PB Heat TC Series, TC-04, TC-05, TC-06, TC-07 Installation, Operation & Maintenance Manual
...
TC
™
Gas/Oil Boilers
Series
Oil, Gas &
Installation,
Operation &
Maintenance
Manual
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
TABLE OF CONTENTS
1
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
USING THIS MANUAL
Indicates a condition or hazard which may potentially
cause severe personal injury, death or major property
damage.
WARNING
2
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
3
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.
4
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.
5
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)
6
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
7
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)
8
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
D
76025 JB2
TC- 10
CF2500
76026
R10.1
TC- 11
76024
1150FF
D
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
9
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
10
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
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