ECR International ULTIMATE PF Series Technical Document

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]

3
! !
! !
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.
US

4
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
62
129
54
112
87.6
82.9
88.40
83.77 3 5” 11”
PFO-4T Min.
Max.
.65
1.45
80
169
70
147
87.5
83.3
88.35
84.24 4 6” 14¼”
PFO-5T Min.
Max.
.80
1.75
99
208
86
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
56
105
48
91
87.5
82.8
88.22
83.19 3 5” 11”
PFO-4 Min.
Max.
.60
1.35
74
159
64
138
87.5
83.3
88.23
83.91 4 6” 14¼”
PFO-5 Min.
Max.
.75
1.70
93
199
81
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

5
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

6
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.

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.
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.

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.
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.

9
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.

10
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.

11
THE PUMP PRESSURE OF THE STANDARD
BECKETT BURNER IS SET AT 140 PSI.
The output of the burner nozzle will be 18% greater than rated.
Rated Output (gph) at
100 psi (nozzle label)
Actual Output (gph) at
140 psi (approximate)
.40
.50
.60
.65
.75
.85
1.00
1.10
1.20
1.25
1.35
1.50
1.65
1.75
2.00
2.25
2.50
.47
.59
.71
.77
.89
1.01
1.18
1.30
1.42
1.48
1.60
1.77
1.95
2.07
2.37
2.66
2.96
RULES FOR SAFE INSTALLATION AND OPERATION
! !
• Frequent and mysterious lifting of the relief valve
may be a sign of an improperly sized expansion
tank. Installation and sizing of the expansion tank
must consider the heating system’s total water
volume, temperature, boiler initial fill pressure, and
system arrangement. For proper installation and
maintenance follow the guidelines established by
ECR and the manufacturer.
• Expansion tank performance and life expectancy
can be hindered by overfilling the boiler. ECR
recommends an initial fill pressure of 10 – 12 psig.
For higher fill pressures, the expansion tank’s
air charge will need to match the fill pressure.
Consult the manufacturer’s guidelines for sizing
and selection.
• Purging the heating system of air and gases during
the boiler’s initial commissioning is critical for proper
circulation and quiet performance. Once the air
and gases are purged, for boiler installations using
float type vents, the air vents should be closed for
normal operation. If air is heard or noticed by a
loss of heat, purge the system and open the vents
for a short period of time.
CAUTION
This boiler has been designed for residential
installations. If used for commercial applications,
all jurisdictional requirements must be met. This
may require wiring and/or piping modifications.
The manufacturer is not responsible for any
changes to the original design.
DO NOT USE GASOLINE CRANKCASE
DRAININGS OR ANY OIL CONTAINING
GASOLINE.
! !
BEFORE YOU START
Check to be sure you have the right size boiler
before starting the installation. See rating and
capacity tables on preceding pages. Check the
rating plate on the right side of the boiler.
You must see that the boiler is supplied with the
proper fuel, fresh air for combustion, and a suitable
electrical supply. Also, the boiler must be connected
to a suitable venting system and an adequate piping
system. Finally, a thermostat, properly located, is
needed for control of the heating system. If you
have any doubts as to the various requirements,
check with local authorities and obtain professional
help where needed.
These installation instructions are vital to the proper
and safe operation of the heating system. Take the
time to be sure they are carefully followed.
CAUTION
Always keep the manual fuel supply valve shut
off, if the burner is shut down for an extended
period of time.

