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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
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TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 1 5. BURNER SETUP & BOILER OPERATION 13 A. INSTALLATION CLEARANCE . . . . . . . . . . . . .1 A. BURNER INSTALLATION . . . . . . . . . . . . . . .13 B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1 B. BURNER START-UP AND ADJUSTMENT . .13 1. PREINSTALLATION 2 C. CHECK BOILER CONTROLS . . . . . . . . . . . .13 D. PURGE AIR FROM THE SYSTEM A. CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . .2 (WATER BOILERS ONLY) . . . . . . . . . . .
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USING THIS MANUAL USING THIS MANUAL Indicates a condition or hazard which DANGER A. INSTALLATION CLEARANCE will cause severe personal injury, death or major property damage. Follow the installation instructions provided in this manual in the order shown. The order of these Indicates a condition or hazard which instructions has been set in order to provide the installer WARNING may cause severe personal injury, with a logical sequence of steps that will minimize death or major property damage. po
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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, i
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PREINSTALLATION For Example: C. CHIMNEY / VENT AND DRAFT CONTROL Old New An oil-fired unit shall be connected Comments Installation Installation CAUTION to a flue having sufficient draft at all times, to assure safe proper No change, but older operation of the unit. Chimney chimneys (especially unlined -.04" -.04" Draft ones) have leaks which 1. Draft Requirement – Minimum draft required in the reduce draft. vent system is -.03" to -.06" W.C. depending on Boiler boiler model, see Table 7.1 (Sect
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BOILER PLACEMENT AND ASSEMBLY 2. BOILER PLACEMENT AND ASSEMBLY A. SETTING THE BOILER C. JACKET ASSEMBLY (KNOCKDOWN BOILERS) 1. Provide a level foundation, located as close as possible to the center of the heating system. 1. If the boiler is to be installed with a rear flue outlet, remove the square knock-out in the back panel. 2. Refer to Figures 2.1 and 2.2 for exploded view of boiler while checking and/or assembling parts of the 2. Attach back panel to bosses on middle of back boiler. section
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BOILER PLACEMENT AND ASSEMBLY Figure 2.1: Steam boiler Figure 2.2: Water boiler (See Table 8.1 for parts identification). 5
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PIPING AND CONTROLS 3. PIPING AND CONTROLS Do not pipe boiler before jacket is 4. When the return temperature from the system will be NOTICE installed. 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 A. PRESSURE TEST BLOCK ASSEMBLY condensation. Condensation will damage the boiler and will lead to shortened boiler life and 1. Make up cold water supply connection to the boiler. maintenance
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PIPING AND CONTROLS 2. If not using a tankless coil, cover the heater opening E. TANKLESS HEATER OR COVERPLATE with cover plate (item 7 or 16). 1. If a tankless coil is used (item 9), install as pictured. Be sure rubber gasket is in place On water boilers, install in opening in front section. NOTICE between cover plate or water heater On steam boilers, install in opening in rear section. plate and boiler section. For suggested piping of tankless water heaters refer to Figures 3.3 and 3.4. F. CON
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PIPING AND CONTROLS Figure 3.5: Piping to Isolate Boiler from Chilled Medium on Chiller Systems Figure 3.7: Float Low Water Cut-off Figure 3.6: Piping with Peerless Indirect Water Tank 8
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ELECTRICAL 4. ELECTRICAL 3. Install burner harness located in the burner carton. A. GENERAL Beckett or Carlin – PP7024 Harness All electrical wiring shall be done in accordance with the (11-1/2" conduit) National Electrical Code and Local Requirements. Single Riello – PP7023 Harness (17-1/2" conduit) pole switches including those of safety controls or protective devices shall not be wired in a grounded line. 4. For complete information on servicing and adjustment of controls, refer to the attac
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ELECTRICAL Figure 4.2: Water Boilers, Knockdown Figure 4.3: Water Boilers, Packaged 10
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ELECTRICAL Figure 4.4: Steam with Float Low Water Cut-Off Figure 4.5: Steam with Probe Low Water Cut-off 11
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ELECTRICAL Figure 4.6: Zoning with Circulators Figure 4.7: Zoning with Zone Valves 12
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BURNER SETUP & BOILER OPERATION 5. BURNER SETUP & BOILER OPERATION Burn only #2 Fuel Oil in this 2. Adjust burner and barometric draft control for CAUTION appliance. Do not use gasoline, highest CO (Maximum 13%) while maintaining a 0 ² crankcase drainings or any oil Smoke and -.01 to -.02" W.C. draft overfire. containing gasoline. All adjustments must be made using suitable instruments such as found in a Bacharach A. BURNER INSTALLATION Combustion Test Kit. 1. The oil burner is supplied with a m
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BURNER SETUP & BOILER OPERATION Do not leave boiler unattended while CAUTION E. CLEAN THE BOILER firing burner. Operating boiler with (STEAM BOILERS ONLY) water below minimum permissible water level may fracture sections. 1. Clean the boiler within one week after initial start-up. Cleaning will be more effective if boiler operates a 7. Turn on burner. Allow boiler water to heat up to just day or two to loosen sediment and impurities in below steaming (180 - 200°F). Do not allow boiler to system.
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BURNER SETUP & BOILER OPERATION Table 5.1: Beckett Burner Specifications BECKETT BURNER SPECIFICATIONS Start-up Settings Boiler Burner Burner Static Pump Head Nozzle Size Model No. Model No. Head Plate Pressure 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-03-105 AFG-F4 F4 3-3/8" 0.90 80° B HAGO 140 PSI 6.0 0 N/A 4 WBV-04-095 AFG-F4 F4 3-3/8" 0.85 80° B DEL 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-
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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 par
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MAINTENANCE A. GENERAL C. WEEKLY MAINTENANCE (WITH BOILER OPERATING) 1. Check pipes adjacent to cold walls or in unheated spaces. Insulate and tape them if necessary to be 1. Flush float-type low-water cut-off (if used) to remove sure they can't freeze up. Keeping the water moving sediment from the float bowl as stated in the at all times will reduce the likelihood of freezing. manufacturer's instructions. 2. If there is considerable foreign matter in the boiler D. MAINTENANCE OF SAFETY RELIEF w
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MAINTENANCE 2. To thoroughly clean the boiler it must be brushed G. IF A LONG SHUTDOWN IS REQUIRED down from the top. Alternatively, for limited space or minimum clearance to combustible installations, 1. To take boiler out of service if the boiler and system cleaning the heat exchanger from the combustion are not to be used when temperatures are below chamber side is acceptable. If unit is extremely dirty, it freezing: may be necessary to brush from both directions. The a. Drain the boiler and
