PEERLESS PSC II Series Installation, Operation & Maintenance Manual

[Page 1] PEERLESS PSC II Series

PSC II ™ Boilers Series Gas 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. ...

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USING THIS MANUAL 1 A. INSTALLATION SEQUENCE . . . . . . . . . . . . .1 B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1 1. PREINSTALLATION 2 A. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2 B. CLEARANCE FROM COMBUSTIBLE CONSTRUCTION . . . ....

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A. INSTALLATION SEQUENCE 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 int...

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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 required for servicing. B. CLEARANCE FROM COMBUSTIBLE CONSTRUCTION Th...

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DETECTORS: Each carbon monoxide detector shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. • SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of...

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4 1. Provide a sound, level foundation. Locate boiler as near to the outside wall as possible and centralized with respect to the heating system. 2. Locate boiler in front of installation position before removing crate. 4. Separate the wood shipping...

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5 A. BOILER SUPPLY 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 Hydronics Institute Residential Hydronic Heating Installation Design Guide and the PB Heat Water Su...

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6. Install this boiler so that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacements, etc.). 7. If this boiler and ...

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C. PIPING FOR ZONED SYSTEMS 1. See Figures 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 required, provide means to isolate and drain each zone separately. 7 WATER ...

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8 D. EXPANSION TANK 1. Consult the tank manufacturer’s instructions for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity. See Table 10.2 in Section 10 for boiler water capacity....

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9 A. GENERAL Install vent system in accordance with Venting of Equipment part of the National Fuel Gas Code, ANSI z223.1/NFPA 54 or sections 7.2, 7.3 or 7.4 of CAN/CSA B149.1, Natural Gas and Propane Installation Code. B. WALL THIMBLE (SIDEWALL VENTI...

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10 5. Slide Stainless Steel Collar over vent pipe and slide to end of pipe. 6. Insert pipe with collar through Outside Vent Cap and slide 3" (76 mm) diameter hose clamp over collar. 7. Leave at least 2" (51 mm) of vent pipe protruding beyon...

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11 C. ROOF TERMINATIONS (VERTICAL VENTING) 1. Vent pipe and air inlet terminations must be within the maximum and minimum vent and air intake lengths shown in Tables 4.1 and 4.2. 2. Vent pipe and air inlet pipe must terminate 12" (305 mm) above...

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12 E . VENT PIPE INSTALLATION 1. For minimum and maximum vent pipe lengths see Table 4.1. 2. Use only 3" (76 mm) diameter Type AL29-4C stainless steel vent pipe and fittings for venting of flue gases from the boiler. When using other than Heat-...

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13 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 pressure between the meter and the boiler. 2. Determine the volume of gas to be provided to the boil...

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14 GAS PIPING Table 5.2: Pipe Capacity Capacity of pipe of different diameters and lengths in cubic feet per hour (cubic meter per hour) with pressure drop of 0.3 inches of water (75 Pa) and specific gravity of 0.60. No allowance for an ordinary numb...

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15 A. WIRING 1. See Figure 6.1 for location of wiring and controls. Use Figure 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 fu...

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16 D. SEQUENCE OF OPERATION 1. Thermostat calls for heat, energizes Control Relay (CR). 2. Control Relay (CR) energizes circulator. 3. Limit senses boiler water temperature. Prevents boiler operation until water temperature falls approximately 15 ° ...

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17 ELECTRICAL Figure 6.3: Ignition System Operating Sequence ...

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18 ELECTRICAL Figure 6.4: Zone Wiring with Zone Valves Figure 6.5: Zone Wiring with Circulators ...

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19 A. COMPLETING THE INSTALLATION 1. Confirm that all water, gas and electricity are turned off. 2. Inspect the boiler combustion chamber for foreign objects and remove if present. 3. Check physical condition of burners and pilot. Make certain that t...

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20 START-UP PROCEDURES Figure 7.1: Gas Valve, Manifold and Burner Assembly – Intermittent Ignition Figure 7.2: Valve Tapping and Adjustment Screw Locations ...

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21 START-UP PROCEDURES Figure 7.3: Operating Instructions ...

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B. CONTROL DESCRIPTIONS See Figure 6.1 in Section 6 (Electrical) for locations of these devices. 1. FLAME ROLL-OUT SAFETY SHUT-OFF SWITCH (FLAME ROLL-OUT SWITCH) – A thermally activated switch located between the first burner from the left and the ...

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23 3. Low Water 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 there are no leaks or overfilling problems which might cause excessive make-up wat...

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24 A. SHUT-DOWN CAUSED BY PILOT OUTAGE, 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 pressure switch or flame roll-out safety shut- off switch effecting a shut-down of ...

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25 TROUBLESHOOTING * Figure 8.1: Measuring Fan Suction Pressure Table 8.1: Boiler Troubleshooting Guide (Burners Functioning) PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONS Burners not functioning. See Figure 8.2 See Figure 8.2 Burners will not shut do...

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26 TROUBLESHOOTING Figure 8.2: Boiler Troubleshooting Guide (Burners Not Functioning) SYSTEM IS OKAY CHECK FOR PROPER VOLTAGE AT CONTROL HARNESS (SEE INSET A). VOLTAGE SHOULD BE 24V BETWEEN THERMOSTAT AND 24V COMMON, AND 24V BETWEEN 24V COMMON AND 2...

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27 MAINTENANCE 9. 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 Agenc...

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28 A. GENERAL 1. Disconnect this boiler from the gas supply piping during any pressure 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. Kee...

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29 b. Remove jacket removable door, air inlet pipe, air box cover, and air box diffuser screen. c. Remove burner hitch pin clips. Disconnect pilot tubing at compression elbow. d. Disconnect pilot harness at gas valve. Gently pull pilot harness furthe...

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30 MAINTENANCE Figure 9.2: Inspection of Flueways, Burners, and Vent System. ...

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31 BOILER DIMENSIONS & RATINGS 10. BOILER DIMENSIONS & RATINGS Figure 10.1: Boiler Views Table 10.1: Series PSC II™ Boiler Dimensions Table 10.2: Series PSC II™ Boiler Ratings 1 Net I=B=R water ratings based on an allowance of 1.15. 2 Con...

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32 REPAIR PARTS REPAIR PARTS SERIES PSC II™ GAS BOILER Repair parts are available from your installer or by contacting PB Heat, LLC, New Berlinville, PA. Use the figures and tables on pages 32-36 to assist in ordering parts. Note: Remember to inclu...

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33 REPAIR PARTS Description Quantity Required Stock Code 1 Base Assembly – PSCII-03 – 7800 Base Assembly – PSCII-04 – 7801 Base Assembly – PSCII-05 – 7802 Base Assembly – PSCII-06 – 7803 2 Floor Pan – PSCII-03 – 50100 Floor Pan �...

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34 REPAIR PARTS Figure 11.2 ...

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35 REPAIR PARTS Table 11.2 Description Quantity Required Stock Code 16 Insulation Blanket, 1/2" x 1.50", Block to Base – 50867 17 Block – PSCII-03 – 90419 Block – PSCII-04 – 90420 Block – PSCII-05 – 90421 Block – PSCII-06 �...

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36 NOTES ...

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37 NOTES ...

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PSC II ™ Boilers Series Gas Installation, Operation & Maintenance Manual TO THE INSTALLER: 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...