PEERLESS SERIES 62, 61 Series, 61-03, 61-04, 61-05 Installation, Operation & Maintenance Manual

61/62

Boilers

Installation,

Operation Et
Maintenance

Manual

3-8 90,0 Up to 81.7% AFUE

Natural or LP Gas
Standing Pilot (Steam Only) or Spark Ignition (Hot Water and Steam)

Natural Draft (chimney) Venting
Factory Assembled Sections on Knockdown Boilers

• Reduces Installation Time

Large Water Content

• Ideal for Steam and Large Volume Hot Water Applications

Skim Tapping

• For Cleaning Steam Boilers

Low Profile Design

• Horizontal to Vertical Draft Diverter

• Ideal for Installations with Low Ceilings

Steel Push Nipples

• Provide a Permanent Water Tight Seal Between Sections

• Unaffected by Petroleum and Other Contaminants

Tankless Coils

• For Domestic Hot Water Production on Hot Water Boilers

Deluxe Insulated Enameled Steel Jacket

• Reduces Boiler Heat Loss

• Completely Encloses Gas Valve and Burners

Safety Controls

• Low Water Cut-Offon Steam Boilers

• Flame Roll-Out Shut-OffSwitch

• Blocked Vent Shut-OffSwitch

• Honeywell Operating Controls

• Vent Damper

• Float Type LWCO on Steam Boilers

• Taco 007 Circulator on Packaged Water Boilers

• Tankless Coil for Hot Water Boilers

• Gnmdfos Circulator on Packaged Hot Water Boilers

• Probe Type LWCO on Steam Boilers

Peerless Heater Comparly is pleased to offer one of the most comprehensive warranty programs

icl tile indnstn 1, All Peerless residential cast troll _x_ilers include a fidl one-yea" warranty. A limited.

lifetone warranty is provided.for the cast iron sections ol Peerless residential hot water boilers.
Peerless also provides a limited, ten year warranty ot_ the cast iron sections of its residential steam

boilers. Five and ten year extended warratlties on parts and labor are now available. Pl_'asc consult
Peerl_,ss Heater Company for complete warranty inJbrmation.

PGGRLESS _

CAST IRON BOILERS

Peerless Heater Company * 231 North Walnut Street • Boyertown, PA 19512-1021 • 610-3S7-2153 * www.peerless-heater.eom

FAB-61 R1 (3/02 3M)

Printed in US A

pr=-I RLESS o

CAST IRON BOILERS

Series 61

o Residential Gas Boilers

• Packaged or Knockdown

o Natural Draft Venting
o Standing Pilot or

Spark Ignition

Q Steam or Hot Water Boilers
o Natural or LP Gas

Water

Steam

Q This large water content boiler

installsindifficultsteam or water
applications.

o AFUE ranges from 76.8%

(standing pilot) to 80.7% (spark
ignition) on steam boilers and
80,3% to 81.7% (spark ignition
only) on water boilers, significantly

exceeding the federal standards
for residential boiler efficiency.

o Low profile design ideal for boiler

installationsin areas with a low

ceiling.
An optional tankless domestic

hot water coil can be installed on
hotwater boilers, insuringample

domestichotwater production.

o Probe or float-type lowwater

cutoff available.

DOE

Heating Capacity

MBH--

Stdg.PilotwlDamper

Seasonal Efficiency

(AFUE)4

Net I=B=R Ratings 3

Steam Steam Water
Sq. Ft. MBH 2 MBH 1

225 54 63

304 73 85

4O4 97 113

504 121 140
604 145 168
704 169 196

Spark Ign. wlDamper
Seasonal Efficiency

(AFUE) 4

Water Content

(GaL)

I A,G.A.
I Input

N MBH Water Steam Water I Steam Water I Steam Water Steam

90 73 72 N/A I 76.8 80.5 I 80.6 8.16 4.80

120 98 97 N/A I 77.7 81.7 I 80.7 10.32 5.88
160 130 129 N/A I 77,8 81.3 I 80.6 12.48 6.96

200 I 161 161 N/A I 78.0 81.0 I 80.6 14.64 8.04
240 193 193 N/A I 78.1 80.6 I 80.6 16.80 9.12

280 225 225 N/A I 78.3 80.3 I 80.6 18.96 18.20

1 Net I=B=R water ratings based on an allowance of 1.15,
2 Net I=B=R steam ratings based on an allowance of 1.333.

3 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping

systems, etc.

