PEERLESS PSC II Series Installation, Operation & Maintenance Manual

PSC

II

™

Boilers

Series

Gas

Installation,
Operation &
Maintenance
Manual

As an ENERGY STAR®Partner, PB Heat, LLC has determined that this
product meets the ENERGY STAR guidelines for energy efficiency.

USING THIS MANUAL 1

A. INSTALLATION SEQUENCE . . . . . . . . . . . . .1

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

1. PREINSTALLATION 2

A. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2

B. CLEARANCE FROM COMBUSTIBLE

CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . .2

C. INSTALLATION SURVEY . . . . . . . . . . . . . . . .2

D. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .2

E. MASSACHUSETTS INSTALLATIONS . . . . . .2

2. BOILER SET-UP 4

3. WATER PIPING AND CONTROLS 5

A. BOILER SUPPLY AND RETURN . . . . . . . . . . .5

B. SAFETY RELIEF VALVE . . . . . . . . . . . . . . . . .6

C. PIPING FOR ZONED SYSTEMS . . . . . . . . . .7

D. EXPANSION TANK . . . . . . . . . . . . . . . . . . . . .8

E. INDIRECT-FIRED WATER HEATER . . . . . . . .8

F. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .8

4. VENTING, VENTILATION AND
AIR INLET 9

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

B. WALL THIMBLE . . . . . . . . . . . . . . . . . . . . . . .9

C. ROOF TERMINATIONS . . . . . . . . . . . . . . . .11

D. CONDENSATE TRAP INSTALLATION . . . . .11

E. VENT PIPE INSTALLATION . . . . . . . . . . . . .12

F. AIR INLET PIPE INSTALLATION . . . . . . . . .12

G. AIR FOR VENTILATION . . . . . . . . . . . . . . . .12

H. BOILER REMOVAL FROM COMMON

VENTING SYSTEM . . . . . . . . . . . . . . . . . . .12

5. GAS PIPING 14

6. ELECTRICAL 15

A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

B. ZONED SYSTEM WIRING . . . . . . . . . . . . . .15

C. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . .15

D. SEQUENCE OF OPERATION . . . . . . . . . . . .16

7. START-UP PROCEDURES 19

A. COMPLETING THE INSTALLATION . . . . . .19

B. CONTROL DESCRIPTIONS . . . . . . . . . . . . .22

C. ADJUSTMENT OF GAS PRESSURE

REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . .22

D. CHECKING BURNER INPUT . . . . . . . . . . . . .22

E. CHECK-OUT PROCEDURE . . . . . . . . . . . . . .22

8. TROUBLESHOOTING 24

A. SHUT-DOWN CAUSED BY PILOT OUTAGE,

PRESSURE SWITCH OR FLAME ROLL-OUT

SAFETY SHUT-OFF SWITCH . . . . . . . . . . . .24

B. TROUBLESHOOTING GUIDES . . . . . . . . . .24

C. MEASURING SUCTION PRESSURE . . . . . .24

9. MAINTENANCE 27

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .28

B. DAILY (WITH BOILER IN USE) . . . . . . . . . . .28

C. WEEKLY (WITH BOILER IN USE) . . . . . . . . .28

D. MONTHLY (WITH BOILER IN USE) . . . . . . .28

E. ANNUALLY (BEFORE START OF HEATING

SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . .28

10. BOILER DIMENSIONS & RATINGS 31

11. REPAIR PARTS 32

TABLE OF CONTENTS

TABLE OF CONTENTS

A. INSTALLATION SEQUENCE

Follow the installation instructions provided in this
manual in the order shown. The order of these
instructions has been set in order to provide the installer
with a logical sequence of steps that will minimize
potential interferences and maximize safety during
boiler installation.

B. SPECIAL 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 PB Heat, LLC:

1

USING THIS MANUAL

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 minor 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 cause
severe personal injury, death or major property
damage.

WARNING

A. ACCESSIBILITY CLEARANCES

Install boiler not less than 24" (610 mm) between the left
side, top, and front of the boiler and adjacent wall or
other appliance, when access is required for servicing.

B. CLEARANCE FROM COMBUSTIBLE

CONSTRUCTION

The design of this boiler is certified for closet installation
with the following clearances:

1. 6" (152 mm) between right side, front and
combustible construction.

2. 12" (305 mm) between top of jacket and combustible
construction.

3. 1" (25 mm) between left side, rear and combustible
construction.

4. 2" (51 mm) between vent pipe and combustible
construction.

5. Zero clearance between wall thimble and combustible
construction.

6. This boiler is design certified for use on combustible
flooring.

C. INSTALLATION SURVEY

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

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

D. PLANNING THE LAYOUT

Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring. Review limitations
on vent pipe, vent terminal, and air inlet pipe locations
and ventilation air requirements in Section 4.

E. MASSACHUSETTS INSTALLATIONS

Massachusetts requires manufacturers of Side Wall
Vented boilers to provide the following information
from the Massachusetts code:

•

A hard wired carbon monoxide detector with an
alarm and battery back-up must be installed on
the floor level where the gas equipment is to be
installed AND on each additional level of the
dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment.

•

In the event that the side wall horizontally vented
gas fueled equipment is installed in a crawl space
or an attic, the hard wired carbon monoxide
detector with alarm and battery back-up may be
installed on the next adjacent floor level.

•

Detector(s) must be installed by qualified licensed
professionals.

•

APPROVED CARBON MONOXIDE

2

PREINSTALLATION

1. PREINSTALLATION

Do not install this boiler on carpeting. Boiler
installation on carpeting is a fire hazard. Install this
boiler on non-combustible flooring or use a
combustible floor pan to install this boiler on other
non-carpeted flooring.

DANGER

Liquefied Petroleum (LP) is heavier than air and may
collect or “pool” in a low area in the event of a leak
from defective equipment. This gas may then ignite,
resulting in a fire or explosion.

WARNING

Read carefully, study these instructions before beginning work.

This boiler must be installed by a qualified contractor.

The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly.

The equipment must be installed in accordance with those installation requirements of the authority having
jurisdiction or, in the absence of such requirements, to the current edition of the

National Fuel Gas Code,

ANSI

Z223.1/NFPA 54 and/or CAN/CSA B49.1,

Natural Gas and Propane Installation Code

.

Where required by the authority having jurisdiction, the installation must conform to

American Society of Mechanical

Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers,

ANSI/ASME CSD-1.

NOTICE

DETECTORS: Each carbon monoxide detector
shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.

•

SIGNAGE: A metal or plastic identification plate
shall be permanently mounted to the exterior of
the building at a minimum height of eight (8) feet
above grade directly in line with the exhaust vent
terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall
read, in print size no less than one-half (1/2) inch
in size, “GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS”.

•

EXEMPTIONS to the requirements listed above:

°

The above requirements do not apply if the
exhaust vent termination is seven (7) feet or
more above finished grade in the area of the
venting, including but not limited to decks and
porches.

°

The above requirements do not apply to a
boiler installed in a room or structure separate
from the dwelling, building or structure used in
whole or in part for residential purposes.

•

This boiler installation manual shall remain with
the boiler at the completion of the installation.

See the latest edition of Massachusetts Code 248 CMR
for complete verbage and also for additional (non-vent
related) requirements (248 CMR is available online).

If your installation is NOT in Massachusetts, please
see your authority of jurisdiction for requirements that
may be in effect in your area. In the absence of such
requirements, follow the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.

Venting System Installation Instructions – See
boiler manual and instructions provided with the
Venting System components. Additional copies may
be obtained from the Venting System Manufacturer by
visiting the following web addresses:

Heat-Fab – www.selkirkcorp.com/heatfab
Z-Flex – www.NovaFlex.com
Pro-Tech – www.protechinfo.com

3

PREINSTALLATION

4

1. Provide a sound, level foundation. Locate boiler as
near to the outside wall as possible and centralized
with respect to the heating system.

2. Locate boiler in front of installation position before
removing crate.

4. Separate the wood shipping pallet from the boiler
base by removing two (2) hold-down bolts at each
end of the boiler base.

5. Move boiler into final position.

BOILER SET-UP

2. BOILER SET-UP

5

A. BOILER SUPPLY AND RETURN

1. Size the supply and return to suit the system. A typical
piping arrangement is shown in Figure 3.1. Refer also
to the Hydronics Institute Residential Hydronic
Heating Installation Design Guide and the PB Heat
Water Survey for additional guidance during water
piping installation.

