PB Heat TC Series, TC-04, TC-05, TC-06, TC-07 Installation, Operation & Maintenance Manual

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Page 1

™

Gas/Oil Boilers

Series

Oil, Gas &

Installation, Operation & Maintenance Manual

Page 2

USING THIS MANUAL 1

A. MANUAL ORGANIZATION . . . . . . . . . . . . . .1

B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1

1. PREINSTALLATION 2

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

B. CODES & REGULATIONS . . . . . . . . . . . . . . .2

C. BOILER LOCATION . . . . . . . . . . . . . . . . . . . . .2

D. COMBUSTION & VENTILATION AIR . . . . . . .3

E. CHIMNEY & BREECHING. . . . . . . . . . . . . . . .3

F. BOILER FOUNDATION . . . . . . . . . . . . . . . . . .4

G. INSTALLATION SURVEY . . . . . . . . . . . . . . . .5

H. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .6

I. VERIFY COMPONENTS . . . . . . . . . . . . . . . . . .6

2. BOILER ASSEMBLY 9

A. PACKAGED BOILERS . . . . . . . . . . . . . . . . . . .9

B. ASSEMBLED BLOCKS . . . . . . . . . . . . . . . . . .9

C KNOCKDOWN BOILERS . . . . . . . . . . . . . . . .9

D. HYDROSTATIC TESTING . . . . . . . . . . . . . . .13

E. CLEAN-OUT COVER INSTALLATION . . . . .13

F. BURNER MOUNTING PLATE . . . . . . . . . . .14

G. REAR OBSERVATION PORT . . . . . . . . . . . .14

H. FLUE COLLECTOR INSTALLATION . . . . . . .15

I. BURNER MOUNTING . . . . . . . . . . . . . . . . . .15

3. INSTALLATION 16

A. PREPARATION . . . . . . . . . . . . . . . . . . . . . . .16

B. STEAM BOILER PIPING . . . . . . . . . . . . . . . .16

C. MULTIPLE STEAM BOILER PIPING . . . . . . .17

D. WATER BOILER PIPING . . . . . . . . . . . . . . . .17

E. MULTIPLE WATER BOILER PIPING . . . . . . .21

F. TANKLESS HEATER INSTALLATION . . . . . .21

G. JACKET PREPARATION . . . . . . . . . . . . . . . .22

H. JACKET ASSEMBLY . . . . . . . . . . . . . . . . . .22

I. FUEL PIPING . . . . . . . . . . . . . . . . . . . . . . . . .23

J. INSTALL CONTROLS AND TRIM . . . . . . . .24

4. OPERATION 28

A. STARTING THE BOILER . . . . . . . . . . . . . . . .28

B. CLEANING BOILER WATERWAYS . . . . . . .29

5. MAINTENANCE 30

6. REPAIR PARTS 32

7. BOILER RATING & DIMENSIONS 34

TABLE OF CONTENTS

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A. MANUAL ORGANIZATION

The Series TC™ Installation, Operation & Maintenance Manual is divided into five basic sections:

1. Preinstallation (Sections A through I)

2. Boiler Assembly (Sections A through I)

3. Installation (Sections A through J)

4. Operation (Section A through B)

5. Maintenance

B. SPECIAL ATTENTION BOXES

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 the PB Heat, LLC:

Indicates special attention is needed, but not directly related to potential personal injury or property damage.

NOTICE

Indicates a condition or hazard which will or can cause moderate personal injury or property damage.

CAUTION

DANGER

Indicates a condition or hazard which will cause severe personal injury, death or major property damage.

USING THIS MANUAL

Indicates a condition or hazard which may potentially cause severe personal injury, death or major property damage.

WARNING

Page 4

A. GENERAL

Series TC™ boilers are supplied completely knocked down for field assembly, completely assembled as packaged boilers or as assembled blocks of cast iron sections. All items should be inspected for damage upon receipt and any damage reported to wholesaler and trucking company. All components should be stored in a clean, dry area.

Carefully read these instructions, burner instructions, and control instructions before beginning work. This boiler must be installed by a qualified contractor. The boiler warranty may be voided if the boiler is not installed correctly.

B. CODES & REGULATIONS

1. All work is to be peformed in strict accordance with the requirements of state and local regulating agencies and codes dealing with boiler installations.

2. In the absence of such local requirements, the following codes should be followed:

ASME B & PV Code, Section IV – "Heating Boilers"

ASME B & PV Code, Section VI – "Care and Operation of Heating Boilers"

ANSI/NFPA 31 – "Installation of Oil Burning Equipment"

ANSI Z223.1 – "National Fuel Gas Code"

ANSI/NFPA 70 – "National Electric Code"

ASME CSD-1 – "Controls & Safety Devices for Automatically Fired Boilers"

ANSI/NFPA 211 – "Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances"

3. In Canada, the following codes should be used in addition to those in Section 1.B.2.

CAN1.3.1-77 (R1996) – "Industrial and Commercial Gas Fired Package Boilers”

CSA B140.0-M87 – "General Requirements for Oil Burning Equipment"

CSA B140.7.2-1967 – "Oil-Fired Steam and Hot Water Boilers for Commercial and Industrial Use"

CAN/CSA C22.2 No.0-M91 – "General Requirements – Canadian Electrical Code Part II

CSA C22/2 No.3-M1988 – "Electrical Features of Fuel Burning Equipment"

C. BOILER LOCATION

1. Locate the boiler close to the chimney to minimize the breeching length, but allow adequate clearance for piping, service, maintenance, and tankless coil replacement. A clearance of 36" [914 mm] on all sides of the boiler and 48" [1219 mm] in front of the boiler is recommended for serviceability.

PREINSTALLATION

1. PREINSTALLATION

WARNING

Do not install this boiler on carpeting. A significant fire hazard could result, with potential for property damage, personal injury or death.

Figure 1.1: Clearance Requirments

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2. The minimum clearances to combustible materials, based on ANSI/NFPA 31 are as follows. See Figure 1.1.

Right Side: 6 inches [152 mm]

Left Side: 24 inches [610 mm]

Rear of Jacket: 6 inches [152 mm]

Front of Boiler: 24 inches [610 mm]

Top of Jacket: 6 inches [152 mm]

Vent/Chimney/Flue Collector: 9" [229 mm]

D. COMBUSTION & VENTILATION AIR

1. Provide adequate air for combustion and ventilation.

2. Unless the boiler room construction and natural air infiltration supply all necessary combustion air, provide an outside air opening or duct. The free cross-sectional area of the opening or duct shall meet or exceed 1 square inch [645 square millimeters] per 4000 Btu/hr [1.17 kW] input for all installed appliances. At altitudes greater than 2000 feet [610 meters] above sea level, this requirement is to be increased by 4% per each thousand feet [304 meters] above sea level.

Example: at 5000 feet above sea level.

Free Area = 1 + (0.04 x 5)

Free Area =

1.20 sq. in.

Free Area =

4000

Btu/hr

Example: at 1500 meters above sea level.

Free Area = 1 + (0.04 x

1500

)

Free Area = 1 + (0.04 x

304

Free Area = 1.2 x 645 =

772 sq. mm

Free Area = 1 + (0.04 x

1.17 kW

3. The boiler room must never be under negative pressure. If exhaust fans or other equipment that can potentially cause a negative pressure are used, the air openings must be engineered to assure a neutral or slightly positive pressure in the boiler room at all times of operation.

a) If the equipment design and air openings cannot

assure this, the boiler must be located in a room isolated from these appliances.

b) If the vent system terminates in any area where

wind-generated down drafts are likely, install a suitable vent cap which can control wind effects.

4. If motorized dampers are used on the combustion and ventilation air openings they must include an interlock device that prevents the boiler from operating if they do not open. See Figure 1.2 for this configuration.

E. CHIMNEY & BREECHING

1. Vent System Inspection:

a) Inspect the existing chimney or vent system.

Look for damage due to corrosion or other causes. Make sure the vent system is in good condition and all vent connectors and chimneys are properly supported.

b) Inspect the chimney liner and repair or replace as

necessary.

2. Vent System Sizing:

a) The vent system must be sized and installed to

remove all combustion products. If the vent system is not sized properly, the burner may not operate correctly. This may cause poor combustion or sooting.

b) The breeching connection between the boiler

and chimney should be as short as possible with a minimum number of elbows.

c) Breeching Diameter:

The breeching must be the same diameter as the boiler outlet for Model TC-04 through TC-16 and 18" [457 mm] diameter for Model TC-17 & TC18 Boilers.

The vent sizes for all Series TC™ Boilers are listed in the "Ratings and Dimensions" section of this manual.

d) If extreme length, excessive elbows, or a

reduction in diameter is necessary, consult your PB Heat representative for recommendations.

PREINSTALLATION

Figure 1.2: Motorized Vent Damper Interlock

WARNING

If this boiler is to be installed on combustible flooring, consult local building authorities for proper installation, or in the absence of regulations consult ANSI/NFPA 31 – "Installation of Oil Burning Equipment." Failure to comply with this warning may result in a fire, severe personal injury or death.

Page 6

3. Vent System Installation: a) 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 local building codes.

b) Vent Terminations:

1. Vent terminations must be extended to three feet above expected snow accumulation. See Figure 1.3.

2. If the vent system terminates in any area where wind-generated down drafts are likely, install a suitable vent cap to help control wind effects.

c) Vent Connection Support

1. Support the vent system independently of the boiler flue connection.

2. Provide support of the vent connector (breeching) at maximum 12 foot [3.66 meter] intervals to prevent sagging.

d) Horizontal runs of vent are to be sloped back

toward the boiler at approximately ¼" per foot [2 cm per meter].

e) Breeching used with forced draft boilers must be

sealed, of heavy gauge construction and must comply with all applicable codes of construction.

f) Exterior Vents: Insulate vent pipes that pass

through unheated spaces sufficiently to prevent excessive condensation and ensure adequate draft.

g) Multiple Appliances: Do not vent multiple

appliances with venting that operates under positive pressure into a common chimney or vent connector. This may cause products of combustion to circulate into the boiler room when one of the appliances is not operating.

h) Draft Regulator: Install a barometric draft

regulator when using a high chimney or any high draft vent.

1. This is necessary to prevent negative draft conditions in the boiler.

2. Excessive draft will cause flame lifting, poor combustion, or impingement.

4. Vent System Operation: a) This boiler is designed to fire only with a

pressurized combustion chamber. The breeching and vent may be sized for negative, neutral, or positive pressure as desired.

b) Maintain maximum of +0.1 inches [2.5 mm] of

water at the boiler outlet.

c) Avoid excessive negative pressure in the

combustion chamber. This may cause the flame to lift off of the burner causing unstable combustion. In addition, this may cause impingement of the burner flame onto the crown sheet, which may lead to overheating.

F. BOILER FOUNDATION

1. If the boiler room floor is not level or if additional

structural support is required, provide a level concrete foundation pad for the boiler. The flooring and structural support system must be suitable for the operating weight of the boiler and any connected piping.

a) Figure 1.4 shows the Foundation Layout for

Knocked-Down Boilers and Packaged Boilers.

b) Dimensions for the foundation are given in Table

1.1a and 1.1b.

2. Do not operate the boiler until the foundation, if

newly poured concrete, has thoroughly cured. Rapid heating may damage the concrete due to expanding moisture.

Figure 1.3: Typical Vent Termination

PREINSTALLATION

WARNING

Configuration of the breeching and chimneys on some installations may result in a positive breeching pressure. In these cases, the breeching must be constructed of pressure tight materials. Consult local building authorities for proper installation. Failure to comply with this warning may result in carbon monoxide poisoning or fire, resulting in severe personal injury or death.

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3. If the boiler is installed in a penthouse or if wiring of any sort is run underneath the boiler foundation, construct the foundation with a provision for air flow between the main floor and the top of the boiler foundation.

a) An acceptable foundation would be concrete

blocks laid on their sides with the openings lined up.

b) If the foundation must be a concrete slab, use an

air cell high temperature insulating board, at least ½" [13 mm] thick, with aluminum backing. ½" [13 mm] thick, high temperature millboard with aluminum backing is also acceptable. Place the insulating board on the slab, with the aluminum side up, between the angle rails.

