EC/ECTBoilers

Installation,

Operation bMaintenance

Manual

Pr=-r=-I_LESS"

CAST IRON BOILERS

Packaged or Knockdown, Hot Water or Steam Boilers11 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

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, pinsand fins are designed into modem boilers to transfer as much heat as possible from the hot gases to thewater 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. Newchimneys 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 tohave 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) haveleaks which reduce draft.

Boiler Design Pressure Drop +.01" +.04" Required for mandatedefficiency increases.

Draft Over Fire -.03" 0.00" The old installation would have

had a higher temperature in the

chimney [as high as 800 degreesvs. 400 degrees F], which wouldincrease 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] ona 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 ofa burner supplied by Peerless Heater Company wouM assure you of a quality, trouble free installation.

INSTALLATIONINSTRUCTIONS- SERIES EC and ECT

Readcarefully beforebeginningwork.It willsavetime.Studythe includeddrawings.

This boilermust be installedby a qualifiedcontractor.

The boiler warrantycan bevoidedif the boiler is not installed,maintained,andserviced correctly.

The equipmentshallbe installedinaccordancewiththoseinstallationregulationsinforce inthe localareawheretheinstallationis to bemade,includingthecurrenteditionof NFPA-31.Theseshallbecarefullyfollowedin all cases.Authordieshavingjurisdictionshallbeconsultedbeforeinstallationsare made.

A - ACCESSIBILITYCLEARANCES

1 - To provide for reasonableconditionsof accessibilityfor servicing, the following minimumclearancesare recommendedbetweenthe boiler andadjacentwalls or otherappliances--at least24" inthe front,rearand onboth sides.

B- AIR FORCOMBUSTIONANDVENTILATION

1 - Be certainadequatefacilitiesare availableto provideair for satisfactorycombustionandventilation.

2 - AppliancesLocatedin UnconfinedSpaces.a. For installationsin unconfinedspaceswith conventionalconstructionand large areas suchas basements,the supplyof air for combustionand

ventilationcanusuallybe consideredadequate.

3 - AppliancesLocatedin ConfinedSpaces.a. If all air for combustionand ventilationis to comefrom withinthebuilding;two openings,one near the ceilingandone nearthe floor of the boiler

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

b. If all air for combustionandventilationis to come fromoutsidethebuilding;twoopenings,one near theceilingand one nearthefloor of the boilerroomshall beprovidedwiththeminimumfree areaof eachopeningequalto 35sq. in. par gallonof oil burned.If ductsare usedto conveytheair,areasof 35 sq. in.per gallonof oil burnedfor verticalductsor 70 sq.in. per gallonof oil burnedfor horizontalductsareto beprovided.Ductsshallhavethesame areaas thefree areaof theopeningsto whichthey areconnected.

C - SETTINGBOILERBLOCK

1-The Series EC/ECT boiler sectionsare factoryassembledwiththe target wallshipped in place. Providea levelfoundation,locatedas close aspossibleto thecenterofthe heatingsystemandto thechimney.Theheatingsurfaceof theSedesEC/ECTboilersis designedto becleanedfromeitherthetop or left side of the unit.Allowadequateclearanceon the leftof unit if servicingis to bedone fromthe side.

2 - Open fluecollector carton.Removefluecollector (Item9, Fig. 4) and hightemperaturerope.Lay rope(Item8, Fig.4) on top of boileragainst beadprovided.Placefluecollectoron top of ropeand attachto boilerwith1/4"-20x 13/4"studswith nutsthroughfluecollectorbracketsinto thetappedlugsprovidedin thetopof 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 flat washerand steelnutas showninFigure1 lockingthemintoplace.Pressthe clean-outplatewithinsulationoverthe protrudingcarriageboltsuntiltheboltspunchthroughtheinsulationsoflat washerand brassnutcanbe installed,Tightendownnutssnuglycompressingthe insulationto forma goodsealaroundthecleen-outopening,

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

INSTALLATIONOF SIDECLEAN-OUTCOVERPLATES

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

Figure1

D- SWINGDOORANDOBSERVATIONCOVERASSEMBLY

1- Removeburnermountingplateincludingright side mountingstudsfor burnermountingplate(do not removeleft side studs)2 - Collectthe Swing DoorCarton(90924)containingthehinge assemblyandhardware.