4 Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are based on U.S. Government test. Before purchasing this appliance, read important

information about its estimated annual energy consumptions or energy efficiency rating that is available from your retailer.

7 Sizes 9-15 Sections

320 to 560 MBH Input 80% Combustion Efficiency

Natural or LP Gas

Standing Pilot or Spark Ignition

Natural Draft (chimney) Venting

Factory Assembled Sp/it Block Sections on Knockdown Boilers

• For Ease of Handling

Large Water Content

• Ideal for Steam and Large Volume Hot Water Jobs

Skim Tapping

• For Cleaning Steam Boilers

Low Profile Design

• Horizontal to Vertical Draft Diverter

• Idealfor Installatiolis with Low Ceilings

Steel Push Nipples

• Provide a Permal_ent Water Tight Seal Between S_ctioris

• Unaffected by Petroleum arid Other Cor_tamiTlalltS

Tankless Coils

• For Domestic Hot Water Production o_ Hot Water Boilers

Deluxe Insulated Enameled Steel Jacket

• Reduces Boiler Heat Loss

• Completely Encloses Gas Valve and Burners

Safety Controls

• Low Water Ctlt Q[l'orl Steam Boil_'rs

• HoT_eywell Operating Co_ltrols

• Mar_ltal Reset High Limit Corltrol (12-15 Section)

• Float Type LWCO orl Steam Boilers

• Tcxl_lcless Coiljor Hol Watcr Boilers

• Moclultxtillg Fi1_rlg Systems (12 15 S<:cliorl}

• F_'I _rid IRI Colltrol S!]slerTls (12 15 Sectioll)

• Prot)t> "I_upe I.WCO o11Sle(lfll Boilers

_ll lilt" il_(lll._lr'!]. ./Ill I_'_'r'l( '.,_.s ('ollilll_'r('i(¢l _'cl.'q/ _rt)ll I)oih>l_ _ll_'h_(l_ >(I /illl. oil(' ! (>_'lr" tl,_ls't(_ll[ 1. A

lilliilt>(I. It'll !]('(1I II'_llltll_l[/ I)ll I]l(" _'tl._l il'oll ._('t'l_oll._ i.'_ [)l()l'l_ll'_ [i_t (ill ( Ollllll<'F('i_ll 11(>I I_ll('I _lll([

,'_l_>(llll I?l_il(>I'_. I+'il'( ' _lll_'l [I'll I I>tlr ('._l_'tl_l(>_l ll'_l_'ltlllll_'_ I)ll l_(It l_ (lll_l I_l!)ol (It't' /loll' ttl'(li[(l!)_('. CAST IRON BOILERS

!'lt>(_._;( ' €'otl.'_ll/I I>_'('t'l_ '.'q_ I h'_ll_'t ( "olllt)_lltt].[O_" _'Oml)lt'f_" it,t_r_t_i_l!] ir!]Oi rIl(llioll.

Peerless Heater Company • 231 North Walnut Street * Boyertown. PA 19512 1021 • 610 367-2153 - www.peerless-heater.com

FAB 6_7t9 02 :_,%

pGr=-RLESS o

CAST IRON BOILERS

Series 62

o Semi-Commercial Gas Boiler

• Packaged or Knockdown

o Natural Draft Venting
o 320 to 560 MBH Input

o Steam or Hot Water Boilers
o Natural or LP Gas

Steam

Water

o The large water content of this

knockdown or completely packaged
boiler makes it ideal for difficult steam

or water applications.

o Available in standing pilot or spark

ignition.

o Combustion efficiency meets the

80% ASHRAE 90.1 minimum as
required by the federal standards for

commercial boilers.

O

Horizontal to vertical draft hood

and aluminized steel flue collector
provide a low boiler profile to allow

installation in areas with low
clearance.

r_ An optional tankless hot water coil

can be installed on water boilers,
insuring ample domestic hot water
production.

o Probe or float-type low water cutoff

available.

