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PeerlessBoilers PSC II Installation, Operation & Maintanance Manual

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Series
Gas
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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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Summary of Contents for PeerlessBoilers PSC II

  • 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 TABLE OF CONTENTS USING THIS MANUAL 5. GAS PIPING A. INSTALLATION SEQUENCE ... . .1 6. ELECTRICAL B. SPECIAL ATTENTION BOXES ... .1 A.

  • Page 3: Using This Manual

    USING THIS MANUAL USING THIS MANUAL A. INSTALLATION SEQUENCE DANGER Follow the installation instructions provided in this Indicates a condition or hazard which will cause manual in the order shown. The order of these severe personal injury, death or major property instructions has been set in order to provide the installer damage.

  • Page 4: Preinstallation

    PREINSTALLATION 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. 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 B49.1, Natural Gas and Propane Installation Code .

  • Page 5: Installation Survey

    Water Installation Survey, contact your PB Heat The above requirements do not apply if the ° representative or download it from PeerlessBoilers.com. exhaust vent termination is seven (7) feet or more above finished grade in the area of the D. PLANNING THE LAYOUT venting, including but not limited to decks and porches.

  • Page 6: 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 7: Water Piping And Controls

    WATER PIPING AND CONTROLS 3. WATER PIPING AND CONTROLS 3. Supply Piping: A. BOILER SUPPLY AND RETURN a. Pipe the supply to the 1-1/2" NPT supply tapping 1. Size the supply and return to suit the system. A typical at the top of the boiler. piping arrangement is shown in Figure 3.1.

  • Page 8: 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 9: 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 10: Expansion Tank

    WATER PIPING AND CONTROLS D. EXPANSION TANK FREEZE PROTECTION 1. Consult the tank manufacturer’s instructions for For new or existing systems that must be freeze-protected: specific information relating to tank installation. Size the expansion tank for the required system volume WARNING and capacity.

  • Page 11: Venting, Ventilation And Air Inlet

    VENTING, VENTILATION AND AIR INLET 4. VENTING, VENTILATION AND AIR INLET 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 12 VENTING, VENTILATION AND AIR INLET 5. Slide Stainless Steel Collar over vent pipe and slide to 11. Secure Inside Thimble cap to Wall Thimble with #10 end of pipe. screws. Seal Thimble Cap perimeter with silicone. 6. Insert pipe with collar through Outside Vent Cap and 12.

  • Page 13: Roof Terminations

    VENTING, VENTILATION AND AIR INLET C. ROOF TERMINATIONS (VERTICAL E . VENT PIPE INSTALLATION VENTING) 1. For minimum and maximum vent pipe lengths see Table 4.1. 1. Vent pipe and air inlet terminations must be within the maximum and minimum vent and air intake lengths 2.
  • Page 14 VENTING, VENTILATION AND AIR INLET Figure 4.3: Vertical Venting System...

  • Page 15: Air Inlet Pipe Installation

    VENTING, VENTILATION AND AIR INLET b. Visually inspect the venting system for proper size and AIR INLET PIPE INSTALLATION horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies 1. For maximum air inlet pipe lengths see Table 4.2. which could cause an unsafe condition.
  • Page 16 VENTING, VENTILATION AND AIR INLET g. Any improper operation of the common venting system should be corrected so that the installation conforms with 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. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using...

  • Page 17: 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 18 GAS PIPING Table 5.1: Natural Gas Natural Gas Input LP Gas Input Boiler Model Cu. Ft/hr Cu. Meter/hr Cu. Ft/hr Cu. Meter/hr PSCII-03 PSCII-04 PSCII-05 PSCII-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.

  • Page 19: 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 20 ELECTRICAL Figure 6.2: Wiring Diagram, Spark Ignited Pilot, Becket 7600 Limit Control Figure 6.3: Wiring Diagram, Spark Ignited Pilot, Hydrolevel 3200 Limit control...

  • Page 21: Boiler Sequence Of Operation

    ELECTRICAL 7. Pilot flame detected. D. BOILER SEQUENCE OF OPERATION a. Ignitor off. 1. Thermostat calls for heat. b. Main gas on, igniting main burners. 2. Limit control energizes circulator. Note: If pilot flame is not detected within 90 seconds, the igniter and pilot are turned off for 5 minutes.

