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PB Heat DE User's Manual

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1. 33 4 VENTING 11 B DAILY WITH BOILER IN USE 33 A GENERAL 11 C WEEKLY WITH BOILER IN USE 33 B CHIMNEY VENTING 11 D MONTHLY WITH BOILER IN USE 33 C DIRECT EXHAUST E ANNUALLY BEFORE START OF HEATING HORIZONTAL VENTING 11 SEASON scum ak anos ine area ae 34 D DIRECT EXHAUST VERTICAL VENTING 14 10 BOILER DIMENSIONS amp RATINGS 35 E BOILER REMOVAL FROM COMMON VENTING SYSTEM 15 11 REPAIR PARTS 36 A BLOCK BASE FLOOR PAN 5 GAS PIPING 16 JACKET FLUE COLLECTOR 36 B BASE BURNERS MANIFOLD 37 USING THIS MANUAL A INSTALLATION SEQUENCE A DANGER Follow the installation instructions provided in this manual in the order shown The order of these Indicates a condition or hazard which will cause instructions has been set in order to provide the installer severe personal injury death or major property with a logical sequence of steps that will minimize damage potential interferences and maximize safety during boiler installation B SPECIAL ATTENTION BOXES A WARNING Throughout this manual you will see special attention Indicates a condition or hazard which may cause boxes intended to supplement the instructions and make severe personal injury death or major property special notice of potential hazards These categories damage mean in th
2. 39NO NO MOVE 3440 37949 TIIM H31IN9I ALON 4388 SMO19 SWHVM AW140 TIVNH3LNI HOS TOHLNOO 3A1VA SV9 OLNI SS3NHVH 4 S3A LOH Avc NOWNWOO Abe N33A 138 NOWINOO Abe 5 33 38 Ave 38 GINOHS 35VLIOA 13SNI 33S SS3NHVH 10H1NOO LV H3dOHd HOS 93 9 15 OL IVLSONWH3HI 135 e SS3NHVH WALSAS LOANNOOSIC e NOILISOd NO NI SI HOLIMS AATWA SV9 SHNSSV e XlddNs 509 440 NYNL e 1 1OHLNOO LIWITHOIH SVA0ZL HOS MOSHD S878H 39V1d3ti YAMOd H3dOHd dl XO8 ACISNI YAMOd SNIWOONI 323H2 OL HO TVNINH31 HOLIMS aunssaud 3 LV ADVLIOA ON 41 HOLIMS 3unssaud 39v1d3H dl 38n 1 03350718 93 9 NOILISOd NI MONLS SI HOLIMS lt 5 Wz 80Hd LON LNG N LV 3SVLTOA die gant aNnOHD OL N ANY 9 STWNINYAL 19388 HOLIMS SYNSSAYd LV DVAvZ HOS MOAHO SHA amp NnH Y37108 5301 IOHLNOO LIWI139V 1d3H HLOS LON 1n8 1VNIWH3 L3NO LY YIMOd 8828H NO ONY Du SNOILOANNOD Lv A1VISOWH3HI ON HOLIAS 9NIOVTd3H 380338 1nO T1Oti dO 3snVO 19388090 SI HOLIMS 4 H LIMS 100 1109 SWV14 LY OVAvC HOS 93 9 3A193430 SI AV 13H OS JI S3HIM
3. Honeywell SV9501M2064 Gas Valve LP Gas 51691 51691 51691 Honeywell SV9601M4167 Gas Valve Natural Gas 51683 Honeywell SV9601M4225 Gas Valve LP Gas 51692 Honeywell Q3480B1025 Pilot Natural Gas 51684 51684 51684 51684 Honeywell Q3480B1058 Pilot LP Gas 50205 50205 50205 50205 Honeywell L4080B1253 Limit 50210 50210 50210 50210 Zettler ZC90113 177 Relay Center 50786 50786 50786 50786 Endura ES2035 0136 Pressure Switch 0 2000 Ft 0 610 m Elevation 50093 Endura ES2035 0135 Pressure Switch 0 2000 Ft 0 610 m Elevation 50092 50092 Endura ES2035 0133 Pressure Switch 0 2000 Ft 0 610 m Elevation 50091 Zettler Relay ZC90341 50790 50790 50790 50790 Safety Relief Valve 30 PSI Conbraco 10 408 05 Safety Relief Valve 50 PSI Watts 350 Temperature Pressure Gauge For elevations over 2000 feet above sea level contact PB Heat LLC 38 NOTES 39 NOTES 40 Gas Boilers Installation Operation amp Maintenance 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 o HI Division ASME of gama p D PeerlessBoilers com PB HEAT LLC PO BOX 447 NEW BERLINVILLE PA 19545 0447 2007 DE8022 R8 5 07 3M Printed in U S A
4. Boilers Installation Operation amp Maintenance Manual TABLE OF CONTENTS USING THIS MANUAL 1 6 ELECTRICAL 18 A INSTALLATION SEQUENCE 1 A WIRING 18 B SPECIAL ATTENTION BOXES 1 B ZONED SYSTEM WIRING 18 C CONTROLS 18 1 PREINSTALLATION 2 D SEQUENCE OF OPERATION 19 A ACCESSIBILITY CLEARANCES 2 B CLEARANCE FROM COMBUSTIBLE 7 START UP PROCEDURES 22 CONSTRUCTION 2 A COMPLETING THE INSTALLATION 22 C AIR FOR COMBUSTION AND B CONTROL DESCRIPTIONS 25 VENTILATION 2 C ADJUSTMENT OF GAS PRESSURE D INSTALLATION SURVEY 5 REGULATOR 25 E PLANNING THE LAYOUT 5 D CHECKING BURNER INPUT 25 E CHECK OUT PROCEDURE 26 2 BOILER SET UP 6 8 TROUBLESHOOTING 28 3 WATER PIPING AND CONTROLS 7 A SHUT DOWN CAUSED BY PILOT OUTAGE A BOILER SUPPLY AND RETURN 7 PRESSURE SWITCH OR FLAME ROLL OUT B SAFETY RELIEF VALVE 8 SAFETY SHUT OFF SWITCH 28 C PIPING FOR ZONED SYSTEMS 9 B TROUBLESHOOTING GUIDES 28 D EXPANSION TANK 10 C MEASURING SUCTION PRESSURE 28 E INDIRECT FIRED WATER HEATER 10 FREEZE PROTECTION 9 MAINTENANCE 32
5. Condensation at boiler vent connector fan Vent pipe not sloped towards vent terminal Install condensate trap per vent manufacturer s instructions Slope vent pipe towards vent terminal Boiler not heating properly Underfiring Limit set too low Air in system Circulator malfunctioning Circulation system clogged Incorrect thermostat heat anticipator setting Increase rate to input on rating label Reset limit to higher setting Vent air from all points in system Check circulator replace if necessary Shut down and cool boiler drain and flush system Adjust heat anticipator to 0 2 Amp Fumes or gas odors 30 Leaks in gas piping or fittings Leaks in gas service line or meter Obstructed chimney Obstructed flueways or vent Draft problem in boiler room Overfiring Locate and repair or replace Shut down boiler and notify gas provider Check repair and or clean chimney Clean flueways or vent and remove obstructions Check air supply ventilation and venting system Reduce rate to input on rating label a 77 SV9 LON OG d NO MOVE 440 LVLSOWHSHL 319A9 XISWASSV aNV T1d d31IN9I 39V 1d3H S3A X1ddNS ANY HAWHOASNVYL 93 9 ON FATWA SV9 39v 1d3H ON 318 99 1071
6. OW 1 1 4 NPT TEMPERATURE RETURN _ i PRESSURE GAUGE Lo 6 L 3 LIMT 24 11 16 ZG 627mm GAS INLET 1 5 8 S FLOOR 12 3 8 797mm i LINE 314mm i 1 235 pr uA Ses 8 3 8 584mm 213mm 26 5 8 676mm LEFT SIDE FRONT RIGHT SIDE Figure 10 1 Boiler Views Table 10 1 Series DE Boiler Ratings SERIES DE BOILER RATINGS Net I B R Seasonal Boiler DOE Heating Ratings Efficiency Model Capacity Number Water Water AFUE Content MBH kW MBH kW Gallon Liter 1 Net I B R water ratings based on an allowance of 1 15 2 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc 8 3 Heating Capacity and Annual Fuel Utilization Efficiency AFUE ratings are based U S Government test Before purchasing this appliance read important information about its estimated annual energy consumptions or energy efficiency rating that is available from your retailer 35 REPAIR PARTS 11 REPAIR PARTS REPAIR PARTS SERIES DE GAS BOILER Repair parts are available from your installer or by contacting PB Heat LLC New Berlinville PA Use the figures and tables on pages 36 38 to assist in ordering parts Note Remember to include boiler model number and serial number when ordering parts Figure 11 1 Blo
7. 20 6 1 190 5 4 350 9 9 730 20 7 1100 31 1 30 9 1 152 4 3 285 8 1 590 16 7 890 25 2 40 12 2 130 3 7 245 6 9 500 14 2 760 21 5 50 15 2 115 3 3 215 6 1 440 12 5 670 19 0 60 18 3 105 3 0 195 5 5 400 11 3 610 17 3 Maximum Capacity Correction Factors for Specific Gravity other than 0 60 Specific Gravity Correction Factor Specific Gravity Correction Factor Specific Gravity Correction Factor 17 6 ELECTRICAL Install all electrical wiring in accordance with the National Electrical Code and local requirements NOTICE This unit when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the current edition of the National Electrical Code ANSI NFPA 70 and or the Canadian Electrical Code Part 1 CSA C22 1 Electrical Code 1 See Figure 6 1 for location of wiring and controls Use Figure 6 2 to connect the boiler to a power supply and to connect components to the boiler 2 Connect the boiler by a separate permanently live electrical supply line with a fused switch 3 Adjust the thermostat heat anticipator to 0 2 Amp B ZONED SYSTEM WIRING See Figure 6 4 for typical wiring with zone valves See Figure 6 5 for typical wiring with zone circulators When wiring a zoned heating system follow all applic
8. 5 3 Consult the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code for proper sizing options 4 Locate the drop pipe adjacent to but not in front of the boiler 5 Install a sediment trap See Figure 5 1 Locate a tee in the drop pipe at same elevation as the gas inlet connection to the boiler Extend the drop pipe to a pipe cap 6 Install a ground joint union ahead of the gas control assembly to permit servicing of the control Some local codes require an additional service valve when using the combination gas controls If your code requires such a valve a suggested location is shown in Figure 5 1 WARNING Use pipe joint sealing compound that is resistant to the action of liquefied petroleum gas A non resistant compound may lose sealing ability in the presence of this gas resulting in a gas leak and fire or explosion potential 7 Check piping for leaks Use an approved gas detector a non corrosive leak detection fluid or other leak detection method If leaks are found turn off all gas flow and repair as necessary When checking for leaks do not use matches candles open flames or other methods that provide a source of ignition This can ignite a gas leak resulting in fire or explosion 16 SERVICE VALVE JACKET G J UNION SEDIMENT TRAP Figure 5 1 Gas Connection to Boiler 8 Disconnect the bo
