PB Heat WBV Series User's Manual
Contents
1. AQUASTAT wie 2 0 BOILER SWITCH Y PACKAGED BOILERS LOW VOLT HYDROLEVEL 650 P 550 P THERMOSTAT PROBE TYPE L W C O WHEN REQUIRED NOTE MOUNT IN BOILER SUPPLY PIPING BURNER J BOX OF 3 0 BK PRIMARY CRIMP TERMINATION 34 BL r GROUND SCREW G e IGNITOR Q o BL INTERRUPTED FUSED DISCONNECT TRANSFORMER s BY INSTALLER BURNER Y x M i CU L1 HOT POWER WH e BURNER o MOTORS Chw e L2 SUPPLY MOTOR 62 ON LINE L1 L BK YE BK YE BK VOLTAGE CIRCULATOR WH L2 N WH WH BURNER BK DISCONNECT E VALVE VALVE CAD Y CFLL L7224 OR WLSAGE L7248 AQUASTAT T LOW VOLTAGE I T Qu NOTE ALL WIRING MUST COMPLY WITH APPLIANCE CODES i asad C IMPER ORDINANCES AND REGULATIONS Figure 4 3 Water Boilers Packaged 10 LOW VOLTAGE 28 24V THERMOSTAT NOTE ALL WRING MUST COMPLY WITH APPLIANCE CODES ORDINANCES AND REGULATIONS OPERATING CONTROL FOR STEAM W TANKLESS HEATER ONLY Figure 4 4 Steam with Float Low Water Cut Off BOILER SERMCE SWITCH FUSED PROMDED ON PACKAGED BOILERS BY2. rates of this product meet the ENERGY STAR guidelines for ener Jy efficiency ENERGY STAR i 3 17 SET As an ENERGY STAR Partner PB Heat LLC has determined that certain firing Installation Operation amp Maintenance Manual PeerlessBoilers com TABLE OF CONTENTS USING THIS MANUAL 1 5 BURNER SETUP amp BOILER A INSTALLATION CLEARANCE 1 OPERATION 13 B SPECIAL ATTENTION BOXES 1 A BURNER INSTALLATION 13 B BURNER START UP AND ADJUSTMENT 13 1 PREINSTALLATION 2 C CHECK BOILER CONTROLS 13 CLEARANCES 2 D PURGE AIR FROM THE SYSTEM B AIR FOR COMBUSTION AND WATER BOILERS ONLY 13 VENTILATION 2 E CLEAN THE BOILER C CHIMNEY VENT AND DRAFT CONTROL 3 STEAM BOILERS ONLY 14 D INSTALLATION SURVEY 3 E PLANNING THE 3 SEMAINTENANCE 16 A GENERAL 17 Se E E E N B DAILY MAINTENANCE WITH BOILER SETTING THEBOILER OPERATING 17 B CONNECTING THE FLUE OUTLET 4 Ee MAINTENANCE WITH BOILER C JACKET ASSEMBLY KNOCKDOWN OPERATING 47 BOILERS vanes 4 RELIEF VALVE 17 L E T E MONTHLY MAINTENANCE WITH BOILER A PRESSURE TEST BLOCK ASSEMBLY
3. R7184B BURNER BOILER SERVICE SWITCH PRIMARY CONTROL PROVIDED ON PACKAGED BOILERS FUSED DISCONNECT CRIMP BY INSTALLER TERMINATION L2 115 60 1 L1 HOT POWER BURNER GR SUPPLY J BOX ADDITIONAL IGNITOR LIMIT SAFETY SWITCHES BL INTERRUPTED GROUND ax CONTROL WHEN_ REQUIRED TRANSFORMER SCREW S oo BURNER B BURNER O MOTOR BK MOTOR 67 FLOAT TYPE w L W C O OIL VALVE JUNCTION BOX MOLEX CONNECTOR HEYCO BUSHING IN JUNCTION BOX KNOCKOUT LINE VOLTAGE DISCONNECT INSTALLER L L R71848 BURNER PRIMARY CONTROL CRIMP TERMINATION BURNER J BOX HYDROLEVEL CG450 PROBE L W C O IGNITOR BL INTERRUPTED TRANSFORMER MOTOR MOT BURNER _ O JUNCTION BOX MOLEX CONNECTOR HEYCO BUSHING IN JUNCTION BOX KNOCKOUT LINE VOLTAGE LOW VOLTAGE 24V THERMOSTAT OPERATING CONTROL FOR STEAM W TANKLESS HEATER ONLY Figure 4 5 Steam with Probe Low Water Cut off BK 2 115 60 1 1 HOT POWER GR SUPPLY e ADDITIONAL SAFETY SWITCHES WHEN REQUIRED NOTE ALL WRING MUST COMPLY WTH APPLIANCE CODES ORDINANCES AND REGULATIONS 11 ELECTRICAL SEE NOTES BOILER SWITCH PROVIDED L2 11 HOT ON PACKAGED BOILERS
4. Model No Model No Head Nozzle Size Pressure Air Shutter Air Band Setting WBV 03 085 0 75 80 B HAGO 140 PSI WBV 03 105 0 90 80 B HAGO 140 PSI WBV 04 095 0 85 80 B DEL4 140 PSI WBV 04 125 1 10 80 B HAGO 140 PSI WBV 04 150 1 25 80 B HAGO 140 PSI WV 05 175 1 50 60 B HAGO 140 PSI WV 05 195 1 65 60 B HAGO 140 PSI BECKETT NX BURNER SPECIFICATIONS WBV 03 085 NX70LB 0 65 x 60 W DEL 1 5 WBV 03 105 NX70LB 0 85 x 60 B HAGO 25 WBV 04 095 NX70LB 0 75 x 60 W DEL4 2 0 WBV 04 125 NX70LD 1 10 x 60 W DEL 1 0 WBV 04 150 NX70LD 1 25 x 60 W DEL 2 0 Note Burner used to fire the WBV 03 085 and 1 05 rate is also required to fire the WBV 04 95 rate with nozzle indicated in above chart Table 5 2 Carlin Burner Specifications with 98022 PSC motor CARLIN BURNER SPECIFICATIONS WITH 98022 PSC MOTOR Boiler Burner Start up Settings Model No Model No Head Bar Nozzle Size Pump Pressure Aic Shotter Air Band WBV 03 085 0 60 0 65 0 65 70 A DEL 150 PSI WBV 03 105 0 85 1 00 0 85 70 A DEL 150 PSI WBV 04 095 0 75 0 75 70 A DEL 150 PSI WBV 04 125 0 85 1 00 1 00 70 A DEL 150 PSI WBV 04 150 1 10 1 25 1 25 60 B DEL 150 PSI WV 05 175 1 50 60 B HAGO 150 PSI 1096 open WV 05 195 1 65 60 B HAGO 150 PSI 45 open Table 5 3 Riello Burner Specifications RIELLO BURNER SPECIFICATIONS Start Up Settings Turbulator Air
5. SEE NOTES ZONE 1 THERMOSTAT ZONE 2 ZONE 3 CIRCULATOR CIRCULATOR 1 R845A R845A L7248L 6 6 Qu x G e 2 CD ZONE 1 2 2 CIRCULATOR Q 62 i u o on 17224 t mi Pi CONNECT RELAY TO Zp ZC INSTEAD OF L1 ZONE 2 ZONE 3 THERMOSTAT THERMOSTAT NOTES 1 WIRE AS SHOWN FOR PROPER OPERATION OF BOILER SWITCH VERIFY AT START UP THAT BOILER SWITCH SHUTS DOWN BOILER 2 MAXIMUM TOTAL LOAD OF ZONE RELAYS AND ADDITIONAL CIRCULATORS IS 7 4 AMPS TYPICALLY 4 ZONES 3 ALL WIRING MUST COMPLY WITH APPLICABLE CODES ORDINANCES AND REGULATIONS Figure 4 6 Zoning with Circulators n LINE VOLTAGE LOW VOLTAGE THERMOSTATS 24V 120V 60HZ TO MAIN TRANSFORMER DISCONNECT 120 24N 60HZ SWITCH 9 40VA H J HOT LIL2 lip 24 ______ lJJ JUNCTION BOX z IA Y 1 4 i Ls Y N EU SS q DD Y M HHI Hit iil J yo Y ZONE VALVES AQUASTAT it Y I S ZONE ZONE ZONE ZONE FE NO 1 NO 2 NO 3 NO 4 1111 TT mm R J R el B ser fL R p R l R R E ia R 4 R WIRE REMAINDER OF AQUASTAT RELAY IN ACCORDANCE WITH SYSTEM WIRING