2. Return Piping:
Pipe the outlet connection of the circulator to a tee,

provided with a drain valve, at the 1-1/4" NPT return
tapping near the bottom of the right section. Pipe the
return to the inlet connection of the circulator.

3. Supply Piping:
a. Pipe the supply to the 1-1/2" NPT supply tapping

at the top of the boiler.

b. Provide clearance to venting system

(see Section 4).

4. When system return water temperature will be below

130°F (54°C), pipe the boiler with a bypass
arrangement to blend the system return and hot
supply to obtain at least 130°F (54°C)entering the
boiler. For more information on bypass piping, consult
the PB Heat Water Survey.

5. If desired, install the circulator in the alternate location

shown in Figure 3.1. Consult the PB Heat Water
Survey for more information on circulator location.

WATER PIPING AND CONTROLS

3. WATER PIPING AND CONTROLS

Figure 3.1: Supply and Return Piping

6. Install this boiler so that the gas ignition system
components are protected from water (dripping,
spraying, etc.) during appliance operation and service
(circulator replacement, condensate trap, control
replacements, etc.).

7. If this boiler and distribution system is used in
conjunction with a refrigeration system, pipe the
chilled medium in parallel with the boiler and install
the proper valve to prevent the chilled medium from
entering the boiler. A drawing illustrating this hook-up
is provided in Figure 3.2.

8. When the boiler is connected to heating coils located
in air handling units where they may be exposed to
refrigerated air circulation, install flow control valves
or other automatic means to prevent gravity
circulation of the boiler water during the cooling cycle.

9. If this boiler is installed above radiation level, provide
a low water cutoff device, either as a part of the boiler
or at the time of boiler installation.

B. SAFETY RELIEF VALVE

1. Locate safety relief valve and fittings in bag assembly.

2. If air elimination is not required at the safety relief
valve tapping, install valve and piping as shown in
Figure 3.3.

3. For air elimination at the safety relief valve tapping,
install valve and piping as shown in Figure 3.4.

6

WATER PIPING AND CONTROLS

Pipe the discharge of safety relief valve to prevent
injury in the event of pressure relief. Pipe the
discharge to a drain. Provide piping that is the same
size as the safety relief valve outlet.

CAUTION

Figure 3.4: Safety Relief Valve Hook-Up with

Air Elimination

Figure 3.3: Safety Relief Valve Hook-Up

Installation with Air Elimination in
System Piping

Figure 3.2: Parallel Hook-up with Water Chiller

C. PIPING FOR ZONED SYSTEMS

1. See Figures 3.5 and 3.6 for basic zoned system
layouts.

2. Run each zone pipe down then up to zone to prevent
air accumulation in piping.

3. If required, provide means to isolate and drain each
zone separately.

7

WATER PIPING AND CONTROLS

Figure 3.5: Zone Piping with Zone Valves

Figure 3.6: Zone Piping with Circulators

8

D. EXPANSION TANK

1. Consult the tank manufacturer’s instructions for
specific information relating to tank installation. Size
the expansion tank for the required system volume
and capacity. See Table 10.2 in Section 10 for boiler
water capacity.

2. Expansion tanks are available with built-in fill valves
and check valves for reducing supply water pressure
and maintaining minimum system pressure. Check the
design features of the tank and provide valves as
necessary.

Refer back to Figure 3.1 for typical expansion tank piping.

E. INDIRECT-FIRED WATER HEATER

If the boiler is to be used in conjunction with an indirect­fired water heater, refer to Figure 3.7 for typical piping.
Follow the instructions provided by the water heater
manufacturer. Pipe the water heater as a separate zone.

F. FREEZE PROTECTION

For new or existing systems that must be freeze-protected:

1. Glycol in hydronic applications is specially formulated
for this purpose. It includes inhibitors which prevent
the glycol from attacking metallic system components.
Make certain that the system fluid is checked for the
correct glycol concentration and inhibitor level.

2. The glycol solution should be tested at least once a
year and as recommended by the antifreeze
manufacturer.

3. Glycol solutions expand more than water. For
example, a 50% by volume solution expands 4.8% in
volume for a temperature increase from 32°F (0°C) to
180°F (82°C) , while water expands 3% with the same
temperature rise. Allowance must be made for this
expansion in system design.

4. For more information, consult the PB Heat Water
Installation Survey and the antifreeze manufacturer.

A. GENERAL

WATER PIPING AND CONTROLS

Figure 3.7: Typical Piping with Indirect-Fired Water Heater

Use only inhibited propylene glycol solutions of up to
50% by volume with water. Ethylene glycol is toxic
and can attack gaskets and seals used in hydronic
systems.

WARNING

9

A. GENERAL

Install vent system in accordance with Venting of
Equipment part of the National Fuel Gas Code, ANSI
z223.1/NFPA 54 or sections 7.2, 7.3 or 7.4 of CAN/CSA
B149.1, Natural Gas and Propane Installation Code.

B. WALL THIMBLE (SIDEWALL

VENTING ONLY)

1. Determine vent cap (terminal) location.
a. Must be within the maximum and minimum vent

and air intake lengths shown in Tables 4.1 and 4.2.

b. Maximum wall thickness for the 19-1/2" (495 mm)

long Wall Thimble (standard) is 11-1/2" (292 mm).
Maximum wall thickness for the optional 28" (711
mm) long thimble is 20" (508 mm).

c. Provide 2" (51 mm) clearance between vent pipe

and combustible construction. No clearance is
required between Thimble and combustible
construction.

d. Provide 3 feet (1 meter) clearance above any

forced air inlet within 10 feet (3 meters).

e. Provide 1 foot (0.3 meters) clearance below and 1

foot (0.3 meters) beside, or 1 foot (0.3 meters)
above any door, window, or gravity air inlet into
any building.

f. Provide 1 foot (0.3 meters) clearance between

bottom of vent terminal and ground level and
normal snow lines.

g. Provide 4 feet (1.2 meters) horizontal clearance

from electric meters, gas meters, regulators and
relief equipment. In Canada, this dimension must
be 6 feet (2 meters).

h. Do not locate vent terminal over public walkways

where condensate could create a nuisance or
hazard.

i. When adjacent to a public walkway, locate vent

terminal at least 7 feet (2.1 meters) above grade.

j. Do not locate directly under roof overhangs to

prevent icicles from forming.

2. Cut a 5-1/8" (130 mm) square hole in sidewall to
allow Peerless

®

Wall Thimble to go through.

3. Insert Thimble from inside wall with 4" (102 mm)
diameter air inlet connection facing down. Extend
Thimble 3-1/2" (89 mm) past outside wall surface.
The cut-out opening of thimble is pointed down.

4. Use a minimum 2-1/2 foot (762 mm) piece of 3"
(76 mm) diameter AL29-4C stainless steel vent pipe
for insertion through Wall Thimble. See Vent Pipe
section below for vent pipe requirements.

VENTING, VENTILATION AND AIR INLET

4. VENTING, VENTILATION AND AIR INLET

Figure 4.1: Wall Thimble

This vent system will operate with a positive
pressure in the vent pipe. Do not connect vent
connectors serving appliances vented by natural
draft into any portion of mechanical draft systems
operating under positive pressure.

Flue gases will condense as they exit the vent
termination. This condensate can freeze on exterior
building surfaces which may cause discoloration of
these surfaces.

NOTICE

WARNING

WARNING

All joints of positive pressure vent systems must be
sealed completely to prevent leakage of flue products
into the living space.

10

5. Slide Stainless Steel Collar over vent pipe and slide to
end of pipe.

6. Insert pipe with collar through Outside Vent Cap and
slide 3" (76 mm) diameter hose clamp over collar.

7. Leave at least 2" (51 mm) of vent pipe protruding
beyond face of Vent Cap and secure hose clamp and
collar to vent pipe.

8. Place Outside Vent Cap over Wall Thimble with air
openings in Vent Cap facing down. Secure Cap to
Thimble with #10 sheet metal screws.

9. Place 3" (76 mm) diameter hose clamp over pipe
protruding through inside of Wall Thimble.

10. Place Inside Thimble Cap and Collar onto Wall
Thimble. Access hose clamp through 4" (102 mm)
diameter collar on bottom of Thimble and secure hose
clamp over collar and vent pipe as per step 7 above.

