Page 1 PEERLESS CAST IRON BOILERS INSTALLATION

Page 1 PEERLESS CAST IRON BOILERS INSTALLATION
PEERLESS
EE
CAST IRON BOILERS
INSTALLATION INSTRUCTIONS
HANG THESE INSTRUCTIONS IN VICINITY OF BOILER
SERIES MC
GAS BOILER
THE PEERLESS HEATER COMPANY
DIVISION OF PEERLESS INDUSTRIES INCORPORATED
BOYERTOWN, PENNSYLVANIA 19512 / PHONE (610) 367-2153
HEATING PRODUCTS SINCE 1908
Form No. YY-8001-9
Read carefully, study the control folder and consult drawings before beginning work.
Shipping list is enclosed with each boiler, listing the items as packed at the factory. Check list as you unpack parts. If any parts are
missing or damaged, report the discrepancy to the delivering carrier immediately.
— IMPORTANT —
The equipment shall be installed in accordance with those installation requirements of the authority having jurisdiction or, in the ab-
sence of such requirements, to the current edition of the National Fuel Gas Code. ANSI 7223.1.
Where required by the authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety
Code for Controls and Safety Devices for Automatically Fired Boilers, No. CSD-1.
A — ACCESSIBILITY CLEARANCES
1—To provide for reasonable conditions of accessibility, the following minimum clearances are recommended.
a. 24” between the sides, back and front of the boiler and adjacent wall or other appliance, when access is required for servicing.
B — CLEARANCE FROM COMBUSTIBLE CONSTRUCTION
1—The design of this boiler is certified for the following standard clearances:
a. design certified for alcove installation.
b. 6" between sides and combustible construction.
c. 24" between top of jacket and combustible construction.
d. 6" between draft hood, flue pipe, hot water pipes and combustible construction.
e. 10" between rear of jacket and combustible construction.
NOTE: ACCESSIBILITY CLEARANCE SHALL TAKE PREFERENCE OVER FIRE PROTECTION CLEARANCE.
9_CAUTION: This boiler is NOT DESIGN CERTIFIED for use on combustible flooring unless it is installed on a special base, Part No.
YY-2011. Refer to special instructions enclosed in combustible floor pan carton.
WARNING: UNIT MUST NOT BE INSTALLED ON CARPETED FLOORS.
C— AIR FOR COMBUSTION AND VENTILATION
1—Be certain adequate facilities are available to provide air for satisfactory combustion, ventilation and draft hood dilution.
2—Appliances Located in Unconfined Spaces:
a. Installations in unconfined spaces with conventional construction and large areas: the supply of air for combustion and
ventilation can usually be considered adequate.
3—Appliances Located in Confined Spaces:
a If all air for combustion and ventilation is to come from within the building; two openings shall be provided with one opening
commencing within 12 inches of the top and one opening commencing within 12 inches of the bottom of the enclosure. These
openings shall not be located closer than 3 inches from either the top or bottom of the enclosure and shall be open into areas
communicating freely with the outdoors. The area of each opening shall be equal to one square inch per 1000 BTU/HR of total
input rating of all appliances within the enclosure; with a minimum of 100 square inches for each opening.
b. If all air for combustion and ventilation is to come from outside the building; two openings shall be provided with one opening
commencing within 12 inches of the top and one opening commencing within 12 inches of the bottom of the enclosure These
openings shall not be located closer than 3 inches from either the top or bottom of the enclosure and shall communicate directly
or by ducts with the outdoors. The area of each opening shall be equal to one square inch per 4000 BTU/HR of total input rat-
ing. If ducts are used to convey the air, vertical ducts require areas of one square inch per 4000 BTU/HR; horizontal ducts
require one square inch per 2000 BTU/HR. Ducts shall have the same cross sectional area as the full area of the openings to
which they connect.
c. The upper opening is essential for maintenance of proper circulation of air with the boiler room and reasonable ambient
temperature in order to maintain proper control temperatures.
