PeerlessBoilers ECT-03-120, ECT-04-125, ECT-04-150, ECT-04-175, ECT-05-175 Installation, Operation & Maintenance Manual

EC/ECT

Boilers

Installation,

Operation b

Maintenance
Manual

Pr=-r=-I_LESS"

CAST IRON BOILERS

Packaged or Knockdown, Hot Water or Steam Boilers

11 Sizes 3-6 Sections .75 to 3.0 GPH Input 82.9% to 86.6% AFUE

Natural Draft (chimney) Venting

Factory Assembled Sections on Knockdown Boilers

• Reduces Installation Time

High Efficiency Flame Retention Burners

• Choice ofBeckett, Carlin or Riello

Full Plate Swing-Out Door

• Standard on All Boilers

• Provides Easy Access to Combustion Chamber AreaJor Cleaning and Servicing

Large Water Content, Wet Base Section Design

• Ideal for Steam and Large Volume Hot Water Applications

Steel Push Nipples

• Provide a Permanent Woter Tigh[ Seal Between Sections

• Unaffected by Petroleum and Other Contaminants

Easy to Clean

• Flueways carl be Cleaned from Either the Left Side or Top

Deluxe Insulated Enameled Steel Jacket

• Reduces Boiler Heat Loss

Safety Controls

• Probe or Float Type Low Water Cut OffApprovr_d on Steam Boilers

Tankless Coils

• For Domestic Hot Water Production on Hot Water Boilers

• Honeywell Operating Controls

• Barometric Draft Damper

• Taco 007 Circulalor on Packctged WcJler Boilers

• Float Type LWCO on Packagt'd Steam Boilers

\ Ix .,,p_o__ I

• "l_mkless Coils

• Gnlnc!lbs Circulalor on Pctckaged Water Boilers

.,,_ *Pcob<" Tt.ip_" LWCO olt Packaged Sly,am Boilers

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Peerless Boilers * 610-367-2153 • www.peerless-heater.eom

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Background Information - Draft Requirements

Modern boilers operate with higher efficiencies than older boilers. Smaller flueways, as well as bars, pins
and fins are designed into modem 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 pres-

sure, 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 combus-

tion. A -.06" draft is desirable and preferred. Older, unlined chimneys may require a replacement liner to
have them perform well enough to support combustion.

An example follows:

Chimney Draft

Old installation New installation

-.04" -.04"

Comments

No change, but older chimneys
(especially unlined ones) have

leaks which reduce draft.

Boiler Design Pressure Drop +.01" +.04"

Required for mandated
efficiency increases.

Draft Over Fire -.03" 0.00"

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].

A-.01 _ to -.02" minimum draft over fire is required for a good installation where no oil fumes

would be present. The draft would vent them up the chimney.

The above discussion which concerns draft in the chimney and draft loss in the boiler, is incomplete with-
out discussing the effect of draft on the burner. Very simply, increasing the fuel usage [higher gallonage] on

a unit which has multiple firing rates, requires more air for combustion and a higher draft loss in the boiler.
As an example, increasing the firing rate 1/4 gallon will increase the draft loss in the unit by approximately
+.01". The actual burner used on a particular boiler also effects the draft and smoke condition. The use of

a burner supplied by Peerless Heater Company wouM assure you of a quality, trouble free installation.

INSTALLATIONINSTRUCTIONS- SERIESECand ECT

Readcarefullybeforebeginningwork.Itwillsavetime.Studythe includeddrawings.
This boilermust beinstalledbya qualifiedcontractor.
Theboilerwarrantycan bevoidedifthe boileris not installed,maintained,andservicedcorrectly.

Theequipmentshallbe installedinaccordancewiththoseinstallationregulationsinforce inthelocalareawheretheinstallationisto bemade,includingthe
currenteditionof NFPA-31.Theseshallbecarefullyfollowedin allcases.Authordieshavingjurisdictionshallbeconsultedbeforeinstallationsaremade.

A- ACCESSIBILITYCLEARANCES

1 - To provide for reasonableconditionsof accessibilityfor servicing,the following minimumclearancesare recommendedbetweenthe boiler and

adjacentwallsor otherappliances--atleast24" inthe front,rearandonboth sides.

B- AIRFORCOMBUSTIONANDVENTILATION

1- Becertainadequatefacilitiesareavailableto provideairfor satisfactorycombustionandventilation.
2- AppliancesLocatedinUnconfinedSpaces.

a. For installationsin unconfinedspaceswith conventionalconstructionandlargeareas suchas basements,the supplyof air for combustionand

ventilationcanusuallybe consideredadequate.

3- AppliancesLocatedinConfinedSpaces.

a. If all air for combustionandventilationis to comefromwithinthebuilding;twoopenings,onenearthe ceilingandone nearthe floorofthe boiler

roomshallbe providedwiththe minimumfreearea ofeachopeningequalto 140sq.in.pergallonofoil burned.

b. If all airfor combustionandventilationisto comefromoutsidethebuilding;twoopenings,one neartheceilingand one nearthefloorofthe boiler

roomshallbeprovidedwiththeminimumfreeareaof eachopeningequalto 35sq.in. pargallonofoil burned.Ifductsare usedto conveytheair,
areasof35 sq.in.pergallonofoil burnedfor verticalductsor 70 sq.in.per gallonofoil burnedfor horizontalductsareto beprovided.Ductsshall
havethesame areaasthefreeareaof theopeningstowhichthey areconnected.

