PeerlessBoilers WBV Series Instruction manual

WBV
®
Boilers
Series
Oil
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.

ii
USING THIS MANUAL 1
A. INSTALLATION CLEARANCE ............1
B. SPECIAL ATTENTION BOXES............1
1. PREINSTALLATION 2
A. CLEARANCES ........................2
B. AIR FOR COMBUSTION &
VENTILATION.........................2
C. CHIMNEY / VENT & DRAFT CONTROL.....3
D. INSTALLATION SURVEY ................3
E. PLANNING THE LAYOUT ...............3
F. BOILER WATER TREATMENT............3
2. BOILER PLACEMENT & ASSEMBLY 4
A. SETTING THE BOILER ..................4
B. FLUE BAFFLES........................4
C. CONNECTING THE FLUE OUTLET ........4
D. JACKET ASSEMBLY (KNOCKDOWN
BOILERS) ............................4
3. PIPING & CONTROLS 6
A. PRESSURE TEST BLOCK ASSEMBLY .....6
B. BOILER RETURN CLEARANCE ...........6
C. WATER BOILER PIPING.................6
D. STEAM BOILER PIPING .................6
E. TANKLESS HEATER OR COVERPLATE ....7
F. CONTROLS...........................7
4. ELECTRICAL 9
A. GENERAL ............................9
B. WIRING ..............................9
5. BURNER SETUP & BOILER
OPERATION 14
A. BURNER INSTALLATION...............14
B. BURNER START-UP & ADJUSTMENT ....14
C. CHECK BOILER CONTROLS ............14
D1. FILL THE BOILER (WATER BOILERS) ....14
D2. FILL THE BOILER (STEAM BOILERS) ... .15
E. PURGE AIR FROM THE SYSTEM
(WATER BOILERS ONLY) ..............15
F. CLEAN THE BOILER
(STEAM BOILERS ONLY) ..............15
6. MAINTENANCE 17
A. GENERAL ...........................18
B. DAILY MAINTENANCE (WITH BOILER
OPERATING) ........................18
C. WEEKLY MAINTENANCE (WITH BOILER
OPERATING) ........................18
D. MAINTENANCE OF SAFETY
RELIEF VALVE .......................18
E. MONTHLY MAINTENANCE (WITH BOILER
OPERATING) ........................18
F. MAINTENANCE – ANNUAL.............18
G. IF A LONG SHUTDOWN IS REQUIRED ...19
7. BOILER DIMENSIONS & RATINGS 20
8. REPAIR PARTS 22
TABLE OF CONTENTS
TABLE OF CONTENTS

A. INSTALLATION CLEARANCE
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:
USING THIS MANUAL
1
USING THIS MANUAL
Indicates a hazardous situation, which, if not avoided,
will result in death or serious injury and major
property damage.
⚠ DANGER
Indicates a hazardous situation, which, if not avoided,
could result in death or serious injury and major
property damage.
⚠ WARNING
Indicates special attention is needed,
not related to personal injury or property damage.
NOTICE
⚠ CAUTION
Indicates a hazardous situation, which, if not avoided,
could result in minor or moderate injury, and minor
property damage.

2
A. CLEARANCES
Unit may be installed on combustible flooring, provided the
boiler is not set on carpet and a metal drip pan is placed
under the appliance.
Unit may be installed in a closet with the above clearances.
See also Section B, Air for Combustion and Ventilation.
B. AIR FOR COMBUSTION &
VENTILATION
1. Be certain adequate facilities are available to provide
air for satisfactory combustion and ventilation.
2. Appliances Located in Unconfined Spaces.
a. For installation in unconfined spaces with
conventional construction and larger areas such
as basements, the supply of air for combustion
and ventilation can usually be considered
adequate.
3. Appliances Located in Confined Spaces.
a. All air from inside the building: Provide two
permanent openings communicating directly with
an additional room. If all air for combustion and
ventilation is to come from within the building:
two openings, one near the ceiling and one near
the floor of the boiler room shall be provided
with the minimum free area of each opening
equal to 140 sq. in. per gallon of oil burned.
b. If all air for combustion and ventilation is to
come from outside the building: two openings,
one near the ceiling and one near the floor of the
boiler room shall be provided with the minimum
free area of each opening equal to 35 sq. in. per
gallon of oil burned.
If ducts are used to convey the air, areas of
35 sq. in. per gallon of oil burned for vertical
ducts or 70 sq. in. per gallon of oil burned for
horizontal ducts are to be provided. Ducts shall
have the same area as the free area of the
openings to which they are connected.
PREINSTALLATION
1. PREINSTALLATION
Read carefully, study these instructions before beginning work. It will save time. Study the included drawings. Save these
instructions for reference.
The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly.
Table 1.1: Clearances from Jacket and Vent System
Required from Jacket
to Combustible
Construction
Recommended From Jacket for
Accessibility and Mounting Controls
Top 5”* 24” to clean flueways.
Front 16.5”* 16.5” from jacket due to burner.
Left 2”* 12” due to burner swing radius.
Right 2”*
18” on steam with tankless heater or with
Float LWCO.
9” in area of boiler service switch and
junction box.
Rear 2”* 9” for mounting relief valve in standard
location**.
Vent Pipe (Single Wall) - 9” to Combustible Construction.
Clearance may be reduced using methods in NFPA 31.
Vent Pipe (Double Wall) - See Manufacturer’s Instructions.
* Consider also vent pipe clearance, including distance from edge of
flue outlet to combustible construction (as applicable).
** See dimensional drawing for alternate relief valve location.
This manual is intended for use by Qualified Heating Professionals only. Installation, service, or adjustment
of this heating appliance by anyone other than a Qualified Heating Professional can cause significant property
damage, personal injury, or death.
WARNING
The equipment shall be installed in accordance with those installation regulations in force in the local area
where the installation is to be made, including the current edition of NFPA-31, Standard for the Installation of
Oil-Burning Equipment, and in Canada, CSA B139, Installation Code for Oil Burner Equipment. These shall be
carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.
NOTICE
Never burn garbage or paper in the unit, and never
leave combustible material around it.
CAUTION
Do not tamper with boiler controls.
CAUTION