G. INSTALLATION SURVEY

For new and existing installations, a Steam or Water Installation Survey is available from PB Heat, LLC. The survey will provide information on how a steam or water boiler works with your specific system and will provide an overview of steam or water system operation.

You can also use this survey to locate system problems that will have to be corrected. To obtain copies of the Steam or Water Installation Survey, contact your PB Heat, LLC Representative or download it from PeerlessBoilers.com.

PREINSTALLATION

Figure 1.4: Foundation Layout

Boiler

Model

Knocked-Down Boilers Packaged Boilers

Boiler Model

Knocked-Down Boilers Packaged Boilers

Rail

Length

(inches)

Foundation

Base

Length

(inches)

Foundation

Rail

Length

(mm)

Foundation

Base

Length

(mm)

Foundation

Width

(inches)

Length

(inches)

Width

(inches)

Length

(inches)

Width

(mm)

Length

(mm)

Width

(mm)

Length

(mm)

TC- 04 34.19 48.5 46.25 66.19 48.5 78.25 TC- 04 868 1232 1175 1681 1232 1988 TC- 05 42.25 48.5 54.25 74.25 48.5 86.25 TC- 05 1073 1232 1378 1886 1232 2191 TC- 06 50.31 48.5 62.50 82.31 48.5 94.50 TC- 06 1278 1232 1588 2091 1232 2400 TC- 07 58.38 48.5 70.50 90.38 48.5 102.50 TC- 07 1483 1232 1791 2296 1232 2604 TC- 08 66.44 48.5 78.50 98.44 48.5 110.50 TC- 08 1688 1232 1994 2500 1232 2807 TC- 09 74.50 48.5 86.50 106.50 48.5 118.50 TC- 09 1892 1232 2197 2705 1232 3010 TC- 10 82.56 48.5 95.00 114.56 48.5 127.00 TC- 10 2097 1232 2413 2910 1232 3226 TC- 11 90.63 48.5 103.00 122.63 48.5 135.00 TC-11 2302 1232 2616 3115 1232 3429 TC- 12 98.69 48.5 111.00 130.69 48.5 143.00 TC-12 2507 1232 2819 3320 1232 3632 TC- 13 106.75 48.5 119.00 138.75 48.5 151.00 TC-13 2711 1232 3023 3524 1232 3835 TC- 14 114.81 48.5 127.00 146.81 48.5 159.00 TC-14 2916 1232 3226 3729 1232 4039 TC- 15 122.88 48.5 135.00 154.88 48.5 167.00 TC-15 3121 1232 3429 3934 1232 4242 TC- 16 130.94 48.5 143.00 162.94 48.5 175.00 TC-16 3326 1232 3632 4139 1232 4445 TC- 17 139.00 48.5 151.00 171.00 48.5 183.00 TC-17 3531 1232 3835 4343 1232 4648 TC- 18 147.06 48.5 159.00 179.06 48.5 191.00 TC-18 3735 1232 4039 4548 1232 4851

Table 1.1a: Foundation Dimensions

(U.S. Customary Units)

Table 1.1b: Foundation Dimensions

(SI Metric Units)

Page 8

H. PLANNING THE LAYOUT

Prepare sketches and notes of the layout to minimize the possibility of interference with new or existing equipment, piping, venting, and wiring.

I. VERIFY COMPONENTS

1. Packaged Boilers: All standard components are located in the boiler package with the following exceptions:

a) Relief Valves are assembled with piping and

included in a separate carton to prevent damage in shipment.

b) The Return Yoke is not mounted or assembled

for shipment. This assembly is included in a separate carton.

c) In some cases, the Burner and/or Gas Train may

be shipped separately.

d) The Optional Barometric Draft Damper is

shipped in a separate carton.

2. Knocked-down Boilers: All components are shipped for field assembly. See Tables 1.2a and 1.2b for standard components. See Tables 1.3 through 1.8 for optional components.

3. Assembled Block Boilers: These are similar to knocked-down boilers except the angle rails, sections and section assembly kit cartons are pre-assembled into a single shipping level component.

PREINSTALLATION

Table 1.2a: Series TC™ Shipping List (Steam Boilers)

Boiler Model Number

Angle Rail

Standard Sections Flue Outlet

Controls Carton

Trim Carton

Section Assembly

Cartons

Graphite Port

Connector Carton

Miscellaneous Parts

Carton

Jacket Panels

Front

Rear

Plain Intermediate

Supply Intermediate

Flue Collector

Outlet Adapter

Jacket Channel

Carton

Jacket Front/Back

Carton

Jacket Top/Side

Carton

TC- 04

Qty. 2 1 1 1 1 1 1 1 1 1 1 1 1 1

SCN 74004 76000 76001 76002 76003 76060 88512 77000 76050 76053 76070 75004 76030 76031

TC- 05

Qty. 2 1 1 2 1 1 1 1 1 1 1 1 1 1

SCN 74005 76000 76001 76002 76003 76060 88512 77000 76051 76054 76070 75005 76030 76032

TC- 06

Qty. 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1

SCN 74006 76000 76001 76002 76003 76060 88512 77001 76052 76055 76070 75006 76030 76033 76035

TC- 07

Qty. 2 1 1 3 2 1 1 1 2 2 1 1 1 1 1

SCN 74007 76000 76001 76002 76003 76061 88512 77001 76050 76053 76070 75007 76030 76031 76036

TC- 08

Qty. 2 1 1 4 2 1 1 1 1 1 1 1 1 1 1 1 1

SCN 74008 76000 76001 76002 76003 76061 88512 77002 76050 76051 76053 76054 76070 75008 76030 76031 76037

TC- 09

Qty. 2 1 1 5 2 1 1 1 2 2 1 1 1 1 1

SCN 74009 76000 76001 76002 76003 76062 88512 77002 76051 76054 76071 75009 76030 76031 76038

TC- 10

Qty. 2 1 1 6 2 1 1 1 1 1 1 1 1 1 1 1 1

SCN 74010 76000 76001 76002 76003 76062 88512 77002 76051 76052 76054 76055 76071 75010 76030 76032 76038

TC- 11

Qty. 2 1 1 6 3 1 1 1 2 2 1 1 1 1 2

SCN 74011 76000 76001 76002 76003 76062 88512 77003 76052 76055 76071 75011 76030 76032 76036

TC- 12

Qty. 2 1 1 7 3 1 1 1 1 2 1 2 1 1 1 1 1 1

SCN 74012 76000 76001 76002 76003 76062 88512 77003 76050 76051 76053 76054 76071 75012 76030 76032 76036 76037

TC- 13

Qty. 2 1 1 8 3 1 1 1 3 3 1 1 1 1 2

SCN 74013 76000 76001 76002 76003 76062 88512 77003 76051 76054 76071 75013 76030 76032 76037

TC- 14

Qty. 2 1 1 9 3 1 1 1 1 2 1 2 1 1 1 1 1 1

SCN 74014 76000 76001 76002 76003 76063 88512 77004 76050 76052 76053 76055 76071 75014 76030 76032 76037 76038

TC- 15

Qty. 2 1 1 10 3 1 1 1 1 2 1 2 1 1 1 1 2

SCN 74015 76000 76001 76002 76003 76063 88512 77004 76051 76052 76054 76055 76071 75015 76030 76032 76038

TC- 16

Qty. 2 1 1 11 3 1 1 1 3 3 1 1 1 1 1 1 1

SCN 74016 76000 76001 76002 76003 76063 88512 77004 76052 76055 76071 75016 76030 76032 76035 76039 76038

TC- 17

Qty. 2 1 1 12 3 1 1 1 1 4 4 1 1 1 1 2 2

SCN 74017 76000 76001 76002 76003 76063 76064 88512 77005 76051 76054 76071 75017 76030 76034 76040 76037

TC- 18

Qty. 2 1 1 13 3 1 1 1 1 3 1 3 1 1 1 1 1 2 1 1

SCN 74018 76000 76001 76002 76003 76063 76064 88512 77005 76051 76052 76054 76055 76071 75018 76030 76034 76040 76037 76038

Page 9

PREINSTALLATION

Boiler Model Number

Angle Rail

Standard Sections Flue Outlet

Controls Carton

Trim Carton

Yoke

Section Assembly Cartons

Graphite Port Connector

Carton

Miscellaneous Parts Carton

Jacket Panels

Front

Rear

Plain Intermediate

Flue Collector

Outlet Adapter

Jacket Channel Carton

Jacket Front/Back

Carton

Jacket Top/Side Carton

TC- 04

Qty. 2 1 1 2 1 1 1 1 1 1 1 1 1 1

SCN 74004 76000 76001 76002 76060 78510 77030 76072 76050 76053 76070 75004 76030 76031

TC- 05

Qty. 2 1 1 3 1 1 1 1 1 1 1 1 1 1

SCN 74005 76000 76001 76002 76060 78510 77031 76072 76051 76054 76070 75005 76030 76032

TC- 06

Qty. 2 1 1 4 1 1 1 1 1 1 1 1 1 1 1

SCN 74006 76000 76001 76002 76060 78510 77031 76072 76052 76055 76070 75006 76030 76033 76035

TC- 07

Qty. 2 1 1 5 1 1 1 1 2 2 1 1 1 1 1

SCN 74007 76000 76001 76002 76061 78510 77032 76072 76050 76053 76070 75007 76030 76031 76036

TC- 08

Qty. 2 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1

SCN 74008 76000 76001 76002 76061 78510 77032 76072 76050 76051 76053 76054 76070 75008 76030 76031 76037

TC- 09

Qty. 2 1 1 7 1 1 1 1 2 2 1 1 1 1 1

SCN 74009 76000 76001 76002 76062 78510 77032 76072 76051 76054 76071 75009 76030 76031 76038

TC- 10

Qty. 2 1 1 8 1 1 1 1 1 1 1 1 1 1 1 1 1

SCN 74010 76000 76001 76002 76062 78510 77032 76072 76051 76052 76054 76055 76071 75010 76030 76032 76038

TC- 11

Qty. 2 1 1 9 1 1 1 1 2 2 1 1 1 1 2

SCN 74011 76000 76001 76002 76062 78510 77033 76072 76052 76055 76071 75011 76030 76032 76036

TC- 12

Qty. 2 1 1 10 1 1 1 1 1 2 1 2 1 1 1 1 1 1

SCN 74012 76000 76001 76002 76062 78510 77033 76072 76050 76051 76053 76054 76071 75012 76030 76032 76036 76037

TC- 13

Qty. 2 1 1 11 1 1 1 1 3 3 1 1 1 1 2

SCN 74013 76000 76001 76002 76062 78510 77033 76072 76051 76054 76071 75013 76030 76032 76037

TC- 14

Qty. 2 1 1 12 1 1 1 1 1 2 1 2 1 1 1 1 1 1

SCN 74014 76000 76001 76002 76063 78510 77033 76072 76050 76052 76053 76055 76071 75014 76030 76032 76037 76038

TC- 15

Qty. 2 1 1 13 1 1 1 1 1 2 1 2 1 1 1 1 2

SCN 74015 76000 76001 76002 76063 78510 77034 76072 76051 76052 76054 76055 76071 75015 76030 76032 76038

TC- 16

Qty. 2 1 1 14 1 1 1 1 3 3 1 1 1 1 1 1 1

SCN 74016 76000 76001 76002 76063 78510 77034 76072 76052 76055 76071 75016 76030 76032 76035 76039 76038

TC- 17

Qty. 2 1 1 15 1 1 1 1 1 4 4 1 1 1 1 2 2

SCN 74017 76000 76001 76002 76063 76064 78510 77034 76072 76051 76054 76071 75017 76030 76034 76040 76037

TC- 18

Qty. 2 1 1 16 1 1 1 1 1 3 1 3 1 1 1 1 1 2 1 1

SCN 74018 76000 76001 76002 76063 76064 78510 77034 76072 76051 76052 76054 76055 76071 75018 76030 76034 76040 76037 76038

