PEERLESS Series 63, Series 64 Installation, Operation & Maintenance Manual

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Page 1

63/64

™

Boilers

Series

Gas

Installation, Operation & Maintenance Manual

Page 2

USING THIS MANUAL 1

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

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

1. PREINSTALLATION 2

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

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

C. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2

D. CLEARANCE FROM COMBUSTIBLE

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

E. AIR COMBUSTION AND VENTILATION . . . .3

F. INSTALLATION SURVEY . . . . . . . . . . . . . . . .6

G. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .6

2. BOILER PLACEMENT & ASSEMBLY 7

A. PACKAGED BOILER . . . . . . . . . . . . . . . . . . . .7

B. KNOCKDOWN BOILERS – SPLIT BLOCK . . .7 C. KNOCKDOWN BOILERS – ASSEMBLED

BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

D. KNOCKDOWN BOILERS – CONTROL &

MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . .8

E. KNOCKDOWN BOILERS – FLUE COLLECTOR

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .8

F. KNOCKDOWN BOILERS – HYDROSTATIC

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

G. KNOCKDOWN BOILERS – ASSEMBLE

JACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3. VENTING 11

A. CHIMNEY OR VENT . . . . . . . . . . . . . . . . . . .11

B. AUTOMATIC VENT DAMPER

INSTALLATION – GENERAL . . . . . . . . . . . .11

C. BOILER REMOVAL FROM COMMON

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

4. BOILER PIPING 13

A. WATER BOILER PIPING – SINGLE

BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

B. WATER BOILER PIPING – MULTIPLE

BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

C. STEAM BOILER PIPING – SINGLE

BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

D. STEAM BOILER INDIRECT WATER HEATER

PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

E. STEAM BOILER PIPING – MULTIPLE

BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

5. FUEL PIPING 16

A. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .16

B. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .16

6. CONTROLS & TRIM 18

A. WATER BOILER CONTROLS & TRIM . . . . .18

B. STEAM BOILER CONTROLS & TRIM . . . . .19

7. ELECTRICAL 20

A. CONNECT SUPPLY WIRING . . . . . . . . . . . .20

B. MOUNT REMAINING CONTROLS . . . . . . . .20

C. INSTALL CONTROL WIRING . . . . . . . . . . . .21

D. WIRING DIAGRAM INDEX . . . . . . . . . . . . . .21

8. BOILER OPERATION 32

A. SYSTEM INSPECTION . . . . . . . . . . . . . . . .32

B1. FILL THE BOILER (WATER BOILERS) . . . . .32

B2. FILL THE BOILER (STEAM BOILERS) . . . . .32

C. LIGHTING INSTRUCTIONS . . . . . . . . . . . . .32

D. PILOT CHECK . . . . . . . . . . . . . . . . . . . . . . . .32

E. MAIN BURNER CHECK . . . . . . . . . . . . . . . .33

F. CONTROLS CHECK . . . . . . . . . . . . . . . . . . .33

G. PURGING AIR . . . . . . . . . . . . . . . . . . . . . . . .33

H. CHECK SYSTEM PRESSURE . . . . . . . . . . . .33

I. CLEAN THE BOILER . . . . . . . . . . . . . . . . . . .33

J. BOILER SHUT-DOWN . . . . . . . . . . . . . . . . .34

9. MAINTENANCE 39

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .40

B. DAILY MAINTENANCE . . . . . . . . . . . . . . . . .40

C. WEEKLY MAINTENANCE . . . . . . . . . . . . . .40

D. MONTHLY MAINTENANCE . . . . . . . . . . . . .40

E. ANNUAL MAINTENANCE . . . . . . . . . . . . . .40

F. AS REQUIRED MAINTENANCE . . . . . . . . . .41

10. TROUBLESHOOTING 42

11. BOILER DIMENSIONS & RATINGS 45

12. REPAIR PARTS 47

TABLE OF CONTENTS

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USING THIS MANUAL

A. INSTRUCTION MANUALS

The Series 63/64™ Installation, Operation & Maintenance Manual is divided into four basic sections:

1. Preinstallation (Section 1)

2. Installation (Sections 2 through 8)

3. Start-Up (Section 9)

4. Maintenance (Section 10)

B. SPECIAL ATTENTION BOXES

Throughout this manual special attention boxes are provided to supplement the instructions and make special notice of potential hazards. The definition of each of these categories, in the judgement of PB Heat, LLC are as follows.

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.

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

WARNING

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PREINSTALLATION

A. GENERAL

Series 63/64™ boilers are supplied knocked down for field assembly or completely assembled as packaged boilers. All items should be inspected for damage upon receipt and any damage reported to the trucker and wholesaler. All components should be stored in a clean dry area.

Carefully read these instructions before beginning work. Understand all aspects of the installation. Contact PB Heat sales representative or customer service for help in answering questions.

This boiler must be installed by a qualified contractor. The boiler warranty may be voided if the boiler is not installed correctly.

A hot water boiler installed above radiation level or as required by the Authority having jurisdiction, must be provided with a low water cut-off device either as part of the boiler or at the time of installation.

B. CODES & REGULATIONS

1. All work should be performed 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 should govern.

a. ASME Boiler & Pressure Vessel Code, Section

IV – “Heating Boilers”

b. ASME Boiler & Pressure Vessel Code, Section

VI – “Recommended Rules for the Care and Operation of Heating Boilers”

c. ANSI Z223.1/NFPA 54 – “National Fuel Gas

Code”

d. ANSI/NFPA 70 – “National Electrical Code”

e. ASME CSD-1 – “Controls & Safety Devices for

Automatically Fired Boilers”

f. ANSI/NFPA 211 – “Chimneys, Fireplaces, vents,

and Solid Fuel Burning Appliances”

3. Where required by the authority having jurisdiction, the installation must conform to the Standard for

Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

C. ACCESSIBILITY CLEARANCES

The following recommendations allow for reasonable access to the boiler. Local codes or special conditions may require greater clearances.

1. For servicing the boiler provide not less than 24" from the side of the boiler where limit and level controls are mounted.

2. For servicing the burners provide not less than 24" from the front of the boiler.

3. The remaining clearances should be 6" from all sides.

D. CLEARANCES FROM COMBUSTIBLE

CONSTRUCTION

Boiler Models 63-03 through 63-06

1. The design of this boiler is certified for alcove installation with the following clearances to combustible construction.

a. Sides: 6"

b. Top: 30"

c. Front: 18"

d. Rear: 6"

e. Single Wall Vent Pipe: 6"

Boiler Models 64-07 through 64-12

2. The design of this boiler is certified for installation with the following clearances to combustible construction. Boiler must be installed in an area large in comparison to the boiler.

a. Sides: 24"

b. Top: 30"

c. Front: 18"

d. Rear: 24"

e. Single Wall Vent Pipe: 6"

3. All Models

a. Single wall vent pipe must be at least 6" away

from combustible construction.

b. For installation on non-combustible flooring only.

c. If it is necessary to build a non-combustible floor

pad on top of an existing combustible floor, construct pad as described in the Installation of Specific Equipment Chapter of National Fuel Gas Code Handbook.

1. PREINSTALLATION

Do not install this boiler on carpeting.

WARNING

Do not install this boiler on combustible flooring. Boiler installation on combustible flooring is a fire hazard.

WARNING

Page 5

E. AIR FOR COMBUSTION AND

VENTILATION

1. Adequate combustion air and ventilation air must be provided for this appliance in accordance with the section of the National Fuel Gas Code entitled, “Air for Combustion and Ventilation” or applicable provisions of the local building code. Subsections 2 through 8 as follows are based on the National Fuel Gas Code requirements.

2. Required Combustion Air Volume:

The total required volume of indoor air is to be the sum of the required volumes for all appliances located within the space. Rooms communicating directly with the space in which the appliances are installed and through combustion air openings sized as indicated in Subsection 3 are considered part of the required volume. The required volume of indoor air is to be determined by one of two methods.

a. Standard Method: The minimum required

volume of indoor air (room volume) shall be 50 cubic feet per 1000 BTU/Hr (4.8 m

/kW). This method is to be used if the air infiltration rate is unknown or if the rate of air infiltration is known to be greater than 0.6 air changes per hour. As an option, this method may be used if the air infiltration rate is known to be between 0.6 and

0.4 air changes per hour. If the air infiltration rate is known to be below 0.4 then the Known Air Infiltration Rate Method must be used. If the building in which this appliance is to be installed is unusually tight, PB Heat recommends that the air infiltration rate be determined.

b. Known Air Infiltration Rate Method: Where

the air infiltration rate of a structure is known, the minimum required volume of indoor air for appliances other than fan assisted and for the Series 63/64™ Boiler shall be determined as follows:

where:

other

= Input of appliances other than fan

assisted in Btu/hr

ACH = air change per hour (percent of the

volume of the space exchanged per hour, expressed as a decimal)

For fan assisted appliances, calculate the required volume of air using the following equation:

fan

= Input of the fan assisted appliances in

Btu/hr

Note: These calculations are not to be used for infiltration rates greater than 0.60 ACH.

3. Indoor Air Opening Size and Location:

Openings

connecting indoor spaces shall be sized and located as follows:

a. Combining spaces on the same floor:

Provide two permanent openings communicating with additional spaces that have a minimum free area of 1 in

per 1000 Btu/hr (22 cm2per 1000 W) of the total input rating of all gas fired equipment but not less than 100 in

(645 cm2). One opening is to begin within 12 inches (305 mm) from the top of the space and the other is to begin within 12 inches (305 mm) from the floor. The minimum dimension of either of these openings shall be 3 inches (76 mm). See Figure

1.1 for an illustration of this arrangement.

b. Combining spaces on different floors:

Provide one or more permanent openings communicating with additional spaces that have a total minimum free area of 2 in

per 1000

Btu/hr (44 cm

per 1000 W) of total input rating of all equipment. See Figure 1.2 for an illustration of this arrangement.

