PB Heat EC Series User's Manual
Contents
1. ams CHANGE FORTHE As an ENERGY STAR Partner PB Heat LLC has determined that certain firing QM m VP Ad ENERGY STAR rates of this product meet the ENERGY STAR guidelines for energy efficiency Installation Operation amp Maintenance Manual PeerlessBoilers com TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 1 A INSTALLATION CLEARANCE B SPECIAL ATTENTION BOXES 1 PREINSTALLATION 2 A CLEARANCES 2 0 eed 2 B AIR FOR COMBUSTION AND VENTILATION 2 CHIMNEY VENT AND DRAFT CONTROL 3 D INSTALLATION SURVEY PLANNING THE LAYOUT 2 BOILER PLACEMENT AND ASSEMBLY 4 A SETTING THE BOILER 4 B OBSERVATION COVER ASSEMBLY KNOCKDOWN BOILERS 4 C INSTALLATION OF FLUE COLLECTORS amp COVERPLATES KNOCKDOWN BOILERS 4 D TANKLESS HEATER OR COVERPLATE 4 E JACKET ASSEMBLY 4 3 PIPING AND CONTROLS 6 A PRESSURE TEST BLOCK ASSEMBLY 6 B BOILER RETURN CLEARANCE 6 C STEAM BOILER PIPING 6 D WATER BOILER PIPING 7 TANKLESS HEATER OR COVERPLATE 8 CONTROLS PEE 9 4 ELECTRICAL 10 GENERAL 10 B BURNER WIRING 10 5 BURNER SETUP amp BOILER OPERATION 14 A BURNER INSTALLATION 14 B BURNER START UP AND ADJUSTMENT 14 CHECK THE BOILER CONTROLS2. BOILER SERVICE SWITCH PROVIDED ON PACKAGED BOILERS FUSED DISCONNECT BY INSTALLER GR 115 60 1 11 HOT POWER R7184B BURNER 12 SUPPLY PRIMARY CONTROL o CRIMP TERMINATION 17248 BURNER LIMIT CONTROL J BOX mH 24 VOLT THERMOSTAT IGNITOR a OR BL INTERRUPTED GROUND OPERATING CONTROL TRANSFORMER SCREW Z CREE BURNER 2 MOTOR c WH BURNER lt MOTOR 2 BK BK BK 7 4 e lt m o Bi Ww w w W T e amp CIRCULATOR ADDITIONAL SAFETY or VALVE i3 SWITCHES OR FLOAT TYPE L W C O JUNCTION BOX VALVE WHEN REQUIRED CAD Y CELL MOLEX CONNECTOR HEYCO BUSHING IN JUNCTION BOX KNOCKOUT Hl 3 T T LINE VOLTAGE LOW VOLTAGE NOTE ALL WIRING MUST COMPLY WITH APPLIANCE CODES ORDINANCES AND REGULATIONS Figure 4 4 Water Boilers THERMOSTAT 24 VOLT SWITCHING RELAY AQUASTAT RELAY H R845A OR W R 829A 845 WIRE REMAINDER OF AQUASTAT RELAY IN ACCORDANCE WITH SYSTEM WIRING DIAGRAM SUPPLIED ONG o BOILER SER
3. P HAGO EC ECT 06 300 2 50 45 P HAGO Table 5 3 Riello Burner Specifications RIELLO BURNER SPECIFICATIONS i Start Up Settings SM Firing Rate EN Nozzle Size Pump Pressure P 8 Turbulator Air Damper EC ECT 03 075 0 60 60 DEL 155 psig EC ECT 03 100 0 85 60 W DEL 145 psig EC ECT 03 120 1 00 60 W DEL 145 psig EC ECT 04 125 1 00 60 W DEL EC ECT 04 150 1 25 60 B DEL 145 psig EC ECT 04 175 1 35 60 B DEL 165 psig EC ECT 05 175 1 35 60 B DEL 165 psig EC ECT 05 200 1 50 60 B DEL 170 psig 05 250 2 00 60 DEL 155 psig EC ECT 06 275 2 25 60 B DEL 150 psig EC ECT 06 300 2 50 60 B DEL 145 psig Factory Installed Nozzles Packaged Boilers or Burner Cartons are indicated in Boldface 1 Requires Low Firing Rate Baffle 2 Remove Static Plate for 1 20 GPH Rate 3 Shipped Loose with Packaged Boiler or Burner Carton 16 6 MAINTENANCE WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers RCF Airborne RCF when inhaled have been classified by the International Agency for Research on Cancer IARC as a possible carcinogen to humans After the RCF materials have been exposed to temperatures above 1800 F they can change into crystalline silica which has been classified by the IARC as carcinogenic to humans If particles become airbo
4. couplings Figure 3 8 Steam Boiler with Float Low Water Cut Off Use these components along with the gauge glass handles and other components from the Steam Trim Carton and install fittings and controls per Figure 3 10 The shorter gauge glass located in the Steam Trim Carton is not necessary for the probe application 4 Steam boilers subject to UL726 For installations subject to UL726 a second operating control that senses steam pressure is required not provided Use a PA404A or equivalent On probe boilers install the additional pressure control opposite the standard PA404A using a cross instead of a tee along with a second brass siphon not provided On float boilers install the additional pressure control in the location normally used for the standard PA404A on steam probe boilers fittings not provided 5 For complete information on servicing and adjustment of controls refer to the attached control specification sheets PRESSURE TROL OPTIONAL LOCATION Figure 3 9 Assembling Float Low Water Cut Off PA404A LIMIT 3 4 X 3 NIPPLE USE TAPPINGS amp C FOR PRIMARY PROBE APPLICATION TEE 3 4 X 3 4 X 1 4 STEAM GAUGE W 3 4 X 1 4 BUSHING BRASS SIPHON 9 1 4 GAUGE GLASS CG450 PROBE LWCO 1 2 X 1 2 NIPPLE W 1 2 COUPLING Figure 3 10 Steam Boiler with Probe Low Water Cut Off ELECTRICAL 4 ELECTRICAL All electrical wiring sh
5. 14 D PURGE AIR FROM THE SYSTEM WATER BOILERS ONLY 14 E CLEAN THE BOILER STEAM BOILERS 15 6 MAINTENANCE 17 A GENERAL 18 B DAILY MAINTENANCE WITH BOILER 18 WEEKLY MAINTENANCE WITH BOILER 18 D MAINTENANCE OF SAFETY RELIEF VALVE 18 E MONTHLY MAINTENANCE WITH BOILER 18 E MAINTENANCE ANNUAL 18 G IF ALONG SHUTDOWN IS REQUIRED 19 7 BOILER DIMENSIONS amp RATINGS 20 8 REPAIR PARTS 22 USING THIS MANUAL Indicates a condition or hazard which INSTALLATION CLEARANCE DANGER will cause severe personal injury death or major property damage Follow the installation instructions provided in this Jor property 9 manual in the order shown The order of these indicates a condition or hazard which instructions has been set in order to provide the installer WARNING may cause severe personal injury with a logical sequence of steps that will minimize d eath or major property damage potential interferences and maximize safety during boiler Jor property 9 otalangan CAUTION Indicates a condition or hazard which will cause minor personal injury or B SPECIAL ATTENTION BOXES property damage Throughout this manual you will see special attention Indicates special attention is needed bo