3
C. CHIMNEY / VENT & DRAFT CONTROL
1. Draft Requirement - Minimum draft required in the
vent system is -.03” W.C. to -.06” W.C. depending
on boiler model, see Table 7.1 (Section 7). This draft
is necessary to provide the required draft over fire of
-.01” W.C. to -.02” W.C..
2. A barometric draft control is required for regulation
of over fire draft. Follow manufacturer’s instructions
to locate and adjust the control.
3. The vent system and installation must be in
accordance with the current edition of ANSI/
NFPA 211, “Standard for Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances”;
NFPA-31, “Standard for the Installation of Oil-
Burning Equipment” and in Canada, CSA B 139,
“Installation Code for Oil-Burning Equipment” or
applicable provisions of local building codes. Typical
minimum chimney size is 8” x 8” x 15 feet high,
unless otherwise allowed by code. If the vent system
is not sized correctly, the burner may not operate
properly. This can cause poor combustion, sooting,
and odors to occur.
4. NFPA 31 recommends using a listed metal chimney
liner to reduce transient low draft during startup and
flue gas condensation during cyclic operation. Any
doubt on the condition of a chimney or its ability to
prevent the generation and accumulation of flue gas
condensate, must be lined according to NFPA 31.
5. Inspect the existing chimney, chimney liner, and vent
connector. Make sure each are in good condition
and repair or replace as required.
6. Chimney flue gas condensation is affected by a
number of factors such as chimney design, flue
connector length, sulfur content in fuel oil, and flue
gas temperature. If your application experiences flue
gas condensation, installation of a listed corrosion
resistant metal liner is required.
• External chimneys are more susceptible to flue
gas condensation due to colder outside air
temperatures. To prevent corrosion due to flue
gas condensation, use a listed corrosion resistant
metal liner in chimney.
• When firing WBV-e 03 and 04 section models
at 0.6 and 0.95 GPH input rate, respectively,
a listed corrosion resistant metal liner is
recommended.
• When firing the appliance where fuel oil sulfur
content exceeds 300ppm, a listed corrosion
resistant chimney liner is recommended.
D. INSTALLATION SURVEY
For new and existing installations, a Water Installation
Survey or a Steam Installation Survey is available from
P.B. Heat, LLC. The surveys will provide information
on how the boiler works with your specific system and
will provide an overview of boiler system operation in
general.
You can also use this survey to locate system problems
which will have to be corrected. To obtain copies of
these Surveys, contact your PB Heat representative or
download it from PeerlessBoilers.com.
E. PLANNING THE LAYOUT
Prepare sketches and notes of the layout of the
installation. Include boiler location, venting system,
existing piping and wiring. Show existing equipment that
may interfere with installation of new equipment.
F. BOILER WATER TREATMENT
Consult a local qualified water treatment specialist for
recommendations regarding the appropriate chemical
compounds and concentrations which are compatible
with local environmental regulations.
1. Steam Boilers
a. Boiler water pH should be in the 7.5 to 11
range.
b. Boiler water chloride concentration should
be less than 30 ppm.
c. The water hardness should be less than 7 grains
per gallon to prevent scale build-up and foaming.
2. Water Boilers
a. Boiler water pH should be in the 7.5 to 11
range.
b. Boiler water chloride concentration should
be less than 30 ppm.
c. The water hardness should be less than 9 grains
per gallon to prevent scale build-up.
PREINSTALLATION
This boiler shall be connected to a venting system
having sufficient draft. Follow draft requirements
below.
Improper venting may result in the release of flue
gases which contain deadly carbon monoxide into
the home, which can cause severe personal injury,
death, or substantial property damage.
WARNING
A masonry chimney must have a clay flue liner.
If flue gas condensation is occurring, install a listed
corrosion resistant metal liner.
Failure to install a clay flue liner may cause severe
injury or death.
WARNING
Series WBV bis approved at listed firing rates only.
Failure to fire the boiler at its designed input may
cause excessive flue gas condensation and may
cause products of combustion to enter the home
resulting in severe property damage, personal injury
or death.
WARNING

