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DE Boilers Series Gas Installation, Operation & Maintenance Manual[...]

ii USING THIS MANUAL 1 A . INST ALLA TION SEQUENCE . . . . . . . . . . . . .1 B . SPECIAL A TTENTION BO XES . . . . . . . . . . . .1 1. PREINST ALLA TION 2 A . ACCESSIBILITY CLEARANCES . . . . . . . . . . .2 B . CLEARANCE FROM COMBUSTIBLE CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . .2 C. AIR FOR COMBUSTION AND VENTILA TION . . . . . . . [...]

1 A. INST ALLA TION SEQUENCE F ollow the installation instructions provided in this manual in the order shown. The order of these instructions has been set in order to provide the installer with a logical sequence of steps that will minimize potential interferences and maximize safety during boiler installation. B. SPECIAL A TTENTION BO XES Through[...]

2 A. ACCESSIBILITY CLEARANCES Install boiler not less than 24 ″ (610 mm) between the left side, top, and front of the boiler and adjacent wall or other appliance, when access is requir ed for ser vicing. B. CLEARANCE FROM COMBUSTIBLE CONSTRUCTION The design of this boiler is cer tified for closet installation with the following clearances: 1. 6 ?[...]

3 where: I fan = Input of the fan assisted appliances in Btu/hr ACH = air change per hour (per cent of the volume of the space e xchanged per hour , expr essed as a decimal) F or appliances other than fan assisted, calculate the requir ed volume of air using the following equation: I other = Input of appliances other than fan assisted in Btu/hr Not[...]

4 ii. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free ar ea of 1 in 2 per 2000 Btu/hr (22 cm 2 per 2000 W) of total rated input for all appliances in the space. See Figur e 1.5. b. One P er manent Opening Method: Provide one permanent opening beginning within 12 inches (305 mm) of the top of th[...]

5 c. Each of the appliances ser ved shall be interlocked to the mechanical air supply to prevent main burner operation where the mechanical air supply system is not in operation. d. In buildings wher e the combustion air is provided by the mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the r[...]

6 BOILER SET -UP 1. Provide a sound, level foundation. Locate boiler as near to the chimney or outside wall as possible and centralized with respect to the heating system. 2. Locate boiler in front of installation position before removing crate. 3. If using combustible floor pan, position pan on foundation or flooring. 4. Separate the wood shipping[...]

7 A. BOILER SUPPL Y AND RETURN 1. Size the supply and return to suit the system. A typical piping arrangement is shown in Figure 3.1. Refer also to the I=B=R Guide to Residential Hydronic Heating Installation/Design and the PB Heat, LLC W ater Sur vey for additional guidance during water piping installation. 2. Return Piping: a. P ipe the outlet co[...]

8 6. Install this boiler so that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and ser vice (circulator r eplacement, condensate trap, control replacements, etc.). 7. If this boiler and distribution system is used in conjunction with a refrigeration system, pipe the chilled medium [...]

9 C. PIPING FOR ZONED SYSTEMS 1. See Figur es 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 requir ed, provide means to isolate and drain each zone separately . Figure 3.5: Zone P iping with Zone V alves Figure 3.6: Zone P iping with Circulators WA TER PIPING AND [...]

10 D . EXP ANSION T ANK 1. Consult the tank manufacturer ’s instructions for specific information relating to tank installation. Size the e xpansion tank for the requir ed system volume and capacity . See T able 10.2 in Section 10 for boiler water capacity . 2. Expansion tanks are available with built-in fill valves and check valves for reducing [...]

11 A. GENERAL 1. Install vent system in accordance with the "V enting of Equipment" Chapter of the National F uel Gas Code , ANSI Z223.1/NFP A 54, the "V enting Systems and Air Supply for Appliances" Section of the CAN/CSA B149.1, Natural Gas and P ropane Installation Code . or applicable provisions of the local building codes. [...]