Table 1.2b: Series TC™ Shipping List (Water Boilers)

Page 10

PREINSTALLATION

Boiler

Model

Beckett Carlin Gordon-Piatt

Power Flame

(Gas) Power Flame (Oil)

Power Flame

(Gas/Oil) Webster

Mounting

Plate Stock

Code

Burner Model

Mounting

Plate Stock

Code

Burner Model

Mounting

Plate Stock

Code

Burner

Model

Mounting

Plate Stock

Code

Burner

Model

Mounting

Plate Stock

Code

Burner

Model

Mounting

Plate Stock

Code

Burner

Model

Mounting

Plate Stock

Code

Burner

Model

TC- 04

76027

CF1400

76027

702CRD

76023

R8 76028 J30A

76028 C1 76028 C1

76028 JB1

TC- 05

R8.2

76027

J50ATC- 06

CF2300

801CRD

76027 C2 76027 C2

TC- 07 TC- 08

R8.4

C2TC- 09

1050FF

76025 JB2

TC- 10

CF2500

76026

R10.1

TC- 11

76024

1150FF

76024 C3 76024 C3 76024 C3

TC- 12

76024 CF3500

TC- 13 TC- 14

R10.2

TC- 15 TC- 16 TC- 17

76022 C4 76022 C4 76022 C4 76022 JB3

TC- 18

Table 1.3: Burner Mounting Plates

Section

Standard

With

Inspection

Tappings

Stock Code Stock Code

Front 76000 76010 Intermediate 76002 ---Intermediate with Boss 76005 76007 Intermediate with LWCO Tappings 76011 ---Intermediate Supply with Boss 76003 76008 Intermediate Supply w/ LWCO Taps 76012 ---Intermediate Heater 76004 76009 Intermediate Heater w/ LWCO Taps 76013 ---Back 76001 76006

Description Stock Code

Heater Cover Plate Assembly 76075 Heater Cover Plate Gasket 74019 Tankless Coil -8 GPM 76073 Tankless Coil -12 GPM 76074 Return Yoke - Water Boiler 76072

Description Stock Code

Steam Controls Carton - L404A 88511 Steam Controls Carton - PA404A 88512 Water Controls Carton - L4006A 78510

Table 1.4: Standard & Optional Sections

Table 1.5: Tankless Coil & Cover Plate Options

Table 1.6: Controls Cartons

Description

15 PSI

[103 kPa]

Steam

Description

30 PSI

[207 kPa]

50 PSI

[345 kPa]

80 PSI

[552 kPa]

Stock Code Stock Code Stock Code Stock Code

Steam Trim Carton TC-04

77000

Water Trim Carton TC-04 77030

77050 77080

Steam Trim Carton TC-05 Water Trim Carton TC-05

77031

Steam Trim Carton TC-06

77001

Water Trim Carton TC-06

77051

77081Steam Trim Carton TC-07 Water Trim Carton TC-07

77032

Steam Trim Carton TC-08

77002

Water Trim Carton TC-08

Steam Trim Carton TC-09 Water Trim Carton TC-09

77082

Steam Trim Carton TC-10 Water Trim Carton TC-10

77052

Steam Trim Carton TC-11

77003

Water Trim Carton TC-11

77033

Steam Trim Carton TC-12 Water Trim Carton TC-12 Steam Trim Carton TC-13 Water Trim Carton TC-13

77083

Steam Trim Carton TC-14

77004

Water Trim Carton TC-14

Steam Trim Carton TC-15 Water Trim Carton TC-15

77034

Steam Trim Carton TC-16 Water Trim Carton TC-16

77053Steam Trim Carton TC-17

77005

Water Trim Carton TC-17

77084

Steam Trim Carton TC-18 Water Trim Carton TC-18

Table 1.7: Steam Trim Cartons Table 1.8: Water Trim Cartons

Page 11

A. PACKAGED BOILERS

1. All assemblies should be carefully inspected for shipping damage on arrival. Any damage should be reported immediately to the shipping company and PB Heat.

2. Remove shrink-wrap and inspect the jacket, cast iron sections, and burner (if supplied) for damage. Remove the left side panels and inspect the clean out covers for damaged or missing silicone seals.

3. Continue to Section 3, Installation.

B. ASSEMBLED BLOCKS

1. All assemblies should be carefully inspected for shipping damage on arrival. Any damage should be reported immediately to the shipping company and PB Heat.

2. Check the component list in Tables 1.2a and 1.2b and packing slip to assure that all shipping level items are received. Inspect all packages for shipping damage.

3. Continue to Section 2.F, Burner Mounting Plate Installation.

C KNOCKDOWN BOILERS

1. Check the component list in Tables 1.2a and 1.2b and packing slip to assure that all shipping level items are received. Inspect all packages for shipping damage.

2. Report any damage to the shipping company and PB Heat immediately.

3. Lay the angle rails provided at the point of final installation. Set the angles in parallel position measuring 36-1/2" [927 mm] outside-to-outside of angles as shown in Figure 2.1. Shim the angles to level them and grout under angles after the sections are assembled.

4. Place the Front Section in position on the angles as shown in Figure 2.2. The end of the floor angle must either be flush with the boss for the wash out connection or extend beyond it by as much as 3/8" [10 mm].

5. The Front Section should be supported vertically as shown in Figure 2.3. Install a 3" NPT x 30" [762 mm] long pipe in the wash out connection at the rear of the section and block with wood.

6. Inspect the port connector recesses and rope groove on the cast iron rear section for dirt and obstructions.

7. Clean the port connector recesses with a stiff wire brush.

ASSEMBLY

2. ASSEMBLY

Figure 2.1: Angle Rail Placement

Figure 2.2: Front Section Placement

The cast iron sections are top heavy. Handle with care to avoid tipping or falling.

WARNING

Page 12

8. Apply the spray-on adhesive supplied with the boiler to the rope groove. This will hold the rope gasket in place during assembly.

9. Apply a length of rope gasket (supplied in the section assembly cartons), avoiding bends and twists in the rope. Ensure that the ends of the rope gasket extend past the clean-out cover opening as shown in Figure 2.4.

10. Install the large graphite port connector with steel inner ring into the upper port making sure that the inner ring stays inside the port connector.

11. Install the two small, circular, graphite port connectors with steel inner rings in the lower recess ports. Make sure that the inner rings stay inside the port connectors. Spray adhesive used for attaching rope may be used to keep the port connectors in place during assembly.

12. Select the correct intermediate section (refer to Table

2.2), and slide it into place against the front section. Ensure that the sections are plumb and the port connectors are properly seated in the port recesses as indicated in Figure 2.5.

13. Install the draw rods as shown in Figure 2.3 and tighten them lightly. Note: Draw rods must be installed as shown to ensure correct installation of the Jacket Channel Splice Rail.

14. Inspect the rope gasket to ensure that it remains in the rope groove.

15. Check the section alignment and port connector position by looking through the ports. If necessary, reposition the port connector by loosening the draw rods and then retightening them.

16. Check the floor angles and sections for alignment.

ASSEMBLY

Figure 2.3: Front Section Support

Figure 2.4: Rope Gasket and Port Connector

Instalation

Handle the graphite port connectors with care. Do not bend, twist, stretch or drop the port connectors. If the graphite port conector is damaged it must be replaced.

NOTICE

Figure 2.5: Drawing Up Sections

Page 13

17. Gently tighten the draw rods to the torque specification and sequence as described in Table 2.1. Make sure the port connectors stay inside the boiler ports. Do not completely tighten any draw rod out of sequence. Gradually work each side until the correct torque is reached.

18. If any ports develop leaks during the hydrostatic test, the torque may be increased up to 200 ft. lbs. [270 Nm] on the upper right and 150 ft. lbs. [203 Nm] on both of the lower ports.

19. Prepare the rope groove and gasket recess on the intermediate section as described for the front section in paragraph 2.C.6 through 2.C.11.

20. Select the next appropriate section in accordance with Table 2.2.

21. For TC-08 through TC-18 refer to Figure 2.6, 2.7 and Table 2.3 for correct placement of nuts and washers for jacket channel splice piece.

ASSEMBLY

Table 2.1: Torque Specifications for Series TC™

Boiler with Graphite Port Connectors

Seq.

No.

Draw Rod

Position

Torque

(ft. lbs.)

Torque

(Nm)

1 Upper Right 25 34 2 Lower Left 25 34 3 Lower Right 25 34 4 Upper Left 10 14 5 Upper Right 50 68 6 Lower Left 50 68 7 Lower Right 50 68 8 Upper Right 75 102

9 Lower Left 75 102 10 Lower Right 75 102 11 Upper Left 30 41 12 Upper Right 125 169 13 Lower Left 125 169 14 Lower Right 125 169 15 Upper Right 125 169 16 Upper Left 40 54

Table 2.2a: Steam Section Arrangement

F Front Section

T Intermediate Section w/5" Steam Tapping (Steam Only)

TLIntermediate Section w/5" Steam & LWCO Tappings (Steam Only)

H Optional Intermediate Section w/Heater Connections

HLOptional Intermediate Section w/Heater Connections & LWCO Tapping

P Plain Intermediate Section

PLPlain Intermediate Section & LWCO Tappings

B Back Section

F T HLB

F H TLH B

F T HLT H B

F T HLP T H B F T HLP H T H B

F T HLP H P T H B

F H TLH P H P T H B

F H TLH P T H P T H B

F H TLH P T H P H T H B

F H TLH P H T H P H T H B

F H TLH P H T H P H P T H B

F H TLH P H P T H P H P T H B

F H TLH P H P H T H P P H T H B

F H TLH P H P H T H P

P H T H B

F H TLH P H P H

T H P

P H T H B

TC-04

TC-05

TC-06

TC-07

TC-08

TC-09

TC-10

TC-11

TC-12

TC-13

TC-14

TC-15

TC-16

TC-17

TC-18

Notes:

1) Tapped Intermediate Sections with LWCO Tappings (T

) are optional and if not used are replaced with a Tapped Intermediate Section (T).

2) Intermediate Sections with Heater Connections (H) & (H

) are optional. The locations shown indicate the possible placement of these sections if they

are ordered. Unless Intermediate Heater Sections are specified, the sections provided will be Plain Intermediate Sections (P) or (P

3) Sections with Low Water Cut-Off (LWCO) Tappings are optional. However, if used, they must be placed at the third position from the front in order to assure proper jacket fit.

Page 14

ASSEMBLY

F P HLP H P P H B

F H PLH P H P P H B

F H PLH P P H P P H B

F H PLH P P H P H P H B

F H PLH P H P H P H P H B

F H PLH P H P H P H P P H B

F H PLH P H P P H P H P P H B

F H PLH P H P H P H P P H P H B

F H PLH P H P H P H P

P H P H B

F H PLH P H P H

P H P

P H P H B

TC-04

TC-05

TC-06

TC-07

TC-08

TC-09

TC-10

TC-11

TC-12

TC-13

TC-14

TC-15

TC-16

TC-17

TC-18

Notes:

1) Intermediate Sections with Heater Connections (H) & (H

) are optional. The locations shown indicate the possible placement of these sections if they

are ordered. Unless Intermediate Heater Sections are specified, the sections provided will be Plain Intermediate Sections (P) or (P

2) Sections with Low Water Cut-Off (LWCO) Tappings are optional. However, if used, they must be placed at the third position from the front in order to assure proper jacket fit.

F P HLB

F H PLH B

F P HLP H B

F P HLP P H B F P HLP H P H B

Table 2.2b: Water Section Arrangement

Figure 2.6: Numbered Section Illustration

Page 15

D. HYDROSTATIC TESTING

1. Plug all openings in the boiler waterways and fill the boiler with cold water. While filling the boiler, recheck the torque on all ports and tighten the draw rods if necessary.

2. Hydrostatically test the boiler for leaks in accordance with ASME Code, Section IV.

a) Steam Boilers: The assembled boiler shall be

subjected to a hydrostatic test pressure of not less than 45 psig [310 kPa].

b) Water Boilers: The assembled boiler shall be

subjected to a hydrostatic test pressure of not less than 1-1/2 times the maximum allowable working pressure.

c) The test pressure shall not exceed the minimum

requirements shown above by more than 10 psi [69 kPa].

