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

63/64

™

Boilers

Series

Gas

Installation,
Operation &
Maintenance
Manual

ii

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 14

A. WATER BOILER PIPING – SINGLE

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

B. WATER BOILER PIPING – MULTIPLE

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

C. STEAM BOILER PIPING – SINGLE

BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

D. STEAM BOILER INDIRECT WATER HEATER

PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

E. STEAM BOILER PIPING – MULTIPLE

BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

5. FUEL PIPING 17

A. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .17

B. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .17

6. CONTROLS & TRIM 19

A. STEAM BOILER CONTROLS & TRIM . . . . .19

B. WATER BOILER CONTROLS & TRIM . . . . .20

7. ELECTRICAL 22

A. CONNECT SUPPLY WIRING . . . . . . . . . . . .22

B. MOUNT REMAINING CONTROLS . . . . . . . .22

C. INSTALL CONTROL WIRING . . . . . . . . . . . .23

8. BOILER OPERATION 29

A. SYSTEM INSPECTION . . . . . . . . . . . . . . . .29

B1. FILL THE BOILER (WATER BOILERS) . . . . .29

B2. FILL THE BOILER (STEAM BOILERS) . . . . .29

C. OPERATING INSTRUCTIONS . . . . . . . . . . .29

D. PILOT CHECK . . . . . . . . . . . . . . . . . . . . . . . .29

E. MAIN BURNER CHECK . . . . . . . . . . . . . . . .30

F. CONTROLS CHECK . . . . . . . . . . . . . . . . . . .30

G. PURGING AIR . . . . . . . . . . . . . . . . . . . . . . . .30

H. CHECK SYSTEM PRESSURE . . . . . . . . . . . .30

I. CLEAN THE BOILER . . . . . . . . . . . . . . . . . . .30

J. BOILER SHUT-DOWN . . . . . . . . . . . . . . . . .31

9. MAINTENANCE 35

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .36

B. DAILY MAINTENANCE . . . . . . . . . . . . . . . . .36

C. WEEKLY MAINTENANCE . . . . . . . . . . . . . .36

D. MONTHLY MAINTENANCE . . . . . . . . . . . . .36

E. ANNUAL MAINTENANCE . . . . . . . . . . . . . .36

F. AS REQUIRED MAINTENANCE . . . . . . . . . .37

10. TROUBLESHOOTING 38

11. BOILER DIMENSIONS & RATINGS 42

12. REPAIR PARTS 44

TABLE OF CONTENTS

TABLE OF CONTENTS

1

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

2

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 necessar y 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

3

PREINSTALLATION

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

3

/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:

I

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:

I

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

2

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

2

(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

2

per 1000

Btu/hr (44 cm

2

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

3

I

fan

ACH 1000

Btu

/

hr

Required Volume

fan

=

21 ft

3

I

other

ACH 1000

Btu

/

hr

Required Volume

other

=

⎛
⎜
⎝

⎛

⎜

⎝

⎛
⎜
⎝

⎛

⎜

⎝

4

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

2

per

4000 Btu/hr (22 cm

2

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

2

per 2000

Btu/hr (22 cm

2

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

2

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

5

PREINSTALLATION

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:

A

req

= minimum area of outdoor openings.

A

full

= full size of outdoor openings calculated

in accordance with Subsection 4.

V

avail

= available indoor air volume

V

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

3

/min per

1000 Btu/hr (0.034 m

3

/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 ser ved 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 ser ve 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.

V

avail

1 –

V

req

A

req

= A

full

x

⎛
⎜
⎝

⎛

⎜

⎝

6

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

7

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 por ts 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

8

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 5.4 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 car riage 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

9

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

10

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. Inser t 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

11

VENTING

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

12

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:

Au moment de retirer une chaudière existante, il est
important de suivre les étapes suivantes pour chaque
appareil raccordé au système d’évacuation commun qui
sont en service, alors que les autres appareils demeurant
raccordés au système d’évacuation commun ne sont pas
en service :

a. Seal any unused openings in the common venting

system.
Sceller toute ouverture du système d’évacuation

commun non utilisée.

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.

Effectuer un contrôle visuel du système d’évacuation
pour vérifier la taille et la pente horizontale et
s’assurer qu’il n’existe aucun blocage ou obstruction,
fuite, corrosion ni tout autre problème pouvant
menacer la sécurité.

