HydroTherm PB User manual

HPB9-7
HydroTherm
P
STEA OR
ILER-
INSTALLATI
I
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 •[phone] FAX [phone]
IN CANADA: 7555 TRANMERE DRIVE, MISSlSSAUGA, ONTARIO L5S 1L4 • [phone] FAX [phone]
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
I
SI 'STD
.qU RI
ra]n_C°
D ck Backflow-Prevention
Device
Pumped Byposs
Multiple
CirculQtor Zones
A
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
D
C
SUPPLY IZ_ ?
.......... De PrceeV........
Valved Bypass
Single/Multiple
Zone Valves
\
A
DC
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
15
B
I
21o
:z
u
_<
oS "\ _ --
5 10 15 20 25
FL0W-GPM
3O
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.

PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS Page11
STEAM BOILER TRIM
The steam trim furnished with the boiler consists of:
a 2-1/2" round steam pressure gauge, a Hydrolevel
CG450-2060 or a CGT450-2060 probe style low water
cut-off, water gauge glass set with gauge cocks, side
outlet steam safety valve, and high pressure limit control
with siphon, refer to Figure 10 for correct control and
trim locations. Pipe fittings required to install trim and
controls as shown are furnished.
Figure No. 10
Stearr" Boiler
(With Probe L,W.C.O.)
4x4 BoxJuction
with Swtch
OPTIONAL;LOW LIMIT_
AQUAS]AT USED ,_I_
W/TANKLESS COIL
(FRON] AND REAR)
_1_" REtURN lAPPING $40M-12-1
(FRONT AND REAR) REV A
Figure No. 11 =Piping Connections Steam (3=5 Sections)
SUPPLY
VALVE
GATE
DRAIN
1 1/4"
CLOSE NIPPLE
2" BELOW
WATER LINE
2" HEADE
PRESSURE
RELIEF VALVE
(15 PSI)
NIPPLE
RISER
4"x4" JUNCTION BOX
PROBE LOW WATER CUT-OFF
WATER GAUGEGLASS &:
(OPTIONAL FLOAT
LOW WATER CUT-OFF)
CONTROL
;KIM TAPPING
GAUGE
MAKEUP
GATE VALVE
$_0M-17-3-B
LEAVE SPACE FOR
FLUES
1 1/2" RETURN
CONNECTION

Page 12 PB SERIES BOILER INSTALLATION AND OPERATING INSTRUCTIONS
Figure No. 12 =Piping Connections Steam (6 Section)
GATE
SUPPLY
NIPPLES
GATE
DRAIN
1/4"
CLOSE NIPPLE
2" BELOW
WATER LINE
2"
RELIEF VALVE
(15 PSI)
x 20" RISERS
4"x4" JUNCTION BOX
PROBE LOW WATER CUT-OFF
WATER GAUGEGLASS &:
(OPTIONAL FLOAT
LOW WATER CUT-OFF)
CONTROL
TAPPING
ZSSURE GAUGE
C.W,
MAK
GATE
SlOM- 17-2-B
LEAVE SPACE FOR
FLUES
1 1/2" RETURN
CONNECTION
OPERATING AND LIMIT CONTROLS
The steam boiler is furnished with a high limit pressure
control and low water cutoff. If tankless hot water coil
is furnished, a low limit temperature control is included
and must be field wired. Recommended wiring diagrams
for these boilers are illustrated in the separate electrical
wiring diagram book.
Many jurisdictions require dual limit controls. The boiler
installer must arrange to comply with local requirements
by furnishing and installing any extra controls,
Safety Valve
install safety valve (15 psi) in top 3/4" tapping of back
section,
Figure 13 -Safety Valve Installation
,_ SUPPORT DISCHARGE
DISCHARGE PiPE SIZE _ PIPING SO AS TO AVOID
/
/
EQUAL TO VALVE OUTLET. //STRAIN ON VALVE BODY
DONOTRESTRICTFLOW
_'-_ RELIEF OR SAFETY VALVE.
FOR DISCHARGE ,_--_ DO NOT REMOVE RATING
PIPING THROUGH .... OR WARNING TAGS
ROOF CONSULT <
THE HYDROTHERM CO.
DISCHARGE SO \
AS TO AVOID _\
EXPOSURE OF \
PERSONS TO HOT
LIQUID OR VAPOR.
LEAVE OPEN END
VISIBLE FOR PERIODIC
INSPECTION FOR SLOW
LEAKAGE OR DRIPS.

