PEERLESS CAST 92 Instruction manual

CAST 92
Boilers
Peerless
Gas
Installation,
Operation &
Maintenance
Manual
As an ENERGY STAR®Partner, PB Heat, LLC has determined that this
product meets the ENERGY STAR guidelines for energy efficiency.

USING THIS MANUAL 1
A. INSTALLATION SEQUENCE . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B. CODES & REGULATIONS . . . . . . . . . . . . . . .2
C. BOILER LOCATION REQUIREMENTS . . . . . .3
D. CLEARANCE REQUIREMENTS . . . . . . . . . . .4
E. COMBUSTION AIR REQUIREMENTS . . . . . .4
2. BOILER SET-UP 7
A. REMOVE THE BOILER FROM THE CRATE . .7
B. INSTALL THE RELIEF VALVE . . . . . . . . . . . . .7
C. BOILER PIPING – GENERAL . . . . . . . . . . . . .7
3. VENTING & AIR INLET PIPING 9
A. COMMON VENT SYSTEMS . . . . . . . . . . . . .9
B. VENT AND AIR PIPING, GENERAL . . . . . . .10
C. VENT PIPING . . . . . . . . . . . . . . . . . . . . . . . .10
D. AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . .10
E. TERMINATIONS . . . . . . . . . . . . . . . . . . . . . .10
F. VENT PIPED THROUGH THE ROOF
(COMBUSTION AIR FROM THE BOILER ROOM) . .10
G. VENT PIPED THROUGH THE ROOF
(AIR PIPED THROUGH SIDE WALL) . . . . . . . . . .11
H. VENT & AIR PIPED THROUGH THE ROOF
(SEPARATE VENT AND AIR TERMINATIONS) . . . .11
I. VENT PIPED THROUGH A SIDE WALL
(SEPARATE VENT AND AIR TERMINATIONS) . . . .12
J. VENT & AIR PIPED THROUGH A
SIDE WALL (SEPARATE VENT AND AIR
TERMINATIONS) . . . . . . . . . . . . . . . . . . . . . . .12
K. VENT & AIR PIPED THROUGH A
SIDE WALL (CONCENTRIC VENT/AIR
TERMINATION) . . . . . . . . . . . . . . . . . . . . . . . .13
3A. VENT & AIR PIPING: THROUGH THE ROOF
(COMBUSTION AIR FROM THE BOILER ROOM) 14
A. BOILER VENT CONNECTION . . . . . . . . . . .14
B. VENT PIPING COMPONENTS . . . . . . . . . . .15
C. SUPPORT THE VENT PIPING
COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .15
D. FLOOR AND WALL PENETRATIONS . . . . .15
E. ROOF PENETRATIONS . . . . . . . . . . . . . . . .15
F. RAIN CAP TERMINATION . . . . . . . . . . . . . .15
G. COMBUSTION AIR OPENINGS . . . . . . . . . .16
H. MULTIPLE BOILER INSTALLATIONS . . . . . .16
3B. VENT & AIR PIPING: THROUGH THE ROOF
(AIR PIPED THROUGH SIDE WALL) 17
A. BOILER VENT CONNECTION . . . . . . . . . . .17
B. VENT PIPING COMPONENTS . . . . . . . . . . .18
C. SUPPORT THE VENT PIPING
COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .18
D. FLOOR AND WALL PENETRATIONS . . . . .18
E. ROOF PENETRATIONS . . . . . . . . . . . . . . . .18
F. RAIN CAP TERMINATION . . . . . . . . . . . . . .18
G. AIR PIPE CONNECTION . . . . . . . . . . . . . . . .19
H. SUPPORTING AIR PIPING . . . . . . . . . . . . . .19
I. AIR PIPE TERMINATION . . . . . . . . . . . . . . .19
J. MULTIPLE BOILER INSTALLATIONS . . . . . .21
3C. VENT PIPING: THROUGH THE ROOF
(SEPARATE TERMINATIONS) 22
A. BOILER VENT CONNECTION . . . . . . . . . . .22
B. VENT PIPING COMPONENTS . . . . . . . . . . .23
C. SUPPORT THE VENT PIPING
COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .23
D. FLOOR AND WALL PENETRATIONS . . . . .23
E. ROOF PENETRATIONS . . . . . . . . . . . . . . . .23
F. RAIN CAP TERMINATION . . . . . . . . . . . . . .23
G. AIR PIPE CONNECTION . . . . . . . . . . . . . . . .24
H. SUPPORTING AIR PIPING . . . . . . . . . . . . . .24
