PeerlessBoilers PBC-40, PBC-34, PBC-52 Installation, Operation & Maintenance Manual

PBC

™

Gas Boilers

PBC-34™, PBC-40™, PBC-52™

Combination

Installation,
Operation &
Maintenance
Manual

Series

USING THIS MANUAL 1

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

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

1. PREINSTALLATION 2

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

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

C. ACCESSIBILITY CLEARANCES . . . . . . . . . . . .3

D. COMBUSTION & VENTILATION AIR . . . . . . . .3

2. BOILER SET-UP 7

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

B. MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3. VENTING & AIR INLET PIPING 8

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

B. APPROVED MATERIALS . . . . . . . . . . . . . . . . .8

C. EXHAUST VENT/AIR INTAKE

PIPE LOCATION . . . . . . . . . . . . . . . . . . . . . . . .9

D. EXHAUST VENT/AIR INTAKE PIPE SIZING . .12

E. EXHAUST VENT/AIR INTAKE PIPE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .13

F. EXHAUST

TAPPING FOR VENT SAMPLE

. . .14

G. BOILER REMOVAL FROM COMMON

VENTING SYSTEM . . . . . . . . . . . . . . . . . . . .14

4. WATER PIPING AND CONTROLS 16

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

B. OPERATING PARAMETERS . . . . . . . . . . . . . .16

C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .16

D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .18

E. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .19

5. FUEL PIPING 23

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . . .23

C. GAS SUPPLY PIPING – INSTALLATION . . . .23

D. GAS SUPPLY PIPING – OPERATION . . . . . . .24

E. MAIN GAS VALVE – OPERATION . . . . . . . . .24

6. CONDENSATE DRAIN PIPING 26

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

B. CONDENSATE SYSTEM . . . . . . . . . . . . . . . .26

7. ELECTRICAL CONNECTIONS 27

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

B. CUSTOMER CONNECTIONS . . . . . . . . . . . . .27

C. INTERNAL WIRING . . . . . . . . . . . . . . . . . . . .27

8. BOILER CONTROL: INTERNAL
WIRING & OPERATION 30

A. CONTROL OVERVIEW . . . . . . . . . . . . . . . . . .30

B. AVAILABLE CENTRAL HEAT MODES . . . . . .30

C. AVAILABLE DOMESTIC HOT WATER

MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

D. DISPLAY UTILIZATION . . . . . . . . . . . . . . . . .31

E. USER MENU . . . . . . . . . . . . . . . . . . . . . . . . . .33

F. STATUS MENU–1000 LEVEL . . . . . . . . . . . . .33

G. INSTALLER MENU–2000 LEVEL . . . . . . . . . .35

H. MENU LEVELS 3000, 4000 & 5000 . . . . . . . .37

I. OUTDOOR RESET OPERATION . . . . . . . . . .38

J. IGNITION SEQUENCE . . . . . . . . . . . . . . . . . .39

K. ADDITIONAL SAFETY FUNCTIONS . . . . . . .40

9. START-UP PROCEDURE 41

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

B. CHECK WATER PIPING . . . . . . . . . . . . . . . . .41

C. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . . .41

D. CHECK OPERATION . . . . . . . . . . . . . . . . . . . .41

E. LIGHTING & OPERATING PROCEDURES . . .43

10. TROUBLESHOOTING 44

A. LOCKOUT ERRORS . . . . . . . . . . . . . . . . . . . .44

B. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . . .44

C. WARNING ERRORS . . . . . . . . . . . . . . . . . . . .44

D. TYPICAL OPERATION CYCLE–

CENTRAL HEAT . . . . . . . . . . . . . . . . . . . . . . .44

E. TYPICAL OPERATION CYCLE–DHW . . . . . . .44

11. MAINTENANCE 49

A. GENERAL (WITH BOILER IN USE) . . . . . . . .50

B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .50

C. ANNUALLY (BEFORE START OF

HEATING SEASON) . . . . . . . . . . . . . . . . . . . .50

D. CONDENSATE CLEANING

INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .50

E. INSPECTION AND CLEANING OF

COMBUSTION CHAMBER COILS . . . . . . . . .50

F.

HEAT EXCHANGER GASKET

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . .51

G. FLOW RESTRICTOR MAINTENANCE . . . . . .51

H. PLATE HEAT EXCHANGER

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .52

12. BOILER DIMENSIONS & RATINGS 53

13. REPAIR PARTS 56

TABLE OF CONTENTS

TABLE OF CONTENTS

A. INSTALLATION SEQUENCE

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

B. SPECIAL ATTENTION BOXES

Throughout this manual 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

1

USING THIS MANUAL

Compliance with the Energy Policy and Conservation Act:

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.

Indicates a condition or hazard which will or can
cause minor personal injury or property damage.

WARNING

Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.

NOTICE

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is 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 NOTICE

Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.

CAUTION

A. GENERAL

1. Series PBC™ boilers are supplied completely
assembled as packaged boilers. The package should
be inspected for damage upon receipt; any damage to
the unit should be reported to the shipping company
and wholesaler. The boiler should be stored in a
clean, dry area.

2. Carefully read these instructions and be sure to
understand the function of all connections prior to
beginning installation. Contact your PB Heat, LLC
Representative for help in answering questions.

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

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

5. Series PBC™ boilers are capable of producing
instantaneous domestic hot water to the dwelling. Hot
water over 125°F can cause severe scald burns
instantly. If utilizing the domestic water production
features of the unit, be sure to:

a. Install a temperature limiting device per the device

manufacturer’s instructions to reduce scald hazard.

b. Set the temperature limiting device to the lowest

practical temperature setting.

c. Always feel water before bathing or showering.

d. Do not leave children, the disabled, or the elderly

unattended while bathing.

e. Additional point of use temperature limiting

devices may be required at the fixtures to reduce
scald hazard.

B. CODES & REGULATIONS

1. Installation and repairs are to be performed in strict
accordance with the requirements of state and local
regulating agencies and codes dealing with boiler and
gas appliance installation.

2. In the absence of local requirements the following
should be followed:

a. ASME Boiler and Pressure Vessel Code, Section

IV - “Heating Boilers”

b. ASME Boiler and 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. 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.

**Please read if installing in Massachusetts**

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

•

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

•

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

•

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

•

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

•

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

2

PREINSTALLATION

1. PREINSTALLATION

Liquefied Petroleum (LP) Gas or Propane is heavier
than air and, in the event of a leak, may collect in low
areas such as basements or floor drains. The gas
may then ignite resulting in a fire or explosion.

WARNING

⚠

DANGER

– Water temperatures over 125°F

– (52°C) can cause severe burns
– instantly, or death from scalds.

– Children, the disabled, and the

– elderly are at the highest risk of
– being scalded.

– Feel water before bathing or showering.

– Read this manual in its entirety before setting

domestic hot water setpoint.

– A temperature limiting device (listed to ASSE 1070

or ASSE 1017) is required.

•

EXEMPTIONS to the requirements listed above:

°

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

°

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

·

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

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

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

C. ACCESSIBILITY CLEARANCES

1. The Series PBC™ boiler is certified for closet
installations with zero clearance to combustible
construction. In addition, it is design certified for use
on combustible floors. Do not install on carpeting.

2. Figure 1.1 shows the minimum recommended
clearances to allow reasonable access to the boiler for
Models PBC-34™, PBC-40™ and PBC-52™.
However, Local codes or special conditions may
require greater clearances.

D. COMBUSTION AND VENTILATION AIR

1. The Series PBC™ boiler is designed for operation with
combustion air piped directly to the boiler from
outside the building (sealed combustion). Combustion
air may be supplied from within the building only if
adequate combustion air and ventilation air is
provided in accordance with the National Fuel Gas
Code or applicable sections of the local building code.
Subsections 3 through 10 as follows are based on the
National Fuel Gas Code requirements.

2. If the combustion air is piped directly to the boiler
from outside the building, no additional combustion
or ventilation air is required. Otherwise, follow the
National Fuel Gas Code recommendations
summarized in subsections 3 through 10.

3. 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.

PREINSTALLATION

Figure 1.1: Minimum Accessibility Clearances – PBC-34™, PBC-40™, and PBC-52™

3

DANGER

DO NOT INSTALL ON CARPETING.

a. Standard Method: The minimum required volume

of indoor air (room volume) shall be 50 cubic feet
per 1000 BTU/Hr (4.8 m3/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:

I

fan

= Input of the fan assisted appliances

in Btu/hr

ACH = air change per hour (percent of the

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

Note: These calculations are not to be used for

infiltration rates greater than 0.60 ACH.

4. 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 in2 per 1000 Btu/hr (22 cm2 per 1000 W) of
the total input rating of all gas fired equipment but
not less than 100 in2 (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 1.2 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 cm2per
1000 W) of total input rating of all equipment. See
Figure 1.3 for an illustration of this arrangement.

5. 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 1.4 for openings directly
communicating with the outdoors or Figure

1.5 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 1.6.

4

Figure 1.2: Air Openings – All Air from Indoors

on the Same Floor

Figure 1.3: Air Openings – All Air from Indoors

on Different Floors

PREINSTALLATION

15 ft

3

I

fan

ACH 1000

Btu

/

hr

Required Volume

fan

=

⎛
⎜
⎝

⎛

⎜

⎝

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 1.7 for this arrangement.

6. 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

7. 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.

5

Figure 1.4: Air Openings – All Air Directly from

Outdoors

Figure 1.5: Air Openings – All Air from Outdoors

through Vertical Ducts

Figure 1.6: Air Openings – All Air from Outdoors

through Horizontal Ducts

Figure 1.7: Air Openings – All Air from Outdoors

PREINSTALLATION

A

req

= A

full

x 1 –

V

avail

V

req

⎛
⎜
⎝

⎛

⎜

⎝

8. 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 ft3/min per
1000 Btu/hr (0.034 m3/min per 1000 W) of the
total rated input of all appliances in the space.

b. In installations where exhaust fans are installed,

additional air shall be provided to replace the
exhaust air.

c. Each of the appliances served shall be interlocked

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

d. In buildings where the combustion air is provided

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

9. 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. Non-motorized 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.

10. Combustion Air Ducts:
a. Ducts shall be constructed of galvanized steel or

an equivalent corrosion-resistant material.

b. Ducts shall terminate in an unobstructed space,

allowing free movement of combustion air to the
appliances.

c. Ducts shall serve a single space.

d. Ducts shall not serve both upper and lower

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

e. Ducts shall not be screened where terminating in

an attic space.

f. Horizontal upper combustion air ducts shall not

slope downward toward the source of the
combustion air.

g. 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.

11. Refer to Section 3 of this manual, Venting & Air Inlet

Piping, for specific instructions for piping the exhaust
and combustion air.

6

PREINSTALLATION

Do not install this boiler where gasoline or other
flammable liquids or vapors are stored or are in use.

WARNING

This boiler is certified as an indoor appliance. Do not
install this boiler outdoors or locate where it will be
exposed to freezing temperatures.

WARNING

Do not install this boiler in the attic.

WARNING

7

A. GENERAL

1. Series PBC™ boilers are intended for installation in an
area with a floor drain or in a suitable drain pan. Do
not install any boiler where leaks or relief valve
discharge will cause property damage.

2. The Series PBC™ boiler is not intended to support
external piping. All venting and other piping should
be supported independently of the boiler.

3. Install the boiler level to prevent condensate from
backing up inside the boiler.

4. Series PBC™ boilers are wall mounted.

B. UNPACKING THE UNIT

1. Items included inside of the boiler cabinet:

a. Two vent adapters

b. Miscellaneous parts kit

2. Remove external foam packaging and remove the
front panel from the unit. The unit can be easily lifted
out of the carton by gripping the bottom front edge of
the base panel and the inside of the front edge of the
top panel.

3. With the boiler flat on the back panel, remove the
right side panel to access the vent adapters and
miscellaneous kit. Remove these components.

4. Remove the internal packaging block behind

the gas valve.

5. The boiler can now be placed upright on a flat stable
surface for further pre-installation work.

C. MOUNTING

1. A wall mounting bracket kit (5636) is included for wall
mounting these boiler sizes.

2. Mount the bracket level on the wall using 5/16" lag
bolts. Be sure the lag bolts are fully supported by wall
studs or adequate wall structure.

3. The mounting bracket has (4) holes on 16" centers as
shown in Figure 2.1. This is intended to give installers
the ability to mount the bracket on two wall studs
spaced at this interval. If existing wall studs are spaced
differently or if the desired location is not in line with
the wall studs additional support is required.

4. Install the two ½"-13 by 4" bolts supplied with the
boiler into the weld nuts in the base of the unit. The
depth that these are threaded into the base can be
adjusted to assure the proper level of the boiler. Adjust
the bolts until the unit is tilted slightly off level to the
rear to aid in condensate draining.

5. Be sure that the wall provides adequate support for
the boiler.

6. Be sure to adequately support the boiler while
installing external piping or other connections.

7. Be sure that condensate piping is routed to a suitable
drain or condensate pump.

BOILER SET-UP

2. BOILER SET-UP

The wall mounting bracket is designed to support the
boiler. External piping for water, venting, air intake
and fuel supply is to be supported separately

WARNING

Figure 2.1: Wall Mounting Bracket

This boiler must be installed level to prevent
condensate from backing up inside the boiler.

CAUTION

Make sure the boiler wall bracket is adequately
supported. Do not install this bracket on dry wall
unless adequately supported by wall studs.

WARNING

8

A. GENERAL

1. Install the Series PBC™ boiler venting system in
accordance with these instructions and with the National
Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA B149,
and/or applicable provisions of local building codes.

2. The Series PBC™ boiler is a direct vent appliance and
is ETL Listed as a Category IV appliance with Intertek
Testing Laboratories, Inc.

3. Sources of combustion air contaminated with chlorine,
ammonia or alkali agents must be avoided. Do not
install this boiler near a swimming pool, hot tubs or
laundry. Do not store chemicals near the boiler.

4. The Exhaust Vent and Air Intake adapters are
provided loose inside of the boiler cabinet and must be
installed securely using the provided screws and
gaskets. See Figure 3.1 below for proper orientation.

Ensure that the vent adapter is fully inserted in the
heat exchanger outlet gasket and that the foam seal is
installed between the jacket and the flange of the adapter.

B. APPROVED MATERIALS

1. Table 3.1 lists approved materials for vent pipe (and
adhesives where applicable). Use only these materials
for exhaust vent piping.

2. PVC pipe and fittings are not to be used for venting in
confined spaces such as closet installations. Use only
CPVC or polypropylene (InnoFlue or PolyPro) vent
pipe under these conditions.

3. Cellular core piping is approved for inlet air piping only.

* PVC pipe/fittings are not to be used for venting within

confined spaces.

Notice: Installations in Canada require compliance with
ULC S636 - Standard for Type BH Gas Venting Systems.

VENTING & AIR INLET PIPING

3. VENTING & AIR INLET PIPING

This vent system operates under positive pressure.
Vent connectors serving appliances vented by
natural draft shall not be connected into any portion
of this venting system. Failure to comply may result
in serious injury, death or major property damage.

WARNING

Only the materials listed below are approved for use
with the Series PBC™ boiler. Use only these
components in accordance with these instructions.
Failure to use the correct material may result in
serious injury, death, or major property damage.

