PeerlessBoilers ECT-03-075, ECT-03-100, ECT-03-120, ECT-04-125, ECT-04-175 Installation Manual

...

EC/ECT

™

Boilers

Series

Oil

Installation, Operation & Maintenance Manual

As an ENERGY STAR®Partner, PB Heat, LLC has determined that certain firing rates of this product meet the ENERGY STAR®guidelines for energy efficiency.

USING THIS MANUAL 1

A. INSTALLATION CLEARANCE . . . . . . . . . . . . .1

B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1

1. PREINSTALLATION 2

A. CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . .2

B. AIR FOR COMBUSTION AND

VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . .2

C. CHIMNEY / VENT AND DRAFT CONTROL . .3

D. INSTALLATION SURVEY . . . . . . . . . . . . . . . .3

E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .3

2. BOILER PLACEMENT AND ASSEMBLY 4

A. SETTING THE BOILER . . . . . . . . . . . . . . . . . .4

B. OBSERVATION COVER ASSEMBLY

(KNOCKDOWN BOILERS) . . . . . . . . . . . . . . .4

C. INSTALLATION OF FLUE COLLECTORS &

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

E. TANKLESS HEATER OR COVERPLATE . . . . .8

F. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . .9

4. ELECTRICAL 11

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .11

B. BURNER WIRING . . . . . . . . . . . . . . . . . . . . .11

5. BURNER SETUP & BOILER OPERATION 14

A. BURNER INSTALLATION . . . . . . . . . . . . . . .14

B. BURNER START-UP AND ADJUSTMENT . .14

C. CHECK THE BOILER CONTROLS . . . . . . . .14

D. PURGE AIR FROM THE SYSTEM

(WATER BOILERS ONLY) . . . . . . . . . . . . . . .14

E. CLEAN THE BOILER

(STEAM BOILERS ONLY) . . . . . . . . . . . . . . .15

6. MAINTENANCE 17

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .18

B. DAILY MAINTENANCE (WITH BOILER

OPERATING) . . . . . . . . . . . . . . . . . . . . . . . . .18

C. WEEKLY MAINTENANCE (WITH BOILER

OPERATING) . . . . . . . . . . . . . . . . . . . . . . . . .18

D. MAINTENANCE OF SAFETY

RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . .18

E. MONTHLY MAINTENANCE (WITH BOILER

OPERATING) . . . . . . . . . . . . . . . . . . . . . . . . .18

F. MAINTENANCE – ANNUAL . . . . . . . . . . . . .18

G. IF A LONG SHUTDOWN IS REQUIRED . . .19

7. BOILER DIMENSIONS & RATINGS 20

8. REPAIR PARTS 22

TABLE OF CONTENTS

A. INSTALLATION CLEARANCE

Follow the installation instructions provided in this manual in the order shown. The order of these instructions has been set in order to provide the installer with a logical sequence of steps that will minimize potential interferences and maximize safety during boiler installation.

B. SPECIAL ATTENTION BOXES

Throughout this manual you will see special attention boxes intended to supplement the instructions and make special notice of potential hazards. These categories mean, in the judgment of PB Heat, LLC.

USING THIS MANUAL

Indicates a condition or hazard which will cause severe personal injury, death or major property damage.

DANGER

Indicates a condition or hazard which may cause severe personal injury, death or major property damage.

WARNING

Indicates a condition or hazard which will cause minor personal injury or property damage.

CAUTION

Indicates special attention is needed, but not directly related to potential injury or property damage.

NOTICE

A. CLEARANCES

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.

B. AIR FOR COMBUSTION AND

VENTILATION

1. Be certain adequate facilities are available to provide air for satisfactory combustion and ventilation.

2. Appliances Located in Unconfined Spaces.

a. 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 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.

b. 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.

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.

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 B139, Installation Code for Oil

Burner Equipment

. These shall be carefully followed in all cases. Authorities having jurisdiction

shall be consulted before installations are made.

NOTICE

Never burn garbage or paper in the unit, and never leave combustible material around it.

CAUTION

Do not tamper with boiler controls.

CAUTION

Table 1.1: Clearances from Jacket and Vent System

Required from Jacket

to Combustible

Construction

Recommended From Jacket for

Accessibility and Mounting Controls

To p 5"*

24" if Left Side Clearance less than 24" (to clean flueways from top).

Front 16"* 16" from jacket due to burner.

Left 2"*

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).

C. CHIMNEY / VENT AND DRAFT CONTROL

1. 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.

2. Use barometric provided to control draft. Follow manufacturer's instructions to locate and adjust the control.

3. Inspect the existing chimney or vent system. Make sure it is in good condition. Inspect chimney liner and repair or replace if necessary.

4. The vent system and 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.

5. 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.

For Example:

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 P.B. 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.

An oil-fired unit shall be connected to a flue having sufficient draft at all times, to assure safe proper operation of the unit.

CAUTION

Old

Installation

New

Installation

Comments

Chimney

Draft

-.04" -.04"

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.