3 - InstallInternalHingeP/NEC1021(Item6, Fig,4) to frontsectionof boilerwith(2) 5/16-18UNCx 3/4"hex headcapscrewsand5/16"flat washers(donetuse the 11/4" long screws).

4 - InstallExternalHingeP/NEC10122(Item7, Fig.4) to theoutside of theburnermountingplatewith(2) 5/16-18UNCx 11/4" hexheadcapscrews,flatwashers,and nuts.The capscrewsshouldbe insertedthroughthe backof theburnermountingplate,thenthroughthe hinge.Do NOTtightenExternalHingescrewsat thistime.Thiswillallowfor alignmentof the plateonce it is placedin position.

5 - Hangburnermountingplate in position,then close to align the remainingthree (3) studson left side of section.Once alignmentis accomplished,tightennutson ExternalHinge.DeNOTreinstallnuts!washerson left side studsuntil after jacketinstallation.

6 - Removeobservationdoor (Item4, Fig.4) frominsideburnermountingplate.Attachthe observationdoor to the outsideof the mountingplate.7 - The remainingswingdoorcartonparts willbe usedin SectionH,Wiring.

E - JACKETASSEMBLY

1 - Referto Page4, Fig,4 forexplodedview.Attachthebackpanel(19)tobossesonmiddleof 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 thefront jacketpanel(23)whichallowclearancefor thehinge. Placethefront jacketpanelon the blockand replacetheburnermountingplate.

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

NOTE:ON SERIESECTBOILERS,THEOPTIONALWATERHEATER(17) MUSTBE INSTALLEDINLARGEOPENINGIN BACKSECTIONBEFORETHE LEFTSIDE JACKETPANELSAREATTACHED.

5 - If water heateris used, removeknockout piecesin upperleft side jacketpanel(21)and backjacketpanel(19) beforeinstalling.Attach leftside jacketpanelsin thesame manneras the rightside panel.

6 - Attachthetop panel.Thetop is made intwopieces(26& 27).Join thetwo piecestogetherwithsheetmetalscrews.Securetoppaneltofrontand backpanelwithsheet 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 TEMPERATUFEHOT

MIXED

WATER

MIXER

COLDINLET

HEATER

7lAPPING

CONTROL

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

Figure3A Figure3B

MaximumTanklessWaterHeaterRatings

*CapacityHeaterNo. 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-scalddevice inhotwatersupplypiping.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

Swing OutBurnerMountingPlateHinge- Internal

Swing OutBurnerMountingPlateHinge- 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

Upper LeftSideJacketPanel

Upper LeftSideJacketPanel

Upper LeftSideJacketPanel

Upper LeftSideJacketPanel

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" CarriageBolt w/Nuts

SideClean-OutCoverPlate

RightTopJacketPanel

RightTop JacketPanel

RightTop JacketPanel

RightTop JacketPanel

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 - Makeupcold watersupplyconnectionto the boiler.

3 - Installpressuregaugeor temperature-pressuregaugein tappingprovided.See Figure9.

4 - Pluga!l open tappingsin the boilerandfill withwater.Applyapproximatelythirty(30) poundspressure.Checkto makecertain thatall jointsand fittingsare water tight,

5 - Afterall jointsand connectionshavebeenprovenwatertight,removecold watersupplyandplugsfromall tappingsthat areto beused.See Figure9 for tappinglocations.

6 - The returnpipingto the 1-1/4" NPT lower tappingon the frontsectionmustbe installedin sucha mannerto assureproperclearanceof the oilburnerand mountingplatewhenopeningandclosing the burnermountingplate.Peerlesssuggestsusinga 1-1/4"90 degreestreetelbowat thislower tappingin orderto positionthe returnpipingawayfromthe mountingplateassembly.

