Page 1
WBV/WV
Boilers
Series
Oil
Installation,
Operation &
Maintenance
Manual
As an ENERGY STAR®Partner, PB Heat, LLC has determined that certain firing
rates of this product meet the ENERGY STAR®guidelines for energy efficiency.
Page 2
USING THIS MANUAL 1
A. INSTALLATION CLEARANCE . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . .2
B. AIR FOR COMBUSTION AND
VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . .2
C. CHIMNEY / VENT AND DRAFT CONTROL . .3
D. INSTALLATION SURVEY . . . . . . . . . . . . . . . .3
E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .3
2. BOILER PLACEMENT AND ASSEMBLY 4
A. SETTING THE BOILER . . . . . . . . . . . . . . . . . .4
B. CONNECTING THE FLUE OUTLET . . . . . . . .4
C. JACKET ASSEMBLY (KNOCKDOWN
BOILERS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3. PIPING AND CONTROLS 6
A. PRESSURE TEST BLOCK ASSEMBLY . . . . .6
B. BOILER RETURN CLEARANCE . . . . . . . . . . .6
C. WATER BOILER PIPING . . . . . . . . . . . . . . . . .6
D. STEAM BOILER PIPING . . . . . . . . . . . . . . . . .6
E. TANKLESS HEATER OR COVERPLATE . . . . .7
F. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4. ELECTRICAL 9
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
B. BURNER WIRING . . . . . . . . . . . . . . . . . . . . . .9
5. BURNER SETUP & BOILER
OPERATION 14
A. BURNER INSTALLATION . . . . . . . . . . . . . . .14
B. BURNER START-UP AND ADJUSTMENT . .14
C. CHECK BOILER CONTROLS . . . . . . . . . . . .14
D. PURGE AIR FROM THE SYSTEM
(WATER BOILERS ONLY) . . . . . . . . . . . . . . .14
E. CLEAN THE BOILER
(STEAM BOILERS ONLY) . . . . . . . . . . . . . . .15
6. MAINTENANCE 17
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .18
B. DAILY MAINTENANCE (WITH BOILER
OPERATING) . . . . . . . . . . . . . . . . . . . . . . . . .18
C. WEEKLY MAINTENANCE (WITH BOILER
OPERATING) . . . . . . . . . . . . . . . . . . . . . . . . .18
D. MAINTENANCE OF SAFETY
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . .18
E. MONTHLY MAINTENANCE (WITH BOILER
OPERATING) . . . . . . . . . . . . . . . . . . . . . . . . .18
F. MAINTENANCE – ANNUAL . . . . . . . . . . . . .18
G. IF A LONG SHUTDOWN IS REQUIRED . . .19
7. BOILER DIMENSIONS & RATINGS 20
8. REPAIR PARTS 22
TABLE OF CONTENTS
TABLE OF CONTENTS
Page 3
1
A. INSTALLATION CLEARANCE
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 you will see special attention
boxes intended to supplement the instructions and make
special notice of potential hazards. These categories
mean, in the judgment of PB Heat, LLC.
USING THIS MANUAL
USING THIS MANUAL
Indicates a condition or hazard which
may cause severe personal injury,
death or major property damage.
WARNING
Indicates a condition or hazard which
will cause minor personal injury or
property damage.
CAUTION
Indicates special attention is needed,
but not directly related to potential
injury or property damage.
NOTICE
Indicates a condition or hazard which
will cause severe personal injury,
death or major property damage.
DANGER
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2
A. CLEARANCES
Unit may be installed on combustible flooring, provided the
boiler is not set on carpet and a metal drip pan is placed
under the appliance.
Unit may be installed in a closet with the above clearances.
See also Section B, Air for Combustion and Ventilation.
B. AIR FOR COMBUSTION AND
VENTILATION
1. Be certain adequate facilities are available to provide
air for satisfactory combustion and ventilation.
2. Appliances Located in Unconfined Spaces.
a. For installation in unconfined spaces with
conventional construction and larger areas such
as basements, the supply of air for combustion
and ventilation can usually be considered
adequate.
3. Appliances Located in Confined Spaces.
a. All air from inside the building: Provide two
permanent openings communicating directly with
an additional room. If all air for combustion and
ventilation is to come from within the building:
two openings, one near the ceiling and one near
the floor of the boiler room shall be provided
with the minimum free area of each opening
equal to 140 sq. in. per gallon of oil burned.
b. If all air for combustion and ventilation is to
come from outside the building: two openings,
one near the ceiling and one near the floor of the
boiler room shall be provided with the minimum
free area of each opening equal to 35 sq. in. per
gallon of oil burned.
If ducts are used to convey the air, areas of 35
sq. in. per gallon of oil burned for vertical ducts
or 70 sq. in. per gallon of oil burned for
horizontal ducts are to be provided. Ducts shall
have the same area as the free area of the
openings to which they are connected.
PREINSTALLATION
1. PREINSTALLATION
Read carefully, study these instructions before beginning work. It will save time. Study the included drawings. Save these
instructions for reference.
This boiler must be installed by a qualified contractor.