WARNING

Table 3.1: Approved Materials for Exhaust Vent Pipe

Description Material

Conforming to

Standard

Vent Piping

& Fittings

PVC (Sch 40 or 80)* ANSI/ASTM D1785

CPVC (Sch 40 or 80) ANSI/ASTM F441

PVC-DWV*

ANSI/ASTM D2665

Duravent FastNSeal

®

AL29-4C Stainless

Steel

UL1738 & ULC-S6

PolyPro

®

(Polypropylene)

ULC-S636

InnoFlue

®

(Polypropylene)

ULC-S636

Z-DENS

®

(Polypropylene)

ULC-S636

Pipe Cement

(PVC & CPVC Only)

PVC/CPVC Cement ANSI/ASTM D2564

Figure 3.1: Exhaust and Air Intake Location and

installation

Improper installation of the Vent adapter could result in
the escape of combustion products causing severe
personal injury, death or major property damage.

WARNING

- All 3” SCH40 PVC applications require 9 inches of
straight vent pipe between the vent adapter the first
elbow.

- All 2” SCH40 PVC applications require the first 10
equivalent feet to be of CPVC material

NOTICE

The venting system for this product is to be installed in
strict accordance with these venting instructions.
Failure to install the vent system properly may result in
severe personal injury, death or major property damage.

WARNING

9

C. EXHAUST VENT/AIR INTAKE PIPE

LOCATION

1. Install vent piping before installing water, fuel, or
condensate piping. Working from largest to smallest
diameter reduces the complexity of piping
interferences.

2. Vent and air intake piping is to be installed so that
there is sufficient access for routine inspection as
required in Section 11, of this manual.

3. The vent piping for this boiler is approved for zero
clearance to combustible construction. However, a fire
stop must be used where the vent pipe penetrates
walls or ceilings.

4. The Peerless

®

Series PBC™ boiler, like all high
efficiency, gas-fired appliances, is likely to produce a
vapor plume due to condensation. Surfaces near the
vent termination will likely become coated with
condensation.

5. Air Intake Pipe Location – Sidewall Venting:
a. Provide 1 foot (30 cm) clearance from the bottom

of the air intake pipe to the level of maximum
snow accumulation. Snow removal may be
necessary to maintain clearances.

b. Do not locate air intake pipe in a parking area

where machinery may damage the pipe.

c. Maintain a minimum of 8" horizontal distance

between exhaust vent and the air intake.
Increasing this distance minimizes the potential for
contamination of the inlet air with exhaust.

d. For multiple boiler installations, the minimum

horizontal distance between the inlet of one boiler
to the exhaust of an adjacent boiler is 8" center-to­center. In addition, the minimum vertical distance
between the exhaust and air inlet is 6". See Figure

3.2 for an illustration.

e. The exhaust outlet of the vent pipe should not be

angled any more than 5º from horizontal.

f. Precautions should be taken to prevent

recirculation of flue gases to the air inlet pipe of
the boiler or other adjacent appliances.

7. Sidewall Venting Configuration:
a. See Figure 3.3 for an illustration of clearances for

location of exit terminals of direct-vent venting
systems.

VENTING & AIR INLET PIPING

Figure 3.3: Exit Terminal Location for Mechanical Draft and Direct-Vent Venting Systems

If the maximum equivalent vent length is exceeded,
the maximum burner input rate may be reduced.

NOTICE

Use of cellular core PVC (ASTM F891), cellular core
CPVC, or Radel

®

(polyphenolsulphone) for exhaust
vent is prohibited. Use of these materials as exhaust
vent may result in severe personal injury, death, or
major property damage.

WARNING

Figure 3.2: Vent Pipe Spacing for Multiple Series

PBC™ Boilers

10

• This boiler vent system shall terminate at least
3 feet (0.9 m) above any forced air inlet
located within 10 ft (3 m). Note: This does not
apply to the combustion air intake of a direct­vent appliance.

• Provide a minimum of 1 foot (30 cm) distance
from any door, operable window, or gravity
intake into any building.

• Provide a minimum of 1 foot (30 cm) clearance
from the bottom of the exit terminal above the
expected snow accumulation level. Snow
removal may be required to maintain clearance.

• Provide a minimum of 4 feet (1.22 m)
horizontal clearance from electrical meters, gas
meters, gas regulators, and relief equipment. In
no case shall the exit terminal be above or
below the aforementioned equipment unless
the 4 foot horizontal distance is maintained.

• Do not locate the exhaust exit terminal over
public walkways where condensate could drip
and create a hazard or nuisance.

• When adjacent to public walkways, locate the
exit terminal at least 7 feet above grade.

• Do not locate the exhaust termination directly
under roof overhangs to prevent icicles from
forming or recirculation of exhaust gases from
occurring.

• Provide 3 feet clearance from the inside corner
of adjacent walls.

b. Figures 3.4 through 3.7 show approved sidewall

venting configurations using the standard fittings
supplied.

c. Figure 3.5 is only approved for locations in which

the outdoor temperature is above -5°F (-21°C) in
accordance with ASHRAE 90A-1980
recommendations.

d. Figure 3.8 shows approved sidewall vent

configuration using an optional concentric vent
termination kit. 2" (54837) or 3" (54498).

8. Vertical Venting Configuration:
a. Figure 3.9 shows the approved venting

configuration for vertical venting using the
standard fittings supplied.

b. Locate the air intake pipe inlet a minimum of 12"

above the expected snow accumulation on the
roof surface.

c. Locate the end of the exhaust vent pipe a minimum

of 12" above the inlet to the air intake pipe.

d. Figure 3.10 shows an approved vertical vent

configuration using the optional concentric vent
termination kit.

VENTING & AIR INLET PIPING

Figure 3.4: Standard Exhaust & Air Inlet Pipe

Terminations

Figure 3.5: Offset Exhaust and Air Inlet

Terminations

Condensing flue gases can freeze on exterior
building surfaces which may cause discoloration and
degradation of the surfaces.

CAUTION

11

Figure 3.6: Exhaust and Air Inlet on Opposite Walls

Figure 3.7: Sidewall Exhaust with Indoor Air

Figure 3.8: Optional Concentric Vent Kit

Installation

VENTING & AIR INLET PIPING

12

e. Figure 3.11 shows an option for routing the

exhaust and air inlet piping through an unused
chimney.

f. Figure 3.12 shows this option using inlet air from

a sidewall position.

g. Figure 3.13 shows an option for routing the

exhaust through an unused chimney with the
combustion air supplied from inside the building.
Be sure to note the requirements for combustion
air as listed under Section 1.D. “Combustion and
Ventilation Air”. These requirements are in
accordance with the National Fuel Gas Code.

D. EXHAUST VENT/AIR INTAKE PIPE SIZING

1. Series PBC™ boilers can be installed with 2" or 3"

Exhaust Vent/Air Intake piping with the vent length
restrictions shown in table 3.2 below. 2" applications
require a 3" initial connection with a reduction to 2"
venting.

2. Polypropylene vent systems can be installed using the

vent adapters provided with the boiler. The adapters
are compatible with 3" PVC or CPVC, 3" or 80mm
polypropylene and 3" AL-29-4C grade stainless steel.

Figure 3.9: Standard Vertical Vent Installation

VENTING & AIR INLET PIPING

Figure 3.10: Concentric Vertical Vent Installation

Figure 3.11: Venting Through a Chimney Using

Outside Air

3. Combined systems using separate polypropylene
exhaust & air inlet pipes which transitions to concentric
can also be installed. Contact you Centrotherm,
Duravent or NovaFlex representative for more
information.

4. All 2" SCH40 PVC applications require the

first 10 equivalent feet to be of CPVC or
Polypropylene material.

a. The equivalent length of elbows, tees and other

fittings are listed in Table 3.3.

E. EXHAUST VENT/AIR INTAKE INSTALLATION

1. Figures 12.1 & 12.2 show the exhaust connection on
top of the boiler, near the rear in the center.

a. The exhaust connection for PBC-34™, PBC-40™,

and PBC-52™ boilers is a 3" polypropylene adapter
that will accept PVC, polypropylene or AL29-4C
stainless steel piping. All materials are secured using
the built in band clamp. Tighten securely. DO NO
USE CEMENT ON BOILER CONNECTIONS.

b. All PVC/CPVC connections after the boiler

connection are to be joined with suitable
PVC/CPVC adhesives in accordance with
manufacturers’ instructions.

13

VENTING & AIR INLET PIPING

Figure 3.12: Venting Through a Chimney Using

Sidewall Outside Air

Figure 3.13: Venting with a Chimney Using Inside Air

Maximum Allowable Vent Length (Ft)

2" (60mm) Diameter

Feet (Meters)

3" (60mm) Diameter

Feet (Meters)

PBC-34

60 (18.28) 100 (30.48)

PBC-40

60 (18.28) 100 (30.48)

PBC-52

20 (6.1) 100 (30.48)

Table 3.2: Maximum Allowable Vent Length for

Series PBC™ Boiler Installations

Equivalent Length (Feet)

Vent Size

2" Vent

3" Vent

Elbow, 90°

7 feet

5 feet

Elbow, 45°

4 feet

3 feet

Coupling

0 feet

0 feet

Air Intake Tee

0 feet

0 feet

Concentric Vent Kit

3 feet

3 feet

Table 3.3: Equivalent Length of Fittings

Exhaust Vent/Air Intake length in excess of maximum
listed equivalent feet may result in reduced input due
to excessive pressure drop.

NOTICE

Covering non-metallic exhaust venting material is
prohibited and may result in severe personal injury,
death, or major property damage.

WARNING

14

2. The Air Intake connection is to the right of the exhaust.

3. Remove all burrs and debris from the joints and
fittings.

4. Horizontal lengths of exhaust vent must be installed
with a slope of not less than 1/4" per foot (21 mm per
meter) toward the boiler to allow condensate to drain
from the vent pipe. If the vent pipe must be piped
around an obstacle that causes a low point in the
piping, a drain with an appropriate trap must be
installed.

5. All piping must be fully supported. Use pipe hangers at
a minimum of 4 foot (1.22 meter) intervals to prevent
sagging of the pipe.

6. Exhaust and air inlet piping is to be supported
separately and should not apply force to the boiler.

7. Penetration openings around the vent pipe and air
intake piping are to be fully sealed to prevent exhaust
gases from entering building structures.

8. PVC & CPVC Piping:

a. Use only solid PVC or CPVC Schedule 40 or 80

pipe for exhaust venting. Cellular core PVC or
CPVC is not approved for exhaust vent.

b. All joints in vent pipe, fittings, and all vent

termination joints must be properly cleaned,
primed and cemented. Use only cement and
primer approved for use with PVC or CPVC pipe
that conforms to ANSI/ASTM D2564. Boiler
connections do NOT require cement.

c. A straight coupling is to be used as an

outside vent termination. One of the two
screens is to be installed to prevent birds or
rodents from entering.

d. An air intake tee should be used as an air intake

termination. A screen is to be installed to prevent
birds or rodents from entering.

e. The following are optional combination air

intake/exhaust terminations that are available
separately from your PB Heat, LLC distributor for
use with Series PBC™ boilers.

f. Refer to Figures 3.4 through 3.8 for sidewall

venting options using PVC or CPVC pipe.

g. Refer to Figures 3.9 through 3.13 for vertical

venting options using PVC or CPVC pipe.

F. EXHAUST TAPPING FOR VENT SAMPLE

To properly install the Series PBC™ boiler, carbon dioxide
(CO2) and carbon monoxide (CO) levels in the exhaust
vent must be determined from a sample of combustion
products. To do this use the built in sampling port in the
3-in-1 adapters. Be sure to replace the cap after sampling
the combustions.

G. BOILER REMOVAL FROM COMMON

VENTING SYSTEM

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

Retrait de la chaudière d’un système d’évacuation
commun. 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:

1. Seal any unused openings in the common venting
system.

Sceller toute ouverture du système d’évacuation
commun non utilisée.

2. 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.

3. 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.

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.

4. 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.

VENTING & AIR INLET PIPING

3" 2"

Description

Stock

Code Description

Stock
Code

Sidewall Termination Kit
– PolyPro 3PPS-HK

54498

Sidewall Termination Kit
– PolyPro 2PPS-HKL

54837

Vertical Vent Termination
Kit – PolyPro 3PPS-VK

54500

Vertical Vent Termination
Kit – PolyPro 2PPS-VKL

54838

Table 3.4: Concentric Vent Termination Kits

This appliance uses a positive pressure venting
system. All joints must be sealed completely to
prevent leakage of flue products into living spaces.
Failure to do this may result in severe personal injury,
death or major property damage.

WARNING

15

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.

5. Close fireplace dampers.

Ne pas faire fonctionner les ventilateurs aspirant d’été.
Fermer les registres de foyers.

6. 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.

7. 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.

8. 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.

9. Any improper operation of the common venting system
should be corrected so that the installation conforms
with the National Fuel Gas Code, ANSI Z223.1/NFPA
54 or CAN/CGA B149 Installation Codes.

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.

10. When resizing any portion of the common venting
system, the common venting system should be resized
to approach minimum size as determined using the
appropriate tables located in the chapter “Sizing of
Category I Venting Systems,” of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 or CAN/CGA B149
Installation codes.

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.

VENTING & AIR INLET PIPING

16

A. GENERAL

1. Size water supply and return piping in accordance
with system requirements rather than the boiler
connections.

2. If the Series PBC™ boiler is used to replace an existing
boiler, make sure the system piping is thoroughly
cleaned and free from debris before installing this boiler.
Sentinel Performance Solutions (http://www.sentinel­solutions.net/us/) offers a full line of cleaners (X300),
sludge remover (X400), antifreeze (X500) and
corrosion inhibitors (X100/X500) for hydronic
applications.

3. In hydronic systems where sediment may exist, install
a strainer in the boiler return piping to prevent large
particles and pipe scale from entering the boiler heat
exchanger. Use a large mesh screen in the strainer.

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

5. The Series PBC™ heating boiler is intended for use in
a closed-loop hydronic system. Leaks in the piping
system may require constant make-up water which
may include oxygen, calcium and other substances
which may cause corrosion, calcium scale buildup, or
other attacks on the hydronic system piping. The
system water should have a pH value of between 8.2
and 9.5. The water hardness is to be maintained
between 50 ppm CaCO

3

(3 gr/gal) and 150 ppm

CaCO

3

(9 gr/gal). Also, a minimum water pressure of

14.5 psi is required for proper performance.

B. OPERATING PARAMETERS

1. The Series PBC™ boiler is designed to operate in a
closed loop hydronic system under forced circulation.
This requires the system to be completely filled with
water and requires a minimum water flow through the
boiler to operate effectively.

2. The minimum system pressure is 11.6 psig (80 kPa).
The maximum allowable pressure is 40 psig (275 kPa).

3. The recommended minimum system pressure for
optimal operation at higher temperature is 14.5 psi
(100kPa).

4. The internal pump is sized appropriately to allow for
the minimum flow rate required through the heat
exchanger. Ensure that the piping up to the boiler is
capable of handling a minimum flow rate of 5.0 GPM
to allow for proper flow rates when the boiler is in
CH mode.

