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Summary of Contents for ECR International ULTIMATE PF Series
- Page 1 PF SERIES CAST IRON PRESSURE-FIRED WET BASE HOT WATER BOILERS ULTIMATE BOILERS An ISO 9001-2000 Certified Company 85 Middle Rd. Dunkirk, NY 14048 www.ecrinternational.com P/N 14683825, Rev. 2.1 [11/06]...
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Page 3: Table Of Contents
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS P/N# 14683825, Rev. 2.1 [11/06] • Printed in USA • Made In USA TABLE OF CONTENTS CAUTION Boiler Ratings and Capacities ......4 Indicates a potential hazardous situation Burner Setups ............. 6 which, if not avoided, MAY result in minor or Optional Direct Exhaust System ...... -
Page 4: Boiler Ratings And Capacities
INDOOR BOILER RATINGS AND CAPACITIES Figure #1 INDOOR BOILER DIMENSIONS BURNER CF375 AFG W/AIR CF375 W/AIR RIELLO TYPE INTAKE BOOT INTAKE BOOT 40 SERIES OIL 11½” 14” 18” 19½” 16⅞” ” 8½” 11” 15” 13½” INDOOR OIL-FIRED HOT WATER BOILERS WITH TANKLESS COIL RECOMMENDED HEATING... - Page 5 OUTDOOR BOILER RATINGS AND CAPACITIES Figure #2 WEATHERPROOF BOILER DIMENSIONS WEATHERPROOF OIL BOILERS SPACE HEATERS WITHOUT TANKLESS COIL RECOMMENDED HEATING NET I=B=R ANNUAL FUEL MULTI STEADY STATE “A” DIM. MODEL FIRING RATES CAPACITY RATING UTILIZATION PASS EFFICIENCY % SEC. LENGTH EFFICIENCY % COIL Min.
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Page 6: Burner Setups
BURNER SETUPS CHIMNEY VENT SUGGESTED BECKETT BURNER SETUPS Note: These settings are intended for initial start up only. Final adjustments must be made using combustion test instruments. Firing Beckett Burner Part Nozzle Pump Drawer Low Fire Boiler Size Nozzle Head Rate Burner Number... - Page 7 BURNER SETUPS CHIMNEY VENT SUGGESTED RIELLO BURNER SETUPS Note: These settings are intended for initial start up only. Final adjustments must be made using combustion test instruments. Firing Riello Burner Part Nozzle Pump Turbulator Air Gate Boiler Size Nozzle Rate Burner Number Mfg.
- Page 8 BURNER SETUPS SIDE WALL VENTED (FDVS) SUGGESTED BECKETT BURNERS SETUPS Note: These settings are intended for initial start up only. Final adjustments must be made using combustion test instruments. Drawer Vent Kit Part Vent Kit Part Boiler Firing Beckett Burner Part Nozzle Pump Low Fire...
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Page 9: Optional Direct Exhaust System
OPTIONAL DIRECT EXHAUST SYSTEM The optional FDVS is to be used in conjunction IMPORTANT with the PF boiler for indoor installations requiring through the wall venting. The FDVS is designed Standard indoor PF Series boilers are furnished as an integral part of the PF boiler, eliminating the as knockdown boilers and are shipped as four need for a power venter. -
Page 10: Rules For Safe Installation And Operation
RULES FOR SAFE INSTALLATION AND OPERATION WARNING • Read the installation manual before beginning the installation. Failure to follow the rules for safe operation and the instructions can cause a Improper installation, adjustment, alteration, malfunction of the boiler and result, serious bodily service, or maintenance can use property injury, and/or property damage. - Page 11 RULES FOR SAFE INSTALLATION AND OPERATION • Frequent and mysterious lifting of the relief valve BEFORE YOU START may be a sign of an improperly sized expansion tank. Installation and sizing of the expansion tank Check to be sure you have the right size boiler must consider the heating system’s total water before starting the installation.
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Page 12: Indoor Boiler Assembly
INDOOR BOILER INSTALLATION Figure #3 GENERAL REQUIREMENTS FOR A TYPICAL INSTALLATION Figure #4 RECOMMENDED FIREPROOF BASE FOR INSTALLATION ON COMBUSTIBLE FLOORING NOTE: The above recommendations in regard to clay or concrete blocks exceed the requirements of the National Fire Protection Association as follows: not in excess of 250°... -
Page 13: Jacket Assembly (Indoor Boilers)
LOCATING THE BOILER 2. See Figure #4 for installation on combustible NOTE: Please see the separate Venting flooring. If necessary, place metal shims beneath Instruction for flue size limitation and other feet to ensure a level unit. information on venting. For direct exhaust systems, the total run of horizontal flue pipe 3. -
Page 14: System Near Boiler Piping (Indoor Boilers)
JACKET ASSEMBLY (Indoor Boilers) Continued pipe to the elbow. (Nipple, elbow and overflow be installed in an upper 1½” side tapping of the pipe not supplied.) Do not connect directly to casting with a bushing, nipple, and street elbow. a drain, but leave an air gap. No shutoff of any Valve spindle must be vertical. - Page 15 SYSTEM PIPING (Indoor Boilers) Continued Figure #7 TYPICAL TANKLESS COIL PIPING L8151 CONTROL SETTINGS COLD STANDBY Use the following setting for the first adjustment: 1. Cold standby is suitable only when thermostatic union is used with piping bypass shown in High Setting ....180°F Figure #6.