PB SERIES BOILER INSTALLATION AND OPERATING INSTRUCTIONS Page 13
PROBE LOW WATER CUT-OFF
Two different probe low water cut-offs are used on the
PB steam boilers as standard equipment.The Hydrolevel
model CG450-2060 is used on models without the
tankless coil, the CGT450-2060 probe low water
cut-off is used on models with the tankless coil. The
probe low water cut-off senses water level by sending
an electrical current through a metallic probe mounted
in the water jacket of the boiler. If water is surrounding
the probe the current will travel through the water to the
metal casting and back to the control. The control will
then enable the boiler to run. Hydrolevel recommends
cleaning the probe yearly using a nylon-cleaning pad.
Hydrolevel has developed a "CycleGuard" feature that
uses a timer to shut the boiler down at regular intervals
for a "still water test". The still water test allows time
for foam and condensate to settle before determining
the true water level. This feature prevents foam and
wave action from generating a false high water level.
The Hydrolevel CG450-2060 control is used on all PB
steam boiler that are not equipped with the tankless
coil. The 2060 suffix in the part number refers to the
CycleGuard timing. This timing will allow the boiler to
run for 20 minutes and then will provide a 60-second still
water test. It is the CycleGuard feature, which in many
situations is instrumental in protecting boilers during low
water conditions. Foaming isthe most difficult problem to
overcome with a probe low water cut-off because it has
the same electrical properties as water. Lab experience
has shown that many boilers can have a severe foaming
situation even though the sight glass remains still and
crystal clear. To make matters worse, the generation
of foam often increases as the water level drops and
approaches the top of the crown sheet. The still water
test cycle has a minimum effect on the boiler heating
capacity. The boiler will resume a full rolling boil within 3
to 5 seconds of completing the still water test.
Water levels may fluctuate below the minimal safe level
momentarily as a result of waves generated bythe boiling
action. There is a timer delay function programmed into
the control that prevents the boiler from shutting off
unless the low water condition lasts longer than 10-12
seconds. This allows enough time to eliminate nuisance
shutdowns and yet the duration is short enough to
prevent damage to the boiler in the event of a real low
water condition.
The Hydrolevel control used on the PB steam boilers
has another feature called the SmartCycle. This feature
allows the timer to be reset at the start of each call for
heat to provide a full 20 minute run time between still
water testing. Without this option a boiler with a 2060
control timing that ran for 18 minutes on one call for heat
will only run for 2 minutes on the next call for heat before
shutting down for the still water test. This can appear
to be a "boiler short cycling problem" when in fact the
control timer is just finishing up the 20-minute cycle.
The Hydrolevel control is constantly testing for low water
even during standby when the boiler is idle.Testing is not
limited to the still water test period. Therefore every call
for heat essentially starts with a low water test. Through
testing it was determined the PB boiler could run for 20
minutes without needing a still water test. To utilize this
option an orange wire is connected from the burner to
the Hydrolevel control at the "Burne¢' terminal. This wire
sends a signal to the control each time the burner is
energized resetting the CycleGuard timer. This allows
the boiler to run a full 20-minute cycle on each call for
heat, or until the call for heat is satisfied.
For steam boilers equipped with a tankless coil there
is another SmartCycle feature that suspends the still
water test until the demand for domestic hot water is
satisfied. Normally after the still water test the boiler
is back to a full boil in a few seconds, but cold water
flowing through the tankless coil during this test period
can cause the boiler water temperature to drop. On
smaller boilers the burner output may not be enough
to allow the water temperature to rebound and still
produce domestic hot water. Steam boilers sold with
the tankless coil are provided with a control with a "T"
in the part number. The CGT450-2060 control will have
two extra pairs of terminals. There is a pair of terminals
labeled "Low Limit". These terminals connect to an
aquastat that measures the boiler water temperature
near the tankless coil. The second set of terminals
labeled "Thermostat" will connect to the T-T terminals on
the burner in parallel with the building thermostat. This
feature will suspend the still water test whenever the low
limit aquastat determines that the boiler is being used
to produce domestic hot water. This will help assure the
boiler maintains sufficient temperature for the tankless
coil to produce the hot water required.

