PEERLESS Series MI Manuel d'instructions

MI/MIH

Boilers

Installation,

Operation

Maintenance

Manual

Pr=-EI_LESS _

CAST IRON BOILERS

MI Model Available for Natural or LP Gas

•Standit_g Pilot (3 9 sectior_) with 8(7_ AFUE

•[-Ioneywell SmartValve ®Intermittent Ignition (3-9 section)

with 82% AFUE

MIH Mid-E._f_ency Model Available in 3-6 Sections

for Natural Gas

• Honeywell SmartValve ®Intermittent Ignition with 83% AFUE

•Qualifies for Utility Company Energy Rebates in Some Areas

Natural Draft (Chimney) Venting

Low Profile Design

•Internal Horizontal to Vertical Draft Diverter

•Ideal for Ir_stallations with Low Ceilings

Steel Push Nipples

• Provici( _a Permar_ent _Vct_'r 7"(c)hl Seed Between Sections

•Unaffected by PetroIcum alzd Oilier Contaminants

Deluxe Insulated Enameled Steel Jacket

•Reduces Boiler Heat Loss

•Completely Encloses Gas Valve and Burners

Safety Controls

•Vent Safety ShutoffSwitch

•Flame Rollout Safety ShutoffSwitch •Standing Pilot or Honeywell SmartValve _

Intermittent Ignition

•Honeywell Operating Controls

• Taco Circulator

• Elec. Operated Automatic Vent Damper

•Grundfos Circulator

• 50 PSI Safety Relief Valve

•Non-Combustible Floor Pan

c_xStltartVah;_t i._ r_ rt,gislt_rt,d Ircldt,illark o I llo¢letlw(tll Corporcltion.

l_crless q[f_,r on_ of tll_" mosl c:omprelt_.nsive wctrrarlly prof.jrarrus

in tttt_ ind_Lslr_/. All I_ (_rlt'ss r_'sidt't_ticd c_¢_t iro,_ !_oil<.rs inc'!_d_, c_ lidl one tj_!(_r Illarl€_rlltj. A limited. ['_[_[_-r_kl_SS ®

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/'/(,cLs(_ co¢l._tdt ['(,('rli,ss [ ](,_ll(,_ (2)m[J(lll{/ ]OF Coltll)l(.lt, it)(iFK(llll!j it!]orlnaliorL

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

FAB MI l_l {3/02 5M)

Pnnled _n U S A

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. AIR FOR COMBUSTION AND

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

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

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

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

7. START-UP PROCEDURES 20

A. COMPLETING THE INSTALLATION ...... 20

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

C. ADJUSTMENT OF GAS PRESSURE

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

D. ADJUSTMENT OF PILOT GAS FLOW .... 24

E. CHECKING BURNER INPUT ............ 24

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

8. TROUBLESHOOTING 26

A. SHUT-DOWN CAUSED BY PILOT OUTAGE,

BLOCKED VENT SHUT-OFF SWITCH OR

FLAME ROLL-OUT SAFETY SHUT-OFF

SWITCH ........................... 26

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

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

A. INTEGRAL DRAFT HOOD ............. !0

B. VENT DAMPER INSTALLATION -

GENERAL .......................... 10

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

D. BOILER REMOVAL FROM COMMON

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

A. GENERAL .......................... 29

B. DAILY (WITH BOILER IN USE) .......... 29

C. WEEKLY (WITH BOILER IN USE) ........ 29

D. MONTHLY (WITH BOILER IN USE) ....... 29

E. ANNUALLY (BEFORE START OF HEATING

SEASON) .......................... 30

10. BOILER DIMENSIONS _ _TINGS 31

A. BASE/COMBUSTIBLE FLOOR PAN ....... 32

B. MANIFOLD/GAS TRAIN ............... 34

C. BLOCK/DRAFT HOOD ................ 36

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

E. CONTROLS/CIRCULATOR/VENT

DAMPER .......................... 40

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

B. ZONED SYSTEM WIRING ............. 15

C. CONTROLS ........................ 15

D. SEQUENCE OF OPERATION ........... 16

Follow thetnsta[lattoninstructionspro',,'_dedill this

manual m the order shown The order ot these

mstructLons has been set m order to provide the installer

with a logical sequence ol steps that wdl mulmllze

potenhal interferences and maximize safety, during

boiler mstallatLon

Indicates a condition or hazard which will cause

severe personal injury, death or major property

damage.

Throughout thLs manual you will see speoal attenuon

boxes intended to supplement the mstmct=ons and make

speoal nohce of potenhal hazards These categories

mean m the judgment of Peerless Heater Company

indicates a condition or hazard which may cause

severe personal injury, death or major property

damage.

Indmates 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.

1.!B INS

Read carefully, study these msh-uchons before beginning work

This bo,le_ must be installed by a quahfled con_ac_or

The bonler warranty can be voided _t the boder Is not installed, maintained and serviced correctly

The equipment must be installed maccordance 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 requtred 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.

r_*wr:_o,[o.]:[.."[.."]I:] I ! / ik'd_a,]l :f;1:_r_*l_[q _

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

and tront ot the boiler and adjacent wall or other

apphance, when access is reqmred for servicing

The design of ths boiler _scertffled for alcove mstallatlon

wlth the following clearances

I 6" between s,des and combustible construction

2 24" between top of jacket and combushble

construction

3 6" between draft hood and combustible

COl_ls_uctlon

4 6" between vent pipe and combustLble construction

5 10" between rear of ]acket and combushble

consiluctlon

Do not install this boiler on combusttble 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 11A of this manual.