D — SETTING UP BOILER
1—Separate the wood shipping pallet from the boiler base by removing two (2) hold down bolts at each end of the boiler base.
2—Provide a good level foundation. The boiler should be located as near to the chimney as possible and centralized with respect
to the heating system.
3—The gas manifold and control assembly provided with this boiler meet with all criteria regarding safe lighting and performance as specified in the
latest edition of the American National Standard Z21.13. The gas manifold and control assembly are made up gas tight, completely factory
assembled and installed as integral components of the base assembly. See Figure 1.
1
4—The relief valve is packed in the miscellaneous parts bag.
5—Attach draft hood to the flue collar, extending through the top of the jacket.
ORIFICE
TEST
TAPPING
MANIFOLD
STEEL
BURNER THERMOCOUPLE |
SAFETY PILOT
GAS COCK KNOB
E | Ao O
GAS VALVE o ME __
ps
GAS PRESSURE | A | | || |
REGUL ATOR
THERMOCOUPLE LEAD
PILOT OPTIONAL COMBUSTIBLE
TUBING FLOOR PAN
SECTION A-A
TOP VIEW Figure 1
E — PIPING
1—The recommended piping hook up is as follows. Refer also to the I-B-R installation piping guides Nos. 500 and 700.
a.
b.
NOTE:
NOTE:
NOTE:
NOTE:
The supply and return piping shall be sized to suit the system.
The 34” x 6” nipple is to be installed in the 34” air elimination tapping. Thread the 34” tee onto the top of the nipple. A
ЗА” short nipple and a 34” street ell are used to mount the pressure relief valve as shown on the boiler dimensional draw-
ing at the beginning of Section R.
. Return equipped with circulator: Return shall be piped to the inlet connection of the circulator. The outlet connection of
the circulator is recommended to be piped to a tee, provided with a drain cock, at the 144” return tapping near the bottom
of the right end section.
. Gravity return: Return shall be piped to a tee, provided with a drain cock, at the 1%” return tapping near the bottom of
the right end section.
A HOT WATER BOILER INSTALLED ABOVE RADIATION LEVEL MUST BE PROVIDED WITH A LOW WATER CUTOFF DEVICE. EITHER
AS A PART OF THE BOILER OR AT THE TIME OF BOILER INSTALLATION.
THIS BOILER SHALL BE INSTALLED SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM WATER (DRIPPING,
SPRAYING, ETC.) DURING APPLIANCE OPERATION AND SERVICE (CIRCULATOR REPLACEMENT, CONDENSATE TRAP, CONTROL RE-
PLACEMENTS, ETC.).
IF THIS BOILER AND DISTRIBUTING SYSTEM IS USED IN CONJUNCTION WITH A REFRIGERATION SYSTEM, THE CHILLED MEDIUM
SHALL BE PIPED IN PARALLEL WITH THE BOILER AND THE PROPER VALVE APPLIED TO PREVENT THE CHILLED MEDIUM FROM
ENTERING THE BOILER. A DRAWING ILLUSTRATING THIS HOOK-UP IS PROVIDED IN FIGURE 2.
WHEN THE BOILER IS CONNECTED TO HEATING COILS LOCATED IN AIR HANDLING UNIT WHERE THEY MAY BE EXPOSED TO RE-
FRIGERATED AIR CIRCULATION, THE BOILER PIPING SYSTEM MUST BE EQUIPPED WITH FLOW CONTROL VALVES OR OTHER AUTO-
MATIC MEANS TO PREVENT GRAVITY CIRCULATION OF THE BOILER WATER DURING THE COOLING CYCLE.
CAUTION: PIPE THE DISCHARGE OF RELIEF VALVE TO PREVENT INJURY IN THE EVENT OF PRESSURE RELIEF. SUGGEST DISCHARGE TO BE
PIPED TO DRAIN. PIPE FULL SIZE OF OUTLET.