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Page 16: Burner Wiring
BURNER WIRING ������� ������ ������ �� ���� ���� ������� ���������� ����� ��� ������� ������ ��� ��� ���� ������ � ������� ���� ����� ������ � ��� ���� �� � ����������� ��� ������ ����� ������������ ������ ����� � � �� �� � ��... -
Page 17: Multi-Zone Wiring And Piping
MULTI-ZONE SYSTEM WIRING AND PIPING... - Page 18 MULTI-ZONE SYSTEM WIRING AND PIPING...
- Page 19 MULTI-ZONE SYSTEM WIRING AND PIPING PIPING WITH CIRCULATORS...
- Page 20 MULTI-ZONE SYSTEM WIRING AND PIPING...
- Page 21 MULTI-ZONE SYSTEM WIRING AND PIPING PIPING WITH ZONE VALVES...
- Page 22 INDOOR OIL BURNER AND CONTROLS (STARTUP AND ADJUSTMENT) INDOOR CHIMNEY VENTED BOILERS CAUTION IMPORTANT: Instruction manual enclosed in Too low a firing rate can cause excessive burner carton must be followed in regard to condensation within the boiler and chimney startup and adjustment.
- Page 23 INDOOR OIL BURNER AND CONTROLS (STARTUP AND ADJUSTMENT) START-UP ADJUSTMENT: Start L8181 CONTROL SETTINGS and adjust burner according to manufacturer’s instructions contained in burner carton or included Use the following setting for the first adjustment: with packaged boiler, and pay special attention to the following: High Limit Set Point ..
- Page 24 INDOOR DIRECT EXHAUST BOILERS job properly. Long continuous runs with minimum 12. Before making control adjustments, verify that starts and stops conserve the most energy. The all fuel, water, and electrical connections have been nozzle which provides the highest CO with the made in accordance with the regulations of the least smoke for a particular application is always...
- Page 25 INDOOR DIRECT EXHAUST BOILERS falls to the same temperature as the boiler water. With all high efficiency boilers, care must be taken Adjust the post purge timer to nearest time interval, to minimize condensation. Therefore, cold standby always rounding up if possible. For example, if the is not recommended and may be used only with a time measured is 3 minutes and 20 seconds, then piping bypass as shown in Figure 6.
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Page 26: Weatherproof (Outdoor) Boiler Installation
WEATHERPROOF (OUTDOOR) BOILER INSTALLATION WATERPROOF (OUTDOOR) BOILER LOCATING THE BOILER 1. Place boiler at a location as centralized as 4. Accessibility clearances must take precedence possible with the piping system and as free from over fire protection clearances. Allow at least 24” unusual wind currents as possible. - Page 27 WATERPROOF (OUTDOOR) BOILER ASSEMBLY AND PIPING Figure #9 WEATHERPROOF BOILER PIPING WITH INDOOR WATER HEATING UNIT 7. Referring to Figure #10, place panel 1 over Figure #10 supply and return pipe nipples. WEATHERPROOF JACKET ASSEMBLY 8. Attach panels 2 and 3 to panel 1 using sheet metal screws supplied.
- Page 28 WATERPROOF (OUTDOOR) BOILER ASSEMBLY AND PIPING Figure #10 WEATHERPROOF BOILER PIPING WITHOUT INDOOR WATER HEATING UNIT disturbing combustion chamber when inserting 12. Install burner according to manufacturer’s air tube. Retention head must be set flush with instructions with particular attention given to the inside wall of combustion chamber.
- Page 29 WATERPROOF (OUTDOOR) BOILER ASSEMBLY AND PIPING Figure #11 BECKETT BURNER WIRING DIAGRAM FOR WEATHERPROOF OIL-FIRED BOILER (SPACE HEATING) 3. Because antifreeze forms slush rather than hard 18. Referring again to Figure #10, fasten front jacket ice, it is safe to protect only to 10 degrees above panel (#9) in position with sheet metal screws and coldest temperature anticipated provided slush install jacket top (#5).
- Page 30 WEATHERPROOF OIL BURNER AND CONTROLS (STARTUP AND ADJUSTMENT) ALTERNATE AIR ELIMINATION METHOD BECKETT AFG OR CF375 OIL BURNER As boiler temperature increases, air will move from A Beckett model AFG oil burner is used to fire top of boiler toward float vent even if lower. As boilers at 2.00 gph or less.