Do not install this boiler on carpeting. Boiler

installation on carpeting asafire hazard. Install this

boder on non.combustible flooring or use a

combustible floor pan to install thts boder on other

non-carpeted flooring.

Prowde adequate facflltnes for combustlon and

vent]lahon a_r unaccordance w_th Sechon 5 3. ALrfor

Combustion and Ventilation Nanonal Fuel Gas

Code ANSI -7223 1/NFPA 54, or apphcable

prows_ons of the local budding code Subsechons 2

through 6 below are based on National Fuel Gas

Code ANSI Z223 1!NFPA 54 requnrements

DehnltlOnS

Unconfined Space: a space whose volume usnot

less than fifty (50) cubnc feet per 1000 Btu/hr of the

total input rahng of all apphances installed Jnthat

space Rooms commumeatmg dnrectly w_th the space

m which the apphances are installed, through

opemngs not furmshed w_th doors, are considered

part of the unconfined space

Unusually Tight Construction: Constmchon

where

Walls and cenlmgs exposed to the outsMe

atmosphere have a continuous water vapor

retarder wlth a rating of iperm or less wLth

openings gasketed or sealed, and

b Weatherstnppmg has been added on openable

windows and doors, and

CaulkLng or sealants are supphed to areas such

as joints around window and door frames.

between sole plates and floors, between wall-

ceflmg joints, between wall panels, at

penetratlons for plumbing, electrical and gas

hnes, and at other openings

3Appliances 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.

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 1000 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

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 duets, 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.

i ?

12" max

TWO AIR OPENINGS:

Minimum

Free Area Each -

1 in2per 1000 Btuh

at Least 100 in2

BUILDING

Must communicatefreely

withoutdoors

Must not beunder

negativepressure

12" max

Figure 1: Air Openings -All Air from Indoors

TWO AIR OPENINGS:

Minimum

Free Area Each -

1 in_per 4000 Btuh

Figure 2: Air Openings - All Air Directly from

Outdoors

Figure 3: Air Openings - All Air from Outdoors

through Vertical Ducts

6. :_ IIL_l_uf±lUHff±_ugl[e]L_l[_'q_|J;kVJ_k

Where communicating with the outdoors

through horizontal ducts, size each opening

with a minimum free area of one (1) square

inch per 2000 Btu/hr of total input rating of

all equipment in the enclosure. See Figure 4.

ii) 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.

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.

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_ff±!_l_ll_[dl|ll:lt_VLelll

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.

ii-i ..

12"maxl [ i 1--

, _t [jT TWO AIR OPENINGS: |

)1' Minimum l

Free Area Each =

in_per 2000 Btuh !

_ min

12"max

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.

Prepare sketches and notes of the layout to minimize the

possibility of interferences with new or existing

equipment, piping, venting and wiring.

IIJ ! [o|lJ :l ;i I:ll]'.J :Eld:{o] ! ::[IILVA|_[€-r_,_..

The following LP requirements from the Uniform

Mechanical Code, section 304.6, may be in effect in

your geographic area:

"Liquefied peh'oleum 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."

l_.]llF'4T_'i:i_IrJ_

Provide a sound, level foundahon Locate boiler as

near to the chmney or outside v_ali as possLble and

cennahzed v_Jth respect to the heahng system

Locate boiler [n front of installation pos[hon before

_movll_g crate

If using combushble floor pan, poslhon pan on

foundat,on or flooring

4 Separate the wood shppmg pallet from the boiler

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

end of the boder base

5 Move boder into hnal poslhon If using combustLble

floor pan, install boder on pan as outhned ,n the

instructions included wlth the pan

3. WATER PIPING AND CONTROLS

"-I [:{=]ll_;l[.-llJ'J_Jl_'m_,]l_ll] I;l:i[IJ;|k'

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

t_pical piping arrangement is shown in Figure 5.

Refer also to the I-B-R Installation Guide No. 200

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 i/2 NPT supply tapping at

the top and rear 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.

COLD

WATER

FILL

VAL VE

DRAIN

VAI VE J

DRAIN l

Figure 5: Supply and Return Piping

6. 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 )

7. 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

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 control valves

or other automatic means to prevent gravity

circulation of the boiler water during the cooling

cycle.

9. 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.

C HECj VAILVEI

SUPPLY

LINE

WATER THREE WAY

_HILLER VALVE

Figure 6: Parallel Hook-up with Water Chiller

I:m l-'f!1=:lL'dI;t=l!l=l:l krl±lLvd

i I 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 7.

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

install valve and piping as shown in Figure 8.

SAFETY

RELIEF

VALVE

x6"

NIPPLE

Pipe the discharge of safety relief valve to prevent

injury in the event of pressure relief, Pipe the

discharge to adrain. 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 AIR

ELIMINATION

DE_CE

SUPPLY TEE

SAFETY X6 _

RELIEF NIPPLE

VALVE

NIPPLE

TO DRAIN

5/4" STREET

ELBO_

Figure 8: Safety Relief Valve Hook-Up with

Air Elimination

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