6. PURGE AIR FROM THE SYSTEM WATER BOILERS ONLY 1 Purge the system using purge valves isolating zones in the process or use system vents Do not operate the pump s while purging Pumps will hold air in the eye of the impeller Allow the system to reach 180 F and use manual vents if installed to remove any remaining air Watch the pressure gauge as the system approaches 180 F If the pressure exceeds the design operating pressure check a Fill valve pressure b Expansion or compression tank operation and sizing BURNER SETUP amp BOILER OPERATION Do not leave boiler unattended while E CLEAN THE BOILER CAUTION firing burner Operating boiler with STEAM BOILERS ONLY water below minimum permissible water level may fracture sections 1 Clean the boiler within one week after initial start up Cleaning will be more effective if boiler operates a 7 Turn on burner Allow boiler water to heat up to just day or two to loosen sediment and impurities in system Boiler must be cleaned to remove any accumulation of oil grease sludge etc in the system These substances can cause foaming and surging of boiler water producing an unstable water line and water below steaming 180 200 F Do not allow boiler to steam steaming mixes up contaminants instead of floating them at surface Open make up water valve to continually feed water to boiler Adjust flow to maintain water temperature at 180 200 carryov
7. 2 1 2 28 5 16 Dimensions are approximate Location Size NPT I 22 9 16 TAPPING LOCATIONS Water N A 15 1 16 21 5 8 Low Limit Control Limit Control Pressure Gauge Temperature Pressure Gauge Limit Control N A Gauge Glass and Low Water Cut Off Optional Return Return Secondary Probe Low Water Cut Off Secondary Probe Low Water Cut Off Safety Relief Valve Safety Valve Return N A Drain Valve Drain Valve Optional High Limit Skim N A Primary Probe Low Water Cut Off wl ol 2 z rj 20 N A Gauge Glass w Probe BOILER DIMENSIONS amp RATINGS Table 7 1 Boiler Ratings Series EC ECT Water Content Minimum Net I B R Ratings gal Stack Thermal Combustion Draft Steam Steam Water Efficiency Efficiency Required sqft MBH MBH Water in W C EC ECT 03 EC ECT 03 EC ECT 03 EC ECT 04 EC ECT 04 EC ECT 04 EC ECT 05 EC ECT 05 EC ECT 05 EC ECT 06 EC ECT 06 As an ENERGY STAR Partner PB Heat has determined that these firing rates meet the ENERGY STAR guidelines for energy efficiency t All chimneys are 8 x 8 x 20 except those models denoted with t which are 8 x 12 x 20 1 Burner input based on No 2 fuel oil with a heating value of 140 000 Btu per gallon 2 NetI B R wa
8. 285D S84 ZC90113 p D V 5 Ba 1 WH 9 W at C2 6 DFO 2 LINE VOLTAGE LOW VOLTAGE ZONE 1 CIRCULATOR PARTNER CIRCULATOR Figure 4 7 Partner with Circulator 13 5 BURNER SETUP amp BOILER OPERATION CAUTION Burn only 2 Fuel Oil in this appliance Do not use gasoline crankcase drainings or any oil containing gasoline A BURNER INSTALLATION 1 The oil burner is supplied with a mounting flange fixed in position 2 Mount the burner to the Burner Mounting Plate item 3 with four 4 5 16 studs and nuts provided NOTICE Be sure hi temp gasket is between the burner mounting flange and the Burner Mounting Plate 3 Care must be taken when routing the oil lines so not to interfere with the opening and closing of the burner mounting plate Flexible oil lines or flared copper disconnects with valves when copper lines are used may be installed to assure full opening of the burner mounting plate when servicing NOTICE Two pipe oil supply for Riello burner requires a separate kit Order part C7001026 from Riello dealer 4 Oil burner specifications For information pertinent to the oil burner such as nozzle sizing fuel supply piping adjusting or servicing refer to the charts in this section and the burner installation manual B BURNER START UP AND ADJUSTMENT CAUTION Do not start the burner unless all cleanout doors are in place 1 Burner
9. AR b As an alternative pipe the supply from the top of the front section and return to the bottom of the Figure 3 3 Water Boiler Piping rear section Provide air elimination means within the supply piping TO TANK 4 When the return temperature from the system will be below 150 F on oil boilers for extended periods THREE WAY VALVE heat pump systems outdoor reset snow melt etc provide piping and controls to protect the boiler from condensation Condensation will damage the boiler and will lead to shortened boiler life and maintenance problems B PORT 0 27 DOMESTIC_HOT WATER SUPPLY 279000 WATER 5 If using a Partner indirect fired water heater or other see Figure 3 4 for typical piping Also refer to System additional instructions supplied with the Partner DOMESTIC HOT_WATER STORAGE TANK INTERNAL 6 If the boiler is to be used in conjunction with a eL refrigeration system the chilled medium shall be BOILER piped in parallel with boiler and proper valves applied to prevent the chilled medium from entering the boiler Refer to Figure 3 5 Figure 3 4 Piping with Peerless Indirect 7 Ifthe boiler is connected to heating coils located in Mater Tank air handling units the boiler piping system must be equipped with flow control valves or other automatic devices to prevent gravity circulation of the boiler water during the cooling cycle CHECK VALVE Figure 3 5 Isolating Boil