12
INDOOR BOILER INSTALLATION
GENERAL REQUIREMENTS FOR A TYPICAL INSTALLATION
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:
Figure #3
Figure #4
not in excess of 250° F for water boilers) may be placed
on a combustible floor protected with hollow masonry not
less than 4” (100mm) thick covered with sheet metal not
less than 24 gauge. Such masonry shall be laid with ends
unsealed and joints matched in such a way as to permit free
circulation of air from side to side through the masonry.
N.F.P.A. 31 Section 4-4.1.5 Appliances may be placed on
combustible floors, although not listed for such installation,
provided the floor under the appliance is protected in
accordance with the requirements of accepted building
code practice. (A water-wall-type heating boiler operating

13
LOCATING THE BOILER
1. Place boiler at a location as centralized to the
piping system and as close to the chimney or vent
terminal as possible to minimize condensation.
At input rates up to 1.75 gph (245,000 Btu/hr),
the supply and return from radiation may be
piped on the same end of the boiler. At higher
rates, it is recommended that the supply be
piped from the rear of the boiler and the return
be piped from the front of the boiler. Coordinate
jacket installation with piping. See “Jacket
Assembly Instructions” and “Piping Diagrams”
in this manual for more information.
2. See Figure #4 for installation on combustible
flooring. If necessary, place metal shims beneath
feet to ensure a level unit.
3. Accessibility clearances must take precedence
over fire protection clearances. Allow at least
24” for servicing at the tankless and burner
sides of the unit. Allow at least 18” at a side
where passage is required for access to
another side for servicing. A 6” clearance from
combustible material on all sides and the top
is recommended. 18” clearance is necessary
between smoke pipe and nearest combustible
material. See NFPA 31, latest revision, for safe
methods to reduce clearances where necessary.
NFPA publications are available at Battery Park,
Quincy, MA 02269.
CONSULT FIRE AUTHORITIES
FOR LOCAL REQUIREMENTS
JACKET ASSEMBLY (Indoor Boilers)
JACKET ASSEMBLY (INDOOR BOILERS)
1. See Figure #5 (above) for reference. Note that
all sheet metal screws are #10 unless specified
otherwise.
2. See hardware package in boiler accessory kit for
stand-off bolts, studs, acorn nuts, washers, and
⅛” pipe plug. Note that the sight glass assembly
is also found in the boiler accessory kit.
3. Screw double end stand-off bolts into castings
next to upper supply and lower return tappings
in both ends of the boiler. Screw three 5/16” studs
finger-tight into burner mounting.
4. Hold panels 1 and 1A against burner end of
boiler and insert necessary piping through
jacket openings into boiler casting.
5. Screw acorn nuts onto stand-off bolts.
6. Screw 1” nipple and sight glass holder into hole
above burner.
7. Screw the ⅛” plug into tapping on upper left of
burner mounting.
8. Install panel 2 on opposite side of boiler in same
manner as panel 1.
9. Install panel 3 by attaching it with four sheet
metal screws to panels 1 and 2 (already in
position).
10. Install temperature/pressure gauge into either of
the two ¾” tappings on top of the casting. Using
a ¾” x 4½” nipple, install relief valve in second
top tapping. Install jacket top panel (#4) by
attaching it with four sheet metal screws to the
three jacket side panels already in position.
To permit easy disassembly of overflow pipe in
order to raise jacket top panel for annual cleaning,
screw hand tight a ¾” nipple into the relief valve.
Attach a ¾” elbow to the nipple and an overflow
NOTE: Please see the separate Venting
Instruction for flue size limitation and other
information on venting. For direct exhaust
systems, the total run of horizontal flue pipe
must not exceed 6’ and the total run of vertical
flue pipe must not exceed 10’.
Figure #5

