ECR International ULTIMATE PF Series Document technique

PFSERIESCASTIRONPRESSURE-FIRED

WETBASEHOTWATERBOILERS

An ISO 9001-2000 Certiﬁed Company

INSTALLATIONMANUALANDOPERATINGINSTRUCTIONS

ULTIMATE BOILERS

85 Middle Rd.

Dunkirk, NY 14048

www.ecrinternational.com P/N 14683825, Rev. 2.1 [11/06]

! !

INSTALLATION MANUAL AND OPERATING INSTRUCTIONS

P/N# 14683825, Rev. 2.1 [11/06] • Printed in USA • Made In USA

Tested For 100 LBS.

ASME

Working Pressure

! !

TABLE OF CONTENTS

Boiler Ratings and Capacities ............................. 4

Burner Setups ..................................................... 6

Optional Direct Exhaust System .......................... 9

Rules for Safe Installation and Operation .......... 10

Indoor Boiler Assembly ...................................... 12

Jacket Assembly (Indoor Boilers) ...................... 13

System Near Boiler Piping (Indoor Boilers) ....... 14

Burner Wiring .................................................... 16

Multi-Zone Wiring and Piping ............................ 17

Weatherproof (Outdoor) Boiler Installation ........ 26

Normal Sequence of Operation ......................... 31

Typical Vent Safety Switch Installation .............. 33

Maintenance ...................................................... 34

Service Hints and Troubleshooting .................... 36

Repair Parts ...................................................... 37

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

SAFETY SYMBOLS & WARNINGS

The following deﬁned symbols are used throughout

this manual to notify the reader of potential hazards

of varying risk levels.

DANGER

Indicates an imminently hazardous situation

which, if not avoided, WILL result in death or

serious injury.

WARNING

Indicates a potentially hazardous situation

which, if not avoided, COULD result in death

or serious injury.

! !

CAUTION

Indicates a potential hazardous situation

which, if not avoided, MAY result in minor or

moderate injury. It may also be used to alert

against unsafe practices.

IMPORTANT: Read the following instructions

COMPLETELY before installing!!

WARNING

Keep boiler area clear and free from

combustible materials, gasoline and other

ﬂammable vapors and liquids.

Do not obstruct air openings to the boiler

room.

Modiﬁcation, substitution, or elimination

of factory equipped, supplied, or speciﬁed

components may result in property damage,

personal injury or the loss of life.

TO THE INSTALLER: Leave all instructions

with the boiler for future reference.

INDOOR BOILER RATINGS AND CAPACITIES

INDOOR BOILER DIMENSIONS

BURNER

TYPE

AFG

OIL

CF375

OIL

AFG W/AIR

INTAKE BOOT

CF375 W/AIR

INTAKE BOOT

RIELLO

40 SERIES OIL

X 11½” 14” 18” 19½” 16⅞”

Y 8½” 11” 15” 13½” 13 7/16”

INDOOR OIL-FIRED HOT WATER BOILERS

WITH TANKLESS COIL

MODEL

RECOMMENDED

FIRING RATES

GPH

HEATING

CAPACITY

MBH(1)

NET I=B=R

RATING

MBH(2)

ANNUAL FUEL

UTILIZATION

EFFICIENCY %(3)

STEADY STATE

EFFICIENCY %

NO.

SEC.

FLUE

SIZE(4)

“A” DIM.

LENGTH

PFO-3T Min.

Max.

.50

1.10

129

112

87.6

82.9

88.40

83.77 3 5” 11”

PFO-4T Min.

Max.

.65

1.45

169

147

87.5

83.3

88.35

84.24 4 6” 14¼”

PFO-5T Min.

Max.

.80

1.75

208

182

87.5

83.8

88.31

84.72 5 6” 17½”

PFO-6T Min.

Max.

.95

2.10

117

250

102

217

87.5

84.3

88.26

85.20 6 7” 24”

PFO-8T Min.

Max.