Figure 1.1: Air Openings – All Air from Indoors

on the Same Floor

Figure 1.2: Air Openings – All Air from Indoors

on Different Floors

15 ft

fan

ACH 1000

Btu

Required Volume

fan

21 ft

other

ACH 1000

Btu

Required Volume

other

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⎜

⎝

⎛ ⎜ ⎝

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⎜

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PREINSTALLATION

4. Outdoor Combustion Air: Outdoor combustion air is to be provided through one or two permanent openings. The minimum dimension of these air openings is 3 inches (76 mm).

a. Two Permanent Opening Method: Provide

two permanent openings. One opening is to begin within 12 inches (305 mm) of the top of the space and the other is to begin within 12 inches (305 mm) of the floor. The openings are to communicate directly or by ducts with the outdoors or with spaces that freely communicate with the outdoors. The size of the openings shall be determined as follows:

i. Where communicating directly or through

vertical ducts with the outdoors each opening shall have a minimum free area of 1 in

per

4000 Btu/hr (22 cm

per 4000 W) of total input rating for all equipment in the space. See Figure 1.3 for openings directly communicating with the outdoors or Figure

1.4 for openings connected by ducts to the outdoors.

ii. Where communicating with the outdoors

through horizontal ducts, each opening shall have a minimum free area of 1 in

per 2000

Btu/hr (22 cm

per 2000 W) of total rated input for all appliances in the space. See Figure 1.5.

b. One Permanent Opening Method: Provide

one permanent opening beginning within 12 inches (305 mm) of the top of the space. The opening shall communicate directly with the outdoors, communicate through a vertical or horizontal duct, or communicate with a space that freely communicates with the outdoors. The opening shall have a minimum free area of 1 in

per 3000 Btu/hr of total rated input for all appliances in the space and not less than the sum of the cross-sectional areas of all vent connectors in the space. The gas-fired equipment shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance. See Figure 1.6 for this arrangement.

Figure 1.4: Air Openings – All Air from Outdoors

through Vertical Ducts

Figure 1.5: Air Openings – All Air from Outdoors

through Horizontal Ducts

Figure 1.6: Air Openings – All Air from Outdoors

through One Opening

Figure 1.3: Air Openings – All Air Directly from

Outdoors

Page 7

5. Combination Indoor and Outdoor Combustion Air: If the required volume of indoor air exceeds the available indoor air volume, outdoor air openings or ducts may be used to supplement the available indoor air provided:

a. The size and location of the indoor openings

comply with Subsection 3.

b. The outdoor openings are to be located in

accordance with Subsection 4.

c. The size of the outdoor openings are to be sized

as follows:

where:

req

= minimum area of outdoor openings.

full

= full size of outdoor openings calculated

in accordance with Subsection 4.

avail

= available indoor air volume

req

= required indoor air volume

6. Engineered Installations:

Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and dilution air and shall be approved by the authority having jurisdiction.

7. Mechanical Combustion Air Supply:

a. In installations where all combustion air is

provided by a mechanical air supply system, the combustion air shall be supplied from the outdoors at the minimum rate of 0.35 ft

/min per

1000 Btu/hr (0.034 m

/min per 1000 W) of the

total rated input of all appliances in the space.

b. In installations where exhaust fans are installed,

additional air shall be provided to replace the exhaust air.

c. Each of the appliances served shall be

interlocked to the mechanical air supply to prevent main burner operation when the mechanical air supply system is not in operation.

d. In buildings where the combustion air is provided

by the mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the required ventilation air.

8. Louvers & Grills:

a. The required size of openings for combustion,

ventilation, and dilution air shall be based on the net free area of each opening.

i. Where the free area through a louver or grille

is known, it shall be used in calculating the opening size required to provide the free area specified.

ii. Where the free area through a louver or grille

is not known, it shall be assumed that wooden louvers will have 25% free area and metal louvers and grilles will have 75% free area.

iii. Nonmotorized dampers shall be fixed in the

open position.

b. Motorized dampers shall be interlocked with the

equipment so that they are proven in the full open position prior to ignition and during operation of the main burner.

i. The interlock shall prevent the main burner

from igniting if the damper fails to open during burner startup.

ii. The interlock shall shut down the burner if

the damper closes during burner operation.

9. Combustion Air Ducts

a. Ducts shall be constructed of galvanized steel or

an equivalent corrosion- resistant material.

b. Ducts shall terminate in an unobstructed space,

allowing free movement of combustion air to the appliances.

c. Ducts shall serve a single space.

d. Ducts shall not serve both upper and lower

combustion air openings where both such openings are used. The separation between ducts serving upper and lower combustion air openings shall be maintained to the source of combustion air.

e. Ducts shall not be screened where terminating in

an attic space.

f. Horizontal upper combustion air ducts shall not

slope downward toward the source of the combustion air.

g. The remaining space surrounding a chimney

liner, gas vent, special gas vent, or plastic piping installed within a masonry, metal, or factory built chimney shall not be used to supply combustion air.

h. Combustion air intake openings located on the

exterior of buildings shall have the lowest side of the combustion air intake opening at least 12 inches (305 mm) above grade.

avail

1 –

req

= A

full

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⎜

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F. INSTALLATION SURVEY

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

You can also use this survey to locate system problems which will have to be corrected. To obtain copies of these Surveys, contact your PB Heat representative or download them from PeerlessBoilers.com.

G. 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.

PREINSTALLATION

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

Page 9

BOILER PLACEMENT & ASSEMBLY

A. PACKAGED BOILER

1. Remove the crate top and sides and remove any loose cartons.

2. Lift the boiler from the crate pallet. Move the boiler to the location determined in Chapter 1: Pre-installation.

3. Proceed to Chapter 3: Piping the Boiler.

B. KNOCKDOWN BOILERS – SPLIT BLOCK

ASSEMBLY MODELS 64-07 TO 64-12

1. The boiler sections and base on Model 63-03 to 63-06 are factory assembled. If the boiler is 63-03 through 63-06 begin assembly as described in step 2.C, Knockdown Boilers: Assembled Blocks.

2. Move each block of cast iron sections off of the shipping pallets and support them as shown in Figure 2.1.

3. Clean nipple ports using a wire brush. Make certain there are no burrs around the outside edge of the ports. If necessary, remove any burrs on the edges using a round file (be careful not to score the nipple port).

4. Spread a thin coat of TFE TITE Nipple Sealant in the nipple ports.

5. Insert the push nipples into the nipple ports of one of the split block ends. Make sure the nipples are clean and free of burrs. Use a block of wood to protect the surface of the nipple while setting the nipple into the nipple port with a hammer. Assure that the nipple is firmly seated in the nipple port before proceeding.

6. Apply silicone sealant to the rope groove to hold the rope in place during assembly. Press 1/2" diameter rope into the rope groove.

7. Assure the nipples are perpendicular to the sections and that the blocks are aligned properly.

8. Insert draw rods through the lugs provided on the mating intermediate sections. Use 5/8" draw rods as shown in Figure 2.1.

9. Before starting to draw the sections together, apply lubricating oil to the threads.

10. Tighten the hex nuts and draw the boiler sections together evenly until the small pads on each of the mating sections are in contact:

Periodically measure the gap at all four corners of the section to make sure the sections are drawing together evenly – gaps measured at

all four corners should not vary more than 1/8". Turn wrench no more than 3-4 times before

moving to the next nut (this equates to about an 1/8" draw-up).

Using similar torque on each nut, gradually increase the torque as the sections are drawn closer together. Maximum allowable torque on the draw rod nuts is 80 foot-pounds. Typically only 30 to 60 foot-pounds is required to pull together evenly drawn sections.

If one corner resists moving, loosen the draw rods on the other corners to help pull the subject corner into proper alignment.

2. BOILER PLACEMENT & ASSEMBLY

Never apply nipple sealer on the nipples. Apply only in nipple ports.

NOTICE

Be careful not to damage the burner tray when removing the boiler from the pallet. If necessary, remove the burner tray before moving the boiler.

NOTICE

Figure 2.1: Block Assembly

Never hit the nipple directly with a hammer. This will damage the nipple and cause leaks.

NOTICE

If the nipple is not fully seated in the nipple port, damage to the nipple may occur when the sections are drawn together.

NOTICE

Page 10

BOILER PLACEMENT & ASSEMBLY

11. If the sections do not draw together using the torque specified above, the block must be separated and the nipples replaced before reassembly is attempted.

12. The sections may alternatively be drawn together using long 5/8" rods along with cast iron washers through the nipple ports. Two large cast iron washers (51163), two small cast iron washers (51165) and two long 5/8" NPT rods are required (not provided). Do not attempt to draw sections together without the cast iron washers.

C. KNOCKDOWN BOILERS: ASSEMBLED

BLOCKS

1. If shipping pallet is still attached, move the assembled block off of the pallet.

2. Move the assembled block to the location determined in Chapter 1: Pre-installation. The location should be on a level foundation as near to the chimney as possible and centralized with respect to the heating system.

3. Attach the base front/rear insulated panels to the cast iron block assembly as shown in Figure 2.2 using 3/8" carriage bolts and 3/8" hex nuts.

4. Attach the base lower rear panel to the cast iron block assembly using 3/8" carriage bolts and hex nuts.

D. KNOCKDOWN BOILERS: CONTROL &

MANIFOLD ASSEMBLY

1. Remove the burner tray assembly from the burner and controls carton.

2. Check burners to assure that they are seated correctly in the burner tray rear support.

3. For Series 64™ boilers, assemble the 90° elbow and return bend to the manifold assembly.

4. Remove the gas valve manifold components from the burner tray and controls carton and connect them to the burner manifold. Refer to Figure 5.2 through 5.5 in Section 5 for the specific Gas Train Manifold Configuration.

5. Slide the burner tray under the cast iron block assembly and attach to the end sections using the 1/4" carriage bolts and nuts provided. (See Figure 2.2).

6. Attach the base burner access panel to the base front panel assembly with two #10 x 1/2" sheet metal screws (See Figure 2.2).

E. KNOCKDOWN BOILERS: FLUE

COLLECTOR ASSEMBLY

1. Remove the flue collector and ceramic blanket strip insulation from burner and controls carton.

2. Lay the ceramic blanket strip on top of the boiler using care not to block any flue passageways.

3. Insert the two 1/4"-20 carriage bolts provided with boiler into the lugs on top of the boiler end sections as shown in Figure 2.3.

4. Attach the flue collector to the bolts with the flat washers and hex nuts provided. Tighten the nuts snugly.

Figure 2.3: Flue Collector Attachment

Figure 2.2: Base Panel Attachment

Page 11

F. KNOCKDOWN BOILER: HYDROSTATIC

TESTING

1. Install the pressure gauge and drain valve in the right hand end section.

2. Install a water supply line with a shut-off valve in the right hand end section.

3. Install an air vent valve on the boiler relief valve connection.

4. Plug all open tappings in the boiler.

5. Fill the boiler with water, venting air from the top of the unit as the water level rises.

6. Pressurize the boiler from 75 to 85 psig. Do not exceed 85 psig.

7. Maintain pressure while inspecting the boiler thoroughly for leaks.

8. After inspection is complete, drain the boiler and remove plugs from tappings that are to be used.

G. KNOCKDOWN BOILER: ASSEMBLE

JACKET

1. The Series 63™ boilers employ a wrap-around style jacket while the Series 64™ boilers use an individual back panel.

2. Align the clearance holes on the side panels with the mounting holes in the base front & back plates and attach with #10 x 1/2" sheet metal screws.

3. Wrap-Around Jacket: Bend the side jacket panels at the perforations to form the back of the jacket. The left side should overlap the right for proper attachment. Connect the two panels with three #10 x 1/2" sheet metal screws. See Figure 2.4.