9. C MEASURING SUCTION PRESSURE Refer to Table 8 1 for fan suction pressure required to energize control circuit Measure fan suction pressure as shown in Figure 8 1 Note that as boiler operates suction pressure will decrease Measure after 15 minutes of boiler operation Table 8 1 Fan Suction Pressure Suction Pressure Boiler Model 28 A DANGER When servicing or replacing items that communicate with the boiler water be certain that There is no pressure on the boiler The boiler is not hot The power is off When servicing the gas valve or pilot be certain that The gas is off The electricity is off A WARNING Do not use this appliance if any part has been under water Improper or dangerous operation may result Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water N CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing A CAUTION Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump This may aggravate the problem and increase the likelihood of boiler damage Instead shut off the gas supply at a location external to the appliance TROUBLESHOOTING TO PRESSURE TAP FITTING
10. 93 23 8 3ATVA SV9 ON 8 LASNI YOLOANNOD NI S IVNIIWH3 L SNISSIIN HO Q39VIAVG 93H29 10H LIOA bz LIOA vc HOLO3NNOO SS3NHVH IWLSOWYSHL ve 30 V LASNI K1ISW3SSV 3WV 1d d31IN9l 39VT1d3H GOOD 3AO8V SHL 10 dl e ONIGNL AHL HONOYHL NOLLO3NNOO 7TVOIH193 13 4009 393H9 e 3NV14 YANYNE 1OTld HLIM LOVLNOD A009 SSXVIN LO lld LYHL O3HO9 e AK18W3SSV 1d d31IN9I39V1d3ti SHA G3H3AAOd Q3193NNOO 3ATVA SV9 AHL HLIM 3NOG 38 LSNW 3123HO SIHL ti3dOtid AJILN3QI OL V LASNI 335 G3H3AAOd HLIM 9 VA S 6L ASV31 LV 3HnSV3NW LSNW 3AT1VA SV9 SqQV31NOWNWNOO Atz LOH Av 8 39 e SHA SI 509 10714 3HnSSV OL SNIMO14 SI SV9 107114 e 318V2 10719 LOANNODSY A18W3SSV 3NWVT3 H31IN9I39VT1d3t IVNINON Avz 8 13SNI 33S 1 1 3 ISH SV9 LV 39V L10A 3HnSV3W avo 1o1Id 9n1dNn SNIHIA e IWLSOWHYSHL e H3T1OH1NOO H3WHO4JSNVH1 39 H3MOd ADVLIOA MOAHO SI W31SAS S3A 5 1 9 1 SN3dO ON SHA SLHSIM YANHNE LOTId e ON X1ddNsS 509 NO NYNL e SSA 1 GNODAS 06
11. CLOSEST TO FLUE COLLECTOR TO PRESSURE EON TER TAP FITTING PRESSURE CLOSEST TO FAN TAP 1 8 TEST TEE 1 8 SILICONE HI NEG TUBING PRESSURE TAP oJ LI II 1 8 TEST 1 8 TEST 5 d 1 8 SILICONE TUBING lt TUBING DIFFERENTIAL PRESSURE SWITCH INCLINED MANOMETER 0 2 W C SCALE MINIMUM SUCTION PRESSURE SEE TABLE 7 Figure 8 1 Procedure For Measuring Fan Suction Pressure TROUBLESHOOTING Table 8 2 Boiler Troubleshooting Guide Burners Functioning Problem Burners not functioning Possible Causes See Figure 8 2 Corrective Actions See Figure 8 2 Burners will not shut down Defective gas valve Short circuit Use Figure 8 2 to troubleshoot intermittent ignition gas valve Replace if necessary Check and correct wiring Flashback or burning at orifice spuds Manifold gas pressure too low Improperly sized drilled orifice spuds Leaking gas valve Burrs on orifice Low supply gas pressure Adjust to proper pressure Install correct spuds Replace valve Remove burrs Contact gas supplier if natural gas Adjust regulator if LP gas Delayed ignition Insufficient pilot flame Pilot burner orifice clogged Overfiring Misaligned burners or pilot Increase pilot gas flow Clean pilot burner and orifice Reduce rate to input on rating label Realign burners or pilot
12. IGNITION SYSTEM Figure 6 3 Ignition System Operating Sequence 20 ELECTRICAL THERMOSTAT 24V 120V 60HZ TRANSFORMER DISCONNECT 120 24V 60HZ SWITCH E C 40VA 1 I TRANSFORMER d qu dh RELAY CONTROL nium LL UH E 1 1 ZONE VALVE 1 H V8043E a nnn ONE ZON ZONE ZONE HI III 0 1 M 2 No 3 NO i o j nn E pod I Poy W Ds HH be L 4 L 1 ALL WIRING MUST COMPLY WITH APPLICABLE CODES ORDINANCES AND REGULATIONS LINE VOLTAGE LOW VOLTAGE Figure 6 4 Zone Wiring with Zone Valves 120V 60HZ THERMOSTAT 24V TO MAIN DISCONNECT SWITCH SWITCHING RELAY H R845A W R 829A 845 OR HOT L1 12 TACO SR501 845RP 1 9 TRANSFORMER RELAY CONTROL LINE VOLTAGE LOW VOLTAGE 1 ZONE 2 ZONE 3 NOTE ALL WIRING MUST COMPLY WITH APPLICABLE CODES ORDINANCES AND REGULATIONS Figure 6 5 Zone Wiring with Circulators 21 7 START UP PROCEDURES A COMPLETING THE INSTALLATION 1 22 Confirm that all water gas and electricity are turned off Inspect the boiler combustion chamber for foreign objects and remove if present Check physical condition of bu
13. at each end of the boiler base Move boiler into final position If using combustible floor pan install boiler on pan as outlined in the instructions included with the pan 3 WATER PIPING AND CONTROLS A BOILER SUPPLY AND RETURN 3 Supply Piping Pipe the supply to the 1 1 2 NPT supply tapping at 1 Size the supply and return to suit the system A the top of the boiler typical piping arrangement is shown in Figure 3 1 Refer also to the I B R Guide to Residential 4 When system return water temperature will be below Hydronic Heating Installation Design and the PB 130 F 54 C pipe the boiler with a bypass Heat LLC Water Survey for additional guidance arrangement to blend the system return and hot during water piping installation supply to obtain at least 130 F 54 C entering the boiler For more information on bypass piping 2 Return Piping consult the PB Heat LLC Water Survey a Pipe the outlet connection of the circulator to a tee provided with a drain valve at the 1 1 4 NPT return tapping near the bottom of the left section Pipe the return to the inlet connection of the circulator 5 If desired install the circulator in the alternate location shown in Figure 3 1 Consult the PB Heat LLC Water Survey for more information on circulator location AIR ELIMINATOR CIRCULATOR SAFETY RELIEF VALVE SUPPLY COLD WATER SHUTOFF VALVE PRESSURE REDUCING VALVE CHECK VAVE SHUTOFF VALVE E
14. event of pressure relief Pipe the discharge to a drain Provide piping that is the same size as the safety relief valve outlet CHECK VALVE SUPPLY LINE BOILER WATER CHILLER THREE WAY VALVE Figure 3 2 Parallel Hook up with Water Chiller SAFETY RELIEF VALVE SUPPLY 3 4 X e NIPPLE TO DRAIN Figure 3 3 Safety Relief Valve Hook Up Installation with Air Elimination in System Piping TO AIR ELIMINATION DEVICE SUPPLY 3 4 TEE SAFETY 3 4 X 6 RELIEF NIPPLE VALVE 35 4 X 2 TO DRAIN 3 4 STREET ELBOW Figure 3 4 Safety Relief Valve Hook Up with Air Elimination WATER PIPING AND CONTROLS 1 See Figures 3 5 and 3 6 for basic zoned system layouts 2 Run each zone pipe down then up to zone to prevent air accumulation in piping 3 If required provide means to isolate and drain each zone separately FROM SYSTEM TO SYSTEM ZONE ZONE ZONE ZONE ZONE ZONE 1 2 3 3 2 1 SYSTEM BALANCING CIRCULATOR VALVES ZONE VALVES 3 CONNECT CONNECT TO TO RETURN SUPPLY FROM BYPASS CHECK TO BYPASS VALVE CITY WATER SHUTOFF VALVE PRESSURE REGULATOR EXPANSION TANK Figure 3 5 Zone Piping with Zone Valves FROM SYSTEM TO SYSTEM ZONE ZONE ZONE ZONE ZONE ZONE 1 2 3 3 2 1 ZONE FLOW CIRCULATORS CONTROL VALVES CHECK VALVE CONNECT CONNECT TO TO RETURN CITY WATER SUPPLY TAPPING SHUTOFF VALVE EXPANSION TANK PRESSURE REGULATOR Fig
15. joints etc Check cleanliness of the radiators baseboard units and or convectors Clean them to the extent possible If radiators do not heat evenly vent any remaining air from them Review operation and User s Information Manual with end user Complete the Warranty Card and submit it to PB Heat LLC Hang the Installation Operation and Maintenance Manual and User s Information Manual in an accessible position near the boiler 27 8 TROUBLESHOOTING A SHUT DOWN CAUSED BY PILOT OUTAGE PRESSURE SWITCH OR FLAME ROLL OUT SAFETY SHUT OFF SWITCH In the event of a shut down caused by a pilot outage action of the pressure switch or flame roll out safety shut off switch effecting a shut down of the main burners a Refer to the Operating Instructions in Figure 7 3 to properly turn off the gas to the boiler b Turn off all electric power to the boiler c Call a qualified heating service organization or local gas company and have the cause of the shut down investigated and corrected d Refer to Operating Instructions to re start boiler B TROUBLESHOOTING GUIDES Use Table 8 2 to assist in determining causes and providing corrective actions to boiler problems Refer also to Figure 8 2 to troubleshoot the Intermittent Ignition System Control These guides must be used only by qualified service technicians These individuals must follow all applicable codes and regulations in repair of any boiler problems
