PeerlessBoilers PBC-34 Installation, Operation & Maintenance Manual Download Page 1

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PBC

™

Gas Boilers

PBC-34™, PBC-40™, PBC-52™

Combination

I n s t a l l a t i o n ,
O p e r a t i o n &
M a i n t e n a n c e
M a n u a l

Series

Summary of Contents for PBC-34

Page 1: ...PBC Gas Boilers PBC 34 PBC 40 PBC 52 Combination Installation Operation Maintenance Manual Series...

Page 2: ...R CONNECTIONS 27 C INTERNAL WIRING 27 8 BOILER CONTROL INTERNAL WIRING OPERATION 30 A CONTROL OVERVIEW 30 B AVAILABLE CENTRAL HEAT MODES 30 C AVAILABLE DOMESTIC HOT WATER MODES 31 D DISPLAY UTILIZATIO...

Page 3: ...ich will or can cause minor personal injury or property damage WARNING Indicates special attention is needed but not directly related to potential personal injury or property damage NOTICE In accordan...

Page 4: ...National Electrical Code e ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances 3 Where required by the authority having jurisdiction the installation must conform to the Standar...

Page 5: ...d clearances to allow reasonable access to the boiler for Models PBC 34 PBC 40 and PBC 52 However Local codes or special conditions may require greater clearances D COMBUSTION AND VENTILATION AIR 1 Th...

Page 6: ...ese openings shall be 3 inches 76 mm See Figure 1 2 for an illustration of this arrangement b Combining Spaces on Different Floors Provide one or more permanent openings communicating with additional...

Page 7: ...le indoor air volume outdoor air openings or ducts may be used to supplement the available indoor air provided a The size and location of the indoor openings comply with Subsection 3 b The outdoor ope...

Page 8: ...hey are proven in the full open position prior to ignition and during operation of the main burner i The interlock shall prevent the main burner from igniting if the damper fails to open during burner...

Page 9: ...sing 5 16 lag bolts Be sure the lag bolts are fully supported by wall studs or adequate wall structure 3 The mounting bracket has 4 holes on 16 centers as shown in Figure 2 1 This is intended to give...

Page 10: ...tandard for Type BH Gas Venting Systems VENTING AIR INLET PIPING 3 VENTING AIR INLET PIPING This vent system operates under positive pressure Vent connectors serving appliances vented by natural draft...

Page 11: ...tween exhaust vent and the air intake Increasing this distance minimizes the potential for contamination of the inlet air with exhaust d For multiple boiler installations the minimum horizontal distan...

Page 12: ...from forming or recirculation of exhaust gases from occurring Provide 3 feet clearance from the inside corner of adjacent walls b Figures 3 4 through 3 7 show approved sidewall venting configurations...

Page 13: ...11 Figure 3 6 Exhaust and Air Inlet on Opposite Walls Figure 3 7 Sidewall Exhaust with Indoor Air Figure 3 8 Optional Concentric Vent Kit Installation VENTING AIR INLET PIPING...

Page 14: ...th the National Fuel Gas Code D EXHAUST VENT AIR INTAKE PIPE SIZING 1 Series PBC boilers can be installed with 2 or 3 Exhaust Vent Air Intake piping with the vent length restrictions shown in table 3...

Page 15: ...onnections after the boiler connection are to be joined with suitable PVC CPVC adhesives in accordance with manufacturers instructions 13 VENTING AIR INLET PIPING Figure 3 12 Venting Through a Chimney...

Page 16: ...M COMMON VENTING SYSTEM At the time of removal of an existing boiler follow these steps with each appliance remaining connected to the common venting system placed in operation while the other applian...

Page 17: ...s and any other gas burning appliance to their previous conditions of use Apr s avoir tabli que les r sidus de combustion de chaque appareil qui demeure raccord au syst me commun sont ad quatement vac...

Page 18: ...ately to allow for the minimum flow rate required through the heat exchanger Ensure that the piping up to the boiler is capable of handling a minimum flow rate of 5 0 GPM to allow for proper flow rate...

Page 19: ...flow preventer check valve is required by some jurisdictions to prevent water in the hydronic system from backing up into the city water supply This is especially important on systems in which glycol...

Page 20: ...ng a Primary secondary piping required Series PBC boilers utilize a water tube heat exchanger that requires a minimum flow rate through the unit The internal pump provides enough flow to maintain this...

Page 21: ...e valve kits like Webstone kit 4443WPR or other similar valve kits meet the needs listed above Flow Restriction All Series PBC boilers contain a built in flow restrictor on the domestic water side of...

