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PEERLESS 63 Series Installation, Operation & Maintenance Manual

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Series
!
WARNING
Attention Installer - Affix
these instructions adjacent
to boiler. Provide model
number and serial number
when seeking information and
support.
Attention Building Owner -
Retain these instructions for
future reference. Contact a
qualified installer, service
agency or gas supplier for all
issues and support.
• Steam Boiler
• Cast Iron
• Chimney Vent
• Gas Fired
63-x
Gas
Boilers
63-x-03 63-x-04 63-x-05 63-x-06
Installation,Operation
& Maintenance Manual
Read these instructions carefully before installing.
This boiler must only be installed, serviced, or repaired by a qualified
installer, service agency or gas supplier. Improper installation,
adjustment, alteration, service, or maintenance can cause severe
personal injury, death, or substantial property damage. For assistance
or additional information, consult a qualified installer, service agency
or gas supplier.
!
WARNING

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Summary of Contents for PEERLESS 63 Series

  • Page 1 Series 63-x Boilers 63-x-03 63-x-04 63-x-05 63-x-06 WARNING Attention Installer - Affix these instructions adjacent to boiler. Provide model number and serial number when seeking information and support. Attention Building Owner - Retain these instructions for future reference. Contact a qualified installer, service agency or gas supplier for all issues and support.

  • Page 2: Table Of Contents

    Installation, Operating & Service Instructions Series 63-x Manual Contents Page 1. Qualified Installer, Service Agency or Gas Supplier Read Before Proceeding ......3 2.

  • Page 3: Qualified Installer, Service Agency Or Gas Supplier

    Series 63-x Installation, Operating & Service Instructions Qualified Installer, Service Agency or Gas Supplier Read Before Proceeding DANGER Explosion Hazard. DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in building.

  • Page 4: User/Homeowner Read Before Proceeding

    Installation, Operating & Service Instructions Series 63-x User/Homeowner Read Before Proceeding WARNING CAUTION Asphyxiation Hazard. Fire Hazard. Burn Hazard. Keep children and pets away from hot surfaces • A qualified installer, service agency or gas of the boiler including boiler piping, vent piping, supplier should annually inspect boiler.

  • Page 5: Specifications

    Series 63-x Installation, Operating & Service Instructions Specifications Table 3-1: Ratings Net AHRI Rating Steamable Model Input Output Water Volume AFUE (%) Water Volume Steam Steam Number (MBH) (MBH) (gal) (gal) (square foot) (MBH) 63-x-03 82.0 0.54 63-x-04 82.0 0.64 63-x-05 82.0 11.2...
  • Page 6 Installation, Operating & Service Instructions Series 63-x Specifications (continued) TT8131R3 112387-03 - 1/25...
  • Page 7 Series 63-x Installation, Operating & Service Instructions Specifications (continued) Intermediate Section Left End Section Right End Section Figure 3-5: Section Tappings Table 3-6: Trim and Control Installation in Section Tappings Size Tapping Function (NPT) Supply Return and/or Bushed Down for Drain Skimming Connection (6in.

  • Page 8: Locating Boiler

    Installation, Operating & Service Instructions Series 63-x Locating Boiler NOTICE: Flue side corrosion caused by Code Requirements contaminants is not covered by warranty. 1. Installations must conform to requirements of authority having jurisdiction or, in the absence of such requirements, to National Fuel Table 4-1: Corrosive Combustion Contaminants Gas Code, ANSI Z223.1/NFPA 54.
  • Page 9 Series 63-x Installation, Operating & Service Instructions Locating Boiler (continued) Clearances 1. Provide clearances between boiler jacket and combustible material in accordance with authority having jurisdiction. Minimum clearances to combustible material shown in Figure 4-2. 2. Recommend 24 in. service clearance from left side, right side and front.
  • Page 10 Installation, Operating & Service Instructions Series 63-x Locating Boiler (continued) Before Removing Existing Boiler 4. Place in operation appliance being inspected. Follow Operating Instructions. See Figure 10- Take pictures and measure and/or mark existing 1. Adjust thermo stat so appliance will operate steam and condensate return piping to ensure continuously.