  • Page 22: 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 23 START-UP PROCEDURES Figure 7.1: Gas Valve, Manifold and Burner Assembly – Intermittent Ignition Figure 7.2: Valve Tapping and Adjustment Screw Locations...
  • Page 24 START-UP PROCEDURES Figure 7.3: Operating Instructions...
  • Page 25 START-UP PROCEDURES Figure 7.4: Operating Instructions...

  • Page 26: Control Descriptions

    START-UP PROCEDURES B. CONTROL DESCRIPTIONS D. CHECKING BURNER INPUT See Figure 6.1 in Section 6 (Electrical) for locations of 1. Refer to rating label mounted on the jacket top panel these devices. to obtain the rated BTU per hour input. In no case shall the input to the boiler exceed the value shown 1.
  • Page 27 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 28: Troubleshooting

    TROUBLESHOOTING 8. TROUBLESHOOTING A. SHUT-DOWN CAUSED BY PILOT DANGER 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 29 TROUBLESHOOTING Table 8.1: Boiler Troubleshooting Guide (Burners Functioning) Problem Possible Causes Corrective Actions Burners not functioning, 1. Flame rollout switch open. 1. Replace switch. Locate cause and correct. blower running. 2. Pressure switch in closed position. 2a. Check for plugged or damaged switch tubing. 2b.
  • Page 30 TROUBLESHOOTING START BEFORE TROUBLESHOOTING, NOTE: “CALL FOR HEAT” 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL. FAMILIARIZE YOURSELF WITH THE STARTUP AND CHECKOUT PROCEDURES. TURN GAS SUPPLY OFF, TURN THERMOSTAT (CONTROLLER) TO “CALL FOR HEAT.” CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING ALSO.

  • Page 31: 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 32: General

    MAINTENANCE A. GENERAL D. MONTHLY (WITH BOILER IN USE) 1. Disconnect this boiler from the gas supply piping 1. Verify condensate drain trap (loop) has sufficient during any pressure testing of the gas system. water to maintain seal and is not blocked. Fill and/or unblock as necessary.
  • Page 33 MAINTENANCE b. Remove jacket removable door, air inlet pipe, air r. Examine air box cover seal. Reposition/replace as box cover, and air box diffuser screen. necessary to assure air tight seal. c. Remove burner hitch pin clips. Disconnect pilot s. Reinstall air box cover. tubing at compression elbow.
  • Page 34 MAINTENANCE Figure 9.2: Inspection of Flueways, Burners, and Vent System.

  • Page 35: Boiler Dimensions & Ratings

    BOILER DIMENSIONS & RATINGS 10. BOILER DIMENSIONS & RATINGS Figure 10.1: Boiler Views Table 10.1: Series PSC II™ Boiler Dimensions SERIES PSC II™ BOILER DIMENSIONS Boiler Jacket Width “A” Model Number PSCII-03 12-1/2" 318 mm PSCII-04 15-7/8" 403 mm PSCII-05 19-1/4"...

  • Page 36: Repair Parts

    REPAIR PARTS 11. REPAIR PARTS REPAIR PARTS SERIES PSC II™ GAS BOILER Repair parts are available from your local PB Heat, LLC distributor or from Parts To Your Door at 1 (610) 916-5380 (www.partstoyourdoor.com). Note: Remember to include the boiler model number and serial number when ordering parts.
  • Page 37 REPAIR PARTS Table 11.1: Repair Parts Quantity Stock Description Required Code Base Assembly – PSCII-03 – 7800 Base Assembly – PSCII-04 – 7801 Base Assembly – PSCII-05 – 7802 Base Assembly – PSCII-06 – 7803 Floor Pan – PSCII-03 – 50100 Floor Pan –...
  • Page 38 REPAIR PARTS Figure 11.2...
  • Page 39 REPAIR PARTS Table 11.2: Repair Parts (see note) Quantity Stock Description Required Code Insulation Blanket, 1/2" x 1.50", Block to Base – 50867 Block – PSCII-03 – 90419 Block – PSCII-04 – 90420 Block – PSCII-05 – 90421 Block – PSCII-06 –...
  • Page 40 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 TO T H E I N S TA L L E R : This manual is the property of the owner and must be affixed near the boiler for future reference.

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