical source is utilized,
the boiler, when installed, MUST BE electrically
groundedinaccordancewiththeserequirements.
2. Install a fused disconnect switch between
boiler and meter at a convenient location.
3. When the boiler is equipped with self-ener-
gizedcontrols,nooutsidesourceofelectricpower
shall be connected to the circuit of this system.
(See "Steam Wiring W/MM #67 Mechanical
LWCO" on next page.)
THERMOSTAT INSTALLATION
1. Thermostat should be installed on an inside wall
about four feet above the floor.
2. NEVER install a thermostat on an outside wall.
3.Donotinstallathermostatwhereitwillbeaffected
bydrafts,hotorcoldpipes,sunlight,lightingfixtures,
television, fireplaces, or chimneys.
4.Check thermostat operation byraising and lower-
ing thermostat as required to start and stop the
burner.
5.Instructionsforthe finaladjustmentofthethermo-
stat are packaged with the thermostat (adjusting
heating anticipator, calibration, etc.).

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STEAM WIRING W/MM #67 MECHANICAL LWCO
NOTE:Notallcomponentslistedareusedinallcontrolsystems.
COMPONENT CODING TH-1 Thermostat (Millivolt) MR-PS Manual Reset Pressure Switch CIR Circulator
TH-2 Thermostat (24 Volt) Control Terminal ECO Energy Cut-Off
TH-3 Thermostat (Line Voltage) 1K Relay Coil PSC Pilot Safety Coil
TR-1 Transformer (120V/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
WIRING CODE Line Voltage By Factory
Low Voltage By Factory Line Voltage By Installer Low Voltage By Installer

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NORMAL SEQUENCE OF OPERATION
On a call for heat, the thermostat will actuate, com-
pleting the circuit to the boiler. In turn, theignition
systems are activated and ignition will begin.
In the event of a low water condition, an automatic
low water cut-off device will interrupted power be-
tween the low water cut-off and the burner. The
burner will remain off until the low water condition is
corrected, (i.e., manually restore boiler water or
utilizeawaterfeederdevicewhichwillautomatically
restore water to its normal operating level).
IMPORTANTTO THE INSTALLER - Beforeputting
theboilerinoperation,testthemechanicallowwater
cut-off device for proper operation. While burner is
on, open the blow-off valve located in the lower
portion of the cut-off body. This will drain the water
quickly from the cut-off body and break the circuit to
the burner. If it does not, replace control.
WARNING
WATER WILL BE BOILING HOT.
OPERATING INSTRUCTIONS
The venting system should be inspected at the start
of each heating season. Check the vent pipe from
theboilertothechimneyforsignsofdeteriorationby
rust or sagging joints. Repair if necessary.
Remove the vent pipe at the base of the chimney or
flue and, using a mirror, check for obstruction and
verify compliance to the latest revision of the NFPA
211.
The lever of the pressure relief valve (Figure 12) on
the boiler should be operated periodically to make
sure that it is functioning properly.
WARNING
Dischargewillbeboilinghotwaterandsteam.
The pressure relief valve should open before the
steam pressure exceeds the 15 lb. reading on the
gauge.Ifthispressureisexceededandthepressure
relief valve leaks steam when the boiler is operating
at normal pressures, it should be immediately
replaced.Corrosioncanbuilduprapidlyat the valve
seat and prevent its functioning as a safety device.
START-UPAND ADJUSTMENT
OF OIL BURNER
(See oil burner instructions for nozzle and electrode setting).
CAUTION
DO NOT SET FIRE VISUALLY.
Instruments are the only reliable method to
determine proper air adjustments. An
improperly adjusted burner causes soot and
high fuel bills because of incomplete
combustion of the fuel oil. This in turn may
requireexcessiveboilermaintenance,service
costs,andinsomeinstances,housecleaning
or redecorating. A competent service
mechanic should be consulted to make the
proper adjustments with a smoke tester, CO2
indicator, and draft gauge. NOTE: Bacharach
or Dwyer test kits include these instruments.
A. Check oil burner nozzle to make certain it is tight
in adapter. Burner mounting bolts should be tight.
B. Check electrode setting, as they may have been
jarred out of position during transportation.
C. Lubricate burner motor if necessary.
FIGURE 12