16. located on the exterior of buildings shall have the lowest side of the combustion air intake opening at least 12 inches 305 mm above grade WARNING Liquefied Petroleum LP is heavier than air and may collect or pool in a low area in the event of a leak from defective equipment This gas may then ignite resulting in a fire or explosion D INSTALLATION SURVEY For new and existing installations a Water Installation Survey is available from PB Heat LLC The survey will provide information on how a hot water boiler works with your specific system and will provide an overview of hot water system operation in general You can also use this survey to locate system problems which will have to be corrected To obtain copies of the Water Installation Survey contact your Peerless representative or download it from PeerlessBoilers com E PLANNING THE LAYOUT Prepare sketches and notes of the layout to minimize the possibility of interferences with new or existing equipment piping venting and wiring BOILER SET UP 1 Provide a sound level foundation Locate boiler as near to the chimney or outside wall as possible and centralized with respect to the heating system 2 Locate boiler in front of installation position before removing crate 3 If using combustible floor pan position pan on foundation or flooring Separate the wood shipping pallet from the boiler base by removing two 2 hold down bolts
17. on the left side of the boiler towards the top and rear The temperature sensing element is placed in the supply and will shut down main burner gas if the supply water exceeds the preset temperature limit This is a recycling switch that will automatically reset when the supply water falls below the preset temperature 4 LOW WATER CUT OFF FOR GRAVITY SYSTEMS OR HOT WATER BOILERS INSTALLED ABOVE RADIATION LEVEL A level sensing device float or probe located in supply piping near the boiler If water level in the system drops below the control s position it will shut down main burner gas The control will automatically reset once the water level rises above its position ADJUSTMENT OF GAS PRESSURE REGULATOR 1 Connect a manometer to 1 8 N PT tapping on gas manifold set manifold pressure as follows for various gases a NaturalGas 3 5 W C 0 9 kPa b ruRDES 10 0 W C 2 5 kPa 2 To adjust gas pressure turn adjusting screw of gas pressure regulator counterclockwise to decrease pressure clockwise to increase pressure Refer to Figure 7 2 for location of gas pressure regulator Replace the cap screw when adjustment is complete 3 START UP PROCEDURES In no case should the final manifold pressure vary more than 0 3 inches water column 0 07 kPa from the above specified pressures Any necessary major changes in the flow should be made by changing the size of the burner ori
18. the time of removal of an existing boiler follow these steps with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a b Seal any unused openings in the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on any clothes dryers and any appliance not connected to common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers PIPE p ADAPTER SEE VENT PIPE ADAPTER LISTING SILICONE HOSE DRAIN TRAP FORM 3 76mm DIA LOOP Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe After it has been determined that each a
19. 3 inches 76 mm See Figure outdoors or with spaces that freely communicate 1 1 for an illustration of this arrangement with the outdoors The size of the openings shall be determined as follows i Where communicating directly or through vertical ducts with the outdoors each opening 12 305mm shall have a minimum free area of 1 in per max 4000 Btu hr 22 cm per 4000 W of total Z input rating for all equipment in the space s o ere 2 omm See Figure 1 3 for openings directly per 1000 W lt i communicating with the outdoors or Figure at Least 100 in BUILDING 1 4 for openings connected by ducts to the SPACES outdoors SAME STORY Must not be under negative pressure 3 76mm BOILER peony 12 305mm Z TWO AIR OPENINGS max 3 P T 2 Dea e W da na 2 in per 4000 Btuh t s 22 cm per 4000 W Figure 1 1 Air Openings All Air from Indoors on the Same Floor b Combining spaces on different floors Z 3 76mm 4A Provide one or more permanent openings pate Z communicating with additional spaces that have lt BOILER a total minimum free area of 2 in2 per 1000 12 305mm Btu hr 44 cm per 1000 W of total input rating max of all equipment See Figure 1 2 for an Sager vi z oa illustration of th
20. 31IHM X9V 18 AV 13H tcp N33AL38 OVAOCL HOA 3O3HO YIM 18 INO AINO LV SDVLIOA ON dl 3SOO T N330H8 S3HIM 18 H3HLI3 LY 39VLTOA ON 31 aNnou9 OL S3HIM 3n18 AYTAY NOILV10SI LV HOS HOLIMS lt 5 3ALLO3H3Q dunssaHd NOILONS ALVNOAGV 9NILVH3N39 LON NVd ONIGNL NOILONS G339Vti9 HO HO43 X93HO 35V L10A ON dl aNnOoH5 OL TVNIIWH3 L HOLIMS 3unssaud LY 2VAvZ HOS L 29 SHA ON ATIN3LLINH31NI dn WHVM ti31IN9I 5301 S3A 33S NOILONNA SHA suaNuna oq Boiler Troubleshooting Guide Burners Not Functioning Figure 8 2 31 9 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 980 C they can change into crystalline silica which has been classified by the IARC as carcinogenic to humans If particles become airborne during ser vice or repair inhalation of these particles may be hazardous to your health Avoid Breathing Fiber Particulates and Dust Suppliers of RCF recommend the following precautions be taken whe
21. CT EXHAUST VERTICAL VENTING 5 1 This vent system will operate with a positive pressure in the vent pipe Follow vent pipe manufacturer s instructions for proper assembly of vent pipe and 6 fittings 2 Refer to Table 4 2 for minimum and maximum vent length allowed 7 3 Maintain a minimum 2 51 mm clearance between vent pipe and combustible construction 4 Follow instructions under section C DIRECT 8 EXHAUST HORIZONTAL VENTING items 6b through 6h 9 14 not less than 1 4 per foot 21 mm per meter from the boiler to the vertical vent Provide a horizontal drain tee in the horizontal vent run Use silicone drain hose with a 3 76 mm diameter loop trap with a water seal Pipe to drain per local codes Refer to vent pipe manufacturer s instructions under vertical venting section for recommendation for penetration through floors and roofs Vent must terminate 12 305 mm above expected snow lines See Figure 4 5 for details VENTING 2 51mm MIN ATTACH VENT MANUFACTURERS LISTED RAIN CAP FLASHING CLEARANCE 3 DIA VENT PIPE FLOOR FLOOR SLOPE UP 1 4 a FIRESTOP 20mm PER METER JACKET PANELS 3 HORIZONTAL DRAIN El FAN ADAPTER FAN i FAN ADAPTER GASKET 1 4 20 NUTS amp WASHERS SILICONE Figure 4 5 Direct Exhaust Vertical Venting E BOILER REMOVAL FROM COMMON VENTING SYSTEM At
22. ION RELAY BL LR FLAME LES ef PR ROLLOUT RED LINE VOLTAGE SIZE 14 AWG TYPE TW TFFN OR TEW AWM WIRE LINE VOLTAGE SIZE 16 18 AWG TYPE TW TFFN OR TEW AWM MAE LOW VOLTAGE SIZE 16 18 AWG WIRE TYPE TW TEW AWM TFFN WIRE ORANGE HONEYWELL PILOT WRE BL BLUE BR BROWN NOTES PR PURPLE 1 ALL WIRING MUST COMPLY WITH APPLIANCE CODES ORDINANCES AND REGULATIONS 2 IF ANY OF THE ORIGINAL WRE AS SUPPLIED WITH THE APPLIANCE MUST REPLACED IT MUST BE REPLACED WIRE AS SHOWN Figure 6 2 Wiring and Connection Diagram D SEQUENCE OF OPERATION 1 Thermostat calls for heat energizes Control Relay CR Control Relay CR energizes circulator Limit senses boiler water temperature Prevents boiler operation until water temperature falls approximately 15 F 8 C below the cut out temperature Limit energizes Fan and Isolation Relay IR Negative pressure induced by fan switches Pressure Switch continuing power through closed contacts IR 1 and flame roll out switch Gas valve energizes a Igniter on ELECTRICAL L1 HOT W CIRCULATOR BK PRIMARY TRANSFORMER W CR 1 SECONDARY lt GH Hsiq rd THERMOSTAT VY BL NO Tw Tayp IGNITOR ELEMENT FLAME SENSOR GROUND PILOT TUBING 120V WIRING 24V WIRING b Pilo
