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PeerlessBoilers PBC-40 Installation, Operation & Maintenance Manual

Pbc series combination gas boilers
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Series
Combination
PBC
™
Gas Boilers
PBC-34™, PBC-40™, PBC-52™
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 PBC-40

  • Page 1 ™ Combination Gas Boilers PBC-34™, PBC-40™, PBC-52™ 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...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 8. BOILER CONTROL: INTERNAL WIRING & OPERATION A. INSTALLATION SEQUENCE ....1 A. CONTROL OVERVIEW ....30 B.

  • Page 3: Using This Manual

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

  • Page 4: Preinstallation

    PREINSTALLATION 1. PREINSTALLATION 2. In the absence of local requirements the following A. GENERAL should be followed: 1. Series PBC™ boilers are supplied completely a. ASME Boiler and Pressure Vessel Code, Section assembled as packaged boilers. The package should IV - “Heating Boilers” be inspected for damage upon receipt;...

  • Page 5: Accessibility Clearances

    Do not install on carpeting. volume. The required volume of indoor air is to be determined by one of two methods. DANGER DO NOT INSTALL ON CARPETING. Figure 1.1: Minimum Accessibility Clearances – PBC-34™, PBC-40™, and PBC-52™...
  • Page 6 PREINSTALLATION a. Standard Method: The minimum required volume b. Combining Spaces on Different Floors: Provide of indoor air (room volume) shall be 50 cubic feet one or more permanent openings communicating per 1000 BTU/Hr (4.8 m3/kW). This method is to with additional spaces that have a total minimum be used if the air infiltration rate is unknown or if free area of 2 in...
  • Page 7 PREINSTALLATION b. 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.
  • Page 8 PREINSTALLATION 8. Mechanical Combustion Air Supply: 10. Combustion Air Ducts: a. In installations where all combustion air is a. Ducts shall be constructed of galvanized steel or an equivalent corrosion-resistant material. provided by a mechanical air supply system, the combustion air shall be supplied from the b.

  • Page 9: Boiler Set-Up

    BOILER SET-UP 2. BOILER SET-UP 3. The mounting bracket has (4) holes on 16" centers as A. GENERAL shown in Figure 2.1. This is intended to give installers the ability to mount the bracket on two wall studs 1. Series PBC™ boilers are intended for installation in an spaced at this interval.

  • Page 10: Venting & Air Inlet Piping

    VENTING & AIR INLET PIPING 3. VENTING & AIR INLET PIPING A. GENERAL WARNING 1. Install the Series PBC™ boiler venting system in This vent system operates under positive pressure. accordance with these instructions and with the National Vent connectors serving appliances vented by Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, natural draft shall not be connected into any portion and/or applicable provisions of local building codes.

  • Page 11: Exhaust Vent/Air Intake Pipe Location

    VENTING & AIR INLET PIPING b. Do not locate air intake pipe in a parking area WARNING where machinery may damage the pipe. c. Maintain a minimum of 8" horizontal distance Use of cellular core PVC (ASTM F891), cellular core between exhaust vent and the air intake.
  • Page 12 VENTING & AIR INLET PIPING • This boiler vent system shall terminate at least 3 feet (0.9 m) above any forced air inlet located within 10 ft (3 m). Note: This does not apply to the combustion air intake of a direct- vent appliance.
  • Page 13 VENTING & AIR INLET PIPING Figure 3.6: Exhaust and Air Inlet on Opposite Walls Figure 3.8: Optional Concentric Vent Kit Figure 3.7: Sidewall Exhaust with Indoor Air Installation...

  • Page 14: Exhaust Vent/Air Intake Pipe Sizing

    VENTING & AIR INLET PIPING Figure 3.10: Concentric Vertical Vent Installation Figure 3.9: Standard Vertical Vent Installation e. Figure 3.11 shows an option for routing the exhaust and air inlet piping through an unused chimney. f. Figure 3.12 shows this option using inlet air from a sidewall position.

