PEERLESS SERIES DE, DE-03, DE-04, DE-05, DE-06 Installation, Operation & Maintenance Manual
DE
Boilers
Installation,
Operation Et
Maintenance
Manual
PEERLESS _
CAST IRON BOILERS
4 Sizes 3-6 Sections 70.0 to 165.0 MBH CSA Input
bAFUE ¸¸¸
Natural or LP Gas
Fan Assisted for "Through the Wall" Venting or
Chimney Venting
• Can be Vented into a Lined Masonnj Chimney
• Ideal Where the Chimney is Inadequate or Unavailable
• Uses 3"diameterAL29 4C SS Vent Pipe for 'Through the Wall" or
"Vertical" Venting Applications
Steel Push Nipples
• Provide a Permanent Water Tight Seal Betw_Jen Sections
• Una[['ected by Petroleum and Other Contaminants
Deluxe Insulated Enameled Steel Jacket
• Reduces Boiler Ileal Loss
• Completely Encloses Gas Valve and Bartlel_
Safety Controls
• Flame Roll Out Shirt QffSwitch
• Difj-_.rential Pressure Switch
_)SinarlVt_h_(_ ks a r('gisl(_red Irademark qf Honeywell Corporatioa
• Honeywell Operating Controls
• Honeywell SmartValve ® Intermittent Ignition
• Taco 007 Circulator
• 30 PSI Safety Relief Valve
• Non-Combustible Floor Pan
• Grundfos Circulator
• AL29-4C Stainless Steel Venting Components
• 50 PSI Safety Relief Valve
Ik'cHt'._s l letllt'r Compatiy is pleased to ql]t't otte q[ lhe most compr_zhensive warranty prograrru,; ill
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PGGRLESS ®
CAST IRON BOILERS
Peerless Heater Company - 231 North Walnut Street * Boyertown. PA 19512-1021 * 610-367-2153 • www.peerless-heater.com
FAB DE 1tO 15102 5M}
Prlrlted irl U S A
TABLE OF CONTEN S
USING THIS MANUAL 1
A. INSTALLATION SEQUENCE ............. 1
B. SPECIAL ATTENTION BOXES ........... 1
1. PREINSTALLATION 2
A. ACCESSIBILITY CLEARANCES .......... 2
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION ..................... 2
C. AFR FOR COMBUSTION AND
VENTILATION ....................... 2
D. LIQUEFIED PETROLEUM (LP) GAS ....... 4
E. INSTALLATION SURVEY ............... 4
E PLANNING THE LAYOUT ............... 4
2. BOILER SET.;UP 5
3.