I=B=R Water

Gross Output Net I=B=R Combustion Content

MBH Ratings 3 Efficiency 4 (Gallons)

Model Input Steam Steam Water

Number MBH Water Steam Sq. Ft. MBH2 MBH 1 Water Steam Water Steam

62-09 320.0 256 256 800 192 223 80.0 80.0 21.12 11.28
62-10 360.0 288 288 900 216 250 80.0 80.0 23.18 12.36

62-11 400.0 320 320 1000 240 278 80.0 80.0 25,34 13.44
62-12 440,0 352 352 1100 264 306 80.0 80.0 27.50 14.52
62-13 480.0 384 384 1200 288 334 80.0 80.0 29.66 15.60
62o14 520.0 416 416 1300 312 362 80.0 80.0 31.82 16.68

1 Net I=B=R water ratings based on an allowance 011.15.
2 Net I=B=R steam ratings based on an allowance of 1.333.

3 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation,

extensive piping systems, etc

4 Combustion efficiency determined in accordance with ANSf Z21 13, Gas-Fired Low-Pressure Steam and Hot Water Boilers

I

J

K

L

M

N

O

P

Q

R

m

Boiler
Model

Number

62-09
62-10

62-11
62-12
62-13

62-14

62-15

Steam Water

3/4" Pressure Gauge* Limit Control (Models 09-11)
3/4,, N/A Operating Control (Models 12-15)
3/4" N/A Limit Control (Models 12-15)

V2" N/A Temperature-Pressure Gauge
V2" Gauge Glass and Low Water Cutoff N/A

2" Return Return
3/4" Secondary Probe Low Water Cut-Off N/A
3/4" Safety Relief Valve Safety Relief Valve

1V2" Skim Tapping N/A

¾" Primary Probe Low Water Cut-Off N/A

3o4-

L£_'T SID_ £RON_ RIGH T SIDE

• Pressure gauge, operating control and I_mitcontrol on Models 62 12 to 62 15

Jacket Right of Distance Rear of Distance , . .

Jacketto Betw. Two Jacketto Flue Between !Rt. Sup.& C_uetOy

Width Depth Top to Fir. c/I of Flue Flue c/l's c/I of Flue Size Tappings Tap. Inter. Chimney

"A .... B.... C.... D.... D1 .... E.... F.... G.... GI"

39V2" 30V4" 35" 14" 11%#' 4%s" 2-6" 333/." N/A 9" 9" x 20'
43%" 30V4" 35" 15" 13_V_6" 4%8" 2-7" 37%" N/A 9" 9" x 20'

47_¾_' 30V4" 35" 16" 15_3/lS" 4%4' 2-7" 42V16" N/A 9" 9" x 20'

52" 30V4" 35" 18" 15_%#' 6_/_6" 2-8" 46V4" 21_/_6" 10" 10" x 20'

56Ys" 30V4" 35" 19" 18V_6" 6Vls" 2-8" 50%" 253/16" 10" 10" x 20'

60%6" 30_/4" 35" 20VI4' 20¾e" 6V_6" 2-8" 54%6" 25z/_6" 10" 10" x 20'

64W_6" 30V4" 35" 22W' 203Ae" 6%6" 2-8" 58"A_" 29s/_6" 10" 10" x 20'

STEAM WATER

, , i

t t

"L

Boiler
Model

Number

62-09
62-10
62-11
62-12
62-13

62-14

62-15

NOTE: Provide Tee, Nipple and Cap Fittings below water line to assist in cleaning or draining.

Steam

No. Supply Outlets

2

2

2
3
3

3
3

Size of Outlets

2"

2"

2"

2"

2"
2"

Header Supply

3 _=

3"

3"

3V2"
31/2''

31/2'`
31/2" ,

Equalizer Size

1V4"
11/4"
1V2"
1V2"
1V2"

1W'
1V2"

Boiler

Model

Number

62-09
62-10
62-11
62-12
62-13
62-14

62-15

Htr. No.

X-1020

GPM

4,75

5.00

5.25

5.50

5.50

5.75

5.75

Htr. No. Htr. No.

X-1021 X-1022

GPM GPM

6.25

6.75

7.00

7.25

7.25

m

6.5

7.0

7.5

8.5

9.0

* Water healer ratings in GPM are based on intermittent demand40 ° to 140 _ F rise with 200 ° F bOiler water

CAUTION: Water mixing valve should always be installed in the hot water supply to prevent injury,

SERIES 62 BOILER SPECS

_-_-_ LlJl-J_vd_id

• Cast Iron Sections--Factory Tested and
Assembled with Steel Push Nipples

• Deluxe Insulated Enameled Steel Jacket

• Drain Valve

• Horizontal to Vertical Draft Diverter

• End Cleanout

• Manual Reset Limit (62-12 to 62-15)

• Standing Pilot or Spark Ignition

• Automatic Reset Limit

Water

• 30 PSI Safety Relief Valve

• Temperature-Pressure Gauge

Steam

• 15 PSI Safety Valve

• Pressure Gauge

• Gauge Glass

• Low Water Cutoff - Probe or Float

• Skim Tapping

• HSP-2 Honeywell ignitionSystem

• 50 PSI Safety Relief Valve - Water Boilers

• Insurance Controls

• I.R.I.
,F.M.