  • Page 15: Exhaust Vent/Air Intake Pipe Installation

    1. Figures 12.1 & 12.2 show the exhaust connection on top of the boiler, near the rear in the center. a. The exhaust connection for PBC-34™, PBC-40™, and PBC-52™ boilers is a 3" polypropylene adapter that will accept PVC, polypropylene or AL29-4C stainless steel piping.

  • Page 16: Exhaust Tapping For Vent Sample

    VENTING & AIR INLET PIPING 2. The Air Intake connection is to the right of the exhaust. f. Refer to Figures 3.4 through 3.8 for sidewall venting options using PVC or CPVC pipe. WARNING g. Refer to Figures 3.9 through 3.13 for vertical venting options using PVC or CPVC pipe.
  • Page 17 VENTING & AIR INLET PIPING Mettre en marche les sécheuses et tout autre appareil Après avoir établi que les résidus de combustion de non raccordé au système d’évacuation commun. chaque appareil qui demeure raccordé au système Mettre en marche tous les ventilateurs aspirant, tels commun sont adéquatement évacués lorsque soumis que les hottes de cuisinière et les ventilateurs de salle au test décrit ci-dessus, remettre en place les portes,...

  • Page 18: Water Piping And Controls

    WATER PIPING AND CONTROLS 4. WATER PIPING & CONTROLS A. GENERAL B. OPERATING PARAMETERS 1. Size water supply and return piping in accordance 1. The Series PBC™ boiler is designed to operate in a with system requirements rather than the boiler closed loop hydronic system under forced circulation.
  • Page 19 WATER PIPING AND CONTROLS Figure 4.1: Piping Symbol Key 7. Back Flow Preventer: A back flow preventer (check WARNING valve) is required by some jurisdictions to prevent water in the hydronic system from backing up into the city water supply. This is especially important on systems in Use only inhibited propylene glycol solutions which which glycol solution is used as the heating medium.

  • Page 20: System Piping

    WATER PIPING AND CONTROLS 9. Low Water Cut Off: When installing a probe type NOTICE LWCO, locate the LWCO in the boiler supply above the top jacket panel. Refer to Section 7. Electrical For existing systems that use iron pipe for heating Connection in this manual for wiring details.

  • Page 21: Freeze Protection

    Model Btu/hr (kW) Btu/hr (kW) PBC-34™ 80,000 (23.4) 76,000 (22.3) – Feel water before bathing or showering. PBC-40™ 100,000 (29.3) 95,000 (27.8) – Read this manual in its entirety before setting PBC-52™ 120,000 (35.2) 114,000 (33.4) domestic hot water setpoint.
  • Page 22 WATER PIPING AND CONTROLS Figure 4.6: Recommended Central Heat Piping...
  • Page 23 WATER PIPING AND CONTROLS Figure 4.7: Recommended Domestic Hot Water Piping...
  • Page 24 WATER PIPING AND CONTROLS 6. Due to increased flow rate and fluid viscosity, the 11. Use water that is low in mineral content and make circulator head requirement will increase. Contact the sure that there are no petroleum products in the pump manufacturer to correctly size the circulator for solution.

  • Page 25: Fuel Piping

    FUEL PIPING 5. FUEL PIPING A. GENERAL CAUTION 1. All fuel piping to the Series PBC™ boiler is to be in Use a backing wrench on the gas valve inside of the accordance with local codes. In the absence of local unit when threading the gas pipe into the gas valve regulations refer to the National Fuel Gas Code, ANSI flange.

  • Page 26: Gas Supply Piping - Operation

    FUEL PIPING 1. Do not install any piping directly in front of the boiler Table 5.2: Maximum and Minimum Fuel Pressure or along either side. Always provide access to the Pressure Inches W.C. (Pa) front cover and side panel openings. Fuel Type Minimum Maximum...
  • Page 27 < 200 ppm < 75 ppm < 200 ppm (CO) Carbon 8.8% to 8.5% to 9.8% to 9.5% to Dioxide 11.6% 9.7% 12.5% 10.5% Figure 5.3: PBC-40/52™ Gas Valve and Venturi Detail Figure 5.2: PBC-34™ Gas Valve and Venturi Detail...