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.

Dans la mesure du possible, fermer toutes les portes
et fenêtres de l’immeuble ainsi que toutes les portes
entre l’espace dans lequel les appareils qui
demeurent raccordés au système d’évacuation
commun se trouvent et le reste de l’immeuble.
Mettre en marche les sécheuses et tout autre appareil
non raccordé au système d’évacuation commun.
Mettre en marche tous les ventilateurs aspirant, tels
que les hottes de cuisinière et les ventilateurs de salle
de bain, en les faisant fonctionner à vitesse
maximum. Ne pas faire fonctionner les ventilateurs
aspirant d’été. Fermer les registres de foyers.

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 main burners
are operating.

Le registre doit être en position ouverte lorsque le
brûleur principal de l’appareil fonctionne.

CAUTION

13

VENTING

d. Place in operation the appliance being inspected.

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

Mettre en service l’appareil à inspecter. Suivre les
instructions concernant l’allumage. Régler le
thermostat afin que l’appareil fonctionne sans arrêt.

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.

Vérifier toute fuite à l’orifice de décharge du coupe­tirage après que le brûleur ait fonctionné pendant 5
minutes. Utiliser la flamme d’une allumette ou d’une
chandelle ou encore la fumée d’une cigarette, d’un
cigare ou d’une 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.

Après avoir établi que les résidus de combustion de
chaque appareil qui demeure raccordé au système
commun sont adéquatement évacués lorsque soumis
au test décrit ci-dessus, remettre en place les portes,
fenêtres, portes intérieures, ventilateurs aspirants,
registres de foyer et appareils fonctionnant au gaz.

g. Any improper operation of the common venting

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

Tout fonctionnement inadéquat du système
d’évacuation commun doit être corrigé de manière à
respecter les normes du National Fuel Gas Code,
ANSI Z223.1/NFPA 54 et/ou des Codes d’installation
CAN/ACG B149. Lorsqu’il est nécessaire de modifier
les dimensions de toute portion du système
d’évacuation commun, ces dernières doivent être
modifiées de manière à respecter les dimensions
minimums indiquées dans les tableaux du chapitre «
Sizing of Category I Venting Systems » du National
Fuel Gas Code, ANSI Z223.1/NFPA 54 ou des Codes
d’installation CAN/ACG B149.

14

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

BOILER PIPING

15

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

Use Threaded Fittings for Manifold Piping

16

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 4 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.

17

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"

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"

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

1"

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.

18

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 5.4.

Model

Supply

Pressure

(in. Water)

63-03L 5.00

63-03 5.00

63-04L 5.00

63-04 5.00

63-05L 5.00

63-05 5.00
63-06 5.00
64-07 5.00
64-08 5.50
64-09 5.00
64-10 5.00
64-11 5.00
64-12 5.00

Table 5.4: Minimum Supply

Pressure Natural Gas

Figure 5.2: Gas Train Manifold 63-03L

Through 63-06

Figure 5.4: Gas Train Manifold –

64-09 Through 64-12

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

19

CONTROLS & TRIM

A. 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 6.1. 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 6.2 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 6.3.

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 6.2 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 6.3 and 6.4
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 6.2 for tapping
location.

6. CONTROLS & TRIM

Figure 6.3: Gauge Glass & Low Water Cut-Off

Installation

Figure 6.2: Steam Boiler Tapping Location

Figure 6.1

Figure 6.4: Gauge Glass Installation

20

6. Limit Control(s): (Figure 6.5)
a. Install the operating limit control and pressure

gauge in the 3/4" tappings located on the right
side of the boiler.

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

in the 3/4" tapping on the right side of the boiler.

B. 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

6.6. 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 pipe 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.

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 6.6: Relief Valve Piping Water Boiler

Figure 6.5: Limit Control Installation

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, water boilers are equipped
with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This
feature is equipped with an override which is provided primarily to permit the use of an external energy
management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating
load decreases.

• This boiler is not used for any space heating

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

IMPORTANT

21

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 6.7 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 6.7 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 6.7 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 6.7 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 6.8.