I. AIR PIPE TERMINATION . . . . . . . . . . . . . . .24
J. MULTIPLE BOILER INSTALLATIONS . . . . . .25
3D. VENT & AIR PIPING: THROUGH A SIDE
WALL (COMBUSTION AIR FROM THE
BOILER ROOM) 26
A. BOILER VENT CONNECTION . . . . . . . . . . .26
B. VENT PIPING COMPONENTS . . . . . . . . . . .27
C. SUPPORT THE VENT PIPING
COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .27
D. SIDEWALL TERMINATION . . . . . . . . . . . . . .27
E. COMBUSTION AIR OPENINGS . . . . . . . . . .29
F. MULTIPLE BOILER INSTALLATIONS . . . . . .29
3E. VENT & AIR PIPING: THROUGH A SIDE
WALL (SEPARATE TERMINATIONS) 30
A. BOILER VENT CONNECTION . . . . . . . . . . .30
B. VENT PIPING COMPONENTS . . . . . . . . . . .31
C. SUPPORT THE VENT PIPING
COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .31
D. AIR PIPE CONNECTION . . . . . . . . . . . . . . . .31
E. SUPPORTING AIR PIPING . . . . . . . . . . . . . .32
F. SIDEWALL TERMINATION ASSEMBLIES . .32
G. MULTIPLE BOILER INSTALLATIONS . . . . . .34
TABLE OF CONTENTS
TABLE OF CONTENTS

3F. VENT & AIR PIPING: THROUGH A SIDE
WALL (CONCENTRIC TERMINATION) 35
A. BOILER VENT CONNECTION . . . . . . . . . . .35
B. VENT PIPING COMPONENTS . . . . . . . . . . .36
C. SUPPORT THE VENT PIPING
COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .36
D. AIR PIPE CONNECTION . . . . . . . . . . . . . . . .36
E. SUPPORTING AIR PIPING . . . . . . . . . . . . . .37
F. SIDEWALL TERMINATION/CONCENTRIC
VENT-AIR ASSEMBLY . . . . . . . . . . . . . . . . .37
G. MULTIPLE BOILER INSTALLATIONS . . . . . .37
4. WATER PIPING & CONTROLS 39
A. BOILER PIPING CONNECTIONS . . . . . . . . .39
B. SYSTEM DESIGN . . . . . . . . . . . . . . . . . . . . .39
C. CIRCULATOR REQUIREMENTS . . . . . . . . . .39
D. ADDITIONAL CONTROLS . . . . . . . . . . . . . .40
E. EXPANSION TANK & AIR SEPARATION . . .40
F. ZONING WITH ZONE VALVES . . . . . . . . . .42
G. ZONING WITH CIRCULATORS . . . . . . . . . .43
H. MULTIPLE BOILERS,
PRIMARY/SECONDARY . . . . . . . . . . . . . . . .44
I. MULTIPLE BOILERS, PARALLEL FLOW . . .45
J. CHILLED WATER SYSTEMS . . . . . . . . . . . .46
5. FUEL PIPING 47
A. CHECK THE GAS TYPE . . . . . . . . . . . . . . . .47
B. GAS SUPPLY COMPONENTS . . . . . . . . . . .47
C. GAS PIPING JOINTS . . . . . . . . . . . . . . . . . .48
D. GAS PIPE SIZING . . . . . . . . . . . . . . . . . . . . .48
E. TEST ALL GAS PIPING FOR LEAKS . . . . . .48
6. CONDENSATE DRAIN PIPING 49
A. FILL THE CONDENSATE TRAP . . . . . . . . . .49
B. CONDENSATE LINE INSTALLATION . . . . . .49
C. CONDENSATE LINE REQUIREMENTS . . . .49
7. ELECTRICAL CONNECTIONS 50
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .50
B. POWER SUPPLY (120 VAC) . . . . . . . . . . . . .50
C. CIRCULATOR WIRING . . . . . . . . . . . . . . . . .50
D. SENSOR WIRING . . . . . . . . . . . . . . . . . . . . .51
E. IAR (INDOOR AIR RESET) WIRING,
WHEN USED . . . . . . . . . . . . . . . . . . . . . . . .52
F. DHW WIRING . . . . . . . . . . . . . . . . . . . . . . . .52
8. BOILER CONTROL: OPERATION 55
A. THE CAST 92 BOILER CONTROL . . . . . . . .55
B. BEFORE CONTROL SETUP . . . . . . . . . . . . .56
C. THE CONTROL DISPLAY . . . . . . . . . . . . . . .56
D. RECOMMENDED SETTINGS . . . . . . . . . . . .57
E. ADJUST SETPOINTS . . . . . . . . . . . . . . . . . .57
F. INDOOR AIR . . . . . . . . . . . . . . . . . . . . . . . . .58