  • Page 28: Condensate Drain Piping

    CONDENSATE DRAIN PIPING 6. CONDENSATE DRAIN PIPING A. GENERAL 1. The disposal of all condensate into public sewage systems is to be in accordance with local codes and regulations. In the absence of such codes, follow these instructions. 2. Proper piping and removal of condensation from combustion is critical to the operation of a condensing appliance.

  • Page 29: Electrical Connections

    8. Gas Valve: The gas valve is connected through a the Outdoor Sensor is not installed in the default special cord and connector. The PBC-40™ and central heat mode. PBC-52™ connector is secured with a screw.
  • Page 30 ELECTRICAL CONNECTIONS 9. Ignition Electrode: This electrode is located on the left 15. Stepper Motor: The stepper motor is located in the side of the burner door. A high voltage charge is CHB behind the flow sensor. The motor controls the provided by the external spark generator to provide position of the diverting valve in the CHB that spark for lighting the burner.
  • Page 31 ELECTRICAL CONNECTIONS Figure 7.2: Wiring Schematic and Connection...

  • Page 32: Boiler Control: Internal Wiring & Operation

    BOILER CONTROL: INTERNAL WIRING & OPERATION 8. BOILER CONTROL: INTERNAL WIRING & OPERATION A. CONTROL OVERVIEW The Series PBC™ boiler control is one of the primary safety devices for the boiler. It controls: • Ignition sequence • Temperature Limits • Circulators •...

  • Page 33: Available Domestic Hot Water Modes

    BOILER CONTROL: INTERNAL WIRING & OPERATION C. AVAILABLE DOMESTIC HOT WATER MODES Table 8.2: Series PBC™ Domestic Hot Water Modes Central Heating Mode Description Mode Operation Mode – Disables DHW sensor and functionality. No Domestic Hot Water – Boiler will function only for Central Heat. –...
  • Page 34 BOILER CONTROL: INTERNAL WIRING & OPERATION Figure 8.2: 900LB Display Buttons Table 8.4: Display Icon Descriptions Description and Use Icon # Default Screen Menu Selection – CH loop water pressure and/or Outdoor temperature. – OUTSIDE is lit when temperature is shown. Pressure unit is lit when pressure is shown.

  • Page 35: User Menu

    BOILER CONTROL: INTERNAL WIRING & OPERATION E. USER MENU The User menu is accessible from the default screen by pressing the M button once to enter the menu level selection screen and pressing M again when “0000” is shown in the small digits. The User Menus allow access to basic setpoints, system test, and unit settings.
  • Page 36 BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.6 (cont.): Status Menus (1000 Level) Status Parameter Function (1000) Value/Options Parameters State 1030 Error Number 1031 CH Pressure Pressure 1033 Actual fan speed 1040 Ignition fan speed 1041 Minimum fan speed 1042 Maximum fan speed 1043 1051...

  • Page 37: Installer Menu-2000 Level

    °F period. – Overrides Anti-Cycling Period Maximum CH Power PBC-34™: 57 – Limits maximum CH input available to the control to satisfy a demand PBC-40™: 61 2014 – Default values should not be changed PBC-52™: 54 Minimum CH Power 2015 –...
  • Page 38 BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.7 (cont.): Installer Menus (2000 Level) Status Default Parameter Function (2000) Unit/Value Options Parameters Warm Weather Shutdown Temperature 2025 °F – Outdoor temperature that will block all CH demands until temperature falls below this value Boost Function: Increment –...

  • Page 39: Menu Levels 3000, 4000 & 5000

    Appliance Mode – Determines Fan Speeds of appliance PBC-34- 50 – ALWAYS ENSURE THIS SETTING MATCHES THE UNIT BEING INSTALLED PBC-40- 51 2138 – WARNING: FAILURE TO PROPERLY SET THE APPLIANCE MODE CAN LEAD PBC-52- 52 TO BOILER FAILURE CAUSING PROPERTY DAMAGE, SEVERE PERSONNEL...