  • Page 11: Preparing Boiler

    Series 63-x Installation, Operating & Service Instructions Preparing Boiler Unpack Boiler Remove boiler and miscellaneous parts carton from outer shipping carton. DANGER Use precautions and appropriate rigging apparatus when moving heavy objects. Boiler Pressure Gauge Misc. Parts Carton Relief Valve Vent Damper Drain Valve Rear Air Dam...

  • Page 12: Venting

    Installation, Operating & Service Instructions Series 63-x Venting General C. Size chimney and vent connector in accordance with National Fuel Gas Code, WARNING ANSI Z223.1/NFPA 54. Asphyxiation Hazard. 3. Do not connect vent of this appliance into any • Failure to vent this boiler in accordance with portion of a mechanical vent system operating these instructions could cause products of under positive pressure.
  • Page 13 Series 63-x Installation, Operating & Service Instructions Venting (continued) 11. Install vent damper. 12. Install rear air dam. OPEN VENT DAMPER CARTON and remove Hang air dam on screws located at back of Installation Instructions. READ INSTALLATION boiler. See Figure 6-1 for location. INSTRUCTIONS THOROUGHLY before proceeding.

  • Page 14: Steam Piping

    Installation, Operating & Service Instructions Series 63-x Steam Piping WARNING • Do not use softened water in steam boilers. Accelerated boiler corrosion will result. Tie in fresh water supply to boiler upstream of a water softener. • Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure.
  • Page 15 Series 63-x Installation, Operating & Service Instructions Steam Piping (continued) WRONG Take-off bullheaded into two mains. WRONG WRONG Take-off Header bullheaded between risers. into take-off and equalizer. Figure 7-1: Common Near Boiler Piping Mistakes TT8131R3 112387-03 - 1/25...
  • Page 16 Installation, Operating & Service Instructions Series 63-x Steam Piping (continued) Near Boiler Piping 4. Remove parts carton from boiler crate. 5. Install relief valve (spindle must be in vertical 1. Evaluate existing steam system. position) into tapping on boiler right side using Single most important factor in determining nipple and elbow supplied.
  • Page 17 Series 63-x Installation, Operating & Service Instructions Steam Piping (continued) 63-x-03 thru 63-x-04 63-x-05 thru 63-x-06 (1) 2 in. (2) 2 in. 2 in. 3 in. 1-1/2 in. 2 in. 1-1/4 in. 1-1/2 in. Two 2 inch risers required on 5 & 6 section. First or only riser will be connected to pipe B with 90o elbow.

  • Page 18: Gas Piping

    Installation, Operating & Service Instructions Series 63-x Gas Piping 1. Size gas piping. Design system to provide WARNING adequate gas supply to boiler. Consider these Explosion Hazard. factors: • Failure to properly pipe gas supply to boiler A. Allowable pressure drop from point of delivery could cause improper operation or leaks of to boiler.

  • Page 19: Electrical

    Series 63-x Installation, Operating & Service Instructions Gas Piping (continued) Ignitor/Sensor Manifold Assembly Pilot Burner Combination Gas Valve Pilot Tubing Observation Port Figure 8-3: Gas Manifold and Control Assembly Electrical WARNING DANGER Electrical Shock Hazard. Wiring errors can Electrical Shock Hazard. cause improper or dangerous operation.
  • Page 20 Installation, Operating & Service Instructions Series 63-x Electrical (continued) TT8131R3 112387-03 - 1/25...
  • Page 21 Series 63-x Installation, Operating & Service Instructions Electrical (continued) TT8131R3 112387-03 - 1/25...