CHECK VALVE
SUPPLY SEY
LINE e do
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В RETURN
BOILER > TNE
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WATER = THREE WAY
CHILLER CS VALVE
Figure 2
F — CHIMNEY
1—For connection to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipment, of the current
edition of the National Fuel Gas Code, ANSI Z233.1 or applicable provisions of the local building codes.
2 Draft: Sufficient draft must be available for removal of products of combustion. If draft is not adequate, spillage of the products
of combustion will occur at the bottom outlet of the draft hood. If such a condition should exist, check the flue and chimney to
determine cause of insufficient draft. It is also important that ample air is available in the boiler room to facilitate draft.
3—Flue or vent connector to chimney must be same size as the outlet of the draft hood. The chimney height and size is based on a
6’ length of horizontal flue connector from the chimney to the riser on the boiler and not more than one 90 degree elbow. The
flue pipe should slope upward at least 34” per lineal foot between the draft hood outlet and the chimney.
4—The area of a chimney or flue collector into which two or more appliances are connected, shall not be less than the area of the
largest chimney connectors plus fifty (50) per cent of the area of all other appliance connectors.
5 Flue or vent connector must be inserted into but not beyond the inside wall of the chimney flue.
6—Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems
operating under positive pressure.
7—Horizontal portions of the venting system shall be supported to prevent sagging by use of metal strapping or equivalent means
and be located at no more than 12 ft. intervals.
8— When an existing boiler is removed from a common venting system, the common venting system is likely to too large for praper
venting of the appliances remaining connected to it.
At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to
the common venting system placed in operation, while the other appliances remaining connected to the common venting system are
not in operation.
a. Seal any unused openings in the common venting system.
b. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leak-
age, corrosion and other deficiencies which could cause an unsafe condition.
3
c. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining
connected to the common venting system are located and other spaces of the building. Turn on any clothes dryers and any
appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom ex-
hausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will oper-
ate continuously.
e. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or
candle, or smoke from a cigarette, cigar or pipe.
f. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested
as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous
conditions of use.
g. Any improper operation of the common venting system should be corrected so the installation conforms with the current edition
of the National Fuel Gas Code, ANSI 2223.1. When resizing any portion of the common venting system, the common venting
system should be resized to approach minimum size as determined using the appropriate tables in Appendix G in the current
edition of the National Fuel Gas Code, ANSI 7223.1.
9—Single Wall Type Vent Pipe should be furnished between the draft hood and chimney. If the vent connector shall be located in or
pass through a cold area, the vent connector shall be of listed double-wall Type B or L material.
G — GAS PIPING
1—Gas supply piping is to be sized and installed properly in order to provide supply of gas sufficient to meet the maximum demand
without undue loss of pressure between the meter and the boiler.
2—Consult the following table for proper sizing of gas piping for various lengths and diameters.
CAPACITY OF PIPE OF DIFFERENT DIAMETERS AND LENGTHS IN CU. FT. PER HOUR WITH
PRESSURE DROP OF 0.3 IN. AND SPECIFIC GAVITY OF 0.60. NO ALLOWANCE FOR AN
ORDINARY NUMBER OF FITTINGS IS REQUIRED.
Pipe Length Y" 1” 144” 114”
Feet Pipe Pipe Pipe Pipe
10 278 520 1,050 1,600
20 190 350 730 1,100
30 152 285 590 890
40 130 245 500 760
50 115 215 440 670
60 105 195 400 610
MULTIPLIERS TO BE USED WITH ABOVE TABLE WHEN THE SPECIFIC GRAVITY OF THE
GAS IS OTHER THAN 0.60.
Specific Gravity ...... 0.5 0.55 0.60 0.65 0.70
Multiplier .............. 1.10 1.04 1.00 0.962 0.926
3—Locate the drop pipe adjacent to, but not in front of the boiler.
4—Locate a tee in the drop pipe at same elevation as the gas inlet connection to the boiler. Extend the drop pipe to a pipe cap
as shown in Figure 3 to form a sediment trap.