  • Page 40: Outdoor Reset Operation

    BOILER CONTROL: INTERNAL WIRING & OPERATION OUTDOOR RESET OPERATION Figure 8.3: Outdoor Reset Curve Logic All Series PBC™ boilers come with the default Central 3. The Minimum CH setpoint (2023) controls how low Heat mode set to outdoor reset with room thermostat the calculated setpoint can fall.

  • Page 41: Ignition Sequence

    BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.8 (cont.): Outdoor Reset Parameters Status Default Parameter Function (2000) Unit/Value Options Parameters Mild Weather Design Outdoor Temperature – Sets the Outdoor Temperature at which the boiler will target the Boiler Mild Weather Design °F 2022 Temperature.

  • Page 42: Additional Safety Functions

    BOILER CONTROL: INTERNAL WIRING & OPERATION 6. Frost Protection: The Series PBC™ control monitors K. ADDITIONAL SAFETY FUNCTIONS the unit for potential freeze situation which would cause damage to the internal piping of the unit. If the 1. Ignition Failure Protection: The Series PBC™ control water temperature inside the unit falls below 41°F allows for 3 failed ignition attempts before the control (5°C) the boiler pump will start.

  • Page 43: Start-Up Procedure

    START-UP PROCEDURE 9. START-UP PROCEDURE 4. If a supply pressure check is required, isolate the A. GENERAL boiler and gas valve before performing the pressure test. If the supply pressure is too high or too low, 1. Confirm that all water, gas and electricity are turned off. contact the fuel gas supplier.
  • Page 44 START-UP PROCEDURE a. Using a combustion analyzer with the capability to d. If the values in either of these instances falls outside read carbon dioxide (CO2) and carbon monoxide the parameters listed in Table 5.4, turn off the (CO), place the probe into the combustion test boiler and contact your PB Heat representative.

  • Page 45: Lighting & Operating Procedures

    START-UP PROCEDURE E. LIGHTING & OPERATING PROCEDURES...

  • Page 46: Troubleshooting

    TROUBLESHOOTING 10. TROUBLESHOOTING 3. Warning 204 is for Outdoor Sensor not Connected. The Series PBC™ units will display this warning on start-up if the provided outdoor sensor is not connected. D. TYPICAL OPERATION CYCLE – CENTRAL HEAT 1. Boiler is in standby. No demand. Central Heat Radiator symbol is constant.
  • Page 47 TROUBLESHOOTING 8. Two second flame proving period holds valve open 11. Gas valve closes, Fan returns to ignition speed. while control checks for flame signal 12. 10 second post purge period. 9. Boiler holds at ignition speed for 10 seconds before 13.
  • Page 48 TROUBLESHOOTING Table 10.1 (contl): Lockout Codes Error Error Display Corrective Action Number Fan runs to slow for more than 60 seconds – Check voltage to the blower. A low voltage can cause the blower to run at the incorrect speed due to lack of power. Replace blower if voltage is correct. FAN_ERROR_TOO_SLOW –...
  • Page 49 TROUBLESHOOTING Table 10.2: Blocking Errors Error Error Display Corrective_ Action Number WD_ERROR_RAM Internal software error. If error persists, replace control. WD_ERROR_ROM Internal software error, If error persists, replace control. WD_ERROR_STACK Internal software error. If error persists, replace control. WD_ERROR_REGISTER Internal software error. If error persists, replace control. WE_ERROR_XRL Internal software error.
  • Page 50 TROUBLESHOOTING Table 10.2 (cont.): Blocking Errors Error No. Error Display Corrective Action Outdoor Sensor open – Check sensor wiring for solid connection and continuity. Replace wiring if bad OUTDOOR_OPEN or repair break. – Check for resistance though the sensor by touching meter leads across both pins on the sensor.

  • Page 51: Maintenance

    MAINTENANCE 11. MAINTENANCE WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF fibers, 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, they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans.

  • Page 52: General (With Boiler In Use)

    MAINTENANCE g. Check again to confirm that valve has closed A. GENERAL (WITH BOILER IN USE) completely and is not leaking. General boiler observation can be performed by the owner. If any potential problems are found, a qualified 3. Test low-water cut-off (if used) as described by the installer or service technician/agency must be notified.