23. LUDING THIMBLE VENT WHERE USED TERMINATION 90 ELBOW DRAIN TEE REQUIRED SEE INSTRUCTIONS Figure 4 2 Direct Exhaust Sidewall Venting with Vertical Off Set Z FLEX Z VENT FLEX L METAL FAB PIPE MALE SAF T VENT FASNSEAL STAR 34 CORR GUARD END PIPE VENT PIPE VENT PIPE VENT PIPE MALE END MALE END MALE END MALE END Z FLEX PROTECH FLEX L Z VENT DATERAD FASNSEAL LOCKING BAND SVSLBX03 1 4 BEAD SILICONE FAN ADAPTER 1 4 BEAD SILICONE lc FAN ADAPTER Figure 4 3 Vent Pipe Adapters SAF T VENT 7301AMTK VENT ADAPTER FSA PSC DE 3 VENT ADAPTER S 1 4 BEAD SILICONE FAN ADAPTER STAR 34 VENT ADAPTER 1 4 BEAD SILICONE FAN ADAPTER METAL FAB SCGBA2 VENT ADAPTER FAN ADAPTER 13 VENTING DEM WALL THIMBLE SECURING VENT PIPE J TO THIMBLE WALL SLOPE DOWN 1 4 PER FOOT 20mm PER METER FAN ADAPTER COMBUSTIBLE EXTERIOR WALL CAULK OR SILICONE SILICONE 2 51mm MIN CLEARANCE 90 ELBOW VENT TERMINATION 203mm 3 DIA VENT PIPE SEAL JOINTS PER VENT MANUFACTURER S INSTRUCTIONS Horizontal portions of the vent pipe shall slope up RES 7 E Li FAN ADAPTER GASKET M PIPE ADAPTER 1 4 20 NUTS ADAPTER LISTING SILICONE Figure 4 4 Direct Exhaust Sidewall Venting D DIRE
24. XPANSION TANK TO DRAIN Figure 3 1 Supply and Return Piping WATER PIPING AND CONTROLS 6 Install this boiler so that the gas ignition system components are protected from water dripping spraying etc during appliance operation and service circulator replacement condensate trap control replacements etc 7 If this boiler and distribution system is used in conjunction with a refrigeration system pipe the chilled medium in parallel with the boiler and install the proper valve to prevent the chilled medium from entering the boiler A drawing illustrating this hook up is provided in Figure 3 2 8 When the boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation install flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle 9 If this boiler is installed above radiation level provide a low water cutoff device either as a part of the boiler or at the time of boiler installation B SAFETY RELIEF VALVE 1 Locate safety relief valve and fittings in bag assembly 2 If air elimination is not required at the safety relief valve tapping install valve and piping as shown in Figure 3 3 3 For air elimination at the safety relief valve tapping install valve and piping as shown in Figure 3 4 N CAUTION Pipe the discharge of safety relief valve to prevent injury in the
25. able codes ordinances and regulations NOTICE Do not power zone valves directly from the boiler transformer relay Doing so will greatly reduce the life of the transformer Use a separate transformer sized to handle the total of all zone valve electrical loads TO THERMOSTAT TO CIRCULATOR LIMIT FLAME ROLLOUT SWITCH PRESSURE SWITCH Figure 6 1 Wiring Controls and Safety Devices 18 CONTROLS 1 For proper location of controls and accessories refer to Figure 6 1 and Section 11 See the attached control sheets for specific details regarding the installation of the various controls This boiler is supplied with safety devices in addition to the limit For a description of these devices and how they work to ensure the safe operation of the boiler see Section 7B If the circulator is mounted in the supply piping provide longer wiring harness as required TO LINE VOLTAGE POWER SUPPLY FAN FAN RELAY CENTER GAS VALVE INNER JACKET PANEL gr p THESE ITEMS SUPPLIED BY_INSTALLER 115 60 1 14 POWER SUPPLY TRANSFORMER PRIMARY LEADS PLATE MOUNTED TRANSFORMER RELAY JUNCTION BOX Bk rd THERMOSTAT 24V BY OTHERS HIGH LIMIT CONTROL CIRCULATOR GROUND SCREW UNDERSIDE OF PLATE 120V tA ISOLAT
26. assisted calculate ae pide the required volume of air using the following 44 yo per 1000 W equation 21 9 1 other Required Volumeone ACH 10008 lone Input of appliances other than fan BOILER assisted in Btu hr Note These calculations are not to be used for infiltration rates greater than 0 60 ACH 3 Indoor Air Opening Size and Location Openings Figure 1 2 Air Openings All Air from Indoors connecting indoor spaces shall be sized and located on Different Floors as follows 4 Outdoor Combustion Air Outdoor combustion air is to be provided through one or two permanent openings The minimum dimension of these air a Combining spaces on the same floor Provide two permanent openings communicating with additional spaces that have a minimum free ings is 3 inches 76 area of 1 in per 1000 Btu hr 22 cm per 1000 W Map uo ad MEER of the total input rating of all gas fired equipment a Two Permanent Opening Method Provide but not less than 100 in 645 cm2 One two permanent openings One opening is to opening is to begin within 12 inches 305 mm begin within 12 inches 305 mm of the top of from the top of the space and the other is to the space and the other is to begin within 12 begin within 12 inches 305 mm from the floor inches 305 mm of the floor The openings are The minimum dimension of either of these to communicate directly or by ducts with the openings shall be
27. bustible construction 2 24 610 mm between top of jacket and combustible construction 3 2 51 mm between vent pipe and combustible construction DANGER Do not install this boiler on combustible flooring unless it is installed on a special combustible floor pan provided by PB Heat LLC Boiler installation on combustible flooring without the special pan is a fire hazard To order combustible floor pan use the 5 digit stock codes listed in Section 11 of this manual DANGER Do not install this boiler on carpeting Boiler installation on carpeting is a fire hazard Install this boiler on non combustible flooring or use a combustible floor pan to install this boiler on other non carpeted flooring C AIR FOR COMBUSTION AND VENTILATION 1 Adequate combustion air and ventilation air must be provided in accordance with section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or Sections 7 2 7 3 or 7 4 of CAN CSA B149 1 Natural Gas and Propane Installation Code or applicable provisions of the local building code Subsections 2 through 8 as follows are based on the National Fuel Gas Code requirements 2 Required Combustion Air Volume The total required volume of indoor air is to be the sum of the required volumes for all appliances located within the space Rooms communicating directly with the space in which the appliances are installed and through combust
28. c meter 38 19 39 12 c Igniter will continue to glow for 30 seconds de energize for 30 seconds then re energize and glow for another 30 seconds It will then de energize for 5 minutes before restarting the sequence d Turn gas supply on e Reset the boiler and control by following Operating Instructions f Observe boiler operation through one complete cycle manufacturer s instructions for the low water cut off operational check procedure Check the system to make sure there are no leaks or overfilling problems which might cause excessive make up water to be added Make up water causes liming in the boiler and brings in oxygen Oxygen can cause severe damage to the boiler through oxygen corrosion pitting Check the expansion tank and automatic fill valve if used to confirm that they are operating correctly If either of these components causes high pressure in the system the boiler relief valve will weep or open allowing fresh water to enter the system Do not allow the system controls to subject the boiler to excessively low water temperatures which would cause condensation of flue gases and corrosion of the boiler Operate the boiler at a temperature above 130 F 55 C Adjust the boiler limit as required to maintain boiler temperature above this level 10 START UP PROCEDURES 3 Low Water Cut Off if used Consult the Check the general condition of the system including piping support
29. ce and not less than the sum of the cross sectional areas of all vent connectors in the space The gas fired equipment shall have clearances of at least 1 inch 25 mm from the sides and back and 6 inches 150 mm from the front of the appliance See Figure 1 6 for this arrangement 12 ALTERNATE pet LOCATION 305mm _ x mox 12 305mm OK ONE AIR OPENING Minimum Free Area Each 1 in per 3000 Btuh MXN 22 cm per 3000 W and not less than the sum of the areas of all vent connectors MINIMUM CLEARANCES 1 25mm From sides and back 6 150mm from front BOILER Figure 1 6 Air Openings All Air from Outdoors through One Opening 5 Combination Indoor and Outdoor Combustion Air If the required volume of indoor air exceeds the available indoor air volume outdoor air openings or ducts may be used to supplement the available indoor air provided a The size and location of the indoor openings comply with Subsection 3 The outdoor openings are to be located in accordance with Subsection 4 The size of the outdoor openings are to be sized as follows Vinci i req where minimum area of outdoor openings full size of outdoor openings calculated in accordance with Subsection 4 Vavail available indoor air volume required indoo