  • Page 22: System Start-Up And Checkout

    Installation, Operating & Service Instructions Series 63-x System Start-up and Checkout DANGER Explosion Hazard. Do not use matches, candles, open flames or other ignition source to check for leaks. Failure to comply could result in severe personal injury, death or substantial property damage. WARNING •...
  • Page 23 Series 63-x Installation, Operating & Service Instructions System Start-up and Checkout (continued) Figure 10-1: Operating Instructions TT8131R3 112387-03 - 1/25...
  • Page 24 Installation, Operating & Service Instructions Series 63-x System Start-up and Checkout (continued) Top Panels Step 1 'Up' Front Removable Door Rear Panel Step 2 Step 3 'Forward' 'Down' Lower Front Tie Bar Figure 10-2: Front Door Removal Pilot Burner Pilot Tubing Ignitor/Sensor Pilot Ground Ignition Cable...
  • Page 25 Series 63-x Installation, Operating & Service Instructions System Start-up and Checkout (continued) Table 10-4: Green LED Status Codes Green LED Flash Indicates Next System Action Recommended Service Action Code No “Call for Heat” None Flash Fast Power up - internal check None Normal startup - ignition sequence Heartbeat...
  • Page 26 Installation, Operating & Service Instructions Series 63-x System Start-up and Checkout (continued) Incandescent Outer Mantle Blue with occasional orange flashing Outer Cone Darker transparent blue Inner Cone Sharply outlined with bright light blue Flame Retention Inner Cone Partially lifted from burner Figure 10-5: Main Burner Flame TT8131R3 112387-03 - 1/25...
  • Page 27 Series 63-x Installation, Operating & Service Instructions System Start-up and Checkout (continued) WARNING Failure to follow the following procedure exactly could result in over firing of boiler and a carbon monoxide hazard. 23. Verify auto reset LWCO operation while boiler is 18.
  • Page 28 Installation, Operating & Service Instructions Series 63-x System Start-up and Checkout (continued) Figure 10-6: Combination Gas Valve Detail TT8131R3 112387-03 - 1/25...

  • Page 29: Operation

    Series 63-x Installation, Operating & Service Instructions Operation Ignition Sequence of Operation Control Operation 1. 24 volts is immediately applied to auto reset LWCO – Interrupts burner operation when water in LWCO when boiler is energized. Vent damper boiler drops below cut-off level. Power is restored will close as long as auto reset LWCO is once water in boiler is above cut-off level.

  • Page 30: Before Leaving Jobsite

    Installation, Operating & Service Instructions Series 63-x Before Leaving Jobsite Before Leaving Jobsite: Checked CO alarm installed  Boiler filled with water to normal water line  Performed gas leak test  Checked pilot burner flame  Checked main burner flames ...

  • Page 31: Service And Maintenance

    Series 63-x Installation, Operating & Service Instructions Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
  • Page 32 Installation, Operating & Service Instructions Series 63-x Service and Maintenance (continued) WARNING This boiler should be serviced by a qualified installer, service agency or gas supplier. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. •...
  • Page 33 Series 63-x Installation, Operating & Service Instructions Service and Maintenance (continued) 4. Clean Main Burners and Combustion Chamber. B. Replace gauge if needed. A. To remove manifold/burner assembly for 7. Operate relief valve cleaning or repairs: A. When manually operating relief valve, water i.
  • Page 34 Installation, Operating & Service Instructions Series 63-x Service and Maintenance (continued) CAUTION IF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD MORE WATER THAN INDICATED BELOW. CONSULT A QUALIFIED INSTALLER OR SERVICE AGENCY TO CHECK YOUR SYSTEM FOR LEAKS. Gallons Boiler Model Number Gallons per Year Month...

  • Page 35: How It Works

    Series 63-x Installation, Operating & Service Instructions How It Works See Figure 14-1. When vent damper is opened completely, control module opens pilot valve and activates ignition spark. Ignition Module Control module will sense pilot flame. Once pilot flame is established, control module opens gas valve and main burners will ignite.
  • Page 36 Installation, Operating & Service Instructions Series 63-x How It Works (continued) Figure 14-1: Controls Location TT8131R3 112387-03 - 1/25...

  • Page 37: Troubleshooting

    Series 63-x Installation, Operating & Service Instructions Troubleshooting 1. Troubleshooting should be completed by a qualified installer, service agency or gas supplier. 2. Before seeking technical assistance, the qualified installer, service agency or gas supplier should have an electrical meter and gas pressure gauge available for use.
  • Page 38 Installation, Operating & Service Instructions Series 63-x Troubleshooting (continued) Figure 15-1: Troubleshooting Flow Diagram TT8131R3 112387-03 - 1/25...
  • Page 39 Series 63-x Installation, Operating & Service Instructions Troubleshooting (continued) Figure 15-1: Troubleshooting Flow Diagram (continued from previous page) TT8131R3 112387-03 - 1/25...