3. If any port connector leaks, tighten the draw rods until either the joint achieves full metal-to-metal contact or until or the maximum torque is reached (Upper Right - 200 ft. lbs. [270 Nm]; Lower Ports 150 ft. lbs.[203 Nm]). Check the torque on the other draw rods that may have been affected by the draw rod that was tightened.

E. CLEAN-OUT COVER INSTALLATION

1. Attach the clean-out cover plates and insulation to the clean-out openings on the left side of the boiler. Use the T-bolt assemblies and hex nuts provided in the Section Assembly Cartons. See Figure 2.8.

2. Press each clean-out cover plate with insulation over the protruding T-bolts until the bolts punch through the insulation. Install a 5/16" flat washer and 5/16" brass nut on each bolt and tighten until the insulation forms a good seal around the clean-out opening.

3. Seal tops and bottoms of insulation with silicone sealant.

ASSEMBLY

Table 2.3: Splice Piece Nut & Washer Locations

Boiler Model Splice Piece & Washer Locations

TC- 04 N/A TC- 05 N/A TC- 06 N/A TC- 07 N/A TC- 08 Between Sections 3-4 & Sections 5-6 TC- 09 3-4 & 5-6 TC- 10 5-6 & 7-8 TC- 11 5-6 & 7-8 TC- 12 5-6 & 7-8 TC- 13 5-6 & 7-8 TC- 14 7-8 & 9-10 TC- 15 5-6 & 7-8 9-10 & 11-12 TC- 16 5-6 & 7-8 9-10 & 11-12 TC- 17 5-6 & 7-8 9-10 & 11-12 TC- 18 5-6 & 7-8 11-12 & 13-14

Figure 2.7

Note: Splice Piece nuts and washers are to be installed as shown in Figure 2.7 on the draw rods that connect the sections indicated. The sections are numbered from front to back as indicated in Figure 2.6. The Splice Pieces are shown in Section 3 in Figure 3.12.

Do not exceed the maximum torque specifications (upper Right – 200 ft. lbs. [270 Nm]; Lower Ports – 150 ft. lbs. [203 Nm]). Tighten the rods in the sequence shown in Table 2.2.

Do not continue to tighten the sections after metalto-metal contact is made. Over-tightening the draw rods will not improve the seal and may cause damage to the castings.

NOTICE

When the boiler is put into operation for the first time, the temperature should be brought up slowly (low fire on burners with this capability).

NOTICE

Page 16

. BURNER MOUNTING PLATE

F. BURNER MOUNTING PLATE

INSTALLATION

1. Inspect the rope groove on the Burner Mounting Plate for dirt and obstructions. Use a wire brush if necessary to clean the groove.

2. Spray the rope groove with the spray adhesive provided in the Misc. Parts Carton and apply the 3/8" diameter rope gasket.

3. Install the 7/16" x 2-1/2" Studs provided into the four threaded holes around the perimeter of the burner opening in the Boiler Front Section as shown in Figure 2.9.

4. Insert the Burner Insulation Block into the burner opening with the notch for the Observation Port on the top left side.

5. Place the Burner Mounting Plate over the block and force the block inward until the Studs extend far enough through the holes to accept 7/16" Hex Nuts and Washers. Tighten the nuts.

6. Use a long drill, awl, or other such tool to create holes in the Insulation Block for four 1/4" machine screws.

7. Install the 1/4" x 5" machine screws through the holes in the Burner Mounting Plate, supporting the Insulation Block on the inside to prevent tearing.

8. Install the stainless steel washers and 1/4" hex nuts on the inside of the Insulation Block and tighten lightly. Be careful not to crush the insulation.

9. Install the four 3/8-16 x 1-1/4" studs provided into the screw seats provided on the Burner Mounting Plate.

10. When the burner is installed, the hole in the Insulation Block for the Burner may need to be enlarged and shaped. This can be cut with a hacksaw blade.

G. REAR OBSERVATION PORT

INSTALLATION.

1. Assemble Rear Observation Port as shown in Figure

2.10:

a) Lift up the flapper door on the inside of the

Observation Port and insert the Hex Head Cap Screw provided in the Misc. Parts Carton.

b) Slide the Spring over the hex head screw and

thread the Hex Nut onto the screw.

c) Thread the Knob onto the Hex Head Screw

behind the nut and lock into position using the jam nut.

ASSEMBLY

Figure 2.8: Clean-Out Cover Installation

Figure 2.9: Burner Mounting Plate Installation

Figure 2.10: Rear Observation Port Assembly

Page 17

2. Thread the 5/16" x 1-1/2" studs into the screw seats around the rear observation port opening in the Boiler Back Section.

3. Apply a thin layer of furnace cement over the mounting flap.

4. Install the Rear Observation Port Assembly on the Boiler Back Section using three 5/16" hex nuts and washers.

H. FLUE COLLECTOR INSTALLATION

1. Screw the eight 5/16-18 x 1-1/2" studs provided into the screw seats around the flue collector outlet on the Boiler Back Section.

2. Place the 1/8" [3 mm] thick x 3/4" [19 mm] wide Bolt Tape provided in the Misc. Parts Carton over the studs.

3. Place the flue collector in position and install the 5/16" washers and nuts. Tighten the nuts uniformly.

4. Open the Slide Damper to the full open position to prepare for adjustment during Burner commissioning.

5. Install 1/2" brass plug from Misc. Parts Carton.

I. BURNER MOUNTING

1. Read the Burner Instruction Manual before starting.

2. Remove the Burner from its crate. Verify that all components are included with the burner.

3. Place the high temperature gasket specified by the Burner Manufacturer on the Burner Mounting Plate and secure the Burner using 3/8" flat washers and hex nuts provided.

4. If the Burner is supplied with a pedestal support, install it per the Burner Manufacturer’s Instructions. The pedestal supports the burner and prevents undue stress on the Boiler Castings.

ASSEMBLY

Figure 2.11: Rear Flue Collector Installation

Page 18

A. PREPARATION

1. The boiler must be hydrostatically pressure tested as indicated in Section 2, paragraph D.

2. The jacket panels are designed so that they may be installed after the boiler is piped. Use nipples long enough to extend through the jacket.

B. STEAM BOILER PIPING

1. Refer to the PB Heat Steam Installation Survey for guidance with steam boiler piping and components.

2. Piping for steam boilers is shown in Figure 3.1, 3.2, and 3.3. Table 3.1 contains a pipe size schedule for steam boilers.

3. Series TC™ Boilers are intended to be piped with one, two or three risers to the header depending on the boiler size.

a) Table 3.1 shows a pipe schedule for steam boiler

headers.

b) See Figure 3.1 for a typical piping arrangement

for boilers with one riser. (TC-04 & TC-05)

c) See Figure 3.2 for a typical piping arrangement

for boilers with two risers. (TC-06 through TC-10)

d) See Figure 3.3 for a typical piping arrangement

for boilers with three risers. (TC-11 through TC-18)

4. A Hartford loop, as shown in Figures 3.1, 3.2 and

3.3 is recommended in all steam boiler installations. The loop prevents the boiler from being drained completely due to a leak in a return line.

5. Pumped Return Systems:

a) For pumped return systems, install a spring-

loaded check valve on the pump discharge. This will prevent boiler water from backing up into the condensate receiver.

b) If the pump discharge is looped above the

normal water level, install a spring-loaded check valve at the connection to the boiler return. This will ensure water under pressure in the vertical pipe preventing water hammer due to hot condensate flashing to steam.

INSTALLATION

3. INSTALLATION

Table 3.1: Piping Schedule

Do not reduce the size or number of risers shown in Table 3.1. If the risers are undersized or incorrectly placed, a sloped water line may occur in the boiler. This may lead to the overheating of boiler sections.

CAUTION

Figure 3.1: Typical piping arrangement for boilers

with one riser.

Figure 3.2: Typical piping arrangement for boilers

with two risers.

Steam Boiler Piping

Boiler Model

Number of

5" NPT

Risers

Header Size

(NPT)

Equalizer Size

(NPT

TC-04 & TC-05 1 5" 2-1/2"

TC-06 & TC-07 2 5" 2-1/2"

TC-08 to TC-10 2 6" 4"

TC-11 to TC-18 3 8" 4"

Page 19

c) Install a flow regulating valve on the pump

discharge to allow throttling of the pump flow. Excess return flow may cause water hammer and water level fluctuations.

d) Use a Hartford Loop connection. Oversize the

equalizer slightly to make sure water doesn’t spray into the header and cause hammering.

6. Always locate the steam supply take-off between the equalizer and the last boiler riser. Failure to do this will cause water carryover into the system because the condensate will collect at the entrance to the steam main.

7. Pitch the steam header to allow condensate to flow toward the equalizer.

8. Feedwater requirements for steam boilers at full input are shown in Tables 3.2a and 3.2b. Addition of water to the boiler should be controlled by sensing the boiler water level.

9. 1" NPT water column tappings are provided on the front section for mounting low water cutoffs and level controllers.

10. The front section has 3" NPT tappings at the base for installation of 3" NPT close nipples and 3" NPT pipe caps. Removal of caps allows flushing of sediment from the boiler.

C. MULTIPLE STEAM BOILER PIPING

1. Figure 3.4 shows typical piping for multiple steam boiler gravity return systems.

2. Figure 3.5 shows typical piping for multiple steam boiler pumped return systems.

3. Provide separate feed lines for multiple steam boiler pumped return systems. Use either separate feed pumps or electrically actuated valves to isolate the boiler feed. This is necessary to provide reliable level control and avoid nuisance performance problems.

4. Condensate return units are not recommended for multiple boiler installations. Use a boiler feed system which is actuated by a boiler control that responds to the needs of the boiler.

5. Install a float & thermostatic (F&T) trap at the boiler normal water level on each of the boilers in a multiple boiler system with pumped returns. This will prevent flooding of idle boilers due to condensation of steam.

D. WATER BOILER PIPING

1. Refer to the Peerless®Water Installation Survey for guidance with water boiler piping and components.

2. Typical piping for a Series TC™ water boiler is shown in Figure 3.6.

INSTALLATION

Table 3.2a: Feedwater Requirements -

US Customary Units

Figure 3.3: Typical piping arrangement for boilers

with three risers.

Boiler Model

I=B=R

Gross

Output

MBH

Evap. Rate

GPM

Minimum

Feedwater

Pump Flow

GPM

Condensate

Receiver

Capacity

Gallon

TC- 04 900 1.86 3.7 37 TC- 05 1166 2.41 4.8 48 TC- 06 1433 2.96 5.9 59 TC- 07 1699 3.50 7.0 70 TC- 08 1965 4.05 8.1 81 TC- 09 2232 4.60 9.2 92 TC- 10 2498 5.15 10.3 103 TC- 11 2764 5.70 11.4 114 TC- 12 3031 6.25 12.5 125 TC- 13 3297 6.80 13.6 136 TC- 14 3563 7.35 14.7 147 TC- 15 3830 7.90 15.8 158 TC- 16 4096 8.45 16.9 169 TC- 17 4362 9.00 18.0 180 TC- 18 4629 9.55 19.1 191

Boiler Model

I=B=R

Gross

Output

Evap. Rate

ltr/min

Minimum

Feedwater

Pump Flow

tr/min

Condensate

Receiver

Capacity

Liter

TC- 04 264 7.0 14.1 141 TC- 05 342 9.1 18.2 182 TC- 06 420 11.2 22.4 224 TC- 07 498 13.2 26.5 265 TC- 08 576 15.3 30.7 307 TC- 09 654 17.4 34.8 348 TC- 10 732 19.5 39.0 390 TC- 11 810 21.6 43.2 432 TC- 12 888 23.7 47.3 473 TC- 13 966 25.7 51.5 515 TC- 14 1044 27.8 55.6 556 TC- 15 1122 29.9 59.8 598 TC- 16 1200 32.0 64.0 640 TC- 17 1278 34.1 68.1 681 TC- 18 1357 36.2 72.3 723

Table 3.2b: Feedwater Requirements -

SI Metric Units

1. Evaporation rate is based on heat of vaporization at 212°F, 970 BTU/lbm.

2. Minimum feedwater pump flow is based on 2 times evaporation rate.

3. Condensate receiver capacities are based on 20 minute steam

1. Evaporation rate is based on heat of vaporization at 100°C, 2257 kJ/kb.

2. Minimum feedwater pump flow is based on 2 times evaporation rate.

3. Condensate receiver capacities are based on 20 minute steam cycle. Chart

3. shows actual capacity, not gross receiver volume

Page 20

3. A return yoke as shown in Figure 3.7 is provided as standard equipment for each water boiler. Assemble each joint as follows:

a) Cover edges and outer surface of the gasket with

a thin layer of petroleum-free silicone lubricant (supplied).

b) Install each gasket by placing it over the ends of

the two pipes to be connected.

c) Center the gasket between the grooves.

d) Place the coupling housings over the gasket so

that the keys fully engage into grooves.

e) Insert the bolts into the coupling and tighten the

nuts until finger tight.

f) Alternately tighten the nuts evenly so they do not

bind the gasket. The gasket should not be visible after fully tight.