4
A. SETTING THE BOILER
1. Provide a level foundation, located as close as
possible to the center of the heating system.
2. Refer to Figures 2.2 and 2.3 for exploded view of
boiler while checking and/or assembling parts of the
boiler.
3. On packaged boilers, open burner mounting plate
(item 7) at this time to make certain the target wall
(item 2) is seated in the back of the combustion
chamber. (WBV-e-04/WBV-e-05) Ceramic fiber
blanket base liner (item 3) should be lying flat on
bottom of combustion chamber between target wall
and burner mounting plate. Close burner mounting
plate.
4. See clearance information in Section I,
“Preinstallation.”
B. FLUE BAFFLES
1. Packaged Boilers - Flue baffles are factory installed.
Remove flue baffles if converting to WBV-e-03-060
or WBV-e-04-095 rates.
2. Knock-down Boilers - Flue baffles are located in the
jacket cartons. Bend baffle tabs as shown in Figure
2.1 and suspend baffles from top of flueways. Install
one baffle per flueway. Do not install flue baffles
if converting to WBV-e-03-060 or WBV-e-04-095
rates.
C. CONNECTING THE FLUE OUTLET
The WBV-e-03 and WBV-e-04 boiler models may be
installed as a rear flue outlet unit or a top flue outlet unit.
Packaged WBV-e-03 and WBV-e-04 boiler models are
shipped as rear flue outlet and may be converted. The
WBV-e-05 boiler model is only available as a top flue outlet
unit. On Knockdown boilers, the flue outlet components
are located in the water trim or steam trim carton.
1. If converting to a top flue application on a packaged
boiler, remove the large knockout in the jacket top
panel. Coverplate for rear jacket (item 26) is located
in trim carton. Attach using #10 x 1/2” sheet metal
screws (item 27).
2. On Knockdown boilers, install the flue collector
coverplate and 1/2” rope (items 19 and 20) on top
of the block assembly using four (4) 5/16” x 1-3/4”
studs (item 18), nuts and washers provided. NOTE:
Use of a spray adhesive is advantageous when
applying rope seal to top of the sections.
3. Mount the flue collar adapter and flue gasket seal
(items 24 and 21) to either the rear boiler section for
a rear flue application, or to the flue collector plate
(item 20) for a top flue application. Use 5/16” hex
head bolts (item 25) for rear flue outlet, and #14 x
1/2” sheet metal screws (item 23) for top flue outlet.
4. Attach the rear outlet cover plate (item 22) to the
remaining unused opening using four (4) 5/16”
screws (item 23) and washers provided.
D. JACKET ASSEMBLY (KNOCKDOWN
BOILERS)
1. If the boiler is to be installed with a rear flue outlet,
remove the square knock-out in the back panel.
2. Attach back panel to bosses on middle of back
section with two 1/4” x 3/8” machine screws
(item 28) provided. The back panel has two 5/16”
diameter holes close to the center of the panel.
3. Attach both the left and right side panels to the back
panel and secure with sheet metal screws (Item 30).
4. Remove the burner mounting plate (item 7) and
make certain the target wall (item 2) is in correct
position in back of chamber. Ceramic fiber blanket
liner (item 3, WBV-e-04 and WBV-e-05) should be
on floor of boiler in front of target wall.
5. Remove the two (2) knockouts in the front jacket
panel which will allow clearance for the hinge. Place
the front jacket panel on the block and attach the left
and right side panels in the same manner as they are
attached to the back panel.
6. Reinstall the burner mounting plate.
2. BOILER PLACEMENT & ASSEMBLY
BOILER PLACEMENT & ASSEMBLY
REMOVE FLUE BAFFLES if firing this boiler at its
lowest listed rate:
0.60 GPH on 3 section
0.95 GPH on 4 section
Flue gas condensation may occur, causing
deterioration of the vent system and premature
failure of boiler.
WARNING
Do not install flue baffles on models WBV-e-03-060 or
WBV-e-04-095.
Flue gas condensation may occur, causing
deterioration of the vent system and premature
failure of boiler.
WARNING
90 TOWARDS
FRONT OF
NOT
BOILER
WBV-e-04-095
FLUEWAY.
WBV-e-03-060
BAFFLES,
INSTALL FLUE
1 PER
FLUE BAFFLES ON:
INSTALL
BEND BOTH TABS
DO
ON REAR BAFFLE
ON REMAINING
BAFFLES BEND
TAB 90 IN
OPPOSITE
DIRECTIONS
Figure 2.1:
Flue Baffle
Installation
Secure the flue collar to the vent connector and join
the sections of the vent connector using sheet metal
screws or per listed vent manufacturer’s instructions.
WARNING

BOILER PLACEMENT & ASSEMBLY
5
10
11
12
9
7
8
3
2
4
14B
13B
16B
1
19
20
21
22
21
24
29
17 28
27
26
25
18
23
15
6
30
Figure 2.2: Steam Boiler
23
6
5
29
20A
22
21
24
21
1
4
2
3
8
7
14A
16A
20
19
17
28
18
13A
15
12
9
10
11
25
26
27
30
Figure 2.3: Water Boiler
5

