PEERLESS SERIES DE Manuel d'instructions

Boilers

Installation,

Operation Et

Maintenance

Manual

PEERLESS _

CAST IRON BOILERS

4 Sizes 3-6 Sections 70.0 to 165.0 MBH CSA Input bAFUE ¸¸¸

Natural or LP Gas

Fan Assisted for "Through the Wall" Venting or

Chimney Venting

•Can be Vented into a Lined Masonnj Chimney

•Ideal Where the Chimney is Inadequate or Unavailable

•Uses 3"diameterAL29 4C SS Vent Pipe for 'Through the Wall" or

"Vertical" Venting Applications

Steel Push Nipples

•Provide a Permanent Water Tight Seal Betw_Jen Sections

•Una[['ected by Petroleum and Other Contaminants

Deluxe Insulated Enameled Steel Jacket

•Reduces Boiler Ileal Loss

•Completely Encloses Gas Valve and Bartlel_

Safety Controls

• Flame Roll Out Shirt QffSwitch

•Difj-_.rential Pressure Switch

_)SinarlVt_h_(_ ks a r('gisl(_red Irademark qf Honeywell Corporatioa

• Honeywell Operating Controls

• Honeywell SmartValve ®Intermittent Ignition

• Taco 007 Circulator

•30 PSI Safety Relief Valve

•Non-Combustible Floor Pan

•Grundfos Circulator

• AL29-4C Stainless Steel Venting Components

•50 PSI Safety Relief Valve

Ik'cHt'._s l letllt'r Compatiy is pleased to ql]t't otte q[ lhe most compr_zhensive warranty prograrru,; ill

rht; ilKltlslr'tj. All ['_,_'He._s rt!sidential cas! iron !)oil_'rs inchld¢" a.]ull one !lear tvan_lnly. A limited,

l!]_!litllt, u!ol_Yully is plovi(lt!d.lbr the' ('a,sl it,)It s_,cliotls (!1 Pe_'rlits_; r('sidteiIlinl hal lvalel boilers.

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PGGRLESS ®

CAST IRON BOILERS

Peerless Heater Company - 231 North Walnut Street * Boyertown. PA 19512-1021 *610-367-2153 •www.peerless-heater.com

