PeerlessBoilers WBV-03-060, WV-05-195, WV-05-175, WBV-04-150, WBV-04-125 Installation, Operation & Maintenance 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.

Plastic Jacket

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 . . . . . . . . . . . . . . . .4

E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .4

2. BOILER PLACEMENT AND ASSEMBLY 5

A. SETTING THE BOILER . . . . . . . . . . . . . . . . . .5

B. CONNECTING THE FLUE OUTLET . . . . . . . .5

3. WATER PIPING 6

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

B. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .6

C. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . . .9

D. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .9

E. SPECIAL APPLICATIONS . . . . . . . . . . . . . . . .9

F. TANKLESS HEATER OR COVERPLATE . . . . .9

G. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4. BURNER SETUP & BOILER
OPERATION 11

A. BURNER INSTALLATION . . . . . . . . . . . . . . .11

B. BURNER START-UP AND ADJUSTMENT . .11

C. CHECK BOILER CONTROLS . . . . . . . . . . . .11

D. PURGE AIR FROM THE SYSTEM

(WATER BOILERS ONLY) . . . . . . . . . . . . . . .12

5. ELECTRICAL 14

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .14

B. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

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. WATERSIDE INSPECTION . . . . . . . . . . . . . .19

H. INSPECT HEAT DISTRIBUTION SYSTEM . .19
I. IF A LONG SHUTDOWN IS REQUIRED . . .19

7. BOILER DIMENSIONS & RATINGS 20

8. REPAIR PARTS 22

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

1

USING THIS MANUAL

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.

NOTICE

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

NOTICE

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

CAUTION

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.

WARNING

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 below 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.

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.

Figure 1.1: Appliance Installation Clearances

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

Do not tamper with boiler controls.

CAUTION

DANGER

Do not install this appliance on carpeting.

Do not install this appliance where gasoline or other
flammable liquids are stored or are in use. Do not
store clothing or combustible materials on or against
the venting system or jacket.

WARNING

Never burn garbage or paper in the unit, and never
leave combustible material around it.

CAUTION

3

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.

4. Special Conditions: If the boiler is located in areas

with exhaust fans, direct-fired water heaters or
fireplaces can create conditions for unsatisfactory
combustion or venting, special provisions must be
made.

5. Specially Engineered Installations: The size of the

combustion air openings in this section may not
apply to specially engineered systems. These systems
are to be designed to ensure adequate supply of air
for combustion and ventilation.

C. CHIMNEY / VENT AND DRAFT CONTROL

1. Draft Requirement – Minimum draft required in the

vent system is -0.03" to -0.03" W.C. depending on
boiler model, see Table 7.1 (Section 7). This draft is
necessary to provide the necessary draft over fire of

-0.01" to -0.02" 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 -0.06" 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 +0.01".

PREINSTALLATION

Old

Installation

New

Installation

Comments

Chimney

Draft

-0.04" -0.04"

No change, but older
chimneys (especially unlined
ones) have leaks which
reduce draft.

Boiler

Design

Pressure

Drop

+0.01" +0.01"

Required for mandated
efficiency increases.

Draft

Over Fire

-0.03" -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.

Do not install this appliance where corrosive
materials, such as ammonia, chlorine, water softener
salt, etc. are stored.

CAUTION

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

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

5

A. SETTING THE BOILER

1. Provide a level foundation, located as close as
possible to the center of the heating system.

2. Refer to Figure 8.1 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 1,
"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 top jacket panel and remove the large
knockout in the jacket top panel. A stub vent will be
required to extend the vent above the jacket top
panel (not provided).

2. Remove the rear outlet cover plate (Item 13 Figure

8.1) and mount the flue collar to the flue collector
plate (Item 11 Figure 8.1) with the 4 #12 screws.

3. Attach the rear outlet cover plate (item 13) to the
rear outlet opening using four (4) 5/16" bolts and
washers provided.

2. BOILER PLACEMENT AND ASSEMBLY

BOILER PLACEMENT AND ASSEMBLY

6

A. GENERAL

1. Follow these instructions closely in order to be sure
that the boiler operates as it is intended. Water piping
is extremely important to the system operation.

2. Size water supply and return piping in accordance
with system requirements.

3. If the WBV/WV™ boiler is replacing and existing boiler,
make sure that the system piping is thoroughly cleaned
and free from debris before installing this boiler.

4. Install this boiler so that the oil burner and limit
controls are protected from water (dripping,
spraying, etc.) during operation and service.

5. The WBV/WV™ boiler is designed to operate in a
closed loop hydronic system under forced circulation.
However, there is no minimum water flow rate for
this boiler.

B. SYSTEM COMPONENTS

Figure 3.1 shows the symbol key for the 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
WBV/WV™ boiler to be mounted in the supply
(outlet) piping as shown in figure 3.2. 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. WATER PIPING

WATER PIPING

Figure 3.1: Symbol Key