9—If boiler is equipped with combination gas controls, install a ground joint union ahead of the gas control assembly to permit ser-
vicing of the control. See Figure 3. Some local codes require an additional shut-off valve when using the combination gas controls.
If your code requires such a valve, a suggested location is shown in Figure 3.
6—NOTE: When installing boiler, be sure a pipe compound resistant to the action of liquified petroleum is used.
SERVICE
VALVE
— JACKET
SEDIMENT TRAP
EOE LINE
Figure 3
7—Check piping for leaks. Always check leaks with a water and soap solution or equal. DO NOT USE A FLAME FOR CHECKING
GAS LEAKS.
8 The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of
that system at test pressure in excess of %2 psig (3.5 kPa).
9—The boiler must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure
testing of the gas supply piping system at test pressure equal to or less than Yopsig (3.5 kPa).
H — CONTROLS
1—For proper location of controls and accessories refer to Figures 4 and 5 and Section R “Ratings, Tappings and Dimensional Data”.
2— Specific details regarding the installation of the various controls are given in the control sheets attached.
3—In the event of control failure, the replacement shall be identical to the original equipment.
4—This boiler is supplied with safety limits in addition to the high limit aquastat. The following is a description of these limits
and how they work in conjunction with the safe operation of the boiler.
a. FLAME ROLL-OUT SAFETY SHUT OFF SWITCH—This is a thermally activated switch that is located between the first burner from
the right and the manifold bracket. The flame roll-out safety shut off switch will sense excessive temperature caused by con-
tinued flame roll-out and shut down main burner gas. This is a non-recycling switch that must be replaced once it has been
activated and the cause of the roll-out eliminated.
b. VENT SAFETY SHUT OFF SWITCH—This is a thermally activated, manually resetable switch, located in the draft hood relief
opening. If venting system becomes partially or totally blocked, the vent safety shut off switch will sense excessive tempera-
ture caused by flue products exiting the draft hood relief opening and shut down main burner gas.
NOTE: REFER TO SECTION P FOR INSTRUCTIONS WHEN BOILER IS SHUT DOWN BY THE ACTIVATION OF EITHER OF THE ABOVE
SWITCHES.
5—For installation of automatic vent damper, referto the separate installation instructions, Form X-8001.
| — WIRING
NOTE: THIS UNIT WHEN INSTALLED MUST BE ELECTRICALLY GROUNDED IN ACCORDANCE WITH THE REQUIREMENTS OF THE AUTHORITY
HAVING JURISDICTION OR, IN THE ABSENSE OF SUCH REQUIREMENTS, WITH THE CURRENT EDITION OF THE NATIONAL ELECTRI-
CAL CODE, ANSI/NFPA NO. 70, IF AN EXTERNAL ELECTRICAL SOURCE IS UTILIZED.
1—All electrical wiring shall be done in accordance with The National Electric Code and local requirements.
2—See Figures 4 and 5 for location of wiring and controls. For recommended wiring of controls, refer to Figures 6 and 7.
3—The boiler should be connected by a separate, permanently live electrical supply line with a fused switch.
NOTE: Single pole switches including those of safety controls or protective devices shall not be wired in a grounded line.
CAUTION: LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND
DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING.
LOW VOLTAGE WIRE
a LIMIT CONTROL
TO THERMOSTAT —— |
TO VENT DAMPER а
UE TO LINE VOLTAGE
POWER SUPPLY
WIRING DETAILS
GRAVITY HOT WATER SYSTEM
Figure 4
LOW VOLTAGE WIRE
LIMIT CONT
TO THERMOSTAT —— — II CONTROL
TO VENT DAMPER ———
TO LINE VOLTAGE
POWER SUPPLY
WIRING DETAILS
FORCED HOT WATER SYSTEM
Figure 5
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Figure 6
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Figure 7
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BOILERS EQUIPPED WITH CONSTANT BURNING PILOT
HONEYWELL GAS VALVE LIGHTING INSTRUCTIONS
NOTE: BE CERTAIN SYSTEM IS FULL OF WATER BEFORE PROCEEDING WITH THESE INSTRUCTIONS.