6. OPERATING 17 B BOILER RETURN CLEARANCE 6 P MAIN TENANCE BANNUM sees qaia 1 C WATER BOILER PIPING 6 GAFA MONG See 15 REQUIRED quale D STEAM BOILER PIPING 6 EMUGUEREXSENEIDPESNEEXUNEE 15 E TANKLESS HEATER OR COVERPLATE 7 CONTROLS 7 8 REPAIR PARTS 21 4 ELECTRICAL 9 A GENERAL 9 B BURNER WIRING 9 USING THIS MANUAL Indicates a condition or hazard which A INSTALLATION CLEARANCE DANGER will cause severe personal injury Follow the installation instructions provided in this death major property damage fi nietos a condition or hazard which ha quate cee may cause severe personal injury th or major propert mage potential interferences and maximize safety during boiler death or major property damage Halatan CAUTION Indicates a condition or hazard which will cause minor personal injury or B SPECIAL ATTENTION BOXES property damage Throughout this manual you will see special attention boxes intended to supplement the instructions and make NOTICE Indicates special attention is needed special notice of potential hazards These categories but not directly related to potential mean in the judgment of PB Heat LLC injury or property damage PREINSTALLATION 1 PREINSTALLATION Read carefully study these instructions before beginning wo
7. remove the square knock out in the back panel Attach back panel to bosses on middle of back section with two 1 4 x 3 8 machine screws provided The back panel has two 5 16 diameter holes close to the center of the panel Attach both the left and right side panels to the back panel and secure with sheet metal screws Remove the burner mounting plate item 5 and make certain the target wall item 2 is in correct position in back of chamber Ceramic fiber blanket liner item 3 WBV 04 and WV 05 should be on floor of boiler in front of target wall Remove the two 2 knockouts in the front jacket panel which will allow clearance for the hinge Place the front jacket panel on the block and attach the left and right side panels in the same manner as they are attached to the back panel Reinstall the burner mounting plate BOILER PLACEMENT AND ASSEMBLY Figure 2 1 Steam boiler Figure 2 2 Water boiler See Table 8 1 for parts identification 3 PIPING AND CONTROLS NOTICE Do not pipe boiler before jacket is installed A PRESSURE TEST BLOCK ASSEMBLY 1 Make up cold water supply connection to the boiler 2 Install pressure gauge or pressure temperature gauge in tapping provided See Boiler Dimensional drawing Figures 7 1 and 7 2 Section 7 3 Plug all open tappings in the boiler and fill with water Apply ap
8. turned up and main boiler service switch is turned on If burner does not start check to be sure there is oil in the tank and push reset button on burner control Beckett Square red button Carlin Round red button Riello Round red button inside clear flexible cover on back of burner cover If burner still does not start contact serviceman CAUTION Do not attempt to start the burner when excess oil has accumulated when the unit is full of vapor or when the combustion chamber is very hot 2 Adjust burner and barometric draft control for highest CO2 Maximum 13 while maintaining a 0 Smoke and 01 to 02 W C draft overfire All adjustments must be made using suitable instruments such as found in a Bacharach Combustion Test Kit 3 Burner and boiler can be shut down by turning down the thermostat and moving the main boiler service switch to the off position 4 See burner manufacturer s manual for further information regarding the burner C CHECK BOILER CONTROLS 1 Limit and Operating Controls a Lower the set point of each control until the burner shuts down Note that the system pressure or temperature corresponds to the desired set point b Return the controls to the desired set point 2 Low Water Cut off if used consult the manufacturer s instructions for the low water cut off operational check procedure D PURGE AIR FROM THE SYSTEM WATER BOILERS ONLY 1 Purge the system using purge v
9. heated up Note also that the higher the firing rate on a unit which has multiple firing rates the higher the draft required For example increasing the firing rate 1 4 gallon may increase the draft loss in a unit by approximately 01 D INSTALLATION SURVEY For new and existing installations a Water Installation Survev or a Steam Installation Survev is available from PB Heat LLC The surveys will provide information on how the boiler works with your specific system and will provide an overview of boiler system operation in general You can also use this survey to locate system problems which will have to be corrected To obtain copies of these Surveys contact your PB Heat representative or download it from PeerlessBoilers com E PLANNING THE LAYOUT Prepare sketches and notes of the layout of the installation Include boiler location venting system existing piping and wiring Show existing equipment that may interfere with installation of new equipment 2 BOILER PLACEMENT AND ASSEMBLY A SETTING THE BOILER C JACKET ASSEMBLY KNOCKDOWN BOILERS 1 Provide a level foundation located as close as possible to the center of the heating system 1 If the boiler is to be installed with a rear flue outlet 2 Refer to Figures 2 1 and 2 2 for exploded view of boiler while checking and or assembling parts of the boiler 3 On packaged boilers open burner mounting plate item 5 at this time to make certain