4. Back Panel Jacket: Position the back jacket panel inside the flange of the side jacket panels and attach it with six #10 x 1/2" sheet metal screws. See Figure 2.5.

5. Position the Inner Front Panel between the side panels and align the mounting holes on the side flanges with the clearance holes on the side panels. Attach with four #10 x 1/2" sheet metal screws provided. See Figure 2.6.

6. Attach the Lower Front Panel to the bottom front of the side Jacket Panels with two #10 x 1/2" sheet metal screws. See Figure 2.6.

BOILER PLACEMENT & ASSEMBLY

Figure 2.4: Jacket Assembly, Series 63™ Boilers

Figure 2.5: Jacket Assembly, Series 64™ Boilers

Figure 2.6: Jacket Panel Attachment

Page 12

7. Attach the Draft Hood to the Flue Collector using #10 x 1/2" sheet metal screws provided. Refer to Figure 2.7.

8. Position the Top Jacket Panel so that the flanges overlap the Side Jacket Panels and the air louvers are at the front of the boiler. Attach with six #10 x 1/2" sheet metal screws. See Figure 2.6.

9. Remove the following data plates or labels from the manila envelope that contains the Instruction Manual:

- Boiler Rating Label

- Lighting/Operating Instruction Label

- Wiring Diagram Label Attach labels as shown in Figure 2.8.

10. Insert the top edge of the Front Jacket Panel beneath front flange of the Top Jacket Panel and against the top of the Lower Front Panel.

Figure 2.7: Draft Hood Attachment

Figure 2.8: Label & Rating Plate Locations

BOILER PLACEMENT & ASSEMBLY

Page 13

A. CHIMNEY OR VENT

1. Inspect the existing chimney or vent system. Make sure it is in good condition. Inspect chimney liner and repair or replace if necessary.

2. The vent system and installation must be in accordance with Venting of Equipment chapter of the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building codes.

3. Chimney/Vent Operation: The vent system must be sized and installed to provide the draft needed to remove all combustion products. If the vent system does not provide enough draft, combustion products will spill into the building from the draft hood relief opening. If spillage of combustion products occurs, check the vent system, the combustion and ventilation openings and make sure the boiler room is never under negative pressure.

4. Vent Connection to Boiler:

a. Support the weight of the vent system

independently of the boiler draft hood. The draft hood is not designed to carry structural loading.

b. Provide support of the vent connector

(breeching) at maximum 12 foot intervals to prevent sagging and to provide a minimum upward slope of 1/4" per foot.

c. Do not connect the vent for this boiler into any

vent system which operates with positive pressure.

d. The vent connector must be single wall steel or

Type B double wall vent pipe. The vent connector must be Type B double wall if it is located in or passes through cold areas. The vent connector must extend into, but not beyond, the inside wall of the chimney.

B. AUTOMATIC VENT DAMPER

INSTALLATION – GENERAL

1. Do not use one vent damper to control two or more heating appliances. See Figure 3.1.

2. Follow these and the installation instructions included with the vent damper. Observe the cautions and warnings that accompany all instructions.

3. Provide minimum 6 inch (152 mm) clearance between automatic vent damper and combustible construction. Increase clearance if required by vent damper manufacturer’s instructions. Provide adequate space for vent damper access and service.

4. The automatic vent damper can be mounted directly onto the draft hood outlet or in vent piping close to the boiler.

See Figure 3.2 for installation with vent damper mounted in vertical position. See Figure 3.3 for installation with vent damper mounted in horizontal position. Mount the unit to avoid excessive heat on the operator or condensation drips into the operator.

Figure 3.1: Venting Multiple Appliances

Failure to provide adequate venting can result in severe personal injury or death.

WARNING

3. VENTING

Page 14

VENTING

a. Orient the vent damper operator to facilitate

connection of the vent damper harness to knockout on right side of boiler.

b. Orient vent damper direction arrow in direction

of vent gas flow. Direction arrow must be visible from front of boiler.

C. BOILER REMOVAL FROM COMMON

VENTING SYSTEM

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining appliances connected to it.

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 or CAN/CGA B149 Installation Codes. 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 located in the chapter “Sizing of Category I Venting Systems,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or CAN/CGA B149 Installation codes.

Figure 3.2: Venting with Vent Damper in

Vertical Position

Figure 3.3: Venting with Vent Damper in Horizontal Position

Damper must be in open position when appliance main burner is operating.

CAUTION

Page 15

BOILER PIPING

A. WATER BOILER PIPING – SINGLE

BOILER

1. Refer to the PB Heat Water Installation Survey and

Hydronics Institute Residential Hydronic Heating Installation Design Guide.

2. Figure 4.1 shows typical supply and return piping for a boiler system. If the system expansion tank is located on the boiler loop, it should be located on the supply side of the boiler with the system circulator pumping away from the expansion tank connection.

3. If the boiler is piped in a secondary loop separate from the system expansion tank, the boiler circulator should be located on the return side of the boiler pumping away from the common piping.

4. Return water should not reach the boiler return connection at less than 130°F under normal operating conditions. If the system return temperature is expected to be below 130°F the boiler should be piped in a secondary loop with a bypass arrangement to assure water returning to the boiler is above 130°F. For more information on bypass piping consult the PB Heat Water Installation Survey.

5. If the boiler and distribution system is used in conjunction with a refrigeration system, pipe the chilled medium in parallel with the boiler and provide isolation valves to prevent chilled water form entering the boiler. See Figure 4.2.

6. If the boiler is connected to a heating coil in a forced air combination heating and cooling system, install flow control valves to prevent gravity circulation of the boiler water during cooling cycles.

7. A hot water boiler installed above radiation level or as required by the Authority having jurisdiction, must be provided with a low water cut-off device either as part of the boiler or at the time of installation.

4. BOILER PIPING

Figure 4.1

Figure 4.2: Piping to Isolate Boiler from Chilled Medium on Chiller Systems

Page 16

BOILER PIPING

B. WATER BOILER PIPING – MULTIPLE

BOILERS

Refer to the PB Heat Water Installation Survey and Hydronics Institute Residential Hydronic Heating Installation Design Guide for guidance on multiple boiler

installations.

C. STEAM BOILER PIPING – SINGLE

BOILERS

1. Refer to the PB Heat Steam Installation Survey and

Hydronics Institute Residential Hydronic Heating Installation Design Guide for guidance.

2. Install steam supply pipes as shown in Figure 4.3 for Model 63-03 to 64-07 and Figure 4.4 for Model 64-08 to 64-12. The minimum quantity and size of supply pipes are indicated in Table 4.1.

3. Pipe the steam header a minimum of 24" above the normal water line using swing joints to attach the risers into the steam header.

4. Use threaded fittings for manifold piping to provide flexibility for thermal expansion.

5. Connect the equalizing line as shown in Figure 4.3 or 4.4 assuring that the reducing elbow is facing down and that any bushings are vertical to prevent water build-up in the steam header.

Figure 4.3: Steam Piping – Single Supply

Connection

Use swing joints to attach to the header to avoid damage to the boiler due to thermal expansion and contraction of steam header pipe.

NOTICE

Figure 4.4: Steam Piping – Dual Supply

Connections

• Do not use bushings or concentric reducers in the horizontal header piping. This will prevent water from dropping into the equalizer and cause water carryover into the steam piping.

• Do not reduce the size or number of steam supply risers below the minimum shown in Table 4.1. Insufficient or undersized risers can cause damage to the boiler.

• Do not use a bullhead tee to provide steam supply to the system. This will cause water carryover into the steam piping.

NOTICE

Use Threaded Fittings for Manifold Piping

Page 17

BOILER PIPING

6. The use of a Hartford Loop in all installations is recommended to ensure reliability of the system. A check is required on the pump discharge of all pumped return systems.

7. On pumped return systems, install a globe valve after the pump to allow throttling of the pump discharge. The pressure downstream of the boiler cock should be no more than 5 psig above the boiler operating pressure.

8. Pipe the Hartford Loop such that the top of the close nipple is 2 to 4 inches below the boiler normal water line.

9. If the boiler feed pump discharge piping is elevated at any point above the boiler water line, install spring-loaded check valves at both the pump discharge and at the connection to the boiler.

D. STEAM BOILER INDIRECT WATER

HEATER PIPING

1. See Figure 4.5 for typical installation.

2. Install Boiler Water Temperature Limit Control in 1" Tee on supply connection (same side of boiler as low water cut-off). Set Limit at 160°F to avoid steam generation during periods when only the domestic water is calling for heat.

3. Install circulator and strainer in supply piping. Install check valve to prevent gravity circulation.

E. STEAM BOILER PIPING - MULTIPLE

BOILERS

Refer to the PB Heat Steam Installation Survey and Hydronics Institute Residential Hydronic Heating Installation Design Guide for guidance on multiple boiler

installations.

Table 4.1: Steam Supply and Header Pipe Sizing

Always locate the steam supply take-off of the main header between the equalizer and the last boiler supply riser. Locating the steam supply between the risers will cause a bullhead tee and cause water carryover into the system.

NOTICE

Boiler Model

Number of

Supply

Connections

Supply

Size (NPS)

Header

Size (NPS)

Equalizer

Size (NPS)

Evaporation

Rate (GPM)

63-03L 1 2 2 1-1/4 0.11

63-03 1 2 2 1-1/4 0.15

63-04L

1 2-1/2

2-1/2 1-1/4 0.19

2* 2*

63-04

1 2-1/2

2-1/2 1-1/4 0.23

2* 2*

63-05L

1 3

3 1-1/4 0.27

2* 2*

63-05

1 3

3 1-1/4 0.31

2* 2*

63-06

1 3

3 1-1/4 0.37

2* 2-1/2*

64-07

1 3

3 1-1/2 0.45

2* 2-1/2*

64-08 2 2-1/2 4 1-1/2 0.52

64-09 2 3 4 1-1/2 0.60

64-10 2 3 4 1-1/2 0.67

64-11 2 3 4 1-1/2 0.75

64-12 2 3 5 1-1/2 0.82

Maintain water level near normal water line to avoid steam generation during periods when only the domestic water is calling for heat.

Tank performance reduced when supplied by steam boiler.

NOTICE

Figure 4.5: Typical Steam Boiler Indirect

Water Heater Piping

*Dual supplies may be used in lieu of larger single supply on

63-04L through 64-07 as indicated.

Page 18

FUEL PIPING

A. INSTALLATION

1. Pipe gas to the boiler in accordance with local codes. In the absence of local regulations refer to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

2. Size and install the gas supply piping to provide a supply of gas sufficient to meet the maximum demand of all appliances without excessive pressure drop.

3. The rate of gas to be provided to the boiler can be determined by:

Obtain the gas heating value of the gas from the gas supplier. As an alternative use Table 5.1.