Page14 PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS
FLOAT LOW WATER CUT-OFF
The float style low water cut-off is only offered as an
option on PB boilers. This control consists of a float
in a chamber that operates a switch. The chamber is
plumbed to the boiler at the minimum safe water level.
If the water drops below this level the float opens the
switch and turns the burner off. If the switch has a
second set of contacts a water feeder can be turned
on to automatically refill the boiler to the minimum level.
This control requires regular maintenance to assure
reliability. It is recommended that the float low water cut-
off gets "blown down" weekly to prevent the buildup of
sediment. The blow down procedure consists of placing
a bucket under the device and then opening the blow
down valve located on the control while the boiler is
under pressure. If the blow-down procedure is neglected
sediment can build up under the float holding it at a high
water position even though the water level has actually
dropped to a dangerous level. The float low water cut-off
can fail in a "run" condition when this happens leading
to dry firing of the boiler. In this event the warranty will
be voided. This device will require periodic disassembly
for a more thorough cleaning and inspection. The
mechanical switches will also need periodic replacing.
Consult manufactures literature for recommendations
on servicing.
CONSIDERATIONS WHEN USING
AUTOMATIC WATER FEEDERS ON
STEAM BOILERS
Every steam boiler at some time will need additional
makeup water.Water levels need to be controlled on steam
boilers to maintain correct steam-chest volume, prevent
dry firing or flooding. Excessively low water levels can
cause the iron to overheat creating a "dry fire "condition.
The addition of excessive makeup water can cause the
boiler to "flood" leading to a host of system problems and
damage to personal property.
System leaks that cause a continual loss of water will
require the constant addition of makeup water. Dissolved
minerals and oxygen are introduced with makeup water
and can severely reduce the life of a boiler. Dissolved
oxygen in the water can cause internal corrosion of the
cast iron leading to sludge formation and leaks. Mineral
buildup in conjunction with sludge deposits can reduce
the rate of heat transfer through the cast iron causing
overheating and cracking, ultimately leading to boiler
failure. Leaks must be repaired immediately to prevent
this from happening.
The addition of an automatic water feeder can greatly
reduce the number of nuisance lockouts due to low
water conditions. When selecting a water feeder
consideration should be given to preventing boiler
flooding and the monitoring of water usage as well. A
water feeder usually works in conjunction with the Low
Water Cut-off by means of the alarm terminals. When
the Low Water Cut-off turns off the boiler during a
low water condition the alarm terminals are activated.
These alarm terminals can be used to turn on the
water feeder. The Hydrolevel CycleGard Low Water
Cut-off has a 30 second delay between the time the
probe detects water and when the alarm terminals
are deactivated. If the water feed rate is too great the
boiler can be flooded during this period. The Hydrolevel
VXT-120 (120 Volt model) water feeder works well in
conjunction with the CycleGard Low Water Cut-off. It
has selection switches that are used to precisely meter
the amount of water added, preventing boiler flooding.
It is equipped with a digital counter that will monitor
water usage. This feature can be used to detect
increases in water consumption.
FILLING THE SYSTEM (STEAM)
Stable water level is a necessity for steam boilers. It
is very important to have boiler water free from oil,
grease, foaming materials etc. Therefore, flush the
boiler thoroughly through a bottom drain by introducing
clean water into the upper ports of all sections of the
boiler. After the boiler piping connections are completed
and the boiler can be fired, the boiler water should be
heated up and surface impurities flushed off through a
high connection (1-1/4 tapping provided in heater cover
plate) (see Figures 11 and 12) and then drained through
a bottom opening. The burner should not be operated with
a low water level in the boiler and makeup water should
not be introduced into a hot boiler.
If possible, the heating boiler should be operated for a
time with all condensate returning from the system to a
drain. This will remove impurities from the piping system
which, if not removed early, will eventually enter the boiler
and cause problems. In some instances, more than one
cleaning will be required to obtain a stable water line.

PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS Page15
DomesticHotWaterHeaters
Tanklessdomestichotwaterheatersareavailablefor
steamboilerapplications.
Figure No. 14-Tankless Heater
....................i i_ ......
OPERATING CONTROL
,,,Y
TEMPERING VALVE
CHECK VALVE
\\\\
COLD WATER SUPPLY
ii
TEMPERED HOT
WATER SUPPLY
Table 2
DOMESTIC HOT WATER SUPPLY
STEAM BOILER
No. of Firing Intermittent
Sections Rate Draw (GPM)
Low 2.50
3High 2.50
Low 3.30
4 High 3.5O
Low 3.50
5 High 3.5O
Low 3.50
6 High 3.50
Continuous
Draw (GPM)
1.75
2.00
2.50
2.90
3.30
3.50
3.50
3.50
STEAM BOILER MAINTENANCE
CAUTION: Servicing, inspection and adjustment
must be done by a trained 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 and 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 perfomrance.
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.
Steam
1. WATER LEVEL: Check regularly to be sure the boiler
water level stays at the marked water line during
operation under steam pressure. DO NOT ADD
WATER TO A HOT BOILER. If water level is not
visible in the gauge glass, allow the boiler to cool
before adding makeup water. Locate the cause of
low water and correct before starting operation.
2. LOW WATER CUTOFF: Check the burner cutoff
switch to be certain the switch opens on water level
drop below cutoff level.
3. PRESSURE CONTROL(S): Check regularly to be
certain the pressure limit controls are functioning.
.SAFETY VALVE: Conduct regular visual inspection of
safety valve to detect signs of corrosive deposits, rust
build-up or signs of weeping. It should not weep or
discharge water at normal system pressure. NEVER
try to clean or repair the relief valve! Ifthe valve fails
replace it! Replace the valve with a new valve of
proper capacity and pressure setting if defective.
,GAUGE GLASS: When rust, suspended solids,
etc. appear in the gauge glass, blowdown may
be necessary. BIowdown should be limited only
as necessary to remove sediment from the boiler
waterways. Foaming, fluctuating water line,
steam hammer are signs pointing to the need for
blowdown.

Page16 PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS
HeatingSurfaceCleaning
Disconnectall electricalpowertotheboilerbefore
proceeding.Removethecleanoutcoveraccesspanel
fromtheleftsideoftheboiler.Removethecleanout
cover(s)takingcarenotto damagethe insulation
betweenthecover(s)andtheboiler.Useawirebrush
tothoroughlycleanthefiresidesurfaces.Forthebest
results,startbrushingfromthetopandworkdowntoward
thecombustionchamber.Disconnectthefluepipeand
inspectitandthesmokehoodforsootbuildup.Clean
themthoroughlybeforereconnectingthem.Openthe
cleanoutdoorontherightsideoftheburnermounting
plate.Carefullyvacuumanysootorscalefromthebottom
ofthecombustionchamber.Donotcontacttheceramic
blanketinthebottomofthecombustionchamberorit
willbedamaged.
Inspectthecleanoutdoorgasketandinsulationand
replacethemifdamaged.Closethecleanoutdoorand
tightenitintoplace.Inspectthecleanoutcoverinsulation
andreplaceitifdamaged,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(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.
PB WIRING
The PB boiler comes pre-wired with factory harnesses
that connect the safety control system. These boilers
are equipped with a harness system utilizing a 6-
pin electrical connector that joins the boiler to the
burner. Burners from Carlin, Beckett and Riello can be
connected to both steam and water boilers utilizing this
connector. The harness system is designed to make
burner replacement and routine servicing quicker and
safer to perform. The high limit control system on this
boiler is 120 VAC power. Only trained technicians should
attempt to troubleshoot or repair the control system.
All power should be turned off before attempting any
service work.
When troubleshooting the electrical system on an PB
boiler it is only necessary to check the wires that apply
to the specific burner and boiler combination being used.
There may be wires in the harness that are not used
for the particular application at hand. These wires have
been included to allow for all the various combinations
of boiler and burner choices. Consult the Electrical
Wiring Book shipped with each boiler for details.
Special Boiler Harness Requirements
On each boiler there are two harnesses with a 6-pin
connector -- the "Boiler Harness", which is provided
by the factory, and the "Burner Harness", provided by
the burner manufacturer. The factory manufactures two
different "Boiler Harnesses":
,The "Water" harness is primarily used on water
boilers but is also found on steam boilers with the
optional Float Low Water Cut-off. It runs from the
junction box directly to the burner (Part #79004).
,The "Steam" harness is only used for the steam
boiler with the Probe Low Water Cut-off. This
harness is shorter and has an additional ORANGE
wire used to signal the Cycle Guard timer to reset
at the beginning of the call for heat. (See the steam
boiler section on the Probe Low Water Cut-off for a
description of the Cycle Guard feature). The steam
harness runs from the Low Water Cut-off to the
burner (Part #79002).
Both boiler harnesses have a RED wire that provides
a constant 120V power supply used by the Carlin and
Riello burners. This RED wire is always provided, but
not used, on boilers equipped with the Beckett burner.
The Beckett "Burner Harness will not have a red wire or
corresponding pin in the connector.

PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS Page17
SpecialBurnerHarnessRequirements
AlloftheBurnerHarnesseswillhaveanORANGEwire.
Atthetimeofshippingit isnotknowniftheburnerwill
befiringasteamorwaterboiler.Onallwaterboilersthe
ORANGEwireisnotrequiredandwillterminateinthe
"BurnerHarness"connectorwithnocorrespondingpin
orwireinthe"BoilerHarness"connector.
The"BurnerHarnesses"ontheCarlinandRielloburners
havea REDwirenotfoundontheBeckettharness.The
Carlin60200controloffersa post-purgefeaturethat
cleansescombustionbyproductsafterthecallforheatis
satisfied.Aconstantsupplyofpowermustbeprovidedto
runtheblowermotorforthepost-purgefeature.Asimilar
powerrequirementisfoundwiththeRielloburner.The
Rielloburneris equippedwithan electricshutterthat
requiresconstantpowerforclosingafterthecallforheat
hasbeensatisfied.TheBeckett"BurnerHarness"does
nothavetheredwirebecausetheHoneywellR7184B
controlthatisuseddoesnothaveapost-purgefeature,
andtheburnerdoesnothaveanelectricshutter.
Table3=Wire Color Designation
Wire Color Designation
Red Constant Power
Black Safety Limits
White Neutral
Green Chassis Ground
Orange Low Water Cut-Off Reset
Yellow Circulator Hot
Note: When adding field wiring or if any wire needs to be replaced
use #18AWG MTW wire rated for 105°C and 600V.
Figure No. 15
WIRE HARNESSES
BK
Junction Box _'l_/_
Number
79003
Junction Box to Burner
Number
79004
1-_" RETURN TAPPING
(FRONT AND REAR'
]Water Boiler] r_ 2"(FRoNTSUPPLYANDTAPPtNGREAR)
i o
_--Hydronic Reloy
Honeywell L8124A
or L8148A
_Pressure Guoge
_BURNER
SIOM- 11-2

Page 18 PB SERIES BOILER INSTALLATION AND OPERATING INSTRUCTIONS
Figure No. 16
[ Steam Boiler
Junction Box to 4x4 Juction Box /(With Probe LW.C.O.) SUPPLY TAPPING
Limit Control with (FRONT AND REAR)
Number
79000
Optional:
_'_1_I? Low Limit Aquastat \
Junction Box to Used W/Tankless
Probe Low Water K (Field Supplied Harness
Cut-Off
(See Note)
Number
79006
Junction Box to Burner
Note:
1. Steam boilers built prior to
9-5-05 used a different Junction
Box to Probe Low Water Cut-Off
harness. Harness 79006 is a
dirreet replacement but attaches to
the Low Water Cut-Off at a
knockout located on the bottom of
the control Plug the unused open
knockout.
Number
79002 1-_" RFURN TAPPING
(FRONT AND REAR) SIOM- 12-2
Pressure
Limit Control
Water Guage
Glass
Guage
SKIM TAPPING
Hydrolevel Low
Water Cut-off
CG450-2060
OR
CGT450-2060
Figure No. 17
Junction Box to
Limit Control
Number
79000 B.K_
Junction Box to
Float LW.C.O.
Number
79005
Junction Box to Burner
Number
79004
Junction Box to Burner
(Same Harness Used On
Water Boiler)
Steam Boiler ]
(With Float L.W.C.O.)J
4x4 Juction Box
with
Optional:Low
Aquastat Used
W/Tankless Coil
1-_" RETURN TAPPING
(FRONT AND REAR
SUPPLY TAPPING
(FRONT AND REAR)
Hi Pressure
Limit Control
_Pressure Guage
_tlonal:
Float Low
Water Cut-off
TAPPING
S10M-15-2

