PB Heat Peerless Boilers GM Series Installation, Operation & Maintenance Manual
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PB Heat Peerless Boilers GM Series Installation, Operation & Maintenance Manual

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Summary of Contents for PB Heat Peerless Boilers GM Series

  • Page 1 Series ™ Boilers Installation, Operation & Maintenance Manual...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 7. CSD CODE REQUIREMENTS A. INSTALLATION SEQUENCE ... . . 1 A. GENERAL ......21 B.

  • Page 3: Using This Manual

    These categories mean, in the judgment of PB Heat, LLC: ⚠ CAUTION Indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury, and minor property damage.

  • Page 4: Preinstallation

    Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, ASME CSD-1. Carefully read these instructions before beginning work. Understand all aspects of the installation. Contact your PB Heat sales representative or customer service for help in answering questions.
  • Page 5 Air Infiltration Rate Method must be used. If the building in which this appliance is to be installed b. Combining spaces on different floors: is unusually tight, PB Heat recommends that the Provide one or more permanent openings air infiltration rate be determined.
  • Page 6 PREINSTALLATION i. Where communicating directly or through vertical ducts with the outdoors each opening shall have a minimum free area of 1 in² per 4000 Btu/hr (22 cm² per 4000 W) of total input rating for all equipment in the space.

  • Page 7: Installation Survey

    For new and existing installations, a Water Installation a. The required size of openings for combustion, Survey is available from PB Heat. The survey will ventilation, and dilution air shall be based on the provide information on how a hot water boiler works net free area of each opening.

  • Page 8: Circulators

    PREINSTALLATION E. CIRCULATORS 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. F. PLANNING THE LAYOUT Prepare sketches and notes of the layout to minimize the possibility of interferences with new or existing equipment, piping, venting and wiring.

  • Page 9: Boiler Set-Up

    BOILER SET-UP 2. BOILER SET-UP 1. Provide a sound, level foundation. Locate boiler as 3. Separate the wood shipping pallet from the boiler near to the chimney or outside wall as possible and base by removing two (2) hold-down bolts at each centralized with respect to the heating system.

  • Page 10: Water Piping & Controls

    Design piping and size circulator(s) to suit the system. Refer to the I=B=R - Residential Hydronic Heating Installation/Design Guide and the PB Heat Water Survey for guidance. A. BOILER SUPPLY & RETURN Install boiler to protect the gas ignition system components from water (dripping, spraying, etc.) during...

  • Page 11: Safety Relief Valve

    130°F (54°C) entering the boiler. For more information on bypass piping, consult the PB Heat Water Installation Survey. c. If this boiler and distribution system is used in...

  • Page 12: Piping For Zoned Systems

    1. See Figures 3.6 and 3.7 for basic zoned system layouts. Circulators may be installed in either supply or return piping. Refer to PB Heat Water Installation Survey for additional information. 2. Run each zone pipe down then up to zone to prevent air accumulation in piping.

  • Page 13: Expansion Tank

    3. The glycol solution should be tested at least once a year and as recommended by the glycol manufacturer. 4. For more information, consult the PB Heat Water Installation Survey and the antifreeze manufacturer. Figure 3.8: Typical Piping with Indirect-Fired Water Heater...

  • Page 14: Venting

    VENTING 4. VENTING A. DRAFT HOOD BLOCKED VENT SWITCH ASSEMBLY 1. The boiler is equipped with a draft hood designed SHEET METAL a. provide for the ready escape of flue gases from SCREWS the boiler in the event of no draft. BLOCKED VENT b.

  • Page 15: Automatic Vent Damper Installation - General

    VENTING C. AUTOMATIC VENT DAMPER 3. Do not alter boiler draft hood or place any obstruction or non-listed damper in the vent system. INSTALLATION – GENERAL 4. Before connection of joints, inspect the vent pipe 1. Do not use one vent damper to control two or more interior for foreign objects such as tools, equipment, heating appliances.

  • Page 16: Boiler Removal From Common Venting System

    VENTING Figure 4.4: Venting with Vent Damper in Horizontal Position F. BOILER REMOVAL FROM COMMON c. Insofar as is practical, close all building doors and windows and all doors between the space in which VENTING SYSTEM the appliances remaining connected to the common At the time of removal of an existing boiler, follow these venting system are located and other spaces of steps with each appliance remaining connected to the...
  • Page 17 VENTING d. Place in operation the appliance being inspected. g. Any improper operation of the common venting Follow the lighting instructions. Adjust thermostat so system should be corrected so that the installation appliance will operate continuously. conforms with the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/ Mettre en service l’appareil à...