A. BOILER SUPPLY AND RETURN .......... 6
B. SAFETY RELIEF VALVE ................ 7
C. PIPING FOR ZONED SYSTEMS .......... 8
D. EXPANSION TANK .................... 9
E. INDIRECT-FIRED WATER HEATER ........ 9
E FREEZE PROTECTION ................. 9
4. VENTING _ 10
A. GENERAL .......................... 10
B, CHIMNEY VENTING .................. 10
C. DIRECT EXHAUST
HORIZONTAL VENTING- . ............. 11
D. DIRECT EXHAUST
VERTICAL VENTING .................. 13
E. BOILER REMOVAL FROM
COMMON VENTING SYSTEM .......... 14
5. GASPIPING: ; __ " ....... ........
6. ELECTRICAL 17
A. WIRING ........................... 17
B. ZONED SYSTEM WIRING ............. 17
C. CONTROLS ........................ 17
D. SEQUENCE OF OPERATION ........... 18
7, START-UP PR_CE_URES_ _ _._ 2,1
A. COMPLETING THE INSTALLATION ...... 21
B. CONTROL DESCRIPTIONS ............. 24
C. ADJUSTMENT OF GAS PRESSURE
REGULATOR ....................... 24
D. CHECKING BURNER INPUT ............ 24
E. CHECK-OUT PROCEDURE ............. 25
A. SHUT-DOWN CAUSED BY PILOT OUTAGE,
PRESSURE SWITCH OR FLAME ROLL-OUT
SAFETY SHUT-OFF SWITCH ........... 26
B. TROUBLESHOOTING GUIDES .......... 26
C. MEASURING SUCTION PRESSURE ...... 26
A. GENERAL .......................... 30
B. DAILY (WITH BOILER IN USE) .......... 30
C. WEEKLY (WITH BOILER IN USE) ........ 30
D. MONTHLY (WITH BOILER IN USE) ....... 30
E. ANNUALLY (BEFORE START OF HEATING
SEASON) .......................... 31
A. BLOCK!BASE/FLOOR PAN
JACKET/FLUE COLLECTOR ............ 33
B, BASE/BURNERS/MANIFOLD ........... 34
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Follow the installation instructions provided in this
manuaI in the order shown. The order of these
instructions has been set in order to provide the installer
with a logical sequence of steps that will minimize
potential interferences and maximize safety during
boiler installation.
Throughout this manual you will see special attention
boxes intended to supplement the instructions and make
special notice of potential hazards. These categories
mean, in the judgment of Peerless Heater Company:
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
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.
Read carefully, study these instructions before beginning work.
This boiler must be installed by a qualified contractor.
The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly.
The equipment must be installed in accordance with those installation requirements of the authority having
jurisdiction or, in the absence of such requirements, to the current edition of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54.
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,
ANS//ASME CSD-I.
f__!l l._ll(el:l.'l,.ll:!l! /li'/ [_ I:€_,I:__,1L_[_:(.,.
Install boiler not less than 24" between the left side. top,
and front of the boiler and adjacent wall or other
appliance, when access is required for servicing.
The design of this boiler is certified for closet installation
with the following clearances:
1. 6" between sides, rear and front and combustible
construction.
2. 24" between top of jacket and combustible
construction.
3, 2" between vent pipe and combustible construction.
Do not install this boiler on combustible flooring
unless it is installed on a special combustible floor
pan provided by Peerless Heater Company. Boiler
installation on combustible flooring without the
special pan is a fire hazard.
To order combustible floor pan, use the 5-digit stock
codes listed in Section 11 of this manual.
Do not install this boiler on carpeting. Boiler
installation on carpeting is a fire hazard. Install this
boiler on non-combustible flooring or use a
combustible floor pan to install this boiler on other
non-carpeted flooring.
1.
Provide adequate facilities for combustion and
ventilation air in accordance with Section 5.3, Air for
Combustion and Ventilation, National Fuel Gas
Code, or applicable provisions of the local building
code. Subsections 2 through 6 below are based on
National Fuel Gas Code requirements.
2. Definitions:
Unconfined Space: a space whose volume is not
less than fifty (50) cubic feet per 1000 Btulhr of the
total input rating of all appliances installed in that
space. Rooms communicating directly with the space
in which the appliances are installed, through
openings not furnished with doors, are considered
part of the unconfined space.
Unusually Tight Construction: Construction
where:
a. Walls and ceilings exposed to the outside
atmosphere have a continuous water vapor
retarder with a rating of I perm or less with
openings gasketed or sealed, and
b. Weatherstripping has been added on openable
windows and doors, and
C. Caulking or sealants are supplied to areas such
as joints around window and door frames,
between sole plates and floors, between wall-
ceiling joints, between wall panels, at
penetrations for plumbing, electrical and gas
lines, and at other openings.
3. Appliances Located in Unconfined Spaces:
For installations in unconfined spaceswith other
than unusually tight construction, the supply of air
for combustion and ventilation can usually be
considered adequate.
2
4 Unusually Tight Construction:
For equipment located in buildings of unusually tight
construction as defined on the previous page,
provide air for combustion and ventilation using the
methods described in 5a or 5b below.
5. Appliances Located in Confined Spaces:
a. All air from inside the building: Provide two
permanent openings communicating directly with
an additional room or rooms of sufficient volume
so that the combined volume of all spaces meets
the criteria for an unconfined space. Use the total
input of all gas utilization equipment installed in
the combined space in making this
determination.