10. IXER COLO INLET Figure 3 7 Tankless Coil Piping Steam Boiler PIPING AND CONTROLS F CONTROLS CAUTION Pipe the discharge of the safety valve or relief valve to prevent injury in the event of pressure relief Pipe the discharge to a drain Provide piping that is the same size as the relief valve 1 Water Boiler Controls Install the limit operating control pressure temperature gauge and safety relief valve See Figure 7 1 Section 7 for proper location For installations subject to UL726 a second operating control that senses water temperature is also required not provided Use an L4080B or equivalent Install in the supply piping near the boiler 2 Steam Boiler with Float Low Water Cut Off Install pressure limit control pressure gauge gauge glass trim and safety valve See Figure 3 8 Figure 3 9 and Figure 7 1 Section 7 See also control manufacturer s instruction sheet shipped with the control 3 Steam boilers with Probe Low Water Cut Off CAUTION Use only the Hydrolevel CG450 as a primary probe low water The CG450 includes a cycle timer to sense water level under foaming or surging conditions Failure to use this model could result in a failed heat exchanger Probe models use a longer gauge glass than float models The following components are packed in the Probe Carton 90759 Hydrolevel CG450 LWCO Gauge glass 22 162 10 3 4 3 nipple 3 4 x 3 4 x 1 4 tee 2 1 2
11. OILERS Attach left side jacket panels in the same manner as the right side panel 1 Open flue collector carton Remove flue collector Item 9 and high temperature rope Lay rope Item 8 on top of boiler against bead provided Place flue collector on top of rope and attach to boiler with 1 4 20 x 1 3 4 studs with nuts through flue collector brackets into the tapped lugs provided in the top of the boiler end sections Draw nuts down 7 Attach the top panel Item 26 Secure top panel to front and back panel with sheet metal screws INSTALLATION OF SIDE CLEAN OUT COVER PLATES SIDE CLEAN OUT snugly COVER PLATE W INSULATION 2 Remove clean out cover plates and insulation Item 25 Each clean out cover plate is attached to the boiler by using two carriage bolts nuts and washers Item 24 Install the carriage bolts into the notch at the top and bottom of each clean out opening then secure them with a flat washer and steel nut as shown in Figure 2 1 locking them in place Press the clean out plate with insulation over the protruding HEX NUT FEAT WASHERS carriage bolts until the bolts punch through the BRASS HEX NUT CARRIAGE BOLT insulation so flat washer and brass nut can be 5 16 UNC X 1 3 47 LG installed Tighten down nuts snugly compressing the insulation to form a good seal around the clean out Figure 2 1 Side Clean out Cover Plates opening D TANKLESS HEATER OR COVERPLATE If an ECT steam boiler is to be
12. R SPECIFICATIONS Boiler Burner Air eee Pump Start up Settings Model No Firing Rate Model No Shutter Pressure Air Band Head Bar Nozzle Size EC ECT 03 075 0 60 70 B DEL 150 psig 0 60 0 65 EC ECT 03 100 0 85 70 A DEL 150 psig 0 85 1 00 EC ECT 03 120 1 00 70 A DEL 150 psig 0 85 1 00 Boiler Air Pump Start up Settings Model No Shutter Pressure Head Dim A Air Band EC ECT 04 125 1 00 x 70 DEL 150 psig 40 open EC ECT 04 150 1 25 x 60 B DEL 150 psig 60 open EC ECT 04 175 1 50 x 60 B DEL 150 psig 100 open EC ECT 05 175 1 50 x 60 150 psig 10 open EC ECT 05 200 1 65 x 60 B HAGO 150 psig 45 open EC ECT 05 250 2 00 x 60 BHAGO 150 psig 100 open EC ECT 06 275 102CRD 2 25 x 60 B DEL 150 psig 100 open EC ECT 06 300 102CRD 2 50 x 60 B DEL 150 psig 10096 open Nozzle Size Table 5 2 Beckett Burner Specifications BECKETT BURNER SPECIFICATIONS 140 psig Pump Pressure Boiler Burner Start up Settings Model No Model No Burner Head Static Plate Nozzle Size Hand Head Setting N A EC ECT 03 075 0 65 60 EC ECT 03 100 0 85 60 B HAGO N A EC ECT 03 120 1 00 60 N A EC ECT 04 125 1 10 80 A DEL j N A EC ECT 04 150 1 25 80 B HAGO EC ECT 04 175 1 50 80 B HAGO EC ECT 05 175 1 50 60 B HAGO EC ECT 05 200 1 75 60 B HAGO EC ECT 05 250 2 00 45 B HAGO EC ECT 06 275 2 25 45
13. TALLER This manual is the property of the owner and must be affixed near the boiler for future reference TO THE OWNER This boiler should be inspected annually by a Qualified Service Agency Service Information Name Address PeerlessBoilers com PB HEAT LLC 131 S CHURCH ST BALLY 19503 Phone A LIDI US MEMBER Belus ten ASME 2008 EC8000 R24 2 08 5M Printed in U S A
14. VALVE JUNCTION BOX Y Y MOLEX CONNECTOR HEYCO BUSHING IN JUNCTION BOX KNOCKOUT ROLE VEL 650 55 WHEN REQUIRED NON LINE VOLTAGE NNUS 24 LOW VOLTAGE 25 OPERATING CONTROL NOTE ALL WIRING MUST COMPLY WITH APPLIANCE CODES ORDINANCES AND REGULATIONS FOR STEAM W TANKLESS HEATER ONLY Figure 4 2 Steam Boiler with Float Low Water Cut Off BRIMARY CONTROL BOILER SERVICE SWITCH PROVIDED ON CRIMP PACKAGED BOILERS FUSED DISCONNECT TERMINATION BY INSTALLER 12 115 60 1 BURNER Li HOT POWER J BOX GR SUPPLY IGNITOR BL INTERRUPTED GROUND TRANSFORMER SCREW HYDROLEVEL CG450 Al PROBE L W C O BURNER 0 MOTOR BK e R LIMIT CONTROL BK OIL V N ED o VALVE JUNCTION BOX BK MOLEX CONNECTOR HEYCO BUSHING Y IN JUNCTION BOX KNOCKOUT BK ADDITIONAL SAFETY SWITCHES WHEN REQUIRED LINE VOLTAGE N a 24V THERMOSTAT LOW VOLTAGE OPERATING CONTROL NOTE ALL WRING MUST COMPLY WITH APPLIANCE CODES ORDINANCES AND REGULATIONS FOR STEAM W TANKLESS HEATER ONLY Figure 4 3 Steam Boiler with Probe Low Water Cut Off 11 ELECTRICAL P2 JOIN WITH NEUTRAL IN JUNCTION BOX WHITE x 5d HYDROLEVEL 650 550 PROBE TYPE L W C O WHEN REQUIRED NOTE MOUNT IN BOILER SUPPLY PIPING
