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Series EC/ECT
Oil Boilers
®
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.
Installation,
Operation &
Maintenance
Manual
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TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 1 4. ELECTRICAL 10 A. INSTALLATION CLEARANCE . . . . . . . . . . . . .1 A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .10 B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1 B. BURNER WIRING . . . . . . . . . . . . . . . . . . . . .10 1. PREINSTALLATION 2 5. BURNER SETUP & BOILER OPERATION 14 A. CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . .2 A. BURNER INSTALLATION . . . . . . . . . . . . . . .14 B. AIR FOR COMBUS
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USING THIS MANUAL USING THIS MANUAL Indicates a condition or hazard which DANGER A. INSTALLATION CLEARANCE will cause severe personal injury, death or major property damage. Follow the installation instructions provided in this manual in the order shown. The order of these Indicates a condition or hazard which instructions has been set in order to provide the installer WARNING may cause severe personal injury, with a logical sequence of steps that will minimize death or major property damage. po
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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 NOTICE local area where the installation is to be made, i
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PREINSTALLATION For Example: C. CHIMNEY / VENT AND DRAFT CONTROL Old New An oil-fired unit shall be connected Comments Installation Installation CAUTION to a flue having sufficient draft at all times, to assure safe proper No change, but older operation of the unit. Chimney chimneys (especially unlined -.04" -.04" Draft ones) have leaks which 1. Draft Requirement – Minimum draft required in the reduce draft. vent system is -.03" to -.05" W.C. depending on Boiler boiler model, see Table 7.1 (Sect
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BOILER PLACEMENT AND ASSEMBLY 2. BOILER PLACEMENT AND ASSEMBLY Be sure rubber gasket is in place A. SETTING THE BOILER NOTICE between cover plate or water heater plate and boiler section. 1. Provide a level foundation, located as close as possible to the center of the heating system. E. JACKET ASSEMBLY 2. Refer to Figure 2.2 for exploded view of boiler while 1. Refer to Figure 2.2 for exploded view. checking and/or assembling parts of the boiler. 2. Attach the back panel (Item 19) to bosses on m
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BOILER PLACEMENT AND ASSEMBLY Figure 2.2: Boiler Exploded View (See Table 8.1 in Section 8 for parts identification). 5
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PIPING AND CONTROLS 3. PIPING AND CONTROLS Do not pipe boiler before jacket is NOTICE installed. EQUALIZER 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). FRONT REAR 3. Plug all open tappings in the boiler and fill with water. Apply approximately thirty (30) psig pressure. Figure 3.1: Steam Boiler Piping, EC-03 Check to make c
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PIPING AND CONTROLS 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. A
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PIPING AND CONTROLS 2. If not using a tankless coil, cover the heater opening E. TANKLESS HEATER OR COVERPLATE with cover plate (item 12 or 16). 1. If a tankless coil is used (item 13 or 17), install as pictured. On water boilers, install in opening in front Be sure rubber gasket is in place NOTICE section. On steam boilers, install in opening in rear between cover plate or water heater section. For suggested piping of tankless water plate and boiler section. heaters refer to Figures 3.6 and 3.7
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PIPING AND CONTROLS Use these components along with the gauge glass F. CONTROLS handles and other components from the Steam Trim Carton and install fittings and controls per Figure 3.10. Pipe the discharge of the safety CAUTION valve or relief valve to prevent injury The shorter gauge glass located in the Steam Trim in the event of pressure relief. Pipe Carton is not necessary for the probe application. the discharge to a drain. Provide piping that is the same size as the 4. Steam boilers subje
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ELECTRICAL 4. ELECTRICAL 3. Install burner harness located in the burner carton. A. GENERAL Beckett or Carlin – EC7022 Harness All electrical wiring shall be done in accordance with the (21" conduit) National Electrical Code and Local Requirements. Single Riello – EC7023 Harness (28" conduit) pole switches including those of safety controls or protective devices shall not be wired in a grounded line. 4. For complete information on servicing and adjustment of controls, refer to the attached cont
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ELECTRICAL Figure 4.2: Steam Boiler with Float Low Water Cut-Off Figure 4.3: Steam Boiler with Probe Low Water Cut-Off 11
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ELECTRICAL Figure 4.4: Water Boilers Figure 4.5: Zoning with Circulators 12
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ELECTRICAL Figure 4.6: Zoning with Zone Valves Figure 4.7: Partner with Circulator 13
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BURNER SETUP & BOILER OPERATION 5. BURNER SETUP & BOILER OPERATION Burn only #2 Fuel Oil in this 2. Adjust burner and barometric draft control for CAUTION appliance. Do not use gasoline, highest CO (Maximum 13% [EC-03 - EC-05] or ² crankcase drainings or any oil 12-1/2% [EC-06]) while maintaining a 0 Smoke and containing gasoline. -.01 to -.02" W.C. draft overfire. A. BURNER INSTALLATION All adjustments must be made using suitable instruments such as found in a Bacharach 1. The oil burner is su
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BURNER SETUP & BOILER OPERATION Do not leave boiler unattended while CAUTION E. CLEAN THE BOILER firing burner. Operating boiler with (STEAM BOILERS ONLY) water below minimum permissible water level may fracture sections. 1. Clean the boiler within one week after initial start-up. Cleaning will be more effective if boiler operates a 7. Turn on burner. Allow boiler water to heat up to just day or two to loosen sediment and impurities in below steaming (180 - 200°F). Do not allow boiler to system.
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BURNER SETUP & BOILER OPERATION Table 5.1: Carlin Burner Specifications CARLIN BURNER SPECIFICATIONS Boiler Burner Air Pump Start-up Settings Firing Rate Nozzle Size Head Bar Model No. Model No. Shutter Pressure Air Band EC/ECT-03-075 .75 EZ-1HP Blank 0.60 70° B DEL³ 150 psig 0.55 0.60 - 0.65 EC/ECT-03-100 1.00 EZ-1HP Blank 0.85 70° A DEL 150 psig 0.65 0.85 - 1.00 EC/ECT-03-120 1.20 EZ-1HP Blank 1.00 70° A DEL³ 150 psig 0.80 0.85 - 1.00 Start-up Settings Boiler Burner Air Pump Nozzle Size Model
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MAINTENANCE 6. MAINTENANCE WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF, when inhaled, have been classified by the International Agency for Research on Cancer (IARC), as a possible carcinogen to humans. After the RCF materials have been exposed to temperatures above 1800°F, they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans. If par
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MAINTENANCE A. GENERAL C. WEEKLY MAINTENANCE (WITH BOILER OPERATING) 1. Check pipes adjacent to cold walls or in unheated spaces. Insulate and tape them if necessary to be 1. Flush float-type low-water cut-off (if used) to remove sure they can't freeze up. Keeping the water moving sediment from the float bowl as stated in the at all times will reduce the likelihood of freezing. manufacturer's instructions. 2. If there is considerable foreign matter in the boiler D. MAINTENANCE OF SAFETY RELIEF w
