U.S. Boiler Company PVG3, Installation, Operating And Service Instructions

Page 1: ...d States Environmental Protection Agency EPA Price 5 00 9700609 INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR PVG Gas Fired Boiler For service or repairs to boiler call your heating contractor W...

Page 2: ...http license reg state ma us pubLic pl_products pb_pre_form asp for the latest Approval Code or ask your local Sales Representative The Commonwealth of Massachusetts requires this product to be insta...

Page 3: ...l 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...

Page 4: ...f the boiler is inoperative This boiler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring...

Page 5: ...stallation 7 II Unpack Boiler 8 III Venting 9 IV Water Piping and Trim 19 V Gas Piping 25 VI Electrical 28 VII Modular Installation 33 VIII System Start up 35 IX Operation 39 X Troubleshooting 43 XI S...

Page 6: ...CTION SIZES DIMENSIONS IN INCHES Model Supply Return Vent Relief Valve PVG3 1 NPT 1 NPT 3 NPT PVG4 PVG5 PVG6 PVG7 PVG8 4 PVG9 PVG DIMENSIONAL DATA Model A PVG3 11 65 PVG4 14 72 PVG5 17 78 PVG6 20 84 P...

Page 7: ...water and all additional system components I Pre Installation E Protect gas ignition system components from water dripping spraying rain etc during boiler operation and service circulator replacement...

Page 8: ...Tilt the boiler to its front side or back side and slide a wooden slat under the three raised feet F Tilt the boiler in the opposite direction and slide another wooden slat under the three raised fee...

Page 9: ...r liquids or sources of hydro carbons i e bleaches cleaners chemicals sprays paint removers fabric softeners etc are used stored and or present in the air When installing vent pipe through chimney no...

Page 10: ...ze and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 Insofar as is practical close all building do...

Page 11: ...tinued Au moment du retrait d une chaudi re existante les mesures suivantes doivent tre prises pour chaque appareil toujours raccord au syst me d evacuation commun et qui fonctionne alors que d autres...

Page 12: ...five 5 feet 1 5 m Do not penetrate any part of the vent system with fasteners Soutenez parties horizontales de ventilation pour viter l affaisement Utilisez des colliers de serrage des crochets on ci...

Page 13: ...components as standard equipment for installation of the separate horizontal venting system Figure 3 U S Boiler Gasketed Vent Joint Detail III Venting continued 2 Do not exceed maximum vent lengths R...

Page 14: ...14 Figure 4 Horizontal Vent Installation III Venting continued...

Page 15: ...tal runs at the top to avoid condensate from lying on the seams 4 Install fire stops where vent passes through floors ceilings or framed walls The fire stop must close the opening between the vent pip...

Page 16: ...16 Figure 7 Attic Offset Figure 6 Vertical Vent Installation III Venting continued...

Page 17: ...distance of twelve 12 inches from roof surface Allow additional vertical X distance for expected snow accumulation Canada Extend at least 18 inch 450 mm above highest point where it passes through ro...

Page 18: ...llation 3 Vent left view or 4 Vent right view III Venting continued 3 Install vent piping a Install vent piping for desired venting system Refer to specific section for details for vent pipe installat...

Page 19: ...gen contamination of boiler water will cause corrosion of iron and steel boiler components and can lead to boiler failure U S Boiler s Standard Warranty does not cover problems caused by oxygen contam...

Page 20: ...r boiler as a redundant safety control IV Water Piping and Trim continued Figure 11 Recommended Auxiliary Limit Location 2 The recommended location for an Auxiliary Limit on gas hot water boilers is i...

Page 21: ...used in connection with refrigeration systems boiler must be installed with chilled medium piped in parallel with the heating boiler using appropriate valves to prevent chilled medium from entering bo...

Page 22: ...em the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler To perform a long term pressure test including the boiler ALL trapped air must first be r...

Page 23: ...23 Figure 14 Recommended Boiler Piping For Circulator Zoned Heating Systems IV Water Piping and Trim continued...

Page 24: ...24 Figure 15 Recommended Water Piping for Zone Valve Zoned Heating Systems IV Water Piping and Trim continued...

