PEERLESS Boiler Manual L0308197

User Manual: PEERLESS PEERLESS Boiler Manual PEERLESS Boiler Owner's Manual, PEERLESS Boiler installation guides

Open the PDF directly: View PDF .
Page Count: 19

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

P_'_I'It'ss Boilers is i)It'as_'_{ to QI]_'I oll(' QJ l]lt" IIl()sl co_lpr_.lll'llsit,t' iP(llT_lill_] i)fofjFQlll._ ill lh(' ill(_lisll_t]. All Pt,t'_l(_ss r(,sid_'tlti_ll

casl i!ott I)oilt'is irlt'ltt_l_" _t {illl oae ycat tP(llTTII!l{I. A [Jlllilt'tl. l([i'limt' tt,(¢lr(ull{I is ptY)l,i(]t'({ [or lilt" ('(isl iroii ._t'clioiIs o[ P_'('i[('_s

rz'sidt'llliQl ttot It'(lll'I t)oilt't,_. Pt't'rlt',_s also t)r_)t'itl_'s _l liIIlil+'_l I('ll []t'(ll II'(ll'l'Cllll!] Oll IIR" ('CISl il_)l] _;t'('liOIIS Q]'ilS r('_i(l('Illi(I/ slt'Cllfl

I)oilt'Is. l;'it,_" _llld ll'll !]('(l! <t','li'_Kl_'(I [t,(ll'l'(lll_it'_q ()It 131111.% (lli(l Itll)Ol CIl'(' IIolt, (IP_lil(l!)l_'. PI<'_i.';_' ('Oll.'_llll P('('tl('._.'_ [$oil('r.'_ li)r ('OllllIl('l('

{f!(ll'l'(lllll] it!Jorm(lliol£.

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

FAB EC R_{303 IM)

Prrn_l d _ll U S A

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-SERIES EC and ECT

Readcarefullybeforebeginningwork.It willsavetime.Studythe includeddrawings.

This boilermust beinstalledby a qualifiedcontractor.

The boiler warrantycan be voidedifthe boiler isnot installed,maintained,andserviced correctly.

Theequipmentshallbe installedinaccordancewiththoseinstallationregulationsinforceinthe localareawherethe installationis to bemade,includingthe

currenteditionof NFPA-31.Theseshallbe carefullyfollowedin allcases.Authordieshavingjurisdictionshallbe consultedbeforeinstallationsare made.

A-ACCESSIBILITYCLEARANCES

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

adjacentwallsor otherappliances--atleast24" inthe front,rearand on both sides.

B- AIRFORCOMBUSTIONANDVENTILATION

1 - Be certainadequatefacilitiesare availableto provideairfor satisfactorycombustionandventilation.

2 - AppliancesLocatedin UnconfinedSpaces.

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

ventilationcanusuallybe consideredadequate.

3 - AppliancesLocatedin ConfinedSpaces.

a. If all air for combustionand ventilationisto comefrom withinthebuilding;two openings,one nearthe ceilingandone nearthe floor of the boiler

roomshall be providedwiththe minimumfree area of eachopeningequalto 140sq. in. pergallonof oil burned.

b. If all air for combustionandventilationis tocome fromoutsidethebuilding;twoopenings,one neartheceilingand one nearthefloor of the boiler

roomshall beprovidedwiththeminimumfree areaof eachopeningequalto 35 sq. in. par gallonof oil burned.If ductsare usedto conveythe air,

areasof 35 sq. in.per gallonof oil burnedfor verticalductsor 70 sq.in. per gallonof oil burnedfor horizontalductsareto beprovided.Ductsshall

havethesame area as thefree area of theopeningsto whichthey areconnected.

C-SETTINGBOILERBLOCK

1-The Series EC/ECT boiler sectionsare factoryassembledwiththe target wallshipped in place. Providea levelfoundation,locatedas close as

possibleto the centerofthe heatingsystemandto thechimney.Theheatingsurfaceof theSedesEC/ECTboilersis designedto be cleanedfromeither

thetop or left side of the unit.Allowadequateclearanceon the leftof unit if servicingisto bedonefromthe side.

2 - Open fluecollector carton.Removefluecollector(Item9, Fig. 4) and hightemperaturerope.Lay rope(Item8, Fig.4) ontop of boileragainstbead

provided.Placefluecollectorontop of ropeand attachto boilerwith1/4"-20x 13/4"studswith nutsthroughfluecollectorbracketsintothetappedlugs

providedin the topof the boilerendsections.Draw nutsdownsnugly.

3 - Removeclean-outcoverplatesandinsulation(25).Eachclean-outcoverplateisattachedto the boilerby usingtwo carriagebolts,nutsandwashers(24).

Installthe carriagebolts into thenotchat the top andbottomof eachclean-outopening,then securethemwith a flatwasherand steelnutas shownin

Figure1 lockingthemintoplace.Pressthe clean-outplatewithinsulationoverthe protrudingcarriageboltsuntiltheboltspunchthroughtheinsulationso

flat washerand brassnutcan beinstalled,Tightendownnutssnuglycompressingthe insulationto forma goodsealaroundthecleen-outopening,

4-This boileris suitablefor useon combustibleflooring,providedthe boileris not set on carpetand a metaldrip panis placedunderthe appliance.