12 2. Refer to T able 4.2 for minimum and maximum vent length allowed. 3. Maintain a minimum 2” (51 mm) clearance between vent pipe and combustible construction. 4. When installing vent pipe through a combustible wall, pipe must pass through a metal wall thimble; maintain a 2” (51 mm) clearance between vent pipe and thimble. F ollow thimble man[...]

13 VENTING Figure 4.2: Direct Exhaust, Sidewall V enting with V ertical Off-Set Figure 4.3: V ent Pipe Adapters[...]

14 D . DIRECT EXHAUST ; VERTICAL VENTING 1. This vent system will operate with a positive pressur e in the vent pipe. F ollow vent pipe manufacturer’s instructions for proper assembly of vent pipe and fittings. 2. Refer to T able 4.2 for minimum and maximum vent length allowed. 3. Maintain a minimum 2” (51 mm) clearance between vent pipe and co[...]

15 VENTING E. BOILER REMO V AL FROM COMMON VENTING SYSTEM At the time of r emoval 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. Seal any unused openings in the co[...]

16 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 pressur e between the meter and the boiler . 2. Determine the volume of gas to be provided to the boiler in cubic feet per hour . T o obtain this value, divide the Btu per hour rating (on the boiler r[...]

17 T able 5.3: Pipe Capacity Capacity of pipe of different diameters and lengths in cubic feet per hour [cubic meter per hour] with a pressur e drop of 0.3 inches of water [75 kP a] and a specific gravity of 0.60. No allowance for an ordinary number of fittings is requir ed. T able 5.1: Natural Gas Based on 1000 Btu/Cubic Ft. T able 5.2: LP Gas Bas[...]

18 A. WIRING 1. See Figur e 6.1 for location of wiring and controls. Use Figur e 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. 3. Adjust the thermostat heat anticipator to 0.2 Amp. B. ZONED SYSTEM WIRING See Figu[...]

19 D . SEQUENCE OF OPERA TION 1. Thermostat calls for heat, energizes Control Relay (CR). 2. Control Relay (CR) energizes circulator . 3. Limit senses boiler water temperature. P revents boiler operation until water temperature falls appro ximately 15 ° F (8 ° C) below the cut-out temperature. 4. Limit energizes F an and Isolation Relay (IR). 5. [...]

20 Figure 6.3: Ignition System Operating Sequence ELECTRICAL[...]

21 ELECTRICAL Figure 6.4: Zone Wiring with Zone V alves Figure 6.5: Zone Wiring with Circulators[...]

22 A. COMPLETING THE INST ALLA TION 1. Confirm that all water , gas and electricity are turned off. 2. Inspect the boiler combustion chamber for foreign objects and remove if pr esent. 3. Check physical condition of burners and pilot. Make cer tain that ther e are no unusual bends or perforations in the bur ners or pilot. Replace components if nece[...]

23 Figure 7.1: Gas V alve, Manifold and Burner Assembly – Intermittent Ignition Figure 7.2: V alve T apping and Adjustment Screw Locations ST ART -UP PROCEDURES[...]

24 ST ART -UP PROCEDURES Figure 7.3: Operating Instructions SV9501/SV9601 9318 REV 2 (MM/YY) FOR YOUR SAFETY READ BEFORE LIGHTING W ARNING: If you do not follow these instructions exactly , a fire or explosion may result causing property damage, personal injury , or loss of life. OPERA TING INSTRUCTIONS TO TURN OFF GAS T O APPLIANCE 1. Set the ther[...]

25 B. CONTROL DESCRIPTIONS See Figur e 6.1 in Section 6 (Electrical) for locations of these devices. 1. FLAME ROLL-OUT SAFETY SHUT -OFF SWIT CH (FLAME ROLL-OUT SWIT CH) – A ther mally activated switch located between the first burner from the left and the manifold bracket. The flame roll-out safety shut-off switch will sense e xcessive temperatur[...]

26 E. CHECK - OUT PROCEDURE 1. After star ting the boiler , be cer tain all controls are working properly . Check to be sure that the limit will shut off the boiler in the event of e xcessive water temperature. This can be done by lowering the limit setting until the main burners shut down. When proper limit function is confirmed, return the dial t[...]