4. The recommended supply and return pipe sizing in Tables 3.3a and 3.3b is based on a flow rate through the boiler that produces a 20°F [11°C] temperature rise (1 gpm [3.79 ltr/min] of flow for each 10,000 Btu/hr [2.93 kW] of boiler output).

5. Using higher flow rates is not recommended because it may cause poor distribution through the boiler.

INSTALLATION

Figure 3.4: Multiple Steam Boiler Piping – Gravity Return

Figure 3.5: Multiple Steam Boiler Piping – Pumped Return

Page 21

Figure 3.6: Water Boiler Piping

Figure 3.7: Return Yoke

INSTALLATION

Page 22

INSTALLATION

6. Lower flow rates are acceptable providing that the return temperature to the boiler is a minimum of 130°F [54°C] on gas boilers and 150°F [66°C] on oil boilers to prevent condensation of flue gases.

7. The size of supply and return connections given in Tables 3.3a and 3.3b are the minimum size for a 20°F [36°C] temperature differential. Do not reduce these sizes unless the flow is low enough to keep the velocity from developing noise and erosion problems.

8. When the boiler is connected to heating coils located in air handling units, the boiler piping must be equipped with flow control devices to prevent gravity circulation of the boiler water during the cooling cycle.

9. Low Temperature Return Systems: a) When the system return temperature will be

below 130°F [54°C] on gas or 150°F [66°C] on oil for extended periods (heat pump systems, radiant panels, snow melt, outdoor reset, etc.) provide piping and controls to protect the boiler from condensation. Excessive condensation will lead to corrosion in the boiler and breeching, which will shorten the life of the boiler.

b) Low return water temperatures are likely to occur

whenever the boiler is allowed to cool below design temperatures (cold start). This is acceptable as long as the frequency of these shut-downs is very low.

Boiler Model

I=B=R

Gross Output

(MBH)

Flow Rate

@20 F Rise

(GPM)

Recommended

Supply Size

(NPT)

Return Size

(NPT)

TC- 04 900 90 3 3 TC- 05 1166 117 3 3 TC- 06 1433 143 4 4 TC- 07 1699 170 4 4 TC- 08 1965 196 4 4 TC- 09 2232 223 4 4 TC- 10 2498 250 5 5 TC- 11 2764 276 5 5 TC- 12 3031 303 5 5 TC- 13 3297 329 5 5 TC- 14 3563 356 5 5 TC- 15 3830 383 5 5 TC- 16 4096 409 5 5 TC- 17 4362 436 5 5 TC- 18 4629 463 5 5

Boiler Model

I=B=R

Gross Output

(kW)

Flow Rate

@36 C Rise

(ltr/min)

Recommended

Supply Size

(NPT)

Return Size

(NPT)

TC- 04 264 341 3 3 TC- 05 342 443 3 3 TC- 06 420 541 4 4 TC- 07 498 644 4 4 TC- 08 576 742 4 4 TC- 09 654 844 4 4 TC- 10 732 946 5 5 TC- 11 810 1045 5 5 TC- 12 888 1147 5 5 TC- 13 966 1245 5 5 TC- 14 1044 1348 5 5 TC- 15 1122 1450 5 5 TC- 16 1200 1548 5 5 TC- 17 1278 1650 5 5 TC- 18 1357 1753 5 5

Table 3.3a: Supply & Return Pipe Sizing –

US Customary Units

Table 3.3b: Supply & Return Pipe Sizing –

SI Metric Units

Figure 3.8: Chilled Water Systems

Page 23

INSTALLATION

c) For systems with variable low temperature

returns or constant low temperature returns please refer to the Peerless

Water Survey for

system information.

10. Chilled Water Systems: a) If the boiler will be used in conjuction with a

chilled medium system, the chiller must be piped in parallel with the boiler to prevent the chilled medium from entering the boiler and causing damage. See Figure 3.8.

E. MULTIPLE WATER BOILER PIPING

1. Figure 3.9 shows a typical piping arrangement for

multiple water boilers. The optional bypass valve is used when the system return water temperature is consistently below 130°F [54°C] for gas boilers or 150°F [66°C] for oil boilers.

2. For systems with variable low temperature return

temperature, a three-way valve may be used (see Peerless

Water Installation Survey for details).

F. TANKLESS HEATER INSTALLATION

1 Heater sections must be installed as shown in Table

2.2 in the Assembly section of this manual.

2. Inspect heater section for dirt or rust on the mating surface. Clean with a wire brush if necessary.

3. Install 7/16" x 1-1/2" studs in the screw seats around the heater opening as shown in Figure 3.10.

4. Place the heater gasket over the studs. Be sure the gasket is not twisted.

5. Carefully install the heater coil. Install the nuts and tighten them evenly to ensure uniform compression of the gasket.

6. Install the operating control in the center tapping on the heater mounting plate. Figure 3.11 shows an acceptable piping arrangement for multiple heater coils.

Figure 3.9: Multiple Water Boiler Piping

Figure 3.10: Tankless Heater Coil Installation

Figure 3.11: Typical Piping for Multiple Tankless

Heater Coils

WARNING

Provide anti-scald devices in the system where needed. Failure to control water temperature to showers or other usage areas where scald risk exists may result in severe personal injury.

Page 24

G. JACKET PREPARATION

1. Collect all jacket cartons as listed in Table 1.2 in the Pre-installation section of this manual. One Jacket Channel Carton, one Jacket Front/Back Carton, and one to five Jacket Top/Side Cartons are included.

2. The cartons contain pre-insulated panels and screws for attaching them to the unit.

3. Remove all required knock-outs (Heater Coils, Steam Supply, LWCO, etc.) from jacket panels before assembly.

4. The boiler block must be completely assembled on the Angle Rails supplied by PB Heat before installing the jacket. The Angle Rails are drilled and tapped to accept the Lower Jacket Channels.

5. Any limit controls, steam gauge glass, low water cutoffs or gauges to be mounted on the front of the boiler must be installed after the Front Jacket Panel, F2, as shown in Figure 3.12.

6. All other piping, burner, and control connections may be made before jacket installation.

H. JACKET ASSEMBLY

1. Figure 3.12 shows a typical jacket assembly. a) Lower Channels: Locate Lower Channels on the

Angle Rails. TC-04 through TC-07 boilers require only one Lower Channel per side. TC-08 through TC-14 boilers require two Lower Channels per side and the TC-15 through TC-18 boilers require three Lower Channels per side. On TC-08 through TC-18 be sure that the 5/16" diameter holes in the outer flange of the Lower Channels are at the front and rear of the boiler.

b) Front Panel: Locate Front Panel, F2, over the

front of the boiler with the bottom corners supported by the Lower Channels. Align holes in the Front Panel with those in the Lower Channels and fasten with #10 washer head sheet metal screws. Install panels F1 and F2A with #10 washer head sheet metal screws.

c) Back Panel: Assemble Right Rear Post to Back

Panel (B1) with #10 washer head sheet metal screw. Install Panel/Post assembly on rear of boiler. Assemble Left Rear Post to Back Panel. Align lower holes of right and left posts with Lower Channel holes and attach with #10 washer head sheet metal screws. Install panel B2 with sheet metal screws.

INSTALLATION

Figure 3.12: Jacket Assembly

Page 25

d) Upper Channels:

1. TC-04 through TC-07 Boilers have one piece Upper Channels. These are to be attached to the top of the Front and Back Panels with 1/4"-20 round head machine screws, washers and nuts.

2 TC-08 through TC-18 Boilers have two or three

piece Upper Channels. Install splice pieces with the splice piece mounting hardware as shown in Section 2, Assembly, Figures 2.6 & 2.7. Attach the Upper Channels to the Splice Pieces and to the Front and Back Panels with 1/4"-20 round head machine screws, washers, and nuts.

e) Side and Top Panels

1 Left Side Panels: Attach knobs to Left Side

Panels and install by inserting the top into the Upper Channel and then dropping the Panel into the space between the Lower Channel and the Angle Rail.

2 Top Panels: Lay out the Top Panels so that

the knock-outs and openings correspond to the piping and components on the assembled boiler. After checking the layout, remove the necessary knock-outs and install Top Panels.

f) Right Side Panels: Lay out the Right Side Panels

so that the knock-outs and openings correspond to the piping and components on the assembled boiler. After checking the layout, remove the necessary knock-outs and install the Right Side Panels by inserting them into the Upper Channels then dropping them into the space between the Lower Channels and Angle Rails.

I. FUEL PIPING

1. General: a) Read the Burner Instruction Manual, supplied

with the boiler, or if the burner was purchased separately, with the burner.

b) Review applicable code requirements for the

burner and fuel piping installations.

c) Install piping to allow for removal of burner and

access to combustion chamber for cleaning or service.

2. Install Fuel Oil Piping: a) Place the fuel oil tank and install the piping

in accordance with local codes or in the absence of such codes with the codes listed in paragraph 1.B.

b) Follow guidelines in the Burner Instruction

Manual for sizing oil lines. Never use smaller than 1/2" [12.7 mm] OD copper tubing.

c) Install manual shut-off valves on the suction line

at the burner and at the oil line entrance to the building.

d) If installing a shut-off valve on the return line,

you must provide an oil pressure relief valve piped ahead of the shut-off valve and discharged to the tank to prevent over-pressure conditions.

e) Install a two pipe oil distribution system when

possible. It will improve the reliability of the oil delivery to the burner.

f) Use flare fittings when using copper tubing.

g) If the burner is above the top of the fuel oil tank,

install a check valve on the oil suction line at the burner to prevent oil from evacuating the line.

h) If the burner is below the top of the tank, install

an anti-siphon device to prevent oil flow in the event of an oil line break.

3. Install Gas Supply Piping a) Size gas piping as required by Local codes or in

the absence of such authority, the codes listed in paragraph 1.B.

b) Use Table 3.6 & 3.7 for sizing of piping for

natural gas with a system pressure drop of 0.3 inches of water [0.075 kPa].

