PB Heat PSC-06 Installation, Operation & Maintenance Manual
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PB Heat PSC-06 Installation, Operation & Maintenance Manual

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PSC
Gas
Boilers
I n s t a l l a t i o n ,
O p e r a t i o n &
M a i n t e n a n c e
M a n u a l

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  • Page 1 Series Boilers I n s t a l l a t i o n , O p e r a t i o n & M a i n t e n a n c e M a n u a l...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS A. WIRING ......15 USING THIS MANUAL B. ZONED SYSTEM WIRING ....15 A.

  • Page 3: Using This Manual

    These categories mean, in the judgment of PB Heat, LLC: CAUTION Indicates a condition or hazard which will or can cause minor personal injury or property damage.

  • Page 4: Preinstallation

    For new and existing installations, a Water Installation side, top, and front of the boiler and adjacent wall or Survey is available from PB Heat, LLC. The survey will other appliance, when access is required for servicing. 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.

  • Page 5: Boiler Set-Up

    BOILER SET-UP 2. BOILER SET-UP 1. Provide a sound, level foundation. Locate boiler as 4. Separate the wood shipping pallet from the boiler near to the outside wall as possible and centralized base by removing two (2) hold-down bolts at each with respect to the heating system.

  • Page 6: Water Piping And Controls

    PB Heat Water Survey. 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 Water Survey for more information on circulator location.

  • Page 7: Safety Relief Valve

    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...

  • Page 8: Piping For Zoned Systems

    WATER PIPING AND CONTROLS C. PIPING FOR ZONED SYSTEMS 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.

  • Page 9: Expansion Tank

    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 Water Installation Survey and the antifreeze manufacturer. Figure 3.7:...

  • Page 10: Venting, Ventilation And Air Inlet

    VENTING, VENTILATION AND AIR INLET 4. VENTING c. Provide 2″ (51 mm) clearance between vent pipe A. GENERAL and combustible construction. No clearance is Install vent system in accordance with Venting of required between Thimble and combustible Equipment part of the National Fuel Gas Code, ANSI construction.
  • Page 11 VENTING, VENTILATION AND AIR INLET 5. Slide Stainless Steel Collar over vent pipe and slide 12. Seal all openings between Wall and Thimble and 3″ (76 mm) diameter hose clamp and collar to vent around the 3″ (76 mm) diameter stainless steel vent pipe.

  • Page 12: Roof Terminations

    (305 mm) above expected snow lines. Vent pipe PSC-05 8 feet (2.5 m) 45 feet (13.5 m) must be a minimum 12" (305 mm) above and 12" PSC-06 45 feet (13.5 m) 8 feet (2.5 m) (305 mm) horizontally from air inlet pipe. See Figure 4.3.

  • Page 13: Vent Pipe Installation

    VENTING, VENTILATION AND AIR INLET 6. Support horizontal lengths of the vent system to D . VENT PIPE INSTALLATION prevent sagging by use of metal strapping or equivalent means. Locate supports at not more than 1. For minimum and maximum vent pipe lengths see four (4) foot intervals.

  • Page 14: Air For Ventilation

    VENTING, VENTILATION AND AIR INLET d. Place in operation the appliance being inspected. F. AIR FOR VENTILATION Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. 1. Provide air openings for adequate ventilation to prevent ambient boiler room temperature from e.

  • Page 15: Gas Piping

    GAS PIPING 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.
  • Page 16 Cu. Meter/hr PSC-03 PSC-04 PSC-05 PSC-06 Table 5.2: Pipe Capacity Capacity of pipe of different diameters and lengths in cubic feet per hour (cubic meter per hour) with pressure drop of 0.3 inches of water (75 Pa) and specific gravity of 0.60. No allowance for an ordinary number of fittings is required.

  • Page 17: Electrical

    ELECTRICAL 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 C221.

  • Page 18: Sequence Of Operation

    ELECTRICAL Figure 6.2: Wiring and Connection Diagram 7. Pilot flame detected. D. SEQUENCE OF OPERATION a. Igniter off. 1. Thermostat calls for heat, energizes R8285 Control b. Main gas on, igniting main burners. Relay (CR). 2. R8285 Control Relay (CR) energizes circulator. Note: If pilot flame is not detected within 30 seconds, the igniter is turned off for 30 seconds, and then turned 3.
  • Page 19 ELECTRICAL Figure 6.3: Ignition System Operating Sequence...
  • Page 20 ELECTRICAL Figure 6.4: Zone Wiring with Zone Valves Figure 6.5: Zone Wiring with Circulators...