INSTALLATIONOF SIDECLEAN-OUTCOVERPLATES

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

Figure1

D-SWINGDOORANDOBSERVATIONCOVERASSEMBLY

1- Removeburnermountingplateincludingright side mountingstuds for burnermountingplate(do not removeleft side studs)

2 - Collectthe SwingDoorCarton(90924)containingthehinge assemblyandhardware.

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

netuse the 11/4" long screws).

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

washers,and nuts.Thecapscrewsshouldbeinsertedthroughthe backof theburnermountingplate,thenthroughthe hinge.Do NOTtightenExternal

Hingescrewsat thistime.Thiswillallowfor alignmentof the plateonce it is placedin position.

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

tightennutson ExternalHinge.DeNOTreinstallnuts!washerson left side studsuntil afterjacketinstallation.

6 - Removeobservationdoor (Item4, Fig.4) from insideburnermountingplate.Attachthe observationdoor to the outsideof the mountingplate.

7 - The remainingswingdoorcartonparts willbe usedin SectionH,Wiring.

E - JACKETASSEMBLY

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

(20) provided.The backpanel hastwo shG"diameterholesclose to the centerof thepanel.

2 - Lift off theburnermountingplate.Placeeerafeltliner (28)on floorof boilerin frontof targetwall.

3 - Removethe (2)knock-outsin thefrontjacketpanel(23)whichallowclearancefor thehinge. Placethefrontjacketpanelonthe blockand replacethe

burnermountingplate.

4 - Attach rightside jacketpanel (22)to the frontandbackpanelswithsheetmetal screws,

NOTE:ON SERIESECTBOILERS,THEOPTIONALWATERHEATER(17) MUSTBEINSTALLEDINLARGEOPENINGIN BACKSECTION

BEFORETHE LEFTSIDE JACKETPANELSARE ATTACHED.

5 - If water heateris used, removeknockout piecesin upperleft side jacketpanel(21)and backjacketpanel(19) beforeinstalling.Attach leftside jacket

panelsin thesame manneras the rightside panel.

6 - Attachthetop panel.Thetop is madeintwopieces(26& 27).Join thetwo piecestogetherwithsheetmetalscrews.Securetoppaneltofrontand back

panelwithsheet metalscrews.

7 - Install waterheater(13)whenrequired,in largeopeninginfrontof boiler.SeeFigure3A or3B forsuggestedpiping.Whenwaterheateris notemployed,

coverthe heateropeningwithcover plate(12)or (16).

BESURERUBBERGASKETIS IN 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

*Waterheater ratingsarebasedon intermittentdemand- 40°F.to 140° E with200° F.BoilerWaterTemperature.

DANGER:Installanti-scalddeviceinhotwatersupplypiping.Watertemperatureovert25°F cancausesevereburnsinstantlyordeathfromscalds.

27

_26

-N

._h c

J_h

F4

ItemNo.

1

SERIESECand ECT

Part No.

EC-1001

EC-1001-1

X-1096

X-!096-1

EC-10O2

EC-1OO2-1

X-1097

X-1097-1

X-3019

X-1060

X-1031

X-1061

EC-1021

EC-1022

Description

BlockAssembly-EC-03

BlockAssembly- EC-04

BlockAssembly- EC-05

BlockAssembly- EC-06

BlockAssembly- ECT-03

BlockAssembly- ECT-04

BlockAssembly- ECT-05

BlockAssembly- ECT-06

TargetWall

BurnerMountingPlate

ObservationDoor

5/16"-18x 2-1/4" Studsw/Nuts- 5 Req'd

SwingOutBurnerMountingPlateHinge- Internal

SwingOutBurnerMountingPlateHinge- External

HighTemp.Rope3/8" Diameter.48" Long

HighTemp.Rope3/8" Diameter.56" Long

HighTemp.Rope3/8" Diameter.64" Long

HighTemp.Rope3/8" Diameter.72" Long

FlueCollector

FlueCollector

FlueCollector

FlueCollector

1/4"-20x 1-3/4" Studsw/Nuts- 2 Req'd

RubberGasket

CoverPlate

TanklassCoil(OptionalWaterOnly)

3/8"-16 x 3/4" HexHal.CapScrews- 6 Req'd

RubberGasket(ECT Models)

CoverPlate(OptionalECTModels)

TanklessHeater(OptionalECTModels)

3/8"-16 x 3/4" Hex Hd.CapScrews- 8 Req'd

BackJacketPanel

1/4"-20x 3/8"Truss Hd,Mach.Screws- Cad,Plate- 2 Req'd

UpperLeftSideJacketPanel

UpperLeftSideJacketPanel

UpperLeftSideJacketPanel

UpperLeftSideJacketPanel

EC/ECT-03

X

x

X

X

2 X x

3 X X

4 X X

5 X X

6 X X

7 X X

8 X

X

9 EC-50O0 X

EC-5000-1

EC-5000-2

EC-5000-3 X

10 X-5000 X X

11 X-1023 X X

12 X-1034 X X

13 X-1020 X X

14 X X

15 X-1083 X X

16 X-t084 X X

17 X-t082 X X

18 X X

19 EC-6003 X X

20 X X

21 EC-6007 X

EC-6007-1

EC-6007-2

EC-6007-3 X

ModelNo.