G. OUTDOOR AIR . . . . . . . . . . . . . . . . . . . . . . .58
H. SET THE SYSTEM CLOCK . . . . . . . . . . . . . .59
9. BOILER CONTROL: MULTIPLE
BOILERS OVERVIEW 66
9A. MULTIPLE BOILERS – CAST 92 CONTROL 66
9B MULTIPLE BOILERS – (BMS) . . . . . . . . . . . .66
9C MULTIPLE BOILERS – EXTERNAL 4-20MA
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . .66
9A. BOILER CONTROL: MULTIPLE
BOILERS (CAST 92 CONTROL) 67
A. OVERVIEW: CONTROL SETUP
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . .67
B. POWER SUPPLY (120 VAC) . . . . . . . . . . . . .67
C. CIRCULATOR WIRING . . . . . . . . . . . . . . . . .67
D. IAR (INDOOR AIR RESET) WIRING,
WHEN USED . . . . . . . . . . . . . . . . . . . . . . . .68
E. SENSOR WIRING . . . . . . . . . . . . . . . . . . . . .69
F. DHW WIRING . . . . . . . . . . . . . . . . . . . . . . . .69
G. EXTERNAL INTERLOCKS . . . . . . . . . . . . . .72
H. OVERRIDES – CONTROL PRIORITIES . . . . .72
I. SET TERMINATION DIP SWITCHES . . . . . .72
J. SET CONTROL PARAMETERS ON
KEYPADS . . . . . . . . . . . . . . . . . . . . . . . . . . .73
K. START-UP BOILERS
L. CONNECT NETWORK CABLES . . . . . . . . . .73
M. MASTER BOILER CABLE . . . . . . . . . . . . . . .73
N. MEMBER BOILER CABLES . . . . . . . . . . . . .74
O. CHECK THE NETWORK . . . . . . . . . . . . . . . .74
P. START THE SYSTEM . . . . . . . . . . . . . . . . . .74
9B. BOILER CONTROL: MULTIPLE
BOILERS BUILDING MANAGEMENT
CONTROL (BMS) 75
A. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . .75
B. MODBUS REGISTERS . . . . . . . . . . . . . . . . .75
C. BACNET OR LONWORKS PROTOCOLS . . .76
D. WIRING AND SET-UP . . . . . . . . . . . . . . . . .76
E. CONNECT THE BMS CABLE . . . . . . . . . . . .76
F. VERIFY BMS/HEATNET OPERATION . . . . .76
9C. BOILER CONTROL: MULTIPLE BOILERS
EXTERNAL 4–20MA CONTROL 77
A. OVERVIEW — CONTROL SETUP
SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . .77
B. CONNECT 4-20MA WIRING . . . . . . . . . . . .77
C. POWER SUPPLY (120 VAC) . . . . . . . . . . . . .77
D. CIRCULATOR WIRING . . . . . . . . . . . . . . . . .77
E. 4-20MA OPERATION . . . . . . . . . . . . . . . . . .79
F. IAR (INDOOR AIR RESET) WIRING –
APPLY ONLY IF USING SPACE HEATING
OVERRIDE MODE . . . . . . . . . . . . . . . . . . . .79
G. SENSOR WIRING . . . . . . . . . . . . . . . . . . . . .79
H. DHW WIRING – ONLY IF USING DHW
OVERRIDE MODE . . . . . . . . . . . . . . . . . . . .79
I. OVERRIDES – CONTROL PRIORITIES . . . . .79
TABLE OF CONTENTS

J. SET CONTROL PARAMETERS ON
KEYPADS . . . . . . . . . . . . . . . . . . . . . . . . . . .82
K. START-UP BOILERS . . . . . . . . . . . . . . . . . . .82
L. START THE SYSTEM . . . . . . . . . . . . . . . . . .82
10. FILL AND TEST THE SYSTEM 83
A. CLOSED SYSTEMS ONLY . . . . . . . . . . . . . .83
B. HARD WATER CONDITIONS . . . . . . . . . . . .83
C. PREVENT OXYGEN CORROSION . . . . . . . .83
D. FLUSH AND CLEAN THE SYSTEM . . . . . . .83
E. PURGE AIR FROM THE SYSTEM . . . . . . . .83
F. ADD A CHEMICAL INHIBITOR . . . . . . . . . . .83
G. WATER PH . . . . . . . . . . . . . . . . . . . . . . . . . .84
H. ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . .84
I. SYSTEM PRESSURE . . . . . . . . . . . . . . . . . .84
J. FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . .85
