Series WBV/WV
Oil Boilers
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.
Installation,
Operation &
Maintenance
Manual
TABLE OF CONTENTS
TABLE OF CONTENTS
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 |
USING THIS MANUAL
USING THIS MANUAL
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.
Indicates a condition or hazard which DANGER will cause severe personal injury,
death or major property damage.
Indicates a condition or hazard which WARNING may cause severe personal injury,
death or major property damage.
Indicates a condition or hazard which CAUTION will cause minor personal injury or
property damage.
Indicates special attention is needed, NOTICE but not directly related to potential
injury or property damage.
1
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.
The equipment shall be installed in accordance with those installation regulations in force in the NOTICE 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.
Never burn garbage or paper in the CAUTION unit, and never leave combustible
material around it.
CAUTION Do not tamper with boiler controls.
A. CLEARANCES
Table 1.1: Clearances from Jacket and Vent System
Required from Jacket |
Recommended From Jacket for |
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to Combustible |
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Accessibility and Mounting Controls |
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Construction |
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Top |
5"* |
24" to clean flueways. |
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Front |
16.5"* |
16.5" from jacket due to burner. |
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Left |
2"* |
12" due to burner swing radius. |
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18" on steam with tankless heater or with |
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Right |
2"* |
Float LWCO. |
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9" in area of boiler service switch and |
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junction box. |
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Rear |
2"* |
9" for mounting relief valve in standard |
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location**. |
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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.
*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.
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.
2
PREINSTALLATION
C. CHIMNEY / VENT AND DRAFT CONTROL
An oil-fired unit shall be connected CAUTION to a flue having sufficient draft at all
times, to assure safe proper operation of the unit.
1.Draft Requirement – 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:
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Old |
New |
Comments |
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Installation |
Installation |
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No change, but older |
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Chimney |
-.04" |
-.04" |
chimneys (especially unlined |
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Draft |
ones) have leaks which |
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reduce draft. |
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Boiler |
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Design |
+.01" |
+.04" |
Required for mandated |
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Pressure |
efficiency increases. |
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Drop |
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The old installation would |
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have had a higher |
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Draft |
-.03" |
0.00" |
temperature in the chimney |
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Over Fire |
[as high as 800 degrees vs. |
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400 degrees F], which would |
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increase the draft. |
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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
3
BOILER PLACEMENT AND ASSEMBLY
2. BOILER PLACEMENT AND ASSEMBLY
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.
4
BOILER PLACEMENT AND ASSEMBLY
Figure 2.1: Steam boiler
Figure 2.2: Water boiler
(See Table 8.1 on page 22 for parts identification).
5
PIPING AND CONTROLS
3. PIPING AND CONTROLS
Do not pipe boiler before jacket is NOTICE installed.
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.
Boiler Model |
Supply Riser |
Equalizer |
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No. |
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WBV-03 |
(1) 2" |
1-1/4" |
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WBV-03 |
(1) 2" |
1-1/4" |
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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.
Figure 3.1: Water Boiler Piping |
Figure 3.2: Steam Boiler Piping |
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