10. on top of junction box and insert limit harness Molex Figure 4 6 Zoning with Circulators connector into Heyco bushing until it snaps firmly in Figure 4 7 Zoning with Zone Valves place WARNING Improper installation of burner harness can allow burner to energize with burner mounting plate open creating a severe burn hazard to boiler maintenance personnel SEE JUNCTION JUNCTION BOX BOX DETAILS BURNER WHITE WIRE TO WHITE WIRE TO AQUASTAT AQUASTAT SS LIMIT WPC MODELS ONLY WPC MODELS ONLY gy EFT XUNETI N SIDE PANEL BOX JUNCTION BOX R BK SERVICE SWITCH INSERT MOLEX R BK INSERT MOLEX FIELD SUPPLIED FROM LIMIT FROM LIMIT ON KNOCKDOWN HARNESS INTO HARNESS INTO BOILERS BUSHING BUSHING SPLICE AND ATTACH INCOMING HOT LEAD TO RED WRE BUSHING CONNECT RED BLACK WIRES TO SWITCH SPLICE RED WIRE ON GROUND ATTACH INCOMING KD BOILERS NEUTRAL LEAD TO ATTACH INCOMING WHITE WIRE NEUTRAL LEAD TO ATTACH INCOMING WHITE WRE HOT LEAD HERE J BOX ASSEMBLY LESS SERVICE SWITCH J BOX ASSEMBLY WITH SERVICE SWITCH SEE OTHER DETAIL TO INSTALL FIELD SUPPLIED SERVICE SWITCH SWITCH PROVIDED ON PACKAGED BOILERS Figure 4 1 Junction Box Wiring Steam and Knockdown Water Boilers JOIN WTH NEUTRAL IN JUNCTION BOX WHITE x JUMPER P2 HYDROLEVEL 650 P 550 P PROBE TYPE L W C O WHEN REQUIRED NOT
11. the rating shown on the safety relief valve The valve rating can be found on the top of the safety relief valve Boiler temperature should never be higher than 250 4 Check for water leaks in boiler and system piping 17 MAINTENANCE 2 To thoroughly clean the boiler it must be brushed down from the top Alternatively for limited space or minimum clearance to combustible installations cleaning the heat exchanger from the combustion chamber side is acceptable If unit is extremely dirty it may be necessary to brush from both directions The target wall is made of a soft ceramic fiber Care must be taken not to damage this material during cleaning 3 Remove any scale or soot from the combustion chamber area by vacuum cleaning or any other available means NOTICE Burner mounting plate must be opened to facilitate this operation 4 Replace oil burner and flue collector cover plate making sure all gaskets are in place 5 Replace jacket top panel NOTICE All cover plates enclosures and guards must be maintained in place at all times except during maintenance and servicing 6 Inspect venting system 18 G IF A LONG SHUTDOWN IS REQUIRED 1 To take boiler out of service if the boiler and system are not to be used when temperatures are below freezing a Drain the boiler and system completely and shut off make up water supply b Open main line power disconnect switch to boiler Remove the fuses
12. the target wall item 2 is seated in the back of the combustion chamber WBV 04 WV 05 Ceramic fiber blanket base liner item 3 should be lying flat on bottom of combustion chamber between target wall and burner mounting plate Close burner mounting plate 4 See clearance information in Section I Preinstallation B CONNECTING THE FLUE OUTLET The WBV 03 and WBV 04 boiler models may be installed as a rear flue outlet unit or a top flue outlet unit Packaged WBV 03 and WBV 04 boiler models are shipped as rear flue outlet and may be converted The WV 05 boiler model is only available as a top flue outlet unit On Knockdown boilers the flue outlet components are located in the water trim or steam trim carton 1 If converting to a top flue application on a packaged boiler remove the large knockout in the jacket top panel 2 On Knockdown boilers install the flue collector coverplate and blanket seal items 10 and 11 on top of the block assembly using four 4 5 16 x 1 1 2 studs nuts and washers provided 3 Mount the flue collar adapter and rope seal items 14 and 12 to either the rear boiler section for a rear flue application or to the flue collector cover plate item 11 for a top flue application Use 5 16 hex head bolts for rear flue outlet and sheet metal screws for top flue outlet 4 Attach the rear outlet cover plate item 13 to the remaining unused opening using four 4 5 16 bolts and washers provided
