PeerlessBoilers WV-DV Series Instruction manual

WV-DV™
Boilers
Series
Oil
Installation,
Operation &
Maintenance
Manual

Sidewall Venting
The Peerless®Series WV-DV™is designed and built to be vented through a side wall of a building
using a stainless steel concentric vent terminal (4 inch diameter tube inside an 8 inch diameter
tube). Exhaust gases from combustion contain water vapor. During the cooler months of the year,
this water vapor will condense into a visible vapor plume. This water vapor may condense on any
surface near the vent terminal. Care must be taken not to locate the vent terminal where the exhaust
gas, vapor plume and condensation could cause a hazard or a nuisance. Do not locate terminal
under a deck, for instance, as it may create a coating of ice on the deck during the winter months,
as well as shorten the life of the deck materials. Refer to Chapter 4 in this manual for specific
terminal location requirements. Condensate from a side wall vent terminal may also cause paint on
surrounding surfaces to crack and peel. If the boiler is used to heat potable (tap) water, the boiler
will cycle year round. The effects of hot exhaust gases and odors must be taken into consideration
during summer months.
Side wall vented, oil fired appliances may cause soot staining on wall surfaces surrounding their
terminals. To reduce the potential for staining, the boiler must be serviced annually. Soot and scale
must be completely removed from the combustion chamber and cast iron heat exchanger flueways.
See Chapter 7 in this manual. The oil burner must be completely serviced and set up according to
the specifications shown in Chapter 5 of this manual.
NOTICE
i

1
USING THIS MANUAL 2
A. INSTALLATION SEQUENCE .............2
B. SPECIAL ATTENTION BOXES............2
1. PREINSTALLATION 3
A. ACCESSIBILITY CLEARANCES ...........3
B. CLEARANCES FROM COMBUSTIBLE
CONSTRUCTION ......................3
2. BOILER SET-UP 4
A. SETTING UP THE BOILER ...............4
3. PIPING & CONTROLS 5
A. BOILER SUPPLY & RETURN .............5
B. SAFETY RELIEF VALVE .................5
C. TANKLESS WATER HEATER ............5
D. INDIRECT-FIRED WATER HEATER ........6
E. CONTROLS...........................6
4. VENTING 7
A. VENT SYSTEM INSTALLATION ..........7
5. BURNER SETUP &
BOILER OPERATION 9
A. BURNER INSTALLATION................9
6. ELECTRICAL 11
A. WIRING .............................11
7. MAINTENANCE 14
A. CLEANING HEATING SURFACES ........15
8. BOILER DIMENSIONS & RATINGS 16
9. REPAIR PARTS 17
TABLE OF CONTENTS
TABLE OF CONTENTS

2
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:
USING THIS MANUAL
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.

A. ACCESSIBILITY CLEARANCES
To provide for reasonable conditions of accessibility,
the following minimum clearances are recommended:
Alcove Installation.
1. 12” from left side
2. 24” from top
3. 24” from front
4. 9” from right side and rear
B. CLEARANCES FROM COMBUSTIBLE
CONSTRUCTION
The design of this boiler is certified for the following
clearances from combustible construction:
1. 0” from rear
2. 0” from right and left sides
3. 0” from top
4. 0” from vent pipe
5. 0” from vent connector
6. 0” from vent terminal
7. 24” from front
C. 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. Boiler water pH should be in the 7.5 to 11 range.
2. Boiler water chloride concentration should
be less than 30 ppm.
3. The water hardness should be less than 9 grains per
gallon to prevent scale build-up.
3
PREINSTALLATION
1. PREINSTALLATION
In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is 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.
NOTICE
Never burn garbage or paper in the unit, and never
leave combustible material around it.
CAUTION
Do not tamper with boiler or controls.
CAUTION
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
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.
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

4
BOILER SET-UP
A. SETTING THE BOILER
1. 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. See Section 4-A. “Vent System
Installation,” Page 7, and Figure 4.1.
2. Provide a level foundation, located as close as
possible to the center of the heating system.
3. This boiler is suitable for use on combustible
flooring, provided the boiler is not set on carpet and
a metal drip pan is placed under the appliance.
4. See clearance information in Section 1,
“Preinstallation”.
5. See exploded view (Figure 9.1). After uncrating
boiler and setting it on foundation, open burner
mounting plate (Item 5) and make certain the target
wall (Item 2) is seated in the back of the combustion
chamber. (WV-DV-04) 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.
2. BOILER SET-UP