The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly.
Table 1.1: Clearances from Jacket and Vent System
Required from Jacket
to Combustible
Construction
Recommended From Jacket for
Accessibility and Mounting Controls
To p 5"* 24" to clean flueways.
Front 16.5"* 16.5" from jacket due to burner.
Left 2"* 12" due to burner swing radius.
Right 2"*
18" on steam with tankless heater or with
Float LWCO.
9" in area of boiler service switch and
junction box.
Rear 2"*
9" for mounting relief valve in standard
location**.
Vent Pipe (Single Wall) - 9" to Combustible Construction.
Clearance may be reduced using methods in NFPA 31.
Vent Pipe (Double Wall) - See Manufacturer’s Instructions.
The equipment shall be installed in accordance with those installation regulations in force in the
local area where the installation is to be made, including the current edition of
NFPA-31, Standard
for the Installation of Oil-Burning Equipment
, and in Canada,
CSA B139, Installation Code for Oil
Burner Equipment
.These shall be carefully followed in all cases. Authorities having jurisdiction
shall be consulted before installations are made.
NOTICE
Never burn garbage or paper in the
unit, and never leave combustible
material around it.
CAUTION
Do not tamper with boiler controls.
CAUTION
* Consider also vent pipe clearance, including distance from edge of
flue outlet to combustible construction (as applicable).
** See dimensional drawing for alternate relief valve location.
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C. CHIMNEY / VENT AND DRAFT CONTROL
1. Draft Requir
ement – Minimum draft required in the
vent system is -.03" to -.06" W.C. depending on
boiler model, see Table 7.1 (Section 7). This draft is
necessary to provide the necessary draft over fire of
-.01" to -.02" W.C. See discussion in paragraph 5
below regarding draft.
2. A barometric draft regulator must be used to provide
adequate control of draft. Control should be capable
of adjusting from approximately -0.02 to -0.08
inches of W.C. Follow manufacturer's instructions to
locate and adjust the control.
3. Inspect the existing chimney or vent system. Make
sure it is in good condition. Inspect chimney liner
and repair or replace if necessary.
4. The vent system and installation must be in
accordance with the current edition of the American
National Standard ANSI/NFPA 211, "Chimneys,
Fireplaces, Vents, and Solid Fuel Burning
Appliances," or applicable provisions of the local
building codes. Typical minimum chimney size is
8' x 8', 15 feet high, unless otherwise allowed by
code. If the vent system is not sized properly, the
burner may not operate properly. This can cause
poor combustion, sooting and odors to occur.
5. Background Information Regarding Draft:
Modern boilers operate with higher efficiencies than
older boilers. Smaller flueways, as well as bars, pins
and fins are designed into modern boilers to transfer
as much heat as possible from the hot gases to the
water or steam and prevent heat loss up the
chimney. However, these design features result in
higher pressure, or draft loss, in the boiler.
This draft loss must be taken into account when
installing an oil boiler into a new or old chimney.
New chimneys are less likely to have poor draft.
However, they must have sufficient draft to support
combustion. A -.06" draft is desirable and preferred.
Older chimneys may require a replacement liner to
have them perform well enough to support
combustion.
For Example:
The above readings are "cold" readings (before the
boiler and chimney are heated up).
Note also that the higher the firing rate on a unit
which has multiple firing rates, the higher the draft
required. For example, increasing the firing rate 1/4
gallon may increase the draft loss in a unit by
approximately +.01".
D. INSTALLATION SURVEY
For new and existing installations, a Water Installation
Survey or a Steam Installation Survey is available from
P.B. Heat, LLC. The surveys will provide information on
how the boiler works with your specific system and will
provide an overview of boiler system operation in
general.
You can also use this survey to locate system problems
which will have to be corrected. To obtain copies of
these Surveys, contact your PB Heat representative.
E. PLANNING THE LAYOUT
Prepare sketches and notes of the layout of the
installation. Include boiler location, venting system,
existing piping and wiring. Show existing equipment that
may interfere with installation of new equipment.
LIQUEFIED PETROLEUM (LP) GAS
PREINSTALLATION
Old
Installation
New
Installation
Comments
Chimney
Draft
-.04" -.04"
No change, but older
chimneys (especially unlined
ones) have leaks which
reduce draft.
Boiler
Design
Pressure
Drop
+.01" +.04"
Required for mandated
efficiency increases.
Draft
Over Fire
-.03" 0.00"
The old installation would
have had a higher
temperature in the chimney
[as high as 800 degrees vs.
400 degrees F], which would
increase the draft.
An oil-fired unit shall be connected
to a flue having sufficient draft at all
times, to assure safe proper
operation of the unit.
CAUTION
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4
A. SETTING THE BOILER
1. Provide a level foundation, located as close as
possible to the center of the heating system.
2. Refer to Figures 2.1 and 2.2 for exploded view of
boiler while checking and/or assembling parts of the
boiler.