15. VICE SWITCH PROVIDED o90GQ0 ON PACKAGED L2 BOILERS pus 4 4 120 60 1 L1 4 0 e POWER SUPPLY 12 e CIRCULATOR LINE VOLTAGE LOW VOLTAGE NOTE ZONE 1 ZONE 2 ZONE 43 ALL WRING MUST COMPLY WITH APPLICABLE CODES ORDINANCES AND REGULATIONS Figure 4 5 Zoning with Circulators 12 ELECTRICAL THERMOSTATS 24V 120V 60HZ TO MAIN TRANSFORMER DISCONNECT 120 24V 60HZ SWITCH 1 ij 40VA i Le HOT 2 2 JUNCTION BOX 4 i A MESE e i Y EE uli J Y MN sl Pry aep cuc nee ue 3 Y ZEN Y pn mm 2 ee EE Y J Y 4 Y ZONE VALVES Y POSAIT ZONE ZONE ZONE ZONE os RELAY ni NO 1 NO 2 NO 3 NO 4 1 TT Topo UR I R 1 R 1ve B de Rod R R R L E 5 R J R WRE REMAINDER OF AQUASTAT RELAY IN ACCORDANCE WTH SYSTEM WIRING DIAGRAM SUPPLIED NOTE ALL WIRING MUST COMPLY WITH APPLICABLE CODES ORDINANCES AND REGULATIONS LINE VOLTAGE LOW VOLTAGE Figure 4 6 Zoning with Zone Valves ZONE 1 THERMOSTAT 24V L7248 LIMIT CONTROL PARTNER TRANSFORMER RELAY THERMOSTAT R8
16. all be done in accordance with the National Electrical Code and Local Requirements Single pole switches including those of safety controls or protective devices shall not be wired in a grounded line B BURNER WIRING 1 See Section 5 for mounting burner 2 Install junction box limit harness and Heyco bushing each located in the trim carton See Figure 4 1 Mount junction box to the holes in the left side of jacket with 2 10 x 1 2 sheet metal screws Attach Heyco bushing to 7 8 knockout in front side of junction box Connect limit harness to 7 8 knockout on top of junction box and insert limit harness Molex connector into Heyco bushing until it snaps firmly in place WARNING Improper installation of burner harness can allow burner to energize with burner mounting plate open creating a severe burn hazard to boiler maintenance personnel SEE JUNCTION BOX DETAILS JUNCTION BOX SERVICE SWITCH FIELD SUPPLIED ON KNOCKDOWN INSERT MOLEX BOILERS FROM LIMIT HARNESS INTO BUSHING CONNECT RED WIRES TO SWITCH SPLICE RED WIRE ON KD BOILERS ATTACH INCOMING HOT LEAD HERE ATTACH INCOMING NEUTRAL LEAD TO WHITE WIRE J BOX ASSEMBLY WITH SERVICE SWITCH SWITCH PROVIDED ON PACKAGED BOILERS Figure 4 1 Junction Box Wiring 10 SPLICE AND ATTACH INCOMING HOT LEAD 3 Install burner harness located in the burner carton Beckett or Carlin EC7022 Harness 21 conduit Riello EC7023 Har
17. building two openings one near the ceiling and one near the floor of the boiler room shall be provided with the minimum free area of each opening equal to 140 sq in per gallon of oil burned If all air for combustion and ventilation is to come from outside the building two openings one near the ceiling and one near the floor of the boiler room shall be provided with the minimum free area of each opening equal to 35 sq in per gallon of oil burned If ducts are used to convey the air areas of 35 sq in per gallon of oil burned for vertical ducts or 70 sq in per gallon of oil burned for horizontal ducts are to be provided Ducts shall have the same area as the free area of the openings to which they are connected C CHIMNEY VENT AND DRAFT CONTROL An oil fired unit shall be connected to a flue having sufficient draft at all times to assure safe proper operation of the unit Draft Requirement Minimum draft required in the vent system is 03 to 05 W C depending on boiler model see Table 7 1 Section 7 This draft is necessary to provide the necessary draft over fire of 01 to 02 W C See discussion in paragraph 5 below regarding draft Use barometric provided to control draft Follow manufacturer s instructions to locate and adjust the control Inspect the existing chimney or vent system Make sure it is in good condition Inspect chimney liner and repair or replace if necessary The vent system and
18. ction possible to the center of the heating system E JACKET ASSEMBLY 2 Refer to Figure 2 2 for exploded view of boiler while checking and or assembling parts of the boiler 1 Refer to Figure 2 2 for exploded view 3 See clearance information in Section 1 2 Attach the back panel Item 19 to bosses on middle Preinstallation of back section with two 1 4 x 3 8 truss head machine screws Item 20 provided The back panel 4 On packaged boilers open burner mounting plate has two 5 16 diameter holes close to the center of Item 3 at this time to make certain the target wall the panel Item 2 is seated in the back of the combustion chamber Ceramic fiber blanket base liner Item 28 3 Lift off the burner mounting plate should be lying flat on bottom of combustion chamber between target wall and burner 4 Remove the 2 knock outs in the front jacket panel Item 23 which allow clearance for the hinge Place B OBSERVATION COVER ASSEMBLY 2 KNOCKDOWN BOILERS 5 Attach right side jacket panel Item 22 to the front 1 Remove observation door Item 4 from inside and back panels with sheet metal screws burner mounting plate Attach the observation door to the outside of the mounting plate 6 steam boilers if a tankless heater is used remove the knock out in upper left side jacket panel Item INSTALLATION OF FLUE COLLECTOR 21 and back jacket panel Item 19 before installing COVERPLATES KNOCKDOWN B