• Ignition Systems

• HSP-2

• E1-M

• E1-E

• Modulating Firing Systems

• MFSC

• Mod-U-Pak (12-15 Section)

Approx. Shipping Wts. (Ibs.)

Boiler
Model

Number I Length I Width ! Height I W S

I I I !

62-09 I 57" 31" I 391/2" I 1080 I 1088

I I I I

62-10 I 61" 3t" J 391/2" J 1170 I 1178

I I I I

62-11 I 66" 31" I 391/2`' ! 1265 I 1273

I I I ]

62-12 I 70" 31" I 391/2" ] 1420 I 1428

I I I !

62-13 I 74" 31" I 391/2" I 1520 I 1528

I I I J

62-14 I 78" 31" I 391/2'' ] 1620 I 1628

I I I I

62-15 I 82" 31" I 391/2" I 1720 1 1728

WP SP

1105 1108

1195 1203

1290 1298

1445 1453

1545 1553

1645 1653

1745 1753

nnam

Example:

62 - 09 - STDG/SPRK - WP - N

Series Sects. Natural Gas (Substitute

Standing Pilot or "LP" for LP Gas)
Spark Ignition W = Water Knockdown

WP = Water Package
S = Steam Knockdown

SP = Steam Package

PEERLESSHEATERCO.

231 North Walnut Street

Boyertown, PA 19512-1021

Phone: [phone] • FAX: [phone]

www.peerless-heater.com

HI Division ASME garNa

of gama

CUT-62 F_7(3/03-1M), Printed in U SA. _003 Peedess Heater Company

Readcarefullybeforebeginningwork.It witlsavetime.Studythe includeddrawings.

Theequipmentshallbe installedin accordancewith thoseinstallationrequirementsofthe authorityhavingjurisdictionor, in theabsenceof such
requirements,to thecurrenteditionof the NationalFuelGas CodeZ223.1/NFPA54.

Whererequiredbythe authorityhavingjurisdiction,theinstallationmustconformto the standardforControlsand SafetyDevicesforAutomaticallyFired
Boilers,ANSI/ASMECSD-I.

A - ACCESSIBILITY CLEARANCES

1. Toprovidefor reasonableconditionsofaccessibility,the followingminimumclearancesarerecommended.
a. 24" betweenthesides,top,backandfrontof theboilerand adjacentwallor otherappliance,whenaccessis requiredforservicing.

B- CLEARANCEFROMCOMBUSTIBLECONSTRUCTION

1. Thedesignofthisbelieriscertifiedforthefollowingclearancesfromcombustibleconstruction:

MODELS61-03thru61-08;62-09thru 62-11

18"fromrear

6"from rightand left sides

30"fromtop- frontalcove

6"fromflue connector
6"from steamandhot waterpipes

MODELS62-12thru62-15

24"fromsidesand rear
55"fromtop

6"fromflueconnector
6"fromsteamandhotwaterpipes

2. CAUTION:This boileris NOTDESIGNCERTIFIEDforinstallationon carpetingor combustibleflooring.

C-AIR FORCOMBUSTIONANDVENTILATION

1. Be certainadequatefacilitiesareavailableto provideairforsatisfactorycombustionandventilation.

2. AppliancesLocatedin UnconfinedSpaces:
a. Installationsin unconfinedspaceswithconventionalconstructionandlarge areas:thesupplyofairfor combustionandventilationcanusually

beconsideredadequate,

3, AppliancesLocatedonConfinedSpaces:

Ifallair for combustionand ventilationistocomefromwithinthebuilding:twoopeningsshallbe providedwithone openingcommencingwithin
12inchesof thetop andone openingwithin12inchesof the bottomof theenclosure.Theseopeningsshallnotbe locatedcloserthan 3inches
fromeitherthe topor bottomof the enclosureandshallbeopenintoareascommunicatingfreely withtheoutdoors,Theareaof eachopening
shallbe equaltoonesquareinchper 1000BTU/HRof totalinput ratingof all applianceswithinthe enclosure,witha minimumof100square
inchesforeachopemng,