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.
An <-> CO Mo =
1.
2.
3.
. Wait five (5) minutes to clear out any gas.
This appliance has a pilot which must be lighted by hand.
When lighting the pilot, follow these instructions exactly.
BEFORE OPERATING smell all around the appliance area for
gas. Be sure to smell next to the floor because some gas is
heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
® Do not try to light any appliance.
® Do not touch any electric switch; do not use any phone in
your building.
© Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
C.
e |f you cannot reach your gas supplier, call the fire
department.
Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or turn by hand,
don't try torepair it, call a qualified service technician. Force or
attempted repair may result in a fire or explosion.
Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect the
appliance and to replace any part of the control system and
any gas control which has been under water.
LIGHTING INSTRUCTIONS
. STOP! Read the safety information above on this page.
. Set the thermostat to lowest setting.
. Turn off all electric power to the appliance.
. If the gas valve is not visible, remove control access panel.
. If the gas control knob is not in the “OFF” position, turn the
knob clockwise 7 to “OFF.”
Then smell for
If you smell gas, STOP! Follow
If you
gas, including near the floor.
“B” in the safety information above on this label,
don't smell gas, go to the next step.
. Remove the pilot access panel, if supplied, located below and
behind the gas valve directly above burner tubes.
Find pilot — follow metal tube from gas valve. The pilot is
between two burner tubes.
. Turn the gas control knob counterclockwise g—\to “PILOT.”
SLE cas VALVE
SAFETY yA
|
LL — = 1 = a
SIDE VIEW
10.
11.
12.
13.
14.
15.
Gas Control Knob
{shown in "OFF"
Push in red reset button all the way and hold in. Immediately
light the pilot with a match. Continue to hold the reset button
in for about one (1) minute after the pilot is lit. Release button
and it will pop back up. Pilot should remain lit. If it goes out,
repeat steps 5 through 10.
e |f button does not pop up when released, stop and imme-
diately call your service technician or gas supplier.
o |f the pilot will not stay lit after several tries, turn the gas
control Knob to “OFF” and call your service technician or
gas supplier.
Replace pilot access panel, if applicable.
Turn gas control knob counterclockwise #\to “ON.”
Replace control access panel, if applicable.
Turn on all electric power to the appliance.
Set thermostat to desired setting.
ROOM THERMOSTAT
Cy
JS Reset Button
AA
|
TO TURN OFF GAS TO APPLIANCE
Set the thermostat to lowest setting.
Turn off all electric power to the appliance if service is to be
performed.
If the gas valve is not visible, remove control access panel.
4.
о.
Turn the gas control knob clockwise ato “OFF.”
Replace control access panel, if applicable.
BOILERS EQUIPPED WITH ELECTRIC IGNITION AND A COMBINATION GAS VALVE
OPERATING INSTRUCTIONS
NOTE: BE SURE SYSTEM IS FULL OF WATER BEFORE PROCEEDING WITH THESE INSTRUCTIONS.
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or explosion may
result causing property damage, personal injury, or loss of life.
=> WM
1.
2.
3.
This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot
by hand.
BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the
floor.
WHAT TO DO IF YOU SMELL GAS
e Do not try to light any appliance.
e Do not touch any electric switch; do not use any
phone in your building.
e Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
e |f you cannot reach your gas supplier, call the fire
department.
Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or turn
by hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may resultin afire
or explosion.
Do not use this appliance if any part has been under
water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
OPERATING INSTRUCTIONS
. STOP! Read the safety information above on this page.
. Set the thermostat to lowest setting.
. Turn off all electric power to the appliance.
This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light
the pilot by hand.
If the gas valve is not visible, remove control access
panel.
If the gas control knob is not in the “OFF” position, turn
the knob clockwise ato “OFF.”
Г
Gas Control Knob
(shown in “OFF”
position) N
AN A
Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas, STOP!
Follow “B" in the safety information above on this label.
If you don't smell gas, go to the next step.