EC/ECT-04 EC/ECT.O5

X

X

X

X

X X

X x

X X

X X

X X

X X

X

X

X

X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X

X

EC/ECT-06

ItemNo.

21A

SERIESECand ECT

Part No.

EC-6008

EC-6008-1

EC-6008-2

EC-6008-3

EC-6O02

EC-6002°1

EC-6002-2

EC-6002-3

EC-6000

Description

LowerLeftSideJacketPanel

LowerLeft SideJacketPanel

LowerLeft SideJacketPanel

LowerLeft SideJacketPanel

RightSideJacketPanel

RightSideJacketPenet

RightSideJacketPanel

RightSideJacketPanel

FrontJacketPanel

5/18"-18x 1-3/4" CarriageBoltw/Nuts

SideClean-OutCoverPlate

RightTopJacketPanel

RightTopJacketPanel

RightTopJacketPanel

RightTopJacketPanel

LeftTopJacketPanel

LeftTopJacketPanel

LeftTop JacketPanel

LeftTop JacketPanel

BaseLiner

BaseLiner

BaseLiner

BaseLiner

EC/ECT-03 EC/ECT-06

X

X

22 X

X

23 X X

24 X X

25 X-1085 X X

26 EC-6005 X

EC-6005-1

EC-6005-2

EC-6005-3 X

27 EC-6004 X

EC-6004-1

EC-6004-2

EC-6004-3 X

28 EC-3000 X

EC-3000-1

EC-3000-2

EC-30O0-3 X

ModelNo.

EC/ECTo04 EC/ECT-05

X

X

X

X

X X

X X

X X

X

X

X

X

X

X

E-PIPING

DONOTPIPEBOILERUNTILAFTERJACKETIS INSTALLED.

1- See Figures5 and 6 for suggestedpipingto the boiler.Also,seeHydronicsInstituteResidentialHydronicHeatingGuide2000.

2 - Makeup cold watersupplyconnectionto the boiler.

3 - Installpressuregaugeortemperature-pressuregaugein tappingprovided.See Figure9.

4 - Pluga!l open tappingsin the boilerandfill withwater.Applyapproximatelythirty(30) poundspressure.Checkto makecertainthatalljoints

and fittingsare water tight,

5-Afteralljointsand connectionshavebeenprovenwatertight,removecold watersupplyandplugsfromall tappingsthat areto beused.See Figure

9 for tappinglocations.

6-The returnpipingto the 1-1/4" NPT lowertappingonthe frontsectionmustbe installedin sucha mannerto assureproperclearanceof the oil

burnerand mountingplatewhenopeningandclosingthe burnermountingplate.Peerlesssuggestsusinga 1-1/4"90 degreestreetelbowat this

lowertappingin orderto positionthe returnpipingawayfromthe mountingplateassembly.

NOTE:IFTHISBOILERANDDISTRIBUTINGSYSTEMIS USEDiNCONJUNCTIONWITHA REFRIGERATIONSYSTEM,THECHILLEDMEDIUM

SHALLBE PIPEDIN PARALLELWITHTHE BOILERANDTHE PROPERVALVESAPPLIEDTO PREVENTTHECHILLEDMEDIUMFROM

ENTERINGTHE BOILER.WHENTHEBOILERIS CONNECTEDTOHEATINGCOILSLOCATEDINAIRHANDUNGUNITSWHERETHEY

MAYBE EXPOSEDTO REFRIGERATEDAIRCIRCULATION,THEBOILERPIPINGSYSTEMMUSTBE EQUIPPEDWITHFLOWCONTROL

VALVESOROTHERAUTOMATICMEANSTOPREVENTGRAVITYCIRCULATIONOFTHEBOILERWATERDURINGTHECOOLINGCYCLE.

I

\ i i

ERON[

ID

_ EQUALIZER

X

REAR

FRONT REAR

Boiler

Model

No, Risers Header Equalizer

EC/ECT-03-075 1-2" 11/4"

EC/ECT-03-1O0 1-2" 1V4"

EC/ECT-03-120 1-2" 1V4"

EC/ECT-04-125 2-2" 21/2', 11/2"

EC/ECT-04-150 2-2" 21/2", 11/2"

EC/ECT-04-175 2-2" 21/2" 11/2"

EC/ECT-05-175 2-2" 3" 11/2"

EC/ECT-05-200 2-2" 3" 11/2"

EC/ECT-05-250 2-2" 3" 11/2"

EC/ECT-06-275 2-2" 3" 1112"

EC/ECT-06-300 2-2" 3" 11/2"

Thereturnfrom systemshouldalwaysenterequalizerthrough

HartfordLoop,2" to 4" below normalwaterline (see dimensional

drawingfor normalwaterline).

STEAM

Figure5

Size thesupplyand returnconnectionsto suit thesystem.

