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USER’S INFORMATION MANUAL
S
ERIES
63/64™G
AS
B
OILERS
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.
TO BE COMPLETED BY THE INSTALLER
Service Agency Phone No.
Address
Boiler Model No. Serial No. Date of Installation:
If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
– Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
– WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical 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.
– Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
– Ne pas ranger ou utiliser de la gazoline ou
d’autres liquides ou gaz inflammables à
proximité de cet appareil ou d’un autre du
même type.
– QUE FAIRE SI VOUS DÉTECTEZ UNE
ODEUR DE GAZ
• Ne pas tenter d’allumer l’appareil.
• Ne toucher à aucun interrupteur
électrique ; n’utiliser aucun appareil
téléphonique dans l’immeuble.
• Contacter immédiatement votre fournisseur
de gaz à partir du téléphone d’un voisin.
Suivre les instructions données par votre
fournisseur de gaz.
• S’il est impossible de rejoindre le
fournisseur de gaz, appeler le service
des incendies.
– L’installation et l’entretien doivent être
effectués par un installateur qualifié, une
société d’entretien ou le fournisseur de gaz.
PB HEAT, LLC
131 S. CHURCH ST • BALLY, PA 19503
TT8067 R3 (11/14-3M)
Printed in U.S.A.
©2014 PB Heat, LLC. All rights reserved.
WARNING
Négliger de suivre ces instructions à la
lettre pourrait provoquer un incendie ou
une explosion causant des dégâts
matériels, des blessures ou la mort.
MISE EN GARDE
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Basic Operation
Service on this boiler should be undertaken only by trained and skilled personnel from a
qualified service agency.
Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the
electrical supply to the pump. Instead, shut off the gas supply at a location external to the
appliance.
Do not use this boiler if any part has been under water. Immediately call a qualified service
agency to inspect the boiler and to replace any part of the control system and any gas control
which has been under water.
A. General. This water boiler is a natural draft appliance and is equipped with controls for proper
operation. All controls must be in proper working order. Contact a qualified service agency to provide
annual maintenance as specified in the Installation, Operation and Maintenance Manual.
B. Control Locations. See Figure 1 for Control and Safety Device Locations.
1a. Limit (Steam Boiler). An electrical device that automatically interrupts the boiler operation when
the steam pressure exceeds the “CUT IN” pressure plus the differential (1 to 5 psi). Maximum
Pressure setting is 14 psig. The set point is usually less than 5 psig.
Original equipment with this boiler is a Honeywell PA404A1009. Boiler operation is interrupted
when the steam pressure exceeds the the “CUT IN” pressure plus the differential. Boiler operation
resumes automatically when the system pressure falls below the “CUT IN” pressure.
1b. Limit (Water Boiler). An electrical device that automatically interrupts the boiler operation when
the water temperature exceeds the set point. Maximum temperature setting is 220°F.
Boiler operation is interrupted when the water temperature exceeds the set point. Boiler operation
resumes automatically when the water temperature falls to approximately 15°F below the set point.
1c. Limit Control may incorporate a low water cut-off feature that will interrupt boiler operation upon
loss of water in the boiler. If the low water cut-off function is activated to interrupt boiler operation,
follow the instructions TO TURN OFF GAS TO THE APPLIANCE (see Figures 3-5) and contact a
qualified service agency.
2. Flame Rollout Switch (FRS). An electrical device that automatically interrupts the boiler operation
when excessive heat is present in the combustion area. The control is a thermal fuse device that
will require replacement if it is activated. If the control has been activated to interrupt the boiler
operation, do not attempt to restart the boiler. Contact a qualified service agency.
3. Blocked Vent Switch (BVS) An electrical device that automatically interrupts the boiler operation
when there is a blockage in the vent pipe or chimney. The control is located on the side of the draft
hood and is a manual reset device. If the control is activated to interrupt operation of the boiler, do
not attempt to restart the boiler. Contact a qualified service agency.
WARNING
CAUTION
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4. Pilot. The pilot provides an ignition source for the main burners. Your boiler has either a standing
(continuous) pilot or an intermittent (spark ignited) pilot. The standing pilot should always be lit
while the intermittent pilot ignites only when there is a call for heat and extinguishes when the call
for heat ends. See Figure 6.
