HydroTherm PB Manuel utilisateur

HPB9-7

HydroTherm

STEA OR

ILER-

INSTALLATI

OT WATEIT

&PE

STRUCTI G

DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE

VESSEL CODE, SECTION IV FOR A MAXIMUM ALLOWABLE WORKING PRESSURE OF:

15 PSi STEAM OR 40 PSi WATER.

TO iNSTALLER

NOTE: READ THESE iNSTRUCTiONS CAREFULLY. THEY WiLL

SAVE YOU VALUABLE TiME WHEN ASSEMBLING THE BOILER.

THESE INSTRUCTIONS TO BE LEFT WITH THE BOILER FOR REFERENCE PURPOSES.

CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.

HydroTherm _

IN UNITED STATES: 260 NORTH ELM ST., WESTFIELD, MA 01085 •(413) 564-5515 FAX (413) 568-9613

IN CANADA: 7555 TRANMERE DRIVE, MISSlSSAUGA, ONTARIO L5S 1L4 • (905) 672-2991 FAX (905) 672-2883

www.hydrotherm.com

Page 2 PB SERIES BOILER INSTALLATION AND OPERATING INSTRUCTIONS

CONTENTS

General ....................................................................... 2

Codes, Rules and Regulations ................................... 2

Boiler Location ............................................................ 3

Chimney and Breeching ............................................. 3

Combustion and Ventilation ........................................ 3

Inspection ................................................................... 4

Jacket Assembly ......................................................... 4

Cleanout Cover Plates ................................................ 4

Boiler Trim ......................................... (water)5, (Steam)11

Thermostat and Limit Controls .......... (water)5, (Steam)12

Piping Connections ............................ (water)6, (Steam)11

Circulators .................................................................. 8

Domestic Hot Water Heaters ............. (water)9, (Steam)15

Filling the System .............................. (water)8, (Steam)14

Boiler Maintenance ...................... (water)9-10, (steam)15

Special Boiler Cable Installation ............................... 16

Replacement Parts ................................................... 19

Start-Up Checklist .................................................... 21

Burner Specifications ............................................... 22

GENERAL

The PB boiler-burner unit is a wet-base, vertical flue,

low pressure, sectional, cast iron steam or hot water

heating boiler. It is rated for natural draft firing with

-0.02" W.C. over the fire draft.

The ports between sections are provided with a special

hydronic seal which is resistant to petroleum products.

The flue gas seal between sections is accomplished by

the use of fiberglass rope rated at 1000 ° R

Packaged units are hydrostatically tested for the maxi-

mum working pressures.

An insulated metal jacket is furnished to both enhance

the units looks and to minimize any heat loss. A

full access cleanout cover for cleaning vertical flue

passages is on the left hand side of the boiler and is

accessible by removing the left hand cleanout access

jacket panel.

The PB boiler is offered in 2 different configurations:

1 - Packaged boiler with "burner in the box" shipped

separately.

2 - Packaged boiler with burner mounted and wired.

CODES, RULES AND REGULATIONS

The installation of the boiler, the burner, wiring, controls

and fuel piping must be done in accordance with the

requirements of the local authorities having jurisdiction.

In the absence of local requirements, the following

codes apply:

ANSI/NFPA31 - "Installation of Oil Burning Equipment"

ANSI/NFPA70- "National Electrical Code"

In Canada the following codes apply:

CSA STD. B149 - Latest Edition.

"Installation Code For Oil Burning Equipment."

CSA STD. C22.2 No. 0 - Latest Edition.

"General Requirements - Canadian Electrical Code

Part I1."

All completed boilers shall satisfactorily pass the

hydrostatic tests as prescribed by A.S.M.E., Code

Section IV.

Steam Boilers - The assembled boiler shall be

subjected to a hydrostatic test of not less than 45

psig.

Water Boilers - The assembled boiler shall be

subjected to a hydrostatic test pressure of 60 psig.

The required test shall not exceed the test pressure

by more than 10 psig.

PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS Page3

BOILER LOCATION

Boibr should be located on a smooth level concrete

floor or pad close to the chimney to minimize breeching

length. Allow access for boiler cleaning and burner

maintenance.

Figure 1A

12" OVERHANG

OF BLOCK AND

SHEETMETAL

ALL AROUND ///_H24 GAUGE

EETMETAL

4" HOLLOW CLAY TILE. ALIGN OPENINGS THRU

BLOCKS FOR MAXIMUM COOLING AND VENTILATION.

(VERIFY REQUIREMENTS WITH LOCAL INSPECTOR.)

(PER N.F.P.A.-31, PARAGRAPH 4-4.1.5)

Figure 1B

Clearance to Combustibles

Dimension Minimum * Service

Letter Description Clearance Clearance

A Front 24" 24"

B Back 12" 24"

C Top 6" 24"

D Flue Pipe 9"

E** Left Bide 24" 24"

F Right Side 12" 24"

The Service Clearances listed are only SIOM 79

suggested and ore not manditory.

• * Boiler clean out covers are located on

the left side, Additional clearance may be

needed for service.

Clearances to oil tanks and other hazardous

items will be greeter. Consult local codes.

CHIMNEY AND BREECHING

Attach the smoke hood to the back of the boiler using

the 4 brass machine screws making sure to install the

gasket between the smoke hood and boiler. (Gasket

and hardware located in literature bag.) The 3 and 4

section models are equipped with a 6" smoke hood,

the 5 and 6 section models with a 7" smoke hood. The

boiler must be vented with vent pipe having the same

diameter as the smoke hood collar. Place the flue pipe

over the smoke hood collar and secure it to the collar

with a sheet metal screw.

The flue pipe should be run to the chimney by the most

direct route, with the minimum number of elbows and

with a slight upward pitch. The pipe should terminate

flush with the inside face of the chimney and should be

sealed in place with insulating cement. The boiler must

be vented to the outdoors by means of a tile lined ma-

sonry chimney.

For energy conservation, the boiler can be vented

directly into a chimney without the use of a barometric

draft control, unless required by code or in instances

where the chimney can develop excessive draft.

Overfire draft greater than -0.05 inches W.C., with the

burner in operation, is excessive (normal draft is -0.02

to -0.04" W.C.).

COMBUSTION AND VENTILATION

Normal residential construction usually allows sufficient

air infiltration for combustion. If construction is tight,

consideration should be given for air louvers to the

outside. Local codes or NFPA 31, "Installation of Oil

Burning Equipment", should be referred to for proper

sizing and design and air supply. In Canada refer to CSA

STD. B149 -latest edition.

Page4 PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS

INSPECTION

Careful inspection should be made of all assemblies

to detect possible damage during shipment. Factory

assembled boilers are hydrostatically tested at the factory

to insure pressure tightness. Before piping connections

are made to the boiler, hydrostatically retest boiler

sections to detect leaks that may have developed from

rough handling during shipment. (Maximum allowable

working pressure of 15 psi steam or 40 psi water)

PACKAGED BOILERS

Packaged boilers are shipped on a wood skid with tie

down bands and a wooden crate enclosing the boiler

and burner installed.

Remove the protective crate and skid. Set the boiler in

its final location and shim under the feet to make it level

and secure. Adjust the jacket for proper alignment and

support. Refer to Oil Fired Boiler Electrical Diagrams

(PB) for appropriate wiring diagrams.

The "Burner in the Box"

Packaged boilers with "The Burner in the Box" are

shipped on a wood skid with tie down bands and a

wooden crate enclosing the boiler. The boiler is shipped

without the burner being mounted and wired in place.

The burner is shipped and inventoried independently of

the boiler. Burners from Carlin, Beckett and Riello are

available as options. The PB boiler is equipped with

a universal harness system utilizing a 6-pin electrical

connector. The harness system has been designed to

allow any of these burners to connect to both steam and

water boilers. The harness system is designed to make

burner replacement and routine servicing quicker and

safer to perform.

