PB Heat PSC-06 Instruction manual

PSC
Boilers
Series
Gas
Installation,
Operation &
Maintenance
Manual

i
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. INSTALLATION SURVEY . . . . . . . . . . . . . . . .2
D. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .2
2. BOILER SET-UP 3
3. WATER PIPING AND CONTROLS 4
A. BOILER SUPPLY AND RETURN . . . . . . . . . . .4
B. SAFETY RELIEF VALVE . . . . . . . . . . . . . . . . .5
C. PIPING FOR ZONED SYSTEMS . . . . . . . . . . .6
D. EXPANSION TANK . . . . . . . . . . . . . . . . . . . . .7
E. INDIRECT-FIRED WATER HEATER . . . . . . . .7
F. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .7
4. VENTING, VENTILATION AND
AIR INLET 8
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
B. PSC WALL THIMBLE . . . . . . . . . . . . . . . . . . .8
C. ROOF TERMINATIONS . . . . . . . . . . . . . . . .10
D. VENT PIPE INSTALLATION . . . . . . . . . . . . .11
E. AIR INLET PIPE INSTALLATION . . . . . . . . .11
F. AIR FOR VENTILATION . . . . . . . . . . . . . . . .12
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . .12
5. GAS PIPING 13
6. ELECTRICAL 15
A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
B. ZONED SYSTEM WIRING . . . . . . . . . . . . . .15
C. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . .15
D. SEQUENCE OF OPERATION . . . . . . . . . . . .16
7. START-UP PROCEDURES 19
A. COMPLETING THE INSTALLATION . . . . . . .19
B. CONTROL DESCRIPTIONS . . . . . . . . . . . . .22
C. ADJUSTMENT OF GAS PRESSURE
REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . .22
D. CHECKING BURNER INPUT . . . . . . . . . . . . .22
E. CHECK-OUT PROCEDURE . . . . . . . . . . . . . .22
8. TROUBLESHOOTING 24
A. SHUT-DOWN CAUSED BY PILOT OUTAGE,
PRESSURE SWITCH OR FLAME ROLL-OUT
SAFETY SHUT-OFF SWITCH . . . . . . . . . . . .24
B. TROUBLESHOOTING GUIDES . . . . . . . . . .24
C. MEASURING SUCTION PRESSURE . . . . . .24
9. MAINTENANCE 28
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .29
B. DAILY (WITH BOILER IN USE) . . . . . . . . . . .29
C. WEEKLY (WITH BOILER IN USE) . . . . . . . . .29
D. MONTHLY (WITH BOILER IN USE) . . . . . . .29
E. ANNUALLY (BEFORE START OF HEATING
SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . .30
10. BOILER DIMENSIONS & RATINGS 32
11. REPAIR PARTS 33
TABLE OF CONTENTS

1
USING THIS MANUAL
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 interferences and maximize safety during
boiler installation.
B. SPECIAL ATTENTION BOXES
Throughout this manual you will see special attention
boxes intended to supplement the instructions and make
special notice of potential hazards. These categories
mean, in the judgment of PB Heat, LLC:
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
NOTICE
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
CAUTION
DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
USING THIS MANUAL
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING

2
PREINSTALLATION
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
The design of this boiler is certified for closet installation
with the following clearances:
1. 6″(152 mm) between right side, front and
combustible construction.
2. 12″(305 mm) between top of jacket and
combustible construction.
3. 1″(25 mm) between left side, rear and combustible
construction.
4. 2″(51 mm) between vent pipe and combustible
construction.
5. Zero clearance between wall thimble and
combustible construction.
6. This boiler is design certified for use on combustible
flooring.
C. INSTALLATION SURVEY
For new and existing installations, a Water Installation
Survey is available from PB Heat, LLC. The survey will
provide information on how a hot water boiler works
with your specific system and will provide an overview
of hot water system operation in general.
You can also use this survey to locate system problems
which will have to be corrected. To obtain copies of the
Water Installation Survey, contact your PB Heat
representative.
D. PLANNING THE LAYOUT
Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring. Review
limitations on vent pipe, vent terminal, and air inlet pipe
locations and ventilation air requirements in Section 4.
1. PREINSTALLATION
Read carefully, study these instructions before beginning work.
This boiler must be installed by a qualified contractor.
The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly.
The equipment must be installed in accordance with those installation requirements of the authority having
jurisdiction or, in the absence of such requirements, to the current edition of the
National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CSA B49.1,
Natural Gas and Propane Installation Code .
Where required by the authority having jurisdiction, the installation must conform to
American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
NOTICE
Do not install this boiler on carpeting. Boiler
installation on carpeting is a fire hazard. Install this
boiler on non-combustible flooring or use a
combustible floor pan to install this boiler on other
non-carpeted flooring.
DANGER
Liquefied Petroleum (LP) is heavier than air and may
collect or “pool” in a low area in the event of a leak
from defective equipment.This gas may then ignite,
resulting in a fire or explosion.
WARNING