. Turn the gas control knob counterclockwise &\ to
“ON.”
. Replace control access panel, if applicable.
10.
11.
12.
Turn on all electric power to the appliance.
Set the thermostat to desired setting.
If the appliance will not operate, follow the instructions
“To Turn Off Gas To Appliance and call your service
technician or gas supplier.
TAT
Cy
TO TURN OFF GAS TO APPLIANCE
Set the thermostat to lowest setting.
Turn off all electric power to the appliance if service is
to be performed.
If the gas valve is not visible, remove control access
panel.
4. Turn the gas control knob clockwise/ ato “OFF.”
5. Replace control access panel, if applicable.
J — STARTING BOILER
1—Before starting boiler refer to Instructions For Operation and the lighting/operating label which is mounted to jacket panel.
2—The boiler and its gas connections must be leak tested before placing the boiler in operation. Check gas connections with soap
solution.
K — ADJUSTMENT TO GAS PRESSURE REGULATOR
1—Set manifold pressure as follows for various gases.
a. Natural Gas .................e.... 39727 Water Column b. Propane Gas 10” Water Column
2—To adjust gas pressure, turn adjusting screw of gas pressure regulator, out to decrease pressure, tuin in to increase pressure.
Refer to control sheets supplied with boiler for location of gas pressure regulator.
3—In no case should the final manifold pressure vary more than plus or minus 0.3 inches water column from the above specified
pressures. Any necessary major changes in the flow should be made by changing the size of the burner orifice.
Minimum Permissible Supply Pressure For Purposes Of Input Adjustment .................. 5” W.C. Nat. Gas 11” W.C. LP. Gas
Maximum Permissible Supply Pressure To The Boiler .................—.....mecem rm 14” W.C. Nat. Gas 14” W.C. LP. Gas
L — BURNER INPUT
1—Refer to rating label mounted on the Jacket Top Panel to obtain the required BTU per hour input. In no case shall the input
to the boiler exceed that shown on the rating label.
2—Check input by use of the following formula; Suggest reading meter for 2 Cu. Ft.
3600 x F x H
т = BTU/Hr. Input
3600 — Seconds per hour
F — Cu. Ft. Gas Registered On Meter
H — Heat Value of Gas in BTU/Cu. Ft.
T — Time in seconds the Meter is Read
NUMBER OF ORIFICES REQUIRED
MODEL NUMBER....... MC-03 MC-04 MC-05 MC-06 MC-07 MC-08
ORIFICES iii; 4 6 8 10 12 14
M — ADJUSTMENT OF PRIMARY AIR
1—To adjust primary air, close air shutter until yellow tips appear on the flame, then open air shutter until the yellow tips just dis-
appear.
2—Lock the air shutter in position by means of the lock screw.
N — INSTRUCTIONS FOR OPERATION
1—The installation is not complete until Rating and Lighting Plates are on the boiler and the “Users Information Manual” and “In-
stallation Instructions” are hung near the boiler.
2—System should be maintained in good repair. Radiators, baseboard units and/or convectors must be kept clean.
3—If a radiator does not heat all over, air has probably accumulated and should be vented.
10
4—The following applies to Millivolt Self-Generating systems ONLY during an electrical power failure.
Gravity Hot Water Systems:
a. An electrical power failure will have no effect on the operation of the boiler.
Forced Hot Water Systems:
a Locate switch on side of aquastat relay and push to “Manual”.
b. The flow valve and/or automatic zone valves must be opened manually.
c. Upon resumption of electric power, return flow control valve and/or zone valves to normal position and push switch on
aquastat relay to “Auto”.
NEVER LEAVE THE BOILER UNSUPERVISED WHEN IT IS OPERATING MANUALLY. THE PEERLESS HEATER COMPANY CAN ASSUME NO
RESPONSIBILITY FOR THE SAFE OPERATION OF THE BOILER AND OTHER EQUIPMENT WHEN IT 1$ BEING OPERATED UNDER EMERGENCY
CONDITIONS.