FAB DE 1tO 15102 5M}

Prlrlted irl U S A

TABLE OF CONTEN S

USING THIS MANUAL 1

A. INSTALLATION SEQUENCE ............. 1

B. SPECIAL ATTENTION BOXES ........... 1

1. PREINSTALLATION 2

A. ACCESSIBILITY CLEARANCES .......... 2

B. CLEARANCE FROM COMBUSTIBLE

CONSTRUCTION ..................... 2

C. AFR FOR COMBUSTION AND

VENTILATION ....................... 2

D. LIQUEFIED PETROLEUM (LP) GAS ....... 4

E. INSTALLATION SURVEY ............... 4

EPLANNING THE LAYOUT ............... 4

2. BOILER SET.;UP 5

A. BOILER SUPPLY AND RETURN .......... 6

B. SAFETY RELIEF VALVE ................ 7

C. PIPING FOR ZONED SYSTEMS .......... 8

D. EXPANSION TANK .................... 9

E. INDIRECT-FIRED WATER HEATER ........ 9

E FREEZE PROTECTION ................. 9

4. VENTING _ 10

A. GENERAL .......................... 10

B, CHIMNEY VENTING .................. 10

C. DIRECT EXHAUST

HORIZONTAL VENTING- .............. 11

D. DIRECT EXHAUST

VERTICAL VENTING .................. 13

E. BOILER REMOVAL FROM

COMMON VENTING SYSTEM .......... 14

5. GASPIPING: ; __ " ....... ........

6. ELECTRICAL 17

A. WIRING ........................... 17

B. ZONED SYSTEM WIRING ............. 17

C. CONTROLS ........................ 17

D. SEQUENCE OF OPERATION ........... 18

7, START-UP PR_CE_URES_ _ _._ 2,1

A. COMPLETING THE INSTALLATION ...... 21

B. CONTROL DESCRIPTIONS ............. 24

C. ADJUSTMENT OF GAS PRESSURE

REGULATOR ....................... 24

D. CHECKING BURNER INPUT ............ 24

E. CHECK-OUT PROCEDURE ............. 25

A. SHUT-DOWN CAUSED BY PILOT OUTAGE,

PRESSURE SWITCH OR FLAME ROLL-OUT

SAFETY SHUT-OFF SWITCH ........... 26

B. TROUBLESHOOTING GUIDES .......... 26

C. MEASURING SUCTION PRESSURE ...... 26

A. GENERAL .......................... 30

B. DAILY (WITH BOILER IN USE) .......... 30

C. WEEKLY (WITH BOILER IN USE) ........ 30

D. MONTHLY (WITH BOILER IN USE) ....... 30

E. ANNUALLY (BEFORE START OF HEATING

SEASON) .......................... 31

A. BLOCK!BASE/FLOOR PAN

JACKET/FLUE COLLECTOR ............ 33

B, BASE/BURNERS/MANIFOLD ........... 34

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Follow the installation instructions provided in this

manuaI 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.

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 Peerless Heater Company:

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.

Indicates a condition or hazard which will or can

cause minor personal injury or property damage.

Indicates special attention is needed, but not directly

related to potential personal injury or property

damage.

Read carefully, study these instructions before beginning work.

This boiler must be installed by a qualified contractor.

The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly.

The equipment must be installed in accordance with those installation requirements of the authority having

jurisdiction or, in the absence of such requirements, to the current edition of the National Fuel Gas Code, ANSI

Z223.1/NFPA 54.

Where required by the authority having jurisdiction, the installation must conform to American Society of

Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers,

ANS//ASME CSD-I.

f__!l l._ll(el:l.'l,.ll:!l! /li'/ [_ I:€_,I:__,1L_[_:(.,.

Install boiler not less than 24" between the left side. top,

and front of the boiler and adjacent wall or other

appliance, when access is required for servicing.

The design of this boiler is certified for closet installation

with the following clearances:

1. 6" between sides, rear and front and combustible

construction.

2. 24" between top of jacket and combustible

construction.

3, 2" between vent pipe and combustible construction.

Do not install this boiler on combustible flooring

unless it is installed on a special combustible floor

pan provided by Peerless Heater Company. Boiler

installation on combustible flooring without the

special pan is a fire hazard.

To order combustible floor pan, use the 5-digit stock

codes listed in Section 11 of this manual.

Do not install this boiler on carpeting. Boiler

installation on carpeting is a fire hazard. Install this

boiler on non-combustible flooring or use a

combustible floor pan to install this boiler on other

non-carpeted flooring.

1. Provide adequate facilities for combustion and

ventilation air in accordance with Section 5.3, Air for

Combustion and Ventilation, National Fuel Gas

Code, or applicable provisions of the local building

code. Subsections 2 through 6 below are based on

National Fuel Gas Code requirements.

2. Definitions:

Unconfined Space: a space whose volume is not

less than fifty (50) cubic feet per 1000 Btulhr of the

total input rating of all appliances installed in that

space. Rooms communicating directly with the space

in which the appliances are installed, through

openings not furnished with doors, are considered

part of the unconfined space.

Unusually Tight Construction: Construction

where:

a. Walls and ceilings exposed to the outside

atmosphere have a continuous water vapor

retarder with a rating of I perm or less with

openings gasketed or sealed, and

b. Weatherstripping has been added on openable

windows and doors, and

C. Caulking or sealants are supplied to areas such

as joints around window and door frames,

between sole plates and floors, between wall-

ceiling joints, between wall panels, at

penetrations for plumbing, electrical and gas

lines, and at other openings.

3. Appliances Located in Unconfined Spaces:

For installations in unconfined spaceswith other

than unusually tight construction, the supply of air

for combustion and ventilation can usually be

considered adequate.

4Unusually Tight Construction:

For equipment located in buildings of unusually tight

construction as defined on the previous page,

provide air for combustion and ventilation using the

methods described in 5a or 5b below.

5. Appliances Located in Confined Spaces:

a. All air from inside the building: Provide two

permanent openings communicating directly with

an additional room or rooms of sufficient volume

so that the combined volume of all spaces meets

the criteria for an unconfined space. Use the total

input of all gas utilization equipment installed in

the combined space in making this

determination.