  • Page 18: Gas Piping

    GAS PIPING 5. GAS PIPING 1. Size and install the gas supply piping to provide 4. Connection of boiler to the gas piping system may a supply of gas sufficient to meet the maximum be made on the left side or top of the boiler. See demand of all appliances without undue loss Figure 11.1 for jacket opening locations.
  • Page 19 GAS PIPING 8. Disconnect the boiler and its individual shut-off valve from the gas supply piping system during any pressure testing of that system at test pressure in excess of 1/2 psig (3.5 kPa). ⚠ CAUTION Do not subject the gas valve to more than 1/2 psi pressure (3.5 kPa).

  • Page 20: Electrical

    ELECTRICAL 6. ELECTRICAL This boiler is equipped with a water temperature limit control which includes a low water cutoff function and also a reset feature as described below. It is also equipped with a spark ignited intermittent ignition system. See vendor information in the boiler folder for additional information regarding the boiler controls.
  • Page 21 ELECTRICAL Figure 6.2: Wiring Diagram, Spark Ignited Pilot, Hydrolevel 3200 Limit control...

  • Page 22: Sequence Of Operation, Intermittent Ignition

    ELECTRICAL B. SEQUENCE OF OPERATION, 5. Pilot flame detected. INTERMITTENT IGNITION a. Igniter off. b. Main gas on, igniting main burners. 1. Thermostat calls for heat. Note: If the pilot is not detected within 90 seconds, the 2. Limit senses boiler water temperature. Prevents igniter and pilot gas are turned off for 5 minutes.

  • Page 23: Csd Code Requirements

    CSD CODE REQUIREMENTS 7. CSD CODE REQUIREMENTS A. GENERAL Low Water Cut-off(s) - The Hydrolevel Hydrostat limit ® controls used on Series GM™ boilers meet ASME 1 low This section is in regard to requirements of the water cut-off requirements when used in either modular ASME CSD-1 Code, Controls and Safety Devices for of multiple boiler installations.

  • Page 24: Requirements

    START-UP PROCEDURES 8. START-UP PROCEDURES A. COMPLETING THE INSTALLATION 13. Use the sequence descriptions in Section 6, paragraph B (Electrical) to follow light-off and 1. Confirm that all water, gas and electricity are shutdown sequences and to assist in diagnosing turned off.
  • Page 25 START-UP PROCEDURES Figure 8.3: Operating Instructions, Spark Intermittent Ignition...
  • Page 26 START-UP PROCEDURES Figure 8.4: Operating Instructions, Spark Intermittent Ignition...

  • Page 27: Control Descriptions

    START-UP PROCEDURES B. CONTROL DESCRIPTIONS D. CHECKING BURNER INPUT See Figure 8.5 for locations of these devices. 1. Refer to rating label mounted on the jacket top panel to obtain the rated BTU (kW) per hour input. In no 1. FLAME ROLLOUT SAFETY SHUTOFF SWITCH case shall the input to the boiler exceed the value –...

  • Page 28: Check-Out Procedure

    START-UP PROCEDURES Table 8.1a: Meter Conversion – Natural Gas 3. Low Water Cut-Off – Consult the manufacturer’s Burner inputs in Btu/hr for various meter timings and instructions for the low water cut-off operational heat values. (Table based on 2 cubic feet of gas through check procedure.

  • Page 29: Troubleshooting

    TROUBLESHOOTING 9. TROUBLESHOOTING ⚠ DANGER A. SHUT-DOWN CAUSED BY PILOT OUTAGE, VENT SAFETY SHUTOFF When servicing or replacing items that communicate SWITCH OR FLAME ROLLOUT SAFETY with the boiler water, be certain that: SHUTOFF SWITCH There is no pressure on the boiler. In the event of a shut-down caused by a pilot outage, The boiler is not hot.
  • Page 30 TROUBLESHOOTING Table 9.1: Boiler Troubleshooting Guide PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Burners not funcitoning. 1. No power. 1. Check line voltage wiring and fuses. 2. Limit not working. 2. Check wiring and contacts, relay, temperature setting. Clean and adjust as necessary. 3.
  • Page 31 TROUBLESHOOTING START BEFORE TROUBLESHOOTING, NOTE: “CALL FOR HEAT” 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL. FAMILIARIZE YOURSELF WITH THE STARTUP AND CHECKOUT PROCEDURES. TURN GAS SUPPLY OFF, TURN THERMOSTAT (CONTROLLER) TO “CALL FOR HEAT.” CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING ALSO.