INSTALLATION

Pipe

Length

(Feet)

1-1/4"

Pipe

1-1/2"

Pipe2"Pipe

2-1/2"

Pipe3"Pipe4"Pipe6"Pipe

10 1,050 1,600 3,050 4,800 8,500 17,500 44,000 20 730 1,100 2,100 3,300 5,900 12,000 31,000 30 590 890 1,650 2,700 4,700 9,700 25,000 40 500 760 1,450 2,300 4,100 8,300 22,000 50 440 670 1,270 2,000 3,600 7,400 20,000 60 400 610 1,150 1,850 3,250 6,800 18,000 70 350 560 1,050 1,700 3,000 6,200 17,000

90 320 490 930 1,500 2,600 5,400 15,000 100 305 460 870 1,400 2,500 5,100 14,000 150 250 380 710 1,130 2,000 4,100 11,500

Table 3.6: Capacity of Gas Supply Pipe in Cubic

Feet Per Hour of Natural Gas for a Pressure Drop of 0.30 inches of water

Table 3.7: Capacity of Gas Supply Pipe in Cubic

Meters Per Hour of Natural Gas for a Pressure Drop of 0.075 kPa

Pipe

Length (meter)

1-1/4"

Pipe

1-1/2"

Pipe2"Pipe

2-1/2"

Pipe3"Pipe4"Pipe6"Pipe

3.05 30 45 86 136 241 496 1,246

6.10 21 31 59 93 167 340 878

9.14 17 25 47 76 133 275 708

12.19 14 22 41 65 116 235 623

15.24 12 19 36 57 102 210 566

18.29 11 17 33 52 92 193 510

21.34 10 16 30 48 85 176 481

27.43 9 14 26 42 74 153 425

30.48 9 13 25 40 71 144 396

45.72 7 11 20 32 57 116 326

Specific Gravity 0.50 0.55 0.60 0.65 0.70 0.75

Multiplier 1.10 1.04 1.00 0.96 0.93 0.90

Specific Gravity 0.80 0.85 0.90 1.00 1.10 1.20

Multiplier 0.87 0.84 0.82 0.78 0.74 0.71

Specific Gravity 1.30 1.40 1.50 1.60 1.70 1.80

Multiplier 0.68 0.66 0.63 0.61 0.59 0.58

Above ratings are based on natural gas with a specific gravity of 0.60 allowing pressure drop of 0.3 inces of water (0.075 kPa). No allowance is needed for pipe fittings. Apply the following factors to the above capacities for specific gravity other than 0.60.

Page 26

c) Check the maximum inlet gas pressure in the

Burner Instruction Manual and make sure that the system regulator will not allow the gas pressure to exceed this value.

d) The minimum gas supply pressure is listed on the

Burner Rating Plate. Make sure the system regulator and piping are sized and adjusted properly to provide this pressure under all conditions.

e) Install a Service Valve, Sediment Trap and

Ground Joint Union at the supply connection to the Gas Control Train as shown in Figure 3.13. These components are to be supplied by the installing contractor and are not part of the boiler or burner. Install them in accordance with local codes or in the absence of such authority with the codes listed in paragraph 1.B.

f) Use only pipe joint compounds rated for use with

Liquefied Petroleum Gases.

4. Test Gas Supply Piping a) Isolate the Boiler Gas Control Train from the

system during testing.

b) For test pressures 1/2 psig [3.4 kPa] or less, close

the Manual Shut-Off Valve on the Boiler Gas Control Train.

c) For test pressures above 1/2 psig [3.4 kPa],

disconnect the gas supply piping upstream of the Boiler Manual Shut-Off Valve.

J. INSTALL CONTROLS AND TRIM

1. Install Safety Relief Valve: a) Install a Safety Relief Valve on the 3" NPT

tapping at the top of the rear section for both steam and water boilers as shown in Figure 3.14.

b) Water and Steam Trim Cartons contain safety

relief valves and fittings.

c) Be sure that the relief valve sizing meets local

code requirements.

INSTALLATION

Figure 3.14: Safety Relief Valve Installation

Do not expose the Gas Control Train to excessive pressure. The gas valves can be damaged. This may result in explosion hazard and severe personal injury or death.

Do not test gas supply piping with an open flame. Use a soap suds mixture brushed onto the pipe joints to test for leaks.

WARNING

Pipe the discharge of the Safety Relief Valve away from any traffic area, preferably to a floor drain. This is necessary to prevent injury should the valve discharge. Pipe the discharge in the same size pipe or larger than the valve discharge size. Do not put any valves or restrictions in the Safety Relief Valve discharge piping.

CAUTION

Figure 3.13: Gas Supply Connection to Boiler

Page 27

2. Install Drain/Blowdown Valves a) Water Boilers: Install a drain valve either in the

return piping or in one of the 3" NPT lower tappings in the Front Section of the boiler. See Figure 3.15.

b) Steam Boilers: Install a 1-1/4" NPT Full Port

Blowdown Valve either in the return piping or in one of the 3" NPT connections in the Front Section of the boiler. See Figure 3.15.

c) Pipe the valve discharge to a floor drain if

available or install a nipple and a pipe cap to close off the discharge when not in use.

3. Install Low Water Cut-off a) Mount an optional Float-type Low Water Cutoff

(LWCO) in the tappings provided in the top and side of the Front Section or the Intermediate LWCO Section (this optional section is located at the third section from the front when supplied). See Figure 3.16 for the location of control connection tappings.

b) Figure 3.17 shows a typical control configuration

for a steam boiler and Figure 3.18 shows a typical control configuration for a water boiler.

c) Provide piping for the Float-type LWCO such

that the vertical position of the device is as recommended by the manufacturer.

1. LWCOs that are piped too high will result in water carryover into the steam distribution system and will cause erratic operation of the boiler.

2. LWCOs that are piped too low will expose the boiler crown sheet and cause damage to the boiler.

d) For correct positions of common Float-type

LWCO devices see Figures 3.19 through 3.22.

e) Provide a blowdown valve for each Float-type

LWCO. Pipe the valve discharge away from high traffic areas to a floor drain if possible. The blowdown valve is required for proper maintenance of the control.

f) Maintain a height of 50 1/2” [1283 mm] from

the bottom of the Angle Rails to the Normal Water Level.

g) When using multiple Float-type Low Water

Cutoffs, always pipe them as shown in Figure

3.17. Do not mount these devices on opposite ends of the boiler. This will cause erratic operation and nuisance shut downs of the boiler.

INSTALLATION

Figure 3.16: Control Connection Locations

Tap.

No.

Tapping

Size

Connection Description

Steam Boiler Water Boiler

1 3/4" NPT Optional Probe LWCO –

2 1" NPT

Optional Water Column - (top)

Air Removal, Water Column (top)

3 1" NPT

Manual Reset High Limit, Operating Control & Steam Pressure Gauge

Optional Auxiliary Firing Rate, Limit Controls

4 3/4" NPT – Operating Control

5 3/4" NPT Water Gauge Glass

Manual Reset High Limit (top) Temp/Press Gauge (bottom)

6 1/4" NPT

Overfire Pressure Tapping

7 1" NPT

Water Column (bottom)

7¹⁄₈" x 5¹⁄₄"

Tankless Heater Tankless Heater

1¹⁄₂" NPT

Optional Inspection Tappings

Table 3.4: Control Connections Sizes

(See Figure 3.16)

Figure 3.15: Boiler Drain/Blowdown Valve

Installation

Page 28

4. Install Limit Controls: a) Steam Boilers: See Figure 3.17 for typical control

locations for steam boilers. Additional limit and firing rate controls can be added to the 3/4" NPT piped header.

b) Water Boilers: See Figure 3.18 for typical control

locations for water boilers. Additional limit and firing rate controls can be added to the boiler supply piping.

5. Connect Control Wiring: a) Install all wiring in accordance with local codes,

the National Electrical Code and other controlling agencies or governing bodies.

b) Use #14 gauge or heavier wire for supply wiring.

Protect the circuit with a fused disconnect switch (supplied by others) and a grounded neutral.

c) Mount an electrical junction box on the boiler

Front Panel for connection of boiler controls to the burner control panel.

d) Follow the instructions in the Burner Manual and

the wiring diagram supplied with the burner.

e) Install all line voltage (120 VAC) wiring in

conduit.

f) Do not install single pole switches including

safety controls in the neutral leg of a motor control circuit.

INSTALLATION

Figure 3.19: Optional Model 67PE2 Low Water

Cutoff

Figure 3.18: Water Boiler Control Locations

Figure 3.17: Steam Boiler Control Locations

The boiler/burner must be electrically grounded in accordance with the requirements of the local authority having jurisdiction, or in the absence of such requirements, with the current edition of the National Electric Code, ANSI/NFPA 70.

NOTICE

Page 29

INSTALLATION

Figure 3.20: Optional Model 47-2 Low Water

Cutoff/Feeder

Figure 3.21: Optional Model 157 Low Water

Cutoff/Pump Control

Figure 3.22: Optional Model 51-2 Low Water

Cutoff/Feeder

Page 30

A. STARTING THE BOILER

1. Check the piping. a) Water/Steam Piping

1. The Boiler must have been hydrostatically tested.

2. Check the attached piping for joint tightness.

3. Continue monitoring as you proceed through start up.

b) Gas Piping

1. Make sure the gas system piping and the connections to the boiler Gas Control Train(s) have been leak tested.

2. After the boiler is in operation, check the tightness of all joints in the boiler gas piping with a soap suds solution.

3. Purge the gas piping of all air up to the boiler Gas Control Train.

c) Oil Piping

1. Check the oil piping visually. Make sure all joints are tight.

2. When the burner is firing, check the suction line and return line pressures.

3. If the pressure exceeds the allowable pressure in the Burner Manual or if the suction line vacuum is higher than allowable, correct the piping as needed to bring the suction line and return line pressures within acceptable range.

4. Excess pressure can cause pump seal failures. Excess vacuum will cause fuel flow problems with the burner oil pump.

2. Fill the boiler. a) Steam: Fill the boiler to the normal water line.

1. Gravity Systems and Pumped Return with Condensate Units – Fill to the normal water level mark on front jacket panel.

2. Pumped Return with Boiler Feed Unit – Fill the boiler using the boiler feed unit. Fill level will depend on the control being used, but should be at the normal water level mark on front jacket panel.

3. Fill the boiler. a) Water: Fill the boiler and system.

1. Fill the system with fresh water only. If the water hardness is high, use water treatment to reduce the deposition of minerals in the boiler.

2. If the system requires antifreeze, use only antifreeze designed for hydronic systems. These contain inhibitors to prevent corrosion of the boiler and system components. Do not use ethylene glycol or automotive antifreezes.

• Make sure the antifreeze supplier can provide periodic inhibitor check service.

• If automatic fill is used, the system will have to be checked periodically to make sure the antifreeze concentration has not been diluted below design level.

• Local codes may require the use of a backflow preventer or manual fill only with separation from the city supply.

• Consider the minimum temperature of potential exposure for the system when deciding on the antifreeze concentration. A concentration of 50% generally provides protection from freezing down to -30°F.

3. Purge the air from the system.

4. Run burner check-out. a) Before firing the burner, slide the Slide Gate

Damper on the rear flue box all the way down (full open).

b) Follow the instructions in the Burner Manual for

starting the burner, adjusting air openings and fuel rates. Perform ignition system and flame supervisory control test and checkout as described in the manual.

c) After burner is set at rate, close the damper until

the pressure reading at the test opening in the rear flue box is between 0.0" wc and 0.1" wc positive.

d) When a barometric draft regulator is installed in

the venting system, adjust the boiler damper for

0.0” wc pressure reading at the damper. Adjust the draft regulator for -0.05" wc draft between the boiler damper and the draft regulator.

e) Adjust the burner as needed for a CO

reading of:

1. Oil burners: 12% to 12.5% or 1% less than the level at which the smoke reading goes above a trace on the Bacharach scale.

2. Natural gas burners: 9% to 10% with CO less than 50 ppm.

5. Check boiler controls. a) Limit and Operating Controls

1. Lower the setting of each control until the burner shuts down.

b) Low Water Cutoffs

On installations with high draft, do not leave the boiler with a negative draft reading at the rear flue box or draft damper. High negative draft can pull the flame up into the boiler crown sheet and overheat the iron. This can result in cracked sections or shortened boiler life.

CAUTION

Check the system for leaks and make sure the automatic fill valve (if used) and the expansion tank are operating correctly. Leakage or weeping of the relief valve will cause make-up water to be added to the system. Excessive make-up water will damage the boiler and system components due to liming and oxygen corrosion.

CAUTION

4. OPERATION

OPERATION

Page 31

OPERATION

1. Test probe type controls by using the Pushto-Test Button.

2. Test float type controls. ASME CSD-1 requires the control to be piped with Test-n-Check valves in order to allow isolation for test.

c) Follow additional instructions in the Burner

Manual for proving the burner component operation.

d) Check all controls to make sure they function

correctly.

e) After all controls have been proven, set the

Operating and High Limit Controls to the set point desired.