12
RIELLO SETTINGS
Boiler No. Burner No. Air Damper Pump
Press. Turb. Nozzle
Furnished
KSB3100 F-5 3.6 150 PSI 1 .85 80W
KSB4125 F-5 4 150 PSI 3 1.10 60W
KSB4150 F-5 6 150 PSI 4 1.25 60W
KSB5200 F-10 5 150 PSI 0 1.75 80B
CARLIN SETTINGS
Boiler No. Burner No. Air Damper Pump
Press. Head Bar Nozzle
Furnished
KSB3100 EZ-1 0.85 150 PSI .85-1.00 .85 70B
KSB4125 EZ-1 1.00-1.10 150 PSI 1.10-1.25 1.10 70B
KSB4150 EZ-1 1.25-1.35 150 PSI 1.10-1.25 1.25 70B
KSB5200 EZ-2 1.75 150 PSI 1.65-1.75 1.75 70B
BECKETT SETTINGS
Boiler No. Burner No. Air Damper Air Shut. Pump
Press. Static Disc End
Cone Nozzle Furnished
KSB3100 AFG 1 5 140 PSI 3-3/8U F3 .85 80B
KSB4125 AFG 1 8 140 PSI 2-3/4" F4 1.10 80B
KSB4150 AFG 2 6 140 PSI 2-3/4" F6 1.25 80B
KSB5200 AFG 5 5 140 PSI 3U F12 1.75 70B H
KSB6225 CF375 4 6 140 PSI L1 N/A 2.00 45B
KSB7275 CF375 4 6 140 PSI L1 N/A 2.25 45B
NOTES:
(1)Model KSB6225 needs a head setting of 1 and KSB7275 needs a head setting of 2.
(2)Nozzle sizes with an H designation are Hago brand,all others are Delevan.
(3)Information in above table uses Beckettmodel AFGburner for model numbers KSB365-5200 and Beckett
model CF375 for model numbers 6225 and 7275.
D. Set room thermostat to call for heat, or jump
thermostat contacts on the boiler control.
E. Open all oil line valves.
F. Turn service switch on. Burner should start.
G. On one pipe fuel systems only, bleed pump as
soon as burner starts. Allow oil to run until all traces
of air in the suction line disappear.
H. Turn “OFF” burner and install pressure gauge
port on pump.
I. Start burner again and check oil pressure for 140
lbs. Adjust if necessary.
INSTRUCTIONS TO OBTAIN PROPER OPERATION OF BOILER-BURNER UNIT
A 1/4" diameter slot is provided in the inspection cover plate to take draft readings in the combustion
chamber.(Figure12)A1/4"diameterholewillberequiredinthefluepipebetweentheboilerandbarometric
damper (if used) to take draft, CO2, smoke and temperature readings. Adjust air shutter on oil burner to
obtain a “trace” of smoke. Measure CO2 at this point. Increase air adjustment to lower CO2 approximately
one percent. Check to insure minimum negative .02 w.c., (water column), “overfire” draft and zero smoke.
If -.02 w.c. “overfire” draft can not be maintained, changes and/or modifications may be required in the
venting or the chimney.
Thefollowingtablesare provided as a guidelineforinitialstart-up.FinaladjustmentsMUSTbe made using
combustion instruments as previously mentioned.
IMPORTANT: Check safety control circuit after burner adjustments have been made for satisfactory performance.