NOTE:IFTHISBOILERANDDISTRIBUTINGSYSTEMIS USED iNCONJUNCTIONWITHA REFRIGERATIONSYSTEM,THECHILLEDMEDIUMSHALLBE PIPEDIN PARALLELWITHTHEBOILERANDTHE PROPERVALVESAPPLIEDTO PREVENTTHECHILLEDMEDIUMFROMENTERINGTHE BOILER.WHENTHEBOILERIS CONNECTEDTOHEATINGCOILSLOCATEDINAIR HANDUNGUNITSWHERETHEYMAYBE EXPOSEDTOREFRIGERATEDAIRCIRCULATION,THEBOILERPIPINGSYSTEMMUSTBE EQUIPPEDWITHFLOWCONTROLVALVESOROTHERAUTOMATICMEANSTOPREVENTGRAVITYCIRCULATIONOFTHEBOILERWATERDURINGTHECOOLINGCYCLE.

I

\ i i

ERON[

ID

_ EQUALIZER

X

REAR

FRONT REAR

BoilerModel

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"

The returnfrom systemshouldalwaysenterequalizerthroughHartfordLoop,2" to 4" belownormalwaterline (see dimensionaldrawingfor normalwaterline).

STEAM

Figure5

Size thesupplyand returnconnectionsto suit thesystem.

Pipe the supplyand return inoneof two ways:1) Pipe thesupply fromthetop 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 therearsection.Providean air eliminationmeanswithinthesupplypiping.

HOTWATER

ALTERNATE

SUPPLY

FRONT

r

ALTERNATERETURN

REAR

Figure6

F - OILBURNERINSTALLATION

1- The oilburner is suppliedwitha mountingflangefixed inposition.

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

3 - Routethe oil linesto avoid interferencewhenopeningthe platefor boilerservicing.Useflexibleoil linesor copper.Whenusing flexibleoil lines,providetubing longenoughto allowthe plateto swingfreelyover itsentire range.Whenusingcopper,installflaredcopperdisconnectswithvalves.

4 - See Figure7 for Oil BurnerSpecifications.If exceeding100PSIpumppressureon burnersshownat 100 PSI,seechart onpage 13 to determinetherequiredreductionin nozzlesize.

7

WAYNE BURNER WITH 100 PSI PUMP PRESSURE

Boiler Burner Air Cone Nozzle Start-UpSettingsModelNo, ModelNo, I,D, Size FlameLock Off-CycleDamp, Air Shutter

EC/ECT-03-075 HS 21/2" NoHoles .7580° A DEL 1 1.0 .50EC/ECT-03-100 HS 21/2" NoHoles 1.0080" B DEL 1 1.2 1.50EC/ECT-03-120 HS 21/2"NoHoles 1.2080° B DEL 11/2 1.5 1.75EC/ECT-04-125 HS 21/2" 6 Holes 1.2580° B DEL 1 2.0 2.00EC/ECT-04-150 HS 21/2" 6 Holes 1.5080° B DEL 3 2,0 2.25EC/ECT-04-175 HS 21/2" 6 Holes 1.7580° B DEL 5 2,0 2.50EC/ECT-05-175 HS 21/2" 6 Holes 1.7580° B DEL 5 2.0 2.50EC/ECT-05-200 HS 21/2" 6 Holes 2.00 80° B DEL 5 2,0 3.50EC/ECT-05-250 HS 21/2" 6 Holes 2.50 80° S DEL 8 2.0 5.00EC/ECT-06-275 HS 3-5/16" Str.Bore 2.75 80° B DEL 2 2,0 4.00EC/ECT-06-300 HS 3-5/16'` Str.Bore 3.00 80° B DEL 2 2.0 4.50

CARLIN BURNER

Boiler Burner Start-UpSettingsModelNo. ModelNo. Air Shutter NozzleSize PumpPressure HeadDim.A Air Band