Size each opening with a minimum free area of
one square inch per I000 Btu/hr. of the total
rating of all gas utilization equipment in the
confined space, but not less than I00 square
inches. Begin with one opening 12 inches from
the top, and begin the other opening within 12
inches of the bottom of the enclosure. See Figure
I. Provide air openings with minimum
dimensions not less than three (3) inches.
b. All air from oulside the building. Connect the
confined space with the outdoors in accordance
with methods i) or it) below. Provide air openings
with minimum dimensions not less than three (3)
inches. Where ducts are used, make certain that
they are the same cross-sectional area as the free
area of the openings to which they connect.
Provide two permanent openings, one
commencing within 12 inches of the top and
one commencing within 12 inches of the
bottom of the enclosure. Connect the
openings directly or by ducts, with the
outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
Where directly communicating with the
outdoors (see Figure 2) or where
communicating to the outdoors through
vertical ducts (see Figure 3), size each
opening with a minimum free area of one (I)
square inch per 4000 Btu!hr, of total rating of
all equipment in the enclosure.
Where communicating with the outdoors
through horizontal ducts, size each opening
with a minimum free area of one (i) square
inch per 2000 Blu/hn of total input rating of
all equipment in the enclosure. See Figure 4.
TWO AIR OPENINGS: _-
Minimum \
Free Area Each = \
1 in2per 1000 Btuh \
at Least 100 in2
t 12" max
3" rain
\
BUILDING
Mastcommunicatefreely
withoutdoors
Must notbeunder
negativepressure
_- 3" rain
12" max
Figure 1: Air Openings - All Air from Indoors
TWO AIR OPENINGS:
Minimum
Free Area Each =
1 in2per 4000 Btuh
Figure 2: Air Openings - All Air Directly from
Outdoors
12" max
Minimum
in _ per 4000 Btuh
Figure 3: Air Openings - All Air from Outdoors
through Vertical Ducts
Where the equipment has clearances of at
least one {1) inch from the sides and back
and six (6) inches from the front of the
appliance, the code allows one permanent
opening, commencing within 12 inches of
the top of the enclosure. Connect the
opening directly with the outdoors or through
a vertical or horizontal duct to the outdoors
or spaces (crawl or attic) that freely
communicate with the outdoors Size the
opening with a minimum free area of one
square inch per 3000 Btu/hr. of the total
input rating of all equipment in the enclosure,
and not less than the sum of the areas of all
vent connectors in the confined space.
6,
In calculating free area of an opening, take into
account the blocking affect of louvers, grilles and
screens. Do not use screens smaller than i/4" mesh.
If the free area is known, use this value in calculating
the size of the opening required. If it is not known,
assume that wood louvers provide 20-25% free area,
and metal louvers and grilles provide 60 75% free
area,
I:_ll Ih'_k:-IIw:!I Iz'l / tel [_L"ll I ;kvl:l '
7,
Remove sources of hydrocarbons (bleaches,
cleaners, chemicals, sprays, paint removers, fabric
softeners, etc.) from the boiler area. The vapors
generated by these substances can contaminate the
combustion air and contribute to shortened
boiler/vent system life.
I D_ ! [*Ill :i ;i1:1w] :J:ii| ;{*] Ill:llJ_V_HI _._l[_-'_
The following LP requirements from the Uniform
Mechanical Code, section 304.6, may be in effect in
your geographic area:
12" max
TWO AIR OPENINGS:
Minimum
Free Area Each =
in2per 2000 Btuh
Figure 4: Air Openings - All Air from Outdoors
through Horizontal Ducts
For new and existing installations, a Water Installation
Survey is available from Peerless Heater Company. The
survey will provide information on how a hot water
boiler works with your specific system and will provide
an overview of hot water system operation in general.
You can also use this survey to locate system problems
which will have to be corrected. To obtain copies of the
Water Installation Survey, contact your Peerless
representative.