Ifallair for combustionand ventilationistocomefrom outsidethebuilding:twoopeningsshallbe providedwithone openingcommencing
within12inchesofthetop and oneopeningcommencingwithin12inchesof the bottomof theenclosure.Theseopeningsshallnotbe located

closerthan3 inchesfromeitherthe top or bottomoftheenclosureandshallcomreunicatedirectlyor byductswiththeoutdoors.Theareaof
eachopeningshall beequalto onesquareinchper4000BTU/HRof totalinputrating.If ductsare usedto conveytheair,verticalductsrequire

areasofonesquareinch per4000 BTU/HR:horizontalductsrequireone squareinchper 2000BTU/HR,Ductsshallhavethe samecross
sectionalareaas thefull areaofthe openingsto whichtheyconnect.

c. Theupperopeningsareessentialformaintenanceof propercirculationofairwiththe boilerroomandreasonableambienttemperatureinorder

tomaintainpropercontroltemperatures.

D - SETTING UP BOILER - PACKAGED UNITS

1. A PackagedBoiler isfactoryassembledbeforebeingcrated.Allcontrolsandaccessoriesnecessaryforoperationof the boilerareattachedand
electricallywired.

2. The draft hoodis packedin a separatecarton.

3. When boileris removedfromthecrate,carefulinspectionshouldbe madeandthecarriernotifiedofanydamagefound.

4. Provideagood levelfoundation.

5. Placethe boileronthe foundationnearandinproperpositionwithrelationtothe chimney,andas centralizedwithrespecttothe heatingsystemas
practical,

6. The openingsin thebasesides areprovidedforadmittingsecondaryairand mustneverbeclosed.

7. Removeiackettop andattach drafthoodto flue collectorwithtwo #10x 1/2"sheetmetalscrewsprovided.Replacejackettop.

8. The burnersare installedinthe boiler.Theyaresecuredin placefor shipmentbywoodstripewiradto the Burnermixingtube.Cutthewiresand
removethewood strips.

9. The gasmanifoldandocntrolassemblyaremadeup gastight,completelyfactoryassembledandinstalledas integralcomponentsof thebase
assembly.SeeFigure12.

D - SE'I-rlNG UP BOILER - UNASSEMBLED UNITS

I-- ASSEMBLEDBLOCKS

1--The boilersectionsandbase,Models61-03thru61-07arefactoryassembled.Removeshippingskidfromtheboilerbase.Ifboilerisa61-08,

or62-09thru62-15beginassemblyasnotedin PartII"SplitBlockAssembly".

2--Provideagoodlevelfoundation,The Boilershouldbelocatedasneartothechimneyandcentralizedwithrespecttotheheatingsystemas

possible.

3--Open controlbox.Removecontrolandmanifoldassembly,Referto Figure6 andattachmanifoldto boilerwithfourV4-20x 1"machinescrews

andnutsprovided.Figures43thru45showthestandardcontrolassembliesusedon Models61-08thru 62-15.

4 Openfluecollectorcarton.RemovefluecollectorandHi Tempropeandlay ropeontop of boileragainstbeadprovided.SeeFigure7.
5--Place fluecollectoron topof ropeand attachto boilerwithtwo1/4"-20studs,washersandhex nutsprovided,throughfluecollectorbrackets

intothetappedlugs providedontopof theboilerend sections.Drawboltsdownsnugly.SeeFigure8,

6--Attach castironclean-outplate10clean-outopeningon leftside ofthe boiler.Thisplate, HiTempropeand mountinghardwaremaybe foundin

thecontrolboxreferred1opreviously.

7--Removetheburnersfromthecontrolboxandinstall.Installeachburnerby slippingtheopeninginthe venturioverthe orificespud.Insertthe

pinon thebottomof theburnerintothe holeprovidedintheflangeonthe basebackplate.SeeFigure9.TheBurnerswithpilotsattachedmust
be installedasfollows:Note:Hookbolt isprovidedon models62-11through62-15.