4. Table 5.2 shows the maximum flow capacity of several pipe sizes based on 0.3 inches of water pressure drop. These values are based on a specific gravity of 0.60. Apply the factors indicated in Table

5.3 for gas with specific gravity other than 0.60 to obtain corrected capacities.

B. OPERATION

1. Assure that the gas supply pressure to the boiler is regulated to 1/2 psi or less (approx. 13.5 inches of water).

2. Install a service valve, sediment trap, and ground joint union at the gas supply connection as shown in Figure 5.1.

3. Check piping for leaks. Use an approved gas detector or a non-corrosive leak detection fluid. If leaks are found, turn off all gas supply to the appliance and repair as necessary.

4. The boiler and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5kPa).

The boiler must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).

5. FUEL PIPING

Based on Specific Gravity of 0.60

Pipe Length

(Feet)

1/2"

Pipe

3/4"

Pipe

1-1/4"

Pipe

1-1/2"

Pipe

10 132 278 520 1,050 1,600 20 92 190 350 730 1,100 30 73 152 285 590 890 40 63 130 245 500 760 50 56 115 215 440 670 60 50 105 195 400 610

Table 5.2: Maximum Capacity of Pipe in CFH for a

Pressure Drop of 0.3" of Water

Table 5.3: Maximum Capacity Correction Factors

Specific Gravity other than 0.60

Table 5.1: Gas Input & Valve Inlet

Do not subject the boiler gas valve to pressure in excess of 1/2 psi (3.5 kPa). Doing so may damage the valve.

CAUTION

Figure 5.1

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

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.

CAUTION

Boiler Input (BTU/HR)

CFH =

Gas Heating Value (BTU/FT³)

Model

Gas Input1(CFH) Gas Valve Inlet2(NPT)

Nat. Gas LP Gas Nat. Gat LP Gas

63-03L 88.5 35.4

1/2" 1/2"

63-03 118.0 47.2

63-04L 147.5 59.0

63-04 177.0 70.8

63-05L 206.5 82.6

3/4"

63-05 236.0 94.4 63-06 287.5 115.0 64-07 345.0 138.0 64-08 399.0 159.6 64-09 460.0 184.0

64-10 517.5 207.0 64-11 575.0 230.0 64-12 632.5 253.0

1. Natural Gas Based on 1000 Btu./Cubic Foot, LP Gas Based on 2500 Btu./Cubic Foot.

2. See instructions for sizing gas supply piping.

Page 19

FUEL PIPING

5. Refer to table 5.4 for minimum supply pressure for the purpose of input adjustment.

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

7. The boiler and its gas connection must be leak tested before placing the boiler in operation.

8. Typical gas train manifolds are illustrated in Figure

5.2 through 5.5.

Model

Supply

Pressure

(in. Water)

63-03L 5.00

63-03 5.00

63-04L 5.00

63-04 5.35

63-05L 5.00

63-05 5.00 63-06 5.56 64-07 5.00 64-08 5.27 64-09 5.00 64-10 5.00 64-11 5.00 64-12 5.10

Table 5.4: Minimum Supply

Pressure Natural Gas

Figure 5.2: Gas Train Manifold 63-03L

Through 63-06

Figure 5.5: Gas Train Manifold – Natural & LP Gas

64-09 Through 64-12

Figure 5.4: Gas Train Manifold – 64-07/08 LP Gas,

Standing Pilot & 64-07/08 Spark Ignited Natural & LP Gas

Figure 5.3: Gas Train Manifold – 64-07 & 64-08

Natural Gas, Standing Pilot

Page 20

CONTROLS & TRIM

A. WATER BOILER CONTROLS & TRIM

1. Safety Relief Valve:

a. Pipe the boiler relief valve into the 3/4" tapping

on the left side of the boiler as shown in Figure

6.1. Be sure that the relief valve is sized in accordance with local code requirements. In addition, be sure that the relief valve is designed constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV.

b. If it is necessary to use a boiler relief valve larger

than 3/4" due to local codes, the relief valve should be piped in the boiler skim tapping. Do

not increase the size between the boiler and the valve.

c. Pipe the discharge of the safety relief valve to a

maximum of 12" from the floor. Pipe the relief outlet close to a floor drain.

2. Drain Valve:

Install the 3/4" drain valve provided into the drain tapping on the right hand side of the boiler. Refer to Figure 6.2 for tapping location.

3. Pressure/Temperature Gauge: Install the pressure/temperature gauge (theraltimeter)

supplied with the boiler into the 1/2" tapping located on the right side of the boiler. Refer to Figure 6.2 for tapping location.

4. Limit Control(s):

a. Install the operating limit control provided in the

3/4" tapping located on the right side of the boiler. Refer to Figure 6.2 for tapping location.

b. (64-09 through 64-12) Install a high limit control

in the 3/4" tapping located above the operating limit control. Refer to Figure 6.2 for location.

5. Low Water Cut-off (Level Control)

a. A hot water boiler installed above radiator level

or as required by the authority having jurisdiction must be provided with a low water cut-off device either as part of the boiler or at the time of installation.

b. If a probe-type low water cut-off is used it should

be piped into the boiler supply piping as shown in Figure 6.3.

6. CONTROLS & TRIM

Do not install any valves or restrictions between the relief valve and the boiler. Be sure that the inlet to the relief valve is the same or smaller pipe size than the boiler connection.

CAUTION

Pipe the discharge of the relief valve away from any traffic area. Failure to do this may cause injury if the valve discharges.

CAUTION

Pipe the discharge of the relief valve using the full size of the discharge connection.

CAUTION

Figure 6.2 Water Boiler Tapping Locations

Figure 6.1 Relief Valve Piping Water Boiler

Figure 6.3 Probe Low Water Cut-off Piping

Page 21

CONTROLS & TRIM

B. STEAM BOILER CONTROLS & TRIM

1. Safety Valve: a. Pipe the boiler safety valve provided into the 3/4"

tapping on the left side of the boiler as shown in Figure 6.4. Be sure that the relief valve is sized in accordance with local code requirements. In addition, be sure that the safety valve is designed constructed and stamped in accordance with the ASME Boiler and Pressure Vessel Code, Section IV.

b. If it is necessary to use a boiler relief valve larger

than 3/4" due to local codes, the relief valve should be piped in the boiler skim tapping. Do

not increase the pipe size between the boiler and the valve.

c. Pipe the discharge of the safety valve to a

maximum of 12" from the floor. Pipe the outlet close to a floor drain.

2. Drain Valve:

Install the 3/4" drain valve provided into the drain tapping on the right hand side of the boiler. Refer to Figure 6.5 for tapping location.

3. Low Water Cut-off (Level Control): a. Float Type: Install the float type low water cut-

off (if provided) in conjunction with the gauge glass as shown in Figure 6.6.

b. Probe Type: Install the optional probe type low

water cut-off into the 3/4" tapping on the right side of the boiler. Refer to Figure 6.5 for tapping location. The supplied control incorporates a 60 second off cycle after a 15 minute on cycle. This feature allows the water level in the boiler to settle so that the probe can sense a true water level.

4. Gauge Glass: a. Install the gauge glass provided into two 1/2"

tappings on the right side of the boiler. If a float type low water cut-off is used, it will be piped into these same fittings. See Figure 6.6 and 6.7 for examples of this installation.

5. Pressure Gauge: a. Install the operating limit control and pressure

gauge in the 3/4" tappings located on the right side of the boiler. Refer to Figure 6.5 for tapping location.

6. Limit Control(s): (Figure 6.8) a. Install the operating limit control and pressure

gauge in the 3/4" tappings located on the right side of the boiler. Refer to Figure 6.5 for tapping locations.

b. (64-09 through 64-12) Install a high limit control

in the 3/4" tappings located to the right of the operating limit control. Refer to Figure 6.5 for location.

Figure 6.6: Gauge Glass & Low Water Cut-Off

Installation

Figure 6.5: Steam Boiler Tapping Location

Figure 6.7: Gauge Glass Installation

Figure 6.8: Limit Control Installation

Figure 6.4

Page 22

ELECTRICAL

A. CONNECT SUPPLY WIRING

1. All electrical wiring must be done in accordance with local codes. In the absence of local codes use ANSI/NFPA 70 “The National Electrical Code.”

2. The boiler must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code, ANSI/NFPA 70 and/or the Canadian Electrical Code Part 1, CSA C22.1, Electrical Code.

3. The boiler is to be connected to a separate, permanently live electrical supply line with a fused disconnect switch.

B. MOUNT REMAINING CONTROLS

1. Mount the control transformer on the junction box as shown in Figure 7.1.

2. Mount the blocked vent switch in the rear of the boiler on the draft hood as shown in Figure 7.2.

3. Mount the flame rollout switch as shown in Figure 7.3.

7. ELECTRICAL

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

CAUTION

Figure 7.1

Figure 7.2

Figure 7.3

Page 23

ELECTRICAL

4. Mount the ignition module, if required (spark ignited units only), as shown in Figure 7.4.

5. Mount the thermopilot valve (Johnson L62), if required (standing pilot only on 64-07 & 64-08 Natural Gas), as shown in Figure 7.5.

C. INSTALL CONTROL WIRING

1. Wire the boiler according to the wiring diagram supplied with the boiler (in the Control Envelope). Figures 7.6 to 7.15 are provided for reference only.

2. Install all line voltage wiring in approved electrical conduit.

3. Do not install single pole switches, including safety controls, in the neutral leg.

D. WIRING DIAGRAM INDEX

Figure 7.4

Figure 7.5

63-03L

63-03

63-04L

63-04

63-05L

63-06

64-07

64-08

64-09

64-10

64-11

64-12

Standing Pilot, Natural Gas

Fig. 7.6 Fig. 7.7 N/A

Standing Pilot, LP Gas

Fig. 7.6 N/A

Spark Ignition, Natural Gas

Fig 7.8

Spark Ignition, LP Gas

Fig. 7.8

63-03L

63-03

63-04L

63-04

63-05L

63-06

64-07

64-08

64-09

64-10

64-11

64-12

Standing Pilot, Natural Gas

Fig. 7.9

Fig.

7.10

N/A

Standing Pilot, LP Gas

Fig. 7.9 N/A

Spark Ignition, Natural Gas

Fig 7.11

Spark Ignition, LP Gas

Fig. 7.11

63-03L

63-03

63-04L

63-04

63-05L

63-06

64-07

64-08

64-09

64-10

64-11

64-12

Standing Pilot, Natural Gas

Fig. 7.12

Fig.

7.13

N/A

Standing Pilot, LP Gas

Fig. 7.12 N/A

Spark Ignition, Natural Gas

Fig 7.14

Spark Ignition, LP Gas

Fig. 7.14

Table 7.1: Wiring Diagram Index - Water Boilers

Table 7.2: Wiring Diagram Index - Steam Boilers

w/Float LWCO

Table 7.3: Wiring Diagram Index - Steam Boilers

w/Probe LWCO

Page 24

ELECTRICAL

Figure 7.6: Water Boiler with Standing Pilot. Wiring Diagram for Series 63™ and for Models 64-07 and 64-08 with LP Gas Fuel.