3. On packaged boilers, open burner mounting plate
(item 5) at this time to make certain the target wall
(item 2) is seated in the back of the combustion
chamber. (WBV-04/WV-05) Ceramic fiber blanket
base liner (item 3) should be lying flat on bottom of
combustion chamber between target wall and burner
mounting plate. Close burner mounting plate.
4. See clearance information in Section I,
"Preinstallation."
B. CONNECTING THE FLUE OUTLET
The WBV-03 and WBV-04 boiler models may be
installed as a rear flue outlet unit or a top flue outlet
unit. Packaged WBV-03 and WBV-04 boiler models are
shipped as rear flue outlet and may be converted. The
WV-05 boiler model is only available as a top flue outlet
unit. On Knockdown boilers, the flue outlet components
are located in the water trim or steam trim carton.
1. If converting to a top flue application on a packaged
boiler, remove the large knockout in the jacket top
panel.
2. On Knockdown boilers, install the flue collector
coverplate and blanket seal (items 10 and 11) on top
of the block assembly using four (4) 5/16" x 1-1/2"
studs, nuts and washers provided.
3. Mount the flue collar adapter and rope seal (items
14 and item 12) to either the rear boiler section for a
rear flue application, or to the flue collector cover
plate (item 11) for a top flue application. Use 5/16"
hex head bolts for rear flue out, and sheet metal
screws for top flue outlet.
4. Attach the rear outlet cover plate (item 13) to the
remaining unused opening using four (4) 5/16" bolts
and washers provided.
C. JACKET ASSEMBLY (KNOCKDOWN
BOILERS)
1. If the boiler is to be installed with a rear flue outlet,
remove the square knock-out in the back panel.
2. Attach back panel to bosses on middle of back
section with two 1/4" x 3/8" machine screws
provided. The back panel has two 5/16" diameter
holes close to the center of the panel.
3. Attach both the left and right side panels to the back
panel and secure with sheet metal screws.
4. Remove the burner mounting plate (item 5) and
make certain the target wall (item 2) is in correct
position in back of chamber. Ceramic fiber blanket
liner (item 3, WBV-04 and WV-05) should be on
floor of boiler in front of target wall.
5. Remove the two (2) knockouts in the front jacket
panel which will allow clearance for the hinge. Place
the front jacket panel on the block and attach the left
and right side panels in the same manner as they are
attached to the back panel.
6. Reinstall the burner mounting plate.
2. BOILER PLACEMENT AND ASSEMBLY
BOILER PLACEMENT AND ASSEMBLY
Page 7
BOILER PLACEMENT AND ASSEMBLY
(See Table 8.1 on page 22 for parts identification).
Figure 2.1: Steam boiler
5
Figure 2.2: Water boiler
Page 8
A. PRESSURE TEST BLOCK ASSEMBLY
1. Make up cold water supply connection to the boiler.
2. Install pressure gauge or pressure-temperature gauge
in tapping provided. See Boiler Dimensional
drawing, Figures 7.1 and 7.2 (Section 7)
3. Plug all open tappings in the boiler and fill with
water. Apply approximately thirty (30) psig pressure.
Check to make certain that all joints and fittings are
water tight.
4. After all joints and connections have been proven
tight, remove cold water supply and plugs from all
tappings that are to be used. See Figures 7.1 and 7.2
(Section 7) for tapping locations.
B. BOILER RETURN CLEARANCE
Return water piping must be done in such a manner to
allow clearance of the door to the return piping when
opening and closing the door. PB Heat, LLC suggests
using a 1-1/4" tee, a 90° street elbow, and 1-1/4" x 5"
pipe nipple in the return tapping before a vertical stand
pipe is used.
C. WATER BOILER PIPING
1. Refer to the Water Installation Survey and Hydronics
Institute Residential Hydronic Heating
Installation/Design Guide for guidance.
2. The supply and return connections should be sized to
suit the system. A 1-1/2" to 1-1/4" reducing coupling
may be used where the system piping is 1-1/2".
3. The supply should be out the top of the back section
and return to the bottom of the front section as
shown in Figure 3.1. There is a 3/4" tapping in the
top of the back section for air elimination.
4. When the return temperature from the system will be
below 150°F on oil boilers for extended periods
(heat pump systems, outdoor reset, snow melt, etc.),
provide piping and controls to protect the boiler from
condensation. Condensation will damage the boiler
and will lead to shortened boiler life and
maintenance problems.
5. If using a Partner indirect fired water heater or other,
see Figure 3.6 for typical piping. Also refer to
additional instructions supplied with the Partner.
6. If the boiler is to be used in conjunction with a
refrigeration system, the chilled medium shall be
piped in parallel with boiler and proper valves
applied to prevent the chilled medium from entering
the boiler. Refer to Figure 3.5.
7. If the boiler is connected to heating coils located in
air handling units, the boiler piping system must be
equipped with flow control valves or other automatic
devices to prevent gravity circulation of the boiler
water during the cooling cycle.
D. STEAM BOILER PIPING
1. Refer to the Steam Installation Survey and
Hydronics Institute Residential Hydronic Heating
Installation/Design Guide for assistance.
2. See table below for pipe sizing. The return loop from
system should always enter equalizer through the
Hartford Loop, 2" to 4" below normal water line.