ModelNo. No.Pilots

61-03 1
61-04 1

61-05 1
61-06 1

61-07 1
61-08 2
62-09 2
62-10 2

62-11 2
62-12 2
62-13 2

62-14 2
62-15 2

Location of Pilot

Between2ndand3rdBurnerfromLeft
Between4th and5th BurnerfromLeft
Between4th and5th BurnerfromLeft
Between4th and 51hBurnerfromLeft

Between4th and 5thBurnerfromLeft
Between4th and5th Burnerfrom Leftand4th and5thfrom Right

Between4th and5th BurnerfromLeftand4th and5thfrom Right
Between4th and 5thBurnerfromLeftand4th and5thfrom Right

Between4th and5th Burnerfrom Leftand4th and 5thfrom Right
Between4th and 5thBurnerfromLeftand4th and 5thfrom Right
Between4th and 5thBurnerfromLeftand41hand5thfrom Right

Between41hand5th BurnerfromLeftand6th and7thfrom Right
Between6th and7th BurnerfromLeftand6th and7thfrom Right

8..-Removepilottubingfromcontrolboxand installbetweengas valveandpilot.Referto figures43 through45.
9--If boileris toincorporateatanklessheaterfordomestichot water,installinopeningprovidedin the rightsideofthe boiler.Sixmountingbolts

3/8"16 x3/4 are rovldedBesurerubber asketi I

( - ) p " • g "sbetweencoverplateandtheboier, Ifboilerdoesnot incorporatea fanklessheater,a
blankcoverplateis providedwithrubbergasketand bolts.One3/4"pipeopeningisprovidedin the platefor the operatingand/orlimit control.

This 3/4"tappingis alsousedfor the pressuregaugeonthesteamboiler,

10--For suggestedpipingto fanklessheaterreferto Figure23.

DANGER:Installmixingvalveinhotwatersupplypiping.Watertemperatureover125°Fcancausesevereburnsinstantlyor deathfromscalds,

2

I:'ROC_"OUR lr FOR STACKING PALLtr'rq

II-- SPLITBLOCKASSEMBLY

1--Boiler sectionsfor Models61-08,62-09thru 62-15are shippedintwo parts.Removeskidfromeach blockofsections.
2--Place each blockofsectionson the stackedskids.See Fig.A. Becertainto removethesmall blocksonthetop skid.See Fig.B,
3--To clean nippleportsand removeprotectivecoating,usea wire brushandmineralspiritsor lacquerthinner.Makecertainthereareno burrs

aroundthe outsideedgeof the ports.

4--Spread athincoatof PeerlessNippleSealerinthe nippleports,NEVERON NIPPLES.
5--Insert the push nipples,withthe chamferededgeout. Makecertaintheyare cleanand freeofburrs.

6--Apply a thin coatof PeerlessNippleSealerto the ropegroove.Press5/8"Dia.ropeintothegroove.Thenipplesealeractsasan adhesiveto

holdthe ropeinplaceuntilthesecgonsare drawnup.

7--Arrange bothblocksso that protrudingnippleentersthe openport.Caremustbetakento keepnipplesstraightand blocksaligned.
8--Insert drawrodsthroughthe nippleports.Makecertainthatthe3/4"drawrod is usedonthelargenipple.Payparticularattentiontothe

placementof the drawwashers.SeeFig.A.

9--Before startingdraw,oil thethreadsand betweenthe nutsandwashers.

10--Tightenthe hexnutsanddraw boilerevenlyuntilthe smallpadson each sectionjusttouch.
11--After boilerisdrawn,removethedraw rodsand cut 5" fromthe 6V4" threadedend.Inserttherodthroughthe lugsoneachendsectionand

tightenthehex nutshandtight.

12--Attach3/8"Dia.ropeto baseback platebylayingropeacrosstopofbackplateflangeandinropegrooveon eachendofbackplate.Usenipple

sealerto hold ropein place.Referto figures9 & 12.Attachbase backplate bymeansof V4"-20x lr/2" machinescrewsandnutsfurnished.
Thebase backplateisattachedtobackof boiler.SeeFigure8.Becertainthatthe flange portionofplateistowardstheinsideof the boiler.
Note: hook boltisprovidedon models62-11through62-15only.

13--Install pressuregage,drainvalve,watersupplylinewith shutoffvalve,and meansto ventair.Plugunusedtappings.
14--Fill boilerwith water,ventingair aswaterlevelrises.Pressurizeboilerto75-85psig.Do notexceed85 psig.

15--Verifypressureis maintained.Checkalljointsand fittingsfor leaks.
16--Drainboiler.Removepressuregage,drainvalve,watersupplyandairvent.ContinuewithStep2 underD-1.

E - JACKET ASSEMBLY

A.Wrap-AroundRearJacket PanelStylefor Models61-03thru 61-06

Thisstylejacket designincorporatesa BackJacketPanelaspart of eachRightand Left SideJacketPanel.TheBack JacketPanelis formedwhena

portionofeach SidePanelis bentatperforationsto rearof boile_:

I, Inserttwo (2) 1/4-20x 1"studs intappedholesat bottomof RightEndSection.SeeFiguret.