Pipethe supplyand returninoneof two ways:

1) Pipethesupplyfromthetop of the rearsectionand

return to the bottomof thefrontsection.Use the 3/4"

tappinginthe topof thebacksectionfor air elimination.

2) As anacceptablealternative,pipethe supplyfromthe

topof thefrontsectionandreturnto the bottomof the

rearsection.Providean aireliminationmeanswithinthe

supplypiping.

HOTWATER

ALTERNATE

SUPPLY

FRONT

r

ALTERNATE

RETURN

REAR

Figure6

F-OILBURNERINSTALLATION

1-Theoilburneris suppliedwithamountingflangefixedinposition.

2-Mountthe burnerto theburnermountingplate(3) Figure4 withfour5/16" studsandnuts provided.

BE SUREHIGHTEMPGASKETIS BETWEENTHEBURNERMOUNTINGFLANGEANDTHE BURNERMOUNTINGPLATE.

3-Routethe oillinesto avoid interferencewhenopeningthe platefor boilerservicing.Useflexibleoillinesor copper.Whenusingflexibleoil lines,

providetubinglongenoughto allowthe plateto swingfreelyover its entirerange.When usingcopper,installflared copperdisconnectswithvalves.

4 - See Figure7 for Oil BurnerSpecifications.If exceeding100PSIpumppressureon burnersshownat 100 PSI, seechart on page 13to determine

therequiredreductionin nozzlesize.

