PEERLESS WBV SERIES, WV SERIES, WBV-03-08, WBV-03-110, WBV-04-095 Installation, Operation & Maintenance Manual

WBV/WV

Boilers

Installation,

Operation

Maintenance
Manual

PEERLESS"

CAST IRON BOILERS

Packaged or Knockdo ,

8 Sizes 3-5 Sections .60 to 2.00 GPH Input 82% to 86% AFUE

Natural Draft (chimney) Venting

Factory Assembled Sections on Knockdown Boilers

• Reduces Installation Time

WBV in 3 and 4 Section for Hot Water or Steam

• Convertible from Rear to Top Flue for Venting Flexibility

WV in 5 Section for Hot Water

• Top Flue Only

High Efficiency Flame Retention Burners

• Choice ofBeckett, Carlin or Riello

Full Plate Swing-Out Door

• Standard on All Boilers

• Provides Easy Access to Combustion Chamber Area
jbr Cleaning and Servicing

Large Water Content, Wet Base Section Design

• Reduces On/O_'f'Cycling

Steel Push Nipples

• Provide a Permanent Water Tight Seal Between Sections

• Unaffected by Petroleum and Other Contaminants

Deluxe Insulated Enameled Steel Jacket

• Reduces Boiler Heat Loss

Safety Controls

• Prob_ or Floai Type Low Water

Cut-Qff Approved on Steam Boilers

Tankless Coils

• For Domestic Hot Water Production
on Hot Water Boilers

As an ENERGY STAR _ Partner Peerless Healer Comparl¥ Has delerr#med
that certain f_rin9 rales of this product mee_ Ihe ENERGY STAR" guidelines

for energy efficiency

• Honeywell Operating Controls

• Taco 007 Circulator on Packaged Water Boilers

• Probe Type LWCO on Packaged Steam Boilers

omp\e te J

• Tankless Coils

• Barometric Draft Damper

• Grundfos Circulator on Packaged Water Boilers

• Float Tltpe LWCO on Packaged Steam Boilers

/'_'<'rl(,._.s 1 lec_ttq Compony is p&_a.s_d lo q[]_'r otlt _ @the" most coml)reh_.t_siv¢" u,tu_c_ttty l)i-o()l(lms ill
the. hlHztstry. All P(x'rless tz!sidential cckst iron boilers i11chtde a.fidl orl(! !F.ar It,azTcUlty. A limiled.

li]_'litllt" It,(tt r(iNly is provided jbr Ihe cc_st iron sections q[ Pcerless rt_sidetltial hol [t,(llt_!t boilet_.
P_'_tl('._5 _tl._o i)tol,id<!s o linlit_'d. 11!11_](fOf [tl_UTO/l/t] Oil I_l(_ C€ISt irotl SeCtiotls Q[ il5 I'('si_lt,llllol sl(?at]l
boil_'t._. Fit,(, ariel !('n !j('cw _5\'l_!lld('d [t,olv_lltli('s oil parts €Old lclbor nre IIOIL! (Ip(lilflblt'. P[('_Is_' COllStll/
]_'('rl_'y;5 [ It'(tlt,r ('OmlXUl!lJbr compIt'lt" tt,(ltT_ttll[I il!fbrmation.

PEGRLESS _

CAST IRON BOILERS

Peerless Heater Company * 231 North Walnut Street • Boyertown, PA 19512-1021 * 610-367-2153 • www.peerless-heater.com

FAB WBV RI (5!02 5M)

prlrlf(?(l _rl U S A

Background Information - Draft Requirements

Modern boilers operate with higher efficiencies than older boilers. Smaller flueways, as well as bars, pins
and fins are designed into modern boilers to transfer as much heat as possible from the hot gases to the

water or steam and prevent heat loss up the chimney. However, these design features result in higher pres-
sure, or draft loss, in the boiler.

This draft loss must be taken into account when installing an oil boiler into a new or old chimney. New
chimneys are less likely to have poor draft. However, they must have sufficient draft to support combus-
tion. A -.06" draft is desirable and preferred. Older, unlined chimneys may require a replacement liner to
have them perform well enough to support combustion.

An example follows:

Chimney Draft

Old installation New installation

-.04" -.04 °

Comments

No change, but older chimneys
(especially unlined ones) have

leaks which reduce draft.

Boiler Design Pressure Drop

+.01" +.04"

Required for mandated
efficiency increases.

Draft Over Fire -.03" 0.00"

The old installation would have

had a higher temperature in the
chimney [as high as 800 degrees
vs. 400 degrees F], which would

increase the draft.

The above readings are 'cold' readings [before the boiler and chimney are heated up].

A-.01 _ to -.02 _ minimum draft over fire is required for a good installation where no oil fumes

would be present. The draft would vent them up the chimney.

