PEERLESS FLEX-HEAT GM Series Design & Application Manual
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PEERLESS FLEX-HEAT GM Series Design & Application Manual

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Summary of Contents for PEERLESS FLEX-HEAT GM Series

  • Page 1 Series ™ Boilers Design & Application Guide...

  • Page 2: Table Of Contents

    A. MODULAR VS. MULTIPLE ....2 B. AIR ELIMINATION ....27 B. PEERLESS FLEX-HEAT SYSTEM .

  • Page 3: Introduction To Flex-Heat Modular Boiler Systems

    INTRODUCTION TO FLEX-HEAT MODULAR BOILER SYSTEMS ® 1. INTRODUCTION TO FLEX-HEAT ® MODULAR BOILER SYSTEMS The FLEX-HEAT System consists of a wide array of ® components designed to provide high energy efficiency, STOP VALVES simple installation, and increased comfort from your LIMIT LIMIT LIMIT...

  • Page 4: Modular Vs. Multiple

    FLEX-HEAT SYSTEM COMPONENTS AND RATINGS ® 2. FLEX-HEAT SYSTEM ® COMPONENTS AND RATINGS A. SERIES GM GAS BOILERS ™ 1. The Series GM™ is available in four sizes suitable for modular boiler (or multiple boiler) installations – 214.5 MBH, 268 MBH, 342 MBH and 399 MBH input (Figures 2.1 and 2.4).

  • Page 5: Flex-Heat ® System Components And Ratings

    FLEX-HEAT SYSTEM COMPONENTS AND RATINGS ® C. DOMESTIC WATER HEATING Use FLEX-HEAT modular boilers with the Peerless ® ® Partner indirect-fired water heaters for high recovery ® and energy-efficient service water heating. Partner PP models feature high grade 316L stainless steel construction.

  • Page 6: Flex-Heat ® System Ratings

    FLEX-HEAT SYSTEM COMPONENTS AND RATINGS ® Table 2.1: FLEX-HEAT System Ratings ® TYPICAL FLEX-HEAT MODULAR BOILER SYSTEMS System Module Input Gross Output Gross Output Net Output Number Quantity & Size (MBH) (MBH) (H.P.) (MBH) FH-429 10.9 FH-482 1-5, 1-6 12.2 FH-536 13.5 FH-610...
  • Page 7 SERIES GM™ DIMENSIONS AND RATINGS SERIES GM BOILER DIMENSIONS Boiler Width Distance From Left Height Less Vent Damper Height With Vent Damper Outlet Diameter Model “A” “B” “C” “C” “D” * Number GM-e-05 19-1/4” 9-3/4” 29” 35-7/8” 7” * GM-e-06 22-3/4”...
  • Page 8 PEERLESS PARTNER PP DIMENSIONS AND RATINGS ® ® PEERLESS PARTNER PP DIMENSIONS ® ® Dimensions Pressures (psig) Model Tank Capacity Floor to Floor to Floor to Floor to Number (U.S. Gallons) Diameter Height Test Working “Boiler In’ “Boiler Out’ “Cold-Drain’...
  • Page 9 PEERLESS PARTNER PV DIMENSIONS AND RATINGS ® ® TOP VIEW HX IN PARTNER HOT OUT COLD IN HX OUT 45.00° FRONT PEERLESS PARTNER PV TANK DIMENSIONS ® ® Water Heater Domestic Water Boiler Connection Height Tank Diameter, Model Number Connection Sizes, NPT...