3
BOILER SET-UP
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 pallet from the boiler
base by removing two (2) hold-down bolts at each
end of the boiler base.
5. Move boiler into final position.
2. BOILER SET-UP

4
WATER PIPING AND CONTROLS
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 Survey for additional guidance
during water piping installation.
2. Return Piping:
Pipe the outlet connection of the circulator to a tee,
provided with a drain valve, at the 1-1/4″NPT return
tapping near the bottom of the right section. Pipe the
return to the inlet connection of the circulator.
3. Supply Piping:
a. Pipe the supply to the 1-1/2″NPT supply tapping
at the top of the boiler.
b. Provide clearance to venting system
(see Section 4).
4. When system return water temperature will be below
130°F (54°C), pipe the boiler with a bypass
arrangement to blend the system return and hot
supply to obtain at least 130°F (54°C)entering the
boiler. For more information on bypass piping,
consult the PB Heat Water Survey.
5. If desired, install the circulator in the alternate
location shown in Figure 3.1. Consult the PB Heat
Water Survey for more information on circulator
location.
3. WATER PIPING AND CONTROLS
Figure 3.1: Supply and Return Piping

5
WATER PIPING AND CONTROLS
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 distribution system is used in
conjunction with a refrigeration system, pipe the
chilled medium in parallel with the boiler and install
the proper valve to prevent the chilled medium from
entering the boiler. A drawing illustrating this hook-
up is provided in Figure 3.2.
8. When the boiler is connected to heating coils located
in air handling units where they may be exposed to
refrigerated air circulation, install flow control valves
or other automatic means to prevent gravity
circulation of the boiler water during the cooling
cycle.
9. If this boiler is installed above radiation level,
provide a low water cutoff device, either as a part of
the boiler or at the time of boiler installation.
B. SAFETY RELIEF VALVE
1. Locate safety relief valve and fittings in bag
assembly.
2. If air elimination is not required at the safety relief
valve tapping, install valve and piping as shown in
Figure 3.3.
3. For air elimination at the safety relief valve tapping,
install valve and piping as shown in Figure 3.4.
Pipe the discharge of safety relief valve to prevent
injury in the event of pressure relief. Pipe the
discharge to a drain. Provide piping that is the same
size as the safety relief valve outlet.
CAUTION
Figure 3.4: Safety Relief Valve Hook-Up with
Air Elimination
Figure 3.3: Safety Relief Valve Hook-Up
Installation with Air Elimination in
System Piping
Figure 3.2: Parallel Hook-up with Water Chiller

6
WATER PIPING AND CONTROLS
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.
Figure 3.5: Zone Piping with Zone Valves
Figure 3.6: Zone Piping with Circulators

7
WATER PIPING AND CONTROLS
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.
2. Expansion tanks are available with built-in fill valves
and check valves for reducing supply water pressure
and maintaining minimum system pressure. Check
the design features of the tank and provide valves as
necessary.
Refer back to Figure 3.1 for typical expansion tank piping.
E. INDIRECT-FIRED WATER HEATER
If the boiler is to be used in conjunction with an indirect-
fired water heater, refer to Figure 3.7 for typical piping.
Follow the instructions provided by the water heater
manufacturer. Pipe the water heater as a separate zone.
F. FREEZE PROTECTION
For new or existing systems that must be freeze-
protected:
1. Glycol in hydronic applications is specially
formulated for this purpose. It includes inhibitors
which prevent the glycol from attacking metallic
system components. Make certain that the system
fluid is checked for the correct glycol concentration
and inhibitor level.
2. The glycol solution should be tested at least once a
year and as recommended by the antifreeze
manufacturer.
3. Glycol solutions expand more than water. For
example, a 50% by volume solution expands 4.8%
in volume for a temperature increase from 32°F (0°C)
to 180°F (82°C) , while water expands 3% with the
same temperature rise. Allowance must be made for
this expansion in system design.
4. For more information, consult the PB Heat Water
Installation Survey and the antifreeze manufacturer.
Figure 3.7: Typical Piping with Indirect-Fired Water Heater
Use only inhibited propylene glycol solutions of up to
50% by volume with water. Ethylene glycol is toxic
and can attack gaskets and seals used in hydronic
systems.
WARNING