6
A. PRESSURE TEST BLOCK ASSEMBLY
1. Make up cold water supply connection to the boiler.
2. Install pressure gauge or pressure-temperature
gauge in tapping provided. See Boiler Dimensional
drawing, Figures 7.1 and 7.2 (Section 7)
3. Plug all open tappings in the boiler and fill with
water. Apply approximately thirty (30) psig pressure.
Check to make certain that all joints and fittings are
water tight.
4. After all joints and connections have been proven
tight, remove cold water supply and plugs from all
tappings that are to be used. See Figures 7.1 and 7.2
(Section 7) for tapping locations.
B. BOILER RETURN CLEARANCE
Return piping must allow for opening and closing Burner
Mounting Plate. PB Heat, LLC suggests installing a 1-1/4
NPT tee, a 90° elbow, and a 1-1/4 NPT x 5” long nipple
in the return tapping before a vertical stand pipe is used.
C. WATER BOILER PIPING
1. Refer to the Water Installation Survey and Hydronics
Institute Residential Hydronic Heating Installation/
Design Guide for guidance.
2. The supply and return connections should be sized to
suit the system. A 1-1/2” to 1-1/4” reducing coupling
may be used where the system piping is 1-1/2”.
3. The supply should be out the top of the back section
and return to the bottom of the front section as
shown in Figure 3.1. There is a 3/4” tapping in the
top of the back section for air elimination.
4. When the return temperature from the system will
be below 150°F on oil boilers for extended periods
(heat pump systems, outdoor reset, snow melt, etc.),
provide piping and controls to protect the boiler
from condensation. Condensation will damage the
boiler and will lead to shortened boiler life and
maintenance problems.
5. If using a Partner indirect fired water heater or
other, see Figure 3.6 for typical piping. Also refer to
additional instructions supplied with the Partner.
6. If the boiler is to be used in conjunction with a
refrigeration system, the chilled medium shall be
piped in parallel with boiler and proper valves
applied to prevent the chilled medium from entering
the boiler. Refer to Figure 3.5.
7. If the boiler is connected to heating coils located in
air handling units, the boiler piping system must be
equipped with flow control valves or other automatic
devices to prevent gravity circulation of the boiler
water during the cooling cycle.
D. STEAM BOILER PIPING
1. Refer to the Steam Installation Survey and Hydronics
Institute Residential Hydronic Heating Installation/
Design Guide for assistance.
2. See table below for pipe sizing. The return loop from
system should always enter equalizer through the
Hartford Loop, 2” to 4” below normal water line.
See Figure 3.2.
3. Use swing joints to attach header to avoid damage to
the boiler due to thermal expansion and contraction
of steam header pipe.
4. Pipe the steam header a minimum of 24” above the
normal water line using swing joints to attach the
risers into the steam header.
3. PIPING & CONTROLS
Figure 3.1: Water Boiler Piping Figure 3.2: Steam Boiler Piping
PIPING & CONTROLS
Boiler Model
No.
Supply Riser
“A” Header “B” Equalizer “C”
WBV-e-03 (1) 2” 2” or 3” 1-1/4”
WBV-e-04 (1) 2” 2” or 3” 1-1/4”
Do not pipe boiler before jacket is installed.
NOTICE

7
E. TANKLESS HEATER OR COVERPLATE
1. If a tankless coil is used, install as pictured. On water
boilers (item 16A), install in opening in front section.
On steam boilers (item 16B), install in opening in
rear section. For suggested piping of tankless water
heaters refer to Figures 3.3 and 3.4.
2. If not using a tankless coil, cover the heater opening
with cover plate (item 13A or 13B).
F. CONTROLS
1. Water Boiler Controls:
a. Install the limit / operating control, pressure-
temperature gauge and safety relief valve.
See Figure 7.1 (Section 7) for proper location.
For installations subject to UL726, a second
operating control that senses water temperature
is also required (not provided). Use an L4080B
or equivalent. Install in the supply piping near
the boiler.
2. Steam Boiler Controls:
a. Install the limit / operating control, pressure
gauge, gauge glass trim and safety relief valve.
See Figure 7.2 (Section 7), Figure 3.7 (float
boilers) and cover photo (probe boilers).
b. For installations subject to UL726, a second
operating control that senses steam pressure
is required (not provided). Use a PA404A
or equivalent. On probe boilers, install the
additional pressure control opposite the
standard PA404A using a cross instead of a
tee along with a second brass siphon (not
provided). On float boilers, install the additional
pressure control in the 1/4” tapping on the top of
the float low water cut-off using a vertical (360º)
brass siphon (not provided).
c. For application of a probe low-water cut-off,
use only Hydrolevel CG450. See Figure 7.2
(Section 7) for location. See also control
manufacturers instruction sheet.
d. See Figure 3.7 for application of float low water
cut-offs.
PIPING & CONTROLS
12" MIN.
TAPPING
MIXED 3/4" CONTROL
HEATER
MIXER
COLD WATER INLET
HIGH TEMPERATURE
WATER
HOT WATER
TANKLESS
WATER
FLOW CONTROL
12" MIN.
TANKLESS
HOT WATER
MIXER
HIGH TEMPERATURE
WATER
COLD WATER INLET
FLOW CONTROL
TAPPING
CONTROL
HEATER
3/4"
MIXED
WATER
Figure 3.3: Tankless Coil Piping, Steam Boiler
Figure 3.4: Tankless Coil Piping, Water Boiler
Install anti-scald device in hot water supply piping.
Water temperature above 125°F can cause severe
burns instantly or death from scalds.
DANGER
Be sure rubber gasket is in place between cover
plate or water heater plate and boiler section.
NOTICE
Pipe the discharge of the safety
valve or 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 relief valve.
CAUTION
Series WBV bboilers are not for use in commercial
installations where a secondary low water cut-off is
required.
NOTICE