EC/ECT-04-125 *99FRD Blank 1.00x 70° B DEL 150 PSI 2 40%openEC/ECT-04-150 *99FRD Blank 1.25x 60° B DEL 150 PSI 3 60%openEC/ECT-04-175 *99FRD Blank 1,50x 60° B DEL 150 PSI 4 100%openEC/ECT-05-175 *99FRD Open 1,50x 60° B HAGO 150 PSI 5 10%openEC/ECT-05-200 *99FRD Open 1,65x 60° B HAGO 150 PSI 5 45%openEC/ECT-05-250 *99FRD Open 2,00 x 60° B HAGO 150 PSI 8 100%openEC/ECT-06-275 102CRD Open 2,75 x 60° B DEL 100 PSI 7 100%openEC/ECT-06-300 102CRD Open 3,00 x 60° B DEL 100 PSI 9 100%open

*Model99FRDBurnerEquippedwithModel 98022PSCMotor

CARLIN EZ-IHP OILBURNERWITHMODEL98022PSC MOTOR

Boiler Burner Start-UpSettingsModelNo, 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- 0.65EC/ECT-03-100 1.00 EZ-1HP Blank 0.85 x70° A DEL 150 PSI 0.65 0.85- 1.00EC/ECT-03-120 1.20 EZ-1HP Blank 1.00 x70° A DEL 150 PSI 0.80 0,85- 1.00

BECKETTBURNERWITH140 PSIPUMPPRESSURE

Boiler Burner Burner Static Nozzle Start-UpSettings HeadModelNo. ModelNo. Head Plate Size AirShutter AirBand Setting

AFG-LI* LI* 33/8" .6560" B HAGO 9.0 2 N/AAFG-L1 L1 33/8" .8560° B HAGO 10.0 1 N/AAFG-L1 L1 ** 1.0060° B HAGO 9.0 2 N/AAFG-F6 F6 23/4" 1.1080° A DEL 5.0 1 N/AAFG-F6 F6 23/4" 1.2580° B HAGO 8.0 1 N/AAFG-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 3AFG-MV1 M-V1-3 -- 1.7560° B HAGO 10,0 9 3AFG-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 2CF-375 L1-S -- 2.50 45° P HAGO 10.0 6 3

EC/ECT-03-075EC/ECT-03-100EC/ECT-03-120EC/ECT-04-125EC/ECT-04-150EC/ECT..04-175EC/ECT..05-175EC/ECT,.05-200EC/ECT..05-250EC/ECT..06-275EC/ECT-06-300

* RequiresLowFiringRateBaffle ** Removestatic platefor 1.20GPHrate.

NOTE:Aboveair settingsare start-upsettingsonly -- final adjustmentsare to bemadewithcombustiontest instruments.AdjustburnerforhighestCO2 (Maximum13%)whilemaintaininga 0 smokeand -.01 to -.02ovediredraft.

Figure7 (continuedon nextpage)

8

RIELLOSERIES40 OIL BURNER

Boiler Firing Burner Nozzle Pump Turbulator AirDamperModelNo. Rate ModelNo. Size Pressure Setting Setting

EC/ECT-03-075 .75 F5 .60600B DEL 155 .5 2.1EC/ECT-03-100 1.00 F5 .8560° W DEL 145 2.0 2.6EC/ECT-03-120 1.20 F5 1.00600W DEL 145 3.0 2.9EC/ECT-04-125 1.25 F5 1.0O60° W DEL 155 2.5 3.4EC/ECT-04-150 1.50 F10 1.2560° B DEL 145 1.5 3.1EC/ECT-04-175 1.75 F10 1.3560° B DEL 165 2.0 2.5EC/ECT-05-175 1.75 F10 1.3560° B DEL 165 2.0 2.5EC/ECT-05-200 2.00 F10 1.5060oB DEL 170 2.5 2.8EC/ECT-05-250 2.50 F10 2.00 60" B DEL 155 3.5 4.2EC/ECT-06-275 2.75 F10 2.2560° B DEL 150 4.0 4.2EC/ECT-06-300 3.00 F10 2.50 60° B DEL 145 4.5 4.2

NOTE:AboveTurbulatorand Air DamperSettingsare start-upsettingsonly-- finaladjustmentsmustbemadewithcombustiontest instruments.