VENTING, VENTILATION AND AIR INLET
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. PSC WALL THIMBLE (SIDEWALL
VENTING ONLY)
1. Determine vent cap (terminal) location.
a. Must be within the maximum and minimum vent
and air intake lengths shown in Tables 4.1 and 4.2.
b. Maximum wall thickness for the 19-1/2″(495 mm)
long PSC Wall Thimble (standard) is 11-1/2″(292
mm). Maximum wall thickness for the optional
28″(711 mm) long thimble is 20″
(508 mm).
c. Provide 2″(51 mm) clearance between vent pipe
and combustible construction. No clearance is
required between Thimble and combustible
construction.
d. Provide 3 feet (1 meter) clearance above any
forced air inlet within 10 feet (3 meters).
e. Provide 1 foot (0.3 meters) clearance below, 1 foot
(0.3 meters) beside, or 1 foot (0.3 meters) above
any door, window, or gravity air inlet into any
building.
f. Provide 1 foot (0.3 meters) clearance between
bottom of vent terminal and ground level and
normal snow lines.
g. Provide 4 feet (1.2 meters) horizontal clearance
from from electric meters, gas meters, regulators
and relief equipment. In Canada, this dimension
must be 6 feet (2 meters).
h. Do not locate vent terminal over public walkways
where condensate could create a nuisance or
hazard.
i. When adjacent to a public walkway, locate vent
terminal at least 7 feet (2.1 meters) above grade.
j. Do not locate directly under roof overhangs to
prevent icicles from forming.
2. Cut a 5-1/8″(130 mm) square hole in sidewall to
allow Peerless Wall Thimble to go through.
3. Insert Thimble from inside wall with 4″(102 mm)
diameter air inlet connection facing down. Extend
Thimble 3-1/2″(89 mm) past outside wall surface.
The cut-out opening of thimble is pointed down.
4. Use a minimum 2-1/2 foot (762 mm) piece of 3″
(76 mm) diameter AL29-4C stainless steel vent pipe
for insertion through Wall Thimble. See Vent Pipe
section below for vent pipe requirements.
4. VENTING
Figure 4.1: PSC Wall Thimble
This vent system will operate with a positive
pressure in the vent pipe. Do not connect vent
connectors serving appliances vented by natural
draft into any portion of mechanical draft systems
operating under positive pressure.
Flue gases will condense as they exit the vent
termination.This condensate can freeze on exterior
building surfaces which may cause discoloration of
these surfaces.
NOTICE
WARNING
WARNING
All joints of positive pressure vent systems must be
sealed completely to prevent leakage of flue products
into the living space.
8

VENTING, VENTILATION AND AIR INLET
5. Slide Stainless Steel Collar over vent pipe and slide
3″(76 mm) diameter hose clamp and collar to vent
pipe.
6. Insert pipe with collar through Outside Vent Cap and
slide 3″(76 mm) diameter hose clamp and collar to
vent pipe.
7. Leave at least 2″(51 mm) of vent pipe protruding
beyond face of Vent Cap and secure hose clamp and
collar to vent pipe.
8. Place Outside Vent Cap over Wall Thimble with air
openings in Vent Cap facing down. Secure Cap to
Thimble with #10 sheet metal screws.
9. Place 3″(76 mm) diameter hose clamp over pipe
protruding through inside of Wall Thimble.
10. Place Inside Thimble Cap and Collar onto Wall
Thimble. Access hose clamp through 4″(102 mm)
diameter collar on bottom of Thimble and secure hose
clamp over collar and vent pipe as per step 7 above.
11. Secure Inside Thimble cap to Wall Thimble with #10
screws. Seal Thimble Cap perimeter with silicone.
12. Seal all openings between Wall and Thimble and
around the 3″(76 mm) diameter stainless steel vent
pipe that protrudes through inside and outside of
Wall Thimble.
13. Add any bracing that may be needed to support Wall
Thimble on inside of wall structure.
14. Secure Outside Vent Cap to exterior wall with four
#10 sheet metal screws provided.
15. Attach Z-Flex #2SVSTPF03 terminal to protruding
vent pipe. Refer to Figure 4.2. To attach to HEAT-
FAB pipe, insert into pipe end and fold over tabs to
secure. Otherwise, silicone terminal to vent pipe.
Figure 4.2: Side Wall Venting System
9