See Figure 3.2.
3. Use swing joints to attach header to avoid damage
to the boiler due to thermal expansion and
contraction of steam header pipe.
4. Pipe the steam header a minimum of 24" above the
normal water line using swing joints to attach the
risers into the steam header.
3. PIPING AND CONTROLS
Figure 3.1: Water Boiler Piping
Figure 3.2: Steam Boiler Piping
PIPING AND CONTROLS
Boiler Model
No.
Supply Riser Equalizer
WBV-03 (1) 2" 1-1/4"
WBV-03 (1) 2" 1-1/4"
6
Do not pipe boiler before jacket is
installed.
NOTICE
Page 9
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E. TANKLESS HEATER OR COVERPLATE
1. If a tankless coil is used (item 9), install as pictured.
On water boilers, install in opening in front section.
On steam boilers, install in opening in rear section.
For suggested piping of tankless water heaters refer
to Figures 3.3 and 3.4.
2. If not using a tankless coil, cover the heater opening
with cover plate (item 7 or 16).
F. CONTROLS
1. Water Boiler Controls:
a. Install the limit / operating control, pressure-
temperature gauge and safety relief valve.
See Figure 7.1 (Section 7) for proper location.
For installations subject to UL726, a second
operating control that senses water temperature
is also required (not provided). Use an L4080B
or equivalent. Install in the supply piping near
the boiler.
2. Steam Boiler Controls:
a. Install the limit / operating control, pressure
gauge, gauge glass trim and safety relief valve.
See Figure 7.2 (Section 7), Figure 3.7 (float
boilers) and cover photo (probe boilers).
b. For installations subject to UL726, a second
operating control that senses steam pressure is
required (not provided). Use a PA404A or
equivalent. On probe boilers, install the
additional pressure control opposite the
standard PA404A using a cross instead of a
tee along with a second brass siphon (not
provided). On float boilers, install the additional
pressure control in the 1/4" tapping on the top of
the float low water cut-off using a vertical (360º)
brass siphon (not provided).
c. For application of a probe low-water cut-off,
use only Hydrolevel CG450. See Figure 7.2
(Section 7) for location. See also control
manufacturers instruction sheet.
d. See Figure 3.7 for application of float low water
cut-offs.
3. For complete information on servicing and
adjustment of controls, refer to the attached control
specification sheets.
PIPING AND CONTROLS
Figure 3.3: Tankless Coil Piping, Steam Boiler
Figure 3.4: Tankless Coil Piping, Water Boiler
Pipe the discharge of the safety
valve or relief valve to prevent injury
in the event of pressure relief. Pipe
the discharge to a drain. Provide
piping that is the same size as the
relief valve.
CAUTION
Be sure rubber gasket is in place
between cover plate or water heater
plate and boiler section.
NOTICE
X1019R, X1020R, and PP1011R
coils installed in WBV boilers have
internal flow controls installed.
Do not use external flow controls
with these coils.
NOTICE
Install anti-scald device in hot water
supply piping.Water temperature
above 125°F can cause severe burns
instantly or death from scalds.
DANGER
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8
Figure 3.6: Piping with Peerless Indirect Water Tank
Figure 3.7: Float Low Water Cut-off
PIPING AND CONTROLS
Figure 3.5: Piping to Isolate Boiler from Chilled
Medium on Chiller Systems
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9
A. GENERAL
All electrical wiring shall be done in accordance with the
National Electrical Code and Local Requirements. Single
pole switches including those of safety controls or
protective devices shall not be wired in a grounded line.
B. BURNER WIRING
1. See Section 5 for mounting burner.
2. Install junction box, limit harness, and Heyco
bushing, each located in the trim carton. See Figure
4.1. Mount junction box to the holes in the right side
of jacket with (2) #10 x 1/2" sheet metal screws.
Attach Heyco bushing to 7/8" knockout in left side of
junction box. Connect limit harness to 7/8" knockout
on top of junction box and insert limit harness Molex
connector into Heyco bushing until it snaps firmly in
place.
3. Install burner harness located in the burner carton.
Beckett or Carlin
– PP7024 Harness
(11-1/2" conduit)
Riello
– PP7023 Harness (17-1/2" conduit)
4. For complete information on servicing and
adjustment of controls, refer to the attached control
specification sheets.
5. See the following Wiring Diagrams:
Figure 4.2 - Water Boilers
Figure 4.3 - Steam Boilers with Float LWCO
Figure 4.4 - Steam Boilers with Probe LWCO
Figure 4.5 - Zoning with Circulators
Figure 4.6 - Zoning with Circulators,
Honeywell L8124A, C Aquastat
Figure 4.7 - Zoning with Zone Valves
Figure 4.8 - Partner with Circulator (Non-priority)
4. ELECTRICAL
ELECTRICAL
Figure 4.1: Junction Box Wiring
Improper installation of burner
harness can allow burner to energize
with burner mounting plate open,
creating a severe burn hazard to
boiler maintenance personnel.