PB SERIES BOILER INSTALLATION AND OPERATING INSTRUCTIONS Page 19
WATER AND STEAM REPLACEMENT PARTS
Figure No. 18
Water Boiler
NIPPLE
WITH BOILER
?
ISteam Boiler]
THREAD
COUPLER REQ'D
FIELD SUPPLIED
NIPPLE
SHIPPED WITH BOILER
DETAIL:
CLEANOUT DOOR
HINGE
5D-F
S10M-15

Page20 PBSERIESBOILERINSTALLATIONANDOPERATINGINSTRUCTIONS
WATER AND STEAM BOILER PARTS LIST
Table 4-Boiler parts
11
12
133
I4
15
NS
* Not Shown
Ref Part Description
No. No.
General Boiler Parts
71255 Smokehood 6" (33 & 4 Section)
17133933 Smokehood 7" (5 & 6 Section)
2 60354 Smokehood Gasket
NS* 61518 Replacement Smokehood Draft Plug
61772 Smokehood Mounting Screws 5/16
5 71257 Burner Mounting Plate
4 33385 Observation Cover Plate
NS _ 71319 Observation Cover Plate Screws
5A 33665 Cleanout Door
5B 61136 Cleanout Door Gasket
5C 611338 Cleanout Door Insulation
5D 61155 Cleanout Door Hinge
5E 60820 Cleanout Door Hinge Screws
5F 608333 Cleonout Door Roll Pin
6 61157 Insulation Block
7 600233 Wicking 1/4" (4 ft, Req'd)
74510 Floor Insulation Blanket- 5 Section
7433311 Floor Insulation Blanket- 4 Section
874312 Floor Insulation Blanket- 5 Section
74313 Floor Insulation Blanket- 6 Section
9 69406 Target Wall
55458 Cleanout Cover Plate 14 X 8
10 55459 Cleanout Cover Plate 14 X 12-1/2
651331 Cleanout Cover Plate InsuL 14 X 8
65152 Cleanout Cover Plate tnsuL 14 X t2-I/2
60020 Cleanout Cover Bolt (5/16)
62095 Cleanout Cover Washers (5/16)
60871 Cleanout Cover Jam Nut (5/16)
60881 Cleanout Cover Wlng Nut (5/16)
61875 3/4" Drain Valve
Ref Part Description
No. No.
Water Boiler Parts
70247 complete Jacket-,5 Section Water
NS* 70248 Complete Jacket-4 Section Water
70249 Complete Jacket-5 Section Water
70250 Complete Jacket-6 Section Water
70111 Water Block-3 Section
70112 Water Block-4 Section
16 701133 Water Block-5 Section
701t4 Water Block-6 Section
50523 Aquastat L8148A (Less TonMess)
17 50501 Aquastat L8124A (With Tankless)
18 61988 Relief Valve 30# (Water, Female Thread)
19 60265 Tamp & Pressure Guage
20 61161 Bushing. I"X 1-1/4"
21 5667 Heater Cover Plate (Water)
70009 Tonkless Heater, Water (5.5 GPM)
22 70010 Tankless Heater, Water (5.0 GPM)
25 60248 Heater Plate Gasket EPDM (Water & Steam)
Steam Boiler Parts
55404 Complete Jacket-3 Section
NS* 55405 Complete Jacket-4 Section
55406 Complete Jacket-5 Section
55407 Complete Jacket-6 Section
70272 Universal Block-5 Section
70273 Universal Block-4 Section
24 70274 Universal Block-5 Section
70275 Universal Block-6 Section
25 504933 Steam Pressuretrol PA404A
26 50510 Tenkless CtrL L4007A (Steam)
50084 LWCO Less Tonkless: C0450-20/60
27 50085 LWCO With Tankless: CGT450-20/60
28 61161 Bushing, 1" X 1-1/4"
NS _ 50765 Optional : #67 LWCO (Steam)
29 61980 Relief Valve 15# (Steam, Mate Thread)
330 60289 Guoge Glass Set
5t 60268 Steam Guage
332 70011 Tanktess Heater, Steam ( 3.5 GPM)
3333 69778 Heater Plate (Steam Back)
34 60556 Heater Plate Gasket (Steam Back)
335 33579 Heater Cover Plate w/Skim tapping (Steam)