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PEERLESS SERIES GM Installation, Operation & Maintenance Manual

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GM
Boilers
Installation,
Operation
b
Maintenance
Manual
PEEI_LESS*
CAST IRON BOILERS

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Summary of Contents for PEERLESS SERIES GM

  • Page 1 Boilers Installation, Operation Maintenance Manual PEEI_LESS* CAST IRON BOILERS...
  • Page 2 I_olt_ ¢l'.'_i(l('tll[(ll _ttl(I conmlt,r(itd boik'rs, l)l(,(t_, cott._;tllt l'('('rl('ss l l_'(tt('r" (?OtlllXttly.Jbr (.oml)l(,t(, [t,ttttett_ll itl ()t'_llttltotL Peerless Heater Company • 231 North Walnut Street * Boyertown, 19512-I021 • 610-367-2153 * www.peerless-heater.com FAB GM R2 {7'02 5M) Pr,ltl.0 Irl U S A...
  • Page 3 B. CSD PART CF REQUIREMENTS ..USING THIS MANUAL C. CSD PART CW REQUIREMENTS ..A. INSTALLATION SEQUENCE ..... D. CSD MODULAR AND MULTIPLE BOILER B. SPECIAL ATTENTION BOXES ... REQUIREMENTS ....E. CSD PART CE ELECTRICAL PREINSTALLATION REQUIREMENTS ....A.
  • Page 4 These categories damage. mean, in the judgment of the Peerless Heater Company: 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.
  • Page 5 Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, ASME CSD-I. Carefully read these instTuctions before beginning work. Understand all aspects of the installation. Contact your Peerless Heater Company sales representative or customer service for help in answering questions.
  • Page 6 'qll 4. Unusually Tight Construction: For equipment located in buildings of unusually tight 12" max construction as defined on the previous page, provide air for combustion and ventilation using the methods described in 5a or 5b below. TWO AIR OPENINGS: 3"...
  • Page 7 To obtain copies of the Water Installation Survey. contact your Peerless representative. I:;l! [s,]I :{e,L I JI_,_llie] ;_ The Series GM boiler is not equipped with a circulator or a means to control circulator operation. Provide...
  • Page 8 --m__ Provide a sound, level foundation. Locate boiler as 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. end of the boiler base.
  • Page 9 [_r_ll[:[;| ['.,ll;,11_[€I r =q_im3 [_s]_h II;[*]l!_.'] Design piping and size circulator(s) to suit the system. Refer to TEMPERATURE Hydronics Institute Installation Guide 2000 and the Peerless F1-1/2" PRESSURE Water Installation Survey for guidance. GAGE I:{e]lg:l:t _.'llJ'.J',_l_'l:lL_lm];|:lllJ:|k_ 1/2" X 8"...
  • Page 10 130°F entering the boiler. For more information on bypass piping, consult the Peerless Water Installation Survey. If this boiler and dislTibution system is used in conjunction with a refrigeration system, pipe the...
  • Page 11 1. See Figures i0 and 11 for basic zoned system layouts. Circulators may be installed in either supply or return piping. Refer to Peerless Water Installation Survey for additional information. Run each zone pipe down then up to zone to prevent air accumulation in piping•...
  • Page 12 180°E 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. SUPPLY SYSTErvl ZONE CI RCU LA TORS[}_8.._...
  • Page 13 W! ID);_l_ilil[oIo]B VENT SAFETY The boiler is equipped with a draft hood designed to: a. provide for the ready escape of flue gases from the boiler in the event of no draft. SHUTOFF SCREWSMETALSHEET SWITCH_x b. prevent a backdraft from entering the boiler. VENT SAFETY control stack draft during operation.
  • Page 14 [e,lqkV4:lL'hlii : ,]l:Jh,_felF_qL'_le] [_:ilLVJh'q=h, Install vent piping in accordance with Part 7, Venting of Equipment, National Fuel Gas Code, ANSI Do not use one vent damper to control two or more Z223.1/NFPA 54 or applicable provisions of the local heating appliances. See Figure 14.
  • Page 15 AUTOMATIC /- VENT SLOPE VENT /CHIMNEY A MINIMUM DAMPER 7 OF 1/4" FOOT _ O'CLOCK 1 O'CLOCK POSITION_ , /-- POSITION VJJ/// s DA',,'PER HEAT ..-.'_ OPERATOR NENN ZONEJ __O0_ECONDENSATION O'CLOCK J O'CLOCK POSITION POSITION DO NOT MOUNT DAMPER OPERATOR IN SHADED REGION SECTION A--A...
  • Page 16 Size and install the gas supply piping to provide a 4. Connection of boiler to the gas piping system may 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 of...