WARNING
Page 12
10
ELECTRICAL
Figure 4.3: Steam with Float Low Water Cut-Off
Figure 4.2: Water Boilers
Page 13
11
ELECTRICAL
Figure 4.5: Zoning with Circulators
Figure 4.4: Steam with Probe Low Water Cut-Off
Page 14
12
ELECTRICAL
Figure 4.6: Zoning with Circulators, Honeywell L8124A, C Aquastat
Figure 4.7: Zoning with Zone Valves
Page 15
13
ELECTRICAL
Figure 4.8: Partner with Circulator (Non-priority)
Page 16
14
BURNER SETUP & BOILER OPERATION
A. BURNER INSTALLATION
1. The oil burner is supplied with a mounting flange
fixed in position.
2. Mount the burner to the combustion chamber cover
plate (item 5) with four (4) 5/16" studs and nuts
provided.
3. Care must be taken when routing the oil lines so not
to interfere with the opening and closing of the
burner mounting plate. Flexible oil lines or flared
copper disconnects with valves (when copper lines
are used) may be installed to assure full opening of
the burner mounting plate when servicing.
4. Oil burner specifications:
For information pertinent to the oil burner such as
nozzle sizing, fuel supply piping, adjusting or
servicing, refer to the charts in this section and the
burner installation manual.
B. BURNER START-UP AND ADJUSTMENT
1. Burner should start automatically when thermostat is
turned up and main boiler service switch is turned
on. If burner does not start, check to be sure there is
oil in the tank and push reset button on burner
control:
Beckett: Square red button.
Carlin: Round red button.
Riello: Round red button inside clear flexible
cover on back of burner cover.
If burner still does not start, contact serviceman.
2. Adjust burner and barometric draft control for
highest CO²(Maximum 13%) while maintaining a 0
Smoke and -.01 to -.02" W.C. draft overfire.
All adjustments must be made using suitable
instruments such as found in a Bacharach
Combustion Test Kit.
3. Burner and boiler can be shut down by turning
down the thermostat and moving the main boiler
service switch to the "off" position.
4. See burner manufacturer’s manual for further
information regarding the burner.
C. CHECK BOILER CONTROLS
1. Limit and Operating Controls:
a. Lower the set point of each control until the
burner shuts down. Note that the system pressure
(or temperature) corresponds to the desired set
point.
b. Return the controls to the desired set point.
2. Low Water Cut-off (if used) - consult the
manufacturer's instructions for the low water cut-off
operational check procedure.
D. PURGE AIR FROM THE SYSTEM
(WATER BOILERS ONLY)
1. Purge the system using purge valves, isolating zones
in the process or use system vents. Do not operate
the pump(s) while purging. Pumps will hold air in
the eye of the impeller.
2. Allow the system to reach 180°F and use manual
vents, if installed, to remove any remaining air.
Watch the pressure gauge as the system approaches
180°F. If the pressure exceeds the design operating
pressure, check:
a. Fill valve pressure.
b. Expansion or compression tank operation and
sizing.
5. BURNER SETUP & BOILER OPERATION
Burn only #2 Fuel Oil in this
appliance. Do not use gasoline,
crankcase drainings or any oil
containing gasoline.
CAUTION
Do not attempt to start the burner
when excess oil has accumulated,
when the unit is full of vapor, or
when the combustion chamber is
very hot.
CAUTION
Two-pipe oil supply for Riello burner
requires a separate kit. Order part
#C7001026 from Riello dealer.
NOTICE
Be sure hi temp gasket is between
the burner mounting flange and the
combustion chamber cover plate.
NOTICE
Do not start the burner unless all
cleanout doors are in place.
CAUTION
Page 17
15
BURNER SETUP & BOILER OPERATION
E. CLEAN THE BOILER
(STEAM BOILERS ONLY)
1. Clean the boiler within one week after initial start-up.
Cleaning will be more effective if boiler operates a
day or two to loosen sediment and impurities in
system.
2. Boiler must be cleaned to remove any accumulation
of oil, grease, sludge, etc. in the system. These
substances can cause foaming and surging of boiler
water, producing an unstable water line and water
carryover to system.
3. Connect a skim valve off the 1-1/4"NPT skim
tapping on front of boiler. See WBV steam boiler
figure 7.2 (Section 7) to locate skim tapping. Run a
drain line off skim valve to a point of safe discharge.
4. Provide a means of supplying continuous fresh water
to the boiler for the cleaning process.
5. Open the skim valve. Fill boiler until water begins to
flow out of the valve.
6. Use common washing soda, such as Arm and
Hammer Super Washing Soda. Mix 1/2 pound of
soda with water in a 10 quart pail. Pour the mixture
into the boiler through the safety relief valve tapping.
7. Turn on burner. Allow boiler water to heat up to just
below steaming (180 - 200°F). Do not allow boiler to
steam; steaming mixes up contaminants instead of
floating them at surface.
8. Open make-up water valve to continually feed water
to boiler. Adjust flow to maintain water temperature
at 180 - 200° F.
9. Continue skimming boiler until water flowing from
skim tapping flows clear. This will take some time,
possibly several hours for a dirty system.