CLEANOUT COVER PLATE(S)

It is important to maintain the integrity of the gas seal by

careful installation of the cleanout cover plate. Be sure

there is no opening to allow gases to escape.

JACKET ASSEMBLY

Remove all knockouts that are going to interfere with

your specific installation arrangement. Install the front

panel over the two upper burning mounting plate studs

prior to the installation of the burner mounting plate. Fold

the right side panel at both the front and rear perforated

seams 90° back against the insulation. Slide the front fold

under the front panel and secure with philip head screw.

Lift side panel up slightly to align the slots in jacket with

the bracket holes. Secure with the screws supplied.

Repeat same procedure for the left side panel. Screw

the two folds together at the back of the boiler.

Attach the top panel over the edges of all panels and

secure. The cleanout cover door attaches to the left side

panel by sliding the lower left corner into the slot provid-

ed and up over the fold at the top of the opening in the

side panel. Slide the cover back toward the rear of the

boiler until it makes contact with the back of the slot.

Figure 2- Jacket Assembly

TOP RIGHT SIDE PANEL

PANEL

COVER PANEL

FRONT

PANEL

LEFT SIDE

PB SERIES BOILER INSTALLATION AND OPERATING INSTRUCTIONS Page 5

BOIL ERS Figure 4-Relief Valve Installation

WATER BOILER TRIM

The water trim furnished with the boiler consists of a

2-1/2" round temperature pressure gauge and a 30 psig

pressure relief valve. A circulator relay is furnished for

installation in the upper port cover plate or the tankless

heater cover plate as indicated in Figure No. 3. The

installer must furnish and install air removal devices,

expansion tank, automatic air vents, make-up water

pressure reducing valve, isolating valves and other pipe

fittings and equipment necessary for proper operating

system.

Figure 3

1-_1' RETURN TAPPING

(FRONT AND

Water Boiler 30# PSI PRESSURE

RELIEF VALVE

_i} _2" SUPPLY TAPPING

(FRONT AND REAR)

_HYDRONIC RELAY

HONEYWELL

L8124A OR L8148A

_PRESSURE GUAGE

_BURNER

SIOM-11-1

REV,

Pressure Relief Valve

Install safety relief valve (30 psi) in top 3/4" tapping of

back section.

SUPPORT DISCHARGE

DISCHARGE PIPE SIZE _ PIPING SO AS TQ AVOID

EQUAL TO VALVE OUTLET //STRAIN ON VALVE BODY

DO NOT RESTRICT FLOW. ,_

f- i/b ,: ,

_i_ _'_ RELIEF OR SAFETY VALVE.

FOR DISCHARGE t_ DO NOT REMOVE RATING

PIPING THROUGH . OR WARNING TAGS

ROOF CONSULT ....

THE HYDROTHERM CO.

DISCHARGE SO t: ............. ................................

AS TO AVOID _ ........................................................

EXPOSUREOF ....\

PERSONS TO HOT \:

LIQUIDORVAPOR.

LEAVE OPEN END

VISIBLE FOR PERIODIC_

INSPECTION FOR SLOW

LEAKAGE OR DRIPS.

THERMOSTAT AND LIMIT CONTROLS

Many jurisdictions require dual limit controls. The boiler

installer must arrange to comply with local requirements

by furnishing and installing any extra controls.

The water boiler without tankless water heater isfurnished

with a Honeywell L8148A hydronic relay, which, provides

high limit and circulator switching upon signal from a 24

volt thermostat control, The water boiler with tankless is

furnished with a Honeywell L8124A hydronic relay, which

provides high limit, low limit and reverse action circulator

control under signal from a 24 volt thermostat,

Page6 PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS

PIPING

Pumped Bypass

For these systems that may experience condensation,

an additional circulator and balancing valve can be

used to provide a return water temperature blend. This

method works well with systems with multiple zones

with circulators, see Figure 5. The dedicated bypass

circulator provides a strong blending flow without

diminishing the flow available to any heating zone. Any

residentially sized circulator is adequate for this purpose.