NOTE
SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT-OFF, DO NOT TURN OFF OR DISCONNECT THE ELECTRICAL SUPPLY
TO THE PUMP. INSTEAD, SHUT-OFF THE GAS SUPPLY AT A LOCATION EXTERNAL TO THE APPLIANCE.
DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO IN-
SPECT THE BOILER AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER.
0 — CHECK OUT PROCEDURE
1—After starting boiler, be certain all controls are working properly before leaving it unattended. Check to be sure that the temp-
erature limit control will shut off the boiler in the event of excessive temperature, by lowering limit set point until main burners
shut down. Return limit to desired set point.
2— Check gas tightness of main gas valve when closed to be certain there is no leakage to the burners. Check all joints periodically
for gas leakage. Use soap solution to check leakage.
3—Check the operation of the ignition system safety shut-off device using the following methods:
a. Constant Burning Pilot: With the gas cock knob in the pilot position, extinguish pilot flame and make certain the gas valve
shuts off gas flow to the pilot within two (2) minutes. To relight follow “Lighting Instructions”.
b. Spark Igaition Systems: With the unit operating, turn off the gas at the inlet shut-off valve upstream from the boiler. The unit
will spark and attempt to relight. If pilot lock-out is provided, the spark will stop within ninety (90) seconds. To relight
follow “Operating Instructions”.
P — SHUT-DOWN CAUSED BY PILOT OUTAGE, VENT SAFETY SHUT OFF SWITCH OR FLAME ROLL-OUT SAFETY SHUT OFF SWITCH
1—In the event of a shut-down caused by a pilot outage, action of the vent safety shut off switch or flame roll-out safety shut off
switch effecting a shut-down of the main burners:
a. Turn off all electric power to the boiler.
b. Refer to “Lighting or Operating Instructions” and turn gas cock knob to “off” position.
c. Call a qualified heating service organization or local gas company and have the cause of the shut-down investigated and
corrected.
d. Refer to “Lighting or Operating Instructions” to re-start boiler.
1
Q — MAINTENANCE AND INSPECTION
1—This boiler must be disconnected from the gas supply piping during any pressure testing of this system.
2—The draft hood used on this boiler is of the vertical cone type. The vent and venting system should be inspected thoroughly at the
beginning of each heating season.
3—The area where the boiler is contained should be clear and free from combustible materials, gasoline and other flammable vapors
and liquids. The boiler area should have ample air for combustion and ventilation and there should be no obstructions preventing
a free flow of air.
4—All low water cut-offs should be inspected annually, any float types should be flushed on a weekly basis to remove any sediment
from the float bowl.
I—A visual check of burner and pilot flame should be conducted at least once a year. The flame intercone should be approximately
1% inches high and should have a very sharp, blue color characteristic. See Figure below.
7
PILOT AND MAIN BURNER FLAME
6—At the beginning of each heating season, flueways and burners should be checked for cleanliness and cleaned if necessary. Fol-
lowing procedure would apply if cleaning is required.
a. Turn off all electrical power to boiler before beginning cleaning operation.
b. Remove the flue pipe, draft hood, top jacket panels and flue collector.
с. Brush flueways with wire brush.
d. Replace flue collector. When replacing the flue collector, be certain that the blanket seal between the flue collector and top
section makes a tight seal to prevent leakage of the products of combustion.
e. Replace the top of jacket, draft hood and flue pipe.
f. Remove burners and brush gas outlet ports lightly using soft bristle brush.
12
R — RATINGS, TAPPING LOCATIONS AND DIMENSIONAL DATA
| © -
“Ee | RELIEF VALVE
Ha for" В
5 Ш я
Tr Ч 1-1/2" SUPPLY TAPPING
Ll OT
E
LL
OPERATING CONTROL
ca THERALTIMETER
\
| 1
a”
za
FERN
“a | 7 FLOOR LINE
FRONT
CAUTION: PIPE THE DISCHARGE OF RELIEF VALVE TO PREVENT INJURY IN THE EVENT OF PRESSURE RELIEF.