10. Turn off burner, close make-up water valve.
11. Drain boiler completely. Refill and drain one or two
times to wash out all washing soda.
12. Remove skim valve and piping. Install 1-1/4"NPT plug
in skim tapping.
Cleaning the boiler requires the use
of very hot water and corrosive
chemicals. Use care when handling
to prevent injury.
WARNING
Do not leave boiler unattended while
firing burner. Operating boiler with
water below minimum permissible
water level may fracture sections.
CAUTION
Do not allow make-up water to flow
too fast. Excessive quantities of cold
water may fracture sections.
CAUTION
If gauge glass becomes dirty more
contaminants have worked loose in
system. Repeat cleaning and
skimming process as needed to
clean system.
NOTICE
Page 18
16
BURNER SETUP & BOILER OPERATION
BECKETT BURNER SPECIFICATIONS
Boiler
Model No.
Burner
Model No.
Burner
Head
Static
Plate
Nozzle Size
Pump
Pressure
Start-up Settings
Head
Setting
Air Shutter Air Band
WBV-03-085 AFG-F3¹ F3 3-3/8" 0.75 80° B HAGO³ 140 PSI 6.0 1 N/A
WBV-03-110 AFG-F4 F4 3-3/8" 0.90 80° B HAGO 140 PSI 6.0 0 N/A
WBV-04-095 AFG-F4 F4 3-3/8" 0.85 80° B DEL
4
140 PSI 6.0 0 N/A
WBV-04-125 AFG-F4 F4 3-3/8" 1.10 80° B HAGO³ 140 PSI 5.0 2 N/A
WBV-04-150 AFG-F6 F6 2-3/4" 1.25 80° B HAGO 140 PSI 8.0 1 N/A
WV-05-175 AFG-MV1 V-1 - 1.50 60° B HAGO³ 140 PSI 10.0 3 3
WV-05-200 AFG-MV1 V-1 - 1.75 60° B HAGO 140 PSI 10.0 9 3
CARLIN BURNER SPECIFICATIONS (WITH 98022 PSC MOTOR)
Boiler
Model No.
Burner
Model No.
Head Bar Nozzle Size Pump Pressure
Start-up Settings
Air Shutter Air Band
WBV-03-085 EZ-1HP 0.60 - 0.65 0.65 70° A DEL³ 150 PSI Blank 0.60
WBV-03-110 EZ-1HP 0.85 - 1.00 0.85 70° A DEL 150 PSI Blank 0.65
WBV-04-095 EZ-1HP 0.75 0.75 70° A DEL
4
150 PSI Blank 0.60
WBV-04-125 EZ-1HP 0.85 - 1.00 1.00 70° A DEL³ 150 PSI Blank 0.85
WBV-04-150 EZ-1HP 1.10 - 1.25 1.25 60° B DEL 150 PSI Blank 1.00
WV-05-175 99FRD N/A 1.50 60° B HAGO³ 150 PSI Open 10% open
WV-05-200 99FRD N/A 1.65 60° B HAGO 150 PSI Open 45% open
RIELLO BURNER SPECIFICATIONS
Boiler
Model No.
Burner
Model No.
Burner Series Nozzle Size² Pump Pressure
Start-Up Settings
Turbulator Air Damper
WBV-03-060 F3 Series 40 0.50 90° B 145 0.0 2.9
WBV-03-085 F5 Series 40 0.65 60° W³ 170 1.0 2.45
WBV-03-110 F5 Series 40 0.85 60° W 165 2.5 2.8
WBV-04-095 F5 Series 40 0.75 80° B
4
160 0.5 2.25
WBV-04-125 F5 Series 40 1.00 60° W³ 155 2.5 3.4
WBV-04-140 F5 Series 40 1.10 60° W 160 4.0 4.2
WV-05-175 F10 Series 40 1.35 60° B³ 165 2.0 2.5
WV-05-200 F10 Series 40 1.50 60° B 170 2.5 2.8
Factory Installed Nozzles (Packaged Boilers or Burner Cartons) are indicated in Boldface.
1 Requires Low Firing Rate Baffle
2 Delavan Recommended
3 Shipped Loose with Packaged Boiler or Burner Carton
4 Not included with Packaged Boiler or Burner Carton
Table 5.1: Beckett Burner Specifications
Table 5.2: Carlin Burner Specifications (with 98022 PSC motor)
Table 5.3: Riello Burner Specifications
Page 19
17
MAINTENANCE
6. MAINTENANCE
WARNING
Product Safety Information
Refractory Ceramic Fiber Product
This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF,
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:
Precautionar
y 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.
Fir
st Aid Procedures:
Inhalation: If breathing difficulty or irritation occurs, move to a location with fresh clean air.
Seek immediate medical attention if symptoms persist.
Skin Contact:Wash affected area gently with a mild soap and warm water. Seek immediate
medical attention if irritation persists.
Eye Contact: Flush eyes with water for 15 minutes while holding eyelids apart. Do not rub
eyes. Seek immediate medical attention if irritation persists.