13. 15 feet high unless otherwise allowed by code If the vent system is not sized properly the burner may not operate properly This can cause poor combustion sooting and odors to occur Background Information Regarding Draft Modern boilers operate with higher efficiencies than older boilers Smaller flueways as well as bars pins and fins are designed into modern boilers to transfer as much heat as possible from the hot gases to the water or steam and prevent heat loss up the chimney However these design features result in higher pressure or draft loss in the boiler This draft loss must be taken into account when installing an oil boiler into a new or old chimney New chimneys are less likely to have poor draft However they must have sufficient draft to support combustion A 06 draft is desirable and preferred Older chimneys may require a replacement liner to have them perform well enough to support combustion PREINSTALLATION For Example Chimnev Draft Old Installation New Installation Comments No change but older chimneys especially unlined ones have leaks which reduce draft Boiler Design Pressure Drop Required for mandated efficiency increases The old installation would have had a higher temperature in the chimney as high as 800 degrees vs 400 degrees F which would increase the draft The above readings are cold readings before the boiler and chimney are
14. DIAGRAM SUPPLIED NOTE ALL WIRING MUST COMPLY WITH APPLICABLE CODES ORDINANCES AND REGULATIONS LINE VOLTAGE LOW VOLTAGE Figure 4 7 Zoning with Zone Valves 12 5 BURNER SETUP amp BOILER OPERATION CAUTION Burn only 2 Fuel Oil in this appliance Do not use gasoline crankcase drainings or any oil containing gasoline A BURNER INSTALLATION 1 The oil burner is supplied with a mounting flange fixed in position 2 Mount the burner to the burner mounting plate item 5 with four 4 5 16 studs and nuts provided NOTICE Be sure high temperature gasket is between the burner mounting flange and the burner mounting plate 3 Care must be taken when routing the oil lines so not to interfere with the opening and closing of the burner mounting plate Flexible oil lines or flared copper disconnects with valves when copper lines are used may be installed to assure full opening of the burner mounting plate when servicing NOTICE Two pipe oil supply for Riello burner requires a separate kit Order part C7001026 from Riello dealer 4 Oil burner specifications For information pertinent to the oil burner such as nozzle sizing fuel supply piping adjusting or servicing refer to the charts in this section and the burner installation manual B BURNER START UP AND ADJUSTMENT CAUTION Do not start the burner unless all cleanout doors are in place 1 Burner should start automatically when thermostat is
15. Damper WBV 03 060 Series 40 0 50 90 B 145 PSI 0 0 2 9 WBV 03 085 Series 40 0 65 60 W8 170 PSI WBV 03 105 Series 40 0 85 60 W 165 PSI WBV 04 095 Series 40 0 75 80 B 160 PSI WBV 04 125 Series 40 1 00 60 W8 155 PSI WBV 04 140 Series 40 1 10 60 W 160 PSI WV 05 175 Series 40 1 35 60 B 165 PSI WV 05 195 Series 40 1 50 60 B 170 PSI Boiler P Model No Burner Series Nozzle Size Pump Pressure Factory Installed Nozzles Packaged Boilers or Burner Cartons are indicated in Boldface 1 Requires Low Firing Rate Baffle 2 Delavan Recommended 3 Shipped Loose with Packaged Boiler or Burner Carton 4 Not included with Packaged Boiler or Burner Carton 15 6 MAINTENANCE WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers Airborne 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 particles become airborne during service 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 when handling these materials P
16. E MOUNT IN BOILER SUPPLY PIPING BOILER SERVICE SWITCH PROVIDED ON KAGED BOILERS FUSED DISCONNECT BY INSTALLER GR 115 60 1 11 POWER 671848 BURNER gt 2 SUPPLY PRIMARY CONTROL CRIMP TERMINATION 3334 08 7248 BURNER LIMIT CONTROL J BOX 4 24 VOLT THERMOSTAT IGNITOR OR BL INTERRUPTED GROUND 4 OPERATING CONTROL TRANSFORMER SCREW Y R 7 BURNER lt D sai 4 BurneR o MOTOR e G lt MOTOR 7 BK BK BK lt BK 0 4 BK L2 o Bi lt CIRCULATOR ADDITIONAL SAFETY VALVE SWITCHES OR FLOAT o Y SUNCTION TYPE L W C O VALVE WHEN REQUIRED CAD Y CELL MOLEX CONNECTOR HEYCO BUSHING IN JUNCTION BOX KNOCKOUT Q lt S T I LINE VOLTAGE LOW VOLTAGE NOTE ALL WIRING MUST COMPLY WITH APPLIANCE CODES ORDINANCES AND REGULATIONS Figure 4 2 Water Boilers Knockdown JOIN WITH NEUTRAL IN
17. SS HEATER OR COVERPLATE 2 If not using a tankless coil cover the heater opening with cover plate item 7 or 16 1 Ifa tankless coil is used item 9 install as pictured On water boilers install in opening in front section NOTICE Be sure rubber gasket is in place On steam boilers install in opening in rear section between cover plate or water heater For suggested piping of tankless water heaters refer plate and boiler section to Figures 3 3 and 3 4 F CONTROLS DANGER Install anti scald device in hot water supply piping Water temperature CAUTION Pipe the discharge of the safety above 125 F can cause severe burns valve or relief valve to prevent injury instantly or death from scalds in the event of pressure relief Pipe the discharge to a drain Provide NOTICE X1019R X1020R and PP1011R piping that is the same size as the coils installed in WBV boilers have relief valve internal flow controls installed Do not use external flow controls 1 Water Boiler Controls with these coils a Install the limit operating control pressure temperature gauge and safety relief valve HICH TENPERATURE See Figure 7 1 Section 7 for proper location HOT WATER For installations subject to UL726 a second operating control that senses water temperature is also required not provided Use an L4080B E or equivalent Install in the supply piping near TANKLESS the boiler 2 Steam Boiler Controls a Install the lim