14
pipe to the elbow. (Nipple, elbow and overflow
pipe not supplied.) Do not connect directly to
a drain, but leave an air gap. No shutoff of any
description shall be placed between the safety
relief valve and the boiler, or on discharge pipes
between such safety valves and the atmosphere.
Installation of the safety relief valve shall conform
to the ANSI/ASME Boiler and Pressure Vessel
Code, Section IV. The manufacturer is not
responsible for any water damage.
If preferred, one of the top tappings may be
used for an air vent and the relief valve may
be installed in an upper 1½” side tapping of the
casting with a bushing, nipple, and street elbow.
Valve spindle must be vertical.
11. Install angle iron (#5) open edge up to panels
1 and 2 on the remaining exposed side of the
boiler near floor level. Angle iron is attached
with two sheet metal screws to the inside of the
turned edges of panels 1 and 2.
12. Install knobs (#6) on door panel (#7) using #8
machine screws. Install door panel by resting
lower edge inside angle iron (#5) and snapping
top sides into place.
NEAR BOILER SYSTEM PIPING (Indoor Boilers)
1. Antifreeze added to boilers must be non-toxic, and
must of a type specifically intended for use in closed
hydronic heating systems. Under no circumstances
should automotive antifreeze be used.
2. Use of antifreeze in any boiler may reduce
capacity by 10% or more and increase fuel
consumption. Tankless coil performance will fall
as concentration of antifreeze is increased. See
below for water volumes of boilers and piping.
3. Because antifreeze forms slush rather than hard
ice, it is safe to protect only to 10 degrees above
coldest temperature anticipated provided slush
formed can move towards expansion tank.
BOILER WATER VOLUMES
Model Gallons Model Gallons
PF-3 7 PF-3T 10
PF-4 9 PF-4T 12
PF-5 11 PF-5T 14
PF-7 15 PF-6T 16
PF-9 19 PF-8T 20
PIPING WATER VOLUMES
Divide total length of piping in feet by appropriate factor
below to determine volume in gallons.
Pipe Size Copper Pipe Factor Steel Pipe Factor
½” 82.5 63.5
¾” 40.0 36.0
1” 23.3 22.2
1¼” 15.3 12.8
1½” 10.8 9.5
2” 6.2 5.8
RECOMMENDED BY-PASS PIPING
TO AVOID CONDENSATION
As efficiencies increase and slack temperatures
decrease, it becomes increasingly important to keep
boiler warm enough to discourage condensation. All
steel and cast-iron boilers can rust badly if operated
for extended periods at water temperatures below
140 and chimneys can be damaged as well.
The purpose of the by-pass shown in Figure #6
(above) is to permit the boiler to warm up faster
than the radiation system, thereby decreasing
the potential for condensation in both boiler and
chimney.
JACKET ASSEMBLY (Indoor Boilers) Continued
Figure #6

15
L8151 CONTROL SETTINGS
Use the following setting for the first adjustment:
High Setting ...................180°F
Low Setting ....................160°F
Differential ........................20°F
These settings may be altered based on the heating
system response. During very cold weather if the
heating system does not provide quite enough
heat, the high limit control setting may be raised to
a maximum of 200°F. If more domestic hot water is
required, the low limit control setting may also be
raised to a maximum of 180°F. Whenever adjusting
either the high or low limit, the high limit control
setting must be set at least 20°F above the low
limit. The differential control setting is typically 20°F
but may be adjusted to vary the time it takes the
burner to respond to a call for domestic hot water.
COLD STANDBY
1. Cold standby is suitable only when thermostatic
union is used with piping bypass shown in
Figure #6.
2. A change in control wiring is also required. To
prevent excessive condensation, please contact
factory before making this change.
3. Owners of non-tankless boilers often object to the
burner starting when space heat is not required.
To avoid this, an optional outside thermostat may
be used to shut down the system totally when
outside temperature is above a specific limit set
by the homeowner. See wiring diagrams.
SYSTEM PIPING (Indoor Boilers) Continued
TYPICAL TANKLESS COIL PIPING
Figure #7

16
BURNER WIRING
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























   
 



 

 
 

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








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




17















 


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
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
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
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

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


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

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 
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
   
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

MULTI-ZONE SYSTEM WIRING AND PIPING

18



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        
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
MULTI-ZONE SYSTEM WIRING AND PIPING

19
PIPING WITH CIRCULATORS
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MULTI-ZONE SYSTEM WIRING AND PIPING

20
MULTI-ZONE SYSTEM WIRING AND PIPING
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