1.25

2.75

154

324

134

282

87.4

--(5)

88.15

--(5) 8 8” 30½”

WITHOUT TANKLESS COIL

MODEL

RECOMMENDED

FIRING RATES

GPH

HEATING

CAPACITY

MBH(1)

NET I=B=R

RATING

MBH(2)

ANNUAL FUEL

UTILIZATION

EFFICIENCY %(3)

STEADY STATE

EFFICIENCY %

NO.

SEC.

FLUE

SIZE(4)

“A” DIM.

LENGTH

PFO-3 Min.

Max.

.45

.90

105

87.5

82.8

88.22

83.19 3 5” 11”

PFO-4 Min.

Max.

.60

1.35

159

138

87.5

83.3

88.23

83.91 4 6” 14¼”

PFO-5 Min.

Max.

.75

1.70

199

173

87.5

83.9

88.23

84.63 5 6” 17½”

PFO-7 Min.

Max.

1.05

2.35

130

276

113

240

87.6

--(5)

88.24

--(5) 7 7” 24”

PFO-9 Min.

Max.

1.35

3.00

167

353

146

307

87.6

--(5)

88.26

--(5) 9 8” 30½”

Firing rates of 2.00 gph or less use a Beckett Model AFG oil burner. Firing rates over 2.00 gph use a Beckett Model CF375 oil burner. Optional Riello 40 Series

oil burners also available.

Figure #1

WEATHERPROOF BOILER DIMENSIONS

WEATHERPROOF OIL BOILERS

SPACE HEATERS WITHOUT TANKLESS COIL

MODEL

RECOMMENDED

FIRING RATES

GPH

HEATING

CAPACITY

MBH(1)

NET I=B=R

RATING

MBH(2)

ANNUAL FUEL

UTILIZATION

EFFICIENCY %(3)

STEADY STATE

EFFICIENCY %

NO.

SEC.

MULTI

PASS

COIL

“A” DIM.

LENGTH

PFO-4W Min. .60 71 61 82.9 88.23 4 Less 28⅛”

Max. 1.35 151 131 78.6 83.19

PFO-7W Min. 1.05 124 107 82.9 88.24 7 Less 37⅞”

Max. 2.35 276 240 --(4) --(4)

PFO-9W Min. 1.35 159 138 82.5 88.26 9 Less 44⅜”

Max. 3.00 309 268 --(4) --(4)

IMPORTANT: ANTIFREEZE ADDED TO WEATHERPROOF BOILERS MUST BE NON-TOXIC!!

(1) D.O.E. Heating capacity is indicated in thousands of Btu per hour. Use of antifreeze in any boiler can reduce capacity, net output and

efﬁciency by a signiﬁcant amount.

(2) Net ratings are indicated in thousands of Btu per hour based on a piping and pickup allowance of 1.15.

(3) Annual Fuel Utilization Efﬁciency based on tests performed under U.S. Department of Energy standards and reported to the Federal

Trade Commission.

(4) Capacity greater than that requiring testing under F.T.C. regulations. Firing rates of 2.00 gph or less use a Beckett Model AFG oil

burner. Firing rates over 2.00 gph use a Beckett Model CF375 oil burner.

OUTDOOR BOILER RATINGS AND CAPACITIES

Figure #2

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.

Boiler Size Firing

Rate

Beckett

Burner

Burner Part

Number

Nozzle

Mfg. Nozzle Pump

Presure Head Drawer

Assy Adj.