11. Secure Inside Thimble cap to Wall Thimble with #10
screws. Seal Thimble Cap perimeter with silicone.

12. Seal all openings between Wall and Thimble and
around the 3" (76 mm) diameter stainless steel vent
pipe that protrudes through inside and outside of Wall
Thimble.

13. Add any bracing that may be needed to support Wall
Thimble on inside of wall structure.

14. Secure Outside Vent Cap to exterior wall with four
#10 sheet metal screws provided.

15. Attach Z-Flex #2SVSTPF03 terminal to protruding
vent pipe. Refer to Figure 4.2. To attach to HEAT-FAB
pipe, insert into pipe end and fold over tabs to secure.
Otherwise, silicone terminal to vent pipe.

VENTING, VENTILATION AND AIR INLET

Figure 4.2: Side Wall Venting System

11

C. ROOF TERMINATIONS (VERTICAL

VENTING)

1. Vent pipe and air inlet terminations must be within the
maximum and minimum vent and air intake lengths
shown in Tables 4.1 and 4.2.

2. Vent pipe and air inlet pipe must terminate 12"
(305 mm) above expected snow lines. Vent pipe must
be a minimum 12" (305 mm) above and 12" (305
mm) horizontally from air inlet pipe. See Figure 4.3.

3. Attach a vent manufacturer's listed rain cap to both
the vent pipe and air inlet pipe.

4. Provide 2" (51 mm) clearance between vent pipe and
combustible construction. No clearance is required
between air inlet pipe and combustible construction.

5. See vertical venting section in vent manufacturer's
instructions for recommendations for penetration
through roof.

D . CONDENSATE TRAP INSTALLATION

Locate condensate hose and cable tie in Accessory
Carton. Connect hose to drain fitting on condensate
elbow. Form a 3" diameter loop and secure with cable tie.
Fill loop with water. Pipe to drain or condensate receiver.
See Figure 4.2.

VENTING, VENTILATION AND AIR INLET

Table 4.1

Table 4.2

Figure 4.3: Vertical Venting System

* Each 90° elbow equals 5 feet (1.5 meters) of equivalent

length.

Boiler Model

*Equivalent Length of 4" (102 mm) Diameter

Aluminum/Galvanized Air Inlet Pipe

Minimum Length Maximum Length

PSCII-03
PSCII-04
PSCII-05
PSCII-06

12 feet (4.0 m)
12 feet (4.0 m)
12 feet (4.0 m)
12 feet (4.0 m)

70 feet (21.0 m)
70 feet (21.0 m)
63 feet (19.0 m)
63 feet (19.0 m)

Boiler Model

*Equivalent Length of 3" (76 mm) Diameter

Stainless Steel Vent Pipe

Minimum Vent Length Maximum Vent Length

PSCII-03
PSCII-04
PSCII-05
PSCII-06

8 feet (2.5 m)
8 feet (2.5 m)
8 feet (2.5 m)
8 feet (2.5 m)

52 feet (15.5 m)
52 feet (15.5 m)
45 feet (13.5 m)
45 feet (13.5 m)

12

E . VENT PIPE INSTALLATION

1. For minimum and maximum vent pipe lengths see
Table 4.1.

2. Use only 3" (76 mm) diameter Type AL29-4C
stainless steel vent pipe and fittings for venting of
flue gases from the boiler. When using other than
Heat-Fab vent pipe, an adapter must be installed
on the outlet of condensate elbow. See Figure 4.2.
Adapter part numbers are as follows:

3. Attach remaining pipe and fittings per each
manufacturer’s vent instructions. Use only the silicone
recommended by vent pipe manufacturers. Maintain
proper clearance to combustible construction – see
Section 1, Preinstallation.

4. Horizontal lengths of the vent pipe shall slope upward
not less than 1/4" per lineal foot (21 mm per meter)
from the boiler to the vent terminal.

5. Support horizontal lengths of the vent system to
prevent sagging by use of metal strapping or
equivalent means. Locate supports at not more than
four (4) foot intervals.

6. Vertical Venting Only – If there is no solid anchor
point in the system below the roof for supporting
vertical sections of the vent pipe (i.e. Firestop
Support, etc.), a special vent support system will be
required. See vent manufacturer's instructions for
additional information.

F. AIR INLET PIPE INSTALLATION

1. For maximum air inlet pipe lengths see Table 4.2.

2. Use only 4" (102 mm) diameter galvanized pipe or 4"
(102 mm) diameter flexible aluminum vent for
supplying combustion air to boiler inlet air box.

3. Boiler connection can be from either right or left side
of boiler jacket. Determine which jacket side air inlet
piping is to be routed and remove the 4-1/2" (114
mm) jacket knock-out.

4. Attach a 4" (102 mm) diameter 90 degree elbow to
top of air box and connect air inlet piping.

5. Support air inlet piping using the same methods and
requirements as shown in the previous section for vent
pipe support.

6. Seal all connections using silicone.

7. To prevent condensation from forming on exposed
portions of Wall Thimble and 4" (102 mm) diameter
air inlet piping, wrap exposed areas with insulation.

G. AIR FOR VENTILATION

1. Provide air openings for adequate ventilation to
prevent ambient boiler room temperature from
exceeding 120°F (49°C) during boiler operation. This
is to maintain all the boiler controls below maximum
service temperatures. Openings should be fixed in the
open position during operation.

H. BOILER REMOVAL FROM VENTING

SYSTEM

At the time of removal of an existing boiler, follow these
steps with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation:

a. Seal any unused openings in the common venting

system.

b. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.

c. Insofar as is practical, close all building doors and

windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on any clothes dryers and any
appliance not connected to common venting system.
Turn on any exhaust fans, such as range hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
fireplace dampers.

d. Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar, or
pipe.

f. After it has been determined that each appliance

remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas-burning appliance to their previous
conditions of use.

g. Any improper operation of the common venting

system should be corrected so that the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural
Gas and Propane Installation Code. When resizing any
portion of the common venting system, the common
venting system should be resized to approach
minimum size as determined using the appropriate
tables in the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural
Gas and Propane Installation Code.

VENTING, VENTILATION AND AIR INLET

Pipe Manufacturer Adapter

Flex-L Star-34 SRAPSCA3*

Heat-Fab Saf-T Vent Adapter not required

ProTech FasNSeal FSA-HFA3*

Z-Flex Z-Vent 2SVSSLA2*

* Available from Vent Pipe Manufacturer

13

1. Size and install the gas supply piping properly in order
to provide a supply of gas sufficient to meet the
maximum demand without undue loss of pressure
between the meter and the boiler.

2. Determine the volume of gas to be provided to the
boiler in cubic feet per hour. To obtain this value,
divide the Btu per hour rating (on the boiler rating
plate) by the heating value of the gas in Btu per cubic
feet. Obtain the heating value of the gas from the gas
supplier. As an alternative, use Table 5.1 on the next
page to obtain the volume of gas to be provided to
the boiler.

3. Use the value obtained above as the basis for piping
sizing. Size the gas piping in accordance with Table

5.2. Consult the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural
Gas and Propane Installation Code.

4. Locate the drop pipe adjacent to, but not in front of
the boiler.

5. Install a sediment trap. See Figure 5.1. Locate a tee in
the drop pipe at same elevation as the gas inlet
connection to the boiler. Extend the drop pipe to a
pipe cap.

6. Install a ground joint union ahead of the gas control
assembly to permit servicing of the control. Some
local codes require an additional service valve when
using the combination gas controls. If your code
requires such a valve, a suggested location is shown in
Figure 5.1.

7. Check piping for leaks prior to placing the boiler in
operation.

Use an approved gas detector, a non-corrosive leak
detection fluid or other leak detection method. If leaks
are found, turn off all gas flow and repair as
necessary.

8. Disconnect the boiler and its individual shut-off valve
from the gas supply piping system during any pressure
testing of that system at test pressure in excess of 1/2
psig (3.5 kPa).

Isolate the boiler from the gas supply piping system by
closing its individual service valve during any pressure
testing of the gas supply piping system at test pressure
equal to or less than 1/2 psig (3.5 kPa).