11. START-UP PROCEDURE 86
A. START-UP CHECKLIST . . . . . . . . . . . . . . . . .86
B. LIGHTING & OPERATING PROCEDURES . .89
C. TURN THE BOILER OFF . . . . . . . . . . . . . . . .90
D. CHECK IGNITION . . . . . . . . . . . . . . . . . . . . .90
E. INSERT COMBUSTION ANALYZER
PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
F. CHECK HIGH FIRE OPERATION . . . . . . . . .90
G. ADJUST GAS VALVE THROTTLE
SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
H. VERIFY GAS INLET PRESSURE . . . . . . . . .91
I. TO METER GAS INPUT (NATURAL
GAS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . .92
J. CHECK LOW FIRE OPERATION . . . . . . . . . .92
K. WHEN IS LOW FIRE ADJUSTMENT
REQUIRED? . . . . . . . . . . . . . . . . . . . . . . . . .92
L. REMOVING THE BOILER JACKET TOP . . . .92
M. ADJUSTING THE LOW-FIRE SETTING . . . .93
N. REPLACE THE BOILER JACKET TOP . . . . .93
O. MEASURE FLAME CURRENT . . . . . . . . . . .93
P. CHECK BOILER MODULATION . . . . . . . . . .93
Q. TEST FLAME FAILURE MODES . . . . . . . . .94
R. TEST CONTROL & INTERLOCK
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .94
S. FILL OUT THE COMBUSTION TEST
RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
12. TROUBLESHOOTING 95
13. MAINTENANCE 97
A. READ BEFORE PROCEEDING . . . . . . . . . . .97
B. HANDLING CERAMIC FIBER AND
FIBERGLASS MATERIALS . . . . . . . . . . . . . .97
C. CLEANING THE AIR FILTER . . . . . . . . . . . . .97
D. ACCESSING THE ELECTRODE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .98
E. ACCESSING THE BURNER . . . . . . . . . . . . .99
F. ANNUAL START-UP OVERVIEW . . . . . . . .100
G. ANNUAL START-UP CHECKLIST . . . . . . . .100
14. REPAIR PARTS 102
15.BOILER RATINGS & SPECIFICATIONS 108
APPENDIX A. SUGGESTED WIRING 109
IAR (INDOOR AIR RESET) WIRING, WHEN
USED WIRING FOR 3-WIRE ZONE VALVES
WITHOUT A ZONE CONTROLLER . . . . . . . . .109
IAR (INDOOR AIR RESET) WIRING, WHEN
USED WIRING FOR CIRCULATOR RELAYS
(RELAYS MUST HAVE 24VAC COMMON
TERMINALS) . . . . . . . . . . . . . . . . . . . . . . . . . .110
IAR (INDOOR AIR RESET) WIRING, WHEN
USED WIRING FOR TYPICAL ZONE
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . .111
APPENDIX B. COMBUSTION TEST
RECORD 113
TABLE OF CONTENTS

1
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 special attention boxes are
provided to supplement the instructions and make special
notice of potential hazards. The definition of each of
these categories, in the judgement of PB Heat, LLC
are as follows:
USING THIS MANUAL
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.
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING
USING THIS MANUAL

2
PREINSTALLATION
A. GENERAL
1. Cast 92 boilers are supplied completely assembled as
packaged boilers. The package should be inspected
for damage upon receipt and any damage to the unit
should be reported to the shipping company and
wholesaler. This boiler should be stored in a clean, dry
area.
2. Carefully read these instructions and be sure to
understand the function of all connections prior to
beginning installation. Contact your PB Heat, LLC
Representative for help in answering questions.
3. This boiler must be installed by a qualified contractor.
The boiler warranty may be voided if the boiler is not
installed correctly.