Figure 7 (continued)

COVERPLATE 1 1/2_ 1

W/ WARNINGL

_2BURNER

DISCONNECT BOX

BURNER

_LOWER LEFTSIDE 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. Forapplicationof float lowwatercut-offsee

Figure9 andcontrolmanufacturersinstructionsheetshippedwiththe control.

c. SteamBoilers,PrimaryProbeLowWaterCut-off:

Caution: Donot install a probelowwatercut-off in the boilerprimaryprobetappingunlessthe lowwatercut-off is equippedwitha timedon andoff feature.The cycledoff time willallowthe probelowwatercut-off to sensethe true waterlevelin the boilerandeliminatea falsereadingcausedfromsensinga foamingorsurgingwatercondition.Failureto usea timedlowwatercut-offcouldresultin a failedheatexchanger.

NOTE:Longergaugeglass androds arerequiredfor usewiththeoptionalCG450 PrimaryProbeLowWaterCut-off.The gaugeglasscarton,22-162-10,is providedwitha packagedboiler.Fora KDboilerthe longergaugeglasscarton is locatedin a specialProbeLowWaterCut-OffCarton,90759.

Packaged Boilers:The CG450LWCO,andPA404Alimitare installedandwiredat the factory.The boiler miscellaneousparts carton,locatedwithintheboilercrate,containsthe longergaugeglasscarton22-162-10,GaugeValvesCarton20-105-03,fittingsandcomponents.

KD Boilers:A separatePrimaryProbeLowWaterCut-OffCarton,90759 is required.ThiscartoncontainstheCG450LWCO,22-162-10longerglass/rodscarton,3/4"x 3" nipple,3/4"x 3/4"x 1/4"tee, (2) 1/2"x2" nipplesand(2) Vz"couplings.UsethesecomponentsalongwiththosefromtheSteamTrimCartonandinstallfittingsand controlsperFigure11.

NOTE:ThePA404Alimit andsiphonare not includedaspart of a standardKDboilerofferingfor ECTmodelboilers.

Caution:Pipethe dischargeof thesafetyvalveorsafetyreliefvalveto preventinjury in the eventof pressurerelief.Pipethedischargetoa drain.Pipefull sizeof outlet.

1,3

fRONT

3/4" AIR

P_

REAR

(2)SUPPLY

TANKLESS-COILLOCATIONSTEAM

fN

FLOORLINE

SIDE F_

,,C,,COIL 42"LOCATION

WATER ONLY

Figure9

BoilerModel

EC/ECT-03EC/ECT-04EC/ECT-05EC/ECT-06

Width-A-

221/2"

22112"

221/2"

221/2"

Jacket

Depth"B"

153/4"191_16"24118"288h6"

DIMENSIONS

LengthHeight FireBox"C.... D"

42" 10"42" 143h8"42" 183/8"42" 229/18"

Rearof

Jacketto _LFlue"E"

83/4"

10;/8"

13"

151/18"

FlueOutletDiameter.

-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-PressureGaugeWA

OptionalReturn

SecondaryProbeLowWaterCut-off

SafetyReliefValveReturn

DrainValve

OptionalHighLimit

N/A

STEAM

LowLimitControl

PressureGaugeLimitControl

GaugeGlass andLowWaterCut-offReturn

SecondaryprobeLow WaterCut-off

SafetyValveN/A

DrainValve

Skim

PrimaryProbeLowWaterCut-off

10

McD& M#67PE-2

LOWWATERCUT-OFF

__;OPT'ONAL LCK_TI(]N)

13"