9. Minimum permissible supply pressure for purposes of
input adjustment (Inches Water Column):

Natural Gas 5.0" (1.2 kPa)
LP Gas 11.0" (2.7 kPa)

Maximum permissible supply pressure to the boiler
(Inches Water Column):

Natural Gas 13.5" (3.4 kPa)
LP Gas 13.5" (3.4 kPa)

GAS PIPING

5. GAS PIPING

Figure 5.1: Gas Connection to Boiler

When checking for leaks, do not use matches,
candles, open flames or other methods that provide a
source of ignition. This can ignite a gas leak,
resulting in fire or explosion.

WARNING

Use a pipe joint sealing compound that is resistant to
the action of liquefied petroleum gas. A non-resistant
compound may lose sealing ability in the presence of
this gas, resulting in a gas leak and fire or explosion
potential.

WARNING

Do not subject the gas valve to more than 1/2 psi
(3.5 kPa) pressure. Doing so may damage the valve.

CAUTION

14

GAS PIPING

Table 5.2: Pipe Capacity

Capacity of pipe of different diameters and lengths in cubic feet per hour (cubic meter per
hour) with pressure drop of 0.3 inches of water (75 Pa) and specific gravity of 0.60. No
allowance for an ordinary number of fittings is required.

Table 5.1: Natural Gas

Pipe

Length in

Feet (Meters)

3/4"

Pipe

1"

Pipe

1-1/4"

Pipe

1-1/2"

Pipe

10 (3.0) 278 (7.9) 520 (14.7) 1050 (29.7) 1600 (45.3)

20 (6.1) 190 (5.4) 350 (9.9) 730 (20.7) 1100 (31.1)

30 (9.1) 152 (4.3) 285 (8.1) 590 (16.7) 890 (25.2)

40 (12.2) 130 (3.7) 245 (6.9) 500 (14.2) 760 (21.5)

50 (15.2) 115 (3.3) 215 (6.1) 440 (12.5) 670 (19.0)

60 (18.3) 105 (3.0) 195 (5.5) 400 (11.3) 610 (17.3)

Boiler
Model

Natural Gas Input LP Gas Input

Cu. Ft/hr Cu. Meter/hr Cu. Ft/hr Cu. Meter/hr

PSCII-03 65 1.8 26 0.7

PSCII-04 90 2.5 36 1.0

PSCII-05 120 3.4 48 1.4

PSCII-06 150 4.2 60 1.7

Specific Gravity 0.50 0.55 0.60 0.65 0.70 0.75

Correction Factor 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

Correction Factor 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

Correction Factor 0.68 0.66 0.63 0.61 0.59 0.58

Maximum Capacity Correction Factors for Specific Gravity
other than 0.60.

15

A. WIRING

1. See Figure 6.1 for location of wiring and controls. Use
Figure 6.2 to connect the boiler to a power supply
and to connect components to the boiler.

2. Connect the boiler by a separate, permanently live
electrical supply line with a fused switch.

3. Adjust the thermostat heat anticipator to 0.2 Amp.

B. ZONED SYSTEM WIRING

See Figure 6.4 for typical wiring with zone valves. See
Figure 6.5 for typical wiring with zone circulators. When
wiring a zoned heating system, follow all applicable
codes, ordinances and regulations.

C. CONTROLS

1. For proper location of controls and accessories refer to
Figure 6.1.

2. See the attached control sheets for specific details
regarding the installation of the various controls.

3. This boiler is supplied with safety devices in addition
to the limit. For a description of these devices and
how they work to ensure the safe operation of the
boiler, see Section 7.

4. If the circulator is mounted in the supply piping,
provide longer wiring harness as required.

ELECTRICAL

6. ELECTRICAL

This unit when installed must be electrically grounded in accordance with the requirements of the authority
having jurisdiction or, in the absence of such requirements, with the current edition of the

National Electrical

Code,

ANSI/NFPA 70 and/or the

Canadian Electrical Code

, Part 1, CSA C221.

NOTICE

Figure 6.1: Wiring, Controls and Safety Devices

Install all electrical wiring in accordance with the National Electrical Code and local requirements.

Do not power zone valves directly from the boiler
transformer. Doing so will greatly reduce the life of
the transformer. Use a separate transformer sized to
handle the total of all zone valve electrical loads.

NOTICE

16

D. SEQUENCE OF OPERATION

1. Thermostat calls for heat, energizes Control Relay (CR).

2. Control Relay (CR) energizes circulator.

3. Limit senses boiler water temperature. Prevents boiler
operation until water temperature falls approximately
15

°

F (8°C) below the cut-out temperature.

4. Limit energizes Fan and Isolation Relay (IR).

5. Negative pressure induced by fan switches Pressure
Switch, continuing power through closed contacts
(IR-1) and flame roll-out switch.

6. Gas valve energizes.

a. Igniter on.

b. Pilot gas on, igniting pilot.

7. Pilot flame detected.
a. Igniter off.

b. Main gas on, igniting main burners.

Note: If pilot flame is not detected within 30 seconds, the
igniter is turned off for 30 seconds, and then turned back
on for another 30 seconds. If the pilot remains undetected
in this second ignition period, the igniter and pilot are
turned off for 5 minutes. The sequence then resumes at
Step 6a.

8. Call for heat ends.
a. Pilot and main gas off, extinguishing pilot and

main burners.

b. Fan and circulator off.

ELECTRICAL

Figure 6.2: Wiring and Connection Diagram

17

ELECTRICAL

Figure 6.3: Ignition System Operating Sequence

18

ELECTRICAL

Figure 6.4: Zone Wiring with Zone Valves

Figure 6.5: Zone Wiring with Circulators

19

A. COMPLETING THE INSTALLATION

1. Confirm that all water, gas and electricity are
turned off.

2. Inspect the boiler combustion chamber for foreign
objects and remove if present.

3. Check physical condition of burners and pilot. Make
certain that there are no unusual bends or
perforations in the burners or pilot. Replace
components if necessary.

4. Verify that water piping, venting, gas piping and
electrical wiring and components are installed
properly. Refer back to previous sections of these
instructions as well as equipment manufacturer’s
instructions as necessary.

5. Fill the boiler and system with water, making certain
to vent all air from all points in the system. To check
water level in the system, open and close each vent in
the system. Water should exit from each vent when it
is opened.

6. The pressure reducing valve on the fill line will
typically allow the system to be filled and pressurized
to 12 psi (83 kPa). Consult the valve and expansion
tank manufacturer for more specific information.

7. Check joints and fittings throughout the system for
leaks. If leaks are found, drain the system and repair
as required.

8. Connect a manometer to the 1/8" NPT inlet pressure
tap on the gas valve. See Figure 7.2.

9. Confirm that the gas supply pressure to the boiler is
above the minimum and below the maximum values
for the gas being used. See the end of Section 5 for
these values. If a supply pressure check is required,
isolate the boiler and gas valve before performing the
pressure check. If the supply pressure is too high or
too low, contact the gas supplier.

10. Turn on electricity and gas to boiler.

11. Light the boiler by following the Lighting/Operating
Instructions label mounted to the jacket panel. The
initial ignition may require several tries as the piping is
purged of air.

12. Use the sequence description and Figure 6.3 in
Section 6 (Electrical) to follow light-off and shutdown
sequences and to assist in diagnosing problems. If the
boiler does not function properly, consult Section 8,
Troubleshooting.

START-UP PROCEDURES

7. START-UP PROCEDURES

20

START-UP PROCEDURES

Figure 7.1: Gas Valve, Manifold and Burner Assembly – Intermittent Ignition

Figure 7.2: Valve Tapping and Adjustment Screw Locations

21

START-UP PROCEDURES

Figure 7.3: Operating Instructions

B. CONTROL DESCRIPTIONS

See Figure 6.1 in Section 6 (Electrical) for locations of
these devices.

1. FLAME ROLL-OUT SAFETY SHUT-OFF SWITCH
(FLAME ROLL-OUT SWITCH) – A thermally
activated switch located between the first burner from
the left and the manifold bracket. The flame roll-out
safety shut-off switch will sense excessive temperature
caused by continued flame roll-out and shut down
main burner gas. This is a non-recycling switch that
must be replaced once it has been activated and the
cause of the roll-out eliminated.