C. SYSTEM COMPONENTS

Figure 4.1 shows the symbol key for piping diagrams in
this section. The following are brief descriptions of system
components.

1. Pressure/Temperature Gauge: A combination
pressure/temperature gauge is provided with each
Series PBC™ boiler to be mounted in the piping from
the boiler supply to the system as shown in Figures

4.2 & 4.3. Most local codes require this gauge.

2. Air Elimination: Closed loop hydronic systems require
air elimination devices. As the system water is heated,
dissolved oxygen and other gases will separate from
the liquid. An air elimination device (such as a TACO
Vortech

®

Air Separator) is required to remove the
dissolved gases preventing corrosion in the piping
system and eliminating noise.

3. Expansion Tank: An expansion tank (such as a Bell &
Gossett Series HFT) is required to provide room for
expansion of the heating medium (water or glycol
solution). Consult the expansion tank manufacturer's
instructions for specific information regarding
installation. The expansion tank is to be sized for the
required system volume and capacity. In addition, be
sure that the expansion tank is sized based on the
proper heating medium. Glycol solutions may expand
more than water for a similar temperature rise.

WATER PIPING AND CONTROLS

4. WATER PIPING & CONTROLS

Use only inhibited propylene glycol solutions which
are specifically formulated for hydronic systems.
Unlike automotive antifreeze, solutions for hydronic
applications contain corrosion inhibitors that will
protect system components from premature failure
due to corrosion.

CAUTION

Maximum Flow Rates and Input

Steel Pipe

Pipe Size Maximum Flow (GPM) BTU/HR

1/2"

2 15,000

3/4"

4 40,000

1"

8 80,000

1-1/4"

16 140,000

1-1/2"

25 220,000

2"

50 450,000

Copper Tubing

Tube Size

Maximum Flow (GPM) BTU/HR

1/2"

1.50 15,000

3/4"

4 40,000

1"

8 80,000

1-1/4"

14 140,000

1-1/2"

22 220,000

2"

45 450,000

Table 4.1: Guide of Maximum Flow Rates for

Different Pipe Sizes with Input

17

4. Y-Type Strainer or Filter Ball®Valve: PB Heat recommends
the use of a strainer device in the system to prevent dirt or
sediment from clogging the heat exchanger. A 20 mesh
stainless steel screen is adequate to protect the heat
exchanger. The strainer should be cleaned often in the first
several months of operation. The Filter Ball

®

Valve from
Jomar International incorporates a strainer into a ball
valve which allows the technician to isolate the water
circuit while cleaning the strainer.

5. Flow Control Valve: Flow control valves such as the
TACO Flo-Chek or Bell & Gossett Flo-Control™ are
used to prevent gravity circulation by incorporating a
check valve with a weighted disc.

6. Pressure Reducing Valve: A pressure reducing valve,
such as the Bell & Gossett B-38 or a TACO #329, is
used in a hydronic system to automatically feed water
to the system whenever pressure in the system drops
below the pressure setting of the valve. These valves
should not be used on glycol systems unless close
supervision of the glycol solution is practiced.

7. Back Flow Preventer: A back flow preventer (check
valve) is required by some jurisdictions to prevent water
in the hydronic system from backing up into the city
water supply. This is especially important on systems in
which glycol solution is used as the heating medium.

8. Pressure Relief Valve: The boiler pressure relief valve
is shipped separately for field installation. The valve is
to be installed as shown in Figures 4.2 or 4.3. Pipe the
discharge of the relief valve to within 12" of the floor
and close to a floor drain. Provide piping that is the
same size or larger than the relief valve outlet.

WATER PIPING AND CONTROLS

Figure 4.1: Piping Symbol Key

Use only inhibited propylene glycol solutions which
are specifically formulated for hydronic systems.
Ethylene glycol is toxic and may cause an
environmental hazard if a leak or spill occurs.

WARNING

Do not operate this appliance without installing the
pressure relief valve supplied with the boiler or one
with sufficient relieving capacity in accordance with
the ASME Rating Plate on the boiler heat exchanger.

WARNING

Pipe the discharge of the relief valve as close as
possible to the floor and away from high traffic areas.
Pipe the discharge to a floor drain. Failure to do so
may result in personal injury and/or property
damage.

CAUTION

9. Low Water Cut Off: When installing a probe type
LWCO, locate the LWCO in the boiler supply above
the top jacket panel. Refer to Section 7. Electrical
Connection in this manual for wiring details.

10. Circulator: The Central Heat circulator is to be sized
to overcome the pressure drop of the system while
providing the flow required by the boiler. The PBC™
Series boilers have a built in circulator that guarantees
the minimum flow rate is maintained through the unit.

D. SYSTEM PIPING

The following section describes the piping requirements
for the Series PBC™ boilers as well as some best practices
that will improve the operation and lifetime of the unit.
See Figure 4.6 and 4.7 for suggested boiler piping for
Central Heat and Domestic.

1. Central Heat Piping
a. Primary secondary piping required - Series

PBC™ boilers utilize a water tube heat exchanger
that requires a minimum flow rate through the
unit. The internal pump provides enough flow to
maintain this minimum flow rate. For the pump to
consistently perform the boiler must be piped in a
primary/secondary fashion.

18

WATER PIPING AND CONTROLS

Figure 4.5: ScaleCutter®Water Treatment System

for Domestic Water Plate Heat
Exchanger Protection.

Figure 4.2: Water and Condensate Connection

Points

Figure 4.4: Final Piping Example with Webstone

Plumb Kit.

For existing systems that use iron pipe for heating
piping, the installation of a magnetic filter and a Y­Type strainer is highly recommended. A modulating
condensing boiler such as the Series PBC™ when
operating at ideal system temperatures can cause
scaling to release from older iron pipe systems that
will cause restrictions in the heat exchanger
passages.

NOTICE

Figure 4.3: Safety Relief Valve Location

19

i. Use closely spaced tees, less than 4 pipe

diameters apart.

ii. Use a low loss header system or a hydronic

separator such as a Caleffi 548 series.

b. Central Heat Circulator-A properly sized

circulator should be installed to provide heat out
to the system off of the Primary secondary header.

Piping Recommendations:

- Use 6 wraps of Teflon tape on the supply and
return connections if using a direct NPT
adapter.

- Use two 45° elbows to offset the CH piping
either in front of or behind the domestic water
piping. This allows for easy installation of a
shutoff and cleaning kit along with a domestic
relief valve.

c. PB Heat recommends treating the boiler loop

water with water treatment products such as those
made by Sentinel, Fernox, or other equivalent
water treatment systems to help extend the lifetime
of the heat exchangers.

2. Domestic Water Piping

a. The installer supplied temperature limiting device

must be installed consistent with local, national,
and international plumbing codes as well as the
device manufacturer’s instructions.

b. Additional temperature limiting devices may be

required at the domestic water fixtures in the
dwelling.

c. Choose the lowest practical DHW setpoint.

d. The domestic hot water can be piped directly off

of the structure’s main cold water supply.

e. It is required to install a filtration/water treatment

system before the boiler to protect the plate heat
exchanger from scale build up. This is good
practice even in areas with high quality water to
extend the life of the heat exchanger PB Heat
recommends products such as those made by
ScaleCutter

®

(shown in Figure 4.5) or other
equivalent water treatment systems to improve the
water quality before it enters the boiler.

f. A properly sized safety relief valve (not provided) is

required on the domestic outlet side of the boiler.

g. A drain valve should be located immediately

before the domestic inlet and after the domestic
outlet of the boiler. This allows for easy flushing
and descaling of the plate heat exchanger. A set of
shutoff valves should be placed before the
domestic inlet drain valve and after the domestic
outlet drain valves as well in order to isolate the
rest of the domestic supply to the structure (as
shown in Figure 4.7). Domestic water service
valve kits, like Webstone kit 4443WPR or other
similar valve kits, meet the needs listed above.

Flow Restriction:

All Series PBC™ boilers contain a built-in flow
restrictor on the domestic water side of the boiler.
This restrictor protects the flow sensor from
abnormal wear and contains a screen filter to
protect against large sediment. Regular
maintenance of this screen is recommended. See
Section 11 for further maintenance instructions.

The Flow restrictor is sized at 4.75 gallons per
minute. If it is found that an application for the
PBC-52™ requires additional DHW flow rate, the
flow regulator can be removed if the following
conditions are met:

1. An inline filter is installed prior to the Domestic
Inlet connection of the unit.

2. DHW flow rate is limited to 6.5 GPM or below
through the boiler by some means.

E. FREEZE PROTECTION

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

2. Use only inhibited polypropylene glycol solutions of
up to 50% by volume. Ethylene glycol is toxic and
can chemically attack gaskets and seals used in
hydronic system.

3. The anti-freeze solution should be tested at least once
per year and as recommended by the manufacturer of
the product.

4. Anti-freeze solutions expand more than water. For
example, a 50% by volume solution expands 4.8%
with a 148°F temperature rise while water expands
about 3% for the same temperature increase.
Allowance for this expansion must be considered in
sizing expansion tanks and related components.

5. The flow rate in systems utilizing glycol solutions
should be higher than in a water system to
compensate for decreased heating capacity of the fluid.

WATER PIPING AND CONTROLS

Series PBC™

Model

Boiler Input

Btu/hr (kW)

Gross Output

Btu/hr (kW)

PBC-34™ 80,000 (23.4) 76,000 (22.3)
PBC-40™ 100,000 (29.3) 95,000 (27.8)
PBC-52™ 120,000 (35.2) 114,000 (33.4)

Table 4.2: Series PBC™ Series Heating Input and

Gross Outputs

⚠

DANGER

– Water temperatures over 125°F

– (52°C) can cause severe burns
– instantly, or death from scalds.

– Children, the disabled, and the

– elderly are at the highest risk of
– being scalded.

– Feel water before bathing or showering.

– Read this manual in its entirety before setting

domestic hot water setpoint.

– A temperature limiting device (listed to ASSE 1070

or ASSE 1017) is required.

20

WATER PIPING AND CONTROLS

Figure 4.6: Recommended Central Heat Piping

21

Figure 4.7: Recommended Domestic Hot Water Piping

WATER PIPING AND CONTROLS

6. Due to increased flow rate and fluid viscosity, the
circulator head requirement will increase. Contact the
pump manufacturer to correctly size the circulator for
a particular application based on the glycol
concentration and heating requirements.

7. A strainer, sediment trap, or some other means for
cleaning the piping system must be provided. It
should be located in the return line upstream of the
boiler and must be cleaned frequently during the
initial operation of the system. Glycol is likely to
remove mill scale from new pipe in new installations.

8. Glycol solution is expensive and leaks should be
avoided. Weld or solder joints should be used where
possible and threaded joints should be avoided.
Make-up water should not be added to the system
automatically when glycol solution is used. Adding
make-up water will dilute the system and reduce the
ability of the solution to protect from freezing.

9. Check local regulations to see if systems containing
glycol solutions must include a back-flow preventer or
require that the glycol system be isolated from the
water supply.

10. Do not use galvanized pipe in glycol systems.

11. Use water that is low in mineral content and make
sure that there are no petroleum products in the
solution.

a. Less than 50 ppm of calcium

b. Less than 50 ppm of magnesium

c. Less than 100 ppm (5 grains/gallon) of total

hardness

d. Less than 25 ppm of chloride

e. Less than 25 ppm of sulfate

12. Check with the local water supplier for chemical
properties of the water.

13. The following test will determine if the water is of the
appropriate hardness. Collect a sample of 50% water
to 50% propylene glycol. Let the solution stand for 8­12 hours shaking it occasionally. If white sediment
forms, the water is too hard and should not be used
to dilute the glycol.

14. Mix the solution at room temperature.

15. Do not use a chromate treatment.

16. Refer to Technical Topics #2a published by the
Hydronics Institute for further glycol system
considerations.

22

WATER PIPING AND CONTROLS

23

A. GENERAL

1. All fuel piping to the Series PBC™ boiler is to be 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 fuel piping to provide a supply of gas
sufficient to meet the maximum demand of all
appliances supplied by the piping.

3. Series PBC™ boilers are intended for operation with
Natural Gas or Propane with sulfur content of less than
105 ppm (150 mg/m

3

) peak with an annual average of

less than 20 ppm (30 mg/m

3

). Excessive sulfur content
in fuel input can result in black deposits resembling
coffee grounds in the combustion chamber of the boiler.

B. FUEL LINE SIZING

1. The required flow rate of gas fuel to the boiler can be
determined by the following.

The gas heating value can be supplied by the gas
supplier.

2. As an alternative, use Table 5.1 to determine the
required gas flow rate which uses typical heating values
for natural gas and liquefied petroleum (LP) gas.

3. Table 5.1 shows the maximum flow capacity of
several pipe sizes based on 0.3" of pressure drop.

a. The values shown are based on a gas specific

gravity of 0.60 (Typical for natural gas).

b. Multiply the capacities listed by the correction

factors listed for gas with a specific gravity other
than 0.60 to obtain the corrected capacity.

4. Size and install the fuel gas supply piping for no more
than 0.5 inches of water pressure drop between the
gas regulator and the boiler.

C. GAS SUPPLY PIPING - INSTALLATION

FUEL PIPING

5. FUEL PIPING

Pipe

Length

ft (m)

1/2" NPT

Pipe

3/4" NPT

Pipe

1" NPT

Pipe

1-1/4"

NPT
Pipe

1-1/2"

NPT
Pipe

10

(3.0)

132

(3.7)

278

(7.9)

520

(14.7)

1,050
(29.7)

1,600
(45.3)

20

(6.1)

92

(2.6)

190

(5.4)

350

(9.9)

730

(20.7)

1,100
(31.1)

30

(9.1)

73

(2.1)

152

(4.3)

285

(8.1)

590

(16.7)

890

(25.2)

40

(12.2)

63

(1.8)

130

(3.7)

245

(6.9)

500

(14.2)

760

(21.5)

50

(15.2)

56

(1.6)

115

(3.3)

215

(6.1)

440

(12.5)

670

(19.0)

60

(18.3)

50

(1.4)

105

(3.0)

195

(5.5)

400

(11.3)

610

(17.3)

70

(21.3)

46

(1.3)

96

(2.7)

180

(5.1)

370

(10.5)

560

(15.9)

80

(24.4)

43

(1.2)

90

(2.5)

170

(4.8)

350

(9.9)

530

(15.0)

90

(27.4)

40

(1.1)

84

(2.4)

160

(4.5)

320

(9.1)

490

(13.9)

100

(30.5)

38

(1.1)

79

(2.2)

150

(4.2)

305

(8.6)

460

(13.0)

The values are based on a specific gravity of 0.60 (typical for
natural gas). See Table 4.3 for capacity correction factors for
gases with other specific gravities.

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

Table 5.1: Pipe Capacity:

Maximum Capacity of pipe in cubic feet per hour (cubic meters
per hour) with a pressure drop of 0.3" of water (75 Pa).

Boiler Input Rate

Gas Heating Value

Input Rate

(

ft

³

/

hr

)

=

(

Btu

/

hr

)

(

Btu

/

ft

³

)

Figure 5.1: Suggested Near Boiler Gas Piping

Use a backing wrench on the gas valve inside of the
unit when threading the gas pipe into the gas valve
flange. Over torqueing the gas valve can cause
damage to the blower, gas valve or other components
inside the unit.