Figure10

LIMIT

USE TAPPINGS A & CFOR PRIMARY

APPLICATION

,3 NIPPLE

GAUGE

w/ 3/4 x 1/4BUSHING

CG450 PROBE

GAUGE GLASS

1/2 x 1/2w/ 1/2 COUPLING

Figure11

11

H -WIRING

1 - Allelectricalwiringshallbedonein accordancewiththeNationalElectricalCodeand LocalRequirements,2 - Locatejunctionbox in the swingdoorcarton.Mountjunctionboxto theholeson the left sideof jacketwith(2) #10 x 1" sheet metalscrews.3 - Locatethe polarized harness(es)in the swing doorcarton. If your cartonhas two polarizedharnesses,select the 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).The additionalharnessis a duplicateof the harnessnow locatedin the burnercar-ton and maybediscardedif usinga Peerlesssuppliedburner(harnessin burnercartonincludesconduit),

Warning:Improperinstallationof burnerharnesscanallowburnerto energizewithswingdooropen,creatinga severeburnhazardto boiler maintenancepersonnel

4a- Locatethe polarizedburnerharnessin the burnercarton.Attach harnessbetweenburnerandjunctionboxas shownin Figure8.4b- If usinga non-Peerlesssuppliedburner,obtainappropriateburnerharnessfroma PeerlessDistributor,or hardwireburnersuch thatburnerswingdoor

cannotbe openedwithoutdisconnectingpower.*Harnessfor Beckettor Carlinburner- 50233(polarized,21" longconduit)*Harnessfor Rielloburner- 50234(polarized,28" longconduit)

5_ Forcompleteinformationonservicingandadjustmentof 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

A BK _1 BK

MOTOR G

L2 W W

UMIT

STEAM WITH OR

I wo.o T =.ESSi 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 TYPELWCO

SER_ICE SV_ITCH

(BY INSTALLER)

x <_OT)--x--x L2 _15/60/I

FUSED DISCONNECT

(BY INSTALLER)

HYOROLIEVEL 650-p/550-pPROBE 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_-Pp,R_ ,_o E t.w¢. 0

LS_A __C_ S_eTC_(BY "VSt;_£_)• R71S_g g_l_(R LeI_ c

_ ,, _ _,_L I J ] 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, removefluepipe,leff top jacketpane_andfluecollector.

3 - Brushthe fluepassageswitha wire brush to removeall scaleor soot.

4 - Removescale andsoot fromcombustionchamberby vacuumcleaningor anyother means.

NOTE:BURNERMOUNTINGPLATEMUST BE REMOVEDOR SWUNGOPENTO FACILITATETHISOPERATION.TARGETWALL IS MADEOFSOFTCERAMICFIBER.DO NOTDAMAGETHIS MATERIALDURINGBRUSHINGANDVACUUMCLEANING.

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

6 - Installjacketpanelsandfluepipeas required.

J - CLEANINGTHESERIESECSTEAMBOILERWITH SKIMTAPPING

The followingcleaning procedureshaftbe performedbya qualifiedserviceperson.Referto Figure9 for locationof skimtapping.

1 - Clean the boileras describedbelowno laterthan one weekafter the initialstart up.Cleaningwill bemoreeffectiveif the boileroperatesa dayortwo to loosensedimentand impuritiesin thesystem.

2 -The boilermust becleanedto removeanyaccumulationof oil, grease,sludge,etc. that maybe inthe system.Thesesubstancescancausefoamingand surgingof the boilerwater,producingan unstablewaterline andwatercarryoverto the system.

WARNING:CLEANINGTHEBOILERREQUIRESTHEUSEOFVERY HOTWATERAND CORROSIVECHEMICALS.USECAREWHENHANDLINGTO PREVENTINJURY,

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

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

5 - Close all valvesto thesystem.Providea meansof continuousfresh waterto 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 andpour into theboilerthroughthesafetyvalvetapping.Mix a proportionof one (1) poundof washingsodaforeach800 squarefeetEDRnetboiterrating.

CAUTION:DONOTLEAVETHEBOILERUNATTENDEDWHILEFIRING.TAKEGREATCARENOTTOALLOWTHEWATERLEVELTODROPBELOWTHE BOTTOMOFTHEGAUGEGLASSORTOALLOWFRESHWATERMAKEUPTOFLOWINTOO FAST.THISWILLAVOIDTHEPOSSIBILITYOFCAUSINGTHE BOILERSECTIONSTOFRACTURE.