Page 25

ELECTRICAL

Figure 7.7: Water Boiler with Standing Pilot. Wiring Diagram for 64-07 and 64-08 with Natural Gas Fuel.

Page 26

ELECTRICAL

Figure 7.8: Water Boiler with Spark Ignition. Wiring Diagram for all Models.

Page 27

ELECTRICAL

Figure 7.9: Steam Boiler with Float Low Water Cut-off only and Standing Pilot Wiring Diagram for Series 63™ and 64-07 and 64-08 with

LP Gas Fuel

Page 28

ELECTRICAL

Figure 7.10: Steam Boilers with Float Low Water Cut-off only and Standing Pilot. Wiring Diagram for Models 64-07 and 64-08 Natural Gas Only.

Page 29

ELECTRICAL

Figure 7.11: Steam Boiler with Spark Ignition. Wiring Diagram for Models with Float Low Water Cut-off.

Page 30

ELECTRICAL

Figure 7.12: Steam Boilers with Probe Low Water Cut-off and Standing Pilot Wiring Diagram for Series 63™ and Models 64-07 and 64-08 LP

Gas Only.

Page 31

ELECTRICAL

Figure 7.13: Steam Boilers with Probe Low Water Cut-off and Standing Pilot. Wiring Diagram for Models 64-07 and 64-08 Natural Gas.

Page 32

ELECTRICAL

Figure 7.14: Steam Boiler with Spark Ignition. Wiring Diagram for Models with Probe Low Water Cut-off.

Page 33

ELECTRICAL

Figure 7.15: Typical Steam Boiler Indirect Water Heater Wiring

Page 34

BOILER OPERATION

8. BOILER OPERATION

A. SYSTEM INSPECTION

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

2. Inspect the boiler combustion chamber for obstructions. Clear any debris from the combustion chamber.

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

4. Verify that water piping, gas piping and electrical wiring are installed properly. Be sure that all components are installed correctly. Refer to these instructions as well as to component manufacturer’s instructions.

B1. FILL THE BOILER (WATER BOILERS)

1. Fill the boiler and system with water making certain to vent air from all high points in the system. Water should bleed from each air vent when it is opened.

2. The pressure reducing valve on the fill line will typically allow the system to be filled and pressurized to 12 psi. Consult the valve and expansion tank manufacturer for more detailed information.

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

4. If the water hardness is high, use water treatment to reduce the deposition of minerals in the boiler.

5. If the system requires antifreeze protection, use only propylene glycol specially formulated for hydronic systems. These contain inhibitors that prevent corrosion of the boiler and system components. Do not use ethylene glycol or automotive antifreezes.

a. Make sure that the antifreeze supplier can

provide periodic testing of antifreeze concentration and inhibitor level.

b. If an automatic fill valve is used, the solution

strength in the system must be checked to assure that the antifreeze concentration has not been overly diluted.

c. Local codes may require the addition of a

backflow preventer or manual fill only with separation from the city water supply.

d. Consider the minimum temperature of potential

exposure in the system when deciding on the antifreeze concentration. A concentration of 50% generally provides protection from freezing to -30°F.

B2. FILL THE BOILER (STEAM BOILERS)

1. Gravity Systems and Pumped Return with Condensate Units – Fill the boiler to the normal water line as indicated on the boiler jacket. The

normal water level is about 25-7/8" above the boiler foundation (about 2/3 of the gauge glass).

2. Pumped Return Systems with Boiler Feed Unit Fill the boiler using the boiler feed unit. The fill level will depend on the control being used but should be roughly 25-7/8" above the boiler foundation (about 2/3 of the gauge glass) when the feed pump stops.

3. Check all joints and fittings in system piping below the water line for leaks and repair as necessary.

C. STUDY LIGHTING INSTRUCTIONS

Before starting the boiler, study the Lighting Instructions supplied with the boiler. Figure 8.2 to 8.5 show typical Lighting Instructions for typical boilers.

See Table 8.1 to determine the correct figure.

D. RUN PILOT CHECK-OUT

1. Shut off all electrical power to the boiler.

2. Close Main and Pilot gas shut-off valves. Wait for five (5) minutes.

3. Set the Operating and Limit Temperature Controls to minimum setting so they will not call for heat.

4. Perform Pilot Check:

a. Turn main electric disconnect switch to the “ON”

position.

b. Turn up the settings on the Operating and Limit

Temperature Controls so they will call for heat.

c. Check for a continuous spark at the electronic

spark-ignited pilot.

d. Spark-ignited pilot systems – The control will

spark for 90 seconds (trial for ignition), then shut down for a 5 to 6 minute wait period before attempting another ignition.

e. Standing pilot systems – Within 180 seconds the

control will click, indicating a safety lockout.

f. Turn down the Operating Temperature Control to

stop the call for heat.

g. Wait 60 seconds to allow the control to reset

before proceeding with the next step.

5. Light Manual Pilot

a. Follow the procedure in the Lighting Instructions

to manually light any standing pilots.

63-03L

63-03

63-04L

63-04

63-05L

63-06

64-07

64-08

64-09

64-10

64-11

64-12

Standing Pilot, Nat. Gas Fig. 8.2 Fig.8.3

N/A

Standing Pilot, LP Gas Fig. 8.2 Spark Ignition, Nat. Gas Fig 8.4 Fig. 8.5 Spark Ignition, LP Gas Fig. 8.4

Table 8.1: Lighting & Operating Instructions

Figure Selection Chart

Page 35

BOILER OPERATION

6. Spark-Ignited Pilot Ignition Check a. Turn up the Operating Temperature Control for a

call for heat.

b. The spark-ignited pilot should ignite.

c. Turn down the Operating Temperature Control to

stop the call for heat.

d. The spark-ignited pilot should shut off.

7. Check Main Burner Ignition a. With the Operating Temperature Control turned

down, open the main gas shut-off valve(s).

b. Turn up the Operating Temperature Control for a

call for heat.

c. The electronic spark-ignited pilot(s) should ignite.

d. The main gas valves will then open and the main

burners should ignite.

e. Turn down the Operating Temperature Control to

stop the call for heat.

f. The electronic spark-ignited pilot(s) and main

burners should shut off.

E. CHECK MAIN BURNER SYSTEM

1. Remove the pressure test plug at the Main gas shut-

off valve. Attach a U-tube manometer.

2. Restart the boiler by turning up the Operating

Temperature Control for a call for heat.

3. Leak test all gas train joints with a soap suds

solution.

4. Check the gas pressure at the entrance to the Gas

Control train.

a. The pressure reading under flow should be

between 5.5 and 13.5 inches water column

b. If the pressure to the Gas Control Train exceeds

13.5 inches under any conditions, the system must be provided with a lockup type gas pressure regulator to provide 13.5 inches maximum.

5. Check the Manifold gas pressure. a. Remove the 1/8" pipe plug from the manifold gas

pressure tapping.

b. Attach a U-tube manometer.

c. Adjust the Main Gas Pressure Regulator to obtain

3.5 inches water column on Natural Gas or 10 inches water column on Propane (LP) Gas.

d. NOTE: If the pressure is adjusted to set the

nameplate input to the boiler, do not set it more than 0.3 inches plus or minus from the specified settings. If more adjustment to the rate is needed, it must be done by changing the burner gas orifices.

6. Check the burner input by reading the gas meter. a. The required input rate is listed for each model in

Section II, Dimensions & Ratings.

b. Determine the input by multiplying “F” – Meter

Reading (Cubic Feet of Gas) times “H” – Heating Value of Gas (Btu per Cubic Foot) times 3600. Divide by “T” – the time in seconds at the meter reading.

c. Note: If the meter is not automatically corrected

for temperature and pressure, the meter reading must be corrected to actual conditions during the rate test.

7. Check the burner and pilot flames (see Figure 8.1). The flame inner cone should be about 1-1/2" high and should have a very sharp blue color. Poor flame conditions can be caused by dirty burners, obstructed orifices or incorrect gas pressure.

F. CHECK BOILER CONTROLS

1. Limit and Operating Controls:

Lower the set point of each control until the burners shut down. Note that the system pressure (or temperature) corresponds to the limit setting.

Return the controls to the desired set point.

2. Low Water Cut-off (if used):

Consult the manufacturer’s instructions for the low water cut-off operational check procedure.

3. Main Gas Safety Shut-off Valve:

Close main supply manual shut-off valve. The main gas safety shut-off valve should de-energize.

Open the manual supply valve. Re-light the boiler in accordance with the lighting instructions.

G. PURGE AIR FROM THE SYSTEM

(WATER BOILERS ONLY)

1. Purge the system using purge valves, isolating zones in the process or use system vents. Do not operate the pump(s) while purging. Pumps will hold air in the eye of the impeller.

2. Allow the system to reach 180°F and use manual vents, if installed, to remove any remaining air.

H. CHECK THE SYSTEM PRESSURE

(WATER BOILERS ONLY)

Watch the pressure gauge as the system approaches 180°F. If the pressure exceeds the design operating pressure, check:

a. Fill valve pressure. b. Expansion or compression tank operation and sizing.

I. CLEAN THE BOILER

(STEAM BOILERS ONLY)

1. Clean the boiler as described below no later than one week after the initial start-up. Cleaning will be more effective if the boiler operates 24 to 48 hours in order to loosen sediment and impurities in the system.

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

Rate, Btu/Hr =

F x H x 3600

Page 36

BOILER OPERATION

3. Thread a 1-1/4" NPT Pipe Nipple into the “Skim Tapping” (Connection “J” in Figure 11.1). Tighten firmly.

4. Thread a 1-1/4" NPT ball valve onto the nipple and connect a 1-1/4" drain line.

5. Close all valves to the system. Provide a means of supplying fresh water to the boiler.

6. Use common washing soda (such as Arm & Hammer Super Washing Soda). For each 800 square feet EDR net boiler rating, mix one pound of washing soda with water. Pour mixture into safety relief valve tapping.

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

8. Turn burners on and allow the boiler water to heat up to between 180ºF and 200ºF. Cycle the burners to maintain temperature during skimming. Do not allow the boiler to steam. Steaming mixes up the contaminants in the water instead of floating them at the surface.

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

10. Continue skimming the boiler until the water flowing from the skim tapping flows clear. This will likely take several hours for a dirty system.

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

12. Close the make up water valve and open the boiler drain valve.

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

14. Open the valves to the system and replace the skim valve with a pipe cap.

J. TO SHUT DOWN THE BOILER

1. Open main line power disconnect switch to boiler.

2. Close Main and Pilot gas shut-off valves.

3. To take boiler out of service if the boiler and system are not to be used when temperatures are below freezing:

a. Drain the boiler and system completely and shut

off make-up water supply.

b. Open main line power disconnect switch to

boiler. Remove the fuses or secure the switch so that the power cannot be turned on accidentally.

c. Be certain that the boiler and system are refilled

before returning to service. Follow the Instructions in this manual and the Lighting Instructions to operate.