Size each opening with a minimum free area of

one square inch per I000 Btu/hr. of the total

rating of all gas utilization equipment in the

confined space, but not less than I00 square

inches. Begin with one opening 12 inches from

the top, and begin the other opening within 12

inches of the bottom of the enclosure. See Figure

I. Provide air openings with minimum

dimensions not less than three (3) inches.

b. All air from oulside the building. Connect the

confined space with the outdoors in accordance

with methods i) or it) below. Provide air openings

with minimum dimensions not less than three (3)

inches. Where ducts are used, make certain that

they are the same cross-sectional area as the free

area of the openings to which they connect.

Provide two permanent openings, one

commencing within 12 inches of the top and

one commencing within 12 inches of the

bottom of the enclosure. Connect the

openings directly or by ducts, with the

outdoors or spaces (crawl or attic) that freely

communicate with the outdoors.

Where directly communicating with the

outdoors (see Figure 2) or where

communicating to the outdoors through

vertical ducts (see Figure 3), size each

opening with a minimum free area of one (I)

square inch per 4000 Btu!hr, of total rating of

all equipment in the enclosure.

Where communicating with the outdoors

through horizontal ducts, size each opening

with a minimum free area of one (i) square

inch per 2000 Blu/hn of total input rating of

all equipment in the enclosure. See Figure 4.

TWO AIR OPENINGS: _-

Minimum \

Free Area Each = \

1in2per 1000 Btuh \

at Least 100 in2

t 12" max

3" rain

\BUILDING

Mastcommunicatefreely

withoutdoors

Must notbeunder

negativepressure

_- 3" rain

12" max

Figure 1: Air Openings - All Air from Indoors

TWO AIR OPENINGS:

Minimum

Free Area Each =

1 in2per 4000 Btuh

Figure 2: Air Openings - All Air Directly from

Outdoors

12" max

Minimum

in _per 4000 Btuh

Figure 3: Air Openings - All Air from Outdoors

through Vertical Ducts

Where the equipment has clearances of at

least one {1) inch from the sides and back

and six (6) inches from the front of the

appliance, the code allows one permanent

opening, commencing within 12 inches of

the top of the enclosure. Connect the

opening directly with the outdoors or through

a vertical or horizontal duct to the outdoors

or spaces (crawl or attic) that freely

communicate with the outdoors Size the

opening with a minimum free area of one

square inch per 3000 Btu/hr. of the total

input rating of all equipment in the enclosure,

and not less than the sum of the areas of all

vent connectors in the confined space.

6, In calculating free area of an opening, take into

account the blocking affect of louvers, grilles and

screens. Do not use screens smaller than i/4" mesh.

If the free area is known, use this value in calculating

the size of the opening required. If it is not known,

assume that wood louvers provide 20-25% free area,

and metal louvers and grilles provide 60 75% free

area,

I:_ll Ih'_k:-IIw:!I Iz'l / tel [_L"ll I;kvl:l '

7, Remove sources of hydrocarbons (bleaches,

cleaners, chemicals, sprays, paint removers, fabric

softeners, etc.) from the boiler area. The vapors

generated by these substances can contaminate the

combustion air and contribute to shortened

boiler/vent system life.

I D_ ! [*Ill :i ;i1:1w] :J:ii| ;{*] Ill:llJ_V_HI _._l[_-'_

The following LP requirements from the Uniform

Mechanical Code, section 304.6, may be in effect in

your geographic area:

12" max TWO AIR OPENINGS:

Minimum

Free Area Each =

in2per 2000 Btuh

Figure 4: Air Openings -All Air from Outdoors

through Horizontal Ducts

For new and existing installations, a Water Installation

Survey is available from Peerless Heater Company. The

survey will provide information on how a hot water

boiler works with your specific system and will provide

an overview of hot water system operation in general.

You can also use this survey to locate system problems

which will have to be corrected. To obtain copies of the

Water Installation Survey, contact your Peerless

representative.

I:1 I "JI_'l L_h_lh_[rill i" 1:11If'-Vl*lll

Liquefied Petroleum (LP) is heavier than air and may

collect or "pool" in a low area in the event of a leak

from defective equipment.This gas may then ignite,

resulting in a fire or explosion. See the instructions

below.

Prepare sketches and notes of the layout to minimize the

possibility of interferences with new or existing

equipment, piping, venting and wiring.