8
Figure 3.6: Piping with Peerless®Indirect Water Tank
Figure 3.7: Float Low Water Cut-off
PIPING & CONTROLS
Figure 3.5: Piping to Isolate Boiler from Chilled
Medium on Chiller Systems
CHILLER
VALVE
SUPPLY LINE
CHECK VALVE
BOILER
WATER
THREE WAY
RETURN
LINE
3. For Canadian installations, a blocked vent switch
must be installed. The optional blocked vent switch
kits listed below include a Field Controls WMO-1
vent switch, draft regulator, and French Clearance/
Rating label. Follow installation instructions provided
by the vent switch manufacturer. Vent switch must
be wired to shut off power to burner.
4. For complete information on servicing and
adjustment of controls, refer to the attached control
specification sheets.
Model Flue Diameter Vent Kit
WBV-e-03/04 6” 50345
WBV-e-05 7” 50346

A. GENERAL
All electrical wiring shall be done in accordance with
the National Electrical Code and Local Requirements.
Single pole switches including those of safety controls or
protective devices shall not be wired in a grounded line.
B. WIRING
1. See Section 5 for mounting burner.
2. Knockdown Boilers:
Install junction box, limit harness, and Heyco bushing,
each located in the trim carton. See Figure 4.1 or
Figure 4.2. Mount junction box to the holes in the
right side of jacket with (2) #10 x 1/2” sheet metal
screws. Attach Heyco bushing to 7/8” knockout in
left side of junction box. Connect limit harness to
7/8” knockout on top of junction box and insert limit
harness Molex connector into Heyco bushing until it
snaps firmly in place.
3. Install burner harness located in the burner carton.
4. For complete information on servicing and
adjustment of controls, refer to the attached control
specification sheets.
5. See the following Wiring Diagrams:
Figure 4.3 - Water Boilers, Hydrolevel 3250
Limit Control
Figure 4.4 - Steam Boilers with Float LWCO
Figure 4.5 - Steam Boilers with Probe LWCO
4. ELECTRICAL
ELECTRICAL
9
In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, water boilers are equipped with
a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature
is equipped with an override which is provided primarily to permit the use of an external energy management
system that serves the same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:
• An external energy management system is installed that reduces the boiler water temperature as the
heating load decreases.
• This boiler is not used for any space heating.
• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.
• This boiler is equipped with a tankless coil.
IMPORTANT
Improper installation of burner harness can allow
burner to energize with burner mounting plate open,
creating a severe burn hazard to boiler maintenance
personnel.
WARNING

10
Figure 4.1: Junction Box Wiring, Knockdown Water Boilers
Figure 4.2: Junction Box Wiring, Steam Boilers
ELECTRICAL

11
Figure 4.3: Water Boilers, Hydrolevel 3250 Limit Control
ELECTRICAL
Figure 4.3a: Hydrolevel HydroStat 3250 Limit Control Wiring Details

12
ELECTRICAL
Figure 4.5: Steam with Probe Low Water Cut-off
Figure 4.4: Steam with Float Low Water Cut-off

13
BURNER SETUP & BOILER OPERATION
A. BURNER INSTALLATION
1. The oil burner is supplied with a mounting flange
fixed in position.
2. Mount the burner to the burner mounting plate (item
5) with four (4) 5/16” studs and nuts provided.
3. Care must be taken when routing the oil lines so
not to interfere with the opening and closing of the
burner mounting plate. Flexible oil lines or flared
copper disconnects with valves (when copper lines
are used) may be installed to assure full opening of
the burner mounting plate when servicing.
4. Oil burner specifications:
For information pertinent to the oil burner such
as nozzle sizing, fuel supply piping, adjusting or
servicing, refer to the charts in this section and the
burner installation manual.
B. BURNER START-UP & ADJUSTMENT
1. Burner should start automatically when thermostat
is turned up and main boiler service switch is turned
on. If burner does not start, check to be sure there
is oil in the tank and push reset button on burner
control:
Beckett: Square red button.
Carlin: Round red button.
Riello: Round red button inside clear flexible
cover on back of burner cover.
If burner still does not start, contact serviceman.
2. Adjust burner and barometric draft control for
highest CO²(Maximum 13.1%) while maintaining a
0 Smoke and a minimum -.01” W.C. draft overfire.
All adjustments must be made using suitable
instruments such as found in a Bacharach
Combustion Test Kit.
3. Burner and boiler can be shut down by turning
down the thermostat and moving the main boiler
service switch to the “off” position.
4. See burner manufacturer’s manual for further
information regarding the burner.
C. CHECK BOILER CONTROLS
1. Limit and Operating Controls:
a. Lower the set point of each control until the
burner shuts down. Note that the system pressure
(or temperature) corresponds to the desired set
point.
b. Return the controls to the desired set point.
2. Low Water Cut-off (if used) - consult the
manufacturer’s instructions for the low water cut-off
operational check procedure.
D1. FILL THE BOILER (WATER BOILERS)
1. Fill the boiler and system with water making certain
to vent air from all high points in the system. Water
should bleed from each air vent when it is opened.
2. The pressure reducing valve on the fill line will
typically allow the system to be filled and pressurized
to 12 psi. Consult the valve and expansion tank
manufacturer for more detailed information.
3. Check all joints and fittings throughout the system for
leaks. If leaks are found, drain the system and repair
as required.
4. See Section 1 - Preinstallation for boiler water
treatment requirements.
5. If the system requires antifreeze protection, use only
propylene glycol specially formulated for hydronic
systems. These contain inhibitors that prevent
corrosion of the boiler and system components. Do
not use ethylene glycol or automotive antifreezes.
a. Make sure that the antifreeze supplier
can provide periodic testing of antifreeze
concentration and inhibitor level.
b. If an automatic fill valve is used, the solution
strength in the system must be checked to assure
that the antifreeze concentration has not been
overly diluted.
5. BURNER SETUP & BOILER OPERATION
Be sure hi temp gasket is between the burner
mounting flange and the Burner Mounting Plate.
NOTICE
Two-pipe oil supply for Riello burner requires a
separate kit. Order part #C7001026 from
Riello dealer.
NOTICE
Burn only #2 Fuel Oil in this appliance. Do not use
gasoline, crankcase drainings or any oil containing
gasoline.
CAUTION
Do not start the burner unless all cleanout doors
are in place.
CAUTION
Do not attempt to start the burner when excess oil
has accumulated, when the unit is full of vapor, or
when the combustion chamber is very hot.
CAUTION