CAUTION

24

1. Do not install any piping directly in front of the boiler
or along either side. Always provide access to the
front cover and side panel openings.

2. Install a sediment trap as shown in Figure 5.1. Be sure
to allow clearance from the floor or other horizontal
surface for removal of the pipe cap.

* Natural gas input rates are based on 1,000 Btu/ft

3

, LP input

rates are based on 2,500 Btu/ft

3

.

3. Install a ground joint union between the sediment trap
and the boiler to allow service to the appliance.

4. Install a service valve as shown in Figure 5.1 to allow
the gas supply to be interrupted for service.

5. Maintain a minimum distance of 10 pipe diameters
between the gas pressure regulator and the boiler.

6. Check all gas piping for leaks prior to placing the
boiler in operation. Use an approved gas detector,
non-corrosive lead detection fluid, or other leak
detection method. If leaks are found, turn off gas flow
and repair as necessary.

7. Figure 5.1 shows the gas shutoff valve for the Series
PBC™ boiler. This valve is to be used in addition to
the gas service valve shown upstream of the sediment
trap.

D. GAS SUPPLY PIPING - OPERATION

1. The gas line must be properly purged of air to allow
the boiler to operate properly. Failure to do so may
result in burner ignition problems.

2. Table 5.3 shows the maximum and minimum fuel gas
supply pressure to be measured at the gas valve inlet
pressure tap. See figure 5.2.

a. Gas pressure below 3.5 inches of water column for

Natural gas and 8 inches of water column for LP
gas may result in ignition failures and hard
ignitions.

b. Gas pressure above 13.5 inches of water may

result in damage to the automatic gas valve.

3. To check the gas supply pressure to the gas valve:
a. Turn off the power at the service switch.

b. Close the gas shutoff valve.

c. Using a flat screwdriver, turn the screw inside the

inlet tap fitting (see Figure 5.2) one turn counter
clockwise.

d. Attach the tube from the manometer to the

pressure tap fitting.

e. Open the gas valve and start the boiler.

f. Read and record the gas pressure while the boiler

is firing at max input as well as with any other
appliances to the same gas line at their maximum
inputs.

g. Turn off the boiler and close the gas shutoff valve.

h. Remove the manometer tube from the pressure

tap fitting.

i. Turn the internal screw clockwise to close the

valve.

j. Turn on the gas shutoff valve and boiler service

switch.

k. Fire the boiler and check for fuel gas odor around

the gas valve. If an odor is evident check to make
sure that the pressure tap fitting is closed.

4. All gas piping must be leak tested prior to placing the

boiler in operation.

a. If the leak test pressure requirement is higher than

13.5 inches of water column, the boiler must be
isolated from the gas supply piping system.

b. If the gas valve is exposed to pressure exceeding

13.5 inches of water column, the gas valve must
be replaced.

5. Install the boiler such that the gas ignition system

components are protected from water (dripping,
spraying, rain, etc.) during operation and service
(circulator replacement, condensate collector and
neutralizer cleanout, control replacement etc.)

E. MAIN GAS VALVE - OPERATION

1. Figure 5.2 is an illustration of the gas valve/venturi

assembly for the Series PBC™ boiler.

a. Adjustments should not be made to the gas valve

without instrumentation to measure carbon
dioxide (CO

2

) and carbon monoxide (CO)

emissions in the vent pipe.

b. Turning the throttle screw clockwise will decrease

the gas flow (decreasing CO

2

) and turning it
counterclockwise will increase the gas flow rate
(increasing CO

2

). Markings adjacent to the throttle

screw show + and – indicating this operation.

c. The recommended CO

2

settings are given in Table

5.4. In no case should the boiler be allowed to
operate with CO emissions above 200 ppm.

FUEL PIPING

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

WARNING

Do not subject the gas valve to more that 1/2 psi
(13.5" W.C.) of pressure. Doing so may damage the
gas valve.

CAUTION

Fuel Type

Pressure Inches W.C. (Pa)

Minimum Maximum

Natural Gas 3.5 13.5

LP Gas 8 13.5

Table 5.2: Maximum and Minimum Fuel Pressure

Use a pipe joint sealing compound that is resistant to
liquefied petroleum gas. A non-resistant compound
may lose sealing ability in the presence of this gas,
resulting in a gas leak. Gas leaks may potentially
cause an explosion or fire.

WARNING

2. Refer to Section 3, Venting and Air Intake for
information on obtaining vent samples from this
boiler.

25

FUEL PIPING

Natural Gas Propane (LP)

Low Fire High Fire Low Fire High Fire

Carbon

Monoxide

(CO)

< 75 ppm < 200 ppm < 75 ppm < 200 ppm

Carbon
Dioxide

(CO

2

)

8.8% to

11.6%

8.5% to

9.7%

9.8% to

12.5%

9.5% to

10.5%

Table 5.3: Recommended CO2Settings

Figure 5.3: PBC-40/52™ Gas Valve and Venturi

Detail

Figure 5.2: PBC-34™ Gas Valve and Venturi Detail

26

A. GENERAL

1. The disposal of all condensate into public sewage
systems is to be in accordance with local codes and
regulations. In the absence of such codes, follow these
instructions.

2. Proper piping and removal of condensation from
combustion is critical to the operation of a condensing
appliance. Follow these instructions carefully to assure
that your Series PBC™ boiler operates correctly.

3. Depending on several factors, the condensate from
gas fired condensing appliances may have a pH value
as low as 2.5 (similar to cola soft drinks). Some local
codes require the use of neutralization equipment to
treat acidic condensate.

B. CONDENSATE SYSTEM

The condensate system for the Series PBC™ is designed
to prevent condensate back-up into the heat exchanger
and the passage of flue gases through the system.

The condensate trap must be installed by the installer:

1. The condensate trap is installed in the condensate
drain hole in the front left side of the unit

2. Insert the barbed and thread portion on the top of the
trap through the hole and secure using the 3/4" G
plastic locknut.

3. Press the condensate drain hose onto the barbed
fitting on the trap and secure using the provided hose
clamp.

4. The condensate traps outlet is a compression fitting
compatible with 3/4" SCH40 PVC piping, 3/4" clear
PVC tubing, as well as 1" flexible corrugated tubing.

CONDENSATE DRAIN PIPING

6. CONDENSATE DRAIN PIPING

Figure 6.1: Condensate Trap System

Failure to or improper installation of the condensate
trap will cause the release of combustion products
into the dwelling leading to severe injury or death.

WARNING

Ensure the blocked vent pressure tap is not
dislodged while attaching the condensate drain.

NOTICE

Condensate from a condensing boiler is highly acidic.
A condensate neutralization system is required by
many local codes and is highly recommended. Older
homes with cast iron or metal drain systems are
highly susceptible to damage and eventual failure if
condensate is not treated properly before disposal.

WARNING

27

A. GENERAL

This appliance is to be wired in accordance with local
codes and regulations as defined by the Authority having
jurisdiction. In the absence of such local codes, the Series
PBC™ boiler is to be wired in accordance with the latest
edition of the National Electrical Code, ANSI/NFPA 70.

B. CUSTOMER CONNECTIONS

1. Electrical knockouts are provided on the top panel of
the boiler to connect supply wiring, circulator wiring
and wiring to various instruments. There are
additional optional knockouts located in the bottom
of the boiler for circulator wiring.

2. Electrical terminals are located in the top right portion
of the unit.

3. Figure 7.2 shows customer connections and wiring
schematic for the Series PBC™ boiler.

a. All Low voltage terminals are on the right terminal

strip.

b. All Line voltage connections are on the left

terminal strip.

c. The orange jumper is to be removed if a 120V

connection to an external LWCO is used. This
connection will disable power to the boiler if the
LWCO is activated and is not meant to power the
external LWCO at this time.

4. An Outdoor Sensor is provided with the Series PBC™
boilers. It must be installed for the unit to operate
properly and to maximize the efficiency of the unit. A
warning message will be displayed on the display of
the Outdoor Sensor is not installed in the default
central heat mode.

a. Connect the sensor to terminals 3 and 4 on the

right hand terminal strip.

b. The sensor should be installed in a location outside

the dwelling that is protected from harsh weather
conditions, such as driving rain and accumulated
snow, and not exposed to direct sunlight.

C. INTERNAL WIRING

Figure 7.2 also shows all internal wiring and sensors for
Series PBC™ boilers.

1. User Interface: The user interface, 975LB Display, is
attached to the front of the electrical panel and is
accessible through the front panel. This interface
allows users and installer to access information on the
boiler operation and change settings on the control.
(See Section 8 for more information).

2. Return Sensors: : This component, located on the right
side of the Combination Hydronic Block (CHB), above
the pump cartridge, monitors the return temperature
inside the boiler loop. The thermistor is a 10 kΩ NTC
immersion Sensor with a bayonet style connection.
Only use a factory provided Series PBC™ return
sensor.

3. Dual Supply Sensor: This component is located on
the left side of the boiler attached to the copper
portion of the supply line. There are two 10 kΩ NTC
sensors in the sensor body that allows it to function as
the boiler safety limit. The 975 control monitors the
deviation between the two sensor readings. If the
deviation is too large the control will shut down the
boiler. This ensures that the supply temperature is
accurate.

4. Flue Sensor: This thermistor provide flue temperature
information to the control. It is located on the top of
the heat exchanger in the front of the vent outlet. The
sensor uses a quarter turn bayonet connection. Use
care if replacing as the plastic housing can be
damaged.

5. Blocked Vent/Condensate PressureSswitch: This
switch is used to determine if there is a blockage in
the vent system and also if there is a blockage in the
condensate drain line after the condensate trap. A rise
in condensate greater than 3.5" above the pressure
switch tap with open the switch.

6. Service Switch: The service switch interrupts the
power to the Series PBC™ boiler to allow service to
be performed.

7. Flame Sensor: The flame sensor uses the principal of
flame rectification to sense the burner flame. This is
located on the right side of the heat exchanger burner
door.

8. Gas Valve: The gas valve is connected through a
special cord and connector. The PBC-40™ and
PBC-52™ connector is secured with a screw.

ELECTRICAL CONNECTIONS

7. ELECTRICAL CONNECTIONS

Figure 7.1: Figure 7.1: High Temperature Limit

Location

28

9. Ignition Electrode: This electrode is located on the left
side of the burner door. A high voltage charge is
provided by the external spark generator to provide
spark for lighting the burner.

10. Combustion Air Blower: The combustion air blower
has two connections. There is a 120 Volt power
connection (3-wire) and a low voltage control
connection (4-Wire). Disconnecting the control wires
will run the blower at full speed.

11. External Spark Generator: The generator is located
on the inside of the electrical panel above the main
control. It receives 120 volts from the main control
and transforms it into a high voltage spark across the
ignition electrode.

12. PC Communication Adapter (Green Plug): This
connection allows Factory Engineers to review control
settings and view advanced diagnostic features.

13. Domestic Supply Sensor: This component is located
on the lower left side of the CHB unit. It is the same
10 kΩ NTC immersion sensor with a bayonet style
connection as the return sensor. The control uses this
sensor to target the domestic hot water setpoint when
the unit is operating in DHW mode.

14. Rotary Flow Sensor: This component is located on
the CHB unit just to the left of the pump cartridge.
When a flow greater than 0.4 gallons per minute is
detected the boiler will fire in DHW mode to provide
domestic hot water.

15. Stepper Motor: The stepper motor is located in the
CHB behind the flow sensor. The motor controls the
position of the diverting valve in the CHB that
determines where the boiler loop supply water can
flow. The stepper motor defaults to the DHW position
for faster response times.

16. Pressure Sensor: The pressure sensor is located on the
left hand side of the CHB unit. It provides a live
readout of the system pressure to the main control
and user interface. The control will not operate the
boiler if the pressure falls below 11.6 psig. This feature
is acceptable as a LWCO in some locations. Check
your local codes.

17. Pump Cartridge: The pump is located on the CHB
unit. The Series PBC™ boiler is equipped with a
Grundfos UPS15-78 pump head that provides all
internal flow requirements for the boiler. It can be
replaced by any UPS series pump cartridge.

ELECTRICAL CONNECTIONS

Maximum Amp Draw for Circulator pumps on the
PBC-34/40/52™ is 3.5 amps total for boiler pump and
CH pump.

NOTICE

IF the fuse blows in the boiler control, a spare fuse
(found in a holder on the control cover) can be used
as a replacement. DIAGNOSE POSSIBLE CAUSES
FOR BLOWN FUSE BEFORE REPLACING. Additional
fuses can be ordered as need from your Peerless
Boiler Distributor (Part #5562). See Figure 7.2 for
location of Boiler Control fuse and spare fuse.

NOTICE

29

Figure 7.2: Wiring Schematic and Connection

ELECTRICAL CONNECTIONS

30

A. CONTROL OVERVIEW

The Series PBC™ boiler control is one of the primary
safety devices for the boiler. It controls:

• Ignition sequence

• Temperature Limits

• Circulators

• Gas Flow

• Setpoints

• Domestic Hot Water Valve

• Fan Speed

• LWCO (When optional LWCO probe is used)

B. AVAILABLE CENTRAL HEAT MODES

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.1: Series PBC™ Central Heat Modes

8. BOILER CONTROL: INTERNAL
WIRING & OPERATION

Central

Heating

Mode

Mode Description

Mode Operation Restrictions

0

Fixed Setpoint

–

Demand initiated by T/TT closure

–

User chosen fixed setpoint

–

Boiler targets CH setpoint and operates of Supply temperature
hysteresis when demand is present

Not for space heating

1

Outdoor reset with Thermostat

–

Demand initiated by T/TT closure

–

Setpoint is calculated based off of Outdoor temperature and CH
demand period to improve fuel usage and boiler efficiency.

–

Setpoint Boost function for long CH demand periods.

–

Boiler targets calculated CH setpoint and operates off of Supply
temperature hysteresis when demand is present

–

When the Boost Function was active and CH demand is not present,
the CH setpoint decreases back to the calculated setpoint.

No restrictions

2

Outdoor reset with Permanent
Demand

–

Demand initiated by control logic. Always present.

–

Setpoint is calculated based off of Outdoor temperature to improve
fuel usage and boiler efficiency.

–

Boiler targets calculated CH setpoint and operates off of Supply
temperature hysteresis.

–

When CH demand is not present, calculated setpoint decreases
gradually.

No restrictions

3

Fixed Setpoint with Permanent
Demand

–

Demand initiated by control logic. Always present.

–

User chosen fixed setpoint

–

Boiler maintains CH setpoint and operates of Supply temperature
hysteresis

Not for space heating

*While accessible via the Installer menu, CH Modes 4 and 5 are not functional with the Series PBC™ boiler.

C. AVAILABLE DOMESTIC HOT WATER

MODES

D. DISPLAY UTILIZATION

31

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.2: Series PBC™ Domestic Hot Water Modes

Central

Heating

Mode

Mode Description

Mode Operation

0

No Domestic Hot Water

–

Disables DHW sensor and functionality.

–

Boiler will function only for Central Heat.

5

Instantaneous Domestic Hot Water

–

Demand initiated by Domestic Flow Sensor detecting an open tap.