Figure 6.7: Water Boiler Tapping Locations

Figure 6.8: Probe Low Water Cut-off Piping

CONTROLS & TRIM

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. Steam Boilers – 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: Steam Boilers

Figure 7.2

Figure 7.3

22

Identifier tous les câbles avant de les débrancher au
moment d’effectuer l’entretien des commandes. Des
erreurs dans le raccordement des câbles
d’alimentation peuvent causer un fonctionnement
inadéquat et dangereux. Vérifier le bon
fonctionnement après les travaux d’entretien.

AVERTISSEMENT

23

ELECTRICAL

4. Mount the ignition module as shown in Figure 7.4.

C. INSTALL CONTROL WIRING

1. Wire the boiler according to the wiring diagram
supplied with the boiler (in the Control Envelope).
Figures 7.5 to 7.9 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.

Figure 7.4

24

ELECTRICAL

Figure 7.5: Steam Boiler – Wiring Diagram for Models with Float Low Water Cut-off

25

ELECTRICAL

Figure 7.6: Steam Boiler – Wiring Diagram for Models with Probe Low Water Cut-off

26

ELECTRICAL

Figure 7.7: Water Boiler with Beckett AquaSmart™ 7600B Limit Control

27

ELECTRICAL

Figure 7.8: Water Boiler with Hydrolevel Hydrostat

®

3200 Limit Control

28

ELECTRICAL

Figure 7.9: Typical Steam Boiler Indirect Water Heater Wiring

29

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 OPERATING INSTRUCTIONS

Before starting the boiler, study the Operating
Instructions supplied with the boiler. Figure 8.2 to 8.4
show typical Lighting Instructions for typical boilers.

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. 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. Turn down the Operating Temperature Control to

stop the call for heat.

f. Wait 60 seconds to allow the control to reset

before proceeding with the next step.

5. 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.

30

BOILER OPERATION

6. 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 shut­off valve. Attach a U-tube manometer.

2. Restart the boiler by tur ning 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 cor rected

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

T

31

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 cer tain 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

32

Figure 8.2: 63-03 thru 64-08 Nat/LP, 64-09 thru 64-12 LP Gas

BOILER OPERATION

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.

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.

OPERATING INSTRUCTIONS

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.

Gas Control Knob
(shown in "OFF"
position)

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.

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.

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.

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.

HSP VR8204/VR8304 9181R REV.2

33

BOILER OPERATION

Figure 8.3: 63-03 thru 64-08 Nat/LP, 64-09 thru 64-12 LP Gas

34

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".

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.

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.

Gas Control Knob
(shown in "OFF"
position)

Figure 8.4: 64-09 thru 64-12 Nat Gas

35

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.

36

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 6.6 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 deter mine that it is

properly installed and supported.
b. Check boiler operating temperature and pressure.
c. Lift the tr y 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 Operating Instructions in Section 8

“To Turn Off Gas to Appliance.”
b. Turn off all electrical power to the boiler.
c. Remove bur ners and brush gas outlet por ts

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

37

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.

38

TROUBLE SHOOTING – SERVICE TIPS

10. TROUBLESHOOTING – SERVICE TIPS

Problem Possible Cause Suggested Remedy

Pilot Outage

Heavy Draft Blowing across Pilot Redirect Air Movement or Eliminate
Plugged Pilot Orifice Replace Orif ice

No Gas

Check Manual Pilot Valve
Check Main Gas Shut-Off Valve
Check Manual Meter Valve
Consult Gas Company

Ignition Control Problem See Table 10.2 and Figure 10.1

Main Gas Valve Will Not Open

No Power

Check Power Source with Meter
Check Fuses

Defective Gas Valve

Replace

Low Water Level in Boiler or System Causing Low
Water Cut-off to Function

Check for Leaks

Check Feeder (if Supplied)
Ignition Control Problem See Table 10.2 and Figure 10.1
High Gas Pressure Switch Open

(if Provided)

Check Switch Setting

Check Manifold Gas Pressure
Low Gas Pressure Switch Open

(if Provided)

Check Switch Setting

Check Manifold Gas Pressure

Burner(s) Burning with Yellow Flame

Air Adjustment Screws Turned in Too Far Adjust Screws Out
Low Gas Pressure in Manifold

(Insufficient Air Injection)

Adjust Main Gas Pressure Regulator

or Check Line Pressure
Burner Ports Partially Closed

(Rust, Dirt, Lint, etc)

Replace Burners or Clean Ports

Insufficient Air for Combustion

Check Size of Combustion Air Openings

to Room

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

Gas Spillage from

Draft Hood Relief Opening

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

Insufficient Draft - Downdraft Caused by
Chimney Location with Respect to Other
Buildings, Roofs, etc.