18. alves isolating zones in the process or use system vents Do not operate the pump s while purging Pumps will hold air in the eye of the impeller 2 Allow the system to reach 180 F and use manual vents if installed to remove any remaining air Watch the pressure gauge as the system approaches 180 F If the pressure exceeds the design operating pressure check a Fill valve pressure b Expansion or compression tank operation and sizing BURNER SETUP amp BOILER OPERATION Do not leave boiler unattended while E CLEAN THE BOILER CAUTION firing burner Operating boiler with STEAM BOILERS ONLY water below minimum permissible 1 Clean the boiler within one week after initial start up Cleaning will be more effective if boiler operates a day or two to loosen sediment and impurities in system Boiler must be cleaned to remove any accumulation of oil arease sludge etc in the system These substances can cause foaming and surging of boiler water producing an unstable water line and water carryover to system WARNING Cleaning the boiler requires the use of very hot water and corrosive 14 chemicals Use care when handling to prevent injury 3 Connect a skim valve off the 1 1 4 NPT skim tapping on front of boiler See WBV Steam Boiler Figure 7 2 Section 7 to locate skim tapping Run a drain line off skim valve to a point of safe discharge Provide a means of supplying continuous fresh water to the boiler
19. ceiling and one near the floor of the boiler room shall be provided with the minimum free area of each opening equal to 35 sq in per gallon of oil burned If ducts are used to convey the air areas of 35 sq in per gallon of oil burned for vertical ducts or 70 sq in per gallon of oil burned for horizontal ducts are to be provided Ducts shall have the same area as the free area of the openings to which they are connected C CHIMNEY VENT AND DRAFT CONTROL An oil fired unit shall be connected to a flue having sufficient draft at all times to assure safe proper operation of the unit Draft Requirement Minimum draft required in the vent system is 03 to 06 W C depending on boiler model see Table 7 1 Section 7 This draft is necessary to provide the necessary draft over fire of 01 to 02 W C See discussion in paragraph 5 below regarding draft A barometric draft control is recommended for regulation of overfire draft Follow manufacturer s instructions to locate and adjust the control Inspect the existing chimney or vent system Make sure it is in good condition Inspect chimney liner and repair or replace if necessary The vent system and installation must be in accordance with the current edition of the American National Standard ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances or applicable provisions of the local building codes Typical minimum chimney size is 8 x 8
20. ction box Right 2 9 for mounting relief valve in standard Rear Vent Pipe Single Wall 9 to Combustible Construction Clearance may be reduced using methods in NFPA 31 Vent Pipe Double Wall See Manufacturer s Instructions Consider also vent pipe clearance including distance from edge of flue outlet to combustible construction as applicable See dimensional drawing for alternate relief valve location Unit may be installed on combustible flooring provided the boiler is not set on carpet and a metal drip pan is placed under the appliance Unit may be installed in a closet with the above clearances See also Section B Air for Combustion and Ventilation location b For installation in unconfined spaces with conventional construction and larger areas such as basements the supply of air for combustion and ventilation can usually be considered adequate 3 Appliances Located in Confined Spaces a All air from inside the building Provide two permanent openings communicating directly with an additional room If all air for combustion and ventilation is to come from within the building two openings one near the ceiling and one near the floor of the boiler room shall be provided with the minimum free area of each opening equal to 140 sq in per gallon of oil burned If all air for combustion and ventilation is to come from outside the building two openings one near the