  • Page 10: Mechanical Room Layout

    MECHANICAL ROOM LAYOUT 3. MECHANICAL ROOM LAYOUT A. CODE COMPLIANCE 1. The suggestions in this Guide are based primarily on the National Fuel Gas Code, ANSI Z223.1 and ASHRAE recommendations for piping, etc. 2. The guidelines for installation and control of the equipment are consistent with the ASME Code Section IV.
  • Page 11 MECHANICAL ROOM LAYOUT For fan assisted appliances, calculate the required volume of air using the following equation: 15 ft Required Volume 1000 Input of the fan assisted appliances in Btu/hr Note: These calculations are not to be used for infiltration rates greater than 0.60 ACH.
  • Page 12 MECHANICAL ROOM LAYOUT Figure 3.3: Typical Mechanical Room Layout with Four Modules and Individual Venting...
  • Page 13 MECHANICAL ROOM LAYOUT Figure 3.4: Typical Mechanical Room Layout with Four Modules and Manifolded Vent...
  • Page 14 MECHANICAL ROOM LAYOUT Figure 3.5: Clearances to Combustible Construction and for Accessibility...
  • Page 15 MECHANICAL ROOM LAYOUT Figure 3.6: Provide Combustion/Ventilation Air Openings as Required by Codes.
  • Page 16 MECHANICAL ROOM LAYOUT Figure 3.7: Provide Combustion/Ventilation Air Openings as Required by Codes. Openings Must Connect to Outside if the Total Volume of All Interconnected Indoor Spaces is Less Than What is Required by 3.B.1.a.

  • Page 17: Venting

    VENTING 4. VENTING A. GENERAL the National Fuel Gas Code, ANSI Z223.1. As allowed in the Code, other vent system designs 1. Vent construction - National Fuel Gas Code may be specially engineered using accepted Requirements engineering practices. a) The National Fuel Gas Code requirements for f) Because of the limitations of single wall vent, this venting have changed significantly.

  • Page 18: Sizing Guide Restrictions

    VENTING B. SIZING GUIDE RESTRICTIONS 5. The vent tables in this guide apply to interior chimneys. See National Fuel Gas Code for sizing guidelines when 1. No other appliances can be connected to the vent when using exterior chimney(s). using the sizing information in this Guide. 6.
  • Page 19 VENTING Figure 4.3: Individual Venting – See Table for Vent Sizing...
  • Page 20 VENTING Table 4.2: Individual Vent Sizing Using Type B Vent or Single Wall Metal Pipe VENT SIZING TABLE - GM MODULAR Individual Venting GM-e-05 GM-e-06 214.5...
  • Page 21 VENTING Figure 4.3: Combined Venting, Constant Diameter Manifold – See Sizing Tables...
  • Page 22 VENTING Table 4.3: Combined Vent Sizing and Connector Requirements for Typical FLEX-HEAT Systems ® for Vent Heights of 10 Feet and 15 Feet, For Type B Vent Only VENT HEIGHT 10 FEET Maximum Individual Vent Connector Common Combined Input Minimum Vent Manifold Minimum Inside Diameter, Inches Model...
  • Page 23 VENTING Table 4.4: Combined Vent Sizing and Connector Requirements for Typical FLEX-HEAT Systems ® for Vent Heights of 20 Feet and 30 Feet, For Type B Vent Only FH-429 GM-e-05 GM-e-05 FH-482 GM-e-06 FH-536 GM-e-06 GM-e-06 FH-610 FH-429 GM-e-05 GM-e-05 FH-482 GM-e-06 FH-536...
  • Page 24 VENTING Figure 4.4: Combined Venting, Graduated Vent Diameter – See Tables for Sizing...
  • Page 25 VENTING Table 4.5: Vent Capacities for Type B Combined Venting with Type B or Single Wall Metal Connectors Vent Connector Minimum Inside Diameter Using Type B Vent Connectors Vent GM-e-05 GM-e-06 GM-05 GM-06 GM-07 GM-08 (228 MBH Input) (285 MBH Input) (342 MBH Input) (399 MBH Input) (214.5 MBH Input)
  • Page 26 VENTING THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 27: Piping

    PIPING 5. PIPING A. PIPING ISSUES when set to manual reset. If a separate system low water cut-off is added, install in control header as 1. FLEX-HEAT Manifolds shown in Figure 5.1. ® a) When using or specifying these manifolds please 4.
  • Page 28 PIPING Figure 5.2: Optional FLEX-HEAT Manifolds ®...