2. DIFFERENTIAL PRESSURE SWITCH – This device
senses a negative or suction pressure in the blower
housing and air box when the blower is energized. If
there is not excessive blockage in the venting system
or air inlet vent the switch will close, allowing power
to energize the ignition system.

3. LIMIT – A thermally activated, manually adjustable
switch located on the right side of the boiler. The
temperature sensing element is placed in the supply
and will shut down main burner gas if the supply
water exceeds the preset temperature limit. This is a
recycling switch that will automatically reset when the
supply water falls below the preset temperature.

4. LOW WATER CUT-OFF (FOR GRAVITY SYSTEMS
OR HOT WATER BOILERS INSTALLED ABOVE
RADIATION LEVEL) – A level-sensing device (float or
probe) located in supply piping near the boiler. If
water level in the system drops below the control’s
position, it will shut down main burner gas. The
control will automatically reset once the water level
rises above its position.

C. ADJUSTMENT OF GAS PRESSURE

REGULATOR

1. Move the manometer to either the outlet pressure tap
on the gas valve or to the burner manifold test tap.
Set manifold pressure as follows for various gases.

a. Natural Gas . . .3.5" Water Column (0.9 kPa)

b. LP Gas . . . . . .10.0" Water Column (2.5 kPa)

2. To adjust gas pressure, turn adjusting screw of gas
pressure regulator counterclockwise to decrease
pressure, clockwise to increase pressure. Refer to
Figure 7.2 for location of gas pressure regulator.
Replace the cap screw when adjustment is complete.

3. In no case should the final manifold pressure vary
more than ±0.3 inches water column (0.07 kPa) from
the above specified pressures. Any necessary major
changes in the flow should be made by changing the
size of the burner orifice spuds.

4. When adjustment is complete, turn off boiler, gas flow
and electricity to boiler. Remove manometer and plug
tapping with plug provided. Turn utilities back on and
resume checkout.

D. CHECKING BURNER INPUT

1. Refer to rating label mounted on the jacket top panel
to obtain the rated BTU per hour input. In no case
shall the input to the boiler exceed the value shown
on the rating label.

2. Check input by use of the following formula
(PB Heat suggests reading meter for 2 Cu.Ft. [0.0566
cubic meter]):

U.S. Customary Units:

Input (BTU/Hr.)= 3600 x F x H

T
Where:
3600 – Seconds per hour

F – Cubic Feet of Gas Registered on Meter

H – Heat Value of Gas in BTU/Cubic Feet

T – Time in Seconds the Meter is Read

SI Metric Units

Input (kW)= 3600 x F x H

T x 3.6
Where:
3600 – Seconds per hour

3.6 – Megajoule (MJ) per kilowatt hour (kWhr)
F – Cubic Meters of Gas Registered on Meter

H – Heating Value of Gas in MJ/Cubic Meter

T – Time in Seconds the Meter is Read

3. As an alternative, use Table 7.1a and 7.1b. Use the
heating value provided by gas supplier. Use a
stopwatch to record the time it takes for 2 cubic feet
(0.0566 cubic meter) of gas to pass through the meter.
Read across and down to determine rate.

E. CHECK-OUT PROCEDURE

1. After starting the boiler, be certain all controls are
working properly. Check to be sure that the limit will
shut off the boiler in the event of excessive water
temperature. This can be done by lowering the limit
setting until the main burners shut down. When
proper limit function is confirmed, return the dial to its
previous setting.

2. To check operation of the ignition system safety
shut-off features:

a. Turn gas supply off.

b. Set thermostat or controller above room

temperature to call for heat. Watch for igniter glow
at pilot burner.

c. Igniter will continue to glow for 30 seconds, de-

energize for 30 seconds, then re-energize and glow
for another 30 seconds. It will then de-energize for
5 minutes before restarting the sequence.

d. Turn gas supply on.

e. Reset the boiler and control by following

Operating Instructions.

f. Observe boiler operation through one complete

cycle.

22

START-UP PROCEDURES

23

3. Low Water Cut-Off (if used) – Consult the
manufacturer’s instructions for the low water cut-off
operational check procedure.

4. Check the system to make sure there are no leaks or
overfilling problems which might cause excessive
make-up water to be added. Make-up water causes
liming in the boiler and brings in oxygen. Oxygen can
cause severe damage to the boiler though oxygen
corrosion pitting.

5. Check the expansion tank and automatic fill valve (if
used) to confirm that they are operating correctly. If
either of these components causes high pressure in the
system, the boiler relief valve will weep or open,
allowing fresh water to enter the system.

6. Do not allow the system controls to subject the boiler
to excessively low water temperatures, which would
cause condensation of flue gases and corrosion of the
boiler. Operate the boiler at a temperature above
130°F (54°C). Adjust the boiler limit as required to
maintain boiler temperature above this level.

7. Check the general condition of the system including
piping support, joints, etc. Check cleanliness of the
radiators, baseboard units and/or convectors. Clean
them to the extent possible. If radiators do not heat
evenly, vent any remaining air from them.

8. Review operation and User’s Information Manual with
end-user.

9. Complete the Warranty Card and submit it to PB
Heat, LLC.

10. Hang the Installation, Operation and Maintenance
Manual, User’s Information Manual, and Vent
Manufacturer’s Information Manual in an accessible
position near the boiler.

START-UP PROCEDURES

Table 7.1a: Meter Conversion Natural Gas

(U.S. Customary Units)

Table 7.1b: Meter Conversion Natural Gas

(SI Metric System)

Burner inputs in kW for various meter timings and
heating values. (Tables based on 0.0566 cubic meters
of gas through the meter).

Burner inputs in Btu/hr for various meter timings and
heating values. (Tables based on 2 cubic feet of gas
through the meter).

Time that

meter is

read (sec)

Heat Value of Gas

(MJ/cubic meter)

37.26 38.19 39.12

25
30
35
40
45
50
55
60
65
70
75
80
85
90

95
100
105
110
115
120
125

84.36

70.30

60.25

52.72

46.86

42.18

38.34

35.15

32.44

30.13

28.12

26.36

24.81

23.43

22.20

21.09

20.08

19.17

18.34

17.57

16.87

86.46

72.05

61.76

54.04

48.03

43.23

39.30

36.03

33.25

30.88

28.82

27.02

25.43

24.02

22.75

21.62

20.59

19.65

18.80

18.01

17.29

88.57

73.81

63.26

55.35

49.20

44.28

40.26

36.90

34.06

31.63

29.52

27.68

26.05

24.60

23.31

22.14

21.09

20.13

19.25

18.45

17.71

Time that

meter is

read (sec)

Heat Value of Gas

(Btu/cubic foot)

1000 1025 1050

25
30
35
40
45
50
55
60
65
70
75
80
85
90

95
100
105
110
115
120
125

288000
240000
205714
180000
160000
144000
130909
120000
110769
102857

96000
90000
84706
80000
75789
72000
68571
65455
62609
60000
57600

295200
246000
210857
184500
164000
147600
134182
123000
113538
105429

98400
92250
86824
82000
77684
73800
70286
67091
64174
61500
59040

302400
252000
216000
189000
168000
151200
137455
126000
116308
108000
100800

94500
88941
84000
79579
75600
72000
68727
65739
63000
60480

24

A. SHUT-DOWN CAUSED BY PILOT

OUTAGE, PRESSURE SWITCH OR
FLAME ROLL-OUT SAFETY
SHUT-OFF SWITCH

In the event of a shut-down caused by a pilot outage,
action of the pressure switch or flame roll-out safety shut­off switch effecting a shut-down of the main burners:

a. Refer to the Lighting/Operating Instructions in Figure

7.3 to properly turn off the gas to the boiler.
b. Turn off all electric power to the boiler.
c. Call a qualified heating service organization or local

gas company and have the cause of the shut-down
investigated and corrected.

d. Refer to Operating Instructions to re-start boiler.

B. TROUBLESHOOTING GUIDES

Use Table 8.1 and Figure 8.2 to assist in determining
causes and providing corrective actions to boiler
problems. These guides must be used only by qualified
service technicians. These individuals must follow all
applicable codes and regulations in repair of any boiler
problems.

C. MEASURING SUCTION PRESSURE

Pressure switch requires minimum -0.45" W.C. (-112 Pa)
fan suction pressure to energize control circuit. Measure
when boiler has been operating at least 15 minutes. See
Figure 8.1.