Page 25: ...ted future gas utilization equipment i e water heater cooking equipment 3 Length of piping and number of fittings Refer to Table 7 for maximum capacity of Schedule 40 pipe Table 8 lists equivalent pip...

Page 26: ...ntinuous and bonded to a grounding electrode Do not use gas piping as grounding electrode Refer to National Electrical Code NFPA 70 or Canadian Electrical Code CSA C22 1 Table 7 Maximum Capacity of Sc...

Page 27: ...utoff valve must be disconnected from gas supply piping For testing at psig 3 5kPa or less isolate boiler from gas supply piping by closing boiler s individual manual shutoff valve 2 Locate leaks usin...

Page 28: ...ed 15 amps Install over current protection in accordance with authority having jurisdiction or in the absence of such requirements follow the National Electric Code NFPA 70 and or CSA C22 1 Electrical...

Page 29: ...29 Figure 17 Wiring Connection Diagram VI Electrical continued...

Page 30: ...agram VI Electrical continued NOTICE All wire wire nuts controls etc are installer supplied unless otherwise noted If an additional system limit is used install in series with the auxiliary limit jump...

Page 31: ...31 Figure 19 Circulator Zoned System Wiring Diagram VI Electrical continued...

Page 32: ...32 Figure 20 Zone Valve Zoned System Wiring Schematic VI Electrical continued...

Page 33: ...be made Each vent termination must be one 1 foot from other terminations D Water Piping See Table 9 and Figure 21 Installing a low water cutoff in the system piping of modular systems is strongly reco...

Page 34: ...34 Figure 21 Modular Boiler Piping VII Modular Installation continued...

Page 35: ...d return piping 5 Open hose bib VIII System Start up 6 Open fill valve Make up water line should be located directly after full port ball valve in system supply piping between air scoop and expansion...

Page 36: ...36 Figure 22 Operating Instructions VIII System Start up continued...

Page 37: ...other controls have not shut off boiler 4 Adjust thermostat to lowest setting Refill boiler M Check limit Jumper Thermostat connections in boiler wiring harness Allow burners to operate until shutdown...

Page 38: ...nt Gas Orifice VIII System Start up continued b Increase input rate if less than 98 of rating plate input Increase manifold gas pressure no more than 0 3 inch w c If measured input rate is still less...

Page 39: ...tus codes that are reported RefertotheTroubleshootingSectionformoreinformation C Using Display The control is located inside the boiler front door Figure 25 Figure 25 Intelligent Hydronic Control Stat...

Page 40: ...STA status display code has the below listed values This list is also available on the control cover Status Code Displayed in STA Mode 1 Standby 2 Waiting for Pressure Switch to Open 3 Waiting for Pre...

Page 41: ...eat ends The Circulator Overrun Time is adjustable between 0 through 10 minutes 4 Circulator Pre purge Time When the boiler is warm boiler water temperature higher than 140 F adjustable using StartTem...

Page 42: ...a second heating zone This is particularly helpful when the home uses only two heating zones The control replaces the need for a two circulator zone panel When DHW Terminal Function is set to the con...

Page 43: ...he boiler are tested at least once in the manufacturing process and a defective control or component is generally the least likely cause Before replacing a component try to rule out all other possible...

Page 44: ...l in excess of 40 mph Replace blower Err 32 Temperature Sensor Failure Temperature sensor or interface failure open or short connection increased connection resistance dual sensor mismatch or control...

Page 45: ...ff for a DHW call for heat Wiring Circulator Issue Check wiring for loose connection miswiring Check circulator Use STA status Number To guide TroubleShooting The control will flash followed by a numb...

Page 46: ...ted and the one hour time delay is completed Boiler can be restarted sooner than the time delay by entering Adjustment Mode and selecting the reset button see Adjustment Mode instructions or by cyclin...

Page 47: ...ly tubes of air b If no gas flow check the following 24 volts across PV and MV PV at gas valve if voltage ok replace defective gas valve Check for break in wiring harness to gas valve 24 volts across...