5
3. PIPING & CONTROLS
PIPING & CONTROLS
A. BOILER SUPPLY AND RETURN
1. See Figure 3.1 for suggested piping to the boiler.
2. Make up cold water supply connection to the boiler.
3. Plug all open tappings in the boiler and fill with
water. Apply approximately thirty (30) psi pressure.
Check to make certain that all joints and fittings are
water tight.
4. After all joints and connections have been proven
water tight, remove cold water supply and plugs
from all tappings that are to be used. See Figure 8.1
for tapping locations.
5. 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.
6. 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 on the return where the
system piping is 1-1/2”.
7. The supply should be out of the top of the back
section and return to the bottom of the front section.
There is a 3/4” tapping in the top of the back section
for air elimination.
8. 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.
9. 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 3.2.
10. 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.
B. SAFETY RELIEF VALVE
1. Remove safety relief valve and 3/4” x 3” nipple from
parts bag. Install nipple and safety relief valve in top
or rear tapping. See Figure 8.1. If rear tapping is
used, installer must supply an elbow so that safety
relief valve is installed in vertical position.
C. TANKLESS WATER HEATER
Figure 3.1
CHILLER
VALVE
SUPPLY LINE
CHECK VALVE
BOILER
WATER
THREE WAY
RETURN
LINE
Figure 3.2
Install mixing valve in hot water supply piping. Water
temperature above 125°F can cause severe burns
instantly or death from scalds.
DANGER
Install anti-scald device in hot water supply piping.
Water temperature above 125°F can cause severe
burns instantly or death from scalds.
DANGER
Pipe the discharge of the 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 relief valve.
CAUTION

6
D. INDIRECT-FIRED WATER HEATER
1. If a Partner indirect fired water heater or other,
refer to Figure 3.4 for typical piping. Also refer to
additional instructions supplied with the Partner.
E. CONTROLS
1. For complete information on servicing and
adjustment of controls, refer to the attached control
specification sheets.
2. This boiler is equipped with a water temperature
limit control which includes a low water cut-off
function.
3. 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.
4. For complete information on servicing and
adjustment of controls, refer to the attached control
specification sheets.
Figure 3.4
PIPING & CONTROLS
IMPORTANT
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.
Figure 3.3
12" MIN.
3/4" CONTROL
TAPPING
TANKLESS
HEATER
HIGH TEMPERATURE
HOT WATER
MIXED
WATER
WATER
MIXER
COLD WATER INLET
FLOW CONTROL

A. VENT SYSTEM INSTALLATION
1. Determine vent terminal location:
a. Vent length must be between 3’ and 20’ long.
See paragraph 4.A.3 and Figure 4.1 for air
intake requirements.
b. No clearance is required between vent terminal
and combustible construction.
c. Vent terminal extends 12” beyond outside wall
surface and at least 16” beyond inside wall
surface. See Figure 4.1.
d. Sidewall vented products are susceptible to
wind conditions that can effect combustion. To
minimize the effects of wind, the exhaust and
air inlet terminations must penetrate the same
wall or vertical surface. In addition, the length of
the exhaust and air inlet pipes must be roughly
equivalent.
e. Condensation from a sidewall vented appliance
may cause paint and other surface coatings to
deteriorate. In addition, soot stains may appear
on surrounding surfaces if the boiler is not
properly maintained.
f. If the boiler is used to heat potable (tap) water,
the boiler will operate year round. The effects
of hot gases and odors must be taken into
consideration during the summer months.
g. See Figure 4.2 for an illustration of clearances for
location of exit terminals for direct-vent, sidewall
venting systems.
h. The boiler vent system shall terminate at least 3
feet (0.9 m) above any forced air inlet located
within 10 feet (3 m). Note: This does not apply
to the combustion air inlet of a direct-vent
appliance.
7
4. VENTING
VENTING
This boiler is shipped with a Z-Flex Vent Terminal
carton, and a Z-Flex Venting Components Kit. The
following components from these two cartons must
be used in the installation of this boiler:
·Z-Flex Oil Vent Terminal
·Z-Flex Vent Pipe
·Z-Flex Appliance Adapter
·Z-Flex Terminal Adapter
·Z-Flex Sealant
NOTICE
Figure 4.1: Venting
This Oil-Fired Unit Shall be Connected to a Direct Vent
System, to Assure Safe Proper Operation of the Unit.
CAUTION
Table 4.1
See Sidewall Venting NOTICE on inside of front cover of this manual.