21. derable foreign matter in the boiler water the boiler should be shut down and allowed to D MAINTENANCE OF SAFETY RELIEF cool then drained and thoroughly flushed out Drain VALVE the boiler at the drain cock Pipe the drain cock to a suitable drain or containment device if antifreeze is 1 Check function and maintain safety relief valve as used Flush the system to remove remaining matter specified by manufacturer typically every other If there is evidence that hard scale has formed on the month or every month per the instructions on the internal surfaces the boiler should be cleaned by tag on the safety relief valve chemical means as prescribed by a qualified water treatment specialist E MONTHLY MAINTENANCE WITH BOILER OPERATING 3 There must be no signs of continuous wetness at the chimney If signs of continuous wetness are e 1 Check boiler room floor drains for proper observed a qualified service agency must be functioning consulted to modify the vent configuration to prevent g the formation of condensate which may damage the 2 Test probe type low water cut off if used by using vent pipe the Push to Test Button WARNING Do not use this appliance if any part has been under water Improper or CAUTION Turn off power to boiler before dangerous operation may result adjusting limit control Immediately call a qualified service 3 Test limit by lowering the limit set point until the technician to inspec
22. e Boiler from Chilled Medium on Chiller Systems Figure 3 7 Float Low Water Cut off A PORT TO TANK THREE WAY VALVE LXI S ECT DOMESTIC HOT WATER SUPPLY B PORT To SYSTEM S DIIS 7 COLD WATER SUPPLY RETURN FROM SYSTEM DOMESTIC HOT WATER STORAGE TANK INTERNAL COIL BOILER CIRCULATOR Figure 3 6 Piping with Peerless Indirect Water Tank 4 ELECTRICAL GENERAL 3 Install burner harness located in the burner carton All electrical wiring shall be done in accordance with the Beckett or Carlin Mir Harness National Electrical Code and Local Requirements Single 11 1 2 conduit pole switches including those of safety controls or Riello PP7023 Harness 17 1 2 conduit protective devices shall not be wired in a grounded line 4 For complete information on servicing and adjustment of controls refer to the attached control specification sheets 1 See Section 5 for mounting burner 5 See the following Wiring Diagrams 2 Install junction box limit harness and Heyco bushing each located in the trim carton See Figure Figure 4 2 Water Boilers Knockdown 4 1 Mount junction box to the holes in the right side Figure 4 3 Water Boilers Packaged of jacket with 2 10 x 1 2 sheet metal screws Figure 4 4 Steam Boilers with Float LWCO Attach Heyco bushing to 7 8 knockout in left side of junction box Connect limit harness to 7 8 knockout Figure he Steam Boilers with Probe LWCO
23. eam Gauge Aquastat Pressuretrol Drain Valve Relief Valve Water Pop Safety Valve Steam Additional Information Specify Size Specify Size Specify Size Specify Size 4 or 5 Section 3 Section Water Only 4 amp 5 Section Water Only 3 amp 4 Section Steam Specify Size Specify Size 5 Section Only Specify Steam or Water Specify Size Specify Size Specify Brand Name 21 NOTES 22 NOTES 28 Series WBV WV Oil 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 2 Service Information Name Address PeerlessBoilers com HEAT LLC 131 S CHURCH ST BALLY PA 19503 Phone Oct member tse US HI Division ASME of gama 2008 PP8046 R26 8 08 10 Printed in U S A
24. for the cleaning process Use common washing soda such as Arm and Hammer Super Washing Soda Mix 1 2 pound of soda with water in a 10 quart pail Pour the mixture into the boiler through the safety relief valve tapping Open the skim valve Fill boiler until water begins to flow out of the valve water level may fracture sections 7 Turn on burner Allow boiler water to heat up to just below steaming 180 200 Do not allow boiler to steam steaming mixes up contaminants instead of floating them at surface 8 Open make up water valve to continually feed water to boiler Adjust flow to maintain water temperature at 180 200 F CAUTION Do not allow make up water to flow too fast Excessive quantities of cold water may fracture sections 9 Continue skimming boiler until water flowing from skim tapping flows clear This will take some time possibly several hours for a dirty system 10 Turn off burner close make up water valve 11 Drain boiler completely Refill and drain one or two times to wash out all washing soda 12 Remove skim valve and piping Install 1 1 4 NPT plug in skim tapping NOTICE If gauge glass becomes dirty more contaminants have worked loose in system Repeat cleaning and skimming process as needed to clean system BURNER SETUP amp BOILER OPERATION Table 5 1 Beckett Burner Specifications BECKETT BURNER SPECIFICATIONS Boiler Burner Burner Pump Start up Settings Head
