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PeerlessBoilers 63 Series Installation, Operation & Maintenance Manual

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Series
63/64
™
Gas
Boilers
I n s t a l l a t i o n ,
O p e r a t i o n &
M a i n t e n a n c e
M a n u a l

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Summary of Contents for PeerlessBoilers 63 Series

  • Page 1 Series 63/64 ™ Boilers I n s t a l l a t i o n , O p e r a t i o n & M a i n t e n a n c e M a n u a l...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 5. FUEL PIPING A. MANUAL ORGANIZATION ....1 A. INSTALLATION ..... . .17 B.

  • Page 3: Using This Manual

    USING THIS MANUAL USING THIS MANUAL DANGER A. INSTRUCTION MANUALS The Series 63/64™ Installation, Operation & Indicates a condition or hazard which will cause Maintenance Manual is divided into four basic sections: severe personal injury, death or major property damage. 1.

  • Page 4: Preinstallation

    PREINSTALLATION 1. PREINSTALLATION 2. For servicing the burners provide not less than 24" A. GENERAL from the front of the boiler. Series 63/64™ boilers are supplied knocked down for field 3. The remaining clearances should be 6" from all sides. assembly or completely assembled as packaged boilers.

  • Page 5: Air Combustion And Ventilation

    PREINSTALLATION a. Combining spaces on the same floor: E. AIR FOR COMBUSTION AND Provide two permanent openings communicating VENTILATION with additional spaces that have a minimum free area of 1 in per 1000 Btu/hr (22 cm per 1000 W) 1. Adequate combustion air and ventilation air must be of the total input rating of all gas fired equipment provided for this appliance in accordance with the but not less than 100 in...
  • Page 6 PREINSTALLATION 4. Outdoor Combustion Air: Outdoor combustion air is ii. Where communicating with the outdoors to be provided through one or two permanent through horizontal ducts, each opening shall openings. The minimum dimension of these air have a minimum free area of 1 in per 2000 openings is 3 inches (76 mm).
  • Page 7 PREINSTALLATION 5. Combination Indoor and Outdoor Combustion Air: If ii. Where the free area through a louver or grille the required volume of indoor air exceeds the is not known, it shall be assumed that wooden available indoor air volume, outdoor air openings or louvers will have 25% free area and metal ducts may be used to supplement the available louvers and grilles will have 75% free area.

  • Page 8: Installation Survey

    You can also use this survey to locate system problems which will have to be corrected. To obtain copies of these Surveys, contact your PB Heat representative or download them from PeerlessBoilers.com.

  • Page 9: Boiler Placement & Assembly

    BOILER PLACEMENT & ASSEMBLY 2. BOILER PLACEMENT & ASSEMBLY 5. Insert the push nipples into the nipple ports of one of A. PACKAGED BOILER the split block ends. Make sure the nipples are clean and free of burrs. Use a block of wood to protect the 1.

  • Page 10: Knockdown Boilers: Assembled Blocks

    BOILER PLACEMENT & ASSEMBLY 11. If the sections do not draw together using the torque 5. Slide the burner tray under the cast iron block specified above, the block must be separated and the assembly and attach to the end sections using the 1/4" nipples replaced before reassembly is attempted.

  • Page 11: Testing

    BOILER PLACEMENT & ASSEMBLY 4. Back Panel Jacket: Position the back jacket panel KNOCKDOWN BOILER: HYDROSTATIC inside the flange of the side jacket panels and attach it TESTING with six #10 x 1/2" sheet metal screws. See Figure 2.5. 1. Install the pressure gauge and drain valve in the right hand end section.
  • Page 12 BOILER PLACEMENT & ASSEMBLY 7. Attach the Draft Hood to the Flue Collector using #10 x 1/2" sheet metal screws provided. Refer to Figure 2.7. Figure 2.7: Draft Hood Attachment Figure 2.8: Label & Rating Plate Locations 8. Position the Top Jacket Panel so that the flanges 10.

  • Page 13: Venting

    VENTING 3. VENTING c. Do not connect the vent for this boiler into any A. CHIMNEY OR VENT vent system which operates with positive pressure. 1. Inspect the existing chimney or vent system. Make sure it is in good condition. Inspect chimney liner d.

  • Page 14: Boiler Removal From Common Venting System

    VENTING a. Orient the vent damper operator to facilitate Au moment de retirer une chaudière existante, il est connection of the vent damper harness to important de suivre les étapes suivantes pour chaque knockout on right side of boiler. appareil raccordé au système d’évacuation commun qui sont en service, alors que les autres appareils demeurant b.
  • Page 15 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 Mettre en service l’appareil à...