14
BURNER SETUP & BOILER OPERATION
c. Local codes may require the addition of a
backflow preventer or manual fill only with
separation from the city water supply.
d. Consider the minimum temperature of potential
exposure in the system when deciding on the
antifreeze concentration. A concentration of
50% generally provides protection from freezing
to -30°F.
D2. FILL THE BOILER (STEAM BOILERS)
1. The normal water line for steam boilers with gravity
returns is shown in Figure 7.2.
2. For systems with pumped returns or boiler feed
units, the fill level will depend on the control being
used. Verify the unit maintains a water level that is
visible in the gauge glass and does not exceed the
normal water level.
3. Check all joints and fittings in the system piping for
leaks and repair as necessary
4. See Section 1 - Preinstallation for boiler water
treatment requirements. E. PURGE AIR FROM
THE SYSTEM
E. PURGE AIR FROM THE SYSTEM
(WATER BOILERS ONLY)
1. Purge the system using purge valves, isolating zones
in the process or use system vents. Do not operate
the pump(s) while purging. Pumps will hold air in the
eye of the impeller.
2. Allow the system to reach 180°F and use manual
vents, if installed, to remove any remaining air.
Watch the pressure gauge as the system approaches
180°F. If the pressure exceeds the design operating
pressure, check:
a. Fill valve pressure.
b. Expansion or compression tank operation and
sizing.
F. (STEAM BOILERS ONLY)
1. Clean the boiler within one week after initial start-
up. Cleaning will be more effective if boiler operates
a day or two to loosen sediment and impurities in
system.
2. Boiler must be cleaned to remove any accumulation
of oil, grease, sludge, etc. in the system. These
substances can cause foaming and surging of boiler
water, producing an unstable water line and water
carryover to system.
3. Connect a skim valve off the 1-1/4 NPT skim tapping
on front of boiler. See Figure 7.2 (Section 7) to
locate skim tapping. Run a drain line off skim valve
to a point of safe discharge.
4. Provide a means of supplying continuous fresh water
to the boiler for the cleaning process.
5. Use common washing soda, such as Arm and
Hammer Super Washing Soda. Mix 1/2 pound of
soda with water in a 10 quart pail. Pour the mixture
into the boiler through the safety relief valve tapping.
6. Open the skim valve. Fill boiler until water begins to
flow out of the valve.
7. Turn on burner. Allow boiler water to heat up to just
below steaming (180 - 200°F). Do not allow boiler
to steam; steaming mixes up contaminants instead of
floating them at surface.
8. Open make-up water valve to continually feed water
to boiler. Adjust flow to maintain water temperature
at 180 - 200° F.
9. Continue skimming boiler until water flowing from
skim tapping flows clear. This will take some time,
possibly several hours for a dirty system.
10. Turn off burner, close make-up water valve.
11. Drain boiler completely. Refill and drain one or two
times to wash out all washing soda.
12. Remove skim valve and piping. Install 1-1/4”NPT plug
in skim tapping.
If gauge glass becomes dirty more contaminants
have worked loose in system. Repeat cleaning and
skimming process as needed to clean system.
NOTICE
Cleaning the boiler requires the use of very hot water
and corrosive chemicals. Use care when handling to
prevent injury.
WARNING
Do not allow make-up water to flow too fast.
Excessive quantities of cold water may fracture
sections.
CAUTION
Do not leave boiler unattended while firing burner.
Operating boiler with water below minimum
permissible water level may fracture sections.
CAUTION

