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PeerlessBoilers DE Installation & Maintenance Manual

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DE
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

    A. GENERAL ......33 B. DAILY (WITH BOILER IN USE) ...33 C.

  • Page 3: Using This Manual

    Throughout this manual you will see special attention boxes intended to supplement the instructions and make special notice of potential hazards. These categories mean, in the judgment of PB Heat, LLC: USING THIS MANUAL DANGER Indicates a condition or hazard which will cause severe personal injury, death or major property damage.

  • Page 4: Preinstallation

    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. 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 .
  • Page 5 where: = Input of the fan assisted appliances in Btu/hr ACH = air change per hour (percent of the volume of the space exchanged per hour, expressed as a decimal) For appliances other than fan assisted, calculate the required volume of air using the following equation: Required Volume other...
  • Page 6 PREINSTALLATION 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 Btu/hr (22 cm per 2000 W) of total rated input for all appliances in the space.

  • Page 7: Installation Survey

    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.

  • Page 8: Boiler Set-Up

    4. Separate the wood shipping pallet from the boiler base by removing two (2) hold-down bolts at each end of the boiler base. 5. Move boiler into final position. If using combustible floor pan, install boiler on pan as outlined in the instructions included with the pan.

  • Page 9: Water Piping And Controls

    For more information on bypass piping, consult the PB Heat, LLC Water Survey. 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.

  • Page 10: 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...

  • Page 11: Piping For Zoned Systems

    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 12: Expansion Tank

    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.

  • Page 13: Venting

    2. Horizontal portions of the venting system shall slope upward at least 1/4” per lineal foot (21 mm per meter) between boiler and chimney. The vent pipe shall be supported to prevent sagging; using metal strapping or equivalent means at no more than 4 ft.
  • Page 14 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.
  • Page 15 Figure 4.2: Direct Exhaust, Sidewall Venting with Vertical Off-Set Figure 4.3: Vent Pipe Adapters VENTING...

  • Page 16: Direct Exhaust Vertical Venting

    5. Horizontal portions of the vent pipe shall slope up not less than 1/4” per foot (21 mm per meter) from the boiler to the vertical vent. 6. 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.

  • Page 17: Boiler Removal From Common Venting System

    Direct Exhaust Vertical Venting E. BOILER REMOVAL FROM COMMON VENTING SYSTEM At 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.

  • Page 18: Gas Piping

    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.
  • Page 19 Table 5.1: Natural Gas Input Model (Cubic Ft/Hr) DE-03 DE-04 DE-05 DE-06 Based on 1000 Btu/Cubic Ft. Table 5.2: LP Gas Input Model (Cubic Ft/Hr) DE-03 DE-04 DE-05 DE-06 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]...

  • Page 20: Electrical

    Code , ANSI/NFPA 70 and/or the Canadian Electrical Code, Part 1 , CSA C22.1, Electrical Code. A. WIRING 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.

  • Page 21: Sequence Of Operation

    D. SEQUENCE OF OPERATION 1. Thermostat calls for heat, energizes Control Relay (CR). 2. Control Relay (CR) energizes circulator. 3. Limit senses boiler water temperature. Prevents boiler operation until water temperature falls approximately 15 F (8 C) below the cut-out °...
  • Page 22 ELECTRICAL Figure 6.3: Ignition System Operating Sequence...
  • Page 23 Figure 6.4: Zone Wiring with Zone Valves Figure 6.5: Zone Wiring with Circulators ELECTRICAL...

  • Page 24: Start-Up Procedures

    8. Connect a manometer to the gas valve inlet pressure tap. See Figure 7.2. 9. 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.
  • Page 25 Figure 7.1: Gas Valve, Manifold and Burner Assembly – Intermittent Ignition Figure 7.2: Valve Tapping and Adjustment Screw Locations START-UP PROCEDURES...

  • Page 26: Operating Instructions

    START-UP PROCEDURES 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.

  • Page 27: Control Descriptions

    2. 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 F x H Where: 3600 –...

  • Page 28: Check-Out Procedure

    72000 68727 65739 63000 60480 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.
  • Page 29 6. 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.

  • Page 30: Troubleshooting

    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.
  • Page 31 TROUBLESHOOTING SEE TABLE 7 Figure 8.1: Procedure For Measuring Fan Suction Pressure...
  • Page 32 2. Reset limit to higher setting. 3. Vent air from all points in system. 4. Check circulator, replace if necessary. 5. Shut down and cool boiler, drain and flush system. 6. Adjust heat anticipator to 0.2 Amp. 1. Locate and repair or replace.
  • Page 33 TROUBLESHOOTING Figure 8.2: Boiler Troubleshooting Guide (Burners Not Functioning)

  • Page 34: Maintenance

    MAINTENANCE 9. MAINTENANCE 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 35: General

    See Section 3 for antifreeze instructions. 3. If there is considerable foreign 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.

  • Page 36: Annually (Before Start Of Heating Season)

    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.

  • Page 37: Boiler Dimensions & Ratings

    DE-06 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. 3 Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are based on U.S.

  • Page 38: Repair Parts

    REPAIR PARTS 11. REPAIR PARTS 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.

  • Page 39: Base/Burners/Manifold

    REPAIR PARTS Figure 11.2: Base/Burners/Manifold...
  • Page 40 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. Part Selection Information Specify length 1 Per Boiler Specify Quantity Natural Gas 0-2000 ft (0-610 m) elevation (specify qty.) *...
  • Page 41 NOTES...
  • Page 42 NOTES...
  • Page 43 Series HI Division of gama PB HEAT, LLC PO BOX 447 • NEW BERLINVILLE, PA 19545-0447 ©2007 Boilers I n s t a l l a t i o n , O p e r a t i o n &...

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