PEERLESS SERIES GM, GM-05, GM-06, GM-07, GM-08 Installation, Operation & Maintenance Manual

GM

Boilers

Installation,
Operation b

Maintenance
Manual

PEEI_LESS*

CAST IRON BOILERS

Packaged Residential/Commercial Gas Fired, Hot

4 Sizes 5-8 Sections 228.0 to 399.0 MBH Input 82% Combustion Efficiency

Natural Gas

• Standing Pilot (5-6 section)

• Honeywell SmartValve ® Intermittent Ignition (5-8 section)

Natural Draft (Chimney) Venting

• Simplifies Installation

Steel Push Nipples

• Provide a Permanent Water Tight Seal Between Sections

• Unaffected by Petroleum and Other Contaminants

Deluxe Insulated Enameled Steel Jacket

• Reduces Boiler Heat Loss

• Completely Encloses Gas Valve, Burners and Controls for

Safe Operation

Front Located Controls and Return Piping

• Ideal for modular and multiple boiler installations

• Easy to service

Packaged Boiler

• Reduces Installation Time

Vertical Draft Hood

• Supports Combustion

Safety Controls

• Vent Safety ShutoffSwilch

• Flame RoUout Safety Shuto[]Switch

• Honeywell SmartValve °-_Intermittent Ignition

• Honeywell Operating Controls

• 30 PSI Sof('ty Relief Valve (unmounted)

• Vent Damper (5-6 section)

• Vertical Draft Hood

! STIIOI I_(llll{! iS II II'( ist(_r_,d Irademrlrk o[ t [I)IEt'IIH_I'II (_oI'lll)I I

• Standing Pilot Ignition (5 6 section)

• Toco 0010 & 0012 Circulators (unmounted)

• Taco 0010 & 0012 Zoning Circulators
with relay (unmounted)

• 50, 80 or 1O0 PSI Safety Reli@ Valve (unmounted)

• Probe _]pe LWCO (unmounted)

• Vent Dampt'r (7 8 section)

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Peerless Heater Company • 231 North Walnut Street * Boyertown, PA 19512-I021 • 610-367-2153 * www.peerless-heater.com

FAB GM R2 {7'02 5M)

Pr,ltl.0 Irl U S A

1=

USING THIS MANUAL 1

A. INSTALLATION SEQUENCE ............. 1

B. SPECIAL ATTENTION BOXES ........... 1

PREINSTALLATION 2

A. ACCESSIBILITY CLEARANCES .......... 2

B. CLEARANCE FROM COMBUSTIBLE

CONSTRUCTION ..................... 2

C. COMBUSTION AND VENTILATION AIR .... 2

D. INSTALLATION SURVEY ............... 4

E. CIRCULATORS ....................... 4

E PLANNING THE LAYOUT ............... 4

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. DRAFT HOOD ...................... 10

B. AUTOMATIC VENT DAMPER .............

INSTALLATION - GENERAL ............ 11

C. VENT PIPING AND CHIMNEY .......... 11

D. BOILER REMOVAL FROM COMMON

VENTING SYSTEM ................... 12

5 _GAs _P|PJNG _':

A. WIRING ........................... 15

B. CIRCULATOR/ZONE VALVE WIRING ..... 15

C. LOW WATER CUTOFF ................ 15

A. GENERAL .......................... 21

B. CSD PART CF REQUIREMENTS ......... 21

C. CSD PART CW REQUIREMENTS ........ 21

D. CSD MODULAR AND MULTIPLE BOILER

REQUIREMENTS .................... 21

E. CSD PART CE ELECTRICAL

REQUIREMENTS .................... 22

23

A. COMPLETING THE INSTALLATION ...... 23

B. CONTROL DESCRIPTIONS ............. 27

C. ADJUSTMENT OF GAS PRESSURE

REGULATOR ....................... 27

D. CHECKING BURNER INPUT ............ 27

E. CHECK-OUT PROCEDURE ............. 28

A. SHUT-DOWN CAUSED BY PILOT OUTAGE,

VENT SAFETY SHUTOFF SWITCH OR

FLAME ROLLOUT SAFETY SHUTOFF

SWITCH ........................... 29

B. TROUBLESHOOTING GUIDES .......... 29

_O.MAINTENANCE 32

A. GENERAL .......................... 32

B. DAILY (WITH BOILER IN USE) .......... 32

C. WEEKLY (WITH BOILER IN USE) ........ 32

D. MONTHLY (WITH BOILER IN USE) ....... 32

E. ANNUALLY (BEFORE START OF HEATING

SEASON) .......................... 33

A. BASE ............................. 35

B. GAS MANIFOLD, ORIFICE SPUDS, AND

MAIN BURNERS ..................... 36

C. BLOCK AND FLUE COLLECTOR ......... 37

D. JACKET ........................... 38

E. CONTROLS, DRAFT HOOD AND

AUTOMATIC VENT DAMPER ........... 39

Follow the installation instructions provided in this
manual in the order shown. The order of these

instructions have 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.