  • Page 17 Disconnect the boiler and its individual shut-off valve Ec_'UIP'dk N from the gas supply piping system during any FiI,' - pressure testing of that system at test pressure in excess of 1/2 psig (3.5 kPa). Isolate the boiler from the gas supply piping system _])IN by closing its individual service valve during any pressure testing of the gas supply piping system at...
  • Page 18 E.']I I:lIF--[,._ ;IC,.I_g This unit when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the current edition of the National Electrical Code, ANSI/NFPA 70. ITl_J I ;] Ib,_ [€ Figure 25 shows typical wiring for one or more circulators.
  • Page 19 [.11 [ =(M = [q,(;( [_f-'1 ml('4_i_rmi' THERMOSTAT OR OPERATING FROM CONTROL TO JUNCTION 115V 60HZ PINK POWER SUPPLY GREY W_RES. Figure 20: Taco Zoning Circulator Wiring I f:J v' E,QIZ FO HAIN DISCONNECT S_'vl ICH A • /, TO TRAXSFORM P B[ A/,_ ,',!;F WHFF...
  • Page 20 [_iR =iai=[_ d;t [,@',_'_i! [(_] VENT SAFETy_CGY _____ DAMPER PLUG VENT DAMPER SHUTOF_yS_TC HARNESS (WHEN USED) TRANSFORMER 120VAC _1 _ o I -i (HOT) =-R ..; 'I_'_DAMPER STUB HARNESS LIMIT SERVICE FUSED S_TCH DISCONNECT , ,' TOMAN f_c'Nwww_ JUNC TION BOX----.._ # "...
  • Page 21 [.II _ [r4"a_al VENT SAFETY OR VENT DAMPER S_TC HARNESS (HOT) fRANSFORMER ltSVAC S_TCH DISCONNECT SER_CE FUSED TO MAIN I15V-60HZ DISCONNECT S_TCH 24VAC OPERATING CONTROl. VENT FLAME SAFETY T FF OPERATING ROLLOUT UMIT S_U I TOH CONTROL SWITCH SUPPLIED INSTALLER DAMPER STUB HARNESS...
  • Page 22 START TO APPLIANCE I APPLY24 CALLS FOR HEAT L THERMOSTAT FIVE-MINUTE DELAY RETRY • WAIT FOR FLAME SIGNAL TO DISAPPEAR I _LA_c_S'_A'_NO '._YES • PILOT VALVE/IGNITER REMAIN OFF INTERNAL CHECK OKAY? [ _YES TRIAL • PILOT VALVE OPENS IGNITION • IGNITER POWERED [ uo "1...
  • Page 23 ZONE ZONE THERMOSTAT THERMOSTAT 24V O II 5V/6OHZ TO MAIN DISCONNECT LI (HOT) SWITCH FIELD INSTALLED TO BOILER JUNCTION PINK & GREY _RES R845A RELAY ZONE ZONE 2 CIRCULATOR CIRCULATOR L_ND LINE VOLTAGE LOW VOLTAGE Figure 25: Circulator Wiring 115V/60HZ --L1 (HOT) TO MAIN...
  • Page 24 × 1 be ordered by calling 1-800-THE-ASME. & I × 3/_. :t! [e,_",le] I bV_,q;tl[el: I:l::[eleJl;t:;l_VAl::iL'qilK The Series GM is CSA certified to ANSI Z21.13 and as such meets all CSD-I Part CF requirements combustion side controls for units under 400,000 btuh input.
  • Page 25 [r_ _-.t,_[o_e_ll_l::[olUJld=l,'_l=l;kn_ [_]_ Note the following elec'aical requirements per CSD-I Section CE-II0(a): "A disconnecting means capable of being locked in the open position shall be installed at an accessible location at the boiler so that the boiler can be disconnected from all sources of potential.
  • Page 26 8. Connect a manometer to 1/8 NPT tapping provided V±_o] _vfl _ IH _il IIIL'I [e,.Im iI-"I_ IIL_ [ ,."_1 ir±lIIIIV_I€[o] i on the manifold. See Figures 31 and 32. Confirm that all water, gas and electridty are 9. Confirm that the gas supply pressure to the boiler is turned off.
  • Page 27 MAIN r GAS BURNER /- PILOT VALVE MANIFOLD PILOT TUBING SECTION Figure 31: Gas, Valve, Manifold and Burner Assembly, GM-05/06 (Standing Pilot shown, Intermittent ignition similar) MAIN BURNER VALVE PILOT PILOT TUBING SECTION L__ GAS MANIFOLD TEST TAPPING ORIFICE SPUD Figure 32: Gas.
  • Page 28 FOR YOUR SAFETY READ BEFORE OPERATING causing property damage, personal injury, or loss of life I WARNING: If you do not follow these instructions exactly, a fire or explosion may result This appliance is equipped with an ignition device • If you cannot reach your gas supplier, call the fire which automatically lights the pilot, Do not try to department light the pilot by hand.