7

WAYNE BURNER WITH 100 PSI PUMP PRESSURE

Boiler Burner Air Cone Nozzle Start-UpSettings

ModelNo, ModelNo, I,D, Size FlameLock Off-CycleDamp, Air Shutter

EC/ECT-03-075 HS 21/2" NoHoles .7580° A DEL 1 1.0 .50

EC/ECT-03-100 HS 21/2" NoHoles 1.0080" B DEL 1 1.2 1.50

EC/ECT-03-120 HS 21/2"NoHoles 1.2080° B DEL 11/2 1.5 1.75

EC/ECT-04-125 HS 21/2" 6 Holes 1.2580° B DEL 1 2.0 2.00

EC/ECT-04-150 HS 21/2" 6 Holes 1.5080° B DEL 3 2,0 2.25

EC/ECT-04-175 HS 21/2" 6 Holes 1.7580° B DEL 5 2,0 2.50

EC/ECT-05-175 HS 21/2" 6 Holes 1.7580° B DEL 5 2.0 2.50

EC/ECT-05-200 HS 21/2" 6 Holes 2.00 80° B DEL 5 2,0 3.50

EC/ECT-05-250 HS 21/2" 6 Holes 2.50 80° S DEL 8 2.0 5.00

EC/ECT-06-275 HS 3-5/16" Str.Bore 2.75 80° B DEL 2 2,0 4.00

EC/ECT-06-300 HS 3-5/16'` Str.Bore 3.00 80° B DEL 2 2.0 4.50

CARLIN BURNER

Boiler Burner Start-UpSettings

ModelNo. ModelNo. Air Shutter NozzleSize PumpPressure HeadDim.A Air Band

EC/ECT-04-125 *99FRD Blank 1.00x 70° B DEL 150 PSI 2 40%open

EC/ECT-04-150 *99FRD Blank 1.25x 60° B DEL 150 PSI 3 60%open

EC/ECT-04-175 *99FRD Blank 1,50x 60°B DEL 150 PSI 4 100%open

EC/ECT-05-175 *99FRD Open 1,50x 60° B HAGO 150 PSI 5 10%open

EC/ECT-05-200 *99FRD Open 1,65x 60° B HAGO 150 PSI 5 45%open

EC/ECT-05-250 *99FRD Open 2,00 x 60° B HAGO 150 PSI 8 100%open

EC/ECT-06-275 102CRD Open 2,75 x 60° B DEL 100 PSI 7 100%open

EC/ECT-06-300 102CRD Open 3,00 x 60° B DEL 100 PSI 9 100%open

*Model99FRDBurnerEquippedwithModel98022PSCMotor

CARLIN EZ-IHP OILBURNERWITHMODEL98022PSC MOTOR

Boiler Burner Start-UpSettings

ModelNo, FiringRate ModelNo, AirShutter NozzleSize PumpPressure AirBand HeadBar

EC/ECT-03-075 .75 EZ-1HP Blank 0.60 x70° B DEL 150 PSI 0.55 0.60- 0.65

EC/ECT-03-100 1.00 EZ-1HP Blank 0.85 x70°A DEL 150 PSI 0.65 0.85- 1.00

EC/ECT-03-120 1.20 EZ-1HP Blank 1.00 x70° A DEL 150 PSI 0.80 0,85- 1.00

BECKETTBURNERWITH140 PSI PUMPPRESSURE

Boiler Burner Burner Static Nozzle Start-UpSettings Head

ModelNo. ModelNo. Head Plate Size AirShutter AirBand Setting

AFG-LI* LI* 33/8" .6560" B HAGO 9.0 2 N/A

AFG-L1 L1 33/8" .8560° B HAGO 10.0 1 N/A

AFG-L1 L1 ** 1.0060° B HAGO 9.0 2 N/A

AFG-F6 F6 23/4" 1.1080°A DEL 5.0 1 N/A

AFG-F6 F6 23/4" 1.2580° BHAGO 8.0 1 N/A

AFG-F6 F6 23/4" 1.5080°B HAGO 10,0 3 N/A

AFG-MV1 M-V1-3 -- 1.5060° B HAGO 10.0 3 3

AFG-MV1 M-V1-3 -- 1.7560° B HAGO 10,0 93

AFG-MV1 M-V1-5 -- 2.00 45° B HAGO I 0.0 5 5

CF-375 L1-S -- 2.25 450P HAGO 10.0 6 2

CF-375 L1-S -- 2.50 45° P HAGO 10.0 6 3

EC/ECT-03-075

EC/ECT-03-100

EC/ECT-03-120

EC/ECT-04-125

EC/ECT-04-150

EC/ECT..04-175

EC/ECT..05-175

EC/ECT,.05-200

EC/ECT..05-250

EC/ECT..06-275

EC/ECT-06-300

* RequiresLowFiring RateBaffle ** Removestatic platefor 1.20GPHrate.

NOTE:Aboveair settingsare start-upsettingsonly -- final adjustmentsare to be madewithcombustiontest instruments.Adjustburnerfor

highestCO2 (Maximum13%)whilemaintaininga 0 smokeand -.01to -.02ovediredraft.

Figure7 (continuedon nextpage)

8

RIELLOSERIES40 OIL BURNER

Boiler Firing Burner Nozzle Pump Turbulator AirDamper

ModelNo. Rate ModelNo. Size Pressure Setting Setting

EC/ECT-03-075 .75 F5 .60600B DEL 155 .5 2.1

EC/ECT-03-100 1.00 F5 .8560° W DEL 145 2.0 2.6

EC/ECT-03-120 1.20 F5 1.00600W DEL 145 3.0 2.9

EC/ECT-04-125 1.25 F5 1.0O60° W DEL 155 2.5 3.4

EC/ECT-04-150 1.50 F10 1.2560°B DEL 145 1.5 3.1

EC/ECT-04-175 1.75 F10 1.3560° B DEL 165 2.0 2.5

EC/ECT-05-175 1.75 F10 1.3560° B DEL 165 2.0 2.5

EC/ECT-05-200 2.00 F10 1.5060oB DEL 170 2.5 2.8

EC/ECT-05-250 2.50 F10 2.00 60" B DEL 155 3.5 4.2

EC/ECT-06-275 2.75 F10 2.2560° B DEL 150 4.0 4.2

EC/ECT-06-300 3.00 F10 2.50 60° B DEL 145 4.5 4.2

NOTE:AboveTurbulatorand Air DamperSettingsare start-upsettingsonly-- finaladjustmentsmustbe madewithcombustiontest instruments.

Figure 7 (continued)

COVERPLATE 1 1/2_ 1

W/ WARNINGL

_2

BURNER

DISCONNECT BOX

BURNER

_LOWER LEFT

SIDE PANEL

Figure8

G-CONTROLS

1-Applycontrolsas follows:

a. Water Boilers:

installthe limitor operatingcontrol,temperature-pressuregaugeand safetyreliefvalve.See Figure9 for properlocation.

b. SteamBoilers,FloatLowWaterCut-Off:

installpressurelimitcontrol,pressuregauge,gaugeglasstrimand safetyvalve.See Figure9. For applicationof float lowwatercut-offsee

Figure9 andcontrolmanufacturersinstructionsheetshippedwiththe control.

c. SteamBoilers,PrimaryProbeLowWaterCut-off:

Caution: Donotinstall a probelowwatercut-offin the boilerprimaryprobetappingunlessthe lowwatercut-offis equippedwitha timedon and

off feature.The cycledoff time willallowthe probelowwatercut-offto sensethe true waterlevelin the boilerandeliminatea false

readingcausedfromsensinga foamingorsurgingwatercondition.Failureto use a timedlowwatercut-offcouldresultin a failedheat

exchanger.

NOTE:Longergaugeglass androds arerequiredfor usewiththeoptionalCG450 PrimaryProbeLowWaterCut-off.Thegaugeglasscarton,22-

162-10,is providedwitha packagedboiler.Fora KDboilerthe longergaugeglasscartonis locatedin a specialProbeLowWaterCut-Off

Carton,90759.

Packaged Boilers:The CG450LWCO,andPA404Alimitare installedandwiredat the factory.The boiler miscellaneousparts carton,located

withintheboilercrate,containsthelongergaugeglasscarton22-162-10,GaugeValvesCarton20-105-03,fittingsandcomponents.

KD Boilers:A separatePrimaryProbeLowWaterCut-OffCarton,90759is required.ThiscartoncontainstheCG450LWCO,22-162-10longer

glass/rodscarton,3/4"x 3" nipple,3/4"x 3/4"x 1/4"tee, (2) 1/2"x2" nipplesand(2) Vz"couplings.Usethesecomponentsalongwiththosefrom

theSteamTrimCarton andinstallfittingsand controlsperFigure11.

NOTE:ThePA404Alimit andsiphonare not includedas part of a standardKDboilerofferingfor ECTmodelboilers.