  • Page 16: Boiler Piping

    BOILER PIPING 4. BOILER PIPING 3. If the boiler is piped in a secondary loop separate A. WATER BOILER PIPING – SINGLE from the system expansion tank, the boiler circulator BOILER should be located on the return side of the boiler pumping away from the common piping.

  • Page 17: Water Boiler Piping - Multiple Boilers

    BOILER PIPING 3. Pipe the steam header a minimum of 24" above the B. WATER BOILER PIPING – MULTIPLE normal water line using swing joints to attach the BOILERS risers into the steam header. Refer to the PB Heat Water Installation Survey and Hydronics Institute Residential Hydronic Heating Use Threaded Fittings for Manifold Piping Installation Design Guide for guidance on multiple boiler...

  • Page 18: Steam Boiler Indirect Water Heater Piping

    BOILER PIPING 6. The use of a Hartford Loop in all installations is D. STEAM BOILER INDIRECT WATER recommended to ensure reliability of the system. A HEATER PIPING check is required on the pump discharge of all pumped return systems. 1.

  • Page 19: Fuel Piping

    FUEL PIPING 5. FUEL PIPING Table 5.1: Gas Input & Valve Inlet A. INSTALLATION Gas Input (CFH) Gas Valve Inlet (NPT) 1. Pipe gas to the boiler in accordance with local codes. Model Nat. Gas LP Gas Nat. Gat LP Gas In the absence of local regulations refer to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
  • Page 20 FUEL PIPING 5. Refer to table 5.4 for minimum supply pressure for 8. Typical gas train manifolds are illustrated in Figure the purpose of input adjustment. 5.2 through 5.4. Table 5.4: Minimum Supply Pressure Natural Gas Supply Pressure Model (in. Water) 63-03L 5.00 63-03...

  • Page 21: Controls & Trim

    CONTROLS & TRIM 6. CONTROLS & TRIM 3. Low Water Cut-off (Level Control): A. STEAM BOILER CONTROLS & TRIM a. Float Type: Install the float type low water cut- 1. Safety Valve: off (if provided) in conjunction with the gauge glass as shown in Figure 6.3.

  • Page 22: Water Boiler Controls & Trim

    CONTROLS & TRIM 6. Limit Control(s): (Figure 6.5) a. Install the operating limit control and pressure gauge in the 3/4" tappings located on the right side of the boiler. b. (64-09 through 64-12) Install a high limit control in the 3/4" tapping on the right side of the boiler. Figure 6.5: Limit Control Installation IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, water boilers are equipped...
  • Page 23 CONTROLS & TRIM 2. Drain Valve: 5. Low Water Cut-off (Level Control) a. A hot water boiler installed above radiator level Install the 3/4" drain valve provided into the drain or as required by the authority having jurisdiction tapping on the right hand side of the boiler. Refer to must be provided with a low water cut-off device Figure 6.7 for tapping location.

  • Page 24: Electrical

    ELECTRICAL 7. ELECTRICAL 2. Mount the blocked vent switch in the rear of the A. CONNECT SUPPLY WIRING boiler on the draft hood as shown in Figure 7.2. 1. All electrical wiring must be done in accordance with local codes. In the absence of local codes use ANSI/NFPA 70 “The National Electrical Code.”...

  • Page 25: Install Control Wiring

    ELECTRICAL 4. Mount the ignition module as shown in Figure 7.4. Figure 7.4 C. INSTALL CONTROL WIRING 1. Wire the boiler according to the wiring diagram supplied with the boiler (in the Control Envelope). Figures 7.5 to 7.9 are provided for reference only. 2.
  • Page 26 ELECTRICAL...
  • Page 27 ELECTRICAL...
  • Page 28 ELECTRICAL...
  • Page 29 ELECTRICAL...
  • Page 30 ELECTRICAL...

  • Page 31: Boiler Operation

    BOILER OPERATION 8. BOILER OPERATION A. SYSTEM INSPECTION B2. FILL THE BOILER (STEAM BOILERS) 1. Confirm that all water, gas, and electricity are 1. Gravity Systems and Pumped Return with turned off. Condensate Units – Fill the boiler to the normal water line as indicated on the boiler jacket.

  • Page 32: Main Burner Check

    BOILER OPERATION 6. Check Main Burner Ignition 7. Check the burner and pilot flames (see Figure 8.1). The flame inner cone should be about 1-1/2" high a. With the Operating Temperature Control turned and should have a very sharp blue color. Poor flame down, open the main gas shut-off valve(s).

  • Page 33: Boiler Shut-Down

    BOILER OPERATION WARNING 12. Close the make up water valve and open the boiler drain valve. Cleaning the boiler requires the use of very hot water 13. Drain the boiler completely. Then refill and drain and corrosive chemicals. Use care when handling to again one or two times to make sure all of the soda prevent injury.