TROUBLESHOOTING

8. TROUBLESHOOTING

Should overheating occur or the gas supply fail to
shut off, do not turn off or disconnect the electrical
supply to the pump. This may aggravate the problem
and increase the likelihood of boiler damage. Instead,
shut off the gas supply at a location external to the
appliance.

CAUTION

Do not use this appliance if any part has been under
water. Improper or dangerous operation may result.
Immediately call a qualified service technician to
inspect the boiler and to replace any part of the
control system and any gas control which has been
under water.

WARNING

Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.

CAUTION

When servicing or replacing items that communicate
with the boiler water, be certain that:

●

There is no pressure on the boiler.

●

The boiler is not hot.

●

The power is off.

When servicing the gas valve or pilot, be certain that:

●

The gas is off.

●

The electricity is off.

DANGER

25

TROUBLESHOOTING

Figure 8.1: Measuring Fan Suction Pressure

Table 8.1: Boiler Troubleshooting Guide (Burners Functioning)

PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONS

Burners not functioning.

See Figure 8.2 See Figure 8.2

Burners will not shut down.

1. Defective gas valve.

2. Short circuit.

1. Use Figure 8.2 to troubleshoot intermittent
ignition gas valve. Replace if necessary.

2. Check and correct wiring.

Flashback or burning
at orifice spuds.

1. Manifold gas pressure too low.

2. Improperly sized/drilled orifice spuds.

3. Leaking gas valve.

4. Burrs on orifice.

5. Low supply gas pressure.

1. Adjust to proper pressure.

2. Install correct spuds.

3. Replace valve.

4. Remove burrs.

5. Contact gas supplier if natural gas. Adjust
regulator if LP gas.

Delayed ignition.

1. Insufficient pilot flame.

2. Pilot burner/orifice clogged.

3. Overfiring.

4. Misaligned burners or pilot.

1. Increase pilot gas flow.

2. Clean pilot burner and orifice.

3. Reduce rate to input on rating label.

4. Realign burners or pilot.

Boiler not heating
properly.

1. Underfiring.

2. Limit set too low.

3. Air in system.

4. Circulator malfunctioning.

5. Circulation system clogged.

6. Incorrect thermostat heat anticipator setting.

1. Increase rate to input on rating label.

2. Reset limit to higher setting.

3. Vent air from all points in system.

4. Check circulator, replace if necessary.

5. Shut down and cool boiler, drain and flush
system.

6. Adjust heat anticipator.

Fumes or gas odors.

1. Leaks in gas piping or fittings.

2. Leaks in gas service line or meter.

3. Leaks in venting system.

4. Overfiring.

1. Locate and repair or replace.

2. Shut down boiler and notify gas provider.

3. Locate and repair or replace.

4. Reduce rate to input on rating label.

*

26

TROUBLESHOOTING

Figure 8.2: Boiler Troubleshooting Guide (Burners Not Functioning)

24 VOLT

HOT

END VIEW OF

CONTROL

HARNESS

CONNECTOR

24

VOLTS

INSET A

INSET B

HSI

TERMINAL

24

VOLTS

24 VOLT

THERMOSTAT

24 VOLT

COMMON

CHECK FOR DAMAGED OR MISSING

TERMINALS IN CONNECTOR

REPLACE GAS VALVE

RECONNECT PILOT BURNER

CABLE

NO

YES

LINE VOLTAGE POWER

LOW VOLTAGE TRANSFORMER

LIMIT CONTROLLER

WIRING

THERMOSTAT

CHECK:

ASSURE GAS VALVE SWITCH IS

IN "ON" POSITION

TURN OFF GAS SUPPLY

●●●

●

●●●●●

NO

YES

DISCONNECT SYSTEM CONTROL

HARNESS

SET THERMOSTAT TO CA LL

FOR HEAT

●

●

●

CHECK FOR PROPER VOLTAGE

AT CONTROL HARNESS (SEE INSET

A). VOLTAGE SHOULD BE 24V

BETWEEN THERMOSTAT AND

24V COMMON, AND 24V BETWEEN

24V COMMON AND 24V HOT.

PLUG HARNESS INTO GAS VALVE

UNPLUG PILOT BURNER CABLE.

MEASUR E VOLTAG E AT G AS VALVE

NO

CONTROL. WAIT FOR INTERNAL

IGNITER WARMS UP AND

CHECK DELAY

HSI ELEMENT OUTPUT (SEE INSET B)

24V NOMINAL

GLOWS RED

REPLACEIGNITER/FLAME RODASSEMBLY

NOTE: IGNITERWILL CYCLE OFF

AND BACK ON ONCE DURINGTHE

90 SECOND IGNITION TRIAL

YES

REPLACE GAS VALVE

CHECK THAT PILOT GAS IS FLOWING.

WAITTO ASSURE PILOT GAS TUBING

●●●

IS PURGED.

RECONNECT PILOT BURNER CABLE

NO NO

PILOT BURNER LIGHTS

TURN ON GAS SUPPLY

●

●

CHECK TRANSFORMER AND

LINE VOLT SUPPLY

NO

YES

MEASURE VOLTAGE BETWEEN 24V

VALVE. MUST MEASURE AT LEAST

HOT AND 24V COMMON LEADS TO GAS

●●●●●●●

19.5 VAC WITH IGNITER POWERED.

SEE INSET A TO IDENTIFY PROPER

YES

LEAD.THIS CHECK MUST BE DONE

YES

WITH THE GASVALVE CONNECTED

AND IGNITER POWERED.

●

CYCLE THERMOSTAT OFF AND BACK ON

CHECK THAT PILOT FLAME MAKES

REPLACEIGNITER/FLAME RODASSEMBLY

●

IF MAIN BURNERS DO NOT LIGHT,

REPLACE GAS VALVE

CHECK FOR GOOD ELECTRICAL

FLAME ROD.

CONNECTION THROUGHTHE PILOT

●●●●●●●

IF BOTH OF THE ABOVE ARE GOOD,

TUBING

REPLACE IGNITER/FLAME ROD

ASSEMBLY.

●

GOOD CONTACT WITH PILOT BURNER

NO

YES

MAIN VALVE OPENS AND

MAIN BURNER LIGHTS

SYSTEM IS OKAY

SEE TABLE 8.1

YES

DO BURNERS

FUNCTION?

YES

NO

DOES IGNITER WARM

UP AND GLOW RED?

(INTERMITTENTLY)

YES

NO

SWITCH "NO" TERMINALTO GROUND.

x

1) CHECK FOR 24VAC AT PRESSURE

1)x

IS FAN RUNNING?

TUBING.

IF NO VOLTAGE, CHECK FOR:

- BLOCKED OR CRACKED SUCTION

- FAN NOT GENERATING ADEQUATE

1)x

1)x

1)x-

1)x

SUCTION PRESSURE.

- DEFECTIVE PRESSURE SWITCH.

1)x-

1)xx2)x

2) CHECK FOR 24VAC AT ISOLATION RELAY

BLUE WIRESTO GROUND:

- IF NO VOLTAGE AT EITHER BLWIRES,

2)x

CHECK FOR BROKEN/LOOSE WIRE.

2)x-

CHECK FOR 120VAC BETWEEN RELAY

- IF NO VOLTAGE AT ONLY ONE BL WIRE,

2)x

2)x-

BLACK AND WHITEWIRES. IF SO,

2)x-

REPLACE RELAY.

2)x-x3)x

SWITCH. IF SWITCH IS BLOWN, CORRECT

CAUSE OF ROLL-OUT BEFORE

REPLACING SWITCH.

3) CHECK FOR 24VAC AT FLAME ROLL-OUT

3)x

3)x

SWITCH.

AIR TUBE. IF OKAY,REPLACE PRESSURE

RUNNING POSITION. CHECK FOR BLOCKED

CHECK FOR 24VAC AT PRESSURE SWITCH

TERMINALS "C" AND "NC" TO GROUND:

IF VOLTAGE AT "NC" BUT NOT "C",

CHECKFOR 120VACHIGH LIMITCONTROL.IF

POWERATONETERMINAL BUTNOTBOTH,

REPLACELIMIT CONTROL.