–

Boiler Targets user chosen DHW setpoint.

–

30 min domestic hot water priority (installer adjustable).

–

Domestic hot water pre-heat.

*While accessible via the Installer menu, DHW modes 2, 3, 4, 6, 7, and 8 are not functional with the Series PBC™ boiler.

Figure 8.1: 900LB Display Buttons

Table 8.3: Display Button Functions

Button

Default Screen

Menu Selection- User/Installer Level Lockout

L1

Adjust CH setpoint up
(CH Mode 0 and 3 only)

Back

None

L2

Adjust CH setpoint down
(CH Mode 0 and 3 only)

Back

None

R1

Adjust DHW setpoint up

Change Selection Up

None

R2

Adjust DHW setpoint down

Change Selection Down

None

M

Enter Menu Selection

Enter menu
Select item for change,
Confirm change (return to menu selection)
Confirm PIN digit (Password menu)

Hold for Manual Reset

(2sec)

32

BOILER CONTROL: INTERNAL WIRING & OPERATION

Figure 8.2: 900LB Display Buttons

Table 8.4: Display Icon Descriptions

Icon #

Description and Use

Default Screen

Menu Selection

1

–

CH loop water pressure and/or Outdoor temperature.

–

OUTSIDE is lit when temperature is shown. Pressure unit is lit when
pressure is shown.

–

Alternates every 2 seconds

–

Special Status codes

• “ALEg”- Anti-Legionella active

• “Loc”- Boiler in Lockout state

• “Err”- Boiler in Blocking error state

• “AttE”- Non-blocking warning present requiring attention.

–

Menu or Parameter number

–

“CODE” when PIN input is enabled

2

–

CH Temperature

–

DHW Temperature

–

Special Status Code number

–

Parameter value

–

Blinking parameter value- Parameter actively being
adjusted

3

–

Units of value being displayed by Icon #2

Not used

4

–

Pressure unit when Icon #1 is displaying CH loop water pressure

–

“OUTSIDE” when Icon #1 is displaying Outdoor Temperature

Not used

5

–

Shown when Central Heat is enabled

–

Flashing when CH demand is being handled

Not used

6

–

Shown when Domestic Hot Water is enabled

–

Flashing when DHW demand is being handled

Not used

7

–

Flashing when service is required Not used

8

–

Shown when burner is ON

9

–

Shown when appliance is unable to start. Lockout or Blocking error
present

Not used

10

–

Shown when Frost Protection is active Not used

11

–

Shown when Outdoor Reset is active

Not used

E. USER MENU

The User menu is accessible from the default screen by
pressing the M button once to enter the menu level
selection screen and pressing M again when “0000” is
shown in the small digits.

The User Menus allow access to basic setpoints, system
test, and unit settings. Use buttons R1 and R2 to move
between parameters.

F. STATUS MENU – 1000 LEVEL

The Status Menu is accessible from the default screen by
pressing the M button once to enter the menu level
selection screen. Using R1 and R2, select “1000” in the
small digit area. Press M to enter the Status Menu.

The Status Menu allows for in-depth boiler information to
be viewed but cannot access parameters for modification.

33

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.5: User Menus (0000 Level)

User

(0000)

Parameters

Parameter Function

Units/Options

0003

–

CH Setpoint, CH enable/disable

Temperature

0048

–

DHW Setpoint, DHW enable/disable

Temperature

0200

–

10 minute System Test. Once 10 minute timer is over boiler
will return to normal state.

–

Additional Access with Installer access PIN

–

Input installer PIN using CODE menu then return to User
Menu for advanced system test functions.

–

OFF-System Test Disabled

–

FAN-Test blower (fixed speed)

–Lo-

Test burner at low power

–

Ign-Test burner at igniton power

–Hi-

Test burner on high power

–

REg-Test burner at high power with supply setpoint enabled

Installer level only:
–

Stb-Test maximal thermostat

–

LCO1-Test Low Water Cut-off 1

0901

–

Temperature unit setting °C/°F

0902

–

Pressure unit setting Bar/psi

0997

–

Screen Test

– Pressing select activates all LCD options

No options

Table 8.6: Status Menus (1000 Level)

Status
(1000)

Parameters

Parameter Function

Value/Options

1001

Supply temperature Temperature

1002

DHW temperature Temperature

1004

Outside temperature Temperature

1005

2nd Supply temperature Temperature

1006

Flue temperature Temperature

1007

Return temperature Temperature

1008

Ionization / flame current µA

1010

CH Pump On/Off

1012

Actual CH setpoint Temperature

1013

Room Thermostat (RT) input Open/Closed

34

Table 8.6 (cont.): Status Menus (1000 Level)

Status
(1000)

Parameters

Parameter Function

Value/Options

1030

State #

1031

Error Number #

1033

CH Pressure Pressure

1040

Actual fan speed RPM

1041

Ignition fan speed RPM

1042

Minimum fan speed RPM

1043

Maximum fan speed RPM

1051

Last lockout error number #

1052

Last blocking error number #

1053

Number of flame failures #

1054

Number of successful ignitions #

1055

Number of failed ignitions #

1056

Total hours of operation for CH Hours x 10

1057

Total hours of operation for DHW Hours x 10

1058

Total system run time Days

1059

Interval between lockout

1:MIN
2:HRS
3:DAY

4:WK

1060

Interval between blocking error

1:MIN
2:HRS
3:DAY

4:WK

1061

Instantaneous turbine speed (value used to measure parameter 1062) RPM

1062

Water flow (rate) l/min

1063

0-10V input Volt

1098

975MN Group number Hexadecimal

1099

975MN CRC (Software Version) Hexadecimal

1995

975LB CRC (Software Version) Hexadecimal

BOILER CONTROL: INTERNAL WIRING & OPERATION

G. INSTALLER MENU – 2000 LEVEL

The Installer Menu is accessible by inputting the proper
PIN number into screen CODE of the User Menu. When
CODE is the parameter selected press the M button. Use
the R1 and R2 buttons to select the proper number for
the flashing place in the PIN. Pressing M will advanced to
the next digit. If an incorrect number is selected, it is
required to cycle through all four places with the M button
to return and correct the number.

Once the 4 digit passcode has been entered, press L1 or
L2 until the menu selection screen is shown. Press R1 or
R2 until 2000 is shown in the small digits. Press M to
enter the Installer Menu

35

Table 8.7: Installer Menus (2000 Level)

Status
(2000)

Parameters

Parameter Function

Unit/Value

Default

Options

2001

Central Heat Mode

# 1

2003

CH Setpoint

°F 160

2005

CH Post Purge –Circulator

Seconds 10

2007

CH Hysteresis UP

–

Controls Boiler shutoff point above Setpoint

°F 9

2009

Anti-cycling period

–

Delay period during which boiler will not fire the burner if a supply temperature of CH
Setpoint + CH Hysteresis is reached during a single demand period.

Seconds 180

2010

Anti-cycling Differential

–

Supply temperature drop below CH setpoint that must be reached before the burner will fire
if a supply temperature of CH Setpoint + CH Hysteresis is reached during a single demand
period.

–

Overrides Anti-Cycling Period

°F 16

2014

Maximum CH Power

–

Limits maximum CH input available to the control to satisfy a demand

–

Default values should not be changed

%

PBC-34™: 57
PBC-40™: 61
PBC-52™: 54

2015

Minimum CH Power

–

Limits the minimum power available to the boiler to satisfy a demand

% 1

2019

Boiler Supply Design Temperature

–

Sets the reset curve design temperature that will be targeted when the outdoor temperature
is at the chosen outdoor design temperature.

–

For default: Boiler will target 190°F when the outdoor temperature is 23°F or lower.

°F 190

2020

Outdoor Design Temperature

–

Sets the Outdoor Temperature at which the boiler will target the Boiler Supply Design
Temperature.

–

For default: Boiler will target 190°F when the outdoor temperature is 23°F or lower.

°F 23

2021

Boiler Mild Weather Temperature

–

Sets the reset curve design temperature that will be targeted when the outdoor temperature
is at the Outdoor Mild Weather temperature.

–

For default: Boiler will target 104°F when the outdoor temperature is 68°F.

°F 104

2022

Mild Weather Design Outdoor Temperature

–

Sets the Outdoor Temperature at which the boiler will target the Boiler Mild Weather Design
Temperature.

–

For default: Boiler will target 104°F when the outdoor temperature is 68°F.

°F 68

2023

Maximum CH Setpoint –Design Supply Maximum (limit)

–

Sets upper limit of Calculated CH setpoint

–

Calculated CH setpoint will always be at or below this value

°F 68

2024

Minimum CH Setpoint –Design Supply minimum (limit)

–

Sets lower limit of Calculated CH setpoint

–

Calculated CH setpoint will always be at or above this value

°F 190

BOILER CONTROL: INTERNAL WIRING & OPERATION

Installer Code is 0231

NOTICE

Status
(2000)

Parameters

Parameter Function

Unit/Value

Default

Options

2025

Warm Weather Shutdown Temperature

–

Outdoor temperature that will block all CH demands until temperature falls below this value

°F 72

2026

Boost Function: Increment

–

Calculated Setpoint increase after boost delay time period is met

–

Boost will continually increase setpoint every boost time period until demand is met or
Maximum CH Setpoint design limit is reached.

°F 5

2027

Boost Function: Delay

–

Time delay before boost function activates during a single demand

Minutes 20

2028

CH Night Setback Temperature

–

Calculated CH Setpoint setback value when the Night Setback Function is activated

°F 10

2035

DHW mode

# 5

2036

NON FUNCTIONAL

2037

NON FUNCTIONAL

2038

NON FUNCTIONAL

2042

Domestic Hot Water Priority

–

Does not function for Series PBC™ Applications

0/1/2/3 2

2043

Domestic Hot Water Priority Time

–

Does not function in Series PBC™ Applications

Minutes 60

2044

DHW Post Purge- Circulator

Seconds 10

2048

DHW Setpoint

°F 122

2064

Preheat Mode

–

0: OFF

–

1: Anti Frost –plate heat exchanger is kept above 41°F

–

2: Eco Mode –plate heat exchanger is kept above 86°F for faster response at expense of
fuel utilization.

–

3: Comfort Mode –plate heat exchanger is kept at DHW for fastest response at greatest
expense to fuel utilization

# 1

2091

Maximum DHW Setpoint °F 176

2096

Minimum DHW Setpoint °F

2109

CH Calculated Setpoint Offset

–

Allows the manual adjustment of the Calculated CH Setpoint by this value

°F 0

2110

Minimum CH Setpoint °F 68

2111

Maximum CH Setpoint °F 190

2112

CH Hysteresis Down °F 9

2113

Maximum DHW Power

–

Limits the maximum available input to the boiler to satisfy DHW demands

% 100

2114

Minimum DHW Power

–

Limits the minimum available input to the boiler to satisfy DHW demands

% 1

2115

NON FUNCTIONAL

2124

-FACTORY SET. DO NOT CHANGE

-WARNING: CHANGING THESE SETTINGS
WILL CAUSE BOILER TO NOT OPERATE
PROPERLY

# 0

2125

# 2

2126

# 9

2127

# 0

2128

# 0

2129

# 0

2130

Flow Scaling Factor

–

NON FUNCTIONAL

2131

Minimum CH Loop Pressure

–

Pressure at Boiler will shut down after “FILL” warning will appears

PSI 10.2

36

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.7 (cont.): Installer Menus (2000 Level)

37

H. MENU LEVELS 3000, 4000 AND 5000

Menu levels 3000, 4000 and 5000 are non-functional for
the Series PBC™ and shouldn’t be modified.

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.7 (cont.): Installer Menus (2000 Level)

Status
(2000)

Parameters

Parameter Function

Unit/Value

Default

Options

2132

Fill Hysteresis

–

NON FUNCTIONAL

2133

NON FUNCTIONAL

2134

NON FUNCTIONAL

2135

NON FUNCTIONAL

2136

NON FUNCTIONAL

2137

NON FUNCTIONAL

2138

Appliance Mode

–

Determines Fan Speeds of appliance

–

ALWAYS ENSURE THIS SETTING MATCHES THE UNIT BEING INSTALLED

–

WARNING: FAILURE TO PROPERLY SET THE APPLIANCE MODE CAN LEAD
TO BOILER FAILURE CAUSING PROPERTY DAMAGE, SEVERE PERSONNEL
INJURY OR DEATH

#

PBC-34- 50
PBC-40- 51
PBC-52- 52

2139

De-Air Functionality

–

On power cycle the unit will go through a period of 3 minutes of pump cycling to drive air
out of the system

Enable/Disable Enable

2140

NON FUNCTIONAL

2141

NON FUNCTIONAL

2201

CH Enable Setting

–

Enables or Disables Central Heat Boiler Functions

Enable/Disable Enable

2202

DHW Enable Setting

–

Enables or Disables Domestic Hot Water Boiler Functions

Enable/Disable Enable

2203

Service Remainder Setting

–

Allows for a service notification to be displayed after the Service Days time period is met

ON/OFF/Reset OFF

2204

Service Days Days 0

38

I. OUTDOOR RESET OPERATION

All Series PBC™ boilers come with the default Central
Heat mode set to outdoor reset with room thermostat
(ODR). This feature uses the information from the
provided Outdoor Sensor to automatically adjust the
boiler setpoint based on the required heat load on the
building as the outdoor temperature changes. Figure 8.3
above visualizes the curve that is controlled by parameters
2019 through 2027.

1. The Boiler Design Temperature (2019) and Outdoor
Design Temperature (2020) control the maximum
setpoint and the temperature at which it will be
targeted.

2. The Boiler Mild Weather Temperature (2021) and
Outdoor Mild Weather Temperature (2022) control the
minimum setpoint and temperature at which it will be
targeted

3. The Minimum CH setpoint (2023) controls how low
the calculated setpoint can fall.

4. The maximum CH setpoint (2024) controls how high
the calculated setpoint can rise when boost is active.

5. The Mild Weather Shutdown Temperature (2025)
allow for control over what outdoor temperature the
boiler will begin ignoring CH demands.

6. The Boost Function Increment (2026) allows for control
over how aggressively the Boost function will increase
the calculated setpoint after the boost delay is met.

7. The Boost Function Delay allows for control over the
timeframe the CH demand must be present without
the call being satisfied before the Boost Function will
begin increasing the calculated setpoint.

Figure 8.3: Outdoor Reset Curve Logic

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.8: Outdoor Reset Parameters

Status
(2000)

Parameters

Parameter Function

Unit/Value

Default

Options

2019

Boiler Supply Design Temperature

–

Sets the reset curve design temperature that will be targeted when the outdoor temperature
is at the chosen outdoor design temperature.

–

For default: Boiler will target 190°F when the outdoor temperature is 23°F or lower.

°F 190

2020

Outdoor Design Temperature

–

Sets the Outdoor Temperature at which the boiler will target the Boiler Supply Design
Temperature.

–

For default: Boiler will target 190°F when the outdoor temperature is 23°F or lower.

°F 23

2021

Boiler Mild Weather Temperature

–

Sets the reset curve design temperature that will be targeted when the outdoor temperature
is at the Outdoor Mild Weather temperature.

–

For default: Boiler will target 104°F when the outdoor temperature is 68°F.