The above discussion which concerns draft in the chimney and draft loss in the boiler, is incomplete with-
out discussing the effect of draft on the burner. Very simply, increasing the fuel usage [higher gallonage] on
a unit which has multiple firing rates, requires more air for combustion and a higher draft loss in the boiler.

As an example, increasing the firing rate 1/4 gallon will increase the draft loss in the unit by approximately
+.01". The actual burner used on a particular boiler also effects the draft and smoke condition. The use of

a burner supplied by Peerless Heater Company would assure you of a quality, trouble free installation.

INSTALLATIONINSTRUCTIONS- SERIESWBVandWV

Readcarefullybeforebeginningwork.It willsavetime.Studytheincludeddrawings.

Theequipmentshallbeinstalledinaccordancewiththoseinstallationregulationsin forceinthe localareawherethe installationisto be made,including
the currenteditionof NFPA-31.Theseshallbecarefullyfollowedinall cases.Authoritieshavingjurisdictionshall beconsultedbeforeinstallationsare
made.

Theboiler mustbe installedbya qualifiedcontractor.
Theboiler warrantycanbe voidedifthe boileris notinstalled,maintainedandservicedcorrectly.

A - ACCESSIBILITYCLEARANCES

1- Toprovidefor reasonableconditionsofaccessibility,thefollowingminimumclearancesarerecommended.

a. TopOutletFlue:At least24" in thefront,rear andon bothsides.
b. RearOutletFlue:At least24" infrontand bothsides;at least30" inthe rear.

B- AIRFORCOMBUSTIONANDVENTILATION

1- Be certainadequatefacilitiesareavailableto provideairforsatisfactorycombustionand ventilation.

2 -Appliances Locatedin UnconfinedSpaces.

a. Forinstallationsin unconfinedspaceswith conventionalconstructionand larger areassuchas basements,the supplyof airfor combustionand

ventilationcan usuallybe consideredadequate.

3 - AppliancesLocatedin ConfinedSpaces.

a. If all airfor combustionandventilationis to come fromwithinthe building:twoopenings,onenearthe ceilingand one nearthe floor of the boiler

roomshallbe providedwiththe minimumfree areaof eachopeningequalto 140sq. in. pergallonof oilburned.

b. If allairfor combustionandventilationisto comefromoutsidethe building:twoopenings,onenearthe ceilingandone nearthefloorofthe boiler

roomshallbeprovidedwiththe minimumfreeareaof eachopeningequalto 35 sq.in. pergallonof oil burned.
If ductsare usedto conveythe air,areasof 35 sq. in.pergallon ofoil burnedfor verticalductsor 70 sq.in.pergallonof oil burnedforhorizontal

ductsaretobe provided.Ductsshallhavethesameareaasthe freeareaof theopeningsto whichtheyare connected.

C- SETTINGTHE BOILER

1- TheWBV/WVBoilerSectionsare FactoryAssembledwiththeTargetWallShippedinplace.Providealevelfoundation,locatedas closeas possibleto

the center of the heatingsystemandtothe chimney.TheWBV/WVSeries is availableasa completepackage,or in a knockeddownform. Referto

page5 for explodedviewof boilerif on-the-jobassemblyisrequired.
2-This boileris suitableforuseon combustibleflooring,providedtheboiler is not setoncarpetand a metal drippan isplacedunderthe appliance.
3- TheWBV-03andWBV-04boilermodelsmaybe installedas a rearflueoutletunit ora topflue outletunit.This maybedonebymountingthe FlueCollar

Adapter(Item14)to eithertherear boilersectionfora rearflueapplication,orto the FlueCollectorCoverPlate(Item11)fora topflueapplication.The

RearOutletCoverPlate(Item13) isthenusedto closetheremainingopening.OnPackagedUnitsthe largeknockoutintheTopJacketPanelmustbe

removedtoconvertto a topflue application.NOTE:TheWV-05boilermodelisonlyavailableasa top flueoutletunit.
4- Open trim carton.RemoveFlueCollectorCoverPlateandBlanketSeal(Items10 and 11)and attachwith thefour (4)5/16" x 1_/2"studs,nutsand

washersprovided.Attacheitherthe FlueCollarAdapter(Item14)or the OutletCoverPlate(Item 13)to the FlueCollectorCoverPlatewiththe nuts
andwashersprovidedmakingsurethe ropeseal(Item12)is in place.Attachthe remainingFlueCollaror CoverPlatetothe rearsectionwithfour(4)

5/r6"bolts andwashers.

5- If a tanklesscoilisused,(Item9)installaspictured.WaterBoiler- frontsectionopening.SteamBoiler- rearsectionopening.Forsuggestedpipingof

tanklesswaterheatersreferto Figures4 and5.

6- Whena tanklesscoilis notemployed,covertheopeningwithcoverplate(Item 7 or 16).

