PEERLESS SERIES GM Manuel d'instructions

Boilers

Installation,

Operation b

Maintenance

Manual

PEEI_LESS*

CAST IRON BOILERS

Packaged Residential/Commercial Gas Fired, Hot

4 Sizes 5-8 Sections 228.0 to 399.0 MBH Input 82% Combustion Efficiency

Natural Gas

•Standing Pilot (5-6 section)

•Honeywell SmartValve ®Intermittent Ignition (5-8 section)

Natural Draft (Chimney) Venting

•Simplifies Installation

Steel Push Nipples

•Provide a Permanent Water Tight Seal Between Sections

•Unaffected by Petroleum and Other Contaminants

Deluxe Insulated Enameled Steel Jacket

•Reduces Boiler Heat Loss

•Completely Encloses Gas Valve, Burners and Controls for

Safe Operation

Front Located Controls and Return Piping

•Ideal for modular and multiple boiler installations

•Easy to service

Packaged Boiler

•Reduces Installation Time

Vertical Draft Hood

•Supports Combustion

Safety Controls

•Vent Safety ShutoffSwilch

•Flame RoUout Safety Shuto[]Switch

•Honeywell SmartValve °-_Intermittent Ignition

•Honeywell Operating Controls

• 30 PSI Sof('ty Relief Valve (unmounted)

• Vent Damper (5-6 section)

• Vertical Draft Hood

! STIIOI I_(llll{! iS II II'( ist(_r_,d Irademrlrk o[ t[I)IEt'IIH_I'II (_oI'lll)I I• Standing Pilot Ignition (5 6 section)

• Toco 0010 & 0012 Circulators (unmounted)

• Taco 0010 &0012 Zoning Circulators

with relay (unmounted)

• 50, 80 or 1O0 PSI Safety Reli@ Valve (unmounted)

•Probe _]pe LWCO (unmounted)

•Vent Dampt'r (7 8 section)

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Peerless Heater Company • 231 North Walnut Street * Boyertown, PA 19512-I021 •610-367-2153 * www.peerless-heater.com

FAB GM R2 {7'02 5M)

Pr,ltl.0 Irl U S A

USING THIS MANUAL 1

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

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

PREINSTALLATION 2

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

B. CLEARANCE FROM COMBUSTIBLE

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

C. COMBUSTION AND VENTILATION AIR .... 2

D. INSTALLATION SURVEY ............... 4

E. CIRCULATORS ....................... 4

E PLANNING THE LAYOUT ............... 4

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 .... _ :

A. DRAFT HOOD ...................... 10

B. AUTOMATIC VENT DAMPER .............

INSTALLATION - GENERAL ............ 11

C. VENT PIPING AND CHIMNEY .......... 11

D. BOILER REMOVAL FROM COMMON

VENTING SYSTEM ................... 12

5_GAs _P|PJNG _':