13
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A.PressureControl-Removecoverandnotepressure
setting. With boiler operating, decrease the setting.
When the setting is lower than boiler pressure, the
control will open and turn off the boiler. After checking
pressure control, reset control to original setting.
B. Mechanical Low Water Cut-off - May be checked
byopeningthe blow-off valve on thelowerportionof
the cut-off body while the boiler is running. This will
drain the water from the boiler and break the circuit
to the burner.
WARNING
WATER WILL BE BOILING HOT.
Refill boiler to its normal water line.
C. Primary Control and Flame Sensor -
To Check:
1. Flame Failure - simulate by shutting off oil
supply with hand valve while burner is on. Sixty
seconds after flameout, the safety switch locks
out, ignition stops, motor stops and oil valve -
when used - closes. To restart, open oil supply
valve and reset safety switch.
2. Ignition Failure - With burner off, close oil supply
valve and run through start-up procedure, The
safety switch should lock out as in flame failure.
3. Power Failure - Turn off main power supply
switch while burner is operating. When burner
stops, restore power and burner should start. If
operation is not as described as above, check
wiring and controls.
Preventativemaintenanceofanoilfiredboilerreduces
operating costs. The boiler and vent pipe should be
inspected for accumulation of soot or scale deposits
periodicallybutatleastonceeveryyearbeforethestart
of each heating season. When soot is present on the
section walls and flueways, improper combustion will
result, causing additional sooting and scaling until
flueways are completely closed. To remove soot and
scale from the flueways, remove top jacket panel, top
clean-out plate, open burner swing door. (Figure 12)
OPENING THE BURNER SWING DOOR
1.Turnoffpowertoboilerandallowboilertocooldown.
2.Disconnectpowercableatfactorysuppliedburner
electrical disconnect. (Figure 12)
3. Loosen screws on the sides of the lower front
jacket panel. (Figure 6) Pull the bottom part of the
lowerfrontpanelforwardandliftthelowerfrontpanel
up and off the boiler. (Figure 12)
4. Close oil valve (Figures 10-11) anddisconnect oil
line from burner.
IMPORTANT:Donotopenswingdoorwithoillineattached.
5. Remove nut from swing door stud on right hand
side of door.
6. Swing open burner and door to the left. Using a
flue brush, brush the soot and scale into the
combustionspacewhereitcanberemovedthrough
the swing door opening.
CAUTION
Use caution when vacuuming in the chamber
area. Damage to chamber could result.
It is recommended to replace the nozzle at the start
of each heating season. Lubricate the burner motor
andcirculatormotor-ifrequired-withafewdropsof
a good grade of light motor oil. Do not over oil. Have
a competent service person service the burner and
check the controls and check the electrodes for
carbonorcracksintheinsulators.Burnersshouldbe
adjustedtoproducetheconditionsshownin"Startup
and Adjustment of Oil Burner."
CLOSING THE BURNER SWING DOOR
1. Swing burner and door to the right until insulation
is slightly compressed and the stud is exposed.
2. Attach nut to the stud and tighten it until the built
in stop contacts the mounting door.
3. Reconnect oil line to burner.
4.Replacelowerjacketpanel,andtightenthescrews.
5. Connect the power cable at the factory supplied
burner electrical disconnect.
6. Turn on power to boiler and bleed oil line.

14
! !
! !
! !
Before seasonal start up it is advisable to have a
competent service agency check the boiler for soot
and scale in the flues, change oil filter and nozzle,
clean the burner and readjust burner input rate to
maintain high operating efficiency.
On steam boilers make certain the boiler is filled to
the water line as indicated in Figure 12. The gauge
cocksshouldbenormallyopen. To remove dirt from
thegaugeglass the petcock may beopenedtoflush
out the glass.
WARNING
Discharge may be boiling hot water.
The radiator valves on a one-pipe steam system
must be either wide open or tightly shut. Do not
attempt to regulate room temperature by partially
closing the radiator valve.
Air vents on steam radiators and the supply main
release air from the system. If radiators do not heat
satisfactorily, make sure the air vents are clean and
operational.
The lever of the pressure relief valve on the boiler
(Figure 12) should be operated periodically to make
sure that it is functioning properly.
WARNING
Dischargewillbeboilinghotwaterandsteam.
The safety valve should open before the steam
pressure exceeds the 15 lb. reading on the gauge.
(Figure 12) If this pressure is exceeded and the
safetyvalvedoesnotopen,itmustbereplaced.Ifthe
safetyvalveleakssteamwhentheboilerisoperating
at normal pressures, it should be immediately
replaced.Corrosioncanbuilduprapidlyat the valve
seat and prevent its functioning as a safety device.
If the water in a steam boiler appears to be dirty or
oily, or the water level in the gauge glass fluctuates
considerably, the boiler should be cleaned. A com-
petent service person will use approved cleaning
compounds and properly clean and flush out the
boiler.He/she should alsoclean or replace airvents
andtraps,cleanfluepassagesand check for proper
operation of all controls and safety devices.
The venting system should be inspected at the start
of each heating season. Check the vent pipe from
theboilertothechimneyforsignsofdeteriorationby
rust or sagging joints. Repair if necessary.
Impuritiesinboilerwaterofasteamboilermaycause
foaming and an unsteady water line, or prevent
steam generation. They may result in objectionable
odorsescapingfromtheventsonwaterboilers.This
condition is caused by oil, grease, and sediment
from pipe fittings collecting within the boiler and can
be remedied only by giving the boiler a thorough
cleaning.
BOILERS SHOULD BE CLEANED BY SKIMMING
OR BLOWING DOWN.
CAUTION
The boiler should not be left unattended dur-
ing the cleaning process.
SKIMMING OFF IMPURITIES
Someoftheimpuritiesintheboilerwaterwillfloaton
the water and must be skimmed off.
With the boiler empty and cool, slowly begin to add
water. After water has entered boiler - never before
-turn“on”oilburner andadjustwaterflowsothatthe
water being added is kept just below boiling point.
Avoid boiling and turbulence.
Gradually raise hot water level to skimming hole
(Figure 6) installed on the rear section of the boiler
being careful not to raise it above the opening of the
hole. Skim until there are no impurities. Repeat the
process if necessary.
Water may be checked to make sure it is free from
oil by drawing off a sample at the skimming hole. If
thesampleisreasonablyfreefromoil,itwillnotfroth
whenboiledonstove.Thistestdoesnotindicatethe
amount of sediment which may lay in the bottom of
theboiler.It is therefore necessary thattheboilerbe
further cleaned by “blowing down.”
BLOWING DOWN THE BOILER
Beforeblowingdowntheboiler,fillittothewaterline.
Turn on burner and allow five pounds of steam
MAINTENANCE PROCEDURES