19. elihood of freezing 2 If there is considerable foreign matter in the boiler water the boiler should be shut down and allowed to cool then drained and thoroughly flushed out Drain the boiler at the drain cock Pipe the drain cock to a suitable drain or containment device if antifreeze is used Flush the system to remove remaining matter If there is evidence that hard scale has formed on the internal surfaces the boiler should be cleaned by chemical means as prescribed by a qualified water treatment specialist 3 There must be no signs of continuous wetness at the chimney If signs of continuous wetness are observed a qualified service agency must be consulted to modify the vent configuration to prevent the formation of condensate which may damage the vent pipe WARNING Do not use this appliance if any part has been under water Improper or dangerous operation may result Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any control which has been under water B DAILY MAINTENANCE WITH BOILER OPERATING Daily boiler observation can be performed by the owner If any potential problems are found a qualified installer or service technician agency must be notified 1 Remove any combustible materials gasoline and other flammable liquids and substances that generate flammable vapors from the area where the boiler is contained Make certain that the boile
20. er from Chilled Medium on Chiller Systems PIPING AND CONTROLS E TANKLESS HEATER OR COVERPLATE 1 Ifa tankless coil is used item 13 or 17 install as pictured On water boilers install in opening in front section On steam boilers install in opening in rear section For suggested piping of tankless water heaters refer to Figures 3 6 and 3 7 DANGER Install anti scald device in hot water supply piping Water temperature above 125 F can cause severe burns instantly or death from scalds NOTICE X1020R and X1082R coils installed in EC ECT 03 amp 04 packaged boilers have internal flow controls installed Do not use external flow controls with these coils TANKLESS HIGH TEMPERATURE HEATER HOT WATER TAPPING WATER MIXER COLD WATER INLET Figure 3 6 Tankless Coil Piping Water Boiler 3 4 CONTROL 2 If not using a tankless coil cover the heater opening with cover plate item 12 or 16 NOTICE Be sure rubber gasket is in place between cover plate or water heater plate and boiler section 3 See Table 3 2 for tankless coil ratings Table 3 2 Maximum Tankless Water Heater Ratings a 1020 Series X1020R X1082 X1082R Series ECT Water Heater ratings are based on intermittent demand 40 F to 140 F with 200 F Boiler Water HIGH TEMPERATURE HOT WATER 3 4 CONTROL TAPPING 12 MIN MIXED WATER FLOW CONTROL WATER M
21. er to system CAUTION Do not allow make up water to flow WARNING Cleaning the boiler requires the use too fast Excessive quantities of cold of very hot water and corrosive water may fracture sections chemicals Use care when handling to prevent injury 9 Continue skimming boiler until water flowing from skim tapping flows clear This will take some time 3 Connect a skim valve off the 1 1 2 NPT skim tapping possibly several hours for a dirty system on rear of boiler See Figure 7 1 Section 7 for skim tapping location Run a 1 1 2 NPT drain line off skim valve to a point of safe discharge 10 Turn off burner close make up water valve 11 Drain boiler completely Refill and drain one or two 4 Provide a means of supplying continuous fresh water times to wash out all washing soda to the boiler for the cleaning process pr 12 Remove skim valve and piping Pipe a nipple and 5 Use common washing soda such as Arm and cap in the skim valve Hammer Super Washing Soda Mix 1 2 pound of soda with water in a 10 quart pail Pour the mixture NOTICE If gauge glass becomes dirty more into the boiler through the safety relief valve tapping contaminants have worked loose in system Repeat cleaning and skimming process as needed to 6 Open the skim valve Fill boiler until water begins to clean system flow out of the valve 15 BURNER SETUP amp BOILER OPERATION Table 5 1 Carlin Burner Specifications CARLIN BURNE
22. installation must be in accordance with the current edition of the American National Standard ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances or applicable provisions of the local building codes See Table 7 1 Section 7 for typical chimney size If the vent system is not sized properly the burner may not operate properly This can cause poor combustion sooting and odors to occur Background Information Regarding Draft Modern boilers operate with higher efficiencies than older boilers Smaller flueways as well as bars pins and fins are designed into modern boilers to transfer as much heat as possible from the hot gases to the water or steam and prevent heat loss up the chimney However these design features result in higher pressure or draft loss in the boiler This draft loss must be taken into account when installing an oil boiler into a new or old chimney New chimneys are less likely to have poor draft However they must have sufficient draft to support combustion A 06 draft is desirable and preferred Older chimneys may require a replacement liner to have them perform well enough to support combustion PREINSTALLATION For Example Chimney Draft Old Installation New Installation Comments No change but older chimneys especially unlined ones have leaks which reduce draft Boiler Design Pressure Drop Required for mandated efficiency increases Draf