PRESSURE SWITCH IS STUCK IN

●

●●●●●

●

IF NO VOLTAGE AT EITHER PRESSURE

SWITCH TERMINAL "C" OR "NC"TO

GROUND, CHECK FOR 120VAC INCOMING

●●●●●

INCOMING POWER, REPLACE

POWER INSIDE JUNCTION BOX. IF PROPER

TRANSFORMER/RELAY.

NO

NO

NO

JUMPER THERMOSTAT

AT CONNECTIONS

"G" AND "Y" ON

TRANSFORMER.

DOES BOILER RUN?

YES

CORRECT

THERMOSTAT

PROBLEM

27

MAINTENANCE

9. MAINTENANCE

WARNING

Product Safety Information

Refractory Ceramic Fiber Product

This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF,
when inhaled, have been classified by the International Agency for Research on Cancer
(IARC), as a possible carcinogen to humans. After the RCF materials have been exposed to
temperatures above 1800°F (980°C), they can change into crystalline silica, which has been
classified by the IARC as carcinogenic to humans. If particles become airborne during serv­ice or repair, inhalation of these particles may be hazardous to your health.

Avoid Breathing Fiber Particulates and Dust

Suppliers of RCF recommend the following precautions be taken when handling these
materials:

Precautionary Measures:
Provide adequate ventilation.
Wear a NIOSH/MSHA approved respirator.
Wear long sleeved, loose fitting clothing and gloves to prevent skin contact.
Wear eye goggles.
Minimize airborne dust prior to handling and removal by water misting the material and
avoiding unnecessary disturbance of materials.
Wash work clothes separately from others. Rinse washer thoroughly after use.
Discard RCF materials by sealing in an airtight plastic bag.

First Aid Procedures:
Inhalation: If breathing difficulty or irritation occurs, move to a location with fresh clean air.
Seek immediate medical attention if symptoms persist.
Skin Contact: Wash affected area gently with a mild soap and warm water. Seek immediate
medical attention if irritation persists.
Eye Contact: Flush eyes with water for 15 minutes while holding eyelids apart. Do not rub
eyes. Seek immediate medical attention if irritation persists.
Ingestion: Drink 1 to 2 glasses of water. Do not induce vomiting. Seek immediate medical
attention.

28

A. GENERAL

1. Disconnect this boiler from the gas supply piping
during any pressure testing of the gas system.

2. Check pipes adjacent to cold walls or in unheated
spaces. Insulate and tape them if necessary to be sure
they can’t freeze up. Keeping the water moving at all
times will reduce the likelihood of freezing. See
Section 3 for antifreeze instructions.

3. If there is considerable foreign matter in the boiler
water, the boiler should be shut down and allowed to
cool, then drained and thoroughly flushed out. Use
the drain valve at the bottom of the return connection
to drain the boiler. Pipe the drain cock to a suitable
drain or containment device if antifreeze is used. Flush
the system to remove remaining matter. If there is
evidence that hard scale has formed on the internal
surfaces, the boiler should be cleaned by chemical
means as prescribed by a qualified water treatment
specialist.

B. DAILY (WITH BOILER IN USE)

Daily boiler observation can be performed by the owner.
If any potential problems are found, a qualified installer
or service technician/agency must be notified.

1. Remove any combustible materials, gasoline and
other flammable liquids and substances that generate
flammable vapors from the area where the boiler is
contained. Make certain that the boiler area has
ample air for ventilation and that there are no
obstructions to the free flow of air to and from the
boiler.

2. Observe general boiler conditions (unusual noises,
vibrations, etc.)

3. Observe operating temperature and pressure on the
combination gauge located on the right side of the
boiler. Boiler pressure should never be higher than
5 psi (35 kPa) below the rating shown on the safety
relief valve (25 psig [172 kPa] maximum for a 30 psig
[207 kPa] rating, 45 psig [310 kPa] maximum for a
50 psig [345 kPa] rating). The valve rating can be
found on the top of the safety relief valve (see Figure

3.4 for location of the safety relief valve). Boiler
temperature should never be higher than 250°F
(121°C).

4. Check for water leaks in boiler and system piping.

5. Smell around the appliance area for gas. If you smell
gas, follow the procedure listed in the Operating
Instructions to shut down appliance in Figure 7.3.

C. WEEKLY (WITH BOILER IN USE)

1. Flush float-type low-water cut-off (if used) to remove
sediment from the float bowl as stated in the
manufacturer’s instructions.

D. MONTHLY (WITH BOILER IN USE)

1. Verify condensate drain trap (loop) has sufficient
water to maintain seal and is not blocked. Fill and/or
unblock as necessary.

2. Check boiler room floor drains for proper functioning.

3. Check function of the safety relief valve (monthly
unless specified otherwise by manufacturer) by
performing the following test:

a. Check valve piping to determine that it is properly

installed and supported.

b. Check boiler operating temperature and pressure.

c. Lift the try lever on the safety relief valve to the

full open position and hold it for at least five
seconds or until clean water is discharged.

d. Release the try lever and allow the valve to close.

If the valve leaks, operate the lever two or three
times to clear the valve seat of foreign matter. It
may take some time to determine if the valve has
shut completely.

e. If the valve continues to leak, it must be replaced

before the boiler is returned to operation.

f. Check that operating pressure and temperature

have returned to normal.

g. Check again to confirm that valve has closed

completely and is not leaking.

4. Test low-water cut-off (if used) as described by the
manufacturer.

5. Test limit as described in Section 7, “Check-Out
Procedure.”

6. Test function of gas safety shut-off features as
described by gas valve and ignition control
manufacturer.

E. ANNUALLY (BEFORE START OF HEATING

SEASON)

1. Inspect flueways, burners and vent system. See
Figure 9.2.

a. Refer to the Operating Instructions in Figure 7.3 to

properly turn off the gas to the boiler. Turn off all
electrical power to the boiler.

MAINTENANCE

When servicing or replacing components, be
absolutely certain that the following conditions are
met:

●

Water, gas and electricity are off.

●

The boiler is at room temperature.

●

There is no pressure in the boiler.

DANGER

29

b. Remove jacket removable door, air inlet pipe, air

box cover, and air box diffuser screen.

c. Remove burner hitch pin clips. Disconnect pilot

tubing at compression elbow.

d. Disconnect pilot harness at gas valve. Gently pull

pilot harness further inside air box to be able to
remove burner with attached pilot.

e. Remove burners and pilot.

f. Brush gas outlet ports lightly using a soft bristle

brush. If extensive corrosion in outlet ports,
replace.

g. Examine pilot hood and igniter for corrosion,

scale, ceramic cracking. Replace if necessary.

h. Remove 3" (76 mm) diameter vent pipe at

condensate elbow or fan outlet.

i. Remove top jacket panel, flue collector/fan

assembly, and flue baffles.

j. Examine flueways and flue collector/fan for scale,

soot, and loose rust.

k. If necessary, brush flueways with wire brush and

remove scale and loose rust from flue baffles. If
corroded, replace baffles.

l. Reinstall flue baffles.

m. Examine flue collector blanket seal.

Reposition/replace as necessary to assure air tight
seal between flue collector and heat exchanger.

n. Reinstall flue collector/fan assembly.

o. Reinstall jacket top panel.

p. Reinstall pilot, burners, hitch pin clips. Reconnect

pilot harness to gas valve, gently pulling harness
to length required to reach gas valve.

q. Reinstall air box diffuser.

r. Examine air box cover seal. Reposition/replace as

necessary to assure air tight seal.

s. Reinstall air box cover.

t. Examine entire vent system for corrosion, support

and joint integrity. Repair as necessary. Remove
any debris inside vent.

u. Reconnect vent pipe to fan adapter. Reseal using

high-temp silicones as shown in Section 4,
Venting, Ventilation and Air Inlet.

v. Refer to Operating Instructions in Figure 7.3 to

properly return the boiler to operation.

2. Check the pilot and main burner flame. See Figure

9.1. The pilot should provide a steady flame
enveloping 3/8" to 1/2" (1 cm to 1.2 cm) of the flame
sensor. If required, adjust the pilot as stated in the gas
valve manufacturer’s instructions. The main burner
flame inner cone should be approximately
1-1/2" (4 cm) high and should have a very sharp, blue
color characteristic.

MAINTENANCE

Figure 9.1: Intermittent Pilot and Main

Burner Flame

Leaks in the vent system will cause products of
combustion to enter structure (vent system operates
under positive pressure).