30. ck Base Floor Pan Jacket Flue Collector 36 REPAIR PARTS Table 11 1 Repair Parts Block Assembly 90419 90420 90421 Base Assembly 7800 7801 7802 7803 Observation Cover Door 51771 51771 51771 51771 Base Blanket Seal Specify length 50867 50867 50867 50867 Combustible Floor Pan Assembly 90700 90701 90702 90703 Steel Burner w Pilot Clip 1 Per Boiler 51539 51539 51539 51539 Steel Burner Specify Quantity 51537 51537 51537 51537 Gas Manifold 50978 50979 50980 Orifice Spud 48 Natural Gas 0 2000 ft 0 610 m elevation specify qty 50894 50894 50894 Orifice Spud 49 Natural Gas 0 2000 ft 0 610 m elevation specify qty 50895 Orifice Spud 56 LP Gas 0 2000 ft 0 610 m elevation specify qty 50899 50899 50899 50899 9 Flame Rollout Safety Shut Off Switch 51587 51587 51587 51587 Flue Collector Fan Mount 90195 90196 90197 Flue Baffle 8 1 per flue specify qty 51584 51584 51584 12 Flue Collector Blanket Seal Specify length 50866 50866 50866 50866 Fan Gasket 50204 50204 50204 Fan Adapter Gasket 50203 50203 50203 15 Fan Adapter 90199 90199 90199 90199 16 Jacket Assembly 90244 90245 90246 90247 50212 50212 50212 51682 51682 51682 Dio nm Fan Honeywell SV9501M2700 Gas Valve Natural Gas
31. e judgment of PB Heat LLC N CAUTION Indicates a condition or hazard which will or can cause minor personal injury or property damage NOTICE Indicates special attention is needed but not directly related to potential personal injury or property damage 1 PREINSTALLATION Read carefully study these instructions before beginning work 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 A NOTICE The equipment must be installed in accordance with those installation requirements of the authority having jurisdiction or in the absence of such requirements to the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code 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 CSD 1 A ACCESSIBILITY CLEARANCES Install boiler not less than 24 610 mm between the left side top and front of the boiler and adjacent wall or other appliance when access is required for servicing B CLEARANCE FROM COMBUSTIBLE CONSTRUCTION The design of this boiler is certified for closet installation with the following clearances 1 6 152 mm between sides rear and front and com
32. e to determine if the valve has shut completely e If the valve continues to leak it must be replaced before the boiler is returned to operation f Check hat operating pressure and temperature have returned to normal g Check again to confirm that valve has closed completely and is not leaking Test low water cut off if used as described by the manufacturer Test limit as described in Section 7E Check Out Procedure Test function of gas safety shut off features as described by gas valve and ignition control manufacturer 33 MAINTENANCE E ANNUALLY BEFORE START OF HEATING SEASON DANGER When servicing or replacing components be absolutely certain that the following conditions are met Water gas and electricity are off The boiler is at room temperature There is no pressure in the boiler 1 Check flueways and burners for cleanliness and clean if necessary Use the following procedure if cleaning is required a Refer to the Operating Instructions in Figure 7 3 to properly turn off the gas to the boiler b Turn off all electrical power to the boiler c Remove burners and brush gas outlet ports lightly using a soft bristle brush d Remove the vent pipe from fan adapter top jacket panel flue collector fan assembly and flue baffles e Brush flueways with wire brush f To the extent possible inspect inside of vent pipe for obstructions Remove or replace as necessar
33. eet of gas through the meter Time that meter is read sec E CHECK OUT PROCEDURE 1 After starting the boiler be certain all controls are working properly Check to be sure that the limit will shut off the boiler in the event of excessive water temperature This can be done by lowering the limit setting until the main burners shut down When proper limit function is confirmed return the dial to 1000 288000 240000 205714 180000 160000 144000 130909 120000 110769 102857 96000 90000 84706 80000 75789 72000 68571 65455 62609 60000 57600 Heat Value of Gas Btu cubic foot 1025 295200 246000 210857 184500 164000 147600 134182 123000 113538 105429 98400 92250 86824 82000 77684 73800 70286 67091 64174 61500 59040 its previous setting 2 To check operation of the ignition system safety shut off features Turn gas supply off a b 26 302400 252000 216000 189000 168000 151200 137455 126000 116308 108000 100800 94500 88941 84000 79579 75600 72000 68727 65739 63000 60480 Set thermostat or controller above room temperature to call for heat Watch for igniter glow at pilot burner Table 7 1b Meter Conversion Natural Gas SI Metric System Burner inputs in kW for various meter timings and heating values Tables based on 0 0566 cubic meters of gas through the meter Time that meter is read sec 37 26 Heat Value of Gas MJ cubi
34. ew into the vent pipe Horizontal portions of the vent pipe must be supported at intervals no greater than four feet to prevent sagging separation Secure vent pipe to the thimble wall to prevent possible movement from incidental contact on the vent terminal c Type vent material approved is AL29 4C 3 inch 76 mm diameter stainless steel manufactured by Heat Fab Saf T Vent Z Flexe Z Vent ProTech FasNSeal Flex L StaR 34 Metal Fab Corr Guard d Attach the fan adapter to blower outlet flange using gasket and 1 4 6 mm 20 nuts and washers parts located in miscellaneous parts box e Refer to Figure 4 3 that lists special vent adapters for connection to boiler fan adapter These special adapters are not supplied with boiler f Attach vent pipe adapter to boiler fan adapter by applying a 1 4 6 mm bead of high temperature silicone around diameter of fan adapter and slip vent pipe adapter over the fan adapter Fill in any voids with silicone and smooth out with moistened finger or flat tool g If using Z Flex pipe slide vent pipe over the first 2 1 2 64 mm of the fan adapter and secure joint connection with the Z Flex looking bands making sure that locking band has contact with fan adapter at boiler end and vent pipe h Attach remaining pipe and fittings per manufacturer s vent instructions Use only the silicone recommended by the vent pipe manufacturer i The only approved ven
35. fice spuds When adjustment is complete turn off boiler gas flow and electricity to boiler Remove manometer connection from valve and plug tapping with plug provided Turn utilities back on and resume checkout D CHECKING BURNER INPUT T Refer to rating label mounted on the jacket top panel to obtain the rated BTU per hour input In no case shall the input to the boiler exceed the value shown on the rating label Check input by use of the following formula PB Heat suggests reading meter for 2 Cu Ft 0 0566 cubic meter U S Customary Units Input BTU Hr 3600 x Fx H T Where 3600 Seconds per hour F Cubic Feet of Gas Registered on Meter H Heat Value of Gas in BTU Cubic Feet T Time in Seconds the Meter is Read SI Metric Units Input kW 3600 x F x H Tx 3 6 Where 3600 Seconds per hour 3 6 Megajoule MJ per kilowatt hour kwhr F Cubic Meters of Gas Registered on Meter Heating Value of Gas in MJ Cubic Meter T Time in Seconds the Meter is Read As an alternative use Table 7 1a and 7 1b Use the heating value provided by gas supplier Use a stopwatch to record the time it takes for 2 cubic feet 0 0566 cubic meter of gas to pass through the meter Read across and down to determine rate 25 START UP PROCEDURES Table 7 1a Meter Conversion Natural Gas Burner inputs in Btu hr for various meter timings and U S Customary Units heating values Tables based on 2 cubic f
36. floor If you smell gas STOP Follow in the safety information above on this label If you don t smell gas go to the next step Slide the gas control switch to ON Replace control access panel if applicable Turn on all electrical power to the appliance Set thermostat or operating control to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO APPLIANCE 4 Slide the gas control switch to OFF 5 Replace control access panel if applicable SV9501 SV9601 9318 REV 2 MM YY See Figure 6 1 in Section 6 Electrical for locations of these devices 1 FLAME ROLL OUT SAFETY SHUT OFF SWITCH FLAME ROLL OUT SWITCH A thermally activated switch located between the first burner from the left and the manifold bracket The flame roll out safety shut off switch will sense excessive temperature caused by continued flame roll out and shut down main burner gas This is a non recycling switch that must be replaced once it has been activated and the cause of the roll out eliminated 2 PRESSURE SWITCH A pressure sensing device that is located in the jacket vestibule This control senses a suction pressure when fan is energized on a call for heat Switch contacts close allowing control circuit to energize ignition system 3 LIMIT AQUASTAT A thermally activated manually adjustable switch located
37. gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to slide the gas control switch Never use tools If the witch will not slide by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water KW X INSTRUCTIONS 1 STOP Read the safety information above on this label Set the thermostat or operating control to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand GAS CONTROL SWITCH TO TURN OFF GAS Set the thermostat or operating control to lowest setting Turn off all electric power to the appliance if service is to be performed If the gas valve is not visible remove the control access access panel Figure 7 3 Operating Instructions 24 5 If the gas valve is not visible remove control access panel If the gas control switch is not in the OFF postion slide the switch to OFF Wait five 5 minutes to clear out any gas Then smell for gas including near the
38. iler and its individual shut off valve from the gas supply piping system during any pressure testing of that system at test pressure in excess of 1 2 psig 3 5 kPa N CAUTION Do not subject the gas valve to more than 1 2 psi 3 5 kPa pressure Doing so may damage the valve Isolate the boiler from the gas supply piping system by closing its individual service valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 1 2 psig 3 5 kPa 9 Minimum permissible supply pressure for purposes of input adjustment Natural Gas LP Gas 5 0 W C 1 2 kPa 11 0 W C 2 7 kPa Maximum permissible supply pressure to the boiler Inches Water Column Natural Gas LP Gas 13 5 W C 3 4 kPa 13 5 W C 3 4 kPa Table 5 1 Natural Gas Input Input Cubic Ft Hr Cubic Meter Hr 70 105 140 165 Based on 1000 Btu Cubic Ft Table 5 2 LP Gas Input Input Cubic Ft Hr Cubic Meter Hr 28 0 8 42 12 56 1 6 66 19 Based on 2500 Btu Cubic Ft Table 5 3 Pipe Capacity Capacity of pipe of different diameters and lengths in cubic feet per hour cubic meter per hour with a pressure drop of 0 3 inches of water 75 kPa and a specific gravity of 0 60 No allowance for an ordinary number of fittings is required Pipe Length in 3 4 1 1 1 Feet Pipe Pipe Pipe Pipe Meters 10 3 0 278 7 9 520 14 7 1050 29 7 1600 45 3
39. ion air openings sized as indicated in Subsection 3 are considered part of the required volume The required volume of indoor air is to be determined by one of two methods a Standard Method The minimum required volume of indoor air room volume shall be 50 cubic feet per 1000 BTU Hr 4 8 m3 kW This method is to be used if the air infiltration rate is unknown or if the rate of air infiltration is known to be areater than 0 6 air changes per hour As an option this method may be used if the air infiltration rate is known to be between 0 6 and 0 4 air changes per hour If the air infiltration rate is known to be below 0 4 then the Known Air Infiltration Rate Method must be used If the building in which this appliance is to be installed is unusually tight we recommend that the air infiltration rate be determined b Knoun Air Infiltration Rate Method Where the air infiltration rate of a structure is known the minimum required volume of indoor air for the Series DE Boiler and other fan assisted appliances shall be determined as follows umi I fan Required Volume ACH 1000Btu hr PREINSTALLATION BUILDING SPACES ON DIFFERENT STORY where KQ Must not be under negative pressure Ian Input of the fan assisted appliances in Btu hr Z ACH air change per hour percent of the volume of the space exchanged per hour expressed as a decimal ONE OR MORE AIR OPENINGS For appliances other than fan
40. is arrangement Figure 1 3 Air Openings All Air Directly from Outdoors PREINSTALLATION we X 12 305mm max TWO AIR OPENINGS Minimum Free Area Each 1 in per 4000 Btuh 22 cm per 4000 W BOILER 12 3 T 805mm 76mm max SERM min a z z 4 f a Figure 1 4 Air Openings All Air from Outdoors through Vertical Ducts ii Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 in per 2000 Btu hr 22 cm per 2000 W of total rated input for all appliances in the space See Figure 1 5 Z 12 305mm max 12 305mm max li TWO AIR OPENINGS Minimum Z 5 76mm Free Area Each 2 1 in per 2000 Btuh i 22 cm per 2000 W ZA Z 3 76mm PA min Z BOILER mas th E ILE I Figure 1 5 b Air Openings All Air from Outdoors through Horizontal Ducts One Permanent Opening Method Provide one permanent opening beginning within 12 inches 305 mm of the top of the space The opening shall communicate directly with the outdoors communicate through a vertical or horizontal duct or communicate with a space that freely communicates with the outdoors The openings shall have a minimum free area of 1 in per 3000 Btu hr of total rated input for all appliances in the spa
41. n adapter silicone hardware and fan local building codes adapter gasket in boiler miscellaneous parts box and attach to blower outlet flange Refer to Fig 4 1 2 Do not connect vent connectors serving appliances for details vented by natural draft into any portion of mechanical draft systems operating under positive 4 Apply 1 4 6 mm bead of silicone around fan pressure adapter and slip increaser over the fan adapter Refer to Table 4 1 for increaser and chimney sizes 3 Refer to the following venting options to determine Increaser to be provided by installer which method is applicable 5 Single wall vent pipe should be furnished between increaser and chimney If the vent connector shall be WARNING located in or pass through a cold area the vent connector shall be type B material All joints of positive pressure vent systems must be prevent leakage of flue products C DIRECT EXHAUST HORIZONTAL VENTING NOTICE If venting into a masonry chimney chimney must be Flue gases will condense as they exit the vent lined with a fire clay tile liner or corrosion resistant metal termination This condensate can freeze on exterior liner Type B vent may also be used as a lining system or building surfaces which may cause discoloration of as a stand alone chimney vent these surfaces 1 The vent system when installed per the following instructions will operate with a negative pressure draft 1 This vent
42. n handling these materials Precautionary Measures Provide adequate ventilation Wear a NIOSH MSHA approved respirator Wear long sleeved loose fitting clothing and gloves to prevent skin contact Wear eye goggles Minimize airborne dust prior to handling and removal by water misting the material and avoiding unnecessary disturbance of materials Wash work clothes separately from others Rinse washer thoroughly after use Discard RCF materials by sealing in an airtight plastic bag First Aid Procedures Inhalation If breathing difficulty or irritation occurs move to a location with fresh clean air Seek immediate medical attention if symptoms persist Skin Contact Wash affected area gently with a mild soap and warm water Seek immediate medical attention if irritation persists Eye Contact Flush eyes with water for 15 minutes while holding eyelids apart Do not rub eyes Seek immediate medical attention if irritation persists Ingestion Drink 1 to 2 glasses of water Do not induce vomiting Seek immediate medical attention 32 MAINTENANCE 1 Disconnect this boiler from the gas supply piping during any pressure testing of the gas system 2 Check pipes adjacent to cold walls or in unheated spaces Insulate and tape them if necessary to be sure they can t freeze up Keeping the water moving at all times will reduce the likelihood of freezing See Section 3 for antifreeze instructions 3 If there is considerable fo
43. nd arilles will have 75 free area iii Nonmotorized dampers shall be fixed in the open position Motorized dampers shall be interlocked with the equipment so that they are proven in the full open position prior to ignition and during operation of the main burner i The interlock shall prevent the main burner from igniting if the damper fails to open during burner startup ii The interlock shall shut down the burner if the damper closes during burner operation 9 Combustion Air Ducts Ducts shall be constructed of galvanized steel or an equivalent corrosion resistant material Ducts shall terminate in an unobstructed space allowing free movement of combustion air to the appliances Ducts shall serve a single space Ducts shall not serve both upper and lower combustion air openings where both such openings are used The separation between ducts serving upper and lower combustion air openings shall be maintained to the source of combustion air Ducts shall not be screened where terminating in an attic space PREINSTALLATION c Each of the appliances served shall be f Horizontal upper combustion air ducts shall not slope downward toward the source of the combustion air g The remaining space surrounding a chimney liner gas vent special gas vent or plastic piping installed within a masonry metal or factory built chimney shall not be used to supply combustion air h Combustion air intake openings