Low Fire

Bafﬂe

Air

Shutter

Air

Band

PFO-3

0.65 AFG 14619201 Delavan .60 X 80 A 140 F0 Fixed Yes 10.0 1.0

0.75 AFG 14619201 Delavan .65 X 70 A 140 F0 Fixed No 10.0 0.0

0.90 AFG 14619201 Delavan .75 X 80 B 140 F3 Fixed No 10.0 0.0

PFO-3T

0.65 AFG 14619201 Delavan .60 X 80 A 140 F0 Fixed Yes 10.0 2.0

0.85 AFG 14619201 Delavan .75 X 80 A 140 F3 Fixed No 10.0 1.0

1.10 AFG 14619201 Delavan .90 X 80 B 140 F3 Fixed No 10.0 1.0

PFO-3T2

1.10 AFG 14619201 Delavan .90 X 80 B 140 F3 Fixed No 10.0 1.0

PFO-4

0.65 AFG 14619201 Delavan .60 X 80 A 140 F0 Fixed Yes 10.0 1.0

1.00 AFG 14619201 Delavan .75 X 80 A 140 F3 Fixed No 10.0 0.0

1.35 AFG 14619201 Delavan 1.20 X 80 B 140 F6 Fixed No 10.0 2.0

PFO-4T

0.65 AFG 14619201 Delavan .60 X 80 B 140 F0 Fixed Yes 10.0 1.0

0.95 AFG 14619201 Delavan .85 X 80 B 140 F3 Fixed No 10.0 1.0

1.45 AFG 14619201 Delavan 1.25 X 80 B 140 F6 Fixed No 10.0 2.0

PFO-5

0.75 AFG 14619201 Delavan .65 X 80 A 140 F3 Fixed Yes 10.0 1.0

1.10 AFG 14619201 Delavan 1.00 X 80 A 140 F6 Fixed No 10.0 1.0

1.70 AFG 14619201 Delavan 1.50 X 80 A 140 F12 Fixed No 10.0 3.0

PFO-5T

0.80 AFG 14619201 Delavan .65 X 70 A 140 F3 Fixed Yes 10.0 0.0

1.50 AFG 14619201 Delavan 1.00 X 70 A 140 F6 Fixed No 10.0 1.0

1.75 AFG 14619201 Delavan 1.50 X 70 A 140 F12 Fixed No 10.0 3.0

PFO-6T

0.95 AFG 14619201 Delavan .85 X 80 B 140 F3 Fixed No 10.0 2.0

1.45 AFG 14619201 Delavan 1.20 X 80 B 140 F6 Fixed No 10.0 3.0

2.10 CF375 240006445 Delavan 1.75 X 60 B 140 CF56KZ SL1 0 No 10.0 0.0

PFO-6T2

2.10 CF375 240006445 Delavan 1.75 X 60 B 140 CF56KZ SL1 0 No 10.0 0.0

PFO-7

1.00 AFG 14619201 Delavan .90 X 80 B 140 F3 Fixed No 10.0 0.0

1.60 AFG 14619201 Delavan 1.35 X 80 B 140 F12 Fixed No 10.0 1.0

2.35 CF375 240006445 Delavan 2.00 X 60 B 140 CF56KZ SL1 0 No 10.0 2.5

PFO-7TT2

2.00 CF375 240006445 Delavan 1.65 X 60 B 140 CF56KZ SL1 0 No 5.0 1.0

PFO-8T

1.25 AFG 14619201 Delavan 1.00 X 70 A 140 F6 Fixed No 10.0 6.0

1.90 CF375 240006445 Delavan 1.50 X 60 B 140 CF56KZ SL1 1 No 10.0 0.0

2.75 CF375 240006445 Delavan 2.25 X 60 B 140 CF56KZ SL1 1 No 10.0 3.0

PFO-8T2

2.00 CF375 240006445 Delavan 1.65 X 60 B 140 CF56KZ SL1 1 No 5.0 1.0

2.75 CF375 240006445 Delavan 2.25 X 60 B 140 CF56KZ SL1 1 No 10.0 3.0

PFO-9

1.35 AFG 14619201 Delavan 1.20 X 70 A 140 F6 Fixed No 10.0 2.0

2.00 CF375 240006445 Delavan 1.65 X 45 B 140 CF56KZ SL1 0 No 6.5 0.0

3.00 CF375 240006445 Delavan 2.50 X 60 B 140 CF56KZ SL1 3 No 10.0 4.0

1. All burners ﬁred at an over ﬁre pressure of +0.02” w.c.

2. Burner insertion depth is 4 ⅝”

3. Nozzle is NOT factory installed and must be installed in the ﬁeld.

4. All F Heads are ﬁxed with a “Z” dimension of 1 ⅛”. See Beckett burner manual for proper “Z” dimension setup.

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.