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

WARNING

Do not leave the boiler unattended while performing boil out. Do not allow the water to drop below the bottom of the gauge glass or allow make up water to enter too quickly. This will avoid the possibility of causing failure of the boiler sections.

CAUTION

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

NOTICE

Before servicing the boiler:

• Turn off all electrical power to the boiler.

• Close the Gas Service Valve.

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

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

CAUTION

Figure 8.1 Pilot and Burner Flames

Page 37

BOILER OPERATION

H24V VR8200/VR8300 9177R REV.3

If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life.

FOR YOUR SAFETY READ BEFORE LIGHTING

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. If the gas valve is not visible, remove control access panel.

5. If the gas control knob is not in the "OFF" position, turn the knob clockwise to "OFF".

Gas Control Knob (shown in "OFF" position

Red Reset Button

6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step.

7. Remove the pilot access panel, if supplied, located below and behind the gas valve directly above burner tubes.

TO TURN OFF GAS TO APPLIANCE

8. Find pilot - follow metal tube from gas valve. The pilot is between two burner tubes

Pilot Burner

9. Turn the gas control knob counterclockwise to "PILOT".

10. Push in red reset button all the way and hold in. Immediately light the pilot with a match. Continue to hold the reset button in for about one (1) minute after the pilot is lit. Release button and it will pop back up. Pilot should remain lit. If it goes out, repeat steps 5 through 10.

If button does not pop up when released, stop and immediately call your service technician or gas supplier. If the pilot will not stay lit after several tries, turn the gas control knob to "OFF" and call your service technician or gas supplier.

11. Replace pilot access panel, if applicable.

12. Turn gas control knob counterclockwise to "ON".

13. Replace control access panel, if applicable.

14. Turn on all electric power to the appliance.

15. Set thermostat to desired setting.

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. If the gas valve is not visible, remove the control access panel.

4. Turn the gas control knob clockwise to "OFF".

5. Replace control access panel, if applicable.

A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly.

B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch; do not use any phone in your building Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

Figure 8.2 Standing Pilot - 63 Nat/LP, 64 LP Gas

Page 38

BOILER OPERATION

VR8304 L62 9361 REV.0

If you cannot reach your gas supplier, call the fire department.

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life.

FOR YOUR SAFETY READ BEFORE LIGHTING

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. If the gas valve is not visible, remove control access panel.

5. If the gas control knob and pilot cock are not in the "OFF" position, turn both clockwise to "OFF".

7. Remove the pilot access panel, if supplied, located below and behind the gas valve directly above burner tubes.

TO TURN OFF GAS TO APPLIANCE

8. Find pilot - follow metal tube from gas valve. The pilot is between two burner tubes

Pilot Burner

9. Turn the pilot cock handle counterclockwise to "PILOT".

10. Push in red reset button on thermopilot valve all the way and hold in. Immediately light the pilot with a match. Continue to hold the reset button in for about one (1) minute after the pilot is lit. Release button and it will pop back up. Pilot should remain lit. If it goes out, repeat steps 5 through 10.

11. Replace pilot access panel, if applicable.

12. Turn gas control knob counterclockwise to "ON".

13. Replace control access panel, if applicable.

14. Turn on all electric power to the appliance.

15. Set thermostat to desired setting.

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. If the gas valve is not visible, remove the control access panel.

4. Turn the gas control knob clockwise to "OFF".

5. Replace control access panel, if applicable.

A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly.

B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

Gas Control Knob (shown in "OFF" position)

Red Reset Button

Thermopilot

Valve

Pilot Cock (shown in "OFF" position)

Figure 8.3 Standing Pilot - 64 Nat Gas

Page 39

BOILER OPERATION

HSP VR8204/VR8304 9181R REV.2

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life.

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat or operating control to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. If the gas valve is not visible, remove the control access panel.

4. Turn the gas control knob clockwise to "OFF".

5. Replace control access panel, if applicable.

1. STOP! Read the safety information above on this label.

2. Set the thermostat or operating control to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

5. If the gas valve is not visible, remove control access panel.

6. If the gas control knob is not in the "OFF" postion, turn the knob clockwise to "OFF".

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step.

8. Turn the gas control knob counterclockwise to "ON".

9. Replace control access panel, if applicable.

10. Turn on all electrical power to the appliance.

11. Set thermostat or operating control to desired setting.

12. If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.

A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance

Do not touch any electric switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire department.

Gas Control Knob (shown in "OFF" position)

Figure 8.4 Spark Ignition - 63-03 thru 64-08 Nat/LP, 64-09 thru 64-12 LP Gas

Page 40

BOILER OPERATION

SPRK 7000DERHC 9363R REV.0

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life.

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat or operating control to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. If the gas valve is not visible, remove the control access panel.

4. Turn the gas control knob clockwise to "OFF".

5. Replace control access panel, if applicable.

1. STOP! Read the safety information above on this label.

2. Set the thermostat or operating control to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

5. If the gas valve is not visible, remove control access panel.

6. If the gas control knob is not in the "OFF" postion, turn the knob clockwise to "OFF".

8. Turn the gas control knob counterclockwise to "ON".

9. Replace control access panel, if applicable.

10. Turn on all electrical power to the appliance.

11. Set thermostat or operating control to desired setting.

12. If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.

A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance

Do not touch any electric switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire department.

Gas Control Knob (shown in "OFF" position)

Figure 8.5 Spark Ignition - 64-09 thru 64-12 Nat Gas

Page 41

MAINTENANCE

9. MAINTENANCE

WARNING

Product Safety Information

Refractory Ceramic Fiber Product

This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF fibers, when inhaled, have been classified by the International Agency for Research on Cancer (IARC), as a possible carcinogen to humans. After the RCF materials have been exposed to temperatures above 1800°F, they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans. 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.

Page 42

MAINTENANCE

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.

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 right side 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.

4. There must be no signs of continuous wetness at the chimney. If signs of continuous wetness are observed, a qualified service agency must be consulted to modify the vent configuration to prevent the formation of condensate, which may damage the vent pipe.

B. DAILY MAINTENANCE (WITH BOILER

OPERATING)

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 combustion and 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/or pressure on the gauge located on the right side of the boiler. Boiler pressure should never be higher than 5 psi below the rating shown on the safety relief valve. The valve rating can be found on the top of the safety relief valve (see Figure 6.1 or 6.4 for location of the safety relief valve). Boiler temperature should never be higher than 250°F.

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

5. Smell around the appliance area for gas. If you smell gas, follow the “To Turn Off Gas to Appliance” procedure listed in the Lighting/Operating Instructions in Section 8.

C. WEEKLY MAINTENANCE (WITH BOILER

OPERATING)

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 MAINTENANCE (WITH BOILER

OPERATING)

1. Check boiler room floor drains for proper functioning.

2. 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.

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

4. Test limit by lowering the limit set point until the main burners shut down. When proper operation is confirmed, return the set point to the desired setting.

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

6. Cycle the boiler at least once and check operation of the vent damper.

E. ANNUAL MAINTENANCE (BEFORE

START OF HEATING SEASON)

1. Check flueways and burners for cleanliness and clean if necessary. Use the following procedure if cleaning is required:

a. Refer to the Lighting/Operating Instructions in

Section 8 “To Turn Off Gas to Appliance.”

b. Turn off all electrical power to the boiler.

c. Remove burners and brush gas outlet ports

lightly using a soft bristle brush.

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

Page 43

MAINTENANCE

d. Remove the vent pipe, vent damper, top jacket

panels and flue collector.

e. Brush flueways with wire brush.

f. To the extent possible, inspect inside of vent pipe

and vent damper for obstructions in flow or vent damper movement. Remove or replace as necessary.

g. When replacing the flue collector, be certain that

the blanket seal between the flue collector and top section makes a tight seal to prevent leakage of the products of combustion.

h. Re-install the top of the jacket, vent damper and

vent pipe.

i. Connect blocked vent switch wiring harness to

blocked vent switch.

k. Re-install burners.

2. Inspect entire venting system for corrosion, support and joint integrity. Repair as necessary.

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

8.1. The pilot should provide a steady flame enveloping 3/8" to 1/2" 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" high and should have a very sharp, blue color characteristic.

F. AS REQUIRED MAINTENANCE

Test and inspect low water cut-off(s) per manufacturer’s instructions.

If the steam boiler water level is erratic and dirt & deposits appear in the water gauge glass, skim the boiler as described in Section 8.

Page 44

TROUBLE SHOOTING – SERVICE TIPS

10. TROUBLESHOOTING – SERVICE TIPS

Problem Possible Cause Suggested Remedy

Defective Thermocouple Replace

Heavy Draft Blowing across Pilot Redirect Air Movement or Eliminate

Plugged Pilot Orifice Replace Orifice

Pilot Outage Check Manual Pilot Valve

Check Main Gas Shut-Off Valve

No Gas

Check Manual Meter Valve Consult Gas Company

Defective Thermopilot Switch Replace

Defective Ignition Control Replace

No Power

Check Power Source with Meter Check Fuses

Defective Gas Valve Replace

Low Water Level in Boiler

Check for Leaks

or System Causing Low Water Cut-off to

Check Feeder (if Supplied)

Function

Defective Ignition Control Replace

High Gas Pressure Switch Open Check Switch Setting (if Provided) Check Manifold Gas Pressure

Low Gas Pressure Switch Open Check Switch Setting (if Provided) Check Manifold Gas Pressure

No Power

Check Power Source with Meter Check Fuses

Defective Gas Valve Replace

Pilot Out

Relight Pilot (May have defective pilot valve or relay)

Low Water in Boiler

Check for Leaks

or System Causing Low Water Cut-off to

Check Feeder (if Supplied)

Function

Defective Thermopilot Switch Replace

Defective Thermocouple Replace

High Gas Pressure Switch Open Check Switch Setting (if Provided) Check Manifold Gas Pressure

Low Gas Pressure Switch Open Check Switch Setting (if Provided) Check Inlet Gas Pressure

Main Gas Valve Will Not Open

(Spark Ignited Pilot)

Main Gas Valve Will Not Open

(Standing Pilot)

Page 45

TROUBLE SHOOTING – SERVICE TIPS

Problem Possible Cause Suggested Remedy

Air Adjustment Screws Turned in Too Far Adjust Screws Out

Low Gas Pressure in Manifold Adjust Main Gas Pressure Regulator (Insufficient Air Injection) or Check Line Pressure

Burner Ports Partially Closed

Replace Burners or Clean Ports

Burner(s) Burning with Yellow Flame

(Rust, Dirt, Lint, etc)

Check Size of Combustion Air Openings to Room

Insufficient Air for Combustion

If Undersized, Correct as Required Check for Negative Pressure in Boiler Room

Oversized Burner Orifice Install Correct Orifice

High Gas Pressure in Manifold Adjust Main Gas Pressure Regulator

Insufficient Draft - Chimney Too Low Increase Height or Add Induced Draft Fan

Insufficient Draft - Chimney Too Small Replace Chimney or Add Induced Draft Fan

Insufficient Draft - Blockage in Chimney or Vent Repair Chimney or Vent

Gas Spillage from Insufficient Draft - Downdraft Caused by

Draft Hood Relief Opening

Chimney Location with Respect to Other Install Chimney Cap Buildings, Roofs, etc.