B. CLEANING BOILER WATERWAYS

Steam Boilers

1. The boiler must be completely assembled before cleaning. The burner must be installed and made operational with the operating, limit and safety controls functional. Combustion should be adjusted to prevent sooting of the boiler flues.

2. Final burner adjustment is to be made after cleaning. Plug any unused boiler tappings and install gauge glass and safety valve.

3. Install a 2" skim valve and fittings in the 6" N.P.T. tapping of the front section. See Figure 4.1.

4. Clean the boiler as described below no later than one week after the initial start-up. Cleaning will be more effective if the boiler operates a day or two to loosen sediment and impurities in the system.

5. The boiler must be cleaned to remove any accumulation of oil, grease, sludge, etc. that may be in the system. These substances can cause foaming and surging of the boiler water, producing unstable water line and water carryover to the system.

6. Connect a 2 inch drain line off of the skim valve, run to a point of safe discharge.

7. Close all valves to the system. Provide a means of continuous fresh water to the boiler for the cleaning process.

8. Use common washing soda (such as Arm and Hammer Super Washing Soda). Mix the soda with water in a 10 quart pail and pour into the boiler through the safety valve tapping. Use a proportion of one (1) pound of washing soda for each 800 square feet EDR net boiler rating.

9. Open the skim valve. Fill the boiler until water begins to flow out of the valve.

10. Turn burner on and allow the boiler water to heat up to just below steaming (180° to 200°F). Cycle the burner to maintain temperature during skimming. Do not allow the boiler to steam. Steaming mixes up the contaminants in the water instead of floating them at the surface.

11. Open the make-up water valve to continuously feed water to the boiler. Allow water to flow out the skim tapping.

12. Continue skimming the boiler until the water flowing from the skim tapping flows clear. This will take some time, possibly several hours for a dirty system.

13. After skimming is complete, close the skim valve and turn off the boiler.

14. Close the make-up water valve and open the boiler blowdown valves.

15. Drain the boiler completely then refill and drain again one or two times to make sure all of the soda has been washed out.

16. Restore piping to normal. Pipe a nipple and cap in the skim valve.

17. Note: If the gauge glass becomes dirty again, this indicates more contaminants have worked loose in the system. Repeat the cleaning and skimming process as needed to clean the system.

Do not leave the boiler unattended while firing during the cleaning cycle.

Take great care not to allow the water level to drop below the bottom of the gauge glass or to allow fresh water make-up to flow in too fast. This will avoid the possibility of causing the boiler sections to fracture.

CAUTION

Cleaning the boiler requires the use of very hot water and corrosive chemicals. Use care when handling to prevent injury.

WARNING

Figure 4.1: Skim Valve Piping

Page 32

1. Placing boiler in operation. a) Start up the Burner/Boiler per the Burner Manual

and the instructions in this manual on starting the boiler.

b) Prove the correct operation of all controls on the

boiler and burner as outlined below.

c) Check the operation of the ignition and flame

proving controls as described in the Burner Manual.

d) Test the limit and operating controls to assure

they are operating correctly.

e) Inspect and test all low water cutoffs.

f) Test the safety relief valve(s) using the procedure

given by the valve manufacturer on the valve tag.

g) Visually inspect the burner and pilot flames (if

applicable).

2. To shut down the boiler. a) Turn off Burner.

b) Open main line power disconnect switch to

boiler/burner.

c) Close fuel shut-off valves.

d) To take boiler out of service if the boiler and

system are not to be used when temperatures are below freezing:

1. Shut off make-up water supply and drain the boiler and system completely.

2. Open main line power disconnect switch to boiler/burner. Remove the fuses or secure the switch so that the power cannot be turned on accidentally.

3. Do not use ethylene glycol antifreeze in a boiler system.

4. Be certain that the boiler and system are refilled before returning to service. Follow the instructions in this manual and the burner instructions to operate.

3. Maintenance – Annual a) Before the start of each heating season,

inspect and make all necessary adjustments to insure proper boiler and burner operation. Use the maintenance and inspection procedures following.

b) Inspect the Venting System

1. Check the chimney or vent to make sure it is clean and free from cracks or potential leaks.

2. All joints must be tight and sealed.

3. The vent connector must extend into, but not beyond the inside edge of the chimney or vent.

c) Inspect the Boiler Area

1. The boiler area must be clean and free from combustible materials, gasoline or any other flammable liquids or vapors.

2. The combustion air openings and the area around the boiler must be unobstructed.

d) Inspect boiler flueways and burner for

cleanliness. If cleaning is required, use the following procedure.

1. Turn off all electrical power to the boiler.

2. Remove left jacket panels. Remove cleanout cover plates on each flueway.

3. Brush the boiler flue areas through cleanout openings.

4. Remove the burner and burner mounting plate. Remove any scale or soot from the combustion chamber by means of vacuum cleaning or other available means.

5. Reinstall the burner mounting plate, burner and all cleanout cover plates. Make sure all sealing rope and seals are in good condition. Replace sealing rope if necessary.

6. Reinstall all jacket panels.

e) Inspect the boiler and piping for signs of leaks.

Check to see if there are signs of heavy make-up water addition to the system.

MAINTENANCE

5. MAINTENANCE

Do not store or allow combustible or flammable materials near the boiler. Substantial fire or explosion hazard could result, causing risk of personal injury, death or property damage.

Do not use this boiler if any part of it has been under water. Immediately call a qualified service technician to inspect the boiler. Any part of the control system, any gas control or any burner or gas component which has been under water must be replaced.

Should overheating occur or the fuel supply fail to shut off: Shut off the fuel supply at a location external to the boiler. Do not turn off or disconnect the electrical supply to the pump. Immediately call a qualified service technician to inspect the boiler for damage and defective components.

WARNING

Before servicing the boiler:

· Turn off all electrical power to the boiler.

· Close the Gas Service Valve and Oil Shut-Off Valve.

· Allow the boiler to cool if it has been operating.

· Label all wires prior to disconnection when

servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

CAUTION

Page 33

f) When placing boiler into operation, follow

burner manual, all instructions supplied with the boiler and the instructions in this chapter.

g) Test the operation of all limit controls, float

controls and ignition components.

4. Monthly Maintenance a) Inspect the burner and pilot flames.

b) Inspect the boiler and system for any signs of

leakage or excessive make-up water usage.

c) Inspect and check the operation of the venting

system.

5. Daily Maintenance a) Inspect the boiler area to make sure the area is

free from combustible or flammable materials and that there are not obstructions to the flow of air to the boiler or combustion air openings to the room.

b) Make sure there are no signs of abnormal

operation, such as overfilling or leakage.

STEAM BOILERS: Do not place cold boilers in service on a hot steam line or severe damage may occur to boiler and piping. Keep cold boilers valved off line, fire until boiler reaches line pressure and then open steam main isolation valve. Steam entering a cold boiler cools quickly causing severe steam hammer. Boilers not valved off the system should have an overflow installed to prevent idle boilers from flooding. If this is not done, cold boilers must be heated to near steaming conditions (210°F) before the water level is dropped to normal.

WATER BOILERS: Avoid thermal shock of water boilers. Establish water circulation through the boiler before starting burner. Where hot standby is required, special piping and operation procedures are required. Consult your PB Heat, LLC representative.

NOTICE

Be vary careful when adding water to a hot boiler. Add very slowly or, if possible, allow the boiler to cool naturally before adding water.

CAUTION

MAINTENANCE

If an excessive loss of water occurs, check for a leak in the piping and correct the problem. Excessive make-up water will cause corrosion and damage to the boiler.

NOTICE

Page 34

REPAIR PARTS

Figure 6.1: Boiler Assembly

Repair parts are available from your installer or by contacting PB Heat, LLC, 131 S. Church, Bally, PA 19503. Use the Figures and Tables on pages 32-33 to assist in ordering parts.

Note: Remember to include boiler model number and serial number when ordering parts.

6. REPAIR PARTS

Page 35

REPAIR PARTS

Table 6.1: Series TC™ Repair Parts

Item No. Description Stock Code

1 Front Section 76000

Intermediate Section 76002

2 Intermediate Section w/Heater Connection 76004

4 Intermediate Section w/Supply Connection 76003

5 Back Section 76001

Flue Collector Assembly includes: Flue Collector, Slide Damper and Angle Bracket

Flue Collector Assembly (4-6 Section) 76060

Flue Collector Assembly (7-8 Section) 76061

Flue Collector Assembly (9-13 Section) 76062

Flue Collector Assembly (14-18 Section) 76063

Slide Damper Only (4-8 Section) 7664

Slide Damper Only (9-13 Section) 7679

Slide Damper Only (14-18 Section) 7680

11 16"to 18"Increaser (17-18 Section) 76064

12 Tankless Coil Cover Plate Assembly 76075

13 Tankless Coil Cover Plate Gasket 74019

13A Tankless Coil (8 GPM) 76073

13B Tankless Coil (12 GPM) 76074

Cleanout Cover Plate Assembly Includes: Cleanout Plate, Insulation, Rope and Hardware

15 Cleanout Cover Plate 7807

16 Cleanout Cover Plate Bolts 7622

17 Cleanout Cover Plate Nut 51556

18 Cleanout Cover Plate Washer 86

19 Cleanout Cover Plate Insulation 7808

Burner Mounting Plate Assembly Includes: Burner Mounting Plate Observation Port Glass, and Cover

Burner Mounting Plate Assembly - 7-3/4

76028

Burner Mounting Plate Assembly - 8-1/2

76023

Burner Mounting Plate Assembly - 9

76027

Burner Mounting Plate Assembly - 10-1/4"(Web-JB2) 76026

Burner Mounting Plate Assembly - 10-1/4"(GP-R10.1) 76025

Burner Mounting Plate Assembly - 10-1/4"(STD) 76024

Burner Mounting Plate Assembly - 12-1/2

76022

– Burner Mounting Plate Hardware 7653

21 Burner Insulating Block 76029

Item No. Description Stock Code

– Burner Insulating Block Hardware 7720

22 Observation Glass Only 7648

23 Observation Glass Gasket 7650

24 Observation Glass Gasket 7649

25 Observation Glass Retainer 7651

26 Observation Cover Plate 7677

27 Rope Seal (3/8"x 7 ft. Long) 55521

28 Upper Graphite Port Connector 7655

29 Lower Graphite Port Connector

– Rope Seal (1/2"x 12-1/2 ft. Long) Between Sections 7964

33 5/8"x 11"Draw Rod 7621

34 5/8"Hex Nuts 51567

35 5/8"Washer 7289

– Spray Adhesive 55485

36 Rear Observation Port Assembly 7632

– Rear Observation Port Hardware 7722

Steam Trim and Controls

37 3-1/2” Steam Gauge w/Internal Syphon 51769

38 Gauge Glass Set 50521

1-1/4"Safety Relief Valve 15 PSI (4-5 Section) 50508

1-1/2"Safety Relief Valve 15 PSI (6-7 Section) 50509

2"Safety Relief Valve 15 PSI (8-10 Section) 50503

2-1/2"Safety Relief Valve 15 PSI (11-13 Section) 50504

3"Safety Relief Valve 15 PSI (14-16 Section) 50505

2-1/2"Safety Relief Valve 15 PSI (17-18 Section) 50511

40 PA404A Operating Control 50549

41 L4079B Limit Control 50681

Water Trim and Controls

42 Pressure/Temperature Gauge 55737

3/4"- 30 PSI Water Relief Valve (4 Section) 51300

39 1"- 30 PSI Water Relief Valve (4-6 Section) 51301

1-1/4"- 30 PSI Water Relief Valve (7-10 Section) 51302

1-1/2"- 30 PSI Water Relief Valve (11-14 Section) 51303

2"- 30 PSI Water Relief Valve (15-18 Section) 51304

44 L4006A Operating Control 51702

45 L4006E Limit Control 50570

46 Water Return Yoke (Not Shown) 76072

Page 36

BOILER RATINGS & DIMENSIONS

7. BOILER RATINGS & DIMENSIONS

Table 7.1a: Series TC™ Boiler Ratings (U.S. Customary Units)

Notes: 1. Net I=B=R Ratings are based on an allowance of 1.15 for Water Boilers. Net I=B=R Ratings for steam boilers are based on a pick-up factors as follows:

TC-04 & TC-05, 1.333; TC-06, 1.316; TC-07, 1.297; TC-08 through TC-18, 1.288.