  • Page 29: Air Elimination

    PIPING B. AIR ELIMINATION c) By locating the pump suction at the expansion tank, then, the pump discharge pressure adds to the 1. Always use an in-line air separator to accelerate air system pressure. removal from the system. Even when boilers are d) Air is more soluble at high pressure and low equipped with internal separation, the in-line air temperature, so pressurizing the system with the...
  • Page 30 PIPING SUPPLY SYSTEM VENT SENSOR CIRCULATOR GAUGE FLEX-HEAT MANIFOLD SUPPLY HIGH LWCO OPT. LIMIT LWCO RETURN FLOW BALANCING CHECK VALVE VALVE FILL VALVE CIRCULATOR GAUGE EXPANSION DRAIN TANK MODULE MODULE MODULE BOILER PIPING Figure 5.4: Boiler Piping Primary-Secondary Pumping Using Flex-Heat Manifolds, Systems ®...

  • Page 31: Preventing Condensation

    PIPING SUPPLY 12 Max " SENSOR VENT RETURN GAUGE SUPPLY Return Water Temperature Syste m System OPT. Always Above 130°F HIGH LWCO SEPARATOR Secondary Pump P ump LWCO LIMIT Secondary Manifolds Manifolds Make-Up Line With Back-Flow Prevention and Auto Fill Valve FLEX-HEAT T Circulator Kits FLEX-HEA...
  • Page 32 PIPING 12 Max " SUPPLY SUPPLY SENSOR RETURN GAUGE VENT Return Water Temperature System OPT. Always Below 130°F and HIGH LWCO SEPARATOR Pump LWCO Relatively Constant LIMIT (Such as a Heat Pump System) Make-Up Line With Back-Flow Boiler Loop Prevention and Install Manual 3-Way Pump Auto Fill Valve...

  • Page 33: Commercial System Types

    PIPING 12 Max " SUPPLY GAUGE SENSOR VENT SUPPLY RETURN Install Tempering Valves as Shown Return Water Temperature Limit on 3” Valve is 130 gpm Varies, Often Below 130°F System OPT. HIGH LWCO SEPARATOR For a 10-foot Pressure Drop Due to Outdoor Reset or Pump LWCO LIMIT...
  • Page 34 PIPING Figure 5.10: Two-Pipe System with Zone Valves Figure 5.12: Two-Pipe System with Zone Valves for Space Heating/Zone Circulator for DHW The primary loop is the loop containing the system pump. The boilers can either be directly in the primary loop or piped in secondary circuits (preferred method).

  • Page 35: Determining Pressure Drop

    PIPING Figure 5.13: Primary/Secondary Piping Figure 5.14: Primary/Secondary Piping Cross-over Design Series Loop (One-Pipe) E. DETERMINING PRESSURE DROP Total Head Loss = x ∆H feet 1. The pressure drop through a single Series GM™ boiler 100 is 9” W.C. @ 32.7 gpm (design flow for GM08 @ 20°F drop).
  • Page 36 PIPING Table 5.1: Calculating Pressure Drops for Steel and Copper Pipe, Head Loss = (TEL/100) x a x (gpm) Table 5.2: Equivalent Lengths for Typical Pipe Fittings, Feet...

  • Page 37: Pump Selection

    PIPING Figure 5.16: Typical Pump Curve F. PUMP SELECTION Head = Head 1. You can select a pump by using only the system design point (maximum flow and pressure drop). However, you should always select a pump which can operate at plus or minus 25% from the selection point.

  • Page 38: Freeze Protection Issues

    PIPING G. FREEZE PROTECTION ISSUES Table 5.4 1. Use only inhibited propylene glycol solutions up to 50% by volume with water. a) Have the system mixture checked annually to make sure the inhibitor level is adequate. b) Glycol without the inhibitor is very corrosive. 2.
  • Page 39 PIPING Table 5.5: Diaphragm Expansion Tank...
  • Page 40 PIPING Figure 5.17: Typical Diaphragm Tank...
  • Page 41 PIPING Table 5.6: Compression Tank...
  • Page 42 PIPING Figure 5.18: Typical Compression Tank – Note Use of Tank Fitting – See Table for Sizing...

