Instruction/ maintenance manual of the product DE PB Heat
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DE Boilers Series Gas Installation, Operation & Maintenance Manual.
ii USING THIS MANUAL 1 A . INST ALLA TION SEQUENCE . . . . . . . . . . . . .1 B . SPECIAL A TTENTION BO XES . . . . . . . . . . . .1 1. PREINST ALLA TION 2 A . ACCESSIBILITY CLEARANCES . . . . . . . . . . .2 B . CLEARANCE FROM COMBUSTIBLE CONSTRUCTION .
1 A. INST ALLA TION SEQUENCE F ollow 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.
2 A. ACCESSIBILITY CLEARANCES Install boiler not less than 24 ″ (610 mm) between the left side, top, and front of the boiler and adjacent wall or other appliance, when access is requir ed for ser vicing. B. CLEARANCE FROM COMBUSTIBLE CONSTRUCTION The design of this boiler is cer tified for closet installation with the following clearances: 1.
3 where: I fan = Input of the fan assisted appliances in Btu/hr ACH = air change per hour (per cent of the volume of the space e xchanged per hour , expr essed as a decimal) F or appliances other than.
4 ii. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free ar ea of 1 in 2 per 2000 Btu/hr (22 cm 2 per 2000 W) of total rated input for all appliances in the space.
5 c. Each of the appliances ser ved shall be interlocked to the mechanical air supply to prevent main burner operation where the mechanical air supply system is not in operation.
6 BOILER SET -UP 1. Provide a sound, level foundation. Locate boiler as near to the chimney or outside wall as possible and centralized with respect to the heating system. 2. Locate boiler in front of installation position before removing crate. 3. If using combustible floor pan, position pan on foundation or flooring.
7 A. BOILER SUPPL Y AND RETURN 1. Size the supply and return to suit the system. A typical piping arrangement is shown in Figure 3.1. Refer also to the I=B=R Guide to Residential Hydronic Heating Installation/Design and the PB Heat, LLC W ater Sur vey for additional guidance during water piping installation.
8 6. Install this boiler so that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and ser vice (circulator r eplacement, condensate trap, control replacements, etc.
9 C. PIPING FOR ZONED SYSTEMS 1. See Figur es 3.5 and 3.6 for basic zoned system layouts. 2. Run each zone pipe down then up to zone to prevent air accumulation in piping. 3. If requir ed, provide means to isolate and drain each zone separately . Figure 3.
10 D . EXP ANSION T ANK 1. Consult the tank manufacturer ’s instructions for specific information relating to tank installation. Size the e xpansion tank for the requir ed system volume and capacity . See T able 10.2 in Section 10 for boiler water capacity .
11 A. GENERAL 1. Install vent system in accordance with the "V enting of Equipment" Chapter of the National F uel Gas Code , ANSI Z223.1/NFP A 54, the "V enting Systems and Air Supply for Appliances" Section of the CAN/CSA B149.1, Natural Gas and P ropane Installation Code .
12 2. Refer to T able 4.2 for minimum and maximum vent length allowed. 3. Maintain a minimum 2” (51 mm) clearance between vent pipe and combustible construction. 4. When installing vent pipe through a combustible wall, pipe must pass through a metal wall thimble; maintain a 2” (51 mm) clearance between vent pipe and thimble.
13 VENTING Figure 4.2: Direct Exhaust, Sidewall V enting with V ertical Off-Set Figure 4.3: V ent Pipe Adapters.
14 D . DIRECT EXHAUST ; VERTICAL VENTING 1. This vent system will operate with a positive pressur e in the vent pipe. F ollow vent pipe manufacturer’s instructions for proper assembly of vent pipe and fittings. 2. Refer to T able 4.2 for minimum and maximum vent length allowed.
15 VENTING E. BOILER REMO V AL FROM COMMON VENTING SYSTEM At the time of r emoval 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: a.
16 1. Size and install the gas supply piping properly in order to provide a supply of gas sufficient to meet the maximum demand without undue loss of pressur e between the meter and the boiler . 2. Determine the volume of gas to be provided to the boiler in cubic feet per hour .
17 T able 5.3: Pipe Capacity Capacity of pipe of different diameters and lengths in cubic feet per hour [cubic meter per hour] with a pressur e drop of 0.3 inches of water [75 kP a] and a specific gravity of 0.60. No allowance for an ordinary number of fittings is requir ed.
18 A. WIRING 1. See Figur e 6.1 for location of wiring and controls. Use Figur e 6.2 to connect the boiler to a power supply and to connect components to the boiler . 2. Connect the boiler by a separate, permanently live electrical supply line with a fused switch.
19 D . SEQUENCE OF OPERA TION 1. Thermostat calls for heat, energizes Control Relay (CR). 2. Control Relay (CR) energizes circulator . 3. Limit senses boiler water temperature. P revents boiler operation until water temperature falls appro ximately 15 ° F (8 ° C) below the cut-out temperature.