23. installed with a tankless heater coil the coil must be installed before the left side jacket panels are attached When a tankless heater is not employed cover the heater opening with cover plate Item 12 or 16 See Section 3 Piping and Controls for piping information BOILER PLACEMENT AND ASSEMBLY Figure 2 2 Boiler Exploded View See Table 8 1 in Section 8 for parts identification 3 PIPING AND CONTROLS NOTICE Do not pipe boiler before jacket is installed A PRESSURE TEST BLOCK ASSEMBLY 1 2 Make up cold water supply connection to the boiler Install pressure gauge or pressure temperature gauge in tapping provided See Boiler Dimensional drawing Figure 7 1 Section 7 Plug all open tappings in the boiler and fill with water Apply approximately thirty 30 psig pressure Check to make certain that all joints and fittings are water tight After all joints and connections have been proven tight remove cold water supply and plugs from all tappings that are to be used See Figure 7 1 Section 7 for tapping locations B BOILER RETURN CLEARANCE Return piping must allow for opening and closing Burner Mounting Plate PB Heat LLC suggests installing a 1 1 4 NPT tee a 90 elbow and a 1 1 4 NPT x 5 long nipple in the return tapping before a vertical stand pipe is used C STEAM BOILER PIPING 1 Refer to the Steam Installation Survey and Hydronics Institute Residential Hydronic Heating Insta
24. llation Design Guide for guidance See Figures 3 1 and 3 2 The return from system should always enter equalizer through Hartford Loop 2 to 4 below normal water line see dimensional drawing for normal water line See Table 3 1 for pipe size information Use swing joints to attach header to avoid damage to the boiler due to thermal expansion and contraction of steam header pipe Pipe the steam header a minimum of 24 above the normal water line using swing joints to attach the risers into the steam header FRONT FRONT Figure 3 1 Steam Boiler Piping EC 03 HEADER EQUALIZER RISERS REAR Figure 3 2 Steam Piping EC 04 to EC 06 N REAR Table 3 1 Boiler Model No Steam Pipe Sizing Header Equalizer Risers EC ECT 03 075 EC ECT 03 100 EC ECT 03 120 EC ECT 04 125 EC ECT 04 175 EC ECT 04 175 EC ECT 05 200 EC ECT 05 250 EC ECT 06 275 EC ECT 06 300 PIPING AND CONTROLS SUPPLY 1 Refer to the Water Installation Survey and Hydronics Institute Residential Hydronic Heating Installation Design Guide for Guidance 2 The supply and return connections should be sized to suit the system 3 Pipe the supply and return in one of two ways as shown in Figure 3 3 a Pipe the supply from the top of the rear section ALTERNATE and return to the bottom of the front section Use L See the 3 4 tapping in the top of the back section for air elimination FRONT RE
25. ner component operation F MAINTENANCE ANNUAL NOTICE Entire heating system including boiler burner and venting system must be inspected at least once a year by a qualified heating professional Boiler is to be cleaned at least once a year WARNING Disconnect all power to the burner before accessing combustion chamber TO CLEAN 1 Remove top jacket panel and flue collector Item 9 2 To thoroughly clean the boiler it must be brushed down from the top and or left side Alternatively for limited space or minimum clearance to combustible installations cleaning the heat exchanger from the combustion chamber side is acceptable If unit is extremely dirty it may be necessary to brush from all directions The target wall is made of a soft ceramic fiber Care must be taken not to damage this material during cleaning MAINTENANCE 3 Remove any scale or soot from the combustion G IF A LONG SHUTDOWN IS REQUIRED chamber area by vacuum cleaning or any other available means 1 To take boiler out of service if the boiler and system are not to be used when temperatures are below NOTICE Burner mounting plate must be freezing opened to facilitate this operation a Drain the boiler and system completely and shut off make up water supply 4 Replace flue collector and close burner mounting plate making sure all gaskets are in place b Open main line power disconnect switch to boiler Remove the fuses or secure the
26. ness 28 conduit 4 For complete information on servicing and adjustment of controls refer to the attached control specification sheets 5 See the following Wiring Diagrams Figure 4 2 Steam Boilers with Float LWCO Figure 4 3 Steam Boilers with Probe LWCO Figure 4 4 Water Boilers Figure 4 5 Zoning with Circulators Figure 4 6 Zoning with Zone Valves Figure 4 7 Partner with Circulator JUNCTION BOX SIDE PANEL INSERT MOLEX FROM LIMIT HARNESS INTO BUSHING TO RED WIRE BUSHING BLACK GROUND ATTACH INCOMING NEUTRAL LEAD TO SCREW WHITE WIRE J BOX ASSEMBLY LESS SERVICE SWITCH SEE OTHER DETAIL TO INSTALL FIELD SUPPLIED SERVICE SWITCH ELECTRICA BOILER SERMCE SWITCH PROVIDED BOERS FUSED DISCONNECT BY INSTALLER R7184B BURNER PRIMARY CONTROL CRIMP TERMINATION eos En POWER BURNER GR SUPPLY J BOX ADDITIONAL IGNITOR LIMIT SAFETY SWITCHES BL INTERRUPTED GROUND A tae CONTROL WHEN REQUIRED TRANSFORMER SCREW BK Fo o BK OU BURNER BURNR 0 MOTOR motor 67 FLOAT TYPE L W C 0 JUMPER JOIN WITH NEUTRAL IN I JUNCTION Box WHITE OO O Pz 9
27. r area has ample air for combustion and ventilation and that there are no obstructions to the free flow of air to and from the boiler 2 Observe general boiler conditions unusual noises vibrations etc 3 Observe operating temperature and or pressure gauge on the boiler Boiler pressure should never be higher than 5 psi below the rating shown on the safety relief valve The valve rating can be found on the top of the safety relief valve Boiler temperature should never be higher than 250 F 4 Check for water leaks in boiler and system piping C WEEKLY MAINTENANCE WITH BOILER OPERATING 1 Flush float type low water cut off if used to remove sediment from the float bowl as stated in the manufacturer s instructions D MAINTENANCE OF SAFETY RELIEF VALVE 1 Check function and maintain safety relief valve as specified by manufacturer typically every other month or every month per the instructions on the tag on the safety relief valve E MONTHLY MAINTENANCE WITH BOILER OPERATING 1 Check boiler room floor drains for proper functioning 2 Test probe type low water cut off if used by using the Push to Test Button CAUTION Turn off power to boiler before adjusting limit control 3 Test limit by lowering the limit set point until the burner shuts down When proper operation is confirmed return the set point to original setting 4 Follow additional instructions in the Burner Manual for proving the bur