44. ng Operating Instructions label mounted to the jacket panel The initial ignition may require several tries as the piping is purged of air Use the sequence descriptions in Figures 6 2 and 6 3 in Section 6 Electrical to follow light off and shutdown sequences and to assist in diagnosing problems If the boiler does not function properly consult Section 8 Troubleshooting The gas manifold and control assembly are made of gas tight completely factory assembled and installed components of the base assembly See Figure 7 1 and 7 2 START UP PROCEDURES Figure 7 1 Gas Valve Manifold and Burner Assembly Intermittent Ignition Figure 7 2 Valve Tapping and Adjustment Screw Locations 23 START UP PROCEDURES OUICIIII GIGoEIEIIE FoR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the
45. nufacturer 3 Antifreeze solutions expand more than water For example a 50 by volume solution expands 4 8 in volume for a temperature increase from 32 F 0 C to 180 F 82 C while water expands 3 with the same temperature rise Allowance must be made for this expansion in system design 4 For more information consult the PB Heat LLC Water Installation Survey and the antifreeze manufacturer SYSTEM CIRCULATOR CHECK VALVE PRESSURE REGULATOR SUPPLY TO SYSTEM EXPANSION ZONE VALVES TANK da RETURN FROM SYSTEM SHUTOFF VALVE SHUTOFF INDIRECT FIRED VALVE WATER HEATER BALANCING VALVE HOT DOMESTIC WATER SUPPLY SUPPLY COLD BALANCING DOMESTIC VALVE WATER SUPPLY Figure 3 7 Typical Piping with Indirect Fired Water Heater 10 4 VENTING FKTITI Qi 2 Horizontal portions of the venting system shall slope upward at least 1 4 per lineal foot 21 mm per 1 Install vent system in accordance with the Venting meter between boiler and chimney The vent pipe of Equipment Chapter of the National Fuel Gas shall be supported to prevent sagging using metal Code ANSI Z223 1 NFPA 54 the Venting Systems strapping or equivalent means at no more than 4 ft and Air Supply for Appliances Section of the 1 2 meter intervals CAN CSA B149 1 Natural Gas and Propane Installation Code or applicable provisions of the 3 Locate fa
46. ppliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Any improper operation of the common venting system should be corrected so that the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code 15 5 GAS PIPING 1 Size and install the gas supply piping properly in order to provide a supply of gas sufficient to meet the maximum demand without undue loss of pressure between the meter and the boiler 2 Determine the volume of gas to be provided to the boiler in cubic feet per hour To obtain this value divide the Btu per hour rating on the boiler rating plate by the heating value of the gas in Btu per cubic feet Obtain the heating value of the gas from the gas supplier As an alternative use Table 5 1 or 5 2 on the next page to obtain the volume of gas to be provided to the boiler 3 Use the value obtained above as the basis for piping sizing Size the gas piping in accordance with Table
47. r air volume 6 Engineered Installations Engineered combustion air installations shall provide an adequate supply of combustion ventilation and dilution air and shall be approved by the authority having jurisdiction 7 Mechanical Combustion Air Supply a In installations where all combustion air is provided by a mechanical air supply system the combustion air shall be supplied from the outdoors at the minimum rate of 0 35 ft min per 1000 Btu hr 0 034 m3 min per 1000 W of the total rated input of all appliances in the space In installations where exhaust fans are installed additional air shall be provided to replace the exhaust air interlocked to the mechanical air supply to prevent main burner operation where the mechanical air supply system is not in operation In buildings where the combustion air is provided by the mechanical ventilation system the system shall provide the specified combustion air rate in addition to the required ventilation air 8 Louvers amp Grills a The required size of openings for combustion ventilation and dilution air shall be based on the net free area of each opening i Where the free area through a louver or grille is known it shall be used in calculating the opening size required to provide the free area specified ii Where the free area through a louver or grille is not known it shall be assumed that wooden louvers will have 25 free area and metal louvers a
48. reign matter in the boiler water the boiler should be shut down and allowed to cool then drained and thoroughly flushed out Use the drain valve at the bottom of the return connection to drain the boiler Pipe the drain cock to a suitable drain or containment device if antifreeze is used Flush the system to remove remaining matter If there is evidence that hard scale has formed on the internal surfaces the boiler should be cleaned by chemical means as prescribed by a qualified water treatment specialist 4 There must not be signs of continuous wetness at the chimney If signs of continuous wetness are Observed a qualified service agency must be consulted to modify the vent configuration to prevent the formation of condensate B DAILY WITH BOILER IN USE Daily boiler observation can be performed by the owner If any potential problems are found a qualified installer or service technician agency must be notified 1 Remove any combustible materials gasoline and other flammable liquids and substances that generate flammable vapors from the area where the boiler is contained Make certain that the boiler area has ample air for combustion and ventilation and that there are no obstructions to the free flow of air to and from the boiler 2 Observe general boiler conditions unusual noises vibrations etc 3 Observe operating temperature and pressure on the combination gauge located on the left side of the boiler Boiler press
49. rners and pilot Make certain that there are no unusual bends or perforations in the burners or pilot Replace components if necessary Verify that water piping venting gas piping and electrical wiring and components are installed properly Refer back to previous sections of these instructions as well as equipment manufacturer s instructions as necessary Fill the boiler and system with water making certain to vent all air from all points in the system To check water level in the system open and close each vent in the system Water should exit from each vent when it is opened The pressure reducing valve on the fill line will typically allow the system to be filled and pressurized to 12 psi 83 kPa Consult the valve and expansion tank manufacturer for more specific information Check joints and fittings throughout the system for leaks If leaks are found drain the system and repair as required Connect a manometer to the gas valve inlet pressure tap See Figure 7 2 9 10 11 12 13 Confirm that the gas supply pressure to the boiler is above the minimum and below the maximum values for the gas being used See the end of Section 5 for these values If a supply pressure check is required isolate the boiler and gas valve before performing the pressure check If the supply pressure is too high or too low contact the gas supplier Turn on electricity and gas to boiler Light the boiler by following the Lighti
50. system will operate with a positive pressure Table 4 1 Increaser amp Chimney Size in the vent pipe Follow vent pipe manufacturers instructions for proper assembly of vent pipe and lncreaser Size Vent Size Chimney fittings Diameter Height 3 to 4 7 6to 10 2 cm 4 10 2 cm 15 3 to 5 7 6 to 12 7 cm 5 12 7 cm 3 to 5 7 6 to 12 7 cm 5 12 7 cm 15 4 5 m 3 to 5 7 6 to 12 7 cm 5 12 7 cm 15 4 5 m SLOPE UP 1 4 a PER FOOT Le n 20mm PER METER at T A a 4 44 4 SLOPE UP 1 4 A PER FOOT 20mm PER METER JACKET PANELS q FAN FAN ADAPTER OO a uae 5 zd iN X INCREASER V SILICONE L 1 4 20 NUTS te amp WASHERS MASONRY E CHIMNEY I Figure 4 1 Chimney Venting 11 VENTING 12 2 Refer to Table 4 2 for minimum and maximum vent length allowed Maintain a minimum 2 51 mm clearance between vent pipe and combustible construction When installing vent pipe through a combustible wall pipe must pass through a metal wall thimble maintain a 2 51 mm clearance between vent pipe and thimble Follow thimble manufacturer s instructions Seal between thimble and exterior wall using exterior rated caulk or silicone to prevent water damage and also to prevent recirculation of flue products into the structure Determine ven