A. WIRING ........................... 15

B. CIRCULATOR/ZONE VALVE WIRING ..... 15

C. LOW WATER CUTOFF ................ 15

A. GENERAL .......................... 21

B. CSD PART CF REQUIREMENTS ......... 21

C. CSD PART CW REQUIREMENTS ........ 21

D. CSD MODULAR AND MULTIPLE BOILER

REQUIREMENTS .................... 21

E. CSD PART CE ELECTRICAL

REQUIREMENTS .................... 22

A. COMPLETING THE INSTALLATION ...... 23

B. CONTROL DESCRIPTIONS ............. 27

C. ADJUSTMENT OF GAS PRESSURE

REGULATOR ....................... 27

D. CHECKING BURNER INPUT ............ 27

E. CHECK-OUT PROCEDURE ............. 28

A. SHUT-DOWN CAUSED BY PILOT OUTAGE,

VENT SAFETY SHUTOFF SWITCH OR

FLAME ROLLOUT SAFETY SHUTOFF

SWITCH ........................... 29

B. TROUBLESHOOTING GUIDES .......... 29

_O.MAINTENANCE 32

A. GENERAL .......................... 32

B. DAILY (WITH BOILER IN USE) .......... 32

C. WEEKLY (WITH BOILER IN USE) ........ 32

D. MONTHLY (WITH BOILER IN USE) ....... 32

E. ANNUALLY (BEFORE START OF HEATING

SEASON) .......................... 33

A. BASE ............................. 35

B. GAS MANIFOLD, ORIFICE SPUDS, AND

MAIN BURNERS ..................... 36

C. BLOCK AND FLUE COLLECTOR ......... 37

D. JACKET ........................... 38

E. CONTROLS, DRAFT HOOD AND

AUTOMATIC VENT DAMPER ........... 39

Follow the installation instructions provided in this

manual in the order shown. The order of these

instructions have 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.

Indicates a condition or hazard which will cause

severe personal injury, death or major property

damage.

_.'t',J:[I,] r__ Ir*__l/ i _b?Ii[o] L'_I:[o).'4 ::_

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 the Peerless Heater Company:

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.

Theequipmentmustbeinstalledinaccordancewithinstallationrequirementsoftheauthorityhaving

jurisdictionor,intheabsenceofsuchrequirements,tothecurrenteditionoftheNational 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, ASME CSD-I.

Carefully read these instTuctions before beginning work. Understand all aspects of the installation. Contact your Peerless Heater

Company sales representative or customer service for help in answering questions.

This boiler must be installed by a qualified contractor. The boiler warranty can be voided if the boiler is not installed correctly.

r,_! P__] =k'-]_'tlHI l|&'J IN I!__,I ;5_,1=_IN =[<

Install boiler not less than 24" between the top and front

of the boiler and adjacent wall or other appliance, when

access is required for servicing. Do not install boiler on carpeting. Boiler installation

on carpeting is a fire hazard,

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The design of this boiler is certified for alcove installation

with the following clearances from combustible

construction:

I Sides: 2"

2. Top of Jacket: 36"

3. Draft Hood: 6"

4. Vent Pipe: 6" (1" for Type B vent)

5. Rear of Jacket: 6"

Do not install this boiler on combustible flooring.

Boiler installation on combustible flooring is a fire

hazard.

6. If it is necessary to build a non-combustible floor pad

over top of an existing combustible floor, construct

pad as stated in the .National Fuel Gas Code

Handbook Part 6, Installation of Specific Equipment.

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.

Definitions:

Unconfined Space: a space whose volume is not

less than fifty (50) cubic feet per 1000 Btu!hr 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 1 perm or less with

openings gasketed or sealed, and

b. Weatherstripping has been added on openable

windows and doors, and

e. 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 spaces with other

than unusually tight construction, the supply of air

for combustion and ventilation can usually be

considered adequate.

'qll

4. Unusually 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 100 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

1. Provide air openings with minimum

dimensions not less than three (3) inches.

b. All air from outside the building. Connect the

confined space with the outdoors in accordance

with methods i) or ii) 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 flee area of one (i) square

inch per 2000 Btu/hr of total input rating of

all equipment in the enclosure. See Figure 4.

12" max

TWO AIR OPENINGS:

Minimum

Free Area Each =

1 in2per 1000 Btuh

at Least 100 in2

3" m{n

BUILDING

Mustcommunicatefreely

with outdoors

Must not beunder

negativepressure

3" mill

12" max

Figure 1: Air Openings - All Air from Indoors

TWO AIR OPENINGS:

Minimum

Free Area Each =

1 in2per 4000 Btuh

3" min __

12" max,_

Figure 2: Air Openings -All Air Directly from

Outdoors

[_L 12" max

3" rain TWO AIR OPENINGS:

Minimum

Free Area Each =

Figure 3: Air Openings -All Air from Outdoors

through Vertical Ducts

| ill _T_t::]I_t--'_*]]_ [r_ITr_]

ii) Where the equipment has clearances of at

least one (I) 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.