°F 104

39

J. IGNITION SEQUENCE

Figure 8.4 shows a typical ignition and burn cycle for the
Series PBC™ boiler. Pre-purge and Post Pure periods are
shown in a compressed fashion to show the ignition
process in detail.

1. Boiler receives a demand either CH or DHW

2. Blower ramps up to ignition speed and hold for Pre­purge period of 7 seconds

3. Spark is initiated 1 second before gas valve

4. Gas valve opens

5. Gas valve remains open for flame proving period. If
no flame is detected, the gas valve closes and the
blower moves to Post-purge.

6. If flame is detected, the boiler will begin to modulate
to maintain setpoint until the demand is removed.

7. Once demand is removed, gas valve closes and
blower moves to Post-purge for 10 seconds.

8. After Post-purge, blower shuts down and awaits next
demand.

Table 8.8 (cont.): Outdoor Reset Parameters

Status
(2000)

Parameters

Parameter Function

Unit/Value

Default

Options

2022

Mild Weather Design Outdoor Temperature

–

Sets the Outdoor Temperature at which the boiler will target the Boiler Mild Weather Design
Temperature.

–

For default: Boiler will target 104°F when the outdoor temperature is 68°F.

°F 68

2023

Minimum CH Setpoint –Design Supply minimum (limit)

–

Sets lower limit of Calculated CH setpoint

–

Calculated CH setpoint will always be at or above this value

°F 190

2024

Maximum CH Setpoint –Design Supply Maximum (limit)

–

Sets upper limit of Calculated CH setpoint

–

Calculated CH setpoint will always be at or below this value

°F 68

2025

Warm Weather Shutdown Temperature

–

Outdoor temperature that will block all CH demands until temperature falls below this value

°F 72

2026

Boost Function: Increment

–

Calculated Setpoint increase after boost delay time period is met

–

Boost will continually increase setpoint every boost time period until demand is met or
Maximum CH Setpoint design limit is reached.

°F 5

2027

Boost Function: Delay

–

Time delay before boost function activates during a single demand

Minutes 20

BOILER CONTROL: INTERNAL WIRING & OPERATION

Figure 8.4: Ignition Sequence

40

K. ADDITIONAL SAFETY FUNCTIONS

1. Ignition Failure Protection: The Series PBC™ control
allows for 3 failed ignition attempts before the control
goes into a lockout state showing Loc 1. This lockout
can be reset by holding the Menu button until “rst”
appears on the display or by pressing the manual
reset button below the control state LED on the main
control board.

2. Flame Failure Protection: The Series PBC™ control
allows monitors for flame failure during a demand. If
the flame signal is lost more than 3 times during a
single demand the control will go into a lockout state
showing Loc 22. This lockout can be reset by holding
the Menu button until “rst” appears on the display or
by pressing the manual reset button below the control
state LED on the main control board.

3. Flue Temperature Protection: Series PBC™ control
monitors the flue temperature sensor for high
temperatures. If the flue temperature approaches
190°F (88°C), the boiler will begin to modulate input
down regardless of setpoint or demand. If the flue
temperature reaches 190°F (89°C) the boiler will shut
down and run the blower for 5 minutes before re­ignition.

4. Flame Recovery: The Series PBC™ control actively
monitors the ionization current though the flame
sensor. If Flame Signal drops to below 1.5 µA, the
control will increase the minimum fan speed in order
to attempt to maintain flame signal. If this fails, the
control will retry with a further increased minimum fan
speed. If a second flame loss occurs, the control will
retry again at ignition fan speed as the minimum. If at
any point the demand is met the control will reset the
minimum fan speed to default.

5. Stayburn and Startburn Temperatures: When the
supply temperature of the boiler exceeds the maximum
boiler setpoint due to the off hysteresis of 9°F and a
demand is still present, the Series PBC™ control
allows the unit to run at 1% input until the Stayburn
temperature is reached at 190°F (88°F). The boiler will
always shutdown at this temperature and will never
exceed it. The Series PBC™ is not designed to run
beyond this temperature. Steps should be taken to
improve the system to lower the required setpoint if
the Stayburn Temperature is ever reached. The boiler
will not re-ignite until the Startburn temperature is
reached below the setpoint. The Startburn
Temperature is 185°F (85°C).

6. Frost Protection: The Series PBC™ control monitors
the unit for potential freeze situation which would
cause damage to the internal piping of the unit. If the
water temperature inside the unit falls below 41°F
(5°C) the boiler pump will start. If the temperature
continues to fall the burner will ignite to and heat the
unit until the supply temperature reaches 59°F (15°C).

7. Filling Protection: The Series PBC™ control monitors
the system pressure for drops below the required
system pressure of 11.6psig. Pressures below 17.5 psig
will cause the pressure display on the unit to flash as a
warning. Pressures below 10.15 psig will cause the
boiler to shut down and display a “FILL” error. The
unit will not run until the pressure is again above the
minimum pressure

8. De-air: Upon boiler power initiation, the Series PBC™
control will enter a de-air state during which it will
purge any air remaining in the system by cycling the
pump on and off and changing the position of the
switching valve. This period lasts for 4 minutes. It can
be canceled by holding buttons L2 and R2 for 3
seconds simultaneously.

9. Low Water Cut Off: The Series PBC™ control comes
equipped with a probe style LWCO function built into
the control. With the addition of the optional LWCO
probe kit installed in the piping above the boiler, the
control will monitor for low water conditions. If such a
condition occurs the control will go into a lockout
state and must be manually reset.

10. Flue Pressure and Block Condensate Switch: The
Series PBC™ control monitors a pressure switch that
will enter the boiler into a blocking state. This switch
will display Err 156. Clearing of the flue or
condensate line will automatically clear this error.

BOILER CONTROL: INTERNAL WIRING & OPERATION

41

A. GENERAL

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

2. Verify that the water piping, venting & air intake
piping, gas piping, electrical wiring and electrical
components are installed in accordance with the
manufacturer’s instructions. Be sure that the boiler is
installed in accordance with this manual and good
engineering practice.

3. Turn on electricity and gas to the boiler.

B. CHECK WATER PIPING

1. Fill the boiler and system with water, making certain
to purge all air from the system. Open each vent in
the system until all air is released and water begins to
be discharged. Then close the vent.

2. Attach the provided 5/16" hose to the barb tapping in
the top left portion of the heat exchanger. While
holding the open end of the hose into a bucket,
loosen the manual air vent until air begins to flow.
Once all air has been purged and only water is
draining, close the manual air vent and remove
the hose.

3. The pressure reducing valve on the fill line will
typically allow the system to be pressurized to 12 PSI.
Consult manufacturers instructions for operation of
the valve and expansion tank. Adjustment of the
system pressure will most likely be required to meet
the 17.5 psig requirement of the control. Lower
system pressures run the risk of steam flashing in the
unit when a high setpoint and low temperature delta
is present. System fill pressure and expansion tank
should be adjusted.

4. Check joints and fittings throughout the system and
repair as required.

C. CHECK GAS PIPING

1. Turn on gas to the boiler using the shut-off valve
upstream of the sediment trap. Be sure that the gas
shut-off valve supplied with the boiler is in the closed
position.

2. Connect a manometer to the gas supply upstream of
the supplied manual gas valve.

3. Confirm that the gas supply pressure to the boiler is
between the minimum and maximum values as
indicated in Section 5.

4. If a supply pressure check is required, isolate the
boiler and gas valve before performing the pressure
test. If the supply pressure is too high or too low,
contact the fuel gas supplier.

5. Double check the fuel gas supply pressure after the
boiler is running to be sure that the pressure doesn’t
drop off significantly under operation.

D. CHECK OPERATION

1. Either disconnect or set the CH thermostat to ensure
there is no call for heat. Also confirm there is no DHW
flow by shutting the isolation valve to the DHW inlet
connection.

2. Turn on electricity and all manual gas valves to the
boiler. Check to see if the LCD display is lit. The
control will display Supply temperature and water
pressure.

3. Refer to Section 8, Boiler Control, to set up the
control for the desired operation.

4. Use the ignition sequence, Figure 8.4 to follow the
light off and shutdown sequences and to assist in
troubleshooting operation problems. If the boiler does
not function properly, consult Section 10,
Troubleshooting.

5. After starting the boiler, be certain that all controls are
working properly and that the combustion is properly
set up. Paragraphs 6 and 7 below provide instructions
on how to do this.

6. Check that the boiler will shut down when the supply
water temperature reaches the control setpoint.

a. Note the boiler setpoint by accessing the Status

Menu and viewing parameter 1012.

b. Use the System Test Mode, parameter 0200 in the

User Menu to choose High Input Power.

c. Monitor the boiler temperature on the temperature

gauge (supplied for field mounting) and on the
Status display.

d. The boiler should shut down at the boiler setpoint

plus 10°F (5.6°C). If it does not shut down turn off
the boiler and contact your PB Heat representative.

7. Check combustion readings in the boiler vent pipe
utilizing the built in analysis port on the vent adapter
(White threaded cap).

9. START-UP PROCEDURE

START-UP PROCEDURE

Ensure the analysis port is tightly sealed once
combustion readings are taken. Leaving the port
unsealed will allow combustion products to vent into
the indoor space which can lead to severe injury or
death.

WARNING

Recommended system pressure is 17.5 psig. Adjust
expansion tank before filling system.

NOTICE

42

a. Using a combustion analyzer with the capability to

read carbon dioxide (CO2) and carbon monoxide
(CO), place the probe into the combustion test
port. See Figure 9.2.

b. Manually set the boiler to Maximum power by

entering the System Test Mode.

• Verify that the fan speed indicated is within 50
rpm of the maximum power fan speed in
Table 12.3. Status Menu parameter 1040.

• Verify that the CO and CO2 emissions are
within the parameters specified in Table 5.4.

c. Manually set the boiler to Low Power by entering

the System Test Mode.

• Verify that the fan speed indicated is within
100 rpm of the Low Power fan speed listed in
Table 12.3. Status Menu parameter 1040.

• Verify that the CO and CO

2

emissions are

within the parameters specified in Table 5.4.

d. If the values in either of these instances falls outside

the parameters listed in Table 5.4, turn off the
boiler and contact your PB Heat representative. For
best results, the value should be set for the middle
of the range (9% for Natural Gas and 10% for
LP Gas).

e. Be sure to set the System Test mode to Off so that

the boiler will modulate correctly in accordance
with the load.

f. After removing the analysis probe from the vent

pipe, securely screw the analysis port cap back
onto the vent adapter.

g. Record the combustion readings on the “Start-up

Combustion Record” in Appendix D. It is very
important to record all of the information
requested on the sheet for follow up and
troubleshooting.

START-UP PROCEDURE

To prevent moisture damage to control and blower:

During Boiler operation verify that there are no water leaks from any fittings on the boiler header and that
all vent connections are water tight and properly assembled.

NOTICE

E. LIGHTING & OPERATING PROCEDURES

43

START-UP PROCEDURE

44

TROUBLESHOOTING

A. LOCKOUT ERRORS

1. When a lockout error occurs the display will show
“Loc” followed by a number code.

2. Lockout codes require that the control be manually
reset either by holding the center reset button on the
display or by pressing the reset button on the main
control board itself.

3. Lockout errors should be investigated further to
determine the cause of the by a qualified service
technician.

B. BLOCKING ERRORS

1. When a blocking error occurs the display will show
“Err” followed by a number code.

2. Blocking errors will automatically clear if the condition
is corrected.

3. These error messages and some suggested actions are
listed in Table 10.2

C. WARNING ERRORS

1. When a warning error occurs the boiler display will
“Atte” followed by a number code.

2. Warning errors are a will automatically clear once the
condition is corrected and will not prevent the boiler
from operating.

3. Warning 204 is for Outdoor Sensor not Connected.
The Series PBC™ units will display this warning on
start-up if the provided outdoor sensor is not
connected.

D. TYPICAL OPERATION CYCLE –

CENTRAL HEAT

1. Boiler is in standby. No demand. Central Heat
Radiator symbol is constant.

2. Demand is applied. Central Heat Radiator symbol
begins flashing

3. Switching valve stepper motor extends to Central heat
position, boiler pump and CH pump start

4. Blower begins Pre-purge for 7 seconds at ignition
speed.

5. Spark engages 2 seconds

6. Gas valve opens.

7. Spark remains engaged for 2 more seconds.

8. Two second flame proving period holds valve open
while control checks for flame signal

9. Boiler holds at ignition speed for 10 seconds before
modulation begin.

10. Demand is met and removed.

11. Gas valve closes, Fan returns to ignition speed.

12. 10 second post purge period.

13. Switching valve returns to DHW position.

14. Pumps remain energized for pump post purge period.

15. Full unit standby

E. TYPICAL OPERATION CYCLE – DHW

1. Boiler is in standby. No demand. Domestic Faucet
symbol is constant.

2. Demand is applied when flow sensor detects hot
water flow. Domestic Faucet symbol begins flashing

3. Boiler pump starts

4. Blower begins Pre-purge for 7 seconds at ignition
speed.

5. Spark engages 2 seconds

6. Gas valve opens.

7. Spark remains engaged for 2 more seconds.

10. TROUBLESHOOTING

Figure 10.1: Additional Safety Locations

45

8. Two second flame proving period holds valve open
while control checks for flame signal

9. Boiler holds at ignition speed for 10 seconds before
modulation begin.

10. Demand is met and removed.

11. Gas valve closes, Fan returns to ignition speed.

12. 10 second post purge period.

13. Pump remain energized for pump post purge period.

14. Full unit standby

TROUBLESHOOTING

If overheating occurs or the gas supply fails to shut
off, do not turn off electrical power to the circulating
pump. This may aggravate the problem and increase
the likelihood of boiler damage. Instead, shut off the
gas supply to the boiler at the gas service valve.

CAUTION

DANGER

When servicing or replacing components that are in
direct contact with the boiler water, be certain that:

• There is no pressure in the boiler. (Pull the release
on the relief valve. Do not depend on the pressure
gauge reading).

• The boiler water is not hot.

• The electrical power is off.

When servicing or replacing any components of this
boiler be certain that:

• The gas is off.

• All electrical power is disconnected.

WARNING

Do not use this appliance if any part has been under
water. Improper or dangerous operation may result.
Contact a qualified service technician immediately to
inspect the boiler and to repair or replace any part of
the boiler which has been under water.

WARNING

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

CAUTION

Table 10.1: Lockout Codes

Error

Number

Error Display Corrective Action

0 E2PROM_READ_ERROR

Internal Software error. Replace control.

1 IGNIT_ERROR

Three unsuccessful ignition attempts in a row.

–

Check for spark by ear. Also check for 120V across the blue and brown control output wire
to the spark module. If not spark is present but voltage is. Replace module. If no voltage is
present check parameter 2126. Should be set to 9. If setting is correct, replace control.

–

Remove flame sensor and check for white build-up. Clean sensor, re-install and attempt
ignition. If ignition still fails perform other actions listed here. Replace sensor. If sensor
appears cracked or bent, replace sensor.

–

Confirm fuel pressure at the valve inlet when the valve is open. Low gas pressure can
cause ignition failures. High gas pressure can cause the valve to not operate and or
damage the valve.