Page 48: ...or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear 1 A National Institute for Occupational Safety and Health NIOSH approved respira...

Page 49: ...nt tee drain if used must have minimum 6 inch trap and allow condensate to flow freely To Clean a Disconnect drain tube from drain fitting b Flush drain tube with water Fill trap with water c Securely...

Page 50: ...rt Clean as necessary 5 Install main burners by reversing procedure to remove burners a Pilot burner must be installed in original location See Table 16 b Main burners must be properly secured in burn...

Page 51: ...51 Figure 29 Flue and Burner Cleanout 1 Burner XI Service continued...

Page 52: ...iewed from front of boiler Model Minimum Differential Pressure Sea Level to 4 999 Ft Natural Gas Hi Altitude 5 000 Ft to 10 000 Ft Natural Gas Sea Level to 4 999 Ft LP Gas Hi Altitude 5 000 Ft to 10 0...

Page 53: ...U S Boiler Wholesale distributor Should you require assistance in locating a U S Boiler distributor in your area or have questions regarding the availability of U S Boiler products or repair parts ple...

Page 54: ...54 XII Repair Parts continued...

Page 55: ...07003 3 71707003 4 71707003 6 71707003 6 71707003 7 71707003 1C Right End Section 71707002 1D Slip Nipple 3 4 806600009 6 806600009 8 806600009 10 806600009 12 806600009 14 806600009 16 806600009 1E F...

Page 56: ...56 XII Repair Parts continued...

Page 57: ...02707 03 102707 04 102707 05 102707 06 102707 07 102707 08 102707 09 2F Cerafelt Gasket 1 2 x 2 6206002 2G Cerafelt Gasket 1 2 x 2 6206002 2H Base Side Insulation 2 72007001 2J Base Rear Insulation 72...

Page 58: ...PVG9 3 BASE ASSEMBLY 3A Burner Cover Natural Gas Only 102033 03 102033 04 102033 05 102033 06 102033 07 102033 08 102033 09 3B Manifold Support Bracket 718070001 3C Sheet Metal Screw 8 x 1 2 2 8086000...

Page 59: ...7051 61107061 61107071 61107081 61107091 Canopy Assembly High Altitude 61107032 61107042 61107052 61107062 61107072 61107082 61107092 4B Cerafelt 9206005 4C U Clip 4 80861512 4D Sheet Metal Screw 10 x...

Page 60: ...60 XII Repair Parts continued...

Page 61: ...Gas Manifold 82207071 82207081 82207091 5C Burner Orifices Natural Gas 47 4 822710 6 822710 8 822710 10 822710 12 822710 14 822710 16 822710 Burner Orifices LP Gas 56 4 822707 6 822707 8 822707 10 82...

Page 62: ...Clip 102422 01 6F Differential Pressure Switch Sea Level 0 4 999 Natural Gas 80160762 80160761 104576 01 104575 01 104730 01 Differential Pressure Switch Sea Level 0 4 999 LP Gas 80160761 80160760 801...

Page 63: ...043 60407053 60407063 60407073 60407083 60407093 7D Vestibule Panel 60407034 60407044 60407054 60407064 60407074 60407084 60407094 7E Top Panel 60407032 60407042 60407052 60407062 60407072 60407082 60...

Page 64: ...anifold 80607001 8B Temperature Pressure Gauge 100282 01 8C Circulator Wiring Harness 6130701 8D Safety Relief Valve 81660363 8E Boiler Drain Valve 806603061 8F Vent Terminal 8110701 N A 8G Vent Conne...

Page 65: ...mended Boiler Piping for Circulator Zoned Heating Systems Figure 15 24 Recommended Water Piping for Zone Valve Zoned Heating Systems Section V Gas Piping Figure 16 26 Recommended Gas Piping Section VI...

Page 66: ...ttings Valves Section VII Modular Installation Table 9 33 Modular Boiler Water Manifold Sizing Section VIII System Start Up Table 10 37 Gas Flow Rate in Cubic Feet Per Hour Section IX Operation Table...

Page 67: ...67 SERVICE RECORD DATE SERVICE PERFORMED...

Page 68: ...68 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...