Install Chimney Cap

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

Remove Exhaust Fan or

Isolate Fan From Boiler Room

Insufficient Combustion Air Openings

Provide Correctly Sized Combustion and

Ventilation Air Openings

Main Gas Valve Opens

But No Gas Flows

Manual Valve Closed at Gas Train Open Valve
Manual Valve Closed at Meter Open Valve
Test Firing Valve Closed (if Provided) Open Valve

Table 10.1: Boiler Troubleshooting

39

TROUBLE SHOOTING – SERVICE TIPS

Problem Possible Cause Suggested Remedy

System or Boiler Overfilling or

Excessive Make-up Water

(Water Boilers)

Leaks in System Repair L eaks or Replace Piping as Required
Expansion tank (diaphragm or bladder type)

charge pressure not right

Check Charge Pressure, Correct if Required
Air compression tank waterlogged

or diaphragm or bladder defective on
expansion tank

Replace tank

Fill valve not working or set for too high a
cold fill pressure, causing relief valve to weep

Check Fill Valve, Replace if Necessary

Rapid Cycling

(Water Boilers)

Temperature control differential too narrow Adjust Control Differential

Water Hammer On Start-Up

(Steam Boilers)

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
higher than old boiler

Correct Piping or Install Feed System and Traps

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

Install Drip Line and Trap

Water Hammer During Mid-Cycle

(Steam Boilers)

Clogged returns on gravity system Clean or Re-Pipe Return Line(s)
Incorrect near-boiler piping causing wet steam

to system

Correct Piping per Manual

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

{Radiator Hammer} Large radiator may be
vented too quickly

Use smaller Air Vent or Use Two Small Vents in

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

tank, causing water pocketing

Correct Piping

Trap installed at receiver tank, causing water
trapping in return

Remove Trap at Tank, Install Drip Traps and

Radiator Traps where Required
Boiler feed pump or condensate pump feed rate

too fast, causing spraying into equalizer

Throttle Flow Rate

No drip on the inlet side of a forward pitched
motorized valve

Add Drip Line and Trap

Uninsulated steam piping, causing excessive
condensate loads

Insulate Steam Pipes

Water Hammer on Shut-Down

(Steam Boilers)

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
condition on shut-down

Insulate Steam Pipes

Hammering in the Boiler

(Steam Boilers

Poor circulation in the boiler due to sludge
accumulation

Clean and Blowdown the Boiler

No Heat or Poor Heat

Distribution in the Building

(Steam Boilers

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

of the returns

Replace Traps or Trap Elements

Water legs or back slope in return lines to receiver
tank, preventing air from venting out receiver vent

Correct Piping
Boiler pressure too high, causing air vents to lock

up or blowing water loop seals

Reduce Operating Pressure

Table 10.1 (cont’d): Boiler Troubleshooting

40

TROUBLE SHOOTING – SERVICE TIPS

Problem Possible Cause Suggested Remedy

System or Boiler Overfilling or Flooding

(Steam Boilers)

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
steam bubbles in boiler water)

Reduce Feed Rate

Foaming, priming or surging due to poor
water quality

Clean the Boiler

Excessive Water Level Bounce

(Steam Boilers)

Poor water quality, causing foaming and surging Clean the Boiler
Incorrect near-boiler piping, such as undersized

or incorrectly placed risers

Pipe per Manual

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

Rapid Cycling

(Steam Boilers)

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

Replace Vents or Traps

Pressure differential on pressure control too close Adjust Control Differential
Nuisance outages of water level control due to

boiler water level bounce

See Excessive Water Level Bounce Above

Table 10.1 (cont’d): Boiler Troubleshooting

Table 10.2: Capable Controls Series 5 Ignition Module – Sequence of Operation and Error Codes

Trial for Ignition – 90 seconds, 5 minute wait between trials for ignition.