4. A hot water boiler installed above radiation or as
required by the Authority having jurisdiction, must be
provided with a low water fuel cut-off device either as
part of the boiler or at the time of installation.
B. CODES & REGULATIONS
1. Installation and repairs are to be performed in strict
accordance with the requirements of state and local
regulating agencies and codes dealing with boiler and
gas appliance installation.
2. In the absence of local requirements the following
should be followed:
a. ASME Boiler and Pressure Vessel Code, Section
IV - “Heating Boilers”
b. ASME Boiler and Pressure Vessel Code, Section
VI - “Recommended Rules for the Care and
Operation of Heating Boilers”
c. ANSI Z223.1/NFPA 54 - “National Fuel Gas Code”
d. ANSI/NFPA 70 - “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 Standard for
Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1.
**Please read if installing in Massachusetts**
Massachusetts requires manufacturers of Side Wall
Vented boilers to provide the following information
from the Massachusetts code:
·A hard wired carbon monoxide detector with an
alarm and battery back-up must be installed on
the floor level where the gas equipment is to be
installed AND on each additional level of the
dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment.
·In the event that the side wall horizontally vented
gas fueled equipment is installed in a crawl space
or an attic, the hard wired carbon monoxide
detector with alarm and battery back-up may be
installed on the next adjacent floor level.
·Detector(s) must be installed by qualified licensed
professionals.
·APPROVED CARBON MONOXIDE
DETECTORS: Each carbon monoxide detector
shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.
·SIGNAGE: A metal or plastic identification plate
shall be permanently mounted to the exterior of
the building at a minimum height of eight (8) feet
above grade directly in line with the exhaust vent
terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall
read, in print size no less than one-half (1/2) inch
in size, “GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS”.
·EXEMPTIONS to the requirements listed above:
°The above requirements do not apply if the
exhaust vent termination is seven (7) feet or
more above finished grade in the area of the
venting, including but not limited to decks and
porches.
°The above requirements do not apply to a
boiler installed in a room or structure separate
from the dwelling, building or structure used in
whole or in part for residential purposes.
·This boiler installation manual shall remain with
the boiler at the completion of the installation.
See the latest edition of Massachusetts Code 248 CMR
for complete verbage and also for additional (non-vent
related) requirements (248 CMR is available online).
If your installation is NOT in Massachusetts, please
see your authority of jurisdiction for requirements that
may be in effect in your area. In the absence of such
requirements, follow the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.
1. PREINSTALLATION
Liquefied Petroleum (LP) Gas or Propane is heavier
than air and, in the event of a leak, may collect in low
areas such as basements or floor drains. The gas
may then ignite resulting in a fire or explosion.
WARNING

3
C. BOILER LOCATION REQUIREMENTS
1. Indoor Installation Only:
a. Do not install the boiler outside or in an area that
would expose the boiler or its gas or electrical
components to rain or dripping or spraying water.
b. Do not install the boiler in a location that would
subject the boiler to freezing. Where freeze
protection is needed, follow the guidelines in this
manual.
2. Flooring:
a. The boiler can be installed on combustible
flooring, but must not be installed on carpeting.
b. The floor must be structurally sound and capable
of supporting the weight of the boiler.
c. The boiler must be leveled front to back and side
to side. Use metal shims if necessary.
3. Accessibility:
Jacket parts will have to be removed for some service
procedures. Ensure that the location provides a
reasonable means for service and operation of the
boiler.
4. System Piping, Fuel and Electrical Supply:
a. The boiler must be located such that piping for
water, gas, vent and air can reasonable be
connected.
b. There must be a reasonable means of providing
electrical supply to the boiler.
5. Adjacent Construction:
Locate the boiler in an area that will prevent water
damage to adjacent construction should a leak occur
or during routine maintenance.
6. Combustion Air:
a. Do not place the boiler in a location that would
restrict the flow of combustion air into the air
intake or subject the boiler to a negative air
pressure in the space when using air from the
boiler room.
b. Provide required combustion air openings to the
boiler room and the building (when required)
when using air from the boiler room for
combustion (see Section C, “Combustion Air
Requirements”). If air is piped to the boiler air
intake connection, combustion air openings are
not required unless other appliances share the
same room.
c. Buildings will require the installation of a fresh air
duct or other means of providing make-up air if
the intake air option isn't used. Any building
utilizing other gas burning appliances, a fireplace,
wood stove or any type of exhaust fan must be
checked for adequate combustion air when all of
these devices are in operation at one time. Sizing
of an outside air duct must be done to meet the
requirements of all such devices.
d. The boiler must be supplied with combustion air
in accordance with Section 5.3, "Air for
Combustion and Ventilation," of the latest revision
of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and all applicable local building
codes. Canadian installations must comply with
CSA B149.1 or .2 Installation Code for Gas
Burning Appliances and Equipment, or applicable
provisions of the local building codes.