Negative Pressure in Boiler Room Remove Exhaust Fan or (Due to Exhaust Fan or Duct System) Isolate Fan From Boiler Room

Insufficient Combustion Air Openings

Provide Correctly Sized Combustion and Ventilation Air Openings

Main Gas Valve Opens

Manual Valve Closed at Gas Train Open Valve

But No Gas Flows

Manual Valve Closed at Meter Open Valve

Test Firing Valve Closed (if Provided) Open Valve

Leaks in System Repair Leaks or Replace Piping as Required

Expansion tank (diaphragm or bladder type) Check Charge Pressure, Correct if Required charge pressure not right

Air compression tank waterlogged or diaphragm or bladder defective on Replace tank expansion tank

Fill valve not working or set for too high a

Check Fill Valve, Replace if Necessary

cold fill pressure, causing relief valve to weep

Temperature control differential too narrow Adjust Control Differential

Sags in Steam Piping or not enough Pitch Correct Piping Condition

Concentric reducers causing condensate pooling Correct Piping

Drip trap failed closed Replace Trap or Trap Element

Dry returns wetted due to new boiler water line

Correct Piping or Install Feed System and Traps

higher than old boiler

No drip line on the back side of a back-pitched

Install Drip Line and Trap

motorized valve

System or Boiler Overfilling or

Excessive Make-up Water

(Water Boilers)

Water Hammer On Start-Up

(Steam Boilers)

Rapid Cycling

(Water Boilers)

Page 46

TROUBLE SHOOTING – SERVICE TIPS

Problem Possible Cause Suggested Remedy

Clogged returns on gravity system Clean or Re-Pipe Return Line(s)

Incorrect near-boiler piping causing wet steam

Correct Piping per Manual

to system

Trap failed open, allowing steam to enter returns Replace Trap or Trap Element

{Radiator Hammer} Large radiator may be

Use smaller Air Vent or Use Two Small Vents in

vented too quickly

Place of One Large Vent, One Mounted Higher than the Other

Long nipple at Hartford Loop Replace with Close Nipple

Water leg or back slope in return line to receiver

Correct Piping

tank, causing water pocketing

Trap installed at receiver tank, causing water Remove Trap at Tank, Install Drip Traps and trapping in return Radiator Traps where Required

Boiler feed pump or condensate pump feed rate

Throttle Flow Rate

too fast, causing spraying into equalizer

No drip on the inlet side of a forward pitched

Add Drip Line and Trap

motorized valve

Uninsulated steam piping, causing excessive

Insulate Steam Pipes

condensate loads

Close nipple on Hartford Loop too high Repipe 2" to 4" (5cm to 10cm) Below Water Line

Uninsulated steam piping in boiler room, but system piping insulated, causing vacuum Insulate Steam Pipes condition on shut-down

Poor circulation in the boiler due to sludge

Clean and Blowdown the Boiler

accumulation

Main vents not working

Replace Main Vents, Repiping away from End of Lines if Needed

Drip Traps failed closed Replace Traps or Trap Elements

Radiator traps failed open, allowing pressurization

Replace Traps or Trap Elements

of the returns

Water legs or back slope in return lines to receiver

Correct Piping

tank, preventing air from venting out receiver vent

Boiler pressure too high, causing air vents to lock

Reduce Operating Pressure

up or blowing water loop seals

New boiler water content smaller than old boiler

Install Boiler Feed System with Receiver Tank Large enough for Condensate

Boiler water feed rate or pump rate too fast causing water level to collapse (due to collapse of Reduce Feed Rate steam bubbles in boiler water)

Foaming, priming or surging due to poor

Clean the Boiler

water quality

Poor water quality, causing foaming and surging Clean the Boiler

Incorrect near-boiler piping, such as undersized

Pipe per Manual

or incorrectly placed risers

Boiler water feed rate or pump rate too fast Reduce Feed Rate

Air vents or traps not venting air, preventing steam from getting to radiation and pressurizing Replace Vents or Traps the air pocket

Pressure differential on pressure control too close Adjust Control Differential

Nuisance outages of water level control due to

See Excessive Water Level Bounce Above

boiler water level bounce

Water Hammer During Mid-Cycle

(Steam Boilers)

Water Hammer on Shut-Down

(Steam Boilers)

No Heat or Poor Heat

Distribution in the Building

(Steam Boilers)

System or Boiler Overfilling or Flooding

(Steam Boilers)

Excessive Water Level Bounce

(Steam Boilers)

Rapid Cycling

(Steam Boilers)

Hammering in the Boiler

(Steam Boilers)

Page 47

BOILER DIMENSIONS & RATINGS

Boiler Model

Dimensions (Inches)

“A” “B” “C” “D” “E” “F”

63-03L

16-1/8

37-1/4

36-3/8

28-1/8

5-5/8 6

63-03

63-04L

20-3/8 5-1/8 7

63-04

63-05L

24-5/8

39-1/4

6-5/8 8

63-05 63-06 28-7/8

6-1/8 9

64-07 33-1/8 64-08 37-3/8

43-1/8

30-1/8

7-1/2 10

64-09 41-5/8 64-10 45-7/8

45-1/8 8-1/2 12

64-11 50-1/8 64-12 54-3/8

11. BOILER DIMENSIONS & RATINGS

Figure 11.1: Dimensions and Tapping Locations

Table 11.1: Tapping Sizes & Functions

Table 11.2: Dimensions

Tap I D Size NPT Steam Water

J 1-1/4" Skim Tapping Skim Tapping K 1" Tank Supply/Limit N/A

L 1" Tank Return N/A M 3/4" Boiler Drain Boiler Drain N 3" Supply Supply

P 2-1/2" Return Return

R 3/4" Safety Valve Relief Valve S 1/2" Gauge Glass N/A

T 3/4" Primary Probe Low Water Cut-Off N/A U 3/4" Primary Limit Primary Limit V 3/4" Secondary Limit Pressure/Temperature Gauge W 3/4" Pressure Gauge Secondary Limit X 3/4" Secondary Probe Low Water Cut-Off N/A

Page 48

BOILER DIMENSIONS & RATINGS

Table 11.3: Series 63™ Boiler Ratings

1. Net I=B=R Ratings are based on DOE Heating Capacity less an allowance for normal piping and pickup as determined by the Testing and Rating Standard for Low Pressure Cast Iron Heating Boilers of the Hydronics Institute. Water ratings are based on a piping and pickup factor of 1.15. Steam ratings are based on a piping and pickup factor of 1.33. Consult PB Heat before selecting a boiler for gravity hot water installations or for installations having unusual piping and pickup requirements such as exposed piping, night set back, etc. Ratings shown are for elevations up to 2,000 feet. For elevations above 2,000 feet, ratings should be reduced at the rate of 4% for each 1,000 feet above sea level.

2. Minimum Natural Gas Inlet Pressure exceptions: 63-04 STDG 5.3"; 63-06 STDG 5.5"; 63-06 SPRK 5.3".

3. Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are based on U.S. Government tests. Before purchasing this appliance, read important information about its estimated annual energy consumption or energy efficiency rating that is vailable from your retailer.

NOTE: Minimum Inlet Gas Pressure: Natural Gas @ 5.0 in. W.C.², LP Gas @ 11.0 in. W.C.

Series 63™

Boiler

Model

Input,

MBH

Heating Capacity³ Net I=B=R Ratings¹

Standing Pilot

AFUE³

Spark Ignition

AFUE³

Water,

MBH

Steam,

MBH

Steam,

sqft

Steam,

MBH

Water,

MBH

Water,%Steam,%Water,%Steam,

63-03L 88.5 73 74 233 56 63 80.9 80.6 82.4 83.0

63-03 118.0 99 98 308 74 86 82.1 81.2 83.5 82.6

63-04L 147.5 123 123 383 92 107 81.4 80.6 82.7 82.6

63-04 177.0 148 147 458 110 129 82.1 81.0 83.4 82.4

63-05L 206.5 172 171 533 128 150 81.9 80.7 82.9 82.3

63-05 236.0 198 196 613 147 172 82.2 80.9 83.3 82.2

63-06 287.5 241 238 746 179 210 82.3 80.7 83.2 82.0

Water

Content

Approx.

Shipping

Weight,

Water,

gal

Steam,

gal

13.2 9.3 465

15.6 10.8 576

18.0 12.4 700

20.4 13.9 812

Series 64™

Boiler Model

Input,

MBH

Gross Output³ Net I=B=R Ratings¹

Thermal

Efficiency

Combustion

Efficiency³

Water,

MBH

Steam,

MBH

Steam,

sqft

Steam,

MBH

Water,

MBH

Water,%Steam,%Water,%Steam,

64-07 345 286 274 858 206 249 81.0 79.4 83.0 82.5

64-08 399 331 318 996 239 288 81.0 79.6 83.0 82.5

64-09 460 382 367 1146 275 332 81.0 79.7 83.0 82.5

64-10 518 430 413 1292 310 374 81.0 79.8 83.0 82.5

64-11 575 477 459 1433 344 415 81.1 79.8 83.0 82.5

64-12 633 525 506 1583 380 457 81.0 79.9 83.0 82.4

Water

Content

Approx.

Shipping

Weight,

Water,

gal

Steam,

gal

22.8 15.5 945

25.2 17.0 1081

27.6 18.6 1218

30.0 20.1 1354

32.4 21.7 1490

34.8 23.2 1527

1. Net I=B=R Ratings are based on Gross Output less an allowance for normal piping and pickup as determined by the Testing and Rating Standard for Low Pressure Cast Iron Heating Boilers of the Hydronics Institute. Water ratings are based on a piping and pickup factor of 1.15. Steam ratings are based on a piping and pickup factor of 1.33. Consult PB Heat before selecting a boiler for gravity hot water installations or for installations having unusual piping and pickup requirements such as exposed piping, night set-back, etc. Ratings shown are for elevations up to 2,000 feet. For elevations above 2,000 feet, ratings should be reduced at the rate of 4% for each 1,000 feet above sea level.