LED Indications, Normal Operation

Green, blinking rapidly Trial for ignition
Green, on solid Flame detected, pilot/main burners on
Green, 1/2 sec on, 1/2 sec off Wait time between trials for ignition

LED Indications, Error Operation

Upon detection of a fault by the ignition module’s internal diagnostics, sparking is turned off and pilot and/or main gas valve(s) are closed.
See LED error codes below. To reset module and clear error, interrupt call for heat (power).

Red Flashes Error Definition Suggested Remedy

1 flash N/A (non-retry models only) Not applicable
2 flashes Flame sense stuck on If pilot lit with all power off, replace gas valve. Otherwise, replace module.
3 flashes Pilot/Main relay failure Replace module
4 flashes Repetitive flame loss error Check gas pressure, flame size, electrode position.
5 flashes N/A (models with flame rollout) Not applicable
6 flashes N/A (models with APS sensor) Not applicable
7 flashes Internal control error Replace module
Solid Red Line Voltage/Freq Error Verify voltage and frequency of incoming power.

See also Figure 10.1, Troubleshooting Flow Chart.

41

TROUBLE SHOOTING – SERVICE TIPS

Figure 10.1: Ignition System Troubleshooting Guide

BEFORE TROUBLESHOOTING,
FAMILIARIZE Y OURSELF WITH

START

THE STARTUP AND

CHECKOUT PROCEDURES.

TURN GAS SUPPLY OFF,

TURN THERMOSTAT

(CONTROLLER) TO
“CALL FOR HEAT.”

POWER TO

MODULE? (24 V

NOMINAL)

YES

SPARK
ACROSS
IGNITER/

SENSOR

GAP?

YES

TURN GAS SUPPLY
ON AND RECYCLE

“CALL FOR HEAT.”

PILOT BURNER

LIGHTS?

NOTE: “CALL FOR HEAT” 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL.

CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING ALSO.

NO

CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED)
IS MADE.

PULL IGNITION LEAD AND

NO

CHECK SPARK AT MODULE.

CHECK IGNITION CABLE, GROUND WIRING, CERAMIC INSULATOR, AND SPARK GAP ARE CORRECT.
CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING, TAKE PROTECTIVE ACTION TO SHIELD CABLE
AND BOOT FROM EXCESSIVE TEMPERA TURES.

CHECK THAT ALL MANUAL GAS VALVES ARE OPEN, SUPPLY TUBING AND PRESSURES ARE GOOD, AND PILOT BURNER
ORIFICE IS NOT BLOCKED (PILOT GAS FLOWING).
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL.

NO

CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF VOLTAGE IS OKAY, REPLACE GAS CONTROL.
IF NOT, REPLACE MODULE.
NOTE: IT MAY BE NECESSARY TO RECYCLE THE ‘CALL FOR HEAT” MORE THAN ONCE TO CLEAR THE PILOT SUPPL Y TUBES OF AIR.

SPARK OK? NO

YES

REPLACE MODULE

YES

SPARK

STOPS WHEN

PILOT IS

LIT?

YES

MAIN BURNER

LIGHTS?

YES

SYSTEM

RUNS UNTIL “CALL

FOR HEAT”

ENDS?

YES

“CALL FOR HEAT” ENDS

SYSTEM

SHUTS

OFF?

NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE “CALL FOR HEAT.”
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
CLEAN FLAME ROD.
CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE.

NO

CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE.
ADJUST PILOT FLAME.
IF PROBLEM PERSISTS REPLACE MODULE.

CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF NO VOLTAGE, REPLACE MODULE.

NO

CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL INCLUDING SAFETY CONTROLS WIRED IN THE CIRCUIT.
IF OKAY, REPLACE GAS CONTROL.

NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE “CALL FOR HEAT.”
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
NOTE: IF GROUND IS POOR OR ERRATIC, SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL
AT THE TIME OF CHECKOUT.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE, PILOT FLAME MUST NOT BE MOVING AROUND DUE TO

NO

OUTSIDE AIR FLOWS, ETC.
ADJUST PILOT FLAME. CHECK GAS PRESSURE MEETS APPLIANCE SPECIFICATIONS WHILE APPLIANCE MAIN BURNER ON AND ALL
OTHER GAS APPLIANCES ON THE SUPPLY ARE OPERATING AT FULL RATE.
IF CHECKS ARE OKAY, REPLACE MODULE.