7. Negative Room Pressure:
Never operate the boiler in an environment subjected
to a negative pressure unless it is Direct Vented.
Failure to comply with this warning can result in
excessive levels of carbon monoxide.
8. Combustion Air Contamination:
a. Combustion air contaminated with fluorocarbons
or other halogenated compounds such as cleaning
solvents and refrigerants will result in the
formation of acids in the combustion chamber.
These acids will cause premature failure of the
boiler.
b. Construction Dust: If the boiler is operated while
the building is under construction it must be
protected from wood, concrete, sheet rock and
other types of dust. Failure to properly protect the
boiler from construction dust will damage the
boiler.
c. If the boiler has been operated with contaminated
air, it must be thoroughly inspected. Where
possible, boiler components must be cleaned,
following instructions provided in this manual
and/or supplementary instructions from PB Heat.
Where cleaning is not possible, the boiler may
have to be replaced.
d. Never store combustible materials, gasoline or any
product containing flammable vapors or liquids in
the vicinity of the boiler.
9. Clearances:
a. All installations must provide the minimum
clearances to combustible materials given in
Section B, “Clearance Requirements”.
b. The installation should provide the minimum
service clearances given in Section B, “Clearance
Requirements”, when possible. If these clearances
cannot be met, then:
Ensure that boiler components can be
accessed for operation/start-up/maintenance as
required in this manual.
PREINSTALLATION
Do not install the boiler unless the location meets all
of the requirements in Sections 1 through 9 below.
Failure to comply could result in severe personal
injury, death or substantial property damage.
WARNING

4
PREINSTALLATION
D. CLEARANCE REQUIREMENTS
1. Clearances to Combustible Surfaces:
2. Clearances for Service and Operation:
E. COMBUSTION AIR REQUIREMENTS
1. Air Ducted to Boiler Air Intake:
a. If air is ducted from outside to the boiler air
intake, follow instructions in Section 3, “Venting &
Air Inlet Piping”.
b. If the boiler is located in a small room (clearances
less than the recommended SERVICE/OPERATION
clearances given in Figure 1.2):
All installations must provide the minimum
clearances to combustible materials and surfaces
given in Table 1.1. Failure to comply could result in a
fire hazard, causing severe personal injury, death or
substantial property damage.
WARNING
Table 1.1: Minimum Clearances to Combustible
Materials/Surfaces for ALL Installations
(Figure 1.1)
From Inches Millimeters
To p 6153
Back 6153
Left side 6153
Right side 6153
Front 6153
Rear 6153
Vent piping 251
System water piping 125.4
If the boiler is located in a closed room, the room
must be provided with ventilation openings even if
air is ducted to the boiler. See Figure 1.1. Size the
openings with a free area no less than 1 square inch
per BTUH input of all Cast 92 boilers in the room.
EXCEPTION: Ventilation openings are not required if
the boiler room provides at least the minimum
SERVICE/OPERATION clearances given in Table 1.2.
Failure to provide adequate ventilation could result
in overheating of the boiler components or the
room, potentially causing severe personal injury,
death or substantial property damage.
WARNING
The installation must provide reasonable access and
clearance for service and operation of the boiler. Table
2 gives recommended minimum clearances for
service and operation. The boiler may be installed in a
space that does not provide these recommended
clearances provided it is accessible for the service
and operation procedures required in this manual.
Flame observation port — The flame observation
port on the LEFT side of the boiler must be
accessible to view the combustion chamber during
boiler start-up. Make sure that the installation allows
serviceman access to the left side for this purpose.