5. Gas Valve. The gas valve monitors pilot flame and regulates gas flow to the burners and pilot.
6. Safety Relief Valve. A mechanical device that protects the boiler against excessive pressure. The
safety relief valve can discharge a large amount of steam or hot water – the installer should
provide piping to discharge water near the floor close to a floor drain. If the safety relief valve
discharges water, follow the instructions TO TURN OFF GAS TO APPLIANCE on the Lighting
Instructions affixed to the inside of the removable front jacket panel (see Figures 3 through 5 for
typical lighting instructions), and contact a qualified service agency.
C. Lighting Instructions. Instructions to place the boiler in operation and to turn off the boiler are shown
on the Lighting Instructions Label posted on the inside of the front jacket panel of the boiler. Typical
lighting instructions are shown in Figures 3 through 5.
Figure 1: Control Location
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Figure 2: Sequence of Operation Intermittent Pilot
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Figure 3: Operating Instructions, Spark Ignition
63-03 thru 64-08 Natural Gas & LP Gas, 64-09 thru 64-12 LP Gas
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Figure 4: Operating Instructions, Spark Ignition
63-03 thru 64-08 Natural Gas & LP Gas, 64-09 thru 64-12 LP Gas
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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 5: Operating Instructions, Spark Ignition
64-09 thru 64-12 Natural Gas
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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.
User Maintenance
WARNING
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Service on this boiler should be undertaken only by trained and skilled personnel from a
qualified service agency. Inspections should be performed at intervals specified in the
Installation, Operation and Maintenance Manual and this User’s Information Manual. Maintain
manuals in a legible condition.
Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors
and liquids.
Do not place any obstructions in boiler room that will hinder flow of combustion and
ventilation air.
A. General Housekeeping (Continuous).
1. Keep boiler area clear and free of combustible materials and obstructions to the free flow of
combustion and ventilation air to the boiler.
2. Do not store or use gasoline or other flammable vapors or liquids in the vicinity of the boiler or any
other appliance.
3. Do not store or use sources of hydrocarbons in the vicinity of the boiler. Sources of hydrocarbons
include bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners and refrigerants.
4. Check safety relief valve for water leakage. If leakage exists, contact a qualified service agency.
B. Inspect Vent System (Monthly).
1. The vent pipe must be continuous to chimney with no separations, obstructions, or sags. Vent pipe
must be supported at minimum 4 foot intervals and secured with sheet metal screws.
2. The vent system must not have signs of continuous wetness. If signs of continuous wetness are
observed, contact a qualified service agency.
3. The vent system must not have signs of deterioration from corrosion or other sources. If there is
evidence of deterioration contact a qualified service agency.
C. Inspect Pilot and Main Burner Flames (Monthly).
1. Remove front jacket panel by lifting and pulling out.
2. Adjust thermostat to highest setting. Verify operation follows Sequence of Operation (see page 3).
3. View flames through observation port. See Figure 1.
4. Check pilot flame. See Figure 6. The pilot flame should be medium blue covering approximately
3/8" to 1/2" of the thermocouple. If the flame is yellow and lazy, follow instructions TO TURN OFF
GAS TO APPLIANCE (see Figures 3-5), and contact a qualified service agency.
5. Check main burner flames. See Figure 6. The flames should have clearly defined inner cones
approximately 1-1/2" high and should have a very sharp blue color characteristic. If the flame is
yellow and lazy, follow instructions TO TURN OFF GAS TO APPLIANCE (see Figures 3-5), and
contact a qualified service agency.
6. Adjust thermostats to normal setting.
7. Install front jacket panel.
WARNING
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D. Controls (as required by control manufacturer)¹.
1. Safety Relief Valve. Conduct try lever test as outlined in manufacturer’s instruction tag on the
safety relief valve.
2. Low Water Cut-off (if used). Follow instructions provided by control manufacturer.
E. General Inspection and Maintenance (Annual). For continued safe operation a qualified service
agency must provide a more detailed inspection of burners, heat exchanger and vent system, and
provide maintenance as specified in the Installation, Operation and Maintenance Manual.
Figure 6: Pilot and Main Burner Flames
1
Controls maintenance may be part of annual inspection and maintenance by a qualified service agency if annual frequency is
specified by controls manufacturer.
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