CHECK FOR PROPER THERMOSTAT (CONTROLLER) OPERATION.

NO

REMOVE MV LEAD AT MODULE, IF VALVE CLOSES, RECHECK TEMPERATURE CONTROLLER AND WIRING. IF NOT, REPLACE
GAS CONTROL.

YES

REPEAT PROCEDURE UNTIL
TROUBLE FREE OPERATION

IS OBTAINED.

42

11. BOILER DIMENSIONS & RATINGS

Figure 11.1: Dimensions and Tapping Locations

Table 11.1: Tapping Sizes & Functions

Table 11.2: Dimensions

SERIES 63/64™ TAPPING SIZES & FUNCTIONS

Tap I D Size NPT Steam Water

K 1-1/4" Skim Tapping* Skim Tapping*

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

P 3" Supply Supply

R 2-1/2" Return Return

S 3/4" Safety Valve* Relief Valve*

T 1/2" Gauge Glass N/A
U 3/4" Primary Probe Low Water Cut-Off N/A
V 3/4" N/A or Primary Limit (9-12) N/A or Secondary Limit (9-12)
W 3/4" Press Gauge or Secondary Limit (9-12) Press/Temp Gauge or Primary Limit (9-12)
X 3/4" Primary Limit or Press Gauge (9-12) Primary Limit or Temp/Press Guage (9-12)
Y 3/4" Secondary Probe Low Water Cut-Off N/A

BOILER DIMENSIONS & RATINGS

SERIES 63/64™ BOILER DIMENSIONS

Boiler

Model

Number

Jacket
Depth

“A”

Jacket

Width

“B”

Jacket
Height

“C”

Rear of Jkt. to

c/l of Vent

“D”

Left of Jkt. to

c/l of Vent

“E”

Vent

Size Dia.

“F”

Overall

Depth

“G”

Rear of Jkt. to

c/l of Supply

“H”

Rear of Jkt. to
c/l of Gas Inlet

“J”

63-03L 28-1/8" 16-1/8" 36-3/8" 5-5/8" 8-1/16" 6" 37-1/4" 18-11/16" 25-7/8"

63-03 28-1/8" 16-1/8" 36-3/8" 5-5/8" 8-1/16" 6" 37-1/4" 18-11/16" 25-7/8"

63-04L 28-1/8" 20-3/8" 36-3/8" 5-1/8" 10-3/16" 7" or 6"*37-1/4" 18-11/16" 25-7/8"

63-04 28-1/8" 20-3/8" 36-3/8" 5-1/8" 10-3/16" 7" or 6"

*

37-1/4" 18-11/16" 25-7/8"

63-05L 28-1/8" 24-5/8" 36-3/8" 6-5/8" 12-5/16" 8" 39-1/4" 18-11/16" 25-7/8"

63-05 28-1/8" 24-5/8" 36-3/8" 6-5/8" 12-5/16" 8" 39-1/4" 18-11/16" 25-7/8"
63-06 28-1/8" 28-7/8" 36-3/8" 6-1/8" 14-7/16" 9" 39-1/4" 18-11/16" 25-7/8"
64-07 28-1/8" 33-1/8" 36-3/8" 6-1/8" 16-9/16" 9" 39-1/4" 18-11/16" 25-7/8"
64-08 30-1/8" 37-3/8" 36-3/8" 7-1/2" 18-11/16" 10" 43-1/8" 18-15/16" 26-1/8"
64-09 30-1/8" 41-5/8" 36-3/8" 7-1/2" 20-13/16" 10" 43-1/8" 18-15/16" 26-1/8"
64-10 30-1/8" 45-7/8" 36-3/8" 8-1/2" 22-15/16" 12" 45-1/8" 18-15/16" 26-1/8"
64-11 30-1/8" 50-1/8" 36-3/8" 8-1/2" 25-1/16" 12" 45-1/8" 18-15/16" 26-1/8"
64-12 30-1/8" 54-3/8" 36-3/8" 8-1/2" 27-3/16" 12" 45-1/8" 18-15/16" 26-1/8"

*Draft hood outlet and vent damper are 7" diameter on 63-04L and 63.04. These models are also certified in USA with 6" vent

using vent reducer provided in draft hood carton. Install reducer on outlet of vent damper.