PIPE FULL SIZE OF OUTLET.
SUGGEST DISCHARGE TO BE PIPED TO DRAIN.
= “а
на |6 — — — — =
5g
RIGHT SIDE
SERIES MC BOILER DIMENSIONS
Li =
0
Leftof | Rear of
Jacketto | Jacket | Chimney | Draft
Boiler | Jacket | Jacket cof |toclof | orFlue | Hood
Model Width Depth Flue Flue Size Height
Number a En B" щ “nn “pr “E LL
MC-03 12" 19%" 6" g" 4" x 20' 13"
MC-04 15%" 19%" 7" 9" 5" x 20 17"
MC-05 19%" 19%" 9%" 9" 6° x 20' 177"
MC-06 22% 19'" 11%" 9" 6" x 20' 17/2"
MC-07 26" 19%" 13" 9" 7" x 20' 20%
MC-08 29%" 19%" 14"/" 9" 7" x 20' 22%
SERIES MC BOILER RATINGS
' ñ Spark Ign. Std. Pilot
DOE Net I=B=R w/Damper w/Damper
Boiler A.G.A. Heating Ratings Seasonal Seasonal
Model Input Capacity Water Efficiency Efficiency
Number MBH MBH MBH (AFUE) (AFUE)
MC-03 65.0 54 47 82.8 80.1
MC-04 97.5 80 70 82.0 80.1
MC-05 130.0 107 93 82.0 80.2
MC-06 162.5 134 116 82.0 80.9
MC-07 195.0 159 138 81.1 80.0
MC-08 227.5 185 161 81.1 80.1
* Heating Capacity determined in accordance with test procedures prescribed by DOE.
“The Net I-B-R Ratings shown include an allowance for normal piping and pick-up load, in accordance with the Testing and Rating
Standard for Low Pressure Cast Iron Heating Boilers of the Hydronics Institute. Water ratings are based on a piping and pick-up
allowance factor of 1.15.
The Peerless Heater Company should be consulted before selecting a boiler for gravity hot water installations and installations having
unusual piping and pick-up requirements such as exposed piping, night shut-down, etc.
13
|. AIR ELIMINATION
1-1/4" RETURN
FA TAPPING
14
>
REPAIR PARTS
SERIES MC GAS BOILER
REPAIR PARTS ARE AVAILABLE FROM YOUR INSTALLER OR BY CONTACTING
THE PEERLESS HEATER COMPANY, BOYERTOWN, PA. 19512
NOTE: REMEMBER TO INCLUDE BOILER MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS.
tem No.| Part No. Description Additional Information
1 X-1069 Block Assembly Specify Boiler Model
2 YY-2004 Base
3 YY-2007 Observation Cover Door
4 a Gas Manifold Specify Boiler Model
Че Gas Manifold Specify Boiler Model
5 X-4014 Orifice Spud Specify Quantity, Type of Gas and Altitude
6 YY-3012 Steel Burner Specify Quantity
Steel Burner w/Pilot Clip Specify Control System
7 Flue Collector Specify Boiler Model
8 YY-5001 Draft Hood Specify Boiler Model
9 Jacket Assembly Specify Boiler Model
10 YY-2011 Combustible Floor Pan Assembly Specify Boiler Model
11 X-2009 Base Blanket Seal Specify Length in Feet
12 YY-2005 Base Board Insulation Specify Boiler Model
13 X-5001 Flue Collector Blanket Seal Specify Length in Feet
Theraltimeter Gauge
3%" Drain Cock
Lighting/Operation Instruction Label Specify Control System
60T14-250 Vent Safety Shut Off Switch
G4AM0600167 Flame Roll-Out Safety Shut Off Switch
3" MD High Temp Rope
Specify Length in Feet
Gas Valve
Specify Control System and Type of Gas
Pilot
Specify Control System and Type of Gas
Ignition Control
Specify Model
Limit Control
Specify Boiler and Control System
16
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