Ingestion: Drink 1 to 2 glasses of water. Do not induce vomiting. Seek immediate medical
attention.
Page 20
18
MAINTENANCE
A. GENERAL
1. Check pipes adjacent to cold walls or in unheated
spaces. Insulate and tape them if necessary to be
sure they can't freeze up. Keeping the water moving
at all times will reduce the likelihood of freezing.
2. If there is considerable foreign matter in the boiler
water, the boiler should be shut down and allowed to
cool, then drained and thoroughly flushed out. Drain
the boiler at the drain cock. Pipe the drain cock to a
suitable drain or containment device (if antifreeze is
used). Flush the system to remove remaining matter.
If there is evidence that hard scale has formed on the
internal surfaces, the boiler should be cleaned by
chemical means as prescribed by a qualified water
treatment specialist.
3. There must be no signs of continuous wetness at the
chimney. If signs of continuous wetness are
observed, a qualified service agency must be
consulted to modify the vent configuration to prevent
the formation of condensate, which may damage the
vent pipe.
B. DAILY MAINTENANCE (WITH BOILER
OPERATING)
Daily boiler observation can be performed by the owner.
If any potential problems are found, a qualified installer
or service technician/agency must be notified.
1. Remove any combustible materials, gasoline and
other flammable liquids and substances that
generated flammable vapors from the area where the
boiler is contained. Make certain that the boiler area
has ample air for combustion and ventilation and
that there are no obstructions to the free flow of air
to and from the boiler.
2. Observe general boiler conditions (unusual noises,
vibrations, etc.)
3. Observe operating temperature and/or pressure
gauge on the boiler. Boiler pressure should never be
higher than 5 psi below the rating shown on the
safety relief valve. The valve rating can be found on
the top of the safety relief valve. Boiler temperature
should never be higher than 250°F.
4. Check for water leaks in boiler and system piping.
C. WEEKLY MAINTENANCE (WITH BOILER
OPERATING)
1. Flush float-type low-water cut-off (if used) to remove
sediment from the float bowl as stated in the
manufacturer's instructions.
D. MAINTENANCE OF SAFETY RELIEF
VALVE
1. Check function and maintain safety relief valve as
specified by manufacturer, typically every other
month or every month. per the instructions on the
tag on the safety relief valve.
E. MONTHLY MAINTENANCE (WITH BOILER
OPERATING)
1. Check boiler room floor drains for proper
functioning.
2. Test probe type low-water cut-off (if used) by using
the Push-to-Test Button.
3. Test limit by lowering the limit set point until the
burner shuts down. When proper operation is
confirmed, return the set point to original setting.
4. Follow additional instructions in the Burner Manual
for proving the burner component operation.
F. MAINTENANCE – ANNUAL
TO CLEAN:
1. Remove top jacket panel and flue collector cover
plate, Item 11 (Figure 2.1 or 2.2).
2. To thoroughly clean the boiler it must be brushed
down from the top. Alternatively, for limited space or
minimum clearance to combustible installations,
cleaning the heat exchanger from the combustion
chamber side is acceptable. If unit is extremely dirty, it
may be necessary to brush from both directions. The
target wall is made of a soft ceramic fiber. Care must
be taken not to damage this material during cleaning.
Disconnect all power to the burner
before accessing combustion
chamber.
WARNING
Turn off power to boiler before
adjusting limit control.
CAUTION
Entire heating system, including
boiler, burner and venting system,
must be inspected at least once a
year by a qualified heating
professional. Boiler is to be cleaned
at least once a year.
NOTICE
Do not use this appliance if any part
has been under water. Improper or
dangerous operation may result.
Immediately call a qualified service
technician to inspect the boiler and
to replace any part of the control
system and any control which has
been under water.
WARNING
Page 21
19
MAINTENANCE
3. Remove any scale or soot from the combustion
chamber area by vacuum cleaning or any other
available means.
4. Replace oil burner and flue collector cover plate
making sure all gaskets are in place.
5. Replace jacket top panel.
6. Inspect venting system.
G. IF A LONG SHUTDOWN IS REQUIRED
1. To take boiler out of service if the boiler and system
are not to be used when temperatures are below
freezing:
a. Drain the boiler and system completely and shut
off make-up water supply.
b. Open main line power disconnect switch to
boiler. Remove the fuses or secure the switch so
that the power cannot be turned on accidentally.
2. Be certain that the boiler and system are refilled
before returning to service.
Always keep the manual fuel supply
valve shut off if the burner is shut
down for an extended period of time.
CAUTION
All cover plates, enclosures, and
guards must be maintained in place
at all times, except during
maintenance and servicing.
NOTICE
Burner mounting plate must be
opened to facilitate this operation.