2. Burner oil input based on Commercial Standard #2 fuel oil with a heating value of 140,000 BTU/Gal.

3. Burner natural gas input based on natural gas with a heating value of 1,000 BTU/Cu. Ft. and a specific gravity of 0.60.

Table 7.1b: Series TC™ Boiler Ratings (SI Metric Units)

TC™ Series

Model

Number

Input³

MBH

Gross

Output

MBH

Net I=B=R Ratings¹ Gas Oil

Steam

sqft

Steam

MBH

Water

MBH

Combustion

Efficiency

Thermal

Efficiency

Combustion

Efficiency

Thermal

Efficiency

TC- 04 1154 900 2813 675 783 81.0 78.0 83.5 80.4

TC- 05 1491 1166 3645 875 1014 81.0 78.2 83.5 80.7

TC- 06 1827 1433 4537 1089 1246 81.0 78.4 83.5 80.8

TC- 07 2163 1699 5458 1310 1477 81.0 78.5 83.5 81.0

TC- 08 2499 1965 6357 1526 1709 81.0 78.6 83.5 81.1

TC- 09 2836 2232 7220 1733 1941 81.0 78.7 83.5 81.1

TC- 10 3172 2498 8081 1939 2172 81.0 78.8 83.5 81.2

TC- 11 3508 2764 8942 2146 2403 81.0 78.8 83.5 81.2

TC- 12 3844 3031 9805 2353 2636 81.0 78.8 83.5 81.3

TC- 13 4180 3297 10,666 2560 2867 81.0 78.9 83.5 81.3

TC- 14 4517 3563 11,526 2766 3098 81.0 78.9 83.5 81.3

TC- 15 4853 3830 12,390 2974 3330 81.0 78.9 83.5 81.4

TC- 16 5189 4096 13,251 3180 3562 81.0 78.9 83.5 81.4

TC- 17 5525 4362 14,111 3387 3793 81.0 79.0 83.5 81.4

TC- 18 5862 4629 14,975 3594 4025 81.0 79.0 83.5 81.4

Boiler

Oil

Input

GPH

Water Content

Furnace Volume

(Cu. Ft.)

Boiler

Working

Weight

(Lbs)

Heating Surface

(sqft)

Steam

(Gallons)

Water

(Gallons)

27 8.0 103.8 123.4 12.04 4215 81.2

35 10.4 125.8 150.3 16.14 5038 105.3

43 12.6 147.8 177.2 20.24 5861 129.4

51 15.0 169.8 204.1 24.34 6684 153.5

59 17.4 191.8 231.0 28.44 7507 177.6

67 19.6 213.8 257.9 32.54 8331 201.7

75 22.0 235.8 284.8 36.64 9169 225.8

83 24.5 257.8 311.7 40.74 9992 249.9

91 26.5 279.8 338.6 44.84 10,815 274.0

98 29.0 301.8 365.5 48.94 11,649 289.1

106 31.5 323.8 392.4 53.04 12,467 322.2

114 33.5 345.8 419.3 57.14 13,511 346.3

122 36.0 367.8 446.2 61.24 14,375 370.4

130 38.5 389.8 473.1 65.34 15,239 394.5

138 40.5 411.8 500.0 69.44 16,103 418.6

Notes: 1. Net I=B=R Ratings are based on an allowance of 1.15 for Water Boilers. Net I=B=R Ratings for steam boilers are based on a pick-up factors as follows:

TC-04 & TC-05, 1.333; TC-06, 1.316; TC-07, 1.297; TC-08 through TC-18, 1.288.

2. Burner oil input based on Commercial Standard #2 fuel oil with a heating value of 39,000 kJ/liter.

3. Burner natural gas input based on natural gas with a heating value of 37,234 KJ/m

and a specific gravity of 0.60.

TC™ Series

Model

Number

Input³,

Gross

Output

Net I=B=R Ratings¹ Gas Oil

Steam

SteamkWWater

Combustion

Efficiency

Thermal

Efficiency

Combustion

Efficiency

Thermal

Efficiency

TC- 04 338.2 263.8 261 198 229 81.0 78.0 83.5 80.4

TC- 05 437.0 341.7 339 256 297 81.0 78.2 83.5 80.7

TC- 06 535.4 420.0 422 319 365 81.0 78.4 83.5 80.8

TC- 07 633.9 497.9 507 384 433 81.0 78.5 83.5 81.0

TC- 08 732.4 575.9 591 447 501 81.0 78.6 83.5 81.1

TC- 09 831.1 654.1 671 508 569 81.0 78.7 83.5 81.1

TC- 10 929.6 732.1 751 568 637 81.0 78.8 83.5 81.2

TC- 11 1028.1 810.0 831 629 704 81.0 78.8 83.5 81.2

TC- 12 1126.5 888.3 911 690 772 81.0 78.8 83.5 81.3

TC- 13 1225.0 966.2 991 750 840 81.0 78.9 83.5 81.3

TC- 14 1323.8 1044.2 1071 811 908 81.0 78.9 83.5 81.3

TC- 15 1422.2 1122.4 1151 871 976 81.0 78.9 83.5 81.4

TC- 16 1520.7 1200.4 1231 932 1044 81.0 78.9 83.5 81.4

TC- 17 1619.2 1278.4 1311 993 1112 81.0 79.0 83.5 81.4

TC- 18 1718.0 1356.6 1391 1053 1180 81.0 79.0 83.5 81.4

Oil

Input

l/hr

Water Content

Furnace

Volume

Boiler

Working

Weight

Heating Surface

Steam

Liters

Water Liters

30.3 393 467 0.3409 1916 7.54

39.4 476 569 0.4570 2290 9.78

47.7 559 671 0.5731 2664 12.02

56.8 643 773 0.6892 3038 14.26

65.9 726 874 0.8053 3412 16.50

74.2 809 976 0.9214 3787 18.74

83.3 893 1078 1.0375 4168 20.98

92.7 976 1180 1.1536 4542 23.22

100.3 1059 1282 1.2697 4916 25.46

109.8 1142 1383 1.3858 5295 26.86

119.2 1226 1485 1.5019 5667 29.93

126.8 1309 1587 1.6180 6141 32.17

136.3 1392 1689 1.7341 6534 34.41

145.7 1457 1791 1.8502 6927 36.65

153.3 1559 1893 1.9663 7320 38.89

Page 37

BOILER RATINGS & DIMENSIONS

Figure 7.1: Boiler Dimensions – Side View

Figure 7.2: Boiler Dimensions – Auxiliary Views

Page 38

BOILER RATINGS & DIMENSIONS

Boiler

Model

Overall Length - "A"² (inch)

Optional

Packaged

Base

Dimension

"K"

(inch)

Firebox

Length "B"

(inch)

Boiler

Length

"C"

(inch)

Riser Tapping Locations

Dia. Vent

Conn.

"G"

(inch)

Height

Ven t

Conn.

"H"

(inch)

Base

Height

"J"

(inch)Beckett Carlin

Pow er Flame Webster

"D"

(inch)

"E"

(inch)

"F"

(inch)

TC- 04 64-1/4 62-1/4 71-3/4 66-1/2 91-1/4 23-5/16 33 12.5 - - 10 57.625 6 TC- 05 72-1/4 70-1/4 83-1/4 74-1/2 104-1/4 31-5/16 41 20.5 - - 10 57.625 6 TC- 06 80-1/4 80-1/4 91-1/4 82-1/2 112-1/4 39-5/16 49 12.5 16 - 10 57.625 6 TC- 07 88-3/4 88-1/4 99-1/4 90-1/2 120-1/2 47-5/16 57 12.5 24 - 12 56.625 6 TC- 08 96-3/4 96-1/4 107-1/4 98-1/2 128-1/2 55-5/16 65 12.5 32 - 12 56.625 6 TC- 09 104-3/4 108-3/4 115-1/4 110-1/2 136-1/2 63-5/16 73 12.5 40 - 14 55.625 6 TC- 10 116-1/2 116-3/4 128-1/4 118-1/2 144-3/4 71-5/16 81 20.5 40 - 14 55.625 6 TC- 11 124-1/2 125-1/4 137-1/4 126-1/2 157-3/4 79-5/16 89 20.5 24 24 14 55.625 6 TC- 12 132-1/2 133-1/4 145-1/4 134-1/2 166-1/4 87-5/16 97 20.5 24 32 14 55.625 6 TC- 13 N/A 141-1/4 153-1/4 142-1/2 173-3/4 95-5/16 105 20.5 32 32 14 55.625 6 TC- 14 N/A 149-1/4 161-1/4 150-1/2 181-3/4 103-5/16 113 20.5 32 40 16 54.625 6 TC- 15 N/A N/A 169-1/4 158-1/2 189-7/8 111-5/16 121 20.5 40 40 16 54.625 8 TC- 16 N/A N/A 177-1/4 166-1/2 198-1/4 119-5/16 129 20.5 48 40 16 54.625 8 TC- 17 N/A N/A 191-1/4 183-3/4 211-1/4 127-5/16 137 20.5 48 48 18 54.625 8 TC- 18 N/A N/A 199-1/4 191-3/4 219-1/4 135-5/16 145 20.5 56 48 18 54.625 8

Table 7.2a: Boiler Dimensions (U.S. Customary Units)

Table 7.2b: Boiler Dimensions (SI Metric Units)

Boiler

Model

Overall Length - "A"² (mm)

Optional

Packaged

Base

Dimension

"K"

(mm)

Firebox

Length "B"

(mm)

Boiler

Length

"C"

(mm)

Riser Tapping Locations

Dia. Vent

Conn.

"G"

(mm)

Height

Ven t

Conn.

"H"

(mm)

Base

Height

"J"

(mm)

Beckett Carlin

Pow er Flame Webster

"D"

(mm)

"E"

(mm)

"F"

(mm)

TC- 04 1632 1581 1822 1689 2318 592 838 318 - - 254 1464 152 TC- 05 1835 1784 2115 1892 2648 795 1041 521 - - 254 1464 152 TC- 06 2038 2038 2318 2096 2851 999 1245 318 406 - 254 1464 152 TC- 07 2254 2242 2521 2299 3061 1202 1448 318 610 - 305 1438 152 TC- 08 2457 2445 2724 2502 3264 1405 1651 318 813 - 305 1438 152 TC- 09 2661 2762 2927 2807 3467 1608 1854 318 1016 - 356 1413 152 TC- 10 2959 2965 3181 3010 3677 1811 2057 521 1016 - 356 1413 152 TC- 11 3162 3181 3486 3213 4007 2015 2261 521 610 610 356 1413 152 TC- 12 3366 3385 3689 3416 4223 2218 2464 521 610 813 356 1413 152 TC- 13 N/A 3588 3893 3620 4413 2421 2667 521 813 813 356 1413 152 TC- 14 N/A 3791 4096 3823 4616 2624 2870 521 813 1016 406 1387 152 TC- 15 N/A N/A 4299 4026 4823 2827 3073 521 1016 1016 406 1387 203 TC- 16 N/A N/A 4502 4229 5036 3031 3277 521 1219 1016 406 1387 203 TC- 17 N/A N/A 4858 4667 5366 3234 3480 521 1219 1219 457 1387 203 TC- 18 N/A N/A 5061 4870 5569 3437 3683 521 1422 1219 457 1387 203

Notes:

1. When unit is assembled or packaged, add dimension “J” to all height dimensions.

2. Add 2-3/4" (70 mm) to TC-17 & TC-18 for flue outlet adapter.

BOILER RATINGS & DIMENSIO

Page 39

PB HEAT, LLC

131 S. CHURCH STREET • BALLY, PA 19503

™

Gas/Oil Boilers

Series

Oil, Gas &

Installation, Operation & 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.

ASME

TC8001 R7 (7/11-5C)

Printed in U.S.A.