In calculating tree area of an opening, take into

account the blocking affect of louvers, grilles and

screens. Do not use screens smaller than 1/4" 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.

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.

12" max TWO AIR OPENINGS:

Minimum

3" min Free Area Each =

1 in_per 2000 Btuh

3" rain

12"max

Figure 4: Air Openings - All Air from Outdoors

through Horizontal Ducts

Iwl IlO_.llt;lll_'_ll[e]_l _."[IJ;{fj:li"

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:;l! [s,]I :{e,LI JI_,_llie];_

The Series GM boiler is not equipped with a circulator

or a means to control circulator operation. Provide

circulator and zone controls, such as Taco zoning

circulator or Honeywell R845.

i;q "JIr±l L_IL_I1_[_1 i i : 11 II:VLeI Ii

Prepare sketches and notes of the layout to minimize the

possibility of interferences with new or existing

equipment, piping, venting and wiring.

--m__

I Provide a sound, level 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 Separate the wood shipping pallet from the boiler

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

end of the boiler base.

4. Move boiler into final position.

g! [_r_ll[:[;| ['.,ll;,11_[€Ir=q_im3[_s]_h II;[*]l!_.']

Design piping and size circulator(s) to suit the system. Refer to

Hydronics Institute Installation Guide 2000 and the Peerless

Water Installation Survey for guidance.

L'I I:{e]lg:l:t _.'llJ'.J',_l_'l:lL_lm];|:lllJ:|k_

Install boiler to protect the gas ignition system

components from water (dripping, spraying, etc.) during

appliance operation and service (circulator replacement,

condensate hap, control replacements, etc.).

1. Remove shipping nipple from supply tapping.

2. Install temperature-pressure gage with tee in

supply tapping. Nipple, tee, bushing and gage are

located in trim carton. See Figure 5.

3. Install drain valve. Remove jacket front panel.

Install drain valve with tee in return tapping. Nipple,

tee, bushing and drain valve are located in trim

carton. See Figure 7. Tee may be installed with run

in either horizontal or vertical orientation.

4. Install supply piping, return piping and circulator.

See Figure 6.

a. If boiler is installed above radiation level, provide

a low water cutoff device in the supply piping

above boiler. See Figure 6.

TEMPERATURE

PRESSURE

GAGE F1-1/2" TEE

7! 1/2" X 8"

NIPPLE

I/2"× 1/4"

BUSHING

Figure 5: Temperature-Pressure Gage Installation

COLD

WATER

FILL

Figure 6:

SUPPLY

ALTERNATE CIRCULATOR

LOCATION _

SHUTOFF_

VALVEPRESSURE//sHuToPE/F

REDUCNO / / VALVE J L

VALVE_ /

_AIR VENT

AIR ELIMINATOR

CHECK

VALVE _

-- .--_DD,-

RETURN I

CIRCULATOR ___

DRAIN

VAI VE _-.

Typical Supply and Return Piping

i_LOW WATER

/CUTOFF

! DRAFN

When system return water temperature will be

below 130°F,,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 Installation Survey.

If this boiler and dislTibution 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. See Figure 8.

When the boiler is connected to heating coils

located in air handling units where they may be

exposed to refrigerated air circulation, install flow

contzol valves or other automatic means to

prevent gravity circulation of the boiler water

during the cooling cycle.

I:m [__'W_=ISlk'4I;|:lll:l= krl'-11.rd

I. Locate safet_ relief valve and nipple in tzim carton.

2. Install safety relief valve in 3/4 NPT tapping behind

supply tapping. Safety relief valve must be installed

with spindle in vertical position. See Figure 9.

Figure 7: Drain Valve Installation

CHECK VALVE

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, LiN_

WATER tHrEE WAY

I_ci[LL[R VALVE

Figure 8: Parallel Hook-up with Water Chiller

SAFETY

SUPPLY _ RELIEF

VALVE

\/TO DRA_N

Figure 9: Safety Relief Valve Installation

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