10
VENTING, VENTILATION AND AIR INLET
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 expected snow lines. Vent pipe
must be a minimum 12" (305 mm) above and 12"
(305 mm) horizontally from air inlet pipe. See Figure
4.3.
3. Attach a vent manufacturer's listed rain cap to both
the vent pipe and air inlet pipe.
4. Provide 2" (51 mm) clearance between vent pipe
and combustible construction. No clearance is
required between air inlet pipe and combustible
construction.
5. See vertical venting section in vent manufacturer's
instructions for recommendations for penetration
through roof.
52 feet (15.5 m)
52 feet (15.5 m)
45 feet (13.5 m)
45 feet (13.5 m)
PSC-03
PSC-04
PSC-05
PSC-06
Boiler Model
8 feet (2.5 m)
8 feet (2.5 m)
8 feet (2.5 m)
8 feet (2.5 m)
Table 4.1:
*Equivalent Length of 3″(76 mm) Diameter
Stainless Steel Vent Pipe
Minimum Vent Length Maximum Vent Length
70 feet (21.0 m)
70 feet (21.0 m)
63 feet (19.0 m)
63 feet (19.0 m)
PSC-03
PSC-04
PSC-05
PSC-06
Boiler Model
12 feet (4.0 m)
12 feet (4.0 m)
12 feet (4.0 m)
12 feet (4.0 m)
Table 4.2:
*Equivalent Length of 4″(102 mm) Diameter
Aluminum/Galvanized Air Inlet Pipe
Minimum Length Maximum Length
*Each 90° elbow equals 5 feet (1.5 meters) of equivalent
length.
Figure 4.3: Vertical Venting System

Figure 4.4: Vent Connection to Boiler
D . VENT PIPE INSTALLATION
1. For minimum and maximum vent pipe lengths see
Table 4.1.
2. Use only 3″(76 mm) diameter Heat-Fab Saf-T Vent,
Z-Flex Z-Vent, ProTech FasNSeal, or Flex-L Star-34
Type AL29-4C stainless steel vent pipe and fittings for
venting of flue gases from the boiler.
3. Connect vent pipe to boiler by spreading a 1/4″
(6 mm) bead of high-temp GE-106 silicone or
Silicones Unlimited S45005 Red around the fan
adapter. Attach proper vent adapter to fan adapter
(not applicable, Z-Flex). Z-Flex vent pipe/fitting
connects directly to fan adapter, secure to fan adapter
using Z-Flex lock band. See Figure 4.4.
4. Attach remaining pipe and fittings per each
manufacturer’s vent instructions. Use only the silicone
recommended by vent pipe manufacturers. Maintain
proper clearance to combustible construction – see
Section 1, Preinstallation.
5. a. Side Wall Venting Only – Horizontal lengths of
the vent pipe shall slope down not less than 1/4″
per lineal foot (21 mm per meter) from the boiler
to the vent terminal. If vent pipe does slope back
toward boiler, a horizontal drain is required as
described in 5B and Figure 4.3.
b. Vertical Venting Only – A horizontal drain tee is
required. Slope horizontal lengths upward not less
than 1/4" per lineal foot (21 mm per meter) from
the boiler to the vent terminal. Install drain tee as
shown in Figure 4.3. Use silicone hose and form a
3" (76 mm) diameter loop trap with a water seal.
Pipe to drain per local code.
6. Support horizontal lengths of the vent system to
prevent sagging by use of metal strapping or
equivalent means. Locate supports at not more than
four (4) foot intervals.
7. Vertical Venting Only – If there is no solid anchor
point in the system below the roof for supporting
vertical sections of the vent pipe (i.e. Firestop
Support, etc.), a special vent support system will be
required. See vent manufacturer's instructions for
additional information.
E. AIR INLET PIPE INSTALLATION
1. For maximum air inlet pipe lengths see Table 4.2.
2. Use only 4″(102 mm) diameter galvanized pipe or 4″
(102 mm) diameter flexible aluminum vent for
supplying combustion air to boiler inlet air box.
3. Boiler connection can be from either right or left side
of boiler jacket. Determine which jacket side air inlet
piping is to be routed and remove the 4-1/2″(114 mm)
jacket knock-out.
4. Attach a 4″(102 mm) diameter 90 degree elbow to
top of air box and connect air inlet piping.
5. Support air inlet piping using the same methods and
requirements as shown in the previous section for vent
pipe support.
6. Seal all connections using silicone.
7. To prevent condensation from forming on exposed
portions of Wall Thimble and 4″(102 mm) diameter
air inlet piping, wrap exposed areas with insulation.
11
VENTING, VENTILATION AND AIR INLET