  • Page 43: Peerless ® Partner

    2. Select a circulator(s) that will supply the flow rate required for the needed first hour capacity. See Figure B. PIPING 2.6 in Section 2 for the first hour ratings of the Peerless ® Partner indirect-fired water heaters.
  • Page 44 PEERLESS PARTNER DHW SYSTEMS ® ® Figure 6.2: Boiler Modules Dedicated to DHW Heating Only – Primary-Secondary Piping Using FLEX-HEAT Circulators ® DHW Return Water Temperatures Above 130°F...

  • Page 45: Gas Piping

    GAS PIPING 7. GAS PIPING A. CODES & STANDARDS 1. Size and install the piping in accordance with the National Fuel Gas Code, ANSI Z223.1, NFPA 54 and all applicable local and state codes. 2. The sizing information and guidelines given in this Guide are based on the National Fuel Gas Code, 1996.

  • Page 46: Support The Gas Piping

    GAS PIPING C. SUPPORT THE GAS PIPING 3. Gas Piping Drop to Modules a) Select the size of the piping drop to the modules 1. Follow the National Fuel Gas Code and local from the Capacity Table as well. requirements for support of the gas piping. b) Do not size the drop the same as the module 2.
  • Page 47 GAS PIPING Table 7.3: Equivalent Length (feet) for Common Gas Train Components L = equivalent length in feet of Schedule 40 (standard weight) straight pipe Pipe Pipe Valves (screwed, flanged, or welded) Screwed fittings Size I.D. welding close elbows and (In.) (In.) Swing...

  • Page 48: Gas Pipe Sizing Example

    GAS PIPING Figure 7.2: Gas Pipe Sizing Example E. GAS PIPE SIZING EXAMPLE 2. Use the Tables to Size Piping a) Estimate TEL (total equivalent length) as 1.5 times 1. Figure 7.2 is a schematic piping diagram of (6) Natural the running length, so TEL=1.5 x 98.5 =147.8 feet Gas GM-08 modules on 32”...

  • Page 49: Electrical Wiring & Controls

    Note that the tekmar controls are boiler controllers. For information on zone controllers, contact tekmar regarding their 300 series controls. 2. For optimum domestic water control, tekmar recommends inserting the tekmar DWH sensor in the Peerless Partner limit well. Mount the Honeywell ® ®...
  • Page 50 ELECTRICAL WIRING & CONTROLS tekmar 263 Control ® The 263 control allows for the control of two boilers based on outdoor air temperature, control for indirect Domestic Hot Water (DHW) generation and a Setpoint load. Soft Stop Rotate Setback DHW Sensor Advanced Off...
  • Page 51 ELECTRICAL WIRING & CONTROLS tekmar 274 Control ® The 274 control allows for the control of four boilers based on outdoor air temperature, control for indirect Domestic Hot Water (DHW) generation and a Setpoint load. Setback Rotate Pump Sequencer Fixed Last Off...
  • Page 52 ELECTRICAL WIRING & CONTROLS tekmar 268 Control ® The 268 control allows for the control of eight boilers based on outdoor air temperature, control for indirect Domestic Hot Water (DHW) generation (or ninth boiler), and a Setpoint load. External Input Alert Rotate Fixed Last...
  • Page 53 NOTES...
  • Page 54 Series ™ Boilers Design & Application Guide PB HEAT, LLC 131 S. CHURCH STREET • BALLY, PA 19503 PRICE: $20.00 GM8022 R3 (02/21-50) ©2021 PB Heat, LLC. All rights reserved. Printed in U.S.A.

This manual is also suitable for:

Flex-heat gm-e-05Flex-heat gm-e-06Flex-heat gm-07Flex-heat gm-08

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