Caution:Pipethe dischargeof thesafetyvalveorsafetyreliefvalveto preventinjuryin the eventof pressurerelief.Pipethedischargetoa drain.

Pipefull sizeof outlet.

1,3

fRONT

3/4" AIR

P_

REAR

(2)

SUPPLY

TANKLESS-

COIL

LOCATION

STEAM

fN

FLOOR

LINE

SIDE F_

,,C,,

COIL 42"

LOCATION

WATER ONLY

Figure9

Boiler

Model

EC/ECT-03

EC/ECT-04

EC/ECT-05

EC/ECT-06

Width

-A-

221/2"

22112"

221/2"

221/2"

Jacket

Depth

"B"

153/4"

191_16"

24118"

288h6"

DIMENSIONS

Length

Height FireBox

"C.... D"

42" 10"

42" 143h8"

42" 183/8"

42" 229/18"

Rearof

Jacketto _LFlue

"E"

83/4"

10;/8"

13"

151/18"

FlueOutlet

Diameter.

-F-

6"

7"

8"

9"

*Dimensionsare approximate.

DistanceBetween

¢t.Tappings*

"G"

91116"

131k"

17;/18"

215/e"

LOCATION

H

I

L

M

N

O

P

Q

R

S

T

TAPPINGLOCATIONS

SIZENPT

8/4"

3/4"

I/4"

1/2"

2"

8/4"

314"

11/4"

8/4"

11/2"

314-

WATER

N/A

LimitControl

Temperature-PressureGauge

WA

OptionalReturn

SecondaryProbeLowWaterCut-off

SafetyReliefValve

Return

DrainValve

OptionalHighLimit

N/A

STEAM

LowLimitControl

PressureGauge

LimitControl

GaugeGlass andLowWaterCut-off

Return

SecondaryprobeLow WaterCut-off

SafetyValve

N/A

DrainValve

Skim

PrimaryProbeLowWaterCut-off

10

McD& M#67PE-2

LOWWATERCUT-OFF

__;OPT'ONAL LCK_TI(]N)

13"

Figure10

LIMIT

USE TAPPINGS A & C

FOR PRIMARY

APPLICATION

,3 NIPPLE

GAUGE

w/ 3/4 x 1/4

BUSHING

CG450 PROBE

GAUGE GLASS

1/2 x 1/2

w/ 1/2 COUPLING

Figure11

11

H-WIRING

1- Allelectricalwiring shallbedonein accordancewiththeNationalElectricalCodeand LocalRequirements,

2 - Locatejunctionbox in the swingdoor carton.Mountjunctionboxto theholes onthe left sideof jacket with(2) #10 x 1" sheet metalscrews.

3 - Locatethe polarized harness(es)in the swing doorcarton. If your cartonhas two polarizedharnesses,selectthe harnesswith malepins. Connect

harnessfromthejunction box to thelimit (waterboilers)or lowwatercutoff (steamboilers)usingfield-suppliedconduit.Seewiringdiagrams(Fig.12,

13& 14),junctionboxdetail (Fig.8), and photos(Fig.2 & cover).Theadditionalharnessis a duplicateof the harnessnow locatedin the burnercar-

ton and maybediscardedif usinga Peerlesssuppliedburner(harnessin burnercartonincludesconduit),

Warning:Improperinstallationof burnerharnesscan allowburnerto energizewithswingdooropen,creatinga severeburnhazardto boiler maintenance

personnel

4a- Locatethe polarizedburnerharnessinthe burnercarton.Attach harnessbetweenburnerandjunctionbox as shownin Figure8.

4b- If usinga non-Peerlesssuppliedburner,obtainappropriateburnerharnessfroma PeerlessDistributor,or hardwireburnersuchthatburnerswingdoor

cannotbe openedwithoutdisconnectingpower.

*Harnessfor Beckettor Carlin burner- 50233(polarized,21" longconduit)

*Harnessfor Rielloburner- 50234(polarized,28" longconduit)

5_ For completeinformationonservicingandadjustmentof controls,referto the attachedcontrolspecificationsheets.

NOTE:Single PoleSwitchesincludingthoseof SafetyControlsor ProtectiveDevicesshallnotbe wiredin a groundedline.

=

Y

OPERATING CON TROt

FOR STEAM W/

TANKLZSS HZATI_R (3NLY

RT184B BURNER

PRIMARy CON]_ BURNER

J/ BOX

IGNITOR I

INTERRUP'ilED

r--GROUNO

BUI_CR SCREW

ABK _1 BK

MOTOR G

L2 W W

UMIT

STEAM WITH OR

Iwo.o T =.ESS

i i "", "------_ 24 V mfZRMOSTAT

-- LINE V(_.TAG/Z

............... LOW V04_TAG_

ALL Y_IRING MUST COMPLY WI1_ APPLIANCE C00ES, (_OINANC[S AN{) R[GULAT]0NS.