8 -Turn burneronand allowtheboilerwater to heat upto just belowsteaming(180 to 200 degreesF).Cycle theburner to maintaintemperatureduringskimming.Do notallowthe boilerto steam.Steamingmixesup thecontaminantsinthe waterinsteadof floatingthem at the surface.

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

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

11 - After skimmingis 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.Pipea nippleandcap inthe skimvalve.15 - NOTE:If thegaugeglass becomesdirtyagain,this indicatesmorecontaminantshaveworkedlooseinthe system.Repeatthecleaningand

skimmingprocessas neededto cleanthe system.

14

(1)Boiler

ModelNo,

EC/ECT-03-075

EC/ECT-03-100

EC/ECT-03-120EC/ECT-04-125

EC/ECT-04-150

EC/ECT-04-175EC/ECT-05-175

EC/ECT-05-200

EC/ECT-05-250

EC/ECT-06-275

EC/ECT-06-300

(2)a)HeatingCapacityBTU/Hr.

b)GrossOutputWater Steam

a 92,000 a 91,000a 121,000 a 120,000

a 144,008 a 142,000

a 152,000 a 151,000

a 181,000 a 180,000

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 80,00090,000 375 105,000

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-RFiring

RateG.P.H.

.75

1.00

1.20

1.25

1.50

1.751.75

2.00

2.50

2.75

3.00

Chimney

Size Heightinches Feet

8x8 20

8x8 20

8x8 20

8x8 20

8x8 20

8x8 20

8x8 20

8x8 20

8x12 20

8x12 20

8x12 20

MinimumDraft

RequiredinStack

,03"

,04"

.05"

.03"

,04 "t

,05"

,03"

.04 _r

,05"

.04 _

.05"

(1) BoilerModel No.mayhavethe followingsuffixletters:W-Water P-PackagedS-Steam C-CirculatorUq3oiler-BurnerUnit (Unassembled) T-TanklessCoil

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

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

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

The Net I=B=RRatingsshownincludeallowancefor normalpipingandpick-upload.

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

The PeerlessHeaterCompanyshouldbe consultedbeforeselectinga boilerfor gravityhot waterinstallationsandinstallationshavingunusualpipingand pick-uprequirementssuchas exposedpiping,nightshut-down,etc.

(4) Firing rate is based on a fuel oil with a heatingvalueof 140,000BTUper gallon.Burner input based on maximumaltitudeof 2,000 ft. - for otheraltitudesconsultfactory.

ADVERSEFUELCONDITIONS

If an adversefuel conditionsuchas cold oilexists,it maybenecessaryto increasethe pumppressureto the nozzle.Coldoil is muchharder to atomizeat 100psicomparedto roomtemperatureoil.Totheright is a chart giving flowrates of standardnozzlesizesat 120psi and140psi pumppressure.

NOTE:If itwasnecessarytoincreasethepumppressureabovethestandard100psi, to eliminateanyconfusionfor the next rou-tine servicinga tag mustbeplacedon theburner indicatingpumppressureand nozzlesize used.

NozzleRating Approx.NozzleRatesGPHAt 100 PSI 120 PSI 140 PSI

.50 .55 .59

.65 .71 .77

.75 .82 .89

.85 .93 1.00

.90 .99 1.071.00 1.10 1.181.10 1.21 1.301.20 1.31 1.411.25 1.37 1.481.35 1.48 1.601.50 1.64 1.781.65 1.81 1.951.75 1.92 2.072.00 2.19 2.372.25 2.47 2.662.50 2.74 2.962.75 3.00 3.24

15

Series EC/ECTOH Boilers

Installation,

Operation bMaintenance

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 ASMEof 9area

PEERLESS ®

CAST IRON BOILERS

PEERLESS HEATER COMPANY231 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,