PREINSTALLATION

A. SETTING THE BOILER

1. Provide a level foundation, located as close as possible to the center of the heating system.

2. Refer to Figure 2.2 for exploded view of boiler while checking and/or assembling parts of the boiler.

3. See clearance information in Section 1, "Preinstallation."

4. On packaged boilers, open burner mounting plate (Item 3) at this time to make certain the target wall (Item 2) is seated in the back of the combustion chamber. Ceramic fiber blanket base liner (Item 28) should be lying flat on bottom of combustion chamber between target wall and burner.

B. OBSERVATION COVER ASSEMBLY

(KNOCKDOWN BOILERS)

1. Remove observation door (Item 4) from inside burner mounting plate. Attach the observation door to the outside of the mounting plate.

C. INSTALLATION OF FLUE COLLECTOR &

COVERPLATES (KNOCKDOWN BOILERS)

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 snugly.

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 carriage bolts until the bolts punch through the insulation so flat washer and brass nut can be installed. Tighten down nuts snugly compressing the insulation to form a good seal around the clean-out opening.

D. TANKLESS HEATER OR COVERPLATE

If an ECT™ steam boiler is to be 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.

E. JACKET ASSEMBLY

1. Refer to Figure 2.2 for exploded view.

2. Attach the back panel (Item 19) to bosses on middle of back section with two 1/4" x 3/8" truss head machine screws (Item 20) provided. The back panel has two 5/16" diameter holes close to the center of the panel.

3. Lift off the burner mounting plate.

4. Remove the (2) knock-outs in the front jacket panel (Item 23) which allow clearance for the hinge. Place the front jacket panel on the block and replace the burner mounting plate.

5. Attach right side jacket panel (Item 22) to the front and back panels with sheet metal screws.

6. On steam boilers, if a tankless heater is used, remove the knock out in upper left side jacket panel (Item

21) and back jacket panel (Item 19) before installing. Attach left side jacket panels in the same manner as the right side panel.

7. Attach the top panel (Item 26). Secure top panel to front and back panel with sheet metal screws.

2. BOILER PLACEMENT AND ASSEMBLY

BOILER PLACEMENT AND ASSEMBLY

Be sure rubber gasket is in place between cover plate or water heater plate and boiler section.

NOTICE

Figure 2.1: Side Clean-out Cover Plates

BOILER PLACEMENT AND ASSEMBLY

Figure 2.2: Boiler Exploded View (See Table 8.1 in Section 8 for parts identification).

A. PRESSURE TEST BLOCK ASSEMBLY

1. Make up cold water supply connection to the boiler.

2. Install pressure gauge or pressure-temperature gauge in tapping provided. See Boiler Dimensional drawing, Figure 7.1 (Section 7).

3. 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.

4. 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 Installation/Design Guide for guidance.

2. 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).

3. See Table 3.1 for pipe size information.

4. Use swing joints to attach header to avoid damage to the boiler due to thermal expansion and contraction of steam header pipe.

5. Pipe the steam header a minimum of 24" above the normal water line using swing joints to attach the risers into the steam header.

3. PIPING AND CONTROLS

PIPING AND CONTROLS

Do not pipe boiler before jacket is installed.

NOTICE

REAR

FRONT

EQUALIZER

REAR

FRONT

EQUALIZER

HEADER

RISERS

Figure 3.1: Steam Boiler Piping, EC-03

Figure 3.2: Steam Piping, EC-04 to EC-06

Boiler

Model No.

Risers Header Equalizer

EC/ECT-03-075 1-2" 2" 1-1/4"

EC/ECT-03-100 1-2" 2" 1-1/4"

EC/ECT-03-120 1-2" 2" 1-1/4"

EC/ECT-04-125 2-2" 2-1/2" 1-1/2"

EC/ECT-04-175 2-2" 2-1/2" 1-1/2"

EC/ECT-05-175 2-2" 2-1/2" 1-1/2"

EC/ECT-05-200 2-2" 3" 1-1/2"

EC/ECT-05-250 2-2" 3" 1-1/2"

EC/ECT-06-275 2-2" 3" 1-1/2"

EC/ECT-06-300 2-2" 3" 1-1/2"

Table 3.1: Steam Pipe Sizing

D. WATER BOILER PIPING

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

and return to the bottom of the front section. Use the 3/4" tapping in the top of the back section for air elimination.

b. As an alternative, pipe the supply from the top of

the front section and return to the bottom of the rear section. Provide air elimination means within the supply piping.

4. When the return temperature from the system will be below 150°F on oil boilers for extended periods (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.

5. If using a Partner

indirect fired water heater or other, see Figure 3.4 for typical piping. Also refer to additional instructions supplied with the Partner

6. If the boiler is to be used in conjunction with a refrigeration system, the chilled medium shall be piped in parallel with boiler and proper valves applied to prevent the chilled medium from entering the boiler. Refer to Figure 3.5.

7. If the boiler is connected to heating coils located in 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.

PIPING AND CONTROLS

Figure 3.3: Water Boiler Piping

Figure 3.4: Piping with Peerless®Indirect Water Tank

Figure 3.5: Isolating Boiler from Chilled Medium

on Chiller Systems

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