15
! !
! !
pressure to build up. Run a temporary connection
from one of the drain valves to a nearby sewer.
Connect to a drain valve on the opposite end of the
boiler from feed water inlet, if possible. Shut off the
oilburner,opendrainvalveandblowdowntheentire
contents of boiler.
Allowboilertothoroughlycoolandslowlyrefilltowater
line. Repeat as many times as required until blow off
wateris clear. Owner should blowdownboilerat least
once each month of the heating season.
WARNING
WATER WILL BE BOILING HOT.
USING CLEANING COMPOUND
If an exceptional amount of dirt or sludge seems to
bepresent in theboiler, a boiler cleaningcompound
made by a reputable manufacturer may be used
according to the instructions of the manufacturer of
the compound. When any type of cleaning com-
pound is used, care must be taken to thoroughly
flush all traces of the compound out of the boiler.
Following blow down allow the boiler to cool. Add
fresh water slowly. Be certain to blow enough times
as required to remove compounds from system.
The area around the boiler must be kept clear and
free of combustible materials, gasoline and other
flammable vapors and liquids.
Thefree flowofcombustion andventilationair tothe
boiler and boiler room must not 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."
MECHANICAL LOW WATER CUT-OFF
Operation should be checked, with burner on, by
opening the blow-off valve located in the lower
portion of the low water cut-off body. This will drain
thewaterquicklyfromthecut-offbodyandbreakthe
circuittotheburner.Ifitdoesnot,replacethecontrol.
Duringthe heating season,theblow-offvalve on the
low water cut-off should be opened once a week to
flushout thesedimentchamber sothedevice willbe
free to function properly. (Figure 12) Use a pail to
catch the discharge.
WARNING
WATER WILL BE BOILING HOT.
It is suggested that a qualified service agency be
employedtomakeanannualinspection oftheboiler
and heating system. They are experienced in mak-
ing the inspections outlined above and, in the event
repairs or corrections are necessary, can make the
proper changes for safe operation of the boiler.
REPLACEMENT PARTS - COIL AND COVER PLATE
ITEM PART NO. DESCRIPTION QTY.
1 HW-012.02 Bolt - 7/16-14x1½ Square Head 8
2 252-2-2.00 Gasket - B Tankless 1
3 202-2-1.00 Cover Plate - B Tankless Coil 1
4 HW-013.01 Nut 7/16-14 Square 8
5 252-3-1.02 Tankless Coil L-24 1
6 AQ-020.03 Well ¾ x 1½ - 123870A 1
7 275-1-1.00 Harness 1
8 AQ-008.00 Control - L4006A1827 1