*For relief valve larger than ¾”, use “K” boiler skim tapping. Do not increase the pipe size between the boiler and the valve.

43

BOILER DIMENSIONS & RATINGS

Table 11.3: Series 63™ Boiler Ratings

1. Net 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. 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.

Series 63™

Boiler
Model

Input,

MBH

Heating Capacity³ Net Ratings¹ AFUE²

Water,

MBH

Steam,

MBH

Steam,

sqft

Steam,

MBH

Water,

MBH

Water,%Steam,

%

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

63-03 118.0 99 98 308 74 86 83.5 82.6

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

63-04 177.0 148 147 458 110 129 83.4 82.4

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

63-05 236.0 198 196 613 147 172 83.3 82.2
63-06 287.5 241 238 746 179 210 83.2 82.0

Water

Content

Approx.

Shipping

Weight,

lb

Water,

gal

Steam,

gal

13.2 9.3 465

13.2 9.3 465

15.6 10.8 576

15.6 10.8 576

18.0 12.4 700

18.0 12.4 700

20.4 13.9 812

Series 64™

Boiler
Model

Input,

MBH

Gross Output² Net Ratings¹

Thermal

Efficiency

Combustion

Efficiency²

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,

lb

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 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. 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

44

R EPAI R PARTS

12. REPAIR PARTS

Figure 12.1

Repair parts are available from your local PB Heat, LLC distributor or from Parts To
Your Door at 1 [phone] (www.partstoyourdoor.com).

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

45

R EPAI R PARTS

Description

Quantity
Required

Stock

Code

1 Inter mediate Section – w/out Draw Lugs – 90028
2 Inter mediate Section – w/ Draw Lugs (64) – 90029
3 Right Hand Section – 90030
4 L eft 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

11

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

12

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

13

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

14

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

15

Burner Tray Left Side Rail – 50296
Burner Tray Right Side Rail – 50295

16

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

17 Bur ner with Pilot Bracket (Spark) – 50163

Table 12.1

Part numbers may be subject to change without notice.

46

Description

Quantity
Required

Stock

Code

22

Draft Hood – 63-03 – 50252
Draft Hood – 63-04 – 50347
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

– SPRK 63 – 90070
– SPRK 64 – 90071

Conversion Kit LP to Natural Gas

– 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
– Limit Control, Steam – PA404A – 50549

–

Limit Control, Steam Manual Reset –
L4079B

– 50681

– Brass Siphon – 63-03 Thru 64-08 – 6667
– Brass Siphon, Long – 64-09 Thru 64-12 – 6665
– Limit Control, Water – Beckett 7600B – 50335
– Immersion Well, Beckett 7600T – 50341
– Immersion Sensor, Beckett 7600P – 50339

–

Limit Control w/ Sensor, Water –
Hydrolevel 3200

– 50334
– Immersion Well, Hydrolevel – 50723
–

Limit Control, Water Manual Reset –
L4006E

– 50570
– Pressure Gauge – Steam – 51325

– Temperature/Pressure Gauge – Water – 51324
– Transformer, Steam – 40VA – 50787

Description

Quantity
Required

Stock

Code

18

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

– 50589

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

– 50589

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

– 50583

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

– 50247

Gas Valve – LP 63-05,
63-06 Honeywell VR8304M-4010

– 50590

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

– 50724

Gas Valve – LP 64-09 thru
64-12 Honeywell VR8304P-4314

– 50724

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

– 50584

19

Pilot Assembly NAT 63/64
Honeywell Q348A-1002

– 50558

Pilot Assembly LP 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
– Flame Rollout Switch 176°C – 51587

– Ignition Control (non-CSD) – 50767
– Ignition Control (CSD) – 50732

20

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

21

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

Table 12.2

R EPAI R PARTS

47

NOTES

48

NOTES

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 R12 (5/14-3M)

Printed i n U.S.A .

©2014 PB Heat, LLC. All rights reserved.

PB HEAT, LLC

131 S. CHURCH STREET • BALLY, PA 19503