Boiler Size Firing

Rate

Riello

Burner

Burner Part

Number

Nozzle

Mfg. Nozzle Pump

Presure

Turbulator

Setting

Air Gate

Setting

PFO-3

0.90 F5 1050006 Delavan .75 X 60 W 150 3.0 5

PFO-3T

0.95 F5 1050006 Delavan .75 X 60 W 160 3.0 4.5

1.10 F5 1050006 Delavan .85 X 60 W 170 2.0 3.1

PFO-4

1.00 F5 1050006 Delavan .85 X 60 W 150 2.0 3.25

1.35 F5 1050006 Delavan 1.10 X 60 W 150 3.5 4.5

PFO-4T

1.45 F5 1050006 Delavan 1.20 X 60 A 150 4.0 4.3

PFO-5

0.75 F5 1050006 Delavan .60 X 60 W 155 0.5 2.25

1.10 F5 1050006 Delavan .85 X 60 W 170 2.0 3

1.70 F10 14619011 Delavan 1.35 X 60 W 160 1.5 3

PFO-5T

0.80 F5 1050006 Delavan .60 X 60 A 175 1.0 2.3

1.50 F5 1050006 Delavan 1.25 X 60 A 150 4.0 5.5

1.75 F10 14619011 Delavan 1.35 X 60 A 170 1.5 3.2

PFO-6T

0.95 F5 1050006 Delavan .75 X 60 W 175 1.5 2.8

1.45 F5 1050006 Delavan 1.20 X 60 W 170 3.5 5

2.10 F10 14619011 Delavan 1.75 X 60 W 170 2.5 4.5

PFO-7

1.00 F5 1050006 Delavan .85 X 60 W 150 2.0 3.2

1.60 F10 14619011 Delavan 1.35 X 60 W 175 3.0 1.5

2.35 F10 14619011 Delavan 2.00 X 60 W 160 4.0 3.5

PFO-8T

1.25 F5 1050006 Delavan 1.00 X 60 W 175 2.5 4

1.90 F10 14619011 Delavan 1.50 X 45 W 175 2.0 3.4

2.75 F10 14619011 Delavan 2.25 X 45 W 175 5.0 6

PFO-9

1.35 F5 1050006 Delavan 1.10 X 60 W 165 3.5 3.8

2.00 F10 14619011 Delavan 1.65 X 60 W 165 2.5 3.4

3.00 F10 14619011 Delavan 2.50 X 60 B 150 5.0 7.8

1. All burners ﬁred at an over ﬁre pressure of +0.02” w.c.

2. Burner insertion depth is 4 ⅝”

3. Nozzle is NOT factory installed and must be installed in the ﬁeld.

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.