20 Figure 6.3: Ignition System Operating Sequence ELECTRICAL.
21 ELECTRICAL Figure 6.4: Zone Wiring with Zone V alves Figure 6.5: Zone Wiring with Circulators.
22 A. COMPLETING THE INST ALLA TION 1. Confirm that all water , gas and electricity are turned off. 2. Inspect the boiler combustion chamber for foreign objects and remove if pr esent. 3. Check physical condition of burners and pilot. Make cer tain that ther e are no unusual bends or perforations in the bur ners or pilot.
23 Figure 7.1: Gas V alve, Manifold and Burner Assembly – Intermittent Ignition Figure 7.2: V alve T apping and Adjustment Screw Locations ST ART -UP PROCEDURES.
24 ST ART -UP PROCEDURES Figure 7.3: Operating Instructions SV9501/SV9601 9318 REV 2 (MM/YY) FOR YOUR SAFETY READ BEFORE LIGHTING W ARNING: If you do not follow these instructions exactly , a fire or explosion may result causing property damage, personal injury , or loss of life.
25 B. CONTROL DESCRIPTIONS See Figur e 6.1 in Section 6 (Electrical) for locations of these devices. 1. FLAME ROLL-OUT SAFETY SHUT -OFF SWIT CH (FLAME ROLL-OUT SWIT CH) – A ther mally activated switch located between the first burner from the left and the manifold bracket.
26 E. CHECK - OUT PROCEDURE 1. After star ting the boiler , be cer tain all controls are working properly . Check to be sure that the limit will shut off the boiler in the event of e xcessive water temperature. This can be done by lowering the limit setting until the main burners shut down.
27 3. Low W ater Cut-Off (if used) – Consult the manufacturer ’s instructions for the low water cut-off operational check procedure. 4. Check the system to make sure ther e are no leaks or overfilling problems which might cause excessive make-up water to be added.
28 A. SHUT -DOWN CAUSED B Y PIL OT OUT AGE, PRESSURE SWITCH OR FLAME ROLL-OUT SAFETY SHUT - OFF SWITCH In the event of a shut-down caused by a pilot outage, action of the pressur e switch or flame roll-out safety shut-off switch effecting a shut-down of the main burners: a.
29 TROUBLESHOOTING Figure 8.1: P rocedure For Measuring F an Suction Pressure SEE T ABLE 7.
30 TROUBLESHOOTING T able 8.2: Boiler T roubleshooting Guide (Burners Functioning) Problem P ossible Causes Cor rective A ctions 1. See Figur e 8.2 Burners not functioning. 1. See Figur e 8.2 1. Defective gas valve. 2. Short circuit. Burners will not shut down.
31 Figure 8.2: Boiler T roubleshooting Guide (Burners Not Functioning) TROUBLESHOOTING.
32 MAINTENANCE 9. MAINTENANCE W ARNING Product Saf ety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fiber s (RCF). Airborne RCF , when inhaled, have been classified b y the International Agency for Resear ch on Cancer (IARC), as a possible carcinogen to humans.
33 A. GENERAL 1. Disconnect this boiler from the gas supply piping during any pressur e testing of the gas system. 2. 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 fr eezing.
34 E. ANNU ALL Y (BEFORE ST ART OF HEA TING SEASON) 1. Check flueways and burners for cleanliness and clean if necessary . Use the following procedure if cleaning is requir ed: a. Refer to the Operating Instructions in F igure 7.3 to properly turn off the gas to the boiler .
35 BOILER DIMENSIONS & RA TINGS 10. BOILER DIMENSIONS & RA TINGS Figure 10.1: Boiler Views T able 10.1: Series DE Boiler Ratings 1 Net I=B=R water ratings based on an allowance of 1.
36 REP AIR P ARTS Figure 11.1: Block/Base/Floor Pan/Jack et/Flue Collector REP AIR P ARTS SERIES DE GAS BOILER Repair par ts are available from your installer or by contacting PB Heat, LLC, New Berlinville, P A. Use the figures and tables on pages 36-38 to assist in ordering parts.
37 REP AIR P ARTS Figure 11.2: Base/Burners/Manifold.
38 REP AIR P ARTS T able 11.1: Repair Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Block Assembly Base Assembly Observation Cover Door Base Blanket Seal Combustible Floor P an Assembly Steel Burner.
39 NOTES.
40 NOTES.
DE Boilers Series Gas Installation, Operation & Maintenance Manual TO THE INST ALLER: 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.
An important point after buying a device PB Heat DE (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought PB Heat DE yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data PB Heat DE - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, PB Heat DE you will learn all the available features of the product, as well as information on its operation. The information that you get PB Heat DE will certainly help you make a decision on the purchase.
If you already are a holder of PB Heat DE, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime PB Heat DE.
However, one of the most important roles played by the user manual is to help in solving problems with PB Heat DE. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device PB Heat DE along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