8
i. Provide a minimum of 1 foot (300 mm) distance
from any door, operable window, or gravity air
inlet into any building.
j. Do not locate the exhaust termination directly
under an operable window.
k. Provide a minimum of 1 foot (300 mm)
clearance from the bottom of the exhaust
termination above the expected snow
accumulation level. Snow removal may be
necessary to maintain clearance.
l. Provide 4 feet horizontal clearance from
electrical meters, gas meters, air conditioning
condensers or other external equipment. In no
case shall the exit terminal be above or below
the aforementioned equipment unless a 4 foot
horizontal distance is maintained.
m. Do not locate the exit termination over public
walkways where condensate could drip or freeze,
causing a hazard or nuisance.
n. When the exhaust termination is adjacent to a
public walkway, it is to be located at least 7 feet
(2100 mm) above grade.
o. Do not locate exhaust termination directly under
roof overhangs to prevent icicles from forming.
p. Provide 3 feet (0.9 m) clearance from the inside
2. Use Z-Flex 4” diameter Vent Pipe.
3. For air intake, use 4” diameter galvanized smoke
pipe or 4” diameter flexible corrugated aluminum
pipe. Maximum equivalent length of galvanized
smoke pipe is 40’. Allow 5 equivalent feet for
each 90° elbow used. (Example: No more than
20’ straight smoke pipe can be used with four 90°
elbows.) To connect air intake to Riello BF5 burner,
use burner air adapter from trim bag to connect 4”
air intake to 3” opening on top of burner. See Figure
4.1.
4. For specific installation and maintenance instructions
for the Z-Flex Vent Terminal, Appliance Adapter,
Terminal Adapter, Burner Air Adapter (Riello only),
and Sealant that are included with the boiler, as well
as instructions for installation of flexible vent pipe and
air intake pipe, refer to Z-Flex Manual included in
vent kit.
PB Heat, LLC requires that the vent slopes down
1/4” per foot towards the vent terminal. This takes
precedence over the requirements shown in the
Z-Flex manual.
NOTICE
VENTING
"B"
"A"
5 ft.
(1.52m)
3 ft.
(.90m)
7 ft.
(2.13m)
4 ft. (1.22m)
4 ft. (1.22m)
4 ft.
(1.22m)
12" (30cm) ABOVE EXPECTED
SNOW ACCUMULATION
FORCED AIR INLET
DIRECT VENT
TERMINATION
OIL TANK
AIR VENT
Figure 4.2: Location of Exit Terminals of Mechanical Draft and Direct-Venting Systems

9
5. BURNER SETUP & BOILER OPERATION
BURNER SETUP & BOILER OPERATION
A. BURNER INSTALLATION
1. The oil burner is supplied with a mounting flange
fixed in position.
2. 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.
3. 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.
4. Sampling tapping in CeraFlex Appliance Adapter
must be used for CO², smoke and flue pressure
readings.
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.
Riello: Round red button inside clear flexible cover
on back of burner cover.
If burner still does not start, contact serviceman.
2. Adjust burner for highest CO²(Maximum 13.1%)
while maintaining a 0 Smoke. Pressure or draft over
fire and in flue cannot be adjusted. However, draft
and/or pressure measurements must be taken in
these two locations and recorded for reference.
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. Post-purge timing on Riello BF5 burner is controlled
by 3/8” diameter dial near top right corner of
AL1009 circuit board inside burner cover. Post-
purge duration must be a minimum of one minute.
Adjust dial so arrow is pointing directly to the right
(toward mounting screw for AL1009 bracket). Check
post-purge timing to confirm it is at least one minute
long.
5. 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
temperature corresponds to the desired set point.
b. Return the controls to the desired set point.
2. Low Water Cut-off - consult the manufacturer’s
instructions for the low water cut-off operational
check procedure.
D. FILL THE BOILER
1. Set the air pressure on the expansion tank to the
system water pressure before filling boiler. The
pressure reducing valve on the fill line will typically
allow the system to be filled and pressurized to 12
psi (83 kPa). Consult the valve and expansion tank
manufacturer for more specific information.
2. 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.
3. Check all joints and fittings throughout the system for
leaks. If leaks are found, drain the system and repair
as required.
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
Always keep the manual fuel supply valve shut off
if the burner is shut down for an extended period
of time.
CAUTION

10
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.
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.
E. PURGE AIR FROM THE SYSTEM
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.
BURNER SETUP & BOILER OPERATION