12
VENTING, VENTILATION AND AIR INLET
F. AIR FOR VENTILATION
1. Provide air openings for adequate ventilation to
prevent ambient boiler room temperature from
exceeding 120°F (49°C) during boiler operation. This
is to maintain all the boiler controls below maximum
service temperatures. Openings should be fixed in
the open position during operation.
G. BOILER REMOVAL FROM 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 appliances remaining connected to the common
venting system are not in operation:
a. Seal any unused openings in the common venting
system.
b. Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.
c. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on any clothes dryers and any
appliance not connected to common venting system.
Turn on any exhaust fans, such as range hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
fireplace dampers.
d. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame
of a match or candle, or smoke from a cigarette,
cigar, or pipe.
f. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas-burning appliance to their previous
conditions of use.
g. Any improper operation of the common venting
system should be corrected so that the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural
Gas and Propane Installation Code. When resizing
any portion of the common venting system, the
common venting system should be resized to
approach minimum size as determined using the
appropriate tables in the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.

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
boiler in cubic feet per hour. To obtain this value,
divide the Btu per hour rating (on the boiler rating
plate) by the heating value of the gas in Btu per
cubic feet. Obtain the heating value of the gas from
the gas supplier. As an alternative, use Table 5.1 on
the next page to obtain the volume of gas to be
provided to the boiler.
3. Use the value obtained above as the basis for piping
sizing. Size the gas piping in accordance with Table
5.2. Consult the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural
Gas and Propane Installation Code.
4. Locate the drop pipe adjacent to, but not in front of
the boiler.
5. Install a sediment trap. See Figure 5.1. Locate a tee
in the drop pipe at same elevation as the gas inlet
connection to the boiler. Extend the drop pipe to a
pipe cap.
6. Install a ground joint union ahead of the gas control
assembly to permit servicing of the control. Some
local codes require an additional service valve when
using the combination gas controls. If your code
requires such a valve, a suggested location is shown
in Figure 5.1.
7. Check piping for leaks prior to placing the boiler in
operation.
Use an approved gas detector, a non-corrosive leak
detection fluid or other leak detection method. If
leaks are found, turn off all gas flow and repair as
necessary.
8. Disconnect the boiler and its individual shut-off valve
from the gas supply piping system during any
pressure testing of that system at test pressure in
excess of 1/2 psig (3.5 kPa).
Isolate the boiler from the gas supply piping system
by closing its individual service valve during any
pressure testing of the gas supply piping system at
test pressure equal to or less than 1/2 psig (3.5 kPa).
9. Minimum permissible supply pressure for purposes of
input adjustment (Inches Water Column):
Natural Gas 5.0″(1.2 kPa)
LP Gas 11.0″(2.7 kPa)
Maximum permissible supply pressure to the boiler
(Inches Water Column):
Natural Gas 13.5″(3.4 kPa)
LP Gas 13.5″(3.4 kPa)
13
GAS PIPING
5. GAS PIPING
Figure 5.1: Gas Connection to Boiler
When checking for leaks, do not use matches,
candles, open flames or other methods that provide a
source of ignition.This can ignite a gas leak,
resulting in fire or explosion.
WARNING
Use a pipe joint sealing compound that is resistant to
the action of liquefied petroleum gas. A non-resistant
compound may lose sealing ability in the presence of
this gas, resulting in a gas leak and fire or explosion
potential.
WARNING
Do not subject the gas valve to more than 1/2 psi
(3.5 kPa) pressure. Doing so may damage the valve.
CAUTION