Page 22: ...20 WATER PIPING AND CONTROLS Figure 4 6 Recommended Central Heat Piping...

Page 23: ...21 Figure 4 7 Recommended Domestic Hot Water Piping WATER PIPING AND CONTROLS...

Page 24: ...eezing 9 Check local regulations to see if systems containing glycol solutions must include a back flow preventer or require that the glycol system be isolated from the water supply 10 Do not use galv...

Page 25: ...tween the gas regulator and the boiler C GAS SUPPLY PIPING INSTALLATION FUEL PIPING 5 FUEL PIPING Pipe Length ft m 1 2 NPT Pipe 3 4 NPT Pipe 1 NPT Pipe 1 1 4 NPT Pipe 1 1 2 NPT Pipe 10 3 0 132 3 7 278...

Page 26: ...e same gas line at their maximum inputs g Turn off the boiler and close the gas shutoff valve h Remove the manometer tube from the pressure tap fitting i Turn the internal screw clockwise to close the...

Page 27: ...PING Natural Gas Propane LP Low Fire High Fire Low Fire High Fire Carbon Monoxide CO 75 ppm 200 ppm 75 ppm 200 ppm Carbon Dioxide CO2 8 8 to 11 6 8 5 to 9 7 9 8 to 12 5 9 5 to 10 5 Table 5 3 Recommend...

Page 28: ...ndensate drain hole in the front left side of the unit 2 Insert the barbed and thread portion on the top of the trap through the hole and secure using the 3 4 G plastic locknut 3 Press the condensate...

Page 29: ...accessible through the front panel This interface allows users and installer to access information on the boiler operation and change settings on the control See Section 8 for more information 2 Retur...

Page 30: ...0 4 gallons per minute is detected the boiler will fire in DHW mode to provide domestic hot water 15 Stepper Motor The stepper motor is located in the CHB behind the flow sensor The motor controls the...

Page 31: ...29 Figure 7 2 Wiring Schematic and Connection ELECTRICAL CONNECTIONS...

Page 32: ...improve fuel usage and boiler efficiency Setpoint Boost function for long CH demand periods Boiler targets calculated CH setpoint and operates off of Supply temperature hysteresis when demand is pres...

Page 33: ...rity installer adjustable Domestic hot water pre heat While accessible via the Installer menu DHW modes 2 3 4 6 7 and 8 are not functional with the Series PBC boiler Figure 8 1 900LB Display Buttons T...

Page 34: ...ed 2 CH Temperature DHW Temperature Special Status Code number Parameter value Blinking parameter value Parameter actively being adjusted 3 Units of value being displayed by Icon 2 Not used 4 Pressure...

Page 35: ...ture 0200 10 minute System Test Once 10 minute timer is over boiler will return to normal state Additional Access with Installer access PIN Input installer PIN using CODE menu then return to User Menu...

Page 36: ...ful ignitions 1055 Number of failed ignitions 1056 Total hours of operation for CH Hours x 10 1057 Total hours of operation for DHW Hours x 10 1058 Total system run time Days 1059 Interval between loc...

Page 37: ...maximum CH input available to the control to satisfy a demand Default values should not be changed PBC 34 57 PBC 40 61 PBC 52 54 2015 Minimum CH Power Limits the minimum power available to the boiler...

Page 38: ...48 DHW Setpoint F 122 2064 Preheat Mode 0 OFF 1 Anti Frost plate heat exchanger is kept above 41 F 2 Eco Mode plate heat exchanger is kept above 86 F for faster response at expense of fuel utilization...

Page 39: ...LLED WARNING FAILURE TO PROPERLY SET THE APPLIANCE MODE CAN LEAD TO BOILER FAILURE CAUSING PROPERTY DAMAGE SEVERE PERSONNEL INJURY OR DEATH PBC 34 50 PBC 40 51 PBC 52 52 2139 De Air Functionality On p...

Page 40: ...unction Increment 2026 allows for control over how aggressively the Boost function will increase the calculated setpoint after the boost delay is met 7 The Boost Function Delay allows for control over...

Page 41: ...Mild Weather Design Outdoor Temperature Sets the Outdoor Temperature at which the boiler will target the Boiler Mild Weather Design Temperature For default Boiler will target 104 F when the outdoor t...

Page 42: ...oiler will always shutdown at this temperature and will never exceed it The Series PBC is not designed to run beyond this temperature Steps should be taken to improve the system to lower the required...

Page 43: ...nd gas valve before performing the pressure test If the supply pressure is too high or too low contact the fuel gas supplier 5 Double check the fuel gas supply pressure after the boiler is running to...