WARNING

Soot accumulation indicates boiler malfunction.
Cause of malfunction must be determined and
corrected before returning boiler to service.

WARNING

30

MAINTENANCE

Figure 9.2: Inspection of Flueways, Burners, and Vent System.

31

BOILER DIMENSIONS & RATINGS

10. BOILER DIMENSIONS & RATINGS

Figure 10.1: Boiler Views

Table 10.1: Series PSC II™ Boiler Dimensions

Table 10.2: Series PSC II™ Boiler Ratings

1 Net I=B=R water ratings based on an allowance of 1.15.
2 Consult factory before selecting a boiler for installations having unusual piping and pickup

requirements, such as intermittent system operation, extensive piping systems, etc.

3 Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are based on U.S.

Government test.

SERIES PSC II™ BOILER DIMENSIONS

Boiler
Model

Number

Jacket Width “A”

PSCII-03 12-1/2" 318 mm

PSCII-04 15-7/8" 403 mm

PSCII-05 19-1/4" 489 mm

PSCII-06 22-5/8" 575 mm

SERIES PSC II™ BOILER RATINGS

Boiler
Model

Number

Input

DOE Heating

Capacity

3

Net I=B=R

Ratings Water

1,2

Seasonal

Efficiency

3

(AFUE)%

Water Content

MBH kW MBH kW MBH kW Gallon Liter

PSCII-03 65 19 56 16 49 14 86.0 4.72 17.87

PSCII-04 90 26 77 23 67 20 85.0 6.00 22.71

PSCII-05 120 35 102 30 89 26 85.0 7.28 27.56

PSCII-06 150 44 128 37 111 32 85.1 8.56 32.40

32

REPAIR PARTS

REPAIR PARTS

SERIES PSC II™ GAS BOILER

Repair parts are available from your installer or by contacting PB Heat, LLC, New
Berlinville, PA. Use the figures and tables on pages 32-36 to assist in ordering parts.

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

11. REPAIR PARTS

Figure 11.1

33

REPAIR PARTS

Description

Quantity

Required

Stock

Code

1

Base Assembly – PSCII-03 – 7800

Base Assembly – PSCII-04 – 7801

Base Assembly – PSCII-05 – 7802

Base Assembly – PSCII-06 – 7803

2

Floor Pan – PSCII-03 – 50100

Floor Pan – PSCII-04 – 50101

Floor Pan – PSCII-05 – 50102

Floor Pan – PSCII-06 – 50103

3

Base Rear Panel Assembly – PSCII-03 – PSC2000

Base Rear Panel Assembly – PSCII-04 – PSC2000-1

Base Rear Panel Assembly – PSCII-05 – PSC2000-2

Base Rear Panel Assembly – PSCII-06 – PSC2000-3

4 Base Observation Port Cover – 51771

5 Base/Air Box Spacer – 92 2 50152

6 Air Box Right Side – PSC2023

7 Air Box Left Side – PSC2024

8

Air Box Top/Front Cover – PSCII-03 – 50143

Air Box Top/Front Cover – PSCII-04 – 50144

Air Box Top/Front Cover – PSCII-05 – 50145

Air Box Top/Front Cover – PSCII-06 – 50146

9

Air Box Diffuser Screen – PSCII-03 – PSC2025

Air Box Diffuser Screen – PSCII-04 – PSC2025-1

Air Box Diffuser Screen – PSCII-05 – PSC2025-2

Air Box Diffuser Screen – PSCII-06 – PSC2025-3

10 Rope Gasket Seal, Air Box – 50718

11 Flame Rollout Switch, Thermodisc G4AM00_167C – 51587

12 Flame Rollout Switch Bracket – 50136

13

Steel Burner – PSCII-03 3 51536

Steel Burner – PSCII-04 5 51536

Steel Burner – PSCII-05 7 51536

Steel Burner – PSCII-06 9 51536

– Burner with Pilot Bracket – 51535

14

Orifice, #48, Normal Altitude Natural Gas Only – PSCII-03 4 50894

Orifice, #48, Normal Altitude Natural Gas Only – PSCII-04 6 50894

Orifice, #48, Normal Altitude Natural Gas Only – PSCII-05 8 50894

Orifice, #48, Normal Altitude Natural Gas Only – PSCII-06 10 50894

Orifice, #56, Normal Altitude LP Gas Only – PSCII-03 4 50899

Orifice, #56, Normal Altitude LP Gas Only – PSCII-04 6 50899

Orifice, #56, Normal Altitude LP Gas Only – PSCII-05 8 50899

Orifice, #56, Normal Altitude LP Gas Only – PSCII-06 10 50899

15

Gas Manifold – PSCII-03 – 50121

Gas Manifold – PSCII-04 – 50122

Gas Manifold – PSCII-05 – 50123

Gas Manifold – PSCII-06 – 50124

Table 11.1

34

REPAIR PARTS

Figure 11.2

35

REPAIR PARTS

Table 11.2

Description

Quantity

Required

Stock

Code

16 Insulation Blanket, 1/2" x 1.50", Block to Base – 50867

17

Block – PSCII-03 – 90419

Block – PSCII-04 – 90420

Block – PSCII-05 – 90421

Block – PSCII-06 – 90422

18

Flue Baffle – PSCII-03 2 51584

Flue Baffle – PSCII-04 3 51584

Flue Baffle – PSCII-05 4 51584

Flue Baffle – PSCII-06 5 51584

19 Insulation Blanket, 1/2" x .75", Flue Collector to Block – 50866

20

Flue Collector – PSCII-03 – 50171

Flue Collector – PSCII-04 – 50172

Flue Collector – PSCII-05 – 50173

Flue Collector – PSCII-06 – 50174

21 Gasket, Orifice Plate 2 50135

22

Orifice Plate, Normal Altitude Natural Gas Models Only – PSCII-03 – PSC5002

Orifice Plate, Normal Altitude Natural Gas Models Only – PSCII-04 – PSC5002-1

Orifice Plate, Normal Altitude Natural Gas Models Only – PSCII-05 – PSC5002-2

Orifice Plate, Normal Altitude Natural Gas Models Only – PSCII-06 – PSC5002-3

Orifice Plate, Normal Altitude LP Gas Models Only – PSCII-03 – PSC5003

Orifice Plate, Normal Altitude LP Gas Models Only – PSCII-04 – PSC5003-1

Orifice Plate, Normal Altitude LP Gas Models Only – PSCII-05 – PSC5003-2

Orifice Plate, Normal Altitude LP Gas Models Only – PSCII-06 – PSC5003-3

23 Fan – 50775

24 Fan Adapter – 50200

25

Jacket – PSCII-03 – 90729

Jacket – PSCII-04 – 90730

Jacket – PSCII-05 – 90731

Jacket – PSCII-06 – 90732

– Gas Valve, SV9501M2700, Natural Gas Models Only – 51682

– Gas Valve, SV9501M2064, LP Gas Models Only – 51691

– Pilot Assembly, Q3480B1058, w/ Natural Gas Orifice – 7794

– Pilot, Q3480B1058, LP Gas Models Only – 50205

– Limit Control, L4080B1253 (less well) – 50210

– Pressure Switch, Standard altitude, FS6124A2481 – 50080

– Transformer Relay Center, R8285D1026 – 50786

– Relay (mounted on jacket), R4222D1005 – 50790

– Safety Relief Valve, 30 PSI, Conbraco 10-408-05 – 50501

– Safety Relief Valve, 50 PSI, Watts #350 – 99950

– Temperature-Pressure Gauge – 51774

– Condensate Drain Elbow – 51185

– Outside Stainless Steel Vent Cap – 50139

– Wall Thimble (standard, up to 11-1/2" wall) – 50137

– Wall Thimble 20 (for a wall greater than 11-1/2" to 20") – 90350

– Inside Thimble Cap – 50138

– Inside Thimble Collar – 50158

– Screened Vent Termination – 50130

– Vent Clamp – 51900

Blower Gaskets

– Orifice Plate Gaskets 2 50135

– Fan Outlet Gasket – PSC5019

36

NOTES

37

NOTES

PSC

II

™

Boilers

Series

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.

PSC8055 R4 (1/12-7.5C)

Printed in U.S.A.

©2012 PB Heat, LLC. All rights reserved.

ASME

PB HEAT, LLC

131 S. CHURCH STREET • BALLY, PA 19503