PeerlessBoilers WBV-03, WBV-04, WBV-05 Installation Manual
WBV/WV
™
Boilers
Series
Oil
Installation,
Operation &
Maintenance
Manual
As an ENERGY STAR®Partner, PB Heat, LLC has determined that
this product meets the ENERGY STAR guidelines for energy efficiency.
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. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5. BURNER SETUP & BOILER
OPERATION 13
A. BURNER INSTALLATION . . . . . . . . . . . . . . .13
B. BURNER START-UP AND ADJUSTMENT . .13
C. CHECK BOILER CONTROLS . . . . . . . . . . . .13
D. PURGE AIR FROM THE SYSTEM
(WATER BOILERS ONLY) . . . . . . . . . . . . . . .13
E. CLEAN THE BOILER
(STEAM BOILERS ONLY) . . . . . . . . . . . . . . .14
6. MAINTENANCE 16
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .17
B. DAILY MAINTENANCE (WITH BOILER
OPERATING) . . . . . . . . . . . . . . . . . . . . . . . . .17
C. WEEKLY MAINTENANCE (WITH BOILER
OPERATING) . . . . . . . . . . . . . . . . . . . . . . . . .17
D. MAINTENANCE OF SAFETY
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . .17
E. MONTHLY MAINTENANCE (WITH BOILER
OPERATING) . . . . . . . . . . . . . . . . . . . . . . . . .17
F. MAINTENANCE – ANNUAL . . . . . . . . . . . . .17
G. IF A LONG SHUTDOWN IS REQUIRED . . .18
7. BOILER DIMENSIONS & RATINGS 19
8. REPAIR PARTS 21
TABLE OF CONTENTS
TABLE OF CONTENTS
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
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
1
USING THIS MANUAL
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.
3
C. CHIMNEY / VENT AND DRAFT CONTROL
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 control is recommended for
regulation of overfire draft. 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 or
download it from PeerlessBoilers.com.
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.
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
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 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 outlet, 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
BOILER PLACEMENT AND ASSEMBLY
(See Table 8.1 for parts identification).
Figure 2.1: Steam boiler
Figure 2.2: Water boiler
5
6
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 piping must allow for opening and closing
Burner Mounting Plate. PB Heat, LLC suggests installing
a 1-1/4 NPT tee, a 90° elbow, and a 1-1/4 NPT x 5"
long 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
"A"
Header "B" Equalizer "C"
WBV-03 (1) 2" 2” or 3” 1-1/4"
WBV-04 (1) 2" 2” or 3” 1-1/4"
Do not pipe boiler before jacket is
installed.
NOTICE
HEADER
B
EQUALIZER
C
A
RISER
MAKE –UP
CONNECTION
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