D- JACKETASSEMBLY

1- If boiler is tobe installedwitharear flueoutlet,removethesquareknock-outinthe backpanelthenattachtobosseson middleof backsectionwith

two1/4" x 3/8"machinescrewsprovided.The backpanelhas two 5/16"dia.holesclosetothe centerofthe panel.

2 - Attach boththe left and rightsidepanelstothe backpanel andsecurewithsheetmetalscrews.
3 - RemoveBurnerMountingPlate (Item5) andmakecertainthe TargetWall(Item2) and CerafeltLineron floorofboilerin frontoftarget wall(Item3)

arefirmly in place.

4- Removethetwo(2)knockoutsinthefrontjacketpanelwhichwill allowclearanceforthe hinge.Placethefrontjacketpanelonthe blockandattachthe

leftand rightsidepanelsin the samemannerastheyareattachedto thebackpanel.Attachthe CombustionChamberCoverPlate.

5- ReinstallCombustionChamberCoverPlate.
6- If boiler is to be installedwitha top flueoutlet,removetheknock-outinthe topjacketpanelthensecurewith sheetmetalscrews.

E - PIPING

DONOTPIPEBOILERBEFOREJACKET_SINSTALLED.

1- See Figures1 and2 forsuggestedpipingtothe boiler.

2- Makeupcold watersupplyconnectiontothe boiler.

3- Installpressuregaugeor pressure-temperaturegaugein tappingprovided.See page3.

4- Plugal_opentappingsin the boilerandfill with water.Applyapproximatelythirty (30) poundspressure.Checkto make certainthat all iointsand

fittingsarewatertight.

5- Afteralljoints andconnectionshavebeenprovenwatertight,removeooldwatersupplyandplugsfromalltappingsthataretobe used,Seepage3

fortappinglocations.

6- Returnwater pipingmustbe donein sucha mannertoallowelearaooeofthe doortothe circulatorstandpipe

orother pipingwhenopeningandclosingthedoor.Peerlesssuggestsusinga 11/4"tee,a90° streetelbow,and 11/4"x 5" pipenippleinthe

returntappingbeforea verticalcirculatorstandpipeis usedas shownon page3.

HOTWATER

v

Thesupplyand returnconnectionsshouldbe sizedto suitthe
system.A 1r/2" to 11/4" reducingcouplingmaybeusedon the

returnwherethe systempipingis 11/2".

Thesupplyshouldbe outof thetop ofthe backsectionand
returnto thebottomofthe frontsection.Thereisa 3/4"tappingin

the top oftheback sectionfor airelimination,

FIGURE1

STEAM

Boiler
Model Supply

No. Riser Equalizer

WBV-.03 1-2" 11/4"
WBV-04 1- 2" 11/4"

Thereturnfromsystemshouldalwaysenterequalizerthrough
HartfordLoop,2" to 4" belownormalwaterline,

RGURE2

_TER

FIGURE3

Note:If boileris to be usedinconjunctionwitha refrigera-

tionsystem,thechilledmediumshallbepipedin par-
allelwithboilerandpropervalvesappliedtoprevent

thechimedmediumfromenteringtheboiler.Referto

Figure3.
Whentheboilerisconnectedtoheatingcoilslocated

inairhandlingun_S,the boilerpipingsystemmustbe

equippedwithflowcontrolvalvesor otherautomatic
devicestopreventgravitycirculationof theboiler

waterduringthe coolingcycle.

WBV/WVWATERBOILER

SAFETY RELIEF VALVE

.35" VALVE

DRAIN VALVe"

--2 11/16"
3 1/16" _

• 6" REAR
FLUE "C"

_(WBV-O3,

WBV-04
ONLY)

LINE

R_

1

1 I/2" SUPPLY_

OPTIONAL

TANKLESS

HEATER x

LIMIT -

TEMPERATURE

PRESSURE
GAUGE _'

1_3/_ I_-

APPROX '

-_-_2,18"7

1 114"

' "C'"DOLATO"

28 I/2"

DRAIN

VALVE

FRONT

Boiler Jacket RearofJackettoC/L Top/Rear
Model Depth ofTopFlueOutlet FleaSize

Number "A.... B.... C"

WBV-03-085/110 141/8" 71h6" 6"
WBV-04-1251150 18%" 91h6" 6"
WV-05-175/200 22%" 111116" 7" (TopOnly)

WBVSTEAMBOILER

SKIM

PROBE

FLOAT LWCO

[

ALTERNATE

29 7/8"

_OP_ONAL

TANKLESS J

HEATER

-FLOOR LINE

_2 11/16"

_6"

_REAR

FLUE

-C-

'_SAFETY

VALVE

1 I/4" ALTERNATE

RETURN OR DRAIN

VAL'AE.

g_

Boiler
Model

Number

Jacket Rear of Jacketto C/L Top/Rear

Depth of Tap FleaOutlet Flue Size

"A.... B" "C"

WBV-03-085/110 153/4" 87/8" 6"
WBV-04-125/150 19314" 10%" 6"

3