NOTICE
Page 22
20
BOILER DIMENSIONS & RATINGS
7. BOILER DIMENSIONS & RATINGS
Figure 7.1: Boiler Dimensions, Water Boiler
Figure 7.2: Boiler Dimensions, Steam Boiler
Boiler
Model
Number
Jacket
Depth
"A"
Rear of Jacket to
C/L of Top Flue
Outlet "B"
Top
Flue Size
"C"
WBV-03-085/110 14-1/8" 7-1/16" 6"
WBV-04-125/150 18-1/8" 9-1/16" 6"
WV-05-175/200 22-1/8" 11-1/16" 7"
Boiler
Model
Number
Jacket
Depth "A"
Rear of Jacket to
C/L of Top Flue
Outlet "B"
WBV-03-085/110 15-3/4" 8-7/8"
WBV-04-125/150 19-3/4" 10-7/8"
Page 23
21
Table 7.1: Boiler Ratings
SERIES WBV/WV RATINGS
Boiler
Model
Number¹
Heating
Capacity
BTU/Hr.²
Net I=B=R Ratings³
I=B=R
Firing Rate
G.P.H.
4
Chimney
Minimum Draft
Required In
Stack
BTU/Hr.
Steam
Steam
Sq. Ft.
BTU/Hr.
Water
Size
Inches
Height
Feet
WBV-03-60+* 74,000 N/A N/A 64,000 0.60+* 8 x 8 15 -.03"
WBV-03-085 102,000 76,000 317 89,000 0.85 8 x 8 15 -.04"
WBV-03-110 129,000 97,000 404 112,000 1.1 8 x 8 15 -.05"
WBV-04-095+ 116,000 N/A N/A 101,000 0.95+ 8 x 8 15 -.03"
WBV-04-125 150,000 112,000 467 130,000 1.25 8 x 8 15 -.04"
WBV-04-150 178,000 133,000 554 155,000 1.5 8 x 8 15 -.05"
WV-05-175 209,000 N/A N/A 182,000 1.75 8 x 8 15 -.05"
WV-05-200 237,000 N/A N/A 206,000 2 8 x 8 15 -.06"
1 Boiler Model No. may have the following suffix letters:
W-Water P - Packaged
S-Steam C-Circulator
U-Boiler-Burner Unit (Unassembled) T-Tankless Coil
2 Heating Capacity ratings are based on U.S. Government standard tests, with 13.0% CO2 and -0.02" water column draft over fire.
3 The water ratings are based on a piping pick-up allowance of 1.15; steam ratings are based on an allowance of 1.333. Consult factory before
selecting a boiler for gravity hot water installations and installations having unusual piping and pick-up requirements, such as intermittent system
operation, extensive piping systems, etc.
4 Firing rate is based on a fuel oil with a heating value of 140,000 BTU per gallon. Burner input based on maximum altitude of 2,000 ft. - for other
altitudes consult factory.
+ Nozzles for these firing rates not provided as standard equipment. Consult factory for price and availability.
* This firing rate can only be achieved with a Riello F-3 burner. Consult PB Heat, LLC for details.
BOILER DIMENSIONS & RATINGS
Page 24
22
REPAIR PARTS
8. REPAIR PARTS
Repair parts are available from your installer or by contacting PB Heat, LLC,
P.O. Box 447, New Berlinville, PA 19545-0447.
Note: Remember to include boiler model number and serial number when ordering parts.
Table 8.1
Item No.* Stock Code Description
Additional
Information
1
2
3
4
5
6
7
8
9
10
11
11A
12
13
14
15
16
17
18
50795
90538
90158
50794
51210
99812
X1078
51800
90637
90534
90621
90999
90562
51209
90563
90141
51673
PP5011
Block Assembly Water (Open)
Block Assembly Water (Closed)
Block Assembly Steam (Open)
Block Assembly Steam (Closed)
Target Wall
Base Liner
Swing Door Hinge
Burner Mounting Plate Assembly
Burner Mounting Plate Insulation
Burner Mounting Plate Rope Seal
Steel Cover Plate (Front) Water
Steel Cover Plate (Front) Steam
Rubber Gasket (Front) Steam
Tankless Coil
Flue Collector Plate Blanket Seal
Flue Collector Cover Plate
Top Outlet Flue Collector Plate
Rope Seal
Rear Outlet Cover Plate
Flue Collar Adapter
Jacket Assembly (Water)
Jacket Assembly (Steam)
Steel Cover Plate (Rear)
Rubber Gasket (Rear Section Plate)
Flue Outlet Gasket
Oil Burner
Temperature-Pressure Gauge
Steam Gauge
Aquastat
Pressuretrol
Drain Valve
Relief Valve (Water)
Pop Safety Valve (Steam)
Specify Size
Specify Size
Specify Size
Specify Size
4 or 5 Section
3 Section - Water Only
4 & 5 Section - Water Only
3 & 4 Section - Steam
Specify Size
Specify Size
5 Section Only
Specify Steam or Water
Specify Size
Specify Size
Specify Brand Name
* See Figures 2.1 & 2.2 on page 5 for boiler exploded view.
Page 25
23
NOTES
Page 26
PP8046 R20 (7/05-10M)
Printed in U.S.A.
©2005
WBV/WV
Boilers
Series
Oil
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.
HI Division
of gama
ASME
Name:
Address:
Phone:
Service Information
PB HEAT, LLC
P.O. BOX 447 • NEW BERLINVILLE, PA 19545-0447
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