2. Placethe RightSide Panelalongright sideof boiler blockandalignthe slotsof the mountingbrackets,(atbottomofjacketpanel),withthe 1/4-20x
1"studs.Attachjacketpanel toboilersectionwithtwo (2)1/4" nutsandwashers.SeeFigureI.

3. Placethe Left SidePanelalongleftsideof boilerblockand attachto boilersectionin samemannerasperformedforRightSidePanel.

4. Bendat theperforationsofthe RightSidePaneltoform halfof the BackJacketPanel.Dothe sameat perforationsofthe LeftSidePanel.Atthe
centerjointoverlapof the Back Panel,attachpanelswiththree (3) #10x 1/2"sheetmetalscrews.See Figure2.

PositiontheInnerFrontPanelbetweenthe Leftand RightSide Panels.Alignthe two(2)mountingholes,on eachsideflangeofthe InnerFront
Panel,with the clearanceholesin eachSide Panelandattachwith four(4) #10x 1/2"sheetmetalscrews.See Figure4.

6. PlacetheSecondaryAirCoverDooratbottomofInnerFrontPanel.ThetopbendoftheCoverDoorslipsoverthetopreversebendatcutout
openingoftheinnerFrontPanel.RefertoFigure11.

7. AtlachDraftHoodtoFlueCollectorwithtwo(2)#10x1/2"sheetmetalscrews.RefertoFigure10.

8. AttachtheLowerFrontPaneltothebottomtrontoftheLeftandRightSidePanelswithtwo(2)#10x1"sheetmeta_screws.SeeFigure4.

9. PositionTopJacketPanelsotheflangesoverlapSideJacketPanelsandairlouversareatthefrontoftheboiler.Securewithsix(6)#10x1/2"sheet

metalscrews.SeeFigure4.

10.AttachtheCleanOutCoverPlatePaneloveropemnginLeftSideJacketPanet,withfour(4)#10x1/2"jacketscrews.SeeFigure4

11.ThemanilaenvelopethatcontainstheInstallationManualalsocontainstheboilerratinglabel,clearancetocombustiblesplate,Lighting/Operating
instructionplateorlabelandwiringdiagramlabel.SeaFigure5forlocationofplatesandlabels.Attachplateswith#6x3/8"screwsprovided.

12.PositiontheRemovableFrontPanelinplacebyslidingthePanelunderthefrontflangeoftheTopPanelandthendownuntilitrestsonLowerFront
Panel.

B.IndividualBackJacket PanelStyle for Models61-07thru 62-t5

Thisjacketstyle hasaseparateBackJacketPanelthatis attachedtoindividualRightandLeftSidePanels.

1. AttachSide Panelsperinstructionsin #1thru3 above.SeeFigure1.

2. Positionthe BackJacketPanelonthe insideof theLeft and RightPanelflangesand attachwithsix(6) #10x !/2" sheetmetalscrews.SeeFigure3.

3. Followinstructionsaboveper #5thru 12for assemblyof remainingjacketpanels.

SIDE PANEL ATFACHMENT

FIGURE 1

-,_ RIGHT SIDE PANEL

ONEPIECERIGHT

SIDEANDREAR

PANEL

1/4" WASHER

1/4" NUT

J

J

ONEPIECE LEFT

SIDEAND REAR
PANEL

REAR VIEW WRAPPER

STYLE JACKET

(61-03THRU 61-06)

FIGURE 2

LEFTSIDEPANEL

RIGHT

SIDE

PANEL

REAR VIEW OF BACK PANEL

(61-07 THRU 62-15)

FIGURE 3

BACKPANEL

4

JACKET ASSEMBLY

FIGURE 4

/

/

#,

, LIGHTING/OPERATING

, INSTRUCTIONSLABEL

(61-63 THRU 62-11)

" WIRING

_J

/jJ DIAGRAMLABEL

RATINGLABEL

LIGHTING
INSTRUCTIONSPLATE

(62-12 THRU 62-15)

CITYOFNEWYORK

• MEAPLATE
(WHENREQUIRED)

CLEARANCETO
COMBUSTIBLESPLATE

REMOVABLEFRONTPANEL

(INSIDEVIEW)