25. g a Partner indirect fired water heater or other see Figure 3 6 for typical piping Also refer to additional instructions supplied with the Partner 6 If the boiler is to be used in conjunction with a refrigeration system the chilled medium shall be piped in parallel with boiler and proper valves applied to prevent the chilled medium from entering the boiler Refer to Figure 3 5 7 Ifthe boiler is connected to heating coils located in air handling units the boiler piping system must be equipped with flow control valves or other automatic devices to prevent gravity circulation of the boiler water during the cooling cycle D STEAM BOILER PIPING 1 Refer to the Steam Installation Survey and Hydronics Institute Residential Hydronic Heating Installation Design Guide for assistance 2 See table below for pipe sizing The return loop from system should always enter equalizer through the Hartford Loop 2 to 4 below normal water line See Figure 3 2 WBV 03 WBV 04 1 2 1 2 or3 or3 1 1 4 1 1 4 3 Use swing joints to attach header to avoid damage to the boiler due to thermal expansion and contraction of steam header pipe 4 Pipe the steam header a minimum of 24 above the normal water line using swing joints to attach the risers into the steam header HEADER B C EQUALIZER RISER A MAKE UP CONNECTION Figure 3 2 Steam Boiler Piping PIPING AND CONTROLS E TANKLE
26. it operating control pressure MIXED WATER gauge gauge glass trim and safety relief valve See Figure 7 2 Section 7 Figure 3 7 float boilers and cover photo probe boilers 3 4 CONTROL TAPPING 12 MIN FLOW CONTROL b For installations subject to UL726 a second operating control that senses steam pressure is T required not provided Use a PA404A or equivalent On probe boilers install the WATER MIXER additional pressure control opposite the standard PA404A using a cross instead of a tee along with a second brass siphon not Figure 3 3 Tankless Coil Piping Steam Boiler provided On float boilers install the additional pressure control in the 1 4 tapping on the top of the float low water cut off using a vertical 3609 brass siphon not provided 2 zo im 4 TANKLESS HIGH TEMPERATURE TEMPERATURE HEATER c For application of a probe low water cut off HOT WATER bocca parcel use only Hydrolevel CG450 See Figure 7 2 3 4 CONTROL Section 7 for location See also control XD JTAPPING manufacturers instruction sheet d See Figure 3 7 for application of float low water cut offs 3 For complete information on servicing and FLOW adjustment of controls refer to the attached control CONTROL specification sheets WATER MIXER COLD WATER INLET Figure 3 4 Tankless Coil Piping Water Boiler PIPING AND CONTROLS CHECK VALVE Figure 3 5 Piping to Isolat
27. nsive piping systems etc Heating Capacity and Annual Fuel Utilization Efficiency AFUE ratings are based on U S Government tests with 13 and 0 02 w c draft over fire Before purchasing this appliance read important information about its estimated annual energy consumptions or energy efficiency rating that is available from your retailer Chimney Size 8 x 8 x 15 ft REPAIR PARTS 8 REPAIR PARTS Repair parts are available from your installer or by contacting PB Heat LLC 131 S Church St Bally PA 19503 Note Remember to include boiler model number and serial number when ordering parts Table 8 1 Item No Stock Code 90141 51673 PP5011 See Figures 2 1 amp 2 2 on page 5 for boiler exploded view Description Block Assembly Water Open Block Assembly Water Closed Block Assembly Steam Open Block Assembly Steam Closed Target Wall Base Liner Swing Door Hinge Burner Mounting Plate Assembly Burner Mounting Plate Insulation Burner Mounting Plate Rope Seal Steel Cover Plate Front Water Steel Cover Plate Front Steam Rubber Gasket Front Steam Tankless Coil Flue Collector Plate Blanket Seal Flue Collector Cover Plate Top Outlet Flue Collector Plate Rope Seal Rear Outlet Cover Plate Flue Collar Adapter Jacket Assembly Water Jacket Assembly Steam Steel Cover Plate Rear Rubber Gasket Rear Section Plate Flue Outlet Gasket Oil Burner Temperature Pressure Gauge St
28. o LWCO 9 7 8 26 1 2 oproNaL 35 TANKLESS HEATER 9 9 16 LINE 1 1 4 ALTERNATE 1 174 RETURN 13 3 4 a RETURN OR DRAIN APPROX REAR WBV 03 085 110 RIGHT SIDE Jacket Depth A 15 3 4 Rear of Jacket to C L of Top Flue Outlet B 8 7 8 WBV 04 125 150 Figure 7 2 Boiler Dimensions Steam Boiler 19 3 4 10 7 8 19 BOILER DIMENSIONS amp RATINGS Table 7 1 Boiler Ratings Series WBV WV Heating ra Capacity Water Content Minimum Stack B i 4 MBH Net I B R Ratings gal Draft Steam Steam Water Required Water Steam sqft MBH MBH Water Steam in W C RWNH 91 20 As an ENERGY STAR Partner PB Heat LLC has determined that these firing rates meet the ENERGY STAR guidelines for energy efficiency Top venting only Nozzles for these firing rates not provided as standard equipment Consult factory for price and availability This firing rate can only be achieved with a Riello F 3 burner See Table 5 3 Burner input based on No 2 fuel oil with a heating value of 140 000 Btu per gallon Net I B R water ratings based on an allowance of 1 15 Net I B R steam ratings based on an allowance of 1 333 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements such as intermittent system operation exte