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 number of fittings is required.
Table 5.1: Natural Gas
Pipe
Length in
Feet (Meters)
³⁄₄″″
Pipe
1″″
Pipe
1¹⁄₄″″
Pipe
1¹⁄₂″″
Pipe
10 (3.0) 278 (7.9) 520 (14.7) 1050 (29.7) 1600 (45.3)
20 (6.1) 190 (5.4) 350 (9.9) 730 (20.7) 1100 (31.1)
30 (9.1) 152 (4.3) 285 (8.1) 590 (16.7) 890 (25.2)
40 (12.2) 130 (3.7) 245 (6.9) 500 (14.2) 760 (21.5)
50 (15.2) 115 (3.3) 215 (6.1) 440 (12.5) 670 (19.0)
60 (18.3) 105 (3.0) 195 (5.5) 400 (11.3) 610 (17.3)
Boiler
Model
Natural Gas Input LP Gas Input
Cu. Ft/hr Cu. Meter/hr Cu. Ft/hr Cu. Meter/hr
PSC-03 70 2.0 28 0.8
PSC-04 105 3.0 42 1.2
PSC-05 140 4.0 46 1.6
PSC-06 165 4.7 66 1.9
Specific Gravity 0.50 0.55 0.60 0.65 0.70 0.75
Correction Factor 1.10 1.04 1.00 0.96 0.93 0.90
Specific Gravity 0.80 0.85 0.90 1.00 1.10 1.20
Correction Factor 0.87 0.84 0.82 0.78 0.74 0.71
Specific Gravity 1.30 1.40 1.50 1.60 1.70 1.80
Correction Factor 0.68 0.66 0.63 0.61 0.59 0.58
Maximum Capacity Correction Factors for Specific Gravity
other than 0.60.

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 fused switch.
3. Adjust the thermostat heat anticipator to 0.2 Amp.
B. ZONED SYSTEM WIRING
See Figure 6.4 for typical wiring with zone valves. See
Figure 6.5 for typical wiring with zone circulators. When
wiring a zoned heating system, follow all applicable
codes, ordinances and regulations.
C. CONTROLS
1. For proper location of controls and accessories refer
to Figure 6.1.
2. See the attached control sheets for specific details
regarding the installation of the various controls.
3. This boiler is supplied with safety devices in addition
to the limit. For a description of these devices and
how they work to ensure the safe operation of the
boiler, see Section 7.
4. If the circulator is mounted in the supply piping,
provide longer wiring harness as required.
6. ELECTRICAL
This unit when installed must be electrically grounded in accordance with the requirements of the authority
having jurisdiction or, in the absence of such requirements, with the current edition of the
National Electrical
Code,
ANSI/NFPA 70 and/or the Canadian Electrical Code , Part 1, CSA C221.
NOTICE
Figure 6.1: Wiring, Controls and Safety Devices
Install all electrical wiring in accordance with the National Electrical Code and local requirements.
Do not power zone valves directly from the boiler
transformer. Doing so will greatly reduce the life of
the transformer. Use a separate transformer sized to
handle the total of all zone valve electrical loads.
NOTICE
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ELECTRICAL
D. SEQUENCE OF OPERATION
1. Thermostat calls for heat, energizes R8285 Control
Relay (CR).
2. R8285 Control Relay (CR) energizes circulator.
3. Limit senses boiler water temperature. Prevents
boiler operation until water temperature falls
approximately 15°F (8°C) below the cut-out
temperature.
4. Limit energizes Fan and R4222 Isolation Relay (IR).
5. Negative pressure induced by fan switches Pressure
Switch, continuing power through closed R4222
contacts (IR-1) and flame roll-out switch.
6. Gas valve energizes.
a. Igniter on.
b. Pilot gas on, igniting pilot.
7. Pilot flame detected.
a. Igniter off.
b. Main gas on, igniting main burners.
Note: If pilot flame is not detected within 30 seconds,
the igniter is turned off for 30 seconds, and then turned
back on for another 30 seconds. If the pilot remains
undetected in this second ignition period, the igniter and
pilot are turned off for 5 minutes. The sequence then
resumes at Step 6a.
8. Call for heat ends.
a. Pilot and main gas off, extinguishing pilot and
main burners.
b. Fan and circulator off.
Figure 6.2: Wiring and Connection Diagram

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ELECTRICAL
Figure 6.3: Ignition System Operating Sequence

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