GROUND

BK

ADDITIONAL

LIMIT SAFETy S_ TC,HES

CONTROL (WHEN REQUIRED)

_ _BK BK r¸ --:_

67 FLOAT TYPE

LWCO

SER_ICE SV_ITCH

(BY INSTALLER)

x <_OT)

--x--x L2 _15/60/I

FUSED DISCONNECT

(BY INSTALLER)

HYOROLIEVEL 650-p/550-p

PROBE TYPE LWC0

(_EN REQU}RED)

Figure12

12

ALL I_RING MUST CCMPLy I_TH APPLIANC_ C0(_S, 0JROINANCES AND REGULATION S

Figure13

J_P_ x

H_0LE_L 6_O-P/5_-P

p,R_ ,_o E t.w¢. 0

LS_A __C_ S_eTC_

(BY "VSt;_£_)

•R71S_g g_l_(R LeI_ c

_ ,, _ _,_

LIJ ] J J _--_-._I _ FORCED HOT WATER

I[I _ e_< _i_ ij__: \ eK y_ ='-----,_-.... _ WITH TANKLESS HEATER

_j •(_._ HONEYWELL L812AA OR L8124C

]Le_ (ROT)

u_[ _.t_ -- r--- _FORCED HOT WATER

LO_ "_.t_ .......... v_ _WITHOUT TANKL ESS HEATER

Figure14

13

I-CLEANINGHEATINGSURFACES

NOTE:CLEAN BOILERATLEASTONCEPERYEAR.CLEAN BOILERFROMTHELEFTSIDE ORFROMTHETOE

TO CLEAN:

1-Turnoff all electricalpowerto the boiler.Disconnectoilburnerwiringharness.

2a - If cleaningfrom theside, removeleft jacketpaneland sidecleanoutcoverplates.

2b - If cleaningfrom thetop, removeflue pipe,leff topjacket pane_andflue collector.

3 - Brushthe fluepassageswitha wire brush to removeall scaleor soot.

4 - Removescale andsootfrom combustionchamberby vacuumcleaningor any other means.

NOTE:BURNERMOUNTINGPLATEMUST BE REMOVEDOR SWUNGOPENTO FACILITATETHISOPERATION.TARGETWALL IS MADEOF

SOFTCERAMICFIBER.DO NOTDAMAGETHIS MATERIALDURINGBRUSHINGANDVACUUMCLEANING.

5 - Install clean-outcover platesor flue collector.Inspectclean-outcover plate insulation,flue collectorgasket, or rope seal Replaceany piecesnot

forminga gastightseal.

6 - Installjacketpanelsandfluepipeas required.

J-CLEANINGTHESERIESECSTEAMBOILERWITH SKIMTAPPING

Thefollowingcleaningprocedureshaftbe performedbya qualifiedserviceperson.Referto Figure9 for locationof skimtapping.

1 - Clean the boileras describedbelownolaterthan one weekafterthe initialstart up.Cleaningwill be moreeffectiveifthe boileroperatesa dayor

two to loosensedimentand impuritiesin the system.

2 -The boilermust becleanedto removeany accumulationof oil, grease,sludge,etc.that maybe inthe system.Thesesubstancescancause

foamingand surgingof the boilerwater,producingan unstablewaterline andwatercarryoverto the system.

WARNING:CLEANINGTHEBOILERREQUIRESTHEUSEOFVERYHOTWATERAND CORROSIVECHEMICALS.USECAREWHEN

HANDLINGTO PREVENTINJURY,

3 - Connecta 11/2"pipe nippleand shutoff valveto skimtapping.

4 - Connecta 11/2"drain line offofthe skimvalve,run to a pointof safedischarge.

5 - Close allvalvesto thesystem.Providea meansof continuousfreshwaterto the boilerfor thecleaningprocess.

6 - Open the skimvalve.Fiflthe boileruntilwater beginsto flowout of the valve.Shutoff fill valve.

7 - Usecommonwashingsoda(suchas Arm and HammerSuperWashingSoda).Mix thesodawithwater in a 10quart pail andpourintotheboiler

throughthe safetyvalvetapping.Mix a proportionof one (1) poundof washingsodaforeach800 squarefeetEDR netboiterrating.

CAUTION:DONOTLEAVETHEBOILERUNATTENDEDWHILEFIRING.TAKEGREATCARENOTTOALLOWTHEWATERLEVELTODROP

BELOWTHE BOTTOMOFTHEGAUGEGLASSORTOALLOWFRESHWATERMAKEUPTOFLOWINTOO FAST.THISWILL

AVOIDTHEPOSSIBILITYOFCAUSINGTHE BOILERSECTIONSTOFRACTURE.

8-Turn burneron and allowtheboilerwater to heat upto just belowsteaming(180 to 200 degreesF).Cycle theburnerto maintaintemperature

duringskimming.Do notallowthe boilerto steam.Steamingmixesupthecontaminantsinthe waterinsteadof floatingthem at the surface.

9 - Openthe make-upwater valveto continuouslyfeed waterto the boiler.Allow waterto flow outof theskimtapping.

10- Continueskimmingtheboiler untilthewater flowingfromtheskim tappingflowsclear.Thiswill takesometime,possiblyseveralhoursfor a dirty

system.

11- Afterskimmingis complete,closetheskim valveandturn off the boiler.

12- Close themake-upwatervalveand openthe boilerdrain valve.

