PB DE-03, Installation, Operation & Maintenance Manual, Page: 2 / 44

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 . . . . . . . . . . . . . . . . . . . . . .2
C. AIR FOR COMBUSTION AND
VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . .3
D. INSTALLATION SURVEY . . . . . . . . . . . . . . . .5
E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .6
F. MASSACHUSETTS INSTALLATIONS . . . . . .6
2. BOILER SET-UP 7
3. WATER PIPING AND CONTROLS 8
A. BOILER SUPPLY AND RETURN . . . . . . . . . . .8
B. SAFETY RELIEF VALVE . . . . . . . . . . . . . . . . .9
C. PIPING FOR ZONED SYSTEMS . . . . . . . . .10
D. EXPANSION TANK . . . . . . . . . . . . . . . . . . . .11
E. INDIRECT-FIRED WATER HEATER . . . . . . .11
F. FREEZE PROTECTION . . . . . . . . . . . . . . . . .11
4. VENTING 12
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .12
B. CHIMNEY VENTING . . . . . . . . . . . . . . . . . . .12
C. DIRECT EXHAUST
HORIZONTAL VENTING- . . . . . . . . . . . . . . .12
D. DIRECT EXHAUST
VERTICAL VENTING . . . . . . . . . . . . . . . . . .15
E. BOILER REMOVAL FROM
COMMON VENTING SYSTEM . . . . . . . . . .16
5. GAS PIPING 17
6. ELECTRICAL 19
A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
B. ZONED SYSTEM WIRING . . . . . . . . . . . . . .19
C. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . .19
D. BOILER SEQUENCE OF OPERATION . . . . .21
7. START-UP PROCEDURES 22
A. COMPLETING THE INSTALLATION . . . . . .22
B. CONTROL DESCRIPTIONS . . . . . . . . . . . . .26
C. ADJUSTMENT OF GAS PRESSURE
REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . .26
D. CHECKING BURNER INPUT . . . . . . . . . . . . .26
E. CHECK-OUT PROCEDURE . . . . . . . . . . . . . .27
8. TROUBLESHOOTING 29
A. SHUT-DOWN CAUSED BY PILOT OUTAGE,
PRESSURE SWITCH OR FLAME ROLL-OUT
SAFETY SHUT-OFF SWITCH . . . . . . . . . . . .29
B. TROUBLESHOOTING GUIDES . . . . . . . . . .29
C. MEASURING SUCTION PRESSURE . . . . . .29
9. MAINTENANCE 33
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .34
B. DAILY (WITH BOILER IN USE) . . . . . . . . . . .34
C. WEEKLY (WITH BOILER IN USE) . . . . . . . . .34
D. MONTHLY (WITH BOILER IN USE) . . . . . . .34
E. ANNUALLY (BEFORE START OF HEATING
SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . .35
10. BOILER DIMENSIONS & RATINGS 36
11. REPAIR PARTS 38
A. BLOCK/BASE/FLOOR PAN
JACKET/FLUE COLLECTOR . . . . . . . . . . . . .38
B. BASE/BURNERS/MANIFOLD . . . . . . . . . . . .40
TABLE OF CONTENTS
TABLE OF CONTENTS
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