16
REPLACEMENT PARTS - CONTROLS AND HARDWARE
ITEM PART NO. DESCRIPTION QTY
1 PF05501 Pipe Fit - Nipple ½" x 2" Brass 2
2 GA-003.00 Gauge Pressure (Steam) 1
3 GA-004.00 Gauge - Water Level 1
4 PF-025.01 Pipe Fit Tee ¼" 1
5 PF-026.05 Pipe Fit Nipple ¼" x 3" 1
WC-011.00 MLWCO #67-CH-3 24 Volt 1
275-2-3.01 LWCO Assembly Steam* 1
7 753-1-3.00 Siphon 90° Black Iron 1
8 28511301 Harness ELWCO 24" 1
9 28511201 Harness Pressure Switch 30" 1
10 SS-001.01 Pressure Switch PA404A-1009 1
1263012 Harness Burner 22" (Beckett & Riello)
28511801 Harness Aquastat 41" (Carlin)
1263013 Burner Harness 8" (Beckett)
1263011 Burner Harness 8" (Riello)
28511901 Burner Harness 8" (Carlin)
* This includes MLWCO #2, 4, 5, 7, 8, 9, & 10
6
11 1
12 1
REPLACEMENT PARTS - HARDWARE
ITEM PART NO. DESCRIPTION QTY
1 VR-002.02 Relief Valve #15 ¾ 1
2 PF-019.02 Pipe Fit Coupling ¾" 1
3 PF-005.01 Pipe Fit Npl ¾ Close 1
4 HW06701 Stud 5/16-18 x 2-3/8 4
5 2252501 Support - Jacket Brkt 2
6 HW07001 Stud 5/16" x 18 x 1-3/8" 3
7 HW06901 Nut 5/16"-18 Wislock 8
8 HW-016.02 Drain 1
9 PF-004.04 Pipe Fit Bushing 1¼ x ¾ 1
2452906 Flue Collector - 3 Sec.
2452902 Flue Collector - 4 Sec.
2452903 Flue Collector - 5 Sec.
2452907 Flue Collector - 6 Sec.
2452908 Flue Collector - 7 Sec.
10 1

17
REPLACEMENT PARTS - HEAT EXCHANGER
ITEM PART NO. DESCRIPTION QTY
1 100-5-10.01 Rear Section 1
#60 Push Nipple - 3 Sec. 2
#60 Push Nipple - 4 Sec. 3
#60 Push Nipple - 5 Sec. 4
#60 Push Nipple - 6 Sec. 5
#60 Push Nipple - 7 Sec. 6
Center Section - 3 Sec. 1
Center Section - 4 Sec. 2
Center Section - 5 Sec. 3
Center Section - 6 Sec. 4
Center Section - 7 Sec. 5
4 10051202 Front Section Castover 1
5 5611508 Kit - Target Wall & Insulation Blanket 1
6 25511005 Insul Blanket 16x24 (6 & 7 Section) 1
HW-025.05 Tie Rod ½ x 9 - 3 Sec.
HW-025.01 Tie Rod ½ x 12½ - 4 Sec.
HW-025.02 Tie Rod ½ x 16½ - 5 Sec.
HW-025.03 Tie Rod ½ x 20½ - 6 Sec.
HW-025.09 Tie Rod ½ x 23½ - 7 Sec.
#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
73
8 100-1-5.01
2 100-1-8.01
3 10051101
ITEM PART NO. DESCRIPTION QTY
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 ½ ID Flat 3
11 HW-003.05 Nut ½-13 Hex Head 3
10022201
10022202
10022203
10022207
10022208
10022204
10022205
10022206
10022209
10022210
9 MS-006.00
FULLY ASSEMBLED HEAT EXCHANGERS
7 Section With Tankless Coil
3 Section Without Coil
3 Section With Tankless Coil
4 Section With Tankless Coil
5 Section With Tankless Coil
6 Section With Tankless Coil
4 Section Without Coil
5 Section Without Coil
6 Section Without Coil
7 Section Without Coil

18
REPLACEMENT PARTS - JACKETS
ITEM PART NO. DESCRIPTION QTY
21522801 Top Panel - 3 Sec.
21522802 Top Panel - 4 Sec.
21522803 Top Panel - 5 Sec.
21522806 Top Panel - 6 Sec.
21522807 Top Panel - 7 Sec.
2 21521501 Rear Panel 1
21523101 Right Side Panel - 3 Sec.
21523102 Right Side Panel - 4 Sec.
21523103 Right Side Panel - 5 Sec.
21523104 Right Side Panel - 6 Sec.
21523105 Right Side Panel - 7 Sec.
4 21524401 Lower Cowl - Right 1
5 21524301 Lower Cowl - Left 1
6 21524101 Top Front Panel 1
21521803 Left Side Panel - 3 Sec.
21521804 Left Side Panel - 4 Sec.
21521805 Left Side Panel - 5 Sec.
21521806 Left Side Panel - 6 Sec.
21521807 Left Side Panel - 7 Sec.
71
11
31
REPLACEMENT PARTS - SWING DOOR
AND MOUNTING DOOR COMPONENTS
ITEM PART NO. DESCRIPTION QTY
1 2552901 Mounting Door Insulation & Plug 1
1a 2551901 Door Plug Replacement 1
2 HW-005.01 Screw ¼-20x½ Self-Tapping 2
3 10011701 Observation Door 1
4 25511101 Obs. Door Gasket 1
5 HW06801 ¼ x 1¾ Drive Lock Pin 2
6 10011501 Swing Door 1
7 HW06701 5/16 x 18 x2-3/8 Stud 1
2553301 Insulation - Swing Door (Carlin &
Riello Burners)
2553303 Insulation - Swing Door (Beckett
AFG Burners)
9 10011301 Mounting Door 1
81