2 GV_RELAY_ERROR

Failure detected in the Gas Valve Relay. Replace Control

3 SAFETY_RELAY_ERROR

Failure detected in the safety relay. Replace Control.

4 BLOCKING_TOO_LONG

Blocking error present for more than 20 hours.

–

Go to parameter 1052 for last blocking error code. Correct cause.

5 FAN_ERROR_NOT_RUNNING

Fan is not running for more than 60 secs.

–

Check fan condition by disconnecting the 5 pin control plug on the blower. Fan should
ramp to full power when the unit is turned on.

–

If fan does not power on, check for 120 volts across the brown and blue wires in the three
pin connector. If voltage is present, replace blower.

–

If fan powers on check for continuity through blower control harness, 5 pin connector to
J4 connector on control board. If continuity is found replace control. If no continuity is
found, replace harness.

46

TROUBLESHOOTING

Table 10.1 (contl): Lockout Codes

Error

Number

Error Display Corrective Action

6 FAN_ERROR_TOO_SLOW

Fan runs to slow for more than 60 seconds

–

Check voltage to the blower. A low voltage can cause the blower to run at the incorrect
speed due to lack of power. Replace blower if voltage is correct.

–

Check for continuity through blower control harness, 5 pin connector to J4 connector on
control board. If continuity is not found, replace harness.

–

Replace control if other actions do not correct issue.

7 FAN_ERROR_TOO_FAST

Fan runs to fast for more than 60 seconds

–

Check for continuity through blower control harness, 5 pin connector to J4 connector on
control board. If continuity is not found, replace harness.

–

Replace control if other actions do not correct issue.

8 RAM_ERROR

Internal software error. Replace Control.

9 WRONG_EEPROM_SIGNATURE

Contents of E2prom is not up to date. Replace Control.

10 E2PROM_ERROR

Wrong safety parameters in E2prom. Replace Control.

11 STATE_ERROR

Internal software error. Replace Control.

12 ROM_ERROR

Internal software error. Replace Control.

15 MAX_TEMP_ERROR

Thermal Fuse in the main heat exchanger body has tripped. This fuse should only open if

extreme conditions have occurred within the unit.
–

Replace Heat exchanger or entire boiler.

–

Check all safety limits and sensors before resuming operation of the unit.

–

Check target wall and burner door insulation for degradation on old heat exchanger.
Evidence of heavy recirculation.

–

Check internal pump operation.

16 FLUE_GAS_ERROR

Flue Temperature exceeded the maximum flue temperature limit (192.2°F (89°C)).

–

Lower system setpoint to decrease flue temperature.

–

Check temperature delta across the boiler supply and return. A low delta will cause
increased flue temperatures due to poor energy transfer.

17 STACK_ERROR

Internal software error. Replace Control.

18 INSTRUCTION_ERROR

Internal software error. Replace Control.

19 ION_CHECK_FAILED

Internal software error. Replace Control.

20 FLAME_OUT_TOO_LATE

Flame still present 10 seconds after closing the gas valve.

–

Check flame sensor for a short to ground. Replace sensor, sensor gasket or harness if short
is found.

–

Check solenoid on gas valve for operation. Gas valve might not be closing properly.
Replace gas valve.

21 FLAME_BEFORE_IGNIT

Flame is detected before ignition.

–

Check flame sensor for a short to ground. Replace sensor, sensor gasket or harness if short
is found.

23 CORRUPTED_ERROR_NR

Error code RAM byte was corrupted to an unknown error codes. Replace control

29 PSM_ERROR

Internal software error. Replace control.

30 REGISTER_ERROR

Internal software error. Repl;ace control.

33 LWCO_1_ERROR

Low water cut off error.

–

If using LWCO probe kit, check system for leaks and filling valve for operation. Check
wiring to LWCO probe and that the connector to the probe is securely attached. Check
grounding to piping where the LWCO probe is installed. Ensure that the probe is installed
in a location that is not collecting air.

–

If not using the LWCO probe kit, check the jumper across terminal 5 and 6 on the low
voltage terminal block. If broken replace with a 15 kΩ or similar resistor.

38 FLUE_PRESSURE_LOCKING

More than 3 Blocked Flue/ Condensate Switch in 24 hours.

–

Check for blockages in the vent pipe or heat exchanger.

–

Check for blockages in the condensate system inside or after the condensate trap. A slow
drainage of condensate could cause condensate back up that will trip this switch under
certain conditions.

47

TROUBLESHOOTING

Table 10.2: Blocking Errors

Error

Number

Error Display Corrective_ Action

100 WD_ERROR_RAM Internal software error. If error persists, replace control.

101 WD_ERROR_ROM Internal software error, If error persists, replace control.

102 WD_ERROR_STACK Internal software error. If error persists, replace control.

103 WD_ERROR_REGISTER Internal software error. If error persists, replace control.

104 WE_ERROR_XRL Internal software error. If error persists, replace control.

105 HIGH_TEMP_ERROR T_Supply and T_Supply_2 over Stayburn temperature of 190°F

106 REFHI_TOO_HIGH Internal hardware error. If error persists, replace control.

107 REFHI_TOO_LOW Internal hardware error. If error persists, replace control.

108 REFLO_TOO_HIGH Internal hardware error. If error persists, replace control.

109 REFLO_TOO_LOW Internal hardware error. If error persists, replace control.

110 REFHI2_TOO_HIGH Internal hardware error. If error persists, replace control.

111 REFHI2_TOO_LOW Internal hardware error. If error persists, replace control.

112 REFLO2_TOO_HIGH Internal hardware error. If error persists, replace control.

113 REFLO2_TOO_LOW Internal hardware error. If error persists, replace control.

114 FALSE_FLAME

Flame detected in a state in which no flame should be present.

–

Check flame sensor for a short to ground. Replace sensor, sensor gasket or harness
if short is found.

–

Check solenoid on gas valve for operation. Gas valve might not be closing
properly. Replace gas valve.

115 LOW_WATER_PRESSURE_ERROR

Low water pressure sensor error

–

Replace sensor if error does not correct itself

116 LOW_WATER_PRESSURE_SENSOR

Low water pressure in system

–

Check system pressure

–

Check filling valve setting and expansion tank pressure

–

Check system for leaks.

118 WD_COMM_ERROR Watchdog communication error. If error persists, replace control.

119 RETURN_OPEN

Return Sensor open

–

Check sensor wiring for solid connection and continuity. Replace harness if wiring
is bad.

–

Check for resistance though the sensor by touching meter leads across both pins
on the sensor. If no circuit is present replace sensor.

120 SUPPLY_OPEN

Supply Sensor 1 open

–

Check sensor wiring for solid connection and continuity. Replace harness if wiring
is bad.

–

Check for resistance though the sensor by touching meter leads across the left two
pins on the sensor using when the retaining clip is towards you. If no circuit is
present replace sensor.

121 SUPPLY2_OPEN

Supply Sensor 2 open

–

Check sensor wiring for solid connection and continuity. Replace harness if wiring
is bad.

–

Check for resistance though the sensor by touching meter leads across the right
two pins on the sensor using when the retaining clip is towards you. If no circuit is
present replace sensor.

122 DWH_OPEN

DHW Sensor open

–

Check sensor wiring for solid connection and continuity. Replace harness if wiring
is bad.

–

Check for resistance though the sensor by touching meter leads across both pins
on the sensor. If no circuit is present replace sensor.

123 FLUE_OPEN

Flue Sensor open

–

Check sensor wiring for solid connection and continuity. Replace harness if wiring
is bad.

–

Check for resistance though the sensor by touching meter leads across both pins
on the sensor. If no circuit is present replace sensor.

48

TROUBLESHOOTING

Table 10.2 (cont.): Blocking Errors

Error No. Error Display Corrective Action

125 OUTDOOR_OPEN

Outdoor Sensor open

–

Check sensor wiring for solid connection and continuity. Replace wiring if bad
or repair break.

–

Check for resistance though the sensor by touching meter leads across both
pins on the sensor. If no circuit is present replace sensor.

126 RETURN_SHORTED

Return Sensor Shorted

–

Check for resistance through the sensor by touching meter lead across both pins
on the sensor. Resistance should be between 15 kΩ and 500 Ω. If no resistance is
present replace sensor.

127 SUPPLY_SHORTED

Supply Sensor 1 Shorted

–

Check for resistance though the sensor by touching meter leads across the left
two pins on the sensor using when the retaining clip is towards you. . Resistance
should be between 15 kΩ and 500 Ω. If no resistance is present replace sensor.

128 SUPPLY2_SHORTED

Supply Sensor 2 Shorted

–

Check for resistance though the sensor by touching meter leads across the
left two pins on the sensor using when the retaining clip is towards you.
Resistance should be between 15 kΩ and 500 Ω. If no resistance is present
replace sensor.

129 DHW_SORTED

DHW Sensor Shorted

–

Check for resistance through the sensor by touching meter lead across both
pins on the sensor. Resistance should be between 15 kΩ and 500 Ω. If no
resistance is present replace sensor.

130 FLUE_SHORTED

Flue Sensor Shorted

–

Check for resistance through the sensor by touching meter lead across both
pins on the sensor. Resistance should be between 15 kΩ and 500 Ω. If no
resistance is present replace sensor.

132 OUTDOOR_SHORTED

Outdoor Sensor Shorted

–

Check for resistance through the sensor by touching meter lead across both
pins on the sensor. Resistance should be between 15 kΩ and 500 Ω. If no
resistance is present replace sensor.

133 NET_FREQ_ERROR Net freq. error detected by the watchdog. If error persists, replace control.

134 RESET_BUTTON_ERROR

TToo many resets in a short time period

–

Allow a 1 hour wait period for error to clear.

–

Cycle power

135 PHASE_NEUTRAL_RESERVED_ERROR

The line and neutral of the main voltage power supply input are reversed.

–

Check line in power polarity. Correct if reversed.

155 WD_CONFIG_ERROR Watchdog fan configuration setting error. If error persists, replace control.

156 FLUE_PRESSURE_ERROR

Blocked Flue/ Condensate Switch closed.

–

Check for blockages in the vent pipe or heat exchanger.

–

Check for blockages in the condensate system inside or after the
condensate trap. A slow drainage of condensate could cause condensate
back up that will trip this switch under certain conditions.

162 FILL_WARNING

Pressure is too low, demand has stopped, but no error needs to be stored at
this time

165 VSUPPLY_TOO_LOW

Main supply voltage too low for more than 60 seconds

–

Check supply voltage for values below 108 Volts

166 VSUPPLY_TOO_HIGH

Main supply voltage too high for more than 60 seconds

–

Check supply voltage or values above 132 Volts.

49

MAINTENANCE

11. 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.

50

MAINTENANCE

A. GENERAL (WITH BOILER IN USE)

General 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.

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

3. Observe operating temperature and pressure on the
combination gauge located in the supply piping on the
left side of the boiler. Boiler pressure should never be
higher than 5 psi below the rating shown on the safety
relief valve (25 psig maximum for a 30 psig rating).
Boiler temperature should never be higher than 240° 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 procedure listed in the Lighting
Operating Instructions to shut down appliance in
Section 9, Start-Up Procedure Part B.

B. WEEKLY (WITH BOILER IN USE)

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

C. ANNUALLY (BEFORE START OF

HEATING SEASON)

1. Check boiler room floor drains for proper functioning.

2. Check function of the safety relief valve by performing
the following test:

a. Check valve piping to determine that it is properly

installed and supported.

b. Check boiler operating temperature and pressure.

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

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

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

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

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

before the boiler is returned to operation.

f. Check that operating pressure and temperature

have returned to normal.

g. Check again to confirm that valve has closed

completely and is not leaking.

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

4. Test limit as described in Section 9, Part D,
“Check Operation”.

5. Test function of ignition system safety shut-off features
as described in Section 9, Part D,
“Check Operation”.

6. Remove the top/front jacket panel and inspect for any
foreign debris that may have entered through air
intake vent.

7. Inspect burner for deterioration. Replace if necessary.

8. With boiler in operation check that condensate is
dripping from condensate tubing. Check for any
restriction in condensate drain line.

D. CONDENSATE CLEANING

INSTRUCTIONS

1. Check trap for blockages and that the check ball is
free floating. Remove the screw bottom of the
condensate trap to allow any sediment to clear the
trap. Replace once done.

2. Check the condition of any condensate pumps that
are installed. Impellers can deteriorate over time do to
exposure to the acidic condensate.

3. Check the condition of any neutralization systems
installed. Replace neutralizing agent if needed.

4. Check that the pressure switch tap has not been
blocked or clogged with debris.

E. INSPECTION AND CLEANING OF

COMBUSTION CHAMBER COILS

Before beginning this procedure, you must have on hand
the following items:

– a nylon or brass brush (not steel)

– “Rydlyme” (recommended for best results)

(available online www.rydlyme.com) or “CLR”
(available at most hardware stores)

1. Shut the boiler down and access the heat exchanger
using the following steps:

a. Close the manual gas shutoff valve and wait for

the unit to be cool to the touch.

The following annual inspection must be performed
by a qualified service technician.

CAUTION

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

51

MAINTENANCE

b. Disconnect the condensate piping from the outside

connections (not from the Series PBC™ side) so
the flow can be observed.

c. Disconnect compression nut on gas valve inlet

and disconnect the gas valve electrical connector.

d. Remove the four 10 mm nuts from the burner

plate assembly. Disconnect wire leads to the spark
igniter and flame sensor. Disconnect two Molex
plugs from blower motor.

e. Pull the entire burner plate towards you to access

the heat exchanger coils.

f. Significant deposits may be caused by the

recirculation of exhaust gasses, poor fuel quality or
contamination of the air supply. Review Section 3,
Venting & Air Inlet Piping, if deposits are evident.

2. Using a spray bottle filled with the recommended
product “Rydlyme” or “CLR”, spray liberally on the
coils, making sure the solution penetrates and funnels
down through the condensate hose. If the condensate
hose is blocked, let the chemical penetrate for at least
15 minutes or until it drains.

3. Use the nylon or brass brush (do not use steel) and
scrub coils to remove any buildup, then vacuum the
debris from the coils.

4. Spray coils with clear water, making sure to confine
the spray to the area being cleaned (try to avoid
wetting the back ceramic wall of the unit). Flush the
combustion chamber with fresh water. At this point,
the Series PBC™ should be ready to power back up.

5. Reinstall the burner plate assembly using the
following steps:

a. Inspect the inside of the heat exchanger for dirt

and debris.

b. Install the burner plate assembly and replace the

four 10 mm nuts.

c. Reconnect the wire leads to the spark igniter,

flame sensor and gas valve. (Be sure that the
spark igniter is connected to the lead with the
large insulated connection boot.) Reconnect two
Molex plugs on blower motor.

d. Connect the compression nut on the gas valve

inlet and reattach the gas valve electrical
connector.

e. Reset thermostats. (IMPORTANT: BE SURE

THAT THE VENT CONNECTION IS NOT
BLOCKED.)

f. Turn the power to the Series PBC™ on. Observe

the display module to assure proper operation.

g. Initiate a call for heat** and observe the

condensate flow.

h. Reconnect the condensate piping to the drain

connection.

**NOTE: When firing the boiler the first few
times you may experience some fluttering
of the gas burner that may result in a flame
lockout. This is normal and will require you
to recycle the unit until this clears up. This
is caused by water still present in the
combustion chamber.