"Liquefied petroleum gas-burning appliances shall not

be installed in a pit, basement or similar location where

heavier-than-air gas might collect. Appliances so fueled

shall not be installed in an above-grade under-floor

space or basement unless such location is provided with

an approved means for removal of unburned gas."

1 Provide a sound, leveI foundation Locate boiler as

near to the chimney or outside wall as possible and

centralized with respect to the heating system

2. Locate boiler in front of installation position before

removing crate.

3. If using combustible floor pan, position pan on

foundation or flooring.

4. Separate the wood shipping pallet from the boiler

base by removing two (2) hold-down bolts at each

end of the boiler base.

5. Move boiler into final position. If using combustible

floor pan, install boiler on pan as outlined in the

instructions included with the pan.

3. WATER PIPING AND

L"ll I:[e]ll:l;i [--[IJ'];JIk'dlh_'li_l=] .'|:l/IJ;]_,_

I. Size the supply and return to suit the system. A

typical piping arrangement is shown in Figure 5.

R4er also to the Hydronics Institute Installation

Guide 2000 and the Peerless Water Survey for

additional guidance during water piping installation.

2. Return Piping:

a. For boilers equipped with a factory-mounted

circulator, pipe the return to the inlet connection

of the circulator.

b. For boilers equipped with a separate, unmounted

circulator, pipe the outlet connection of the

circulator to a tee, provided with a drain valve,

at the 1-1/4 NPT return tapping near the bottom

of the left section. Pipe the return to the inlet

connection of the circulator,

Supply Piping:

Pipe the supply to the I ]2 NPT supply tapping at

the top of the boiler

When system return water temperature will be below

130°E pipe the boiler with a bypass arrangement to

blend the system return and hot supply to obtain at

least 130°F entering the boiler For more information

on bypass piping, consult the Peerless Water Survey.

If desired, install the circulator in the alternate

location shown in Figure 5 Consult the Peerless

Water Survey for more information on circulator

location.

SUPPLY

ALTERNATE

CIRCULATOR\

LOCATION

COLD _ .4 N_:_.4 _ ,,.

WATER _

F,LL/- / /-.- ;

SHUTOFFJ PRESSUREJ CHECK JSHUTOFF J

VALVE REDUCING VALVE VALVE

VALVE EXPANSION TANKJ

_- AIR VENT

-AIR ELIMINATOR

RELIEF

VALVE

TO DRAIN

RETURN_/.L_

CIRCULATOR_ y

DRAI:--_ X] III

VALVE

Figure 5: Supply and Return Piping

install this boiler so that the gas ignition system

components are protected from water (dripping,

spraying, etc.) during appliance operation and

service (circulator replacement, condensate trap,

control replacements, etc.).

If this boiler and distribution system is used in

conjunction with a refrigeration system, pipe the

chilled medium in parallel with the boiler and install

the proper valve to prevent the chilled medium from

entering the boiler A drawing illustrating this hook

up is provided in Figure 6.

When the boiler is connected to heating coils located

in air handling units where they may be exposed to

refrigerated air circulation, install flow control valves

or other automatic means to prevent gravity

circulation of the boiler water during the cooling

cycle.

If this boiler is installed above radiation level,

provide a low water cutoff device, either as a part of

the boiler or at the time of boiler installation.

CHEEK VALVE _\ \

SUPPLY

LINE

WATER [HREE WAY

VALVE

Figure 6: Parallel Hook-up with Water Chiller

I:_II R_,1:1=11&'dI;t :1111I=1;I lVl,_l&vA

1. Locate safety relief valve and fittings in bag

assembly.

2. If air elimination is not required at the safety relief

valve tapping, install valve and piping as shown in

Figure 71

3. For air elimination at the safety relief valve tapping,

install valve and piping as shown in Figure 8.

Pipe the discharge of safety relief valve to prevent

injury in the event of pressure relief. Pipe the

discharge to a drain. Provide piping that is the same

size as the safety relief valve outlet.

/./// \\ \

Figure 7: Safety Relief Valve Hook-Up Installation

with Air Elimination in System Piping

TO A4R

ELIMINATION

DEVICE

SUPPLY_ F3/4" tEE

SAFETY _3/4" X 6"

RELIE£ NIPPLE

VALVE

TO DRaiN

5/4" _TREET

ELBOW

Figure 8: Safety Relief Valve Hook-Up with

Air Elimination

Ce manuel convient aux modèles suivants

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