28. rne during service or repair inhalation of these particles may be hazardous to your health Avoid Breathing Fiber Particulates and Dust Suppliers of RCF recommend the following precautions be taken when handling these materials Precautionary Measures Provide adequate ventilation Wear a NIOSH MSHA approved respirator Wear long sleeved loose fitting clothing and gloves to prevent skin contact Wear eye goggles Minimize airborne dust prior to handling and removal by water misting the material and avoiding unnecessary disturbance of materials Wash work clothes separately from others Rinse washer thoroughly after use Discard RCF materials by sealing in an airtight plastic bag First Aid Procedures Inhalation If breathing difficulty or irritation occurs move to a location with fresh clean air Seek immediate medical attention if symptoms persist Skin Contact Wash affected area gently with a mild soap and warm water Seek immediate medical attention if irritation persists Eye Contact Flush eyes with water for 15 minutes while holding eyelids apart Do not rub eyes Seek immediate medical attention if irritation persists Ingestion Drink 1 to 2 glasses of water Do not induce vomiting Seek immediate medical attention MAINTENANCE 1 Check pipes adjacent to cold walls or in unheated spaces Insulate and tape them if necessary to be sure they can t freeze up Keeping the water moving at all times will reduce the lik
29. should start automatically when thermostat is turned up and main boiler service switch is turned on If burner does not start check to be sure there is oil in the tank and push reset button on burner control Beckett Square red button Carlin Round red button Riello Round red button inside clear flexible cover on back of burner cover If burner still does not start contact serviceman CAUTION Do not attempt to start the burner when excess oil has accumulated when the unit is full of vapor or when the combustion chamber is very hot 2 Adjust burner and barometric draft control for highest COz Maximum 13 EC 03 EC 05 or 12 1 2 EC 06 while maintaining a 0 Smoke and 01 to 02 W C draft overfire All adjustments must be made using suitable instruments such as found in a Bacharach Combustion Test Kit Burner and boiler can be shut down by turning down the thermostat and moving the main boiler service switch to the off position See burner manufacturer s manual for further information regarding the burner C CHECK BOILER CONTROLS T Limit and Operating Controls a Lower the set point of each control until the burner shuts down Note that the system pressure or temperature corresponds to the desired set point b Return the controls to the desired set point Low Water Cut off if used consult the manufacturer s instructions for the low water cut off operational check procedure D
30. switch so 5 Replace jacket top panel that the power cannot be turned on accidentally All cover plates enclosures and CAUTION Always keep the manual fuel supply valve shut off if the burner is shut guards must be maintaimediin place down for an extended period of time at all times except during p maintenance and servicing 2 Be certain that the boiler and system are refilled before returning to service 6 Inspect venting system 7 BOILER DIMENSIONS amp RATINGS Xi d I 3 4 AIR ELIMINATION 2 13 16 25 TANKLESS N COIL uu r rn LOCATION Mc E 3 5 STEAM y __ 0 ng _ 6 99 TANKLESS 4 NUM COIL 294 p LOCATION A 0 WATER ONLY an 4 N L g FLOOR io A 2 TN T APPROX REAR SIDE FRONT Figure 7 1 Boiler Dimensions Purpose of Tappings Jacket DIMENSIONS Length of Depth 03 22 1 2 15 3 4 Fire Box 10 Rear of Jacket to Flue 8 3 4 Distance Between Tappings 9 1 16 Flue Outlet Diameter E F EC ECT 04 22 1 2 19 15 16 14 3 16 10 7 8 13 1 4 EC ECT 05 22 1 2 24 1 8 18 3 8 13 17 7 16 EC ECT 06 2
31. t Over Fire The old installation would have had a higher temperature in the chimney as high as 800 degrees vs 400 degrees F which would increase the draft The above readings are cold readings before the boiler and chimney are heated up Note also that the higher the firing rate on a unit which has multiple firing rates the higher the draft required For example increasing the firing rate 1 4 gallon may increase the draft loss in a unit by approximately 01 D INSTALLATION SURVEY For new and existing installations a Water Installation Survey or a Steam Installation Survey is available from PB Heat LLC The surveys will provide information on how the boiler works with your specific system and will provide an overview of boiler system operation in general You can also use this survey to locate system problems which will have to be corrected To obtain copies of these Surveys contact your PB Heat representative or download it from PeerlessBoilers com E PLANNING THE LAYOUT Prepare sketches and notes of the layout of the installation Include boiler location venting system existing piping and wiring Show existing equipment that may interfere with installation of new equipment 2 BOILER PLACEMENT AND ASSEMBLY A SETTING THE BOILER NOTICE Be sure rubber gasket is in place between cover plate or water heater 1 Provide a level foundation located as close as plate and boiler se