6. Inspect exhaust vent and air intake vents for proper
support and joint integrity. Repair as necessary. Refer
to Section 3, Venting & Air Inlet Piping.

7. Inspect exhaust vent and air intake vent terminations
for obstructions or corrosion. Corrosion is an
indication of exhaust gas recirculation.

F. HEAT EXCHANGER GASKET

REPLACEMENT

If at any point the silicon burner door gasket shows signs
of damage or after two years of operation it needs to be
replaced. Inspection during annual cleaning is the best
time to check and replace this gasket.

G. FLOW RESTRICTOR MAINTENANCE

The Series PBC™ has a 4.75 GPM flow restrictor installed
inside the CHB block that contains a screen filter. This
filter protects the plate heat exchanger from sediment
infiltration that would be large enough to become stuck
inside the plate heat exchanger passages. This filter should
be checked and flushed clean on an annual basis. More
frequent cleaning might be required in poor water areas.

The following steps can be taken to clean or replace the
flow regulator:

1. Power off the boiler.

2. Isolate the unit from the main domestic water supply
of the dwelling and remove pressure on the Domestic
side of the unit.

3. The flow regulator is located below the flow sensor on
the right half of the CHB unit, immediately left of the
pump. Insert a small screw driver into the rounded
tab or use a pair of pliers to turn the regulator
housing counter-clockwise.

4. When the locking tab are in line with the openings in
the main housing, pull the flow regulator housing out
of the CHB body.

5. The flow regulator is the small white cartridge inside
of the housing. It can be removed by pushing it out of
the housing.

It is extremely important to check for leaks when
reconnecting the gas valve. Failure to do so may
result in severe personal injury, death or major
property damage.

WARNING

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

WARNING

6. Clean and flush the flow regulator with clean water or
air to remove sediment.

7. Replace the flow regulator cartridge into the housing
with the screen facing towards to open end of the
housing.

8. Fully insert the housing back into the CHB unit until
the locking tabs are below the grooves in the CHB
body.

9. Turn counter clockwise until the resistance is felt.

10. Pressurize the DHW side of the boiler and open a hot
water tap to drain air from the system. Check for leaks
around the flow regulator housing.

H. PLATE HEAT EXCHANGER MAINTENANCE

The Series PBC™ uses a high efficiency Plate Heat
Exchanger (PHE) to heat the domestic hot water side of
the unit. The high efficiency nature of the PHE leaves it
susceptible to calcium build up and passage narrowing if
the domestic water is not properly treated before passing
through the PHE. Regular cleaning of the PHE will greatly
extend the lifetime and ease of maintenance for the PHE.
The steps below can be taken to remove and clean the
PHE.

Complete Removal Cleaning

1. Power of the Boiler.

2. Isolate and drain BOTH the Central Heat loop of the
Boiler and the Domestic side of the boiler.

3. Optional: Close the gas shutoff valve to the unit and
disconnect the gas line from the gas valve. The entire
burner plate can be pulled by removing the 4 10mm
nuts on the front of the main heat exchanger. This will
give much more access to the PHE.

4. Using a 4mm or 5/32” Allen wrench, remove the two
flanged screws on the front of the CHB. Hold the
PHE in place when removing the screws. Pull the
PHE up and out of the unit being careful to not get
water onto any of the components.

5. The PHE has 4 gaskets that seal the connections.
Remove and check these gaskets for wear or
degradation. Replace if necessary.

6. The PHE can be cleaned using a solution of
“Rydlyme” (recommended for best results) (available
online www.rydlyme.com) or “CLR” (available at
most hardware stores).

7. Thoroughly flush the PHE with clean water.

8. Replace the gaskets.

9. Place the PHE back in place behind the CHB and
tighten the two screws back in place.

10. Optional: Re-install the burner plate and gas line
connections. Return gas pressure to the unit ensuring
there are no leaks.

11. Return water pressure to the unit and ensure all air is
removed from the Central Heat Side of the boiler.

12. Open the domestic outlet drain (or a nearby faucet’s
hot water valve) and flush the PHE for 1 minute to
ensure all cleaning solution is removed.

13. Close water flow and power on the boiler.

Quick Cleaning (With Webstone kit or isolation
and drain valves installed)

1. Power off the unit.

2. Close both inlet and outlet DHW isolation valves.

3. Open both DHW inlet and outlet drain valves.

4. Flush a solution of “Rydlyme” (recommended for best
results) (available online www.rydlyme.com) or “CLR”
(available at most hardware stores) through the PHE
repeatedly to loosen any debris or buildup.

5. Flush system with clean water. Do not allow cleaning
water into dwellings piping.

6. Once flushing water is running clear, close all drain
valves.

7. Open isolation valves and a hot water tap. Allow
water to flow for one minute to ensure all cleaning
solution is out of the system.

8. Close tap and power on boiler.

52

MAINTENANCE

53

BOILER DIMENSIONS & RATINGS

12. BOILER DIMENSIONS & RATINGS

Table 12.1: Boiler Dimensions

PEERLESS®SERIES PBC™ DIMENSIONS

Boiler
Model

“A” “B” “C” “D” “E” “F”

PBC-34 16-13/16 18-3/16 30-11/16 7-13/16 7-5/8 7-3/16

PBC-40 16-13/16 18-3/16 30-11/16 7-13/16 6-15/16 7-5/8

PBC-52 18-13/16 18-3/16 30-11/16 6-1/16 6-15/16 7-5/8

Figure 12.1: Boiler Dimensions

Table 12.2: Boiler Ratings

Peerless

®

Series PBC

™

Boiler

Model

CH Input

(MBH)

DHW Input

(MBH)

Heating

Capacity

(MBH)

Net Rating

(MBH)

AFUE

(%)

Min. Max. Min. Max.

PBC-34 15.5 80 15.5 130 76.2 64.6 95.1

PBC-40 15.5 100 15.5 155 95.1 80.9 95.2

PBC-52 24.5 120 24.5 199 114.6 97.2 95.3

PEERLESS®SERIES PBC™ BOILER RATINGS

*Note: As an ENERGY STAR®Partner, PB Heat has determined that these firing rates meet the ENERGY STAR guidelines for energy efficiency.

For installations over 2000 Ft above sea level, the boiler will de-rate by 3.5% per every additional 1000 Ft in elevation with no adjustment to the
boiler. Input values based on manufacturer’s recommended CO2 percentages.

54

Table 12.5: Electrical Ratings

PEERLESS® SERIES PBC™ ELECTRICAL RATINGS

Boiler
Model

Supply

Voltage

(-15%,

+10%)

Frequency

(±1.2 hz)

Blower Gas Valve

Internal Gen.

Pumps

CH Pump Contacts

Max Total

Service
Current

to Boiler

(Amps)

Voltage

(VAC)

Current

(Amps)

Voltage

(VAC)

Current

(Amps)

Voltage

(VAC)

Max.
Current
(Amps)

Voltage

(VAC)

Max.

Current

(Amps)

PBC-34 120 VAC 60 hz 120 1.5 120 0.09 120 0.8 120 2 4

PBC-40 120 VAC 60 hz 120 2 120 0.09 120 0.8 120 2 4

PBC-52 120 VAC 60 hz 120 2 120 0.09 120 0.8 120 2 4

Table 12.4: Main Control Specifications

PEERLESS®SERIES PBC™ MAIN CONTROL SPECIFICATIONS

Power Supply 120 VAC Nominal (102-132 VAC); 60 Hertz (40-70 Hz) Phase Neutral

Fuse 5AT, 250V (Type GDG)

Blower Voltage 120 VAC

Gas Valve Voltage 120 VAC Nominal (102-132 VAC); 60 Hertz (40-70 Hz) Phase Neutral

Thermostat Contacts 24 VAC

Flame Current Limits

1.0 µA Minimum

1.5 µA Start Detection

14.0 µA Maximum

Temperature Sensors

All Series PBC™ internal NTC Sensors are 10 kΩ
They operate on 5 VDC.
Dual Supply Sensor:
Return Sensor :
Flue Sensor:
Outdoor Sensor: -40°F (-40°C) to 185°F (85°C)

Standards North America: ANSI Z21.13 / CSA 4.9

BOILER DIMENSIONS & RATINGS

Table 12.3: Combustion Fan Speeds

PEERLESS® SERIES PBC™ FAN SPEEDS

Boiler
Model

Max Input

Rate

(MBH)

Fan Speed (rpm)

Low Power Ignition High Power

PBC-34 130 1400 - 1500 3000 6900 - 7000

PBC-40 155 1150 - 1300 4300 6350 - 6450

PBC-52 199 1250 - 1350 2500 6200 - 6350

THIS PAGE INTENTIONALLY LEFT BLANK

56

REPAI R PARTS

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.

13. REPAIR PARTS

Figure 13.1: General Repair Parts

57

REPAI R PARTS

Table 13.1: General Repair Parts

Description

Quantity

Required

Stock

Code

1 PBC Front Panel 1 PBC6000

2 Logo Plate 1 9372

3 900LB Display 1 5954

4 Electrical Panel 1 PBC6004

5 Carlin 4180002F External Spark Generator 1 54758

6

975MN Boiler Control: PBC-34 1 TBD

975MN Boiler Control: PBC-40 1 TBD

975MN Boiler Control: PBC-52 1 TBD

7 Nut #8-32 6 51573

8 Clevis Pin 3/16" by 1" (Local Hardware Supply) 2 —

9 Retaining Pin Cotter 1" Local Hardware (Local Hardware Supply) 2 —

10 Washer Nylon 3/16" (Local Hardware Supply) 2 —

11 1" Supply Flex Line w / Hx Fitting 1 5957

12 Supply Manifold 1 54764

13 Combiniation Hydronic Block 1 54747

14 O-Ring 20MM for Heat Exchanger 2 5525

15 O-Ring CHB Return: Square #116 3 5909

16 O-Ring CHB Supply 1 5910

17

Heat Exchanger Rail: PBC-34/PBC-40 2 54725

Heat Exchanger Rail: PBC-52 2 54726

18 Heat Exchanher Retention Clamp 2 54723

19 Screw M4 X 6mm 6 54724

20 Screw #10-24 X 1/2" Self Tapping 27 99129

21 Heat Exchanger Mount PBC-34/PBC-40 1 PBC2010

22

Side Panel- PBC-34/PBC-40 2 PBC6001-1

Side Panel- PBC-52 2 PBC6001-1

23 Plastic Locknut 3/4" 1 5863

24 Condensate Trap 96 1 54753

25 Sealing Grommet 1/2" Pipe 1 5526

26 Vent Adapter 3-In-1 2 54571

27 EDPM Foam Vent Gasket 2 TBD

28 Screw #10 X 3/4" Sheet Metal-Pan Head Philips (Local Hardware Supply) 8 —

29 Switch Round Rocker OSLO 1 6050

30 Pressure Switch Cleveland 3.5" W.C. 1 54765

N/S Condensate Hose Assembly With Tap 1 5950

58

REPAI R PARTS

Figure 13.2: PBC-34 Combustion Components

59

REPAI R PARTS

Table 13.2: PBC-34 Combustion Components

Description

Quantity

Required

Stock

Code

1 Ignition Electrode 1 54788

2 Sensor Electrode 1 54786

3 Ignition Electrode Graphite Gasket 1 54787

4 Sensor Electrode Graphite Gasket 1 54789

5 Screw M4 X 10mm for Electrodes 4 6512

6 Burner Door w / Burner PBC-34/PBC-40 1 54795

7 M6 Flange Nut 4 6505

8 Burner Door Gasket 1 54790

9 Burner Door Insulation 1 54791

10 Target Wall Insulation 1 54793

11 PBC-34 / PBC-40 Isothermic Heat Exchanger 1 98105

12 Blower Outlet Gasket 1 54122

13

Kit NRV118 Venturi w / Hardware 1 54722

Kit LP NRV118 Venturi w / Hardware 1 54757

14 Set Screw M5 X 25mm 4 54774

15 Nut M5 Flange 4 54775

16 Flange 1/2" NPT w / Hardware 1 54785

60

REPAI R PARTS

Figure 13.3: PBC-40 and PBC-52 Combustion Components

61

Table 13.3: PBC-40 and PBC-52 Combustion Components

Description

Quantity

Required

Stock

Code

1 Ignition Electrode 1 54788

2 Sensor Electrode 1 54786

3 Ignition Electrode Graphite Gasket 1 54787

4 Sensor Electrode Graphite Gasket 1 54789

5 Screw M4 X 10mm for Electrodes 4 6512

6 Burner Door w / Burner PBC-34/PBC-40 1 54795

7 M6 Flange Nut 4 6505

8 Burner Door Gasket 1 54790

9 Burner Door Insulation 1 54791

10 Target Wall Insulation 1 54793

11

PBC-34/PBC-40 Isothermic Heat Exchanger 1 98105

PBC-52 Isothermic Heat Exchanger 1 98106

12 Blower Outlet Gasket 1 54122

13 RG148 Blower 130W 1 54720

14 O-Ring Venturi to Blower 1 5911

15

HM140 Mixer PBC-40 Natural Gas 1 54766

HM140 Mixer PBC-40 LP Gas 1 54767

HM140 Mixer PBC-52 Natural Gas 1 54768

HM140 Mixer PBC-52 LP Gas 1 54769

16 Screw 4MM X 10mm Pan Head Phillips 3 54784

17 Gas Valve Adapter Gasket 1 54783

18 Gas Valve Adapter - Body 1 54770

19 Gas Valve Adapter- Nut 1 54771

20 GB-ND 055 D01 Gas Valve 1 54721

21 Screw M4X 30mm Philips 1 54125

22 Set Screw M5 X 25mm 4 54774

23 Nut M5 Flange 4 54775

24 Flange 1/2" NPT w / Hardware 1 54785

REPAI R PARTS

Table 13.4: CHB Repair Parts

Item Picture Description

Stock

Code

Plate Heat Exchanger- 24 Plate (w/ Gaskets and Screws) 54798

N/A Plate Heat Exhanger Gaskets 54799

18L Flow Restictor With Screen 54800

Basic Pump Cartridge UPS15-78 54801

NTC 10 kΩ B3977 Sensor- Return And Dhw Sensor (With Clip)

54802

Spare Fillling Valve Short (With Clip) 54803

Pressure Sensor With Clip 54804

Non Return Valve 54805

DHW Water Connection – 1/2" NPT (Inlet and Outlet) (w / O-Ring) 54806

Central Heat Supply Connection – 3/4" NPT (w / O-Ring) 54807

Central Heat Return Connection – 3/4" NPT (w / O-Ring) 54808

3-Way Valve Stepper Motor 54809

Flow Senosr- Honeywell (w / Rotor) 54809

Supply Manifold Clip and O-Ring 54811

N/A Air Venter Complete 54812

Drain Screw w / O-Ring 54813

62

REPAI R PARTS

Gas BoilersCombination

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.

PBC8013 R1 (5/18-3C)

Printed in U.S.A.©2018 PB Heat, LLC. All rights reserved.

PB HEAT, LLC

131 S. CHURCH STREET • BALLY, PA 19503

PBC-34™, PBC-40™, PBC-52™

Series

PBC

™