  • Page 29 FOR YOUR SAFETY READ BEFORE LIGHTING I WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which must be lighted •...
  • Page 30 Check input by use of the following formula the supply water falls below the preset temperature. (Peerless suggests reading meter for 2 Cu.Ft.): BTU/Hr. Input-3600 x F x H LOW WATER CUT-OFF (FOR GRAVITY SYSTEMS...
  • Page 31 "PILOT". The main burner should go out and the pilot should remain lit. Complete the Warranty Card and submit it to Peerless Heater Company. ii) Extinguish the pilot flame. Pilot gas flow should stop within 2-1/2 minutes. Complete Hang the Installation, Operation and Maintenance...
  • Page 32 When servicing or replacing items that communicate with the boiler water, be certain that: • There is no pressure on the boiler. Intheevent ofashut-down caused byapilotoutage, • The boiler is not hot. action o fthevent s afely s hutoff switch o rflame rollout •...
  • Page 33 Table 4: Boiler Troubleshooting Guide 1 Check line voltage wiring and fuses. Burners not functioning 1 No power. 2 Limit (aquastat) not working 2. Check wiring and contacts, relay, temperature setting. Clean and adjust as necessary 3. Replace switch. Locate cause and correct 3 Flame rollout switch open.
  • Page 34 INSET A END VIEW OF 24 VOLT CONTROL THERMOSTAT HARNESS START CONNECTOR • ASSURE GAS VALVE SWITCH VOLTS IN "ON" POSITION • DISCONNECT SYSTEM CONTROL 24 VOLT 24 VOLT HARNESS COMMO I • TURN OFF GAS SUPPLY • SET THERMOSTAT TO CALL VOLTS FOR HEAT...
  • Page 35 Smell around the appliance area for gas. If you smell gas, follow the procedure listed in the Lighting/Operating Instructions in Section 8. Disconnect this boiler from the gas supply piping during any pressure testing of the gas system. [4vA_l _ _ [4 li'mLIivli i" i :[o) IH _ :| I LII_.'_ _ Check pipes adjacent to cold walls or in unheated spaces.
  • Page 36 • ,OLJT[R (ON[ DARK _lllE When servicing or replacing components, absolutely certain that the following conditions are met: -, - • Water, gas and electricity are off. d n _T • The boiler is at room temperature. " " ,h'l,* _ IE,_ [Z _-"...
  • Page 37 1 I/2 RELIEF VALVE INLET Figure 41: Boiler Views Table 5: Series GM Boiler Dimensions _']JlI,II ;_.'][¢J_ n ;[O) III :1:g H I_ I _1_. [,.I [e)_[, Jacket Left of Jacket Front of Jacket Vent Boiler to Centerline of : to Centerline...
  • Page 38 Repair parts are available from your installer or by contacting Peerless Heater Company, Boyertown, PA 19512-1021. Use the figures and tables on pages 35-39 to assist in ordering parts. Note: Remember to include boiler model number and serial number when ordering parts.
  • Page 39 Orifice Spud, #40 Natural Gas, 0-2000 ft. 7157 7157 7157 7157 elevation (specify qty)* *For elevations over 2,000 feet above sea level contact Peerless Heater Company. Figure 43: Gas Manifold, Orifice Spuds, and Main Burners Natural Gas Natural Gas 51688...
  • Page 40 " EP_ I;I =I_±II;I I_7_._ ;la_"] [_!}1 i Honeywell SV9601M4167 Gas Valve Natural Gas i 51683 Honeywell Q3480BI041 Pilot ! Natural Gas 51295 Figure 45: Gas Valve and Pilot, Intermittent Ignition Block 91042 91043 Flue Baffle I per flueway Flue Collector 90975 i 90976 , 90977...
  • Page 41 / _I2G:: Jacket Assembly , Complete jacket* with insulation and screws *Complete Jacket Consists of: Left Side Panel Right Side Panel Rear Panel Inner Front Panel I Removable Front Panel Lower Front Panel Top Panel Figure Jacket...
  • Page 42 \ 16 3/4" Drain Valve*, Conbraco 31-602-04 50517 50517 ! 50517 50517 Flame Rollout Safely Shutoff Switch 51587 51587 51587 51587 • ! Transformer, 4OVA, Johnson Y65T42-O _ 51040 i 51040 51040 51 40 Honeywell L4080B1261 Limit 50539 50539 i 50539 50539 Temperature-Pressure Gage (30, 50 psi safety relief valve)
  • Page 43 This boi/er shou/d inspected annual/y Qualified Service Agency, e®@ei HI Division ASME of gama PEERLESS CAST IRON BOILERS PEERLESS HEATER COMPANY 231 NORTH WALNUT STREET • BOYERTOWN, PA 19512 1021 ° PHONE 610-367-2153 vwvw.peerless-heater.com PREFERRED HEATING CHOICE @2002 Peerless Heater...

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