  • Page 21: Start-Up Procedures

    START-UP PROCEDURES 7. START-UP PROCEDURES 7. Check joints and fittings throughout the system for A. COMPLETING THE INSTALLATION leaks. If leaks are found, drain the system and repair as required. 1. Confirm that all water, gas and electricity are turned off. 8.
  • Page 22 START-UP PROCEDURES Figure 7.1: Gas Valve, Manifold and Burner Assembly – Intermittent Ignition Figure 7.2: Valve Tapping and Adjustment Screw Locations...
  • Page 23 START-UP PROCEDURES Figure 7.3: Operating Instructions...

  • Page 24: Control Descriptions

    2. Check input by use of the following formula from the left and the manifold bracket. The flame (PB Heat suggests reading meter for 2 Cu.Ft. roll-out safety shut-off switch will sense excessive [0.0566 cubic meter]): temperature caused by continued flame roll-out and U.S.
  • Page 25 START-UP PROCEDURES Table 7.1a: Meter Conversion Natural Gas Table 7.1b: Meter Conversion Natural Gas (U.S. Customary Units) (SI Metric System) Burner inputs in Btu/hr for various meter timings and Burner inputs in kW for various meter timings and heating values. (Tables based on 2 cubic feet of gas heating values.

  • Page 26: Troubleshooting

    TROUBLESHOOTING 8. TROUBLESHOOTING DANGER A. SHUT-DOWN CAUSED BY PILOT OUTAGE, PRESSURE SWITCH OR When servicing or replacing items that communicate FLAME ROLL-OUT SAFETY with the boiler water, be certain that: SHUT-OFF SWITCH ● ● There is no pressure on the boiler. In the event of a shut-down caused by a pilot outage, ●...
  • Page 27 TROUBLESHOOTING Figure 8.1: Measuring Fan Suction Pressure...
  • Page 28 TROUBLESHOOTING Table 8.1: Boiler Troubleshooting Guide (Burners Functioning) PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONS Burners not functioning. See Figure 8.2 See Figure 8.2 Burners will not shut 1. Defective gas valve. 1. Use Figure 8.2 to troubleshoot intermittent down. ignition gas valve. Replace if necessary. 2.
  • Page 29 TROUBLESHOOTING Figure 8.2: Boiler Troubleshooting Guide (Burners Not Functioning)

  • Page 30: Maintenance

    MAINTENANCE 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.

  • Page 31: General

    MAINTENANCE 4. Check for water leaks in boiler and system piping. A. GENERAL 5. Smell around the appliance area for gas. If you smell 1. Disconnect this boiler from the gas supply piping gas, follow the procedure listed in the Operating during any pressure testing of the gas system.

  • Page 32: Annually (Before Start Of Heating Season)

    MAINTENANCE 5. Test function of gas safety shut-off features as o. Reinstall flue collector/fan assembly. described by gas valve and ignition control p. Reinstall jacket top panel. manufacturer. q. Reinstall pilot, burners, hitch pin clips. Reconnect DANGER pilot harness to gas valve, gently pulling harness to length required to reach gas valve.
  • Page 33 MAINTENANCE Figure 9.2: Inspection of Flueways, Burners, and Vent System.

  • Page 34: Boiler Dimensions & Ratings

    Jacket Width “A” Model Number PSC-03 12¹⁄₂″ 318 mm PSC-04 15⁷⁄₈″ 403 mm PSC-05 19¹⁄₄″ 489 mm PSC-06 22⁵⁄₈″ 575 mm Table 10.2: Series PSC Boiler Ratings SERIES PSC BOILER RATINGS DOE Heating Net I=B=R Boiler Seasonal Input Water Content...

  • Page 35: Repair Parts

    REPAIR PARTS SERIES PSC 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 32-36 to assist in ordering parts. Note: Remember to include boiler model number and serial number when ordering parts.
  • Page 36 REPAIR PARTS Table 11.1 (Quantity/Length) Stock Code Item Description PSC-03 PSC-04 PSC-05 PSC-06 Base Assembly 7800 7801 7802 7803 50102 Floor Pan 50100 50101 50103 Base Rear Panel Assembly PSC2000 PSC2000-1 PSC2000-2 PSC2000-3 51771 Base Observation Port Cover 51771 51771...
  • Page 37 REPAIR PARTS Figure 11.2...
  • Page 38 REPAIR PARTS Table 11.2 (Quantity/Length) Stock Code Item Description PSC-03 PSC-04 PSC-05 PSC-06 Insulation Blanket, 1/2″ x 1.50″, block to base (47″) 50867 (54″) 50867 (61″) 50867 (67″) 50867 Block 90419 90420 90421 90422 (2) 51584 Flue Baffle (3) 51584...
  • Page 39 TO T H E O W N E R : This boiler should be inspected annually by a Qualified Service Agency. ASME HI Division of gama PB HEAT, LLC PO BOX 447 • NEW BERLINVILLE, PA 19545-0447 ©2005 WEB-1 PSC8030 R6 (9/05-2M) Printed in U.S.A.

This manual is also suitable for:

Psc-05Psc-04Psc-03

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