15
BURNER SETUP & BOILER OPERATION
BECKETT BURNER SPECIFICATIONS
Boiler
Model No.
Burner
Model No.
Burner
Head
Static
Plate Nozzle Size Pump Pressure
Start-up Settings Head
Setting
Air Shutter Air Band
WBV-e-03-085 AFG-F3¹ F3 3-3/8” 0.75 80° B HAGO³ 140 PSI 6.0 1 N/A
WBV-e-03-105 AFG-F4 F4 3-3/8” 0.90 80° B HAGO 140 PSI 6.0 0 N/A
WBV-e-04-095 AFG-F4 F4 3-3/8” 0.85 80° B DEL4140 PSI 6.0 0 N/A
WBV-e-04-125 AFG-F4 F4 3-3/8” 1.10 80° B HAGO³ 140 PSI 5.0 2 N/A
WBV-e-04-150 AFG-F6 F6 2-3/4” 1.25 80° B HAGO 140 PSI 8.0 1 N/A
WBV-e-05-175 AFG-MV1 V-1 - 1.50 60° B HAGO³ 140 PSI 10.0 3 3
WBV-e-05-195 AFG-MV1 V-1 - 1.65 60° B HAGO 140 PSI 10.0 5 3
CARLIN BURNER SPECIFICATIONS (WITH 98022 PSC MOTOR)
Boiler
Model No.
Burner
Model No.
Head Bar or
Head Setting Nozzle Size Pump Pressure Start-up Settings
Air Shutter Air Band
WBV-e-03-085 EZ-1HP 0.60 - 0.65 0.65 70° A DEL³ 150 PSI Blank 0.60
WBV-e-03-105 EZ-1HP 0.85 - 1.00 0.85 70° A DEL 150 PSI Blank 0.65
WBV-e-04-095 EZ-1HP 0.75 0.75 70° A DEL4150 PSI Blank 0.60
WBV-e-04-125 EZ-1HP 0.85 - 1.00 1.00 70° A DEL³ 150 PSI Blank 0.85
WBV-e-04-150 EZ-1HP 1.10 - 1.25 1.25 60° B DEL 150 PSI Blank 1.00
WBV-e-05-175 99FRD 5 1.50 60° B HAGO³ 150 PSI Open 10% open
WBV-e-05-195 99FRD 5 1.65 60° B HAGO 150 PSI Open 45% open
RIELLO BURNER SPECIFICATIONS
Boiler
Model No.
Burner
Model No. Burner Series Nozzle Size² Pump Pressure Start-Up Settings
Turbulator Air Damper
WBV-e-03-060 F3 Series 40 0.50 90° B 145 PSI 0.0 2.9
WBV-e-03-085 F5 Series 40 0.65 60° W³ 170 PSI 1.0 2.45
WBV-e-03-105 F5 Series 40 0.85 60° W 165 PSI 2.5 2.8
WBV-e-04-095 F5 Series 40 0.75 80° B4160 PSI 0.5 2.25
WBV-e-04-125 F5 Series 40 1.00 60° W³ 155 PSI 2.5 3.4
WBV-e-04-140 F5 Series 40 1.10 60° W 160 PSI 4.0 4.2
WBV-e-05-175 F10 Series 40 1.35 60° B³ 165 PSI 2.0 2.5
WBV-e-05-195 F10 Series 40 1.50 60° B 170 PSI 2.5 2.8
Factory Installed Nozzles (Packaged Boilers or Burner Cartons) are indicated in Boldface.
1 Requires Low Firing Rate Baffle
2 Delavan Recommended
3 Shipped Loose with Packaged Boiler or Burner Carton
4 Not included with Packaged Boiler or Burner Carton
Table 5.1: Beckett Burner Specifications
Table 5.2: Carlin Burner Specifications (with 98022 PSC motor)
Table 5.3: Riello Burner Specifications
BECKETT NX BURNER SPECIFICATIONS
Boiler Model No. Burner Model Nozzle Size Pump Pressure Start Up Head/Air
WBV-e-03-085 NX70LB 0.65 x 60° W DEL³ 170 1.5
WBV-e-03-105 NX70LB 0.85 x 60° B HAGO 170 2.5
WBV-e-04-095 NX70LB 0.75 x 60° W DEL4170 2.0
WBV-e-04-125 NX70LD 1.10 x 60° W DEL³ 140 1.0
WBV-e-04-150 NX70LD 1.25 x 60° W DEL 140 2.0
Note: Burner used to fire the WBV-e-03-085 and 1.05 rate is also required to fire the WBV-04-e-095 rate with nozzle indicated in above chart.

16
MAINTENANCE
6. MAINTENANCE
Product Safety Information
Refractory Ceramic Fiber Product
This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF,
when inhaled, have been classified by the International Agency for Research on Cancer
(IARC), as a possible carcinogen to humans. After the RCF materials have been exposed
to temperatures above 1800°F, they can change into crystalline silica, which has been
classified by the IARC as carcinogenic to humans. If particles become airborne during
service or repair, inhalation of these particles may be hazardous to your health.
Avoid Breathing Fiber Particulates and Dust
Suppliers of RCF recommend the following precautions be taken when handling these
materials:
Precautionary Measures:
Provide adequate ventilation.
Wear a NIOSH/MSHA approved respirator.
Wear long sleeved, loose fitting clothing and gloves to prevent skin contact.
Wear eye goggles.
Minimize airborne dust prior to handling and removal by water misting the material and
avoiding unnecessary disturbance of materials.
Wash work clothes separately from others. Rinse washer thoroughly after use.
Discard RCF materials by sealing in an airtight plastic bag.
First Aid Procedures:
Inhalation: If breathing difficulty or irritation occurs, move to a location with fresh clean air.
Seek immediate medical attention if symptoms persist.
Skin Contact: Wash affected area gently with a mild soap and warm water. Seek immediate
medical attention if irritation persists.
Eye Contact: Flush eyes with water for 15 minutes while holding eyelids apart. Do not rub
eyes. Seek immediate medical attention if irritation persists.
Ingestion: Drink 1 to 2 glasses of water. Do not induce vomiting. Seek immediate medical
attention.
WARNING