29. or secure the switch so that the power cannot be turned on accidentally 2 Be certain that the boiler and system are refilled before returning to service CAUTION Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time BOILER DIMENSIONS amp RATINGS 7 BOILER DIMENSIONS amp RATINGS SAFETY RELIEF VALVE OR AIR ELIMINATION 8 5 16 2 11 16 3 1 16 np WBV 03 085 110 96 REAR FLUE WBV O3 WBV 04 ONLY VALVE Md LINE ALTERNATE 3 4 DRAIN VALVE REAR Boiler Model Number 14 1 8 13 3 4 APPROX LEFT SIDE Rear of Jacket to C L of Top Flue Outlet B 7 1 16 1 1 2 SUPPLY OPTIONAL TANKLESS HEATER LIMIT 4 TEMPERATURE PRESSURE Top Flue Size C WBV 04 125 150 18 1 8 9 1 16 WV 05 175 200 22 1 8 Figure 7 1 Boiler Dimensions Water Boiler 11 1 16 11 4 RETURN 221 8 p ALTERNATE 2 SUPPLY 26 SAFETY VALVE TOP m 16 LIMIT AND FLUE T 4 7 8 8 5 16 7 2 11 16 PRESSURE gt GAUGE SAFETY VALVE i 1 2 GAUGE GLASS 6 FLOAT LWCO REAR W L 11 4 T gt SKIM o O VALVE PROBE r
30. proximately thirty 30 psig pressure Check to make certain that all joints and fittings are water tight 4 After all joints and connections have been proven tight remove cold water supply and plugs from all tappings that are to be used See Figures 7 1 and 7 2 Section 7 for tapping locations B BOILER RETURN CLEARANCE Return piping must allow for opening and closing Burner Mounting Plate PB Heat LLC suggests installing a 1 1 4 NPT tee a 90 elbow and a 1 1 4 NPT x 5 long nipple in the return tapping before a vertical stand pipe is used C WATER BOILER PIPING 1 Refer to the Water Installation Survey and Hydronics Institute Residential Hydronic Heating Installation Design Guide for guidance 2 The supply and return connections should be sized to suit the system A 1 1 2 to 1 1 4 reducing coupling may be used where the system piping is 1 1 2 3 The supply should be out the top of the back section and return to the bottom of the front section as shown in Figure 3 1 There is a 3 4 tapping in the top of the back section for air elimination Figure 3 1 Water Boiler Piping 6 4 When the return temperature from the system will be below 150 F on oil boilers for extended periods heat pump systems outdoor reset snow melt etc provide piping and controls to protect the boiler from condensation Condensation will damage the boiler and will lead to shortened boiler life and maintenance problems 5 If usin
31. recautionary 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 MAINTENANCE Fw s MAINTENANCE WITH BOILER OPERATING 1 Check pipes adjacent to cold walls or in unheated spaces Insulate and tape them if necessary to be 1 Flush float type low water cut off if used to remove sure they can t freeze up Keeping the water moving sediment from the float bowl as stated in the at all times will reduce the likelihood of freezing manufacturer s instructions 2 If there is consi
32. rk It will save time Study the included drawings Save these instructions for reference 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 shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made including the current edition of NFPA 31 Standard for the Installation of Oil Burning Equipment and in Canada CSA B139 Installation Code for Oil Burner Equipment These shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made Never burn garbage or paper in the unit and never leave combustible material around it CAUTION Do not tamper with boiler controls B AIR FOR COMBUSTION AND VENTILATION 1 Be certain adequate facilities are available to provide air for satisfactory combustion and ventilation 2 Appliances Located in Unconfined Spaces A CLEARANCES Table 1 1 Clearances from Jacket and Vent System Required from Jacket to Combustible Construction Dt 16 5 PE Recommended From Jacket for Accessibility and Mounting Controls Top 24 to clean flueways Front Left 16 5 from jacket due to burner 12 due to burner swing radius 18 on steam with tankless heater or with Float LWCO 9 in area of boiler service switch and jun
33. t the boiler and burner shuts down When proper operation is to replace any part of the control confirmed return the set point to original setting system and any control which has been under water 4 Follow additional instructions in the Burner Manual i th t tion B DAILY MAINTENANCE WITH BOILER OPERATING MAINTENANCE ANNUAL Daily boiler observation can be performed by the owner If any potential problems are found a qualified installer NOTICE Entire heating system including or service technician agency must be notified boiler burner and venting system must be inspected at least once a year by a qualified heating professional Boiler is to be cleaned at least once a year 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 Disconnect all power to the burner there are no obstructions to the free flow of air to WARNING before accessing combustion and from the boiler chamber 2 Observe general boiler conditions unusual noises vibrations etc TO CLEAN 1 Remove top jacket panel and flue collector cover 3 Observe operating temperature and or pressure a d plate Item 11 Figure 2 1 or 2 2 gauge on the boiler Boiler pressure should never be higher than 5 psi below
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