  • Page 34: To Turn Off Gas To Appliance

    BOILER OPERATION FOR YOUR SAFETY READ BEFORE LIGHTING 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 is equipped with an ignition device Immediately call your gas supplier from a which automatically lights the pilot.
  • Page 35 BOILER OPERATION Figure 8.3: 63-03 thru 64-08 Nat/LP , 64-09 thru 64-12 LP Gas...
  • Page 36 BOILER OPERATION FOR YOUR SAFETY READ BEFORE LIGHTING 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 is equipped with an ignition device Immediately call your gas supplier from a which automatically lights the pilot.

  • Page 37: Maintenance

    MAINTENANCE 9. MAINTENANCE WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF fibers, 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, they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans.

  • Page 38: General

    MAINTENANCE A. GENERAL D. MONTHLY MAINTENANCE (WITH BOILER OPERATING) 1. Disconnect this boiler from the gas supply piping during any pressure testing of the gas system. 1. Check boiler room floor drains for proper functioning. 2. Check pipes adjacent to cold walls or in unheated spaces.

  • Page 39: As Required Maintenance

    MAINTENANCE d. Remove the vent pipe, vent damper, top jacket 2. Inspect entire venting system for corrosion, support panels and flue collector. and joint integrity. Repair as necessary. e. Brush flueways with wire brush. 3. Check the pilot and main burner flame. See Figure f.

  • Page 40: Troubleshooting

    TROUBLE SHOOTING – SERVICE TIPS 10. TROUBLESHOOTING – SERVICE TIPS Table 10.1: Boiler Troubleshooting Problem Possible Cause Suggested Remedy Heavy Draft Blowing across Pilot Redirect Air Movement or Eliminate Plugged Pilot Orifice Replace Orifice Check Manual Pilot Valve Pilot Outage Check Main Gas Shut-Off Valve No Gas Check Manual Meter Valve...
  • Page 41 TROUBLE SHOOTING – SERVICE TIPS Table 10.1 (cont’d): Boiler Troubleshooting Problem Possible Cause Suggested Remedy Leaks in System Repair Leaks or Replace Piping as Required Expansion tank (diaphragm or bladder type) Check Charge Pressure, Correct if Required charge pressure not right System or Boiler Overfilling or Air compression tank waterlogged Excessive Make-up Water...
  • Page 42 TROUBLE SHOOTING – SERVICE TIPS Table 10.1 (cont’d): Boiler Troubleshooting Problem Possible Cause Suggested Remedy Install Boiler Feed System with Receiver Tank New boiler water content smaller than old boiler Large enough for Condensate Boiler water feed rate or pump rate too fast System or Boiler Overfilling or Flooding causing water level to collapse (due to collapse of Reduce Feed Rate...
  • Page 43 TROUBLE SHOOTING – SERVICE TIPS 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.”...

  • Page 44: Boiler Dimensions & Ratings

    BOILER DIMENSIONS & RATINGS 11. BOILER DIMENSIONS & RATINGS Figure 11.1: Dimensions and Tapping Locations Table 11.1: Tapping Sizes & Functions SERIES 63/64™ TAPPING SIZES & FUNCTIONS Tap ID Size NPT Steam Water 1-1/4" Skim Tapping* Skim Tapping* 1" Tank Supply/Limit 1"...
  • Page 45 BOILER DIMENSIONS & RATINGS Table 11.3: Series 63™ Boiler Ratings Series 63™ Water Approx. Heating Capacity³ Net Ratings¹ AFUE² Content Shipping Boiler Input, Water, Steam, Steam, Steam, Water, Water, Steam, Water, Steam, Weight, Model sqft 63-03L 88.5 82.4 83.0 13.2 63-03 118.0 83.5...

  • Page 46: 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. Figure 12.1...
  • Page 47 REPAIR PARTS Table 12.1 Quantity Stock Quantity Stock Description Description Required Code Required Code Intermediate Section – w/out Draw Lugs – 90028 Burner Access Panel – 63-03 – 50271 Intermediate Section – w/ Draw Lugs (64) – 90029 Burner Access Panel – 63-04 –...
  • Page 48 REPAIR PARTS Table 12.2 Quantity Stock Quantity Stock Description Description Required Code Required Code Draft Hood – 63-03 – 50252 Gas Valve – NAT 63-05/06 – 50589 Honeywell VR8304M-4002 Draft Hood – 63-04 – 50347 Gas Valve – NAT 64-07, Draft Hood –...
  • Page 49 NOTES...
  • Page 50 NOTES...
  • Page 51 Series 63/64 ™ Boilers I n s t a l l a t i o n , O p e r a t i o n & M a i n t e n a n c e M a n u a l TO T H E I N S TA L L E R : This manual is the property of the owner and must be affixed near the boiler for future reference.

This manual is also suitable for:

64 series

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