  • Page 32: Maintenance

    MAINTENANCE 10. MAINTENANCE ⚠ WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF, when inhaled, have been classified by the International Agency for Research on Cancer (IARC), as a possible carcinogen to humans. After the RCF materials have been exposed to temperatures above 1800°F (982°C), they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans.

  • Page 33: General

    MAINTENANCE A. GENERAL 4. Check for water leaks in boiler and system piping. 5. Smell around the appliance area for gas. If you 1. Disconnect this boiler from the gas supply piping smell gas, follow the procedure listed in the Lighting/ during any pressure testing of the gas system.

  • Page 34: Annually (Before Start Of Heating Season)

    MAINTENANCE E. ANNUALLY (BEFORE START OF HEATING h. Re-install the top of the jacket, draft hood, vent damper (if used) and vent pipe. SEASON) i. Connect blocked vent switch wiring harness to ⚠ DANGER blocked vent switch. k. Re-install burners. When servicing or replacing components, be absolutely certain that the following conditions are met:...

  • Page 35: Boiler Dimensions & Ratings

    BOILER DIMENSIONS & RATINGS 11. BOILER DIMENSIONS & RATINGS Figure 11.1: Boiler Views Table 11.1: Series GM™ Boiler Dimensions SERIES GM™ BOILER DIMENSIONS Boiler Jacket Jacket Jacket Left of Jacket to Top of Jacket to Vent Size Model Depth Width Height C/L of Vent Vent Connector...

  • Page 36: Repair Parts

    REPAIR PARTS 12. REPAIR PARTS Repair parts are available from your local PB Heat, LLC distributor or from Parts To Your Door at 1 (610) 916-5380 (www.partstoyourdoor.com). Note: Remember to include the boiler model number and serial number when ordering parts.
  • Page 37 REPAIR PARTS Figure 12.2 Table 12.2 Quantity Stock Description Required Code Gas Manifold – GM-e-05 50712 Gas Manifold – GM-e-06 50713 Gas Manifold – GM-07 50714 Gas Manifold – GM-08 50715 Main Burner – GM-e-05 50192 Main Burner – GM-e-06 50192 Main Burner –...
  • Page 38 REPAIR PARTS Figure 12.3a Figure 12.3b...
  • Page 39 REPAIR PARTS Table 12.3 Quantity Stock Description Required Code Block – GM-e-05 91041 Block – GM-e-06 91042 Block – GM-07 91043 Block – GM-08 91044 Flue Baffle GM-e-05/06 (11.75” x 13.13”) 1 per flue 51616 Flue Baffle GM-07/08 (10” x 12”) 1 per flue 51694 Flue Collector, GM-e-05 (requires 5’...
  • Page 40 REPAIR PARTS Figure 12.4...
  • Page 41 REPAIR PARTS Table 12.4 Quantity Stock Description Required Code 3/4” Drain Valve, Conbraco 31-602-04 50764 Flame Rollout Safety Shutoff Switch 51587 Limit Control, Hydrolevel HydroStat 3200, with sensor 50334 Immersion Well, Hydrolevel 50723 Immersion Sensor, Hydrolevel 54522 Temperature-Pressure Gage [30, 50 PSI (207 kPa, 345 kPa) safety relief valve] 51324 Temperature-Pressure Gage [80, 100 PSI (552 kPa, 689 kPa) safety relief valve] 55846...
  • Page 42 NOTES...
  • Page 43 TO THE OWNER: This boiler should be inspected annually by a Qualified Service Agency. PB HEAT, LLC 131 S. CHURCH STREET • BALLY, PA 19503 WEB R1 (4/21) GM8065 R14 (4/19-3C) ©2019 PB Heat, LLC. All rights reserved. Printed in U.S.A.

This manual is also suitable for:

Peerless boilers gm-e-05Peerless boilers gm-e-06Peerless boilers gm-07Peerless boilers gm-08

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