PEERLESS SERIES PSC Manuel d'instructions

PSC

Installation,

Operation

Maintenance

Manual

PEERLESS °

CAST IRON BOILERS

4 Sizes 3-6 Sections 70.0 to 175.0 MBH CSA Input 83% AFUE

Natural or LP Gas

Sealed Combustion, Direct Vent

•Ideal Where the Chimney is Inadequate or Unavailable

•Uses Outside Air For Combustion

• 4" Galvanized or Aluminum Approved For Combustion Air Inlet Piping

•Combustion Air Inlet From Either Side of Boiler

•Uses 3" AL29-4C Stainless Steel Vent Pipe For "Through the Wall" Venting

Applications

Unique Wall Thimble For "Thru the Wall" Venting

• Concentric Design For Combustion Air Inlet and Exhaust

• Requires Only One Hole in Outside Wall

•Exhaust Gases Heat Incoming Combustion Air to Prevent Freezing

of Air Inlet

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 Air Inlet Box

Safety Controls

•Flame Roll-Out Shut-OffSwitch

•Differential Pressure Switch

_SraartValve is a registered trademark oj'Honeywell Corporation.

•Honeywell Operating Controls

•Honeywell SmortValve ® Intermittent Ignition

•Taco 007 Circulator

• Non-Combustible Floor Pan

• Wall Thimble with Stainless Steel Vent Cap and

Screened Vent Termination

•30 PSI Safety Relief Valve

•Grundfos Circulator

•AL29-4C Stainless Steel Venting Components

•50 PSI Safety Relief Valve

Peerless Heater Company is pleased to offer one of the most comprehensive warranty pro_lrams in

the industry. All Peerless residential cast iron boilers include a full one-year warranty. A limited,

lifetime warranty is provided for tile cast iron sectior_s of Peerless residential hot water boilers.

Peerless also provides a limitc, d, ten-year warranty on the cast iron sections of its residential steam

boilers. Five and ten year extended warranties on parts and labor are now available. Please consult

Peerless Heater CorrqgoJly for complete warranty information.

pGERLESS ®

CAST IRON BOILERS

Peerless Heater Company • 231 North Walnut Street •Boyertow_, PA I9512-1021 • 610-367-2153 •www.peerless-heater.com

FAB PSC (11/02-5M)

Printed in U.S.A

TABLE OF CONTENTS

1°

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. LIQUEFIED PETROLEUM (LP) GAS ....... 2

D. INSTALLATION SURVEY ............... 2

E. PLANNING THE LAYOUT ............... 2

BOILER SET-UP 3

WATER PIPING AND CONTROLS 4

A. BOILER SUPPLY AND RETURN .......... 4

B. SAFETY RELIEF VALVE ................ 5

C. PIPING FOR ZONED SYSTEMS .......... 6

D. EXPANSION TANK .................... 7

E. INDIRECT-FIRED WATER HEATER ........ 7

E FREEZE PROTECTION ................. 7

VENTING, VENTILATION AND

AIR INLET 8

A. GENERAL ........................... 8

B. PEERLESS WALL THIMBLE ............. 8

C. ROOF TERMINATION ................. 10

D. VENT PIPE INSTALLATION ............ 11

E. AIR INLET PIPE INSTALLATION ......... 11

E AIR FOR VENTILATION ............... 12

G. BOILER REMOVAL FROM COMMON

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

6. ELECTRICAL 15

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

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

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

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

7. START-UP PROCEDURES 19

A. COMPLETING THE INSTALLATION ...... 19

B. CONTROL DESCRIPTIONS ............. 22

C. ADJUSTMENT OF GAS PRESSURE

REGULATOR ....................... 22

D. CHECKING BURNER INPUT ............ 22

E. CHECK-OUT PROCEDURE ............. 23

8. TROUBLESHOOTING 24

A. SHUT-DOWN CAUSED BY PILOT OUTAGE,

PRESSURE SWITCH OR FLAME ROLL-OUT

SAFETY SHUT-OFF SWITCH ........... 24

B. TROUBLESHOOTING GUIDES .......... 24

C. MEASURING SUCTION PRESSURE ...... 24

9. MAINTENANCE 28

A. GENERAL .......................... 28

B. DAILY (WITH BOILER IN USE) .......... 28

C. WEEKLY (WITH BOILER IN USE) ........ 28

D. MONTHLY (WITH BOILER IN USE) ....... 28

E. ANNUALLY (BEFORE START OF HEATING

SEASON) .......................... 29

10. BOILER DIMENSIONS 8RATINGS 31

11. REPAIR PARTS 33

5. GAS PIPING 13

USING THIS MANUAL

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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 sMet_ during

boiler installation.

Indicates a condition or hazard which will cause

severe personal injury, death or major property

damage.

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Throughout this manual you wil! 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 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.

1. PREINSTALLATION

Read carefully study th_se instructions before beginning \vork

This boiler must be installed by a qualified contractor

The boiler warranty can be voided if the boiler is not instal}ed, 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. f/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, ANSI/ASME CSD-1.

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 right side, front and combustible

cotlstruction

2. ]2" between top of jacket and combustible

construction

3. 1"" between left side, rear and combustible

construction,

4. 2" between vent pipe and combustible construction.