The balancing valve allows for adjustment of the return

temperature (see adjustments procedure in Figure 5).

Pump Away Bypass

For systems that use a single circulator to pump away

from the boiler, the bypass should be installed on the

discharge side of the circulator, see Figure 6. Full

temperature water supplies the baseboard distribution

system as before. Half of the circulator's volume moves

through the bypass, blending and heating the cooler

return water. Again, the cost of installing the bypass is

small and setting it by temperature can be accomplished

with a contact thermometer (see bypass adjustment

procedure Figure 6).

Figure No. 5 - Pumped Bypass

SI 'STD

.qU RI

ra]n_C°

D ck Backflow-Prevention

Device

Pumped Byposs

Multiple

CirculQtor Zones

COLD WATER

MAKE UP

_" 0 <_ (_ Z-_ CheckValve

A: pVaeran_o&r Ex PTans_on Aquastat Th ...... tar RPrie_r ee

System Purging.

1. Close valve A and C.

2. Attach a short hose to valve D and submerge in bucket

of waten Open Valve D.

3. Manually open the fill valve and use the domestic water

system pressure to purge air from each zone one at a

time. When air bubbles stop flowing from the hose

close valve D.

4. Rest fill valve to automatic fill, and open valves A and C.

Bypass Adjustment Procedure To Maintain lnlet

Te mperature Above Dew Point

Tl=Temp Min=130 ° F

1. Turn boiler on and close valve A.

2. After steady_state operation, if T1 is less than 130 ° F

slowly open valve A until T1 climbs to desired operating

temperature above 130° F.

3. Check after system operating temperature has

stabilized. Make final adjustments.

NOTES:

1. Boiler circuit piping must be sized large enough to handle

maximum flow through unit.

2. Boiler pump sized to boiler design flow requirements.

3. All boilers furnished with factory mounted water

temperature/pressuregauge.

4. A plug valve will allow the best flow control for the bypass.

A ball valve may not be suitable and may create noise.

Notice: These drawings show suggested piping configuration

and valving. Check with local codes and ordinances for

specific requirements. S10M-85

Pressure Balance Valve Ball or Gate

Reducing Valve Valve

PB SERIES BOILER INSTALLATION AND OPERATING INSTRUCTIONS Page 7

Figure No. 6 - Pump Away Bypass

SYSTEM

RETURN

Valved Bypass

Single

Circulator Zone

A B

SUPPLY IZ_ ?

.......... De PrceeV........

Valved Bypass

Single/Multiple

Zone Valves

SUPPLY IZ_

RETURN

System Purging.

1. Close valve A and C.

2. Attach a short hose to valve D and submerge in bucket of

water. Open Valve B and D.

3. Manually open the fill valve and use the domestic water

system pressure to purge air from each zone one at a time.

When air bubbles stop flowing from the hose close valve D.

4. Rest fill valve to automatic fill., and open valves A and C.

Bypass Adjustment Procedure To Maintain Inlet

Temperature Above Dew Point

Tl=Temp Min=130 ° F

1. Turn boiler on and open valves A & B.

2. After steady-state operation, if T1 is less than 130 ° F

slowly close valve B until T1 climbs to desired operating

temperature above 130 ° F.

3. If T1 is greater than desired operating temperature, slowly

close valve A to adjust to lower desired temperature above

130 ° F.

4. Check after system operating temperature has

stabilized. Make final adjustments.

NOTES:

1. Boiler circuit piping must be sized large enough to handle

maximum flow through unit.

2. Boiler pump sized to boiler design flow requirements. A

percentage of the pump capacity is used for the bypass blend.

3. All boilers furnished with factory mounted water

temperature/pressure gauge.

4. A plug valve will offer the best flow control for the bypass. A ball

valve may not be suitable and may create noise.