Page 44: ...5 4 d If the values in either of these instances falls outside the parameters listed in Table 5 4 turn off the boiler and contact your PB Heat representative For best results the value should be set f...

Page 45: ...E LIGHTING OPERATING PROCEDURES 43 START UP PROCEDURE...

Page 46: ...onnected D TYPICAL OPERATION CYCLE CENTRAL HEAT 1 Boiler is in standby No demand Central Heat Radiator symbol is constant 2 Demand is applied Central Heat Radiator symbol begins flashing 3 Switching v...

Page 47: ...ON Table 10 1 Lockout Codes Error Number Error Display Corrective Action 0 E2PROM_READ_ERROR Internal Software error Replace control 1 IGNIT_ERROR Three unsuccessful ignition attempts in a row Check f...

Page 48: ...ease flue temperature Check temperature delta across the boiler supply and return A low delta will cause increased flue temperatures due to poor energy transfer 17 STACK_ERROR Internal software error...

Page 49: ...sensor error Replace sensor if error does not correct itself 116 LOW_WATER_PRESSURE_SENSOR Low water pressure in system Check system pressure Check filling valve setting and expansion tank pressure Ch...

Page 50: ..._SHORTED Flue Sensor Shorted Check for resistance through the sensor by touching meter lead across both pins on the sensor Resistance should be between 15 k and 500 If no resistance is present replace...

Page 51: ...rovide adequate ventilation Wear a NIOSH MSHA approved respirator Wear long sleeved loose fitting clothing and gloves to prevent skin contact Wear eye goggles Minimize airborne dust prior to handling...

Page 52: ...tinues to leak it must be replaced before the boiler is returned to operation f Check that operating pressure and temperature have returned to normal g Check again to confirm that valve has closed com...

Page 53: ...t the condensate piping to the drain connection NOTE When firing the boiler the first few times you may experience some fluttering of the gas burner that may result in a flame lockout This is normal a...

Page 54: ...ce when removing the screws Pull the PHE up and out of the unit being careful to not get water onto any of the components 5 The PHE has 4 gaskets that seal the connections Remove and check these gaske...

Page 55: ...el CH Input MBH DHW Input MBH Heating Capacity MBH Net Rating MBH AFUE Min Max Min Max PBC 34 15 5 80 15 5 130 76 2 64 6 95 1 PBC 40 15 5 100 15 5 155 95 1 80 9 95 2 PBC 52 24 5 120 24 5 199 114 6 97...

Page 56: ...upply 120 VAC Nominal 102 132 VAC 60 Hertz 40 70 Hz Phase Neutral Fuse 5AT 250V Type GDG Blower Voltage 120 VAC Gas Valve Voltage 120 VAC Nominal 102 132 VAC 60 Hertz 40 70 Hz Phase Neutral Thermostat...

Page 57: ...THIS PAGE INTENTIONALLY LEFT BLANK...

Page 58: ...rom your local PB Heat LLC distributor or from Parts To Your Door at 1 610 916 5380 www partstoyourdoor com Note Remember to include the boiler model number and serial number when ordering parts 13 RE...

Page 59: ...ation Hydronic Block 1 54747 14 O Ring 20MM for Heat Exchanger 2 5525 15 O Ring CHB Return Square 116 3 5909 16 O Ring CHB Supply 1 5910 17 Heat Exchanger Rail PBC 34 PBC 40 2 54725 Heat Exchanger Rai...

Page 60: ...58 REPAIR PARTS Figure 13 2 PBC 34 Combustion Components...

Page 61: ...X 10mm for Electrodes 4 6512 6 Burner Door w Burner PBC 34 PBC 40 1 54795 7 M6 Flange Nut 4 6505 8 Burner Door Gasket 1 54790 9 Burner Door Insulation 1 54791 10 Target Wall Insulation 1 54793 11 PBC...

Page 62: ...60 REPAIR PARTS Figure 13 3 PBC 40 and PBC 52 Combustion Components...

Page 63: ...PBC 40 Isothermic Heat Exchanger 1 98105 PBC 52 Isothermic Heat Exchanger 1 98106 12 Blower Outlet Gasket 1 54122 13 RG148 Blower 130W 1 54720 14 O Ring Venturi to Blower 1 5911 15 HM140 Mixer PBC 40...

Page 64: ...Sensor With Clip 54802 Spare Fillling Valve Short With Clip 54803 Pressure Sensor With Clip 54804 Non Return Valve 54805 DHW Water Connection 1 2 NPT Inlet and Outlet w O Ring 54806 Central Heat Suppl...

Page 65: ...ty 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 PBC8013 R1 5 18 3C Printed in U S A 2018 PB...

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