17
MAINTENANCE
A. GENERAL
1. Check pipes adjacent to cold walls or in unheated
spaces. Insulate and tape them if necessary to be
sure they can’t freeze up. Keeping the water moving
at all times will reduce the likelihood of freezing.
2. If there is considerable foreign matter in the boiler
water, the boiler should be shut down and allowed
to cool, then drained and thoroughly flushed out.
Drain the boiler at the drain cock. Pipe the drain
cock to a suitable drain or containment device (if
antifreeze is used). Flush the system to remove
remaining matter. See Section 1 - PreInstallation
for water quality requirements If there is evidence
that hard scale has formed on the internal surfaces,
the boiler should be cleaned by chemical means as
prescribed by a qualified water treatment specialist.
3. There must be no signs of continuous wetness
at the chimney. If signs of continuous wetness
are observed, a qualified service agency must be
consulted to modify the vent configuration to prevent
the formation of condensate, which may damage the
vent pipe.
B. DAILY MAINTENANCE (WITH BOILER
OPERATING)
Daily boiler observation can be performed by the owner.
If any potential problems are found, a qualified installer
or service technician/agency must be notified.
1. Remove any combustible materials, gasoline and
other flammable liquids and substances that generate
flammable vapors from the area where the boiler
is contained. Make certain that the boiler area has
ample air for combustion and ventilation and that
there are no obstructions to the free flow of air to
and from the boiler.
2. Observe general boiler conditions (unusual noises,
vibrations, etc.)
3. Observe operating temperature and/or pressure
gauge on the boiler. Boiler pressure should never
be higher than 5 psi below the rating shown on the
safety relief valve. The valve rating can be found on
the top of the safety relief valve. Boiler temperature
should never be higher than 250°F.
4. Check for water leaks in boiler and system piping.
C. WEEKLY MAINTENANCE (WITH BOILER
OPERATING)
1. Flush float-type low-water cut-off (if used) to remove
sediment from the float bowl as stated in the
manufacturer’s instructions.
D. MAINTENANCE OF SAFETY RELIEF
VALVE
1. Check function and maintain safety relief valve as
specified by manufacturer, typically every other
month or every month, per the instructions on the
tag on the safety relief valve.
E. MONTHLY MAINTENANCE (WITH BOILER
OPERATING)
1. Check boiler room floor drains for proper
functioning.
2. Test probe type low-water cut-off (if used) by using
the Push-to-Test Button.
3. Test limit by lowering the limit set point until the
burner shuts down. When proper operation is
confirmed, return the set point to original setting.
4. Follow additional instructions in the Burner Manual
for proving the burner component operation.
F. MAINTENANCE – ANNUAL
Entire heating system, including boiler, burner and
venting system, must be inspected at least once a
year by a qualified heating professional. Boiler is to
be cleaned at least once a year.
NOTICE
Disconnect all power to the burner before accessing
combustion chamber.
WARNING
Do not use this appliance if any part has been under
water. Improper or dangerous operation may result.
Immediately call a qualified service technician to
inspect the boiler and to replace any part of the
control system and any control which has been
under water.
WARNING
Turn off power to boiler before adjusting limit
control.
CAUTION

18
MAINTENANCE
TO CLEAN:
1. Remove top jacket panel and flue collector plate,
Item 20 (Figure 2.2 or 2.3).
2. Remove and clean flue baffles.
3. To thoroughly clean the boiler it must be brushed
down from the top. Alternatively, for limited space
or minimum clearance to combustible installations,
cleaning the heat exchanger from the combustion
chamber side is acceptable. If unit is extremely dirty, it
may be necessary to brush from both directions. The
target wall is made of a soft ceramic fiber. Care must
be taken not to damage this material during cleaning.
4. Remove any scale or soot from the combustion
chamber area by vacuum cleaning or any other
available means.
5. Replace flue baffles (Refer to Section 2.B).
6. Replace oil burner and flue collector cover plate
making sure all gaskets are in place.
7. Replace jacket top panel.
8. Inspect venting system.
G. IF A LONG SHUTDOWN IS REQUIRED
1. To take boiler out of service if the boiler and system
are not to be used when temperatures are below
freezing:
a. Drain the boiler and system completely and shut
off make-up water supply.
b. Open main line power disconnect switch to
boiler. Remove the fuses or secure the switch so
that the power cannot be turned on accidentally.
2. Be certain that the boiler and system are refilled
before returning to service.
Burner mounting plate must be opened to facilitate
this operation.
NOTICE
All cover plates, enclosures, and guards must be
maintained in place at all times, except during
maintenance and servicing.
NOTICE
Always keep the manual fuel supply valve shut off
if the burner is shut down for an extended period of
time.
CAUTION