INNERFRONT PANEL

AGENCY LABEL & PLATE LOCATIONS

FIGURE 5

FIGURE 6

FRONT BOILER VIEW

FIGURE 7

FRONT TOP BOILER VIEW

T_6"- !_UNC NUT & WASHER

_BASE BACK_

-- PLATE

BURNER MANIFOLD-_

HOOK BOLT _'w

FIGURE 9

HOOK BOLT ASSEMBLY

FIGURE8

REAR BOILERVIEW

FIGURE 10

FLUE COLLECTOR/DRAFT HOOD

.f,

H

FIGURE 11

SIDE VIEW OF INNER FRONT

AND COVER DOOR

-"IGURE 12

TOP CUT VIEW OF MANIFOLD

BURNER AND BASE BACK PLATE

6

F-VENTING

A.General

1--For connectionto gasventsor chimneys,ventinstallationshallbein accordancewith Part7,VentingofEquipment,ofthecurrenteditionof the

NationalFuelGas Code,ANSIZ223.1/NFPA54,orapplicableprovisionsofthe localbuildingcodes.

2--Draft: Sufficientdraftmustbeavailableforremovalof productsof combustion.If draftis notadequate,spillageofthe productsof combustion

will occuratthebottomoutletofthe drafthood.Ifsucha conditionshouldexistchecktheflueand chimneytodeterminecauseof insufficient

draft.It isalsoimportantthat ampleairis availablein theboiler roomtofacilitatedraft.
3--Vent connectorshouldslopeupwardat least1/4"per lineal footbetweenthe drafthood outletandthechimney.
4--Flue orvent connectormustbe insertedinto butnot beyondtheinsidewallofthechimneyflue.
5--Vent connectorsservingappliancesventedbynaturaldraftshallnot beconnectedintoany portionof mechanicaldraftsystemsoperating

underpositivepressure.

6--Horizontalportionsof theventingsystemsshall besupportedtopreventsaggingbyuseof metalstrappingor equivalentmeansandbe located

atno morethan 12ft. intervals.

7--When anexistingboilerisremovedfrom acommonventingsystem,thecommonventingsystemis likelytobetoo largeforproperventingof

theappliancesremainingconnectedto it.
Atthetime of removalof an existingboiler,thefollowingstepsshall befollowedwith eachapplianceremainingconnectedtothe common

ventingsystemplacedin operation,whilethe otherappliancesremainingconnectedtothecommonventingsystemarenot inoperation.

a.Sealany unusedopeninginthecommonventingsystem.
b.Visuallyinspecttheventingsystemforpropersizeandhorizontalpitchand determinethereisno blockageorrestriction,leakage,corrosion

andotherdeficiencieswhichcouldcausean unsafecondition.

c.Insofaras is practical,closeall buildingdoorsand windowsandalldoorsbetweenthespacein whichtheappliancesremainingconnected

to thecommonventingsystemarelocatedandotherspacesofthe building.Turnon any clothesdryersandanyappliancenotconnectedto
the commonventingsystem.Turnon anyexhaustfans,suchasrangehoodsand bathroomexhausts,so theywilloperateatmaximum
speed.Donot operateasummerexhaustfan.Close fireplacedampers.

d.Placein operationtheappliancebeing inspected.Followthe lightinginstructions.Adjustthermostatso appliancewill operatecontinuously.
e.Testfor spillageatthedrafthoodreliefopeningafter5 minutesof mainburneroperation.Usethe flameofamatchorcandle, orsmokefrom

a cigarette,cigar orpipe.

f. Afterit hasbeendeterminedthat eachapplianceremainingconnectedtothecommonventingsystemproperlyventswhentestedas

outlinedabove,returndoors,windows,exhaustfans,fireplacedampersandanyothergas-burningappliancetotheir previousconditionsof

use.

g.Anyimproperoperationofthecommonventingsystemshouldbe correctedsotheinstallationconformswiththecurrenteditionof the

NationalFuelGasCode,ANSIZ223.1/NFPA54.When resizinganyportionof the commonventingsystem,thecommonventingsystem

shouldberesizedto approachminimumsizeas determinedusingtheappropriatetableslocatedin the chapter"SizingofCategoryI Venting

Systems",inthe currenteditionof theNationalFuelGasCode,ANSIZ223.1/NFPA54.

8--Single WallTypeVentPipeshouldbefurnishedbetweenthedrafthoodandchimney.Iftheventconnectorshallbelocatedin orpass througha

coldarea,the ventconnectorshallbeoflisteddouble-wallTypeB or L material.