Boiler

Size

Firing

Rate

Beckett

Burner

Burner Part

Number

Nozzle

Mfg. Nozzle Size Pump

Presure Head / Choke

Drawer

Assy

Adj

Low Fire

Bafﬂe

Air

Shutter

Vent Kit Part

Number

Less Burner

Vent Kit Part

Number with

Burner

PFO-3

0.65 AFG 14619202 Delavan .60 X 80 A 140 F0 Fixed Yes 125 550001447 550001450

0.75 AFG 14619202 Delavan .65 X 70 A 140 F0 Fixed No 110 550001447 550001450

0.90 AFG 14619202 Delavan .75 X 80 B 140 F3 Fixed No 55 550001447 550001450

PFO-3T

0.65 AFG 14619202 Delavan .60 X 80 A 140 F0 Fixed Yes 125 550001447 550001450

0.85 AFG 14619202 Delavan .75 X 80 A 140 F3 Fixed No 110 550001447 550001450

1.10 AFG 14619202 Delavan .90 X 80 B 140 F3 Fixed No 55 550001447 550001450

PFO-4

0.65 AFG 14619202 Delavan .60 X 80 A 140 F0 Fixed Yes 80 550001448 550001451

1.00 AFG 14619202 Delavan .75 X 80 A 140 F3 Fixed No 45 550001448 550001451

1.35 AFG 14619202 Delavan 1.20 X 80 B 140 F6 Fixed No 130 550001448 550001451

PFO-4T

0.65 AFG 14619202 Delavan .60 X 80 B 140 F0 Fixed Yes 80 550001448 550001451

0.95 AFG 14619202 Delavan .85 X 80 B 140 F3 Fixed No 45 550001448 550001451

1.45 AFG 14619202 Delavan 1.25 X 80 B 140 F6 Fixed No 130 550001448 550001451

PFO-5

0.75 AFG 14619202 Delavan .65 X 80 A 140 F3 Fixed Yes 75 550001448 550001451

1.10 AFG 14619202 Delavan 1.00 X 80 A 140 F6 Fixed No 155 550001448 550001451

1.70 AFG 14619202 Delavan 1.50 X 80 A 140 F12 Fixed No 222 550001448 550001451

PFO-5T

0.80 AFG 14619202 Delavan .65 X 70 A 140 F3 Fixed Yes 75 550001448 550001451

1.50 AFG 14619202 Delavan 1.00 X 70 A 140 F6 No 155 550001448 550001451

1.75 AFG 14619202 Delavan 1.50 X 70 A 140 F12 Fixed No 222 550001448 550001451

PFO-6T

0.95 AFG 14619202 Delavan .85 X 80 B 140 F3 Fixed No 50 550001448 550001451

1.45 AFG 14619202 Delavan 1.20 X 80 B 140 F6 Fixed No 110 550001448 550001451

2.10 CF375 240006433 Delavan 1.75 X 45 B 140 CF56KZ SL1 0 No 60 550001448 550001449

PFO-7

1.00 AFG 14619202 Delavan .90 X 80 B 140 F3 Fixed No 100 550001448 550001451

1.60 AFG 14619202 Delavan 1.35 X 80 B 140 F12 Fixed No 190 550001448 550001451

2.35 CF375 240006433 Delavan 2.00 x 45 B 140 CF56KZ SL1 0 No 170 550001448 550001449

PFO-8T

1.25 AFG 14619202 Delavan 1.00 X 70 A 140 F6 Fixed No 70 550001448 550001451

1.90* CF375 240006433 Delavan 1.50 X 45 B 140 CF56KY V1 1 No 45 550001448 550001449

2.75 CF375 240006433 Delavan 2.25 X 45 B 140 CF56KZ SL1 1 No 140 550001448 550001449

PFO-9

1.35 AFG 14619202 Delavan 1.20 X 70 A 140 F6 Fixed No 127 550001448 550001451

2.00 CF375 240006433 Delavan 1.65 X 45 B 140 CF56KZ SL1 0 No 55 550001448 550001449

3.00 CF375 240006433 Delavan 2.50 X 45 B 140 CF56KZ SL1 3 No 120 550001448 550001449

1. All burners ﬁred at an over ﬁre pressure of +0.02” w.c.

2. Burner insertion depth is 4 ⅝”

3. Nozzles are NOT factory installed and must be installed in the ﬁeld.

4. All F Heads are ﬁxed with a “Z” dimension of 1 ⅛”. See Beckett burner manual for proper “Z” dimension setup.

* NOTE: The burner for the 8 section FDVS 1.90 GPH input needs a static disk change, see the Kit #550001620 for details.

OPTIONAL DIRECT EXHAUST SYSTEM

The optional FDVS is to be used in conjunction

with the PF boiler for indoor installations requiring

through the wall venting. The FDVS is designed

as an integral part of the PF boiler, eliminating the

need for a power venter.

Oil boiler FDVS kits include an oil burner with

adjustable post purge timer and solenoid valve.

For through the wall venting, this post purge burner

must be used in place of the standard burner that is

furnished with the boiler.

SELECTION OF BOILER SIZE

Selection of boiler size should be based upon “Net

I=B+R Rating MBH being equal to or greater than

the calculated heat loss of the building.

These boilers are low pressure sectional cast

iron boilers constructed and hydrostatically tested

for a maximum working pressure of 50 psi in

accordance with A.S.M.E. (American Society of

Mechanical Engineers) Section IV Standards for

cast iron heating boilers. They are capacity rated

in accordance with the code of the Hydronics

Institute.

These boilers operate on #2 Heating Oil, Natural

Gas, or Propane Gas, with the proper burner.