  • Page 53: Heat Exchanger Gasket Replacement

    MAINTENANCE b. Disconnect the condensate piping from the outside g. Initiate a call for heat** and observe the connections (not from the Series PBC™ side) so condensate flow. the flow can be observed. h. Reconnect the condensate piping to the drain connection.

  • Page 54: Plate Heat Exchanger Maintenance

    MAINTENANCE 6. Clean and flush the flow regulator with clean water or 6. The PHE can be cleaned using a solution of air to remove sediment. “Rydlyme” (recommended for best results) (available online www.rydlyme.com) or “CLR” (available at 7. Replace the flow regulator cartridge into the housing most hardware stores).

  • Page 55: Boiler Dimensions & Ratings

    PEERLESS SERIES PBC™ DIMENSIONS Boiler “A” “B” “C” “D” “E” “F” Model PBC-34 16-13/16 18-3/16 30-11/16 7-13/16 7-5/8 7-3/16 PBC-40 16-13/16 18-3/16 30-11/16 7-13/16 6-15/16 7-5/8 PBC-52 18-13/16 18-3/16 30-11/16 6-1/16 6-15/16 7-5/8 Table 12.2: Boiler Ratings ® PEERLESS SERIES PBC™ BOILER RATINGS ™...
  • Page 56 Boiler Rate Model Low Power Ignition High Power (MBH) PBC-34 1400 - 1500 3000 6900 - 7000 PBC-40 1150 - 1300 4300 6350 - 6450 PBC-52 1250 - 1350 2500 6200 - 6350 Table 12.4: Main Control Specifications ® PEERLESS SERIES PBC™...
  • Page 57 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 58: Repair Parts

    REPAIR PARTS 13. REPAIR PARTS 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. Figure 13.1: General Repair Parts...
  • Page 59 5954 Electrical Panel PBC6004 Carlin 4180002F External Spark Generator 54758 975MN Boiler Control: PBC-34 975MN Boiler Control: PBC-40 975MN Boiler Control: PBC-52 Nut #8-32 51573 Clevis Pin 3/16" by 1" (Local Hardware Supply) — Retaining Pin Cotter 1" Local Hardware (Local Hardware Supply) —...
  • Page 60 REPAIR PARTS Figure 13.2: PBC-34 Combustion Components...
  • Page 61 Sensor Electrode 54786 Ignition Electrode Graphite Gasket 54787 Sensor Electrode Graphite Gasket 54789 Screw M4 X 10mm for Electrodes 6512 Burner Door w / Burner PBC-34/PBC-40 54795 M6 Flange Nut 6505 Burner Door Gasket 54790 Burner Door Insulation 54791 Target Wall Insulation...
  • Page 62 REPAIR PARTS Figure 13.3: PBC-40 and PBC-52 Combustion Components...
  • Page 63 REPAIR PARTS Table 13.3: PBC-40 and PBC-52 Combustion Components Quantity Stock Description Required Code Ignition Electrode 54788 Sensor Electrode 54786 Ignition Electrode Graphite Gasket 54787 Sensor Electrode Graphite Gasket 54789 Screw M4 X 10mm for Electrodes 6512 Burner Door w / Burner PBC-34/PBC-40...
  • Page 64 REPAIR PARTS Table 13.4: CHB Repair Parts Stock Item Picture Description Code Plate Heat Exchanger- 24 Plate (w/ Gaskets and Screws) 54798 Plate Heat Exhanger Gaskets 54799 18L Flow Restictor With Screen 54800 Basic Pump Cartridge UPS15-78 54801 NTC 10 kΩ B3977 Sensor- Return And Dhw Sensor (With Clip) 54802 Spare Fillling Valve Short (With Clip) 54803...
  • Page 65 ™ Combination Gas Boilers PBC-34™, PBC-40™, PBC-52™ 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...

This manual is also suitable for:

Pbc-34Pbc-52

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