13- Drainthe boilercompletely.Refilland drainagainone or two timesto makesure allof the sodahasbeen washedout.

14 - Restorepipingto normal.Pipe a nippleandcap inthe skimvalve.

15- NOTE:If thegaugeglass becomesdirtyagain,this indicatesmorecontaminantshaveworkedlooseinthe system.Repeatthecleaningand

skimmingprocessas neededto clean the system.

14

(1)

Boiler

ModelNo,

EC/ECT-03-075

EC/ECT-03-100

EC/ECT-03-120

EC/ECT-04-125

EC/ECT-04-150

EC/ECT-04-175

EC/ECT-05-175

EC/ECT-05-200

EC/ECT-05-250

EC/ECT-06-275

EC/ECT-06-300

(2)

a)HeatingCapacityBTU/Hr.

b)GrossOutput

Water Steam

a 92,000 a 91,000

a 121,000 a120,000

a 144,008 a 142,000

a152,000 a151,000

a181,000 a180,000

a 209,000 a 208,000

a 214,000 a 212,000

a 241,000 a 240,000

b 286,000 b 286,000

b 321,000 b 321,000

b 347,000 b 347,000

SERIESECAND ECTRATINGS

(3)

NetI-8-RRatings

BTU/H_ Steam BTU/Hr.

Steam Sq.Ft. Water

68,000 283 80,000

90,000 375 105,000

107,000 446 125,000

113,000 471 132,000

135,000 563 157,000

156,000 650 182,000

159,000 663 186,000

180,000 750 210,000

215,000 896 249,000

241,000 1004 279,000

261,000 1083 302,000

(4)

I-B-R

Firing

RateG.P.H.

.75

1.00

1.20

1.25

1.50

1.75

1.75

2.00

2.50

2.75

3.00

Chimney

Size Height

inches Feet

8x8 20

8x8 20

8x8 20

8x8 20

8x8 20

8x8 20

8x8 20

8x8 20

8x12 20

8x12 20

8x12 20

Minimum

Draft

Required

inStack

,03"

,04"

.05"

.03"

,04 "t

,05"

,03"

.04 _r

,05"

.04 _

.05"

(1) BoilerModelNo.mayhavethe followingsuffixletters:

W-Water P-Packaged

S-Steam C-Circulator

Uq3oiler-BurnerUnit (Unassembled) T-TanklessCoil

(2a)HeatingCapacityBTU/Hr.basedon D.O.E.testingprocedureat t3.0% CO_,and -.02" watercolumndraftin firebox.

(2b)GrossOutputBTU/Hr.basedon 12.5%CO=,and -.02" watercolumndraft infirebox.

(3) Net I=B=RRatingsbasedontheTestingand RatingStandardfor Cast Iron andSteelHeatingBoilersofThe HydronicsInstituteDivisionof GAMA.

The Net I=B=RRatingsshownincludeallowancefor normalpipingandpick-upload.

The water ratingsare basedona pipingandpick-upaltowancefactorof 1.15, steamratingsarebased ona!lowanceof 1.333.

The PeerlessHeaterCompanyshouldbe consultedbeforeselectinga boilerfor gravityhot waterinstallationsandinstallationshavingunusualpiping

and pick-uprequirementssuchas exposedpiping,nightshut-down,etc.

(4) Firing rateis basedon a fuel oil with a heatingvalueof 140,000BTUper gallon.Burnerinput based on maximumaltitudeof 2,000ft. - for other

altitudesconsultfactory.

ADVERSEFUELCONDITIONS

If an adversefuel conditionsuchas cold oilexists,it maybe

necessaryto increasethe pumppressureto the nozzle.Coldoil is much

harderto atomizeat 100psicomparedto roomtemperatureoil.Tothe

right is a chart giving flowrates of standardnozzlesizesat 120psi and

140psi pumppressure.

NOTE:If itwasnecessarytoincreasethepumppressureabovethe

standard100psi, to eliminateany confusionfor the nextrou-

tine servicinga tag mustbe placedon theburnerindicating

pumppressureand nozzlesize used.

NozzleRating Approx.NozzleRatesGPH

At 100 PSI 120 PSI 140 PSI

.50 .55 .59

.65 .71 .77

.75 .82 .89

.85 .93 1.00

.90 .99 1.07

1.00 1.10 1.18

1.10 1.21 1.30

1.20 1.31 1.41

1.25 1.37 1.48

1.35 1.48 1.60

1.50 1.64 1.78

1.65 1.81 1.95

1.75 1.92 2.07

2.00 2.19 2.37

2.25 2.47 2.66

2.50 2.74 2.96

2.75 3.00 3.24

15

Series EC/ECT

OH Boilers

Installation,

Operation b

Maintenance

Manual

TO THE INSTALLER:

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.

HI Division ASME

of 9area

PEERLESS ®

CAST IRON BOILERS

PEERLESS HEATER COMPANY

231 NORTH WALNUT STREET •BOYERTOWN, PA 19512-1021 •PHONE 610-367-2153

www.peerless-heater.com

THE PREFERRED HEATING CHOICE

©2002 Peerless Heater Company ECS00O R15 (11/02÷5M)

Printed in U,S,A,