27 3. Low W ater Cut-Off (if used) – Consult the manufacturer ’s instructions for the low water cut-off operational check procedure. 4. Check the system to make sure ther e are no leaks or overfilling problems which might cause excessive make-up water to be added. Make-up water causes liming in the boiler and brings in o xygen. Oxygen can cause[...]

28 A. SHUT -DOWN CAUSED B Y PIL OT OUT AGE, PRESSURE SWITCH OR FLAME ROLL-OUT SAFETY SHUT - OFF SWITCH In the event of a shut-down caused by a pilot outage, action of the pressur e switch or flame roll-out safety shut-off switch effecting a shut-down of the main burners: a. Refer to the Operating Instructions in Figure 7.3 to properly turn off the [...]

29 TROUBLESHOOTING Figure 8.1: P rocedure For Measuring F an Suction Pressure SEE T ABLE 7[...]

30 TROUBLESHOOTING T able 8.2: Boiler T roubleshooting Guide (Burners Functioning) Problem P ossible Causes Cor rective A ctions 1. See Figur e 8.2 Burners not functioning. 1. See Figur e 8.2 1. Defective gas valve. 2. Short circuit. Burners will not shut down. 1. Use Figur e 8.2 to troubleshoot inter mittent ignition gas valve. Replace if necessar[...]

31 Figure 8.2: Boiler T roubleshooting Guide (Burners Not Functioning) TROUBLESHOOTING[...]

32 MAINTENANCE 9. MAINTENANCE W ARNING Product Saf ety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fiber s (RCF). Airborne RCF , when inhaled, have been classified b y the International Agency for Resear ch on Cancer (IARC), as a possible carcinogen to humans. After the RCF materials h[...]

33 A. GENERAL 1. Disconnect this boiler from the gas supply piping during any pressur e testing of the gas system. 2. Check pipes adjacent to cold walls or in unheated spaces. Insulate and tape them if necessary to be sure they can ’t freeze up. Keeping the water moving at all times will reduce the likelihood of fr eezing. See Section 3 for antif[...]

34 E. ANNU ALL Y (BEFORE ST ART OF HEA TING SEASON) 1. Check flueways and burners for cleanliness and clean if necessary . Use the following procedure if cleaning is requir ed: a. Refer to the Operating Instructions in F igure 7.3 to properly turn off the gas to the boiler . b. T ur n off all electrical power to the boiler . c. Remove bur ners and [...]

35 BOILER DIMENSIONS & RA TINGS 10. BOILER DIMENSIONS & RA TINGS Figure 10.1: Boiler Views T able 10.1: Series DE Boiler Ratings 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 requir ements, such as inter mittent system operation, extens[...]

36 REP AIR P ARTS Figure 11.1: Block/Base/Floor Pan/Jack et/Flue Collector REP AIR P ARTS SERIES DE GAS BOILER Repair par ts are available from your installer or by contacting PB Heat, LLC, New Berlinville, P A. Use the figures and tables on pages 36-38 to assist in ordering parts. Note: Remember to include boiler model number and serial number whe[...]

37 REP AIR P ARTS Figure 11.2: Base/Burners/Manifold[...]

38 REP AIR P ARTS T able 11.1: Repair Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Block Assembly Base Assembly Observation Cover Door Base Blanket Seal Combustible Floor P an Assembly Steel Burner w/Pilot Clip Steel Burner Gas Manifold Orifice Spud, #48 Orifice Spud, #49 Orifice Spud, #56 Flame Rollout Safety Shut Off Switch Flue Collector/F an[...]

39 NOTES[...]

40 NOTES[...]

DE Boilers Series Gas Installation, Operation & Maintenance Manual TO THE INST ALLER: 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. DE8022 R8 (5/07-3M) Printed in U .S.A. ©2007 PB HEA T , LLC PO BOX 447 •[...]