Boiler Kit Duct Dia. Wall

Opening

3 sections FDVS 4 4” 6½”

4 to 9 sections FDVS 6 6” 8½”

IMPORTANT

Standard indoor PF Series boilers are furnished

as knockdown boilers and are shipped as four

components (w/o FDVS) or ﬁve components

(with FDVS) are shown below:

• basic boiler assembly

• boiler jacket

• accessory kit

• burner (without post purge)

• FDVS parts (include post purge oil burner

for oil-ﬁred burners)

Weatherproof (outdoor) PF Series boilers are

furnished as knockdown boilers only and are

shipped as ﬁve components as shown below:

• basic boiler assembly

• weatherproof boiler jacket

• exhaust cap, pipe, and weather collar

• accessory kit

• burner

On knockdown oil burners, the oil burner nozzle

is not included. Correctly sized nozzle must be

installed prior to startup.

Indoor oil-ﬁred models PFO (3, 4, 5, 3T, 4T, 5T)

without direct exhaust system are available as

packaged boilers, in which case an oil burner

nozzle for one of three speciﬁed ﬁring rates will

be factory installed in the oil burner.

RULES FOR SAFE INSTALLATION AND OPERATION

• Read the installation manual before beginning

the installation. Failure to follow the rules for

safe operation and the instructions can cause a

malfunction of the boiler and result, serious bodily

injury, and/or property damage.

• Check your local codes and utility requirements

before installation. The installation must be

in accordance with their directives, or, in their

absence, follow NFPA Installation Codes and

good industry practice.

• Before servicing, allow boiler to cool. Always shut

off any electricity and oil to boiler when working on

it. This will prevent any electrical shocks or burns.

• Inspect oil lines and connections for leaks.

• Be certain oil burner nozzle or gas oriﬁce is size

required. Over-ﬁring will result in early failure of

the boiler sections. This will cause dangerous

operation.

• Never vent this boiler into an enclosed space.

Always vent to the outside. Never vent to another

room or inside a building.

• Be sure there is adequate air supply for complete

combustion.

• Follow a regular service and maintenance

schedule for efﬁcient and safe operation.

• Keep boiler area clean and free of combustible

material, gasoline, and other ﬂammable vapors

and liquids.

• Proper through-the-wall venting requires use of

complete FDVS (oil-ﬁred units only).

• Oil and gas burners are not do-it-yourself items.

This boiler must be installed and serviced by

qualiﬁed professionals using combustion test

instruments.

• Be aware when piping the relief valve if the

system pressure exceeds the safe limit of 30 lbs.

per square inch, the relief valve will automatically

open. Lifting of the relief valve can discharge large

quantities of steam and hot water, which may

damage the surroundings. Before installing the

relief valve, read the manufacturer’s instructions

and the maintenance section of the manual on

relief valves.

! !

WARNING

Improper installation, adjustment, alteration,

service, or maintenance can use property

damage, personal injury, or loss of life.

All installations must conform to the

requirements of the authority having

jurisdiction. Such applicable requirements

take precedence over the general instructions

of this manual.

Where required, by the authority having

jurisdiction, the installation must conform to

the American Society of Mechanical Engineers

Safety Code for Controls and Safety Devices

for Automatically Fired Boilers, ANSI/ASME

No. CSD-1. In Canada, all installations must

be in accordance with the authorities having

jurisdiction and CSA B139.

1. The installation must conform to the

requirements of the authority having

jurisdiction or, in absence of such

requirements, to the latest revision

of the National Fuel Gas Code, ANSI

Z223-1. (Available from the American

Gas Association, Pleasant Valley Rd.,

Cleveland, OH, 44134.) Reference should

also be made to local gas utility regulations

and other codes in effect in the area in

which the installation is to be made.

2. Where required by the authority having

jurisdiction, the installation must conform

to American Society of Mechanical

Engineers Safety Code for Controls and

Safety Devices for Automatically Fired

Boilers, ANSI/ASME No. CSD-1.

3. This boiler is classiﬁed as a Category

I and III and vent installation shall be

in accordance with Part 7 of the latest

revision of the National Fuel Gas Code,

ANSI Z223.1 or applicable provisions of

the local building codes.

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REXNOVA

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Radiant

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