32. t to Combustible Construction Recommended From Jacket for Accessibility and Mounting Controls 24 if Left Side Clearance less than 24 to clean flueways from top 16 from jacket due to burner 24 if Top Clearance less than 24 to clean flueways from left side 24 on steam with tankless coil 9 in area of boiler service switch and junction box Right 2 12 due to burner swing radius Rear 2 9 for mounting relief valve Vent Pipe Single Wall 9 to Combustible Construction Clearance may be reduced using methods in NFPA 31 Vent Pipe Double Wall See Manufacturer s Instructions Consider also vent pipe clearance including distance from edge of flue outlet to combustible construction as applicable Unit may be installed on combustible flooring provided the boiler is not set on carpet and a metal drip pan is placed under the appliance Unit may be installed in a closet with the above clearances See also Section B Air for Combustion and Ventilation For installation in unconfined spaces with conventional construction and larger areas such as basements the supply of air for combustion and ventilation can usually be considered adequate 3 Appliances Located in Confined Spaces a All air from inside the building Provide two permanent openings communicating directly with an additional room If all air for combustion and ventilation is to come from within the
33. ter ratings based on an allowance of 1 15 3 4 Net I B R steam ratings based on an allowance of 1 333 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc 5 Output is Heating Capacity for models with inputs 300 MBH and Gross Output for models with inputs 2300 MBH Heating Capacity and Annual Fuel Utilization Efficiency AFUE ratings are based on U S Government tests with 13 CO and 0 02 w c draft over fire Before purchasing this appliance read important information about its estimated annual energy consumption or energy efficiency rating that is available from your retailer 6 Combustion efficiency and gross output are determined in accordance with The Hydronics Institute s Testing and rating standard for Heating Boilers 12 5 CO and 0 02 w c draft over fire 21 8 REPAIR PARTS Repair parts are available from your installer or by contacting PB Heat LLC 131 S Church Bally PA 19503 Note Remember to include boiler model number and serial number when ordering parts Table 8 1 Description EC ECT 03 Repair Part Stock Code EC ECT 04 EC ECT 05 EC ECT 06 i Block Assembly EC 90662 90663 90239 90758 Block Assembly ECT 90664 90665 90242 90755 2 Target Wall 50768 3 Burner Moun
34. ting Plate 93530 4 Observation Door 51677 5 5 16 18 x 2 1 4 Stud use with 5 16 18 Nut 3 51747 6 Burner Mounting Plate Internal Hinge 51149 8 High Temp Rope 1 2 Diameter Medium Density B Du B in 9 dus amp ECO6 stock codes include side 90555 90556 99538 99539 10 1 4 20 x 1 3 4 Stud use with 1 4 20 Nut 2 51751 11 Rubber Gasket 51800 12 Cover Plate 99812 includes gasket and cap screws 13 Tankless Coil Optional Water Only 90534 14 3 8 16 x 3 4 Hex Hd Cap Screws 6 99788 15 Rubber Gasket ECT Models 90547 16 Cover Plate Optional ECT Models 90140 includes gasket and cap screws 17 Tankless Heater Optional ECT Models 90546 18 3 8 16 x 3 4 Hex Hd Cap Screws 6 99788 24 5 16 18 x 1 3 4 Carriage Bolt use with 5 16 18 Nut 4 93997 6 93997 8 93997 10 93997 25 Side Cleanout Cover Plate 2 51772 3 51772 4 51772 5 51772 28 Base Liner 1 2 x 14 50857 6 50858 10 1 2 50846 18 3 4 LG 19 Back Jacket Panel 20 2 1 4 20 x 3 8 Truss Hd Mach Screw Zinc 21 Upper Left Side Jacket Panel 90278 90279 90280 90281 21A Lower Left Side Jacket Panel Jacket Jacket Jacket Jacket 22 Right Side Jacket Panel Assembly Assembly Assembly Assembly 23 Front Jacket Panel 26 Top Jacket Panel See Figure 2 2 on page 5 for boiler exploded view 22 NOTES 23 NOTES 24 Series EC ECT Oil Boilers Installation Operation amp Maintenance Manual TO THE INS
35. xes intended to supplement the instructions and make NOTICE but not directly related to potential special notice of potential hazards These categories injury or property damage mean in the judgment of PB Heat LLC PREINSTALLATION 1 PREINSTALLATION Read carefully study these instructions before beginning work It will save time Study the included drawings Save these instructions for reference This boiler must be installed by a qualified contractor The boiler warranty can be voided if the boiler is not installed maintained and serviced correctly NOTICE The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made including the current edition of NFPA 31 Standard for the Installation of Oil Burning Equipment and in Canada CSA 139 Installation Code for Oil Burner Equipment These shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made CAUTION Never burn garbage or paper in the B AIR FOR COMBUSTION AND unit and never leave combustible VENTILATION material around it 1 Be certain adequate facilities are available to provide CAUTION Do not tamper with boiler controls air for satisfactory combustion and ventilation 2 Appliances Located in Unconfined Spaces A CLEARANCES ui Table 1 1 Clearances from Jacket and Vent System Required from Jacke
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