AIrV_enta _ E _ .... Q"_astat -The21ete Pr es_a re _'_

S_p ...... X_an_ u r Rel e_Jve C ......... Reduc,ng .....

Notice: These drawings show suggested piping configuration

and valving. Check with local codes and ordinances for

specific requirements. S10M-86

Balance Valve Pump "Valve"

Reverse Acting Aquastats

There is an alternative for existing systems experiencing

condensation that does not require re-piping the boiler.

It is very effective on single zones high mass systems

with large water volumes and cast iron radiation. This

option utilizes a reverse acting aquastat, one that makes

on temperature rise. Wired in series with the circulator,

this control allows the burner to fire while holding the

circulator off until the boiler reaches an acceptable

temperature. It then starts the system circulation again,

see Figure 7.

The most commonly available reverse acting aquastat is

a Honeywell L4006B. The aquastat should be mounted

in an immersion well directly installed in the boiler. The

use of heat conductive grease, Honeywell part #972545,

in the immersion well is strongly recommended for

fast and accurate temperature response. Set this

adjustable aquastat to make at no less than 130°R

While this method can cause the circulator to cycle

more frequently, setting the aquastat's differential to the

maximum 25-30°F will minimize short cycling.

Figure No. 7 - Reverse Aquastat

REVERSE

AQUASTAT

SET AT 130 ° F

115 volts ---}_

_._______reverse

N.OO. cJrc-_lator 1

T _

Each of these bypass solutions also has the added

benefit of increasing circulation in the boiler which will

maximize tankless coil output and increase the accuracy

of temperature sensing controls.

Page8 PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS

FILLING THE SYSTEM

Water

Fill the system slowly, while venting air and checking for

leaks. Do not operate the circulator until the system is

full. Run the circulator without firing the burner until all

air has been bled from the system.

When the relief valve is set to operate at 30 psi, the

initial fill pressure should be sufficient to fill the system

to the high point and develop a pressure at that point

so as to prevent the water in the system from boiling

at the maximum operating temperature. Under normal

conditions, a static height of 18-1/2 feet will require an

initial fill pressure of 12 psi. If using the suggested piping

arrangements, see the system purging instructions with

the diagram.

CIRCULATORS

The Taco 007 and 0010 circulators are suitable for use on

a closed heating system with 30 psig maximum operating

pressure. If a circulator is furnished with the boiler does

not have the required capacity to serve the connected

load, provide an extra zone circulator or change the

circulator to the proper size. Capacity curves for the

circulators are provided in these instructions to permit the

sizes to be checked with the system requirements.

Graph 1

21o

oS "\ _ --

5 10 15 20 25

FL0W-GPM

ASpecial Note to Installers of Water Boiler: All Carlin

and Beckett burners, shipped separately under the

"Burner In The Box" program do not have a jumper wire

installed on the T-T terminals on the primary ignition

control. Water boilers require this jumper in order to

operate. On water boilers the thermostat is connected to

the aquastat relay, on a steam boiler the thermostat will

be connected to the T-T terminals on the primay ignition

control (see Figure No. 8).

Figure No. 8

JUMPER

WIRE

T-T

THERMOSTAT

TERMINALS ARE

WlRE_

SIOM-80

NOTE: A JUMPER WIRE MUST BE ADDED TO ALL CARLIN AND

BECKETT BURNER CONTROLS USED ON WATER BOILERS.

FAILURE TO ADD THIS JUMPER WILL RESULT IN AN

iNCOMPLETE CIRCUIT AND A NO RUN CONDITION,

Toco 007

Toco 00t0

Grundfos UP15-42F

Belt & Gossett NFR-22

SIOM-IO

NOTE: The Taco 0010 circulator is rated for 125 psig

maximum operating pressure.

PB SERIES BOILER INSTALLATION AND OPERATING INSTRUCTIONS Page 9

DOMESTIC HOT WATER HEATERS

Tankless domestic hot water heaters are available for

water boiler application.