51. t gas on igniting pilot 7 Pilot flame detected a Igniter off b Main gas on igniting main burners Note If pilot flame is not detected within 30 seconds the igniter is turned off for 30 seconds and then turned back on If the pilot is not detected within 30 seconds the igniter and pilot gas are turned off for 5 minutes The sequence then resumes at Step 6a 8 Call for heat ends a Pilot and main gas off extinguishing pilot and main burners b Fan and circulator off 19 ELECTRICAL START APPLY 24 VAC TO APPLIANCE THERMOSTAT CALLS FOR HEAT FIVE MINUTE RETRY DELAY FLAME SIGNAL WAIT FOR FLAME SIGNAL DETECTED TO DISAPPEAR PILOT VALVE IGNITER REMAIN OFF INTERNAL CHECK OKAY TRIAL FOR PILOT VALVE OPENS THREE SECOND FLAME IGNITION IGNITER POWERED FAILURE RECYCLE DELAY PILOTLIGHTS AND FLAME SPLOT VANE CLOSES IS SENSED DURING OFF TRIAL FOR IGNITION MAIN BURNER IGNITER OFF OPERATION MAIN VALVE OPENS FLAME SIGNAL LOST MAIN AND PILOT VALVES CLOSE NO THERMOSTAT CALL FOR FLAME LOST MORE THAN HEAT ENDS FIVE TIMES IN ONE CALL FOR HEAT MAIN AND PILOT VALVES CLOSE END A IGNITER WILL TURN OFF ABOUT 30 SECONDS INTO THE TRIAL FOR IGNITION IF THE PILOT FLAME HAS NOT LIT IT WILL TURN BACK ON FOR THE FINAL 30 SECONDS OF THE 90 SECOND TRIAL FOR IGNITION THE PILOT VALVE WILL BE ENERGIZED DURING THE ENTIRE TRIAL FOR IGNITION THIS IS NORMAL OPERATION FOR THIS GAS
52. t terminal location a Vent terminal shall be located at least 3 feet 1 meter above any forced air inlet located within 10 feet 3 meters b Vent terminal shall be located at least 4 feet 1 2 meters below 4 feet 1 2 meters horizontally from or 1 foot 0 3 meters above any door window or gravity air inlet into any building c Vent terminal shall be located at least 1 foot 0 3 meters above ground level or normal snow lines See subsection 7 below if terminal needs to be extended above ground level or snow line d Vent terminal shall not be located over public walkways where condensate could create a nuisance or hazard e When adjacent to a public walkway vent terminal shall be at least 7 feet 2 1 meters above grade f Vent terminal shall be located at least 4 feet 1 2 meters horizontally from electric meters gas meters regulators and relief equipment In Canada this dimension must be 6 feet 2 meters g Vent terminal should not be located directly under roof overhangs to prevent icicles from forming 6 Vent Pipe Assembly a Horizontal portions of the vent pipe shall slope down not less than 1 4 per foot 21 mm per meter from the boiler to the vent termination elbow If this horizontal run is pitched toward boiler provide a horizontal drain tee as per instructions in section D Direct Exhaust Vertical Venting b Secure vent pipe using metal strapping clamps and or other means Do not scr
53. t termination is a 3 76 mm 90 elbow Refer to Figure 4 4 Vent pipe must be sealed to the thimble or outside wall if non combustible construction using silicone to prevent recirculation of flue products into the structure Table 4 2 Equivalent Vent Length Equivalent Length of 3 diameter Stainless Steel Vent Pipe Boiler Model Minimum Vent Length Maximum Vent Lenath 50 feet 15 m 50 feet 15 m 45 feet 13 7 m 45 feet 13 7 m 2 1 2 feet 762 m 2 1 2 feet 762 m 2 1 2 feet 762 m 2 1 2 feet 762 m Maximum Vent Length to be reduced by 5 feet 1 5 meters for each 90 elbow added that is manufactured by Z Flex Heat Fab and Protech Maximum Vent Length to be reduced by 7 1 2 feet 2 3 meters for each 90 elbow added that is manufactured by Flex L The outside vent terminal 90 Elbow is not included in Equivalent Vent Length Refer to Figure 4 2 for vertical offset option The maximum offset is 5 feet With the exception of the last 90 elbow which serves as the vent terminal the additional elbows and straight vent pipe must be considered when determining maximum vent length Provide a horizontal drain tee as described in Section D Direct Exhaust Vertical Venting VENTING WALL TO CENTERLINE 8 MIN OF VENT TERMINAL 2 MIN EDGE OF PIPE TO COMBUSTIBLE WALL 90 ELBOW 5 MAX BRACKET SLOPE PIPE TOWARDS BOILER SEAL WALL PENETRATION 90 ELBOW INC
54. ure 3 6 Zone Piping with Circulators WATER PIPING AND CONTROLS For new or existing systems that must be freeze 1 Consult the tank manufacturer s instructions for protected specific information relating to tank installation Size the expansion tank for the required system volume and capacity See Table 10 2 in Section 10 for boiler VN WARNING water capacity Use only inhibited propylene glycol solutions of up to 2 Expansion tanks are available with built in fill valves 50 by volume with water Ethylene glycol is toxic and check valves for reducing supply water pressure and can attack gaskets and seals used in hydronic and maintaining minimum system pressure Check systems the design features of the tank and provide valves as DEE 1 Glycol in hydronic applications is specially Refer back to Figure 3 1 for typical expansion tank piping formulated for this purpose It includes inhibitors which prevent the glycol from attacking metallic E INDIRECT FIRED WATER HEATER system components Make certain that the system fluid is checked for the correct glycol concentration If the boiler is to be used in conjunction with an indirect and inhibitor level fired water heater refer to Figure 3 7 for typical piping Follow the instructions provided by the water heater 2 The antifreeze solution should be tested at least once manufacturer Pipe the water heater as a separate zone a year and as recommended by the antifreeze ma
55. ure should never be higher than 5 psi 35 kPa below the rating shown on the safety relief valve 25 psig 172 kPa maximum for a 30 psig 207 kPa rating 45 psig 310 kPa maximum for a 50 psig 345 kPa rating The valve rating can be found on the top of the safety relief valve see Figure 3 1 for location of the safety relief valve Boiler temperature should never be higher than 250 F 121 4 5 Check for water leaks in boiler and system piping Smell around the appliance area for gas If you smell gas follow the procedure listed in the Operating Instructions in Section 7 C WEEKLY WITH BOILER IN USE 1 Flush float type low water cut off if used to remove sediment from the float bowl as stated in the manufacturer s instructions D MONTHLY WITH BOILER IN USE js Check boiler room floor drains for proper functioning Check function of the safety relief valve monthly unless specified otherwise by manufacturer by performing the following test a Check valve piping to determine that it is properly installed and supported b Check boiler operating temperature and pressure c Liftthe try lever on the safety relief valve to the full open position and hold it for at least five seconds or until clean water is discharged d Release the try lever and allow the valve to close If the valve leaks operate the lever two or three times to clear the valve seat of foreign matter It may take some tim
56. y g Re install baffles When replacing the flue collector fan assembly be certain that the blanket seal between the flue collector and top section makes a tight seal to prevent leakage of the products of combustion h Re install the top jacket panel and vent pipe i Re install burners 34 2 Inspect entire venting system for corrosion support and joint integrity Repair as necessary Inspect vent termination for any obstruction that may hinder proper venting 3 Check the pilot and main burner flame See Figure 8 3 The pilot should provide a steady flame enveloping 3 8 to 1 2 1 cm to 1 2 cm of the flame sensor If required adjust the pilot as stated in the gas valve manufacturer s instructions The main burner flame inner cone should be approximately 1 1 2 4 cm high and should have a very sharp blue color characteristic OUTER CONE IS DARK BLUE IN COLOR PILOT INNER CONE IS FLAMES BLUE IN COLOR Figure 8 3 C Intermittent Pilot and Main Burner Flame BOILER DIMENSIONS amp RATINGS 10 BOILER DIMENSIONS amp RATINGS BOILER DIM A MODEL IN mm DE 03 12 1 2 318 DE 04 15 7 8 403 DE O5 19 1 4 489 _ 20 1 16 DE 06 22 5 8 575 510mm 3 5 16 j 15 11 16 1 1 2 84mm 2 3 8 L SUPPLY 399mm N cens

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