Indicates a condition or hazard which will cause
severe personal injury, death or major property

damage.

_.'t',J:[I,] r__ I r*__l/ i _b?I i [o] L'_I:[o).'4 ::_

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 the Peerless Heater Company:

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.

Theequipmentmustbeinstalledinaccordancewithinstallationrequirementsoftheauthorityhaving
jurisdictionor,intheabsenceofsuchrequirements,tothecurrenteditionoftheNational 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, ASME CSD-I.

Carefully read these instTuctions before beginning work. Understand all aspects of the installation. Contact your Peerless Heater
Company sales representative or customer service for help in answering questions.

This boiler must be installed by a qualified contractor. The boiler warranty can be voided if the boiler is not installed correctly.

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Install boiler not less than 24" between the top and front
of the boiler and adjacent wall or other appliance, when
access is required for servicing.

Do not install boiler on carpeting. Boiler installation
on carpeting is a fire hazard,

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The design of this boiler is certified for alcove installation
with the following clearances from combustible

construction:

I Sides: 2"

2. Top of Jacket: 36"

3. Draft Hood: 6"

4. Vent Pipe: 6" (1" for Type B vent)

5. Rear of Jacket: 6"

Do not install this boiler on combustible flooring.
Boiler installation on combustible flooring is a fire

hazard.

6. If it is necessary to build a non-combustible floor pad

over top of an existing combustible floor, construct
pad as stated in the .National Fuel Gas Code
Handbook Part 6, Installation of Specific Equipment.

].

2.

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.

Definitions:

Unconfined Space: a space whose volume is not
less than fifty (50) cubic feet per 1000 Btu!hr 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 1 perm or less with
openings gasketed or sealed, and

b. Weatherstripping has been added on openable

windows and doors, and

e.

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 spaces with other
than unusually tight construction, the supply of air
for combustion and ventilation can usually be
considered adequate.

=

'qll

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 100 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

1. Provide air openings with minimum
dimensions not less than three (3) inches.

b. All air from outside the building. Connect the

confined space with the outdoors in accordance
with methods i) or ii) 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 flee area of one (i) square

inch per 2000 Btu/hr of total input rating of

all equipment in the enclosure. See Figure 4.

12" max

TWO AIR OPENINGS:

Minimum

Free Area Each =

1 in2 per 1000 Btuh

at Least 100 in2

3" m{n

BUILDING

Mustcommunicatefreely

with outdoors

Must not beunder

negativepressure

3" mill

12" max

Figure 1: Air Openings - All Air from Indoors

TWO AIR OPENINGS:

Minimum

Free Area Each =

1 in2per 4000 Btuh

3" min __

12" max,_

Figure 2: Air Openings - All Air Directly from

Outdoors

[_L 12" max

3" rain TWO AIR OPENINGS:

Minimum

Free Area Each =

Figure 3: Air Openings - All Air from Outdoors

through Vertical Ducts

3

| ill _T_t::]I_t--'_*]]_ [r_ITr_]

6,

7.

ii) Where the equipment has clearances of at

least one (I) 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.

In calculating tree area of an opening, take into
account the blocking affect of louvers, grilles and
screens. Do not use screens smaller than 1/4" 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.

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.

12" max

TWO AIR OPENINGS:

Minimum

3" min Free Area Each =

1 in_per 2000 Btuh

3" rain

12"max

Figure 4: Air Openings - All Air from Outdoors

through Horizontal Ducts

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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:;l! [s,]I :{e,LI JI_,_llie];_

The Series GM boiler is not equipped with a circulator
or a means to control circulator operation. Provide
circulator and zone controls, such as Taco zoning
circulator or Honeywell R845.

i;q "JIr±l L_IL_I1_[_1i i : 11 II:VLeI Ii

Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring.

4

--m__

I Provide a sound, level 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 Separate the wood shipping pallet from the boiler

base by removing two (2) hold-down bolts at each
end of the boiler base.