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Page 31: Normal Sequence Of Operation
NORMAL SEQUENCE OF OPERATION On a call for heat, the thermostat will actuate, com- START-UP AND ADJUSTMENT OF BURNER pleting the circuit to the aquastat. In turnm the circu- lator and ignition systems are activated and ignition (See oil burner instructions for nozzle and electrode setting.) will begin. - Page 32 NORMAL SEQUENCE OF OPERATION • Power Failure: Turn off main power supply PROPER OPERATION OF switch while burner is operating. When burner THE BOILER BURNER UNIT stops, restore power and burner should start. A ¼” diameter slot is provided in the inspection If operation is not as described as above, check cover plate to take draft readings in the combustion wiring and controls.
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Page 33: Typical Vent Safety Switch Installation
TYPICAL VENT SAFETY SWITCH INSTALLATION This boiler may also be installed with a pressure using the screws provided and is wired to the T-T switch. For side-wall vented boilers the unit uses a terminals on the Oil Primary for oil-fired boilers (as .35”... -
Page 34: Maintenance
MAINTENANCE Drain it until pressure is reduced below the safe ANNUAL SERVICE CHECK limit. Then have the valve replaced immediately. The relief valve should be tested monthly. Refer to To assure trouble-free operation, we recommend valve manufacturer’s instructions packaged with that you have the flue passages, burner, combustion relief valve. - Page 35 OIL BURNER MAINTENANCE The following preventive maintenance items 3. Remove relief valve discharge pipe and top should be performed annually, preferably prior to jacket panel. the heating season. 4. Remove the two brass wing nuts holding the flue OIL BURNER MOTOR: Add 2-3 drops of collector top.
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Page 36: Service Hints And Troubleshooting
MAINTENANCE REQUIREMENTS Keep your boiler and the area around it clean. leave combustible material near or around it. Never burn garbage, paper, or any material other Have your boiler checked each year by a qualified than the specified fuel in your boiler and never service technician. -
Page 37: Repair Parts
PF SERIES CAST IRON PRESSURE-FIRED WET BASE HOT WATER BOILERS IMPORTANT – READ THESE INSTRUCTIONS BEFORE ORDERING All parts listed on the following pages may be ordered through your nearest supplier. When ordering parts, first obtain the model number from the data plate on your boiler, then determine the part number and description of each part from the following illustrations. - Page 38 BOILER PARTS...
- Page 39 BOILER PARTS - WITH TANKLESS COIL MODELS ITEM DESCRIPTION MODEL 3T MODEL 4T MODEL 5T MODEL 6T 7TT, 8T Fire Door 41982001 41982002 41982002 41982002 41982002 Front Chamber 14630021 14630021 14630021 14630021 14630021 Cone Chamber Front Plate 14630022 14630022 14630022 14630022 14630022 Durablanket...
- Page 40 INDOOR JACKET PARTS MODEL 7TT, ITEM DESCRIPTION MODEL 3 MODEL 3T, 4 MODEL 4T, 5 MODEL 5T MODEL 6T, 7 8T, 9 KNOB SET 13702153 13702153 13702153 13702153 13702153 13702153 JACKET DOOR 42582049AC 42582044AC 42582045AC 42582046AC 42582047AC 42582048AC TIE BAR 42500653 42500653 42500653...
- Page 41 WEATHERPROOF JACKET PARTS ITEM DESCRIPTION MODELS 3TW, 4W MODELS 6TW, 7W MODELS 7TTW, 8TW, 9W Top Panel 14630411 14630412 14630413 Jacket 14630402 14630403 14630404 Weather Shield 14630421 14630424 14630427 Flue Pipe 14630423 14630426 14630429 Collar 14630422 14630425 14630428...
- Page 42 DIRECT EXHAUST SYSTEM PARTS ITEM DESCRIPTION PART NO. KIT,EV/FVDS-4AL,DIR EXH CTN LESS BURNER 550001447D 4” VENT EXHAUST HOOD 240005873 VACUUM RELIEF DRAFT REGULATOR ASSY PRESSURE SWITCH 240005625 VITON TUBING 30705 BRASS BARB 1230010 PRESS SWITCH WIRE HARNESS 240005767 ROTOR CLAMP 1110001 KIT,EV/FDVS-6AL/SL,DIR EXH CTN LESS BURNER 550001448D...
- Page 43 BOILER CONTROLS AND PIPING ITEM DESCRIPTION PART NO. Beckett AFG Standard Oil Burner (2.00 gph or less) 14619201 Beckett CF375 Standard Oil Burner (2.00 gph or more) 240006445 Riello 40 F5 Standard Oil Burner (0.90 to 1.50 gph) 1050006 Riello 40 F10 Standard Oil Burner (1.60 to 3.00 gph) 14619011 Beckett AFG Direct Vent Oil Burner (2.00 gph or less) 14619202...
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