I:1 I "JI_'l L_h_l h_[rill i" 1:11If'-Vl*lll
Liquefied Petroleum (LP) is heavier than air and may
collect or "pool" in a low area in the event of a leak
from defective equipment.This gas may then ignite,
resulting in a fire or explosion. See the instructions
below.
Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring.
"Liquefied petroleum gas-burning appliances shall not
be installed in a pit, basement or similar location where
heavier-than-air gas might collect. Appliances so fueled
shall not be installed in an above-grade under-floor
space or basement unless such location is provided with
an approved means for removal of unburned gas."
4
1 Provide a sound, leveI foundation Locate boiler as
near to the chimney or outside wall as possible and
centralized with respect to the heating system
2. Locate boiler in front of installation position before
removing crate.
3. If using combustible floor pan, position pan on
foundation or flooring.
4. Separate the wood shipping pallet from the boiler
base by removing two (2) hold-down bolts at each
end of the boiler base.
5. Move boiler into final position. If using combustible
floor pan, install boiler on pan as outlined in the
instructions included with the pan.
3. WATER PIPING AND
L"ll I:[e]ll:l;i [--[IJ'];JIk'dl h_'li_l=] .'|:l/IJ;]_,_
I. Size the supply and return to suit the system. A
typical piping arrangement is shown in Figure 5.
R4er also to the Hydronics Institute Installation
Guide 2000 and the Peerless Water Survey for
additional guidance during water piping installation.
2. Return Piping:
a. For boilers equipped with a factory-mounted
circulator, pipe the return to the inlet connection
of the circulator.
3.
b. For boilers equipped with a separate, unmounted
circulator, pipe the outlet connection of the
circulator to a tee, provided with a drain valve,
at the 1-1/4 NPT return tapping near the bottom
of the left section. Pipe the return to the inlet
connection of the circulator,
4.
5,
Supply Piping:
Pipe the supply to the I ]2 NPT supply tapping at
the top of the boiler
When system return water temperature will be below
130°E pipe the boiler with a bypass arrangement to
blend the system return and hot supply to obtain at
least 130°F entering the boiler For more information
on bypass piping, consult the Peerless Water Survey.
If desired, install the circulator in the alternate
location shown in Figure 5 Consult the Peerless
Water Survey for more information on circulator
location.
SUPPLY
ALTERNATE
CIRCULATOR\
LOCATION
COLD _ .4 N_:_.4 _ , ,.
WATER _
F,LL/- / /-.- ;
SHUTOFFJ PRESSUREJ CHECK J SHUTOFF J
VALVE REDUCING VALVE VALVE
VALVE EXPANSION TANKJ
_- AIR VENT
-AIR ELIMINATOR
RELIEF
VALVE
TO DRAIN
RETURN_/.L_
CIRCULATOR_ y
DRAI:--_ X] III
VALVE
Figure 5: Supply and Return Piping
6
6.
7.
8.
9.
install this boiler so that the gas ignition system
components are protected from water (dripping,
spraying, etc.) during appliance operation and
service (circulator replacement, condensate trap,
control replacements, etc.).
If this boiler and distribution system is used in
conjunction with a refrigeration system, pipe the
chilled medium in parallel with the boiler and install
the proper valve to prevent the chilled medium from
entering the boiler A drawing illustrating this hook
up is provided in Figure 6.
When the boiler is connected to heating coils located
in air handling units where they may be exposed to
refrigerated air circulation, install flow control valves
or other automatic means to prevent gravity
circulation of the boiler water during the cooling
cycle.
If this boiler is installed above radiation level,
provide a low water cutoff device, either as a part of
the boiler or at the time of boiler installation.
CHEEK VALVE _\
\
SUPPLY
LINE
LINE
WATER
[HREE WAY
VALVE
Figure 6: Parallel Hook-up with Water Chiller
I:_II R_,1:1=11&'dI;t :1111I=1;I lVl,_l&vA
1. Locate safety relief valve and fittings in bag
assembly.