2. Minimum Natural Gas Inlet Pressure: 5.0 in. W.C. except for 64-08 STDG 5.3 in., 64-12 STDG 5.1 in.

3. Combustion efficiency and gross output are determined in accordance with ANSI Z21.13 / CSA 4.9, Gas-Fired Low-Pressure Steam and Hot Water Boilers.

Table 11.4: Series 64™ Boiler Ratings

Page 49

REPAIR PARTS

12. REPAIR PARTS

Figure 12.1

Repair parts are available from your installer or by contacting PB Heat, LLC, 131 S. Church, Bally, PA 19503.

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

Page 50

REPAIR PARTS

Description

Quantity Required

Stock

Code

1 Intermediate Section – w/out Draw Lugs – 90028

2 Intermediate Section – w/ Draw Lugs (64) – 90029

3 Right Hand Section – 90030

4 Left Hand Section – 90031

5 Draw Rod 5/8"-11 x 8" (64) – 7797

6 Draw Rod Nut 5/8"-11 (64) – 51567

7 Draw Rod Washer (64) – 7289

8 2" Push Nipple – 51543

9 6" Push Nipple – 51546

10 High Temperature Sealing Rope 1/2" – 51211

– 63-03L Block Assembly – 90684

– 63-03 Block Assembly – 90684

– 63-04L Block Assembly – 90685

– 63-04 Block Assembly – 90685

– 63-05L Block Assembly – 90686

– 63-05 Block Assembly – 90686

– 63-06 Block Assembly – 90687

– Left Hand 64-07 Split Block – 90904

– Right Hand 64-07 Split Block – 90906

– Left Hand 64-08 Split Block – 90904

– Right Hand 64-08 Split Block – 90907

– Left Hand 64-09 Split Block – 90904

– Right Hand 64-09 Split Block – 90908

– Left Hand 64-10 Split Block – 90905

– Right Hand 64-10 Split Block – 90907

– Left Hand 64-11 Split Block – 90905

– Right Hand 64-11 Split Block – 90908

– Left Hand 64-12 Split Block – 90905

– Right Hand 64-12 Split Block – 90909

Base Front Panel – 63-03 – 50324

Base Front Panel – 63-04 – 50325

Base Front Panel – 63-05 – 50326

Base Front Panel – 63-06 – 50327

Base Front Panel – 64-07 – 50328

Base Front Panel – 64-08 – 50329

Base Front Panel – 64-09 – 50330

Base Front Panel – 64-10 – 50331

Base Front Panel – 64-11 – 50332

Base Front Panel – 64-12 – 50333

Base Rear Panel – 63-03 – 61180

Base Rear Panel – 63-04 – 61181

Base Rear Panel – 63-05 – 61182

Base Rear Panel – 63-06 – 61183

Base Rear Panel – 64-07 – 61184

Base Rear Panel – 64-08 – 61185

Base Rear Panel – 64-09 – 61186

Base Rear Panel – 64-10 – 61187

Base Rear Panel – 64-11 – 61188

Base Rear Panel – 64-12 – 61189

Description

Quantity Required

Stock

Code

Burner Access Panel – 63-03 – 50271

Burner Access Panel – 63-04 – 50272

Burner Access Panel – 63-05 – 50273

Burner Access Panel – 63-06 – 50274

Burner Access Panel – 64-07 – 50275

Burner Access Panel – 64-08 – 50276

Burner Access Panel – 64-09 – 50277

Burner Access Panel – 64-10 – 50278

Burner Access Panel – 64-11 – 50279

Burner Access Panel – 64-12 – 50280

Burner Tray Rear Support – 63-03 – 50300

Burner Tray Rear Support – 63-03L – 50301

Burner Tray Rear Support – 63-04 – 50302

Burner Tray Rear Support – 63-04L – 50303

Burner Tray Rear Support – 63-05 – 50304

Burner Tray Rear Support – 63-05L – 50305

Burner Tray Rear Support – 63-06 – 50306

Burner Tray Rear Support – 63-07 – 50307

Burner Tray Rear Support – 63-08 – 50308

Burner Tray Rear Support – 63-09 – 50309

Burner Tray Rear Support – 63-10 – 50310

Burner Tray Rear Support – 63-11 – 50311

Burner Tray Rear Support – 63-12 – 50312

Burner Tray Left Side Rail – 50296

Burner Tray Right Side Rail – 50295

Burner – 63-03L 2 50192

Burner – 63-03 3 50192

Burner – 63-04L 4 50192

Burner – 63-04 5 50192

Burner – 63-05L 6 50192

Burner – 63-05 7 50192

Burner – 63-06 9 50192

Burner – 64-07 11 50192

Burner – 64-08 13 50192

Burner – 64-09 15 50192

Burner – 64-10 17 50192

Burner – 64-11 19 50192

Burner – 64-12 21 50192

Burner with Pilot Bracket (Standing) – 50162

Burner with Pilot Bracket (Spark) – 50163

Table 12.1

Page 51

REPAIR PARTS

Description

Quantity Required

Stock

Code

Flue Collector – 63-03 – 50281 Flue Collector – 63-03L – 50282 Flue Collector – 63-04 – 50283 Flue Collector – 63-04L – 50284 Flue Collector – 63-05 – 50285 Flue Collector – 63-05L – 50286 Flue Collector – 63-06 – 50287 Flue Collector – 64-07 – 50288 Flue Collector – 64-08 – 50289 Flue Collector – 64-09 – 50290 Flue Collector – 64-10 – 50291 Flue Collector – 64-11 – 50292 Flue Collector – 64-12 – 50293

Draft Hood – 63-03 – 50252 Draft Hood – 63-04 – 50254 Draft Hood – 63-05 – 50256 Draft Hood – 63-06 – 50257 Draft Hood – 64-07 – 50258 Draft Hood – 64-08 – 50259 Draft Hood – 64-09 – 50260 Draft Hood – 64-10 – 50261 Draft Hood – 64-11 – 50262 Draft Hood – 64-12 – 50263

23 Insulation Board – 7956

Conversion Kits Natural to LP Gas

– STDG 63 Series – 90068 – STDG 64-07, 64-08 – 90227 – SPRK 63 – 90070 – SPRK 64 – 90071

Conversion Kit LP to Natural Gas

– STDG 63 – 90067 – STDG 64-07, 64-08 – 90226 – SPRK 63 – 90069 – SPRK 64-07, 64-08 – 90051 – SPRK 64-09, 64-12 – 90052

Vent Dampers

– 63-03 – Effikal-RVGP-6BK – 6" – 90613 – 63-04 – Effikal-RVGP-7BK – 7" – 90614 – 63-05 – Effikal-RVGP-8BK – 8" – 90615 – 63-06 – Effikal-RVGP-9BK – 9" – 90417 – 64-07 – Effikal-RVGP-9BK – 9" – 50167

–

64-08 Thru 64-09 – Effikal-RVGP-1 0BK – 10"

– 50168

–

64-10 Thru 64-12 – Effikal-RVGP-1 0BK – 12"

– 90616

Jackets

– 63-03L – 90645 – 63-03 – 90645 – 63-04L – 90646 – 63-04 – 90646 – 63-05L – 90647 – 63-05 – 90647 – 63-06 – 90648 – 64-07 – 90649 – 64-08 – 90650 – 64-09 – 90651 – 64-10 – 90652 – 64-11 – 90653 – 64-12 – 90654

Description

Quantity Required

Stock

Code

Gas Valve – NAT-STDG 63-03/04 Honeywell VR8200A-2116

– 50581

Gas Valve – NAT-STDG 63-05/06 Honeywell VR8300A-4003

– 50587

Gas Valve – NAT-STDG 64-07/08 Honeywell VR8304M-4002*

– 50589

Gas Valve – NAT-SPRK 63-05/06 Honeywell VR8304M-4002

– 50589

Gas Valve – NAT-SPRK 64-07, 64-08 Honeywell VR8304M-4002

– 50589

Gas Valve – NAT-SPRK 63-03, 63-04 Honeywell VR8204A-2001

– 50583

Gas Valve – NAT-SPRK 64-09/64-12 7000DERHC Robert Shaw

– 50247

Gas Valve – LP-STDG 63-03, 63-04 Honeywell VR8200A-2165

– 50582

Gas Valve – LP-STDG 63-05, 63-06 Honeywell VR8300A-4011

– 50588

Gas Valve – LP-SPRK 64-05, 64-06 Honeywell VR8304M-4010

– 50590

Gas Valve – LP-STDG 64-07, 64-08 Honeywell VR8300C-4035

– 91333

Gas Valve – LP-SPRK 64-07, 64-08 Honeywell VR8304P-4314

– 50724

Gas Valve – LP-SPRK 64-09, 64-12 Honeywell VR8304P-4314

– 50724

Gas Valve – LP-SPRK 63-03, 63-04 Honeywell VR8204A-2183

– 50584

*denotes valve requires L62 Pilot Module – 50755

Pilot Assembly NAT-STDG 63-03/63-06 5CH Robert Shaw

– 50248

Pilot Assembly NAT-STDG 64-07/64-12 Honeywell Q327A-1006

– 50556

Pilot Assembly NAT-SPRK 63/64 Honeywell Q348A-1358

– 50558

Pilot Assembly LP-STDG 63-03/63-06 5CH Robert shaw

– 50249

Pilot Assembly LP-STDG 64-07/64-12 Honeywell Q327A-1147

– 50557

Pilot Assembly LP-SPRK 63/64 Honeywell Q348A-1358

– 51814

– Ignition Cable Honeywell 394800-30 – 50640

–

Vent Safety Switch (3L, 3, 4L) 1 NT08L-5621-210°F

– 50040

–

Vent Safety Switch (4-12; not 4L) 1 NT08L-5621-230°F

– 50041

– Ignition Control (non-CSD) UT1 003-632A – 50250 – Ignition Control (CSD) UT1 003-61 0A – 50706 – Lock-Out Module (CSD) UT1 145-2-1 – 50707 – Thermocouple K1 6BA-24D (24) 3-6 – 50838 – Thermocouple K1 5DA-36 (36) 7-8 – 50839

Gas Manifold – 63-03L – 50265 Gas Manifold – 63-04 – 50266 Gas Manifold – 63-04L – 50267 Gas Manifold – 63-05 – 50268 Gas Manifold – 63-05L – 50269 Gas Manifold – 63-06 – 50270 Gas Manifold – 64-07 Assembly Kit – 90411 Gas Manifold – 64-08 Assembly Kit – 90412 Gas Manifold – 64-09 Assembly Kit – 90413 Gas Manifold – 64-10 Assembly Kit – 90414 Gas Manifold – 64-11 Assembly Kit – 90415 Gas Manifold – 64-12 Assembly Kit – 90416

Table 12.2

Page 52

63/64

™

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.

TT8066 R9 (7/11-2M)

Printed in U.S.A.

ASME

PB HEAT, LLC

131 S. CHURCH STREET • BALLY, PA 19503