C- SETTINGBOILERBLOCK

1-The SeriesEC/ECT boilersectionsare factoryassembledwiththe target wallshippedin place. Providea levelfoundation,locatedas close as

possibletothecenteroftheheatingsystemandto thechimney.TheheatingsurfaceoftheSedesEC/ECTboilersisdesignedtobecleanedfromeither
thetopor left sideofthe unit.Allowadequateclearanceon the leftof unitif servicingisto bedonefromthe side.

2- Openfluecollectorcarton.Removefluecollector(Item9, Fig. 4) andhightemperaturerope.Lay rope(Item8, Fig.4) ontop of boileragainstbead

provided.Placefluecollectorontop of ropeand attachto boilerwith1/4"-20x13/4"studswithnutsthroughfluecollectorbracketsintothetappedlugs
providedin thetopof the boilerendsections.Drawnutsdownsnugly.

3- Removeclean-outcoverplatesandinsulation(25).Eachclean-outcoverplateisattachedtothe boilerbyusingtwocarriagebolts,nutsandwashers(24).

Installthe carriageboltsintothenotchatthe top andbottomof eachclean-outopening,thensecurethemwith a flatwasherandsteelnutasshownin
Figure1 lockingthemintoplace.Pressthe clean-outplatewithinsulationoverthe protrudingcarriageboltsuntiltheboltspunchthroughtheinsulationso

flatwasherandbrassnutcanbeinstalled,Tightendownnutssnuglycompressingthe insulationto forma goodsealaroundthecleen-outopening,

4- This boileris suitableforuseon combustibleflooring,providedthe boilerisnot seton carpetand a metaldrippanis placedundertheappliance.

INSTALLATIONOF SIDECLEAN-OUTCOVERPLATES

5/16 UNC X 1 3/4" L(3.

Figure1

D- SWINGDOORANDOBSERVATIONCOVERASSEMBLY

1- Removeburnermountingplateincludingrightsidemountingstudsfor burnermountingplate(donot removeleftsidestuds)

2- CollecttheSwingDoorCarton(90924)containingthehingeassemblyandhardware.

3- InstallInternalHingeP/NEC1021(Item6, Fig,4)to frontsectionof boilerwith(2)5/16-18UNCx 3/4"hex headcapscrewsand5/16"flatwashers(do

netusethe11/4" longscrews).

4- InstallExternalHingeP/NEC10122(Item7, Fig.4) to theoutsideoftheburnermountingplatewith(2)5/16-18UNCx 11/4" hexheadcapscrews,flat

washers,andnuts.Thecapscrewsshouldbeinsertedthroughthe backoftheburnermountingplate,thenthroughthe hinge.Do NOTtightenExternal

Hingescrewsat thistime.Thiswillallowforalignmentofthe plateonceitis placedinposition.

5- Hangburnermounting plate in position,then close to alignthe remainingthree (3) studson leftside of section.Once alignmentis accomplished,

tightennutson ExternalHinge.DeNOTreinstallnuts!washerson left sidestudsuntilafterjacketinstallation.

6- Removeobservationdoor (Item4, Fig.4) frominsideburnermountingplate.Attachthe observationdoortothe outsideofthe mountingplate.

7- Theremainingswingdoorcartonpartswillbe usedinSectionH,Wiring.

E - JACKETASSEMBLY

1- Referto Page4,Fig,4forexplodedview.Attachthebackpanel(19)tobossesonmiddleofbacksectionwithtwo 1/4"x3/8"trussheadmachinescrews

(20) provided.Thebackpanelhastwo shG"diameterholesclosetothe centerof thepanel.

2- Liftoff theburnermountingplate.Placeeerafeltliner(28)on floorof boilerin frontoftargetwall.

3- Removethe (2)knock-outsinthefrontjacketpanel(23)whichallowclearanceforthehinge.Placethefrontjacketpanelonthe blockand replacethe

burnermountingplate.

4- Attachrightside jacketpanel(22)tothe frontandbackpanelswithsheetmetal screws,

NOTE:ON SERIESECTBOILERS,THEOPTIONALWATERHEATER(17) MUSTBEINSTALLEDINLARGEOPENINGIN BACKSECTION

BEFORETHE LEFTSIDE JACKETPANELSAREATTACHED.

5- Ifwater heaterisused, removeknockout piecesin upperleft side jacketpanel(21)and backjacketpanel(19) beforeinstalling.Attachleftsidejacket

panelsin thesamemanneras the rightsidepanel.

6- Attachthetop panel.Thetop ismadeintwopieces(26&27).Join thetwopiecestogetherwithsheetmetalscrews.Securetoppaneltofrontand back

panelwithsheetmetalscrews.

7- Install waterheater(13)whenrequired,inlargeopeninginfrontofboiler.SeeFigure3Aor3Bforsuggestedpiping.Whenwaterheaterisnotemployed,

coverthe heateropeningwithcoverplate(12)or (16).

BESURERUBBERGASKETISIN PLACEBETWEENCOVERPLATEORWATERHEATERPLATEANDBOILERSECTION.

Figure2

HIGH TEMPERATUFE
HOT

MIXED

WATER
MIXER

COLD

INLET

HEATER

7lAPPING

CONTROL

3/4" OOfl'rROL -- I_" MIN.

Figure3A Figure3B

MaximumTanklessWaterHeaterRatings

*Capacity

HeaterNo. G.F_M.

X-1020 5 FurUse inSeriesEC
X-t082 4 ForUse inSeriesECT

*Waterheaterratingsarebasedon intermittentdemand- 40° F.to140° E with200° F.BoilerWaterTemperature.

DANGER:Installanti-scalddeviceinhotwatersupplypiping.Watertemperatureovert25°F cancausesevereburnsinstantlyordeathfromscalds.