2. If air elimination is not required at the safety relief
valve tapping, install valve and piping as shown in
Figure 71
3. For air elimination at the safety relief valve tapping,
install valve and piping as shown in Figure 8.
Pipe the discharge of safety relief valve to prevent
injury in the event of pressure relief. Pipe the
discharge to a drain. Provide piping that is the same
size as the safety relief valve outlet.
I
/./// \\
\
/
/
/
/
Figure 7: Safety Relief Valve Hook-Up Installation
with Air Elimination in System Piping
TO A4R
ELIMINATION
DEVICE
SUPPLY_ F3/4" tEE
SAFETY _3/4" X 6"
RELIE£ NIPPLE
VALVE
TO DRaiN
5/4" _TREET
ELBOW
Figure 8: Safety Relief Valve Hook-Up with
Air Elimination
[o.]NI']l;,ll_[e'li_[_];t,,(o]_l_w]_._k'_J=hVJ_
i See Figures 9 and I0 for basic zoned system layouts
2. Run each zone pipe down then up to zone to
prevent air accumulation in piping.
3. If required, provide means to isolate and drain each
zone separately.
TO SYSTEM
ZONE /O'qE
3 2 I
FROM SYSTEM
ZONE ZONE ZONE
1 2 5
Z S N E
'/A ,/E S °S
I
_h
CONNECT
TO
SUPPLY
BALANCING
VALVES
CONNECT TO
RETURN
(CIRCULAIOR INLET)
z
Figure 9: Zone Piping with Zone Valves
TO SYSTEM
ZONE ZONE ZONE
2 1
FROM SYSTEM
ZONE ZONE ZONE
1 2 3
CONTROL
VALVES
L
I
CONNECT
TO
SUPPLY
ZONE
CIRCULATORS
CONNECT TO
RETURN
TAPPING
Figure 10: Zone Piping with Circulators
8
IlI I:).'4:1._IL'I_ [*] L'II _±Ib._I:
I'_ :t _ :_',4:l :J.*{._ i :_taj/ [.] k
Consult the tank manufacturer's instructions for
specific information relating to tank installation. Size
the expansion tank for the required system volume
and capacity See Table 10 in Section 10 for boiler
water capacity
2.
Expansion tanks are available with built-in fillvalves
and check valves for reducing supply water pressure
and maintaining minimum system pressure. Check
the design features of the tank and provide valves as
necessary.
Refer back to Figure 5 for typical expansion tank piping.
=lq h_l*] I:i::[,_l t_= I ;{ :ID]i_i_l_*_li :_;l I-"I:r_,'11:I:
If the boiler is to be used in conjunction with an indirect-
fired water heater, refer to Figure 11 for typical piping.
Follow the instructions provided by the water heater
manufacturer. Pipe the water heater as a separate zone.
For new or existing systems that must be freeze-
protected:
Use only inhibited propylene glycol solutions of up to
50% by volume with water. Ethylene glycol is toxic
and can attack gaskets and seals used in hydronic
systems.
1.
Glycol in hydronic applications is specially
formulated for this purpose. It includes inhibitors
which prevent the glycol from attacking metallic
system components. Make certain that the system
fluid is checked for the correct glycol concentration
and inhibitor level.
2. The antifreeze solution should be tested at least once
a year and as recommended by the antifreeze
manufacturer.
3,
4.
Antifreeze solutions expand more than water. For
example, a 50% by volume solution expands 4.8%
in volume for a temperature increase from 32°F to
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 TO .
SYSTEM
RETURN FROM •
SYSTEM
HOT DOMESTIC ,.,___
WATER SUPPLY
COLD DOMES_C_
WATER SUPPLY
ZONE VALVE_
INDIRECT-FIRED
WATER HEATER
L
SUPPLY 1
TO TANK
BALANCING
VALVE
BALANCING
VALVE
DRAIN
17_ SYSTEM
i_1 CIRCULATOR
Figure 11: Typical Piping with Indirect-Fired Water Heater
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