5. 0" between wall thimble and combustible

construction

6. This boiler is design certified for use on combustible

flooring

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The following LP requirements from the Uniform

Mechanical Code, section 304.6, may be in effect in

your geographic area:

"Liquefied petToleum 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."

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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.

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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.

Prepare sketches and notes of the layout to minimize the

possibility of interferences with new or existing

equipment, piping, venting and wiring. Review

Limitations on vent pipe, vent terminal, and air inlet pipe

locations and ventilation air requirements in Section 4.

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.

2. BOILER SET-UP

1 Provide a sound, level foundation Locate boiler as

near to the chimney or outside wal! as possible and

centralized with respect to the heating system

2 Locate boiler in front of installation position before

removing crate

4 Separate the wood shipping pallet ff()m the boiler

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

end of the boiler base

5. Move boiler into final position.

3. WATER PIPING AND CONTROLS

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

typical piping arrangement is shown in Figure i.

Refer also to the Hydronics Institute Residential

Hydronic Heating 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 right section Pipe the return to the inlet

connection of the circulator

Supply Piping:

a Pipe the supply to the I I 2 NPT supply tapping

at the top of the boiler.

b Provide clearance to venting system

(see Section 4)

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 Survey

If desired, install the circulator in the alternate

location shown in Figure I. Consult the Peerless

Water Survey for more information on circulator

location

AIR VENT_

AIR ELIMINATOR _

-- SAFETY

RELIEF

VALVE

)_-ALTERNATE

CIRCULATOR

LOCATION

SUPPLY

COLD

WA1ER

NLL

SHUTOFF

VALVE VALVE" REDUCING VALVE

VALVE

_-EXPANStON TANK

TO DRAIN RE_JRN

CIRCULATOR

DRAIN

VALVE

Figure 1: 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 illust_ating this hook-

up is provided in Figure 2.

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.

WATER THREE WAY

VALVE

Figure 2: Parallel Hook-up with Water Chiller

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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 3.

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

install valve and piping as shown in Figure 4.

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.

SAFETY

RELIEF

SUPPLY VALV E

NIPPLE

Figure 3: Safety Relief Valve Hook-Up Installation

with Air Elimination in System Piping

TO AIR

ELIMINATION

DEVICE

SUPPLY I-3/4" TEE

SAFETY r5/4" X 6"

RELIEF NIPPLE

VALVE_-._I_ _3/4" x2"

NIPPLE

Figure 4: Safety Relief Valve Hook-Up with

Air Elimination

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1. See Figures 5 and 6 for basic zoned system layouts.

2. Run each zone pipe down then up to zone to

prevent air accumulation in piping.

3. If required, provide means to isolate and drain each

zone separately.

TO SYSTEM

ZONE ZONE ZONE

5 2 1

ZONE

VALVES _z

CONNECT

SUPPLY

FROM SYSTEM

ZONE ZONE ZONE

1 2 5

BALANCING

VALVES

CONNECT TO

RETURN

(CIRCULATOR INLET)

Figure 5: Zone Piping with Zone Valves

TO SYSTEM

ZONE ZONE ZONE

5 2 !

FROM SYSTEM

ZONE ZONE ZONE

1 2 5

FLOW

CONTROL

VALVES

! I .11

CONNECT

SUPPLY

ZONE

CONNECT TO

TAPPING

Figure 6: Zone Piping with Circulators

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1. Consult the tank manufacturer's instructions for

specific information relating to tank installation Size

the expansion tank for the required system volume

and capacity See Table c) in Section 10 for bof]¢,_

water capacity

2. Expansion tanks are available with built in fill valves

and check valves for reducing supply water pressure

and maintaining minimum system pressure. Check

the design features of the tank and provide valves as

necessary.

Refer back to Figure i for typical expansion tank piping.

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If the boiler is to be used in conjunction with an indirect-

fired water heater, refer to Figure 7 for typical piping

Follow the instructions provided by the water heater

manufacturer. Pipe the water heater as a separate zone.

For new or existing systems that must be freeze-

protected:

Glycol in hydronic applications is specially

formulated for this purpose. It includes inhibitors

which prevent the glvcol from attacking metallic

system components Make certain that the system

fluid is checked for the correct gtycol concentration

and inhibitor level.

The antifreeze solution should be tested at least once

a year and as recommended by the antifreeze

manufacturer.

Antifreeze solutions expand more than water. For

example, a 80% by volume solution expands 4.8%

in volume for a temperature increase from 32°F to

180°F, while water expands 3% with the same

temperature rise. Allowance must be made for this

expansion in system design.

For more information, consult the Peerless Water

Installation Survey and the antifreeze manufacturer

SAFETy

RELIEF

VALVE

TO DRAIN

BALANCING

VALVE

OSYSTEM

{_ OCIRCULATOR

©DRAIN

VALV [

ZONE VALVES

INDIRECT-FIRED

WATER HEAER

SUPPLy

TO TANK

BALANONG

VALVE

SUPPLY TO

SYSTEM

q RETURN FROM

SYSTEM

HOT DOMESTIC

_WATER SUPPLy

COLD DOMESTIC

WAIER SUPPLY

Figure 7: Typical Piping with Indirect-Fired Water Heater

Ce manuel convient aux modèles suivants

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