19
REPLACEMENT PARTS - BURNER COMPONENTS
ITEM PART NO. DESCRIPTION QTY
BN04002 Burner Oil UT902 Beckett (KSB3100)
BN04003 Burner Oil UT903 Beckett (KSB4125)
BN04004 Burner Oil UT904 Beckett (KSB4150)
BN04006 Burner Oil UT906 Beckett (KSB5200)
BN08901 Burner Oil UT1801 Beckett (KSB6225, KSB7275)
30A064202 Burner Oil Riello 40/F5 (KSB3100, KSB4125, KSB4150)
BN07007 Burner Oil Riello 40/F10 (KSB5200)
BN08401 Burner Oil Carlin EZ-1 (KSB3100)
BN08402 Burner Oil Carlin EZ-1 (KSB4125, KSB4150)
BN08403 Burner Oil Carlin EZ-2 (KSB5200)
2 BN08001 Burner Oil Flange Gasket #3616 1
3 CD-001.01 Cad Cell (For Boilers w/Beckett Burners Only) 1
4 RY00701 Control R7184B 1032 (7456U) (For Boilers w/Beckett
Burners Only) 1
1320004 Nozzle .85 80B (KSB3100 Beckett)
1320006 Nozzle 1.10 80B (KSB4125 Beckett)
NZ-002.10 Nozzle 1.25 80B (KSB4150 Beckett)
NZ00206 Nozzle 1.75 80B (KSB5200 Beckett)
NZ01201 Nozzle 2.00 45B (KSB6225 Beckett)
14619346 Nozzle 2.25 45B (KSB7275 Beckett)
NZ00802 Nozzle .85 80W (KSB3100 Riello)
1320012 Nozzle 1.10 60W (KSB4125 Riello)
NZ00804 Nozzle 1.25 60W (KSB4150 Riello)
NZ00206 Nozzle 1.75 80B (KSB5200 Riello)
1320002 Nozzle .85 70B (KSB3100 Carlin)
1320010 Nozzle 1.10 70B (KSB4125 Carlin)
NZ00904 Nozzle 1.25 70B (KSB4150 Carlin)
NZ00905 Nozzle 1.75 70B (KSB5200 Carlin)
5 1
1 1
REPLACEMENT PARTS - BURNER COMPONENTS
(BECKETT BURNERS ONLY)
AFG BURNER PARTS
(Used on all boiler models with Beckett Burners except KSB6225 and KSB7275)
ITEM PART NO. DESCRIPTION
1 RP03801 Blast Tube AFG
RP03701 Fuel Pump, 2 Stage, 140 PSI, AFG
RP03702 Fuel Pump, 1 Stage, 140 PSI, AFG
3 BN07102 Drawer Assembly (Oil Line), AFG
4 BN08001 Burner Gasket
5 RP-015.00 Motor
6 RP-019.01 Transformer
BECKETT CF375 BURNER PARTS
(Used on models KSB6225 and KSB7275)
ITEM PART NO. DESCRIPTION
1 RP04501 Fuel Pump, Cleancut (21844U)
2 RP-015.00 Motor, PSC (21805U)
3 RP02001 Transformer (51771U)
4 RP04601 Oil Burner Valve Coil Kit (21755U)
2

20
SERVICE CHECKLIST
Size Angle Type O.F. INF
Draft CO2or
O2
Flue
Temp °F
Date Nozzle Pump
Pressure PSI Smoke#
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 ]
Controls and Safety Devices [ X ]
Nozzle-Size, Angle, Type [ * ]
Pump Pressure/Vacuum [ * ]
Line Voltage/Motor Amps [ * ]
Smoke Test [ * ]
Draft-Overfire/In Flue [ * ]
CO2or O2[ * ]
Flue Gas Temperature [ * ]
* Measure with instruments and record results
below.