Figure No. 9 -Tankless Heater

OPERATING CONTROL

W VE {

CHECK VALVE

COLDWATERSUPPLY_. Z;_.,_ V";_i

\ _ jJ "TEMPERED HOT

WATER SUPPLY

Table 1

DOMESTIC HOT WATER SUPPLY

WATER BOILER

No. of Firing Intermittent

Sections Rate Draw (GPM)

Low 2.50

3High 2.5O

Low 3.30

4High 3.30

Low 3.80

5 High 4.5O

Low 4.60

6 High 5.OO

40° to 140° temp. rise at 180° F. boiler water.

Continuous

Draw (GPM)

1.75

2.00

2.50

2.90

3.30

3.90

4.00

4.90

WATER BOILER MAINTENANCE

CAUTION: Servicing, inspection and adjustment

must be done by atrained technician in accordance

with all applicable local and national codes.

Improper servicing or adjustment can damage the

boiler!

The boiler must be cleaned and inspected at least once

a year before each heating season. Make sure that the

burner and ignition components are free from dust, soot,

dirt, corrosion or other deposits that would impair the

boiler's performance.

Safety checks should include, but not limited to, the

items listed in the PB Boiler Safety Checklist. This Safety

Checklist is included at the end of the manual. A trained

technician with a calibrated combustion analyzer should

be hired to test and set up the oil burner to assure

maximum safety and efficiency. Consult the manufacturer

of each individual safety control for recommendations for

service and adjustment.

Water Controls

1. WATER PRESSURE:The boiler water pressure must

be sufficient to maintain a full system and to prevent

boiling of the system water. An initial fill pressure of

12 psi provides for 18-1/2 feet of system height. Each

additional 2.3 feet of height requires an additional

one pound pressure. Be sure no air is trapped in

the boiler, system piping or heating units to impede

circulation of the heated boiler water.

2. LOW WATER CUTOFF: Check the cutoff switch

to be certain the switch opens on water level drop

below cutoff point.

3. TEMPERATURE CONTROLS: Check regularly

to be sure the controls are functioning to prevent

excessive high boiler water temperature.

.RELIEF VALVES: Conduct regular visual inspection

of relief valves to detect signs of corrosive deposits,

rust buildup or signs of weeping. It should not weep

or discharge water at normal system pressure.

NEVER try to clean or repair the relief valve! If valve

fails replace it! Replace the valve with a new valve

of proper capacity and pressure setting if defective.

Page10 PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS

MAINTENANCE

Heating Surface Cleaning

Disconnect all electrical power to the boiler before

proceeding. Remove the cleanout cover access panel

from the left side of the boiler. Remove the cleanout

cover plate(s) taking care not to damage the insulation

between the cover plate(s) and the boiler. Use a wire

brush to thoroughly clean the fireside surfaces. For the

best results, start brushing from the top and work down

toward the combustion chamber. Disconnect the flue

pipe and inspect it and the smoke hood for soot build up.

Clean them thoroughly before reconnecting them. Open

the cleanout door on the right side of the burner mounting

plate. Carefully vacuum any soot or scale from the bottom

of the combustion chamber. Do not contact the ceramic

blanket in the bottom of the combustion chamber or it

will be damaged.

Inspect the cleanout door gasket and insulation and

replace them if damaged. Close the cleanout door and

tighten it into place. Inspect the cleanout cover insulation

and replace it if damaged, it is important to maintain

the integrity of the gas seal by careful installation of

the cleanout cover plate. Be sure there is no opening

to allow gases to escape. Install the cleanout cover

plate(s) and tighten into place. Install the cleanout cover

access panel, Restore electrical power to the boiler and

ensure that it operates properly,

Chimney and Smoke Pipe

Be sure that the chimney and smoke pipe do not

become obstructed by birds nests, squirrels, soot,

chimney liner deterioration, or other debris. Keep

chimney cleanout doors closed and sealed tight around

the frames. Be sure the smoke pipe is inserted only at

the nearest chimney liner surface and seal around the

pipe with insulating cement.

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