11
BURNER SETUP & BOILER OPERATION
Table 5.1
Beckett NX Burner Specifications
Boiler Model No. Burner Model Nozzle Manufacturer, Size Pump Pressure (psig) Head/Air Setting Low Fire Baffle
WV-DV-03-075 NX70LB Delavan 0.60 60° W 175 2.25 Yes
WV-DV-04-115 NX70LD Hago 0.85 60° B 170 1.50 Yes
WV-DV-04-130 NX70LD Hago 1.00 60° B¹ 170 1.50 No
Table 5.2
Riello BF5 Burner Specifications
Boiler Model No. Nozzle Size Pump Pressure
(psig)
Turbulator
Setting
Air Damper
Setting
WV-DV-03-075 Delavan .60 80° B 165 1 3.3
WV-DV-04-115 Hago .85 60° B¹ or Delavan .85 60° W¹ 180 2 5.0
WV-DV-04-130 Hago 1.10 60° B¹ or Delavan 1.10 60° W¹ 140 4 5.0
Start-up and adjustment recommendations: Above Turbulator, Pin, Air Damper, and Air Dial settings are start-up settings only. Adjust burner for highest
CO²(no more than 13.1%) while maintaining a 0 smoke spot. Pressure or draft over fire and in flue cannot be adjusted. However, draft and/or pressure
measurements must be taken in these two locations and recorded for reference. All adjustments and measurements must be made using suitable
instruments such as those found in a Bacharach Combustion Test Kit.
Factory Installed Nozzles are indicated in Boldface.
1. Shipped Loose

12
ELECTRICAL
Figure 6.1: Hydrolevel 3250 Limit Control, Beckett and Carlin Burners
A. WIRING
1. 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.
6. ELECTRICAL
Do not connect power supply to Aquastat. To assure
service switch interrupts power to all boiler controls,
power supply must be connected to junction box as
shown below.
CAUTION

13
ELECTRICAL
Figure 6.2: Hydrolevel 3250 Limit Control, Riello Burner

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.
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.)
14
MAINTENANCE
7. MAINTENANCE
WARNING
Product Safety Information
Refractory Ceramic Fiber Product
This appliance contains materials made from refractory ceramic fibers (RCF). Airborne
RCF fibers, 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 mate-
rials:
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.
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

15
MAINTENANCE
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. 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.
D. 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.
E. MAINTENANCE – ANNUAL
TO CLEAN:
1. Turn off all electrical power to the boiler before
beginning cleaning operation.
2. Remove top jacket panel and flue collector cover
plate, Item 11.
3. To thoroughly clean the boiler it must be brushed
down from the top. Alternately, 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,
brushing up from the combustion chamber area also
may be necessary. 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 oil burner and flue collector cover plate
making sure all gaskets are in place.
6. Replace jacket top panel.
7. Inspect venting system.
8. Systems using freeze protection - the glycol solution
should be tested at least once a year and as
recommended by the glycol manufacturer.
F. 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.
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
Combustion chamber cover 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
Combustion chamber and flue collector may be
under pressure when burner is running. Flue
collector cover plate and combustion chamber
must be completely sealed before boiler is returned
to operation.
CAUTION
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
Turn off power to boiler before adjusting limit
control.
CAUTION

16
MAINTENANCE
2. Be certain that the boiler and system are refilled
before returning to service.
Always keep the manual fuel supply valve shut off
if the burner is shut down for an extended period of
time.
CAUTION

17
BOILER DIMENSIONS & RATINGS
8. BOILER DIMENSIONS & RATINGS
Figure 8.1: Boiler Views
Table 7.1: Boiler Ratings
1 Boiler Model No. may have the following suffix letters: WPC = Water Package w/Burner & Circulator; WPCT = Water Package w/Burner,
Circulator & Tankless Coil.
2 Firing rate is based on a fuel oil with a heating value of 140,000 BTU per gallon. Burner input based on maximum altitude of 2,000 ft. – for other
altitudes consult factory.
3 Net water ratings based on an allowance of 1.15. Consult Factory before selecting a boiler for installations having unusual piping and pickup
requirements, such as intermittent system operation, extensive piping systems, etc.
4 Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are based on U.S. Government test.
5 Must be used with factory supplied 4” flexible insulated venting system.
Series WV-DV™
Water
Content,
gal
Model
Number¹
Input² Heating
Capacity4,
MBH
Net Ratings
Water3,
MBH
AFUE4,
%
GPH MBH
WV-DV-03 0.75 105 92 80 86.7 11.75
WV-DV-04 1.15 161 141 122 86.7 14.75
WV-DV-04 1.30 182 158 137 86.0 14.75
Boiler
Model
Number
Jacket
Depth
“A”
Jacket
Width
“B”
Jacket
Height
“C”
Rear of Jacket
to c/l of Vent
“D”
Right Side of
Jacket to
c/l of Vent
“E”
Vent Size
Diameter
“F”
WVDV-03 14-1/8” 22-1/8” 35” 7-1/16” 8-5/16” 4”
WVDV-04 18-1/8” 22-1/8” 35” 9-1/16” 8-5/16” 4”

18
REPAIR PARTS
9. REPAIR PARTS
Figure 9.1: Repair Parts
Repair parts are available from your local PB Heat, LLC distributor or from Parts To Your
Door at 1 [phone] (www.partstoyourdoor.com).
Note: Remember to include the boiler model number and serial number when ordering parts.
5a
5c
5d
5e
5b