  • Page 40: Service Parts

    Installation, Operating & Service Instructions Series 63-x Service Parts Service parts are available from your local PB Heat, LLC distributor or from Parts To Your Door at 1 (610) 916-5380 (www.partstoyourdoor.com). Part Number [Quantity] Key No. Description 63-x-03 63-x-04 63-x-05 63-x-06 Block Assembly 63X001 [1]...
  • Page 41 Series 63-x Installation, Operating & Service Instructions Service Parts (continued) Part Number [Quantity] Key No. Description 63-x-03 63-x-04 63-x-05 63-x-06 Base Assembly 63X015 [1] 63X016 [1] 63X017 [1] 63X018 [1] Base Gasket 1/2 in. x 2-1/4 in. x 10 ft. 63X019 TT8131R3 112387-03 - 1/25...
  • Page 42 Installation, Operating & Service Instructions Series 63-x Service Parts (continued) Part Number [Quantity] Key No. Description 63-x-03 63-x-04 63-x-05 63-x-06 Gas Train Assembly 63X020 [1] 63X021 [1] 63X022 [1] 63X023 [1] 63X024 [1] 63X025 [1] Gas Valve VR8204P2335, 1/2 in. x 1/2 in. VR8304P4496, 3/4 in.
  • Page 43 Series 63-x Installation, Operating & Service Instructions Service Parts (continued) Part Number [Quantity] Key No. Description 63-x-03 63-x-04 63-x-05 63-x-06 Jacket Carton 63X027 [1] 63X028 [1] 63X029 [1] 63X030 [1] TT8131R3 112387-03 - 1/25...
  • Page 44 Installation, Operating & Service Instructions Series 63-x Service Parts (continued) Part Number [Quantity] Key No. Description 63-x-03 63-x-04 63-x-05 63-x-06 Ignition Control Module, S8610M 63X031 [1] 24 VAC, Transformer, 40VA 63X032 [1] Relay, R8222K1000, 24V 63X033 [1] Part Number [Quantity] Key No.
  • Page 45 Series 63-x Installation, Operating & Service Instructions Service Parts (continued) Wiring Part Number [Quantity] Key No. Description 63-x-03 63-x-04 63-x-05 63-x-06 Harness S8610 63X044 [1] Pilot Ground Wire 63X045 [1] Ignition Wire 63X046 [1] Accessories Part Number [Quantity] Key No. Description 63-x-03 63-x-04...

  • Page 46: Appendix A Steam Boiler Skimming

    Installation, Operating & Service Instructions Series 63-x Appendix A Steam Boiler Skimming Steam Boiler Skimming 5. Install a full-port ball valve on the skim tapping pipe nipple provided. This valve is a "just-in-case" ALL STEAM BOILERS REQUIRE PROPER valve. You will not close this after the skimming SKIMMING.

  • Page 47: Appendix B Indirect Water Heater

    Series 63-x Installation, Operating & Service Instructions Appendix B Indirect Water Heater In this type of system, hot water is drawn from 4. Boiler Limit Control - Use a SPST break-on-rise below boiler's NWL and passed through IWH's heat temperature limit control such as the Honeywell exchanger.
  • Page 48 Installation, Operating & Service Instructions Series 63-x Appendix B Indirect Water Heater (continued) 6. Figure B-2 shows field wiring for an indirect If there is a call for space heat, heating water heater. A Honeywell R8845U or thermostat will make boiler “T”-“T” circuit equivalent DPST relay and transformer is and boiler will fire without regard to status required.

  • Page 49: Service Record

    Series 63-x Installation, Operating & Service Instructions SERVICE RECORD DATE SERVICE PERFORMED TT8131R3 112387-03 - 1/25...
  • Page 50 Installation, Operating & Service Instructions Series 63-x SERVICE RECORD DATE SERVICE PERFORMED TT8131R3 112387-03 - 1/25...
  • Page 51 Series 63-x Installation, Operating & Service Instructions SERVICE RECORD DATE SERVICE PERFORMED TT8131R3 112387-03 - 1/25...
  • Page 52 Installation, Operating & Service Instructions Series 63-x Series 63-x Boilers 63-x-03 63-x-04 63-x-05 63-x-06 Installation, Operation & Maintenance Manual TO THE INSTALLER: This manual is the property of the owner and must be affixed near the boiler for future reference. TO THE OWNER: This boiler should be inspected annually by a Qualified Service Agency.

This manual is also suitable for:

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