WARNING
Table 1.2: Recommended Minimum Clearances for
Service/Operation (Figure 1.2)
From Inches Millimeters
To p 24 610
Back 24 610
Left side 24 610
Right side 24 610
Front 36 914
Rear 18 457
Figure 1.1: Clearance to Combustibles Materials
Figure 1.2: Service/Operation Clearance References

5
PREINSTALLATION
i. No Other Appliances in the Room: Provide
two ventilation openings through one of the
enclosure walls. Each opening must be sized
for a free area of at least 1 square inch per
1,000 BTUH input of the Cast 92 boilers in
the room. One opening must be within 12
inches of the ceiling, the other within 12
inches of the floor.
ii. Other Appliances in the Same Room: The room
must have combustion air openings sized for
the other appliances. Increase the free area of
the air openings by one square inch per 1,000
BTUH of the Cast 92 boilers located in the
room.
2. Air From Boiler Room:
When the Boiler Draws Combustion Air from the
Boiler Room:
i. If the room volume is at least 50 cubic feet per
BTUH of the combined input of all appliances
in the room, no special openings are needed
UNLESS the building is of tight construction
(see definition). If the building is of tight
construction, provide openings to the building
in accordance with all applicable codes.
ii. If the boiler is in a space smaller than 50 cubic
feet volume per BTUH input, provide air
openings using one of the methods in Figure 1.3.
3. Definitions:
a. Free Area: Louvers or grilles reduce the area of an
opening. Free area is the area remaining with the
louver or grille in place. If the free area of a louver
is unknown, use the following:
i. Metal Louver: Multiply required free area of
the opening times 1.7 to determine actual area
of the required opening.
ii. Wood Louver: Multiply required free area of
the opening times 5 to determine actual area
of the required opening.
b. Tight Construction: When a building is extensively
sealed to prevent air infiltration, it cannot provide
enough air for combustion unless openings are
provided to the outside. The National Fuel Gas
Code defines such buildings as having all of the
following:
i. Walls and ceilings exposed to the outside
atmosphere have a continuous water vapor
retarder with a rating of 1 perm or less with
openings gasketed.
ii. Weather-stripping has been added on
openable windows and doors.
iii. Caulking or sealants are applied to areas such
as joints around windows and door frames,
between sole plates and floors, between wall-
ceiling joints, between wall panels, at
penetrations for plumbing, electrical, and gas
lines, and in other openings.
4. Conversion Factors:
In2/1,000 BTUH to cm2/kw — Multiply In2/1,000
BTUH times 22
In2/2,000 BTUH to cm2/kw — Multiply In2/2,000
BTUH times 11
In2/3,000 BTUH to cm2/kw — Multiply In2/3,000
BTUH times 7.4
In2/4,000 BTUH to cm2/kw — Multiply In2/4,000
BTUH times 5.5
5. Air Opening Options for Combustion Air
Drawn from Boiler Room:
Upper openings (U) must be within 12 inches of the
ceiling. Lower openings (L) must be within 12 inches
of the floor.
Option 1 – Air Openings Through Interior Wall:
When air is supplied to the boiler room through
openings in an interior wall (air supply from inside the
building), size each opening to provide minimum free
area of:
1 in2per 1,000 BTUH of all Cast 92 boilers in the
room.
Figure 1.3: Air opening options for combustion air
drawn from boiler room
If other appliances are located in the same room as
the boiler, increase the size of air openings to
provide the free area required for the other
appliances in addition to the air required for the Cast
92 boiler(s).
WARNING

6
PREINSTALLATION
Option 2 – Air Openings Through Outside Wall:
When air is supplied to the boiler room through
openings in an outside wall (air supply from outside
the building), size each opening to provide minimum
free area of:
1 in2per 4,000 BTUH of all Cast 92 boilers in the
room.
Option 3 – Horizontal Ducts to Outside Wall:
When air is supplied to the boiler room through
horizontal ducts to an outside wall (air supply from
outside the building), size each opening to provide
minimum free area of:
1 in2per 3,000 BTUH of all Cast 92 boilers in the
room.
Option 4 – Openings to Attic/Crawl Space:
Air openings can be connected to a ventilated attic or
crawl space. The upper opening must be to the attic.
The lower opening can be a vertical duct from the
attic or an opening in the floor from the crawl space.
Size each opening to provide minimum free area of:
1 in2per 3,000 BTUH of all Cast 92 boilers in the
room.
Option 5 – Single Opening (not shown):
A single opening directly connected to the outdoors
through a wall or a vertical or horizontal duct can be
used if the installation provides the clearances of
Figure 1.2, and the top of the opening is within 12
inches of the ceiling. Size the opening to provide
minimum free area of:
1 in2per 3,000 BTUH of all Cast 92 boilers in the
room.