4. Move boiler into final position.

5

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Design piping and size circulator(s) to suit the system. Refer to
Hydronics Institute Installation Guide 2000 and the Peerless
Water Installation Survey for guidance.

L'I I:{e]lg:l:t _.'llJ'.J',_l_'l:lL_lm];|:lllJ:|k_

Install boiler to protect the gas ignition system
components from water (dripping, spraying, etc.) during
appliance operation and service (circulator replacement,
condensate hap, control replacements, etc.).

1. Remove shipping nipple from supply tapping.

2. Install temperature-pressure gage with tee in
supply tapping. Nipple, tee, bushing and gage are
located in trim carton. See Figure 5.

3.

Install drain valve. Remove jacket front panel.
Install drain valve with tee in return tapping. Nipple,
tee, bushing and drain valve are located in trim
carton. See Figure 7. Tee may be installed with run

in either horizontal or vertical orientation.

4.

Install supply piping, return piping and circulator.

See Figure 6.

a. If boiler is installed above radiation level, provide

a low water cutoff device in the supply piping
above boiler. See Figure 6.

TEMPERATURE
PRESSURE
GAGE

F1-1/2" TEE

7! 1/2" X 8"

NIPPLE

I/2"× 1/4"

BUSHING

Figure 5: Temperature-Pressure Gage Installation

COLD

WATER

FILL

Figure 6:

SUPPLY

ALTERNATE CIRCULATOR

LOCATION _

SHUTOFF_

VALVE PRESSURE/ / sHuToPE/F

REDUCNO / / VALVE J L

VALVE_ /

_AIR VENT

AIR ELIMINATOR

CHECK

VALVE _

-- .--_DD,-

RETURN I

CIRCULATOR ___

DRAIN

VAI VE _-.

Typical Supply and Return Piping

i_LOW WATER

/ CUTOFF

/

! DRAFN

6

b,

c.

d,

When system return water temperature will be
below 130°F,,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 Installation Survey.

If this boiler and dislTibution 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. See Figure 8.

When the boiler is connected to heating coils
located in air handling units where they may be
exposed to refrigerated air circulation, install flow
contzol valves or other automatic means to
prevent gravity circulation of the boiler water
during the cooling cycle.

I:m [__'W_=ISlk'4I;|:lll:l= krl'-11.rd

I. Locate safet_ relief valve and nipple in tzim carton.

2. Install safety relief valve in 3/4 NPT tapping behind
supply tapping. Safety relief valve must be installed

with spindle in vertical position. See Figure 9.

Figure 7: Drain Valve Installation

CHECK VALVE

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,

LiN_

WATER tHrEE WAY

I_ci[LL[R VALVE

Figure 8: Parallel Hook-up with Water Chiller

SAFETY

SUPPLY _ RELIEF

VALVE

/

/

\

/ TO DRA_N

Figure 9: Safety Relief Valve Installation

7

1. See Figures i0 and 11 for basic zoned system

layouts. Circulators may be installed in either supply

or return piping. Refer to Peerless Water Installation

Survey for additional information.

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.

3

FROM SYSTEM

ZONE ZONE ZONE

1 2 5

TO

BALANCING

VALVES

CONNECT TO

RETURN

(CIRCULATOR INLET)

H

Figure 10: Zone Piping with Zone Valves

Z C'r,!E _'_:'-

i

i

' _ I 'F I

• d - i

I i

f

• • t + 4

(_ :£) ['i bJE I :

Z! i L}

FROM SYS!EI',,/

I

!

I

,. , • L, _¸ I .• _ .2.

....................... ] 0

' -: 'i :t;

[ }

l

Figure 11: Zone Piping with Circulators

8

I_il 1:1t,1:1:1_4::in-.J:Telld:loCiiI [el _

1, 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 5 in Section 11 for boiler's
water content,

2.

Expansion tanks are available with built-in fill valves
and check valves for reducing supply water pressure

and maintaining minimum system pressure. Check
the design features of the tank and provide valves as

necessa_j.

Refer to Figure 6 for typical expansion tank piping.

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Boiler may be used as heat soume for indirect-fired
water heater. Refer to Figure 12 for typical piping.
Follow the instructions provided by the water heater
manufacturer. Pipe the water heater as if a separate
space heating 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.

2.

3.

Glycol for hydronic applications is specially
formulated with 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.

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 TC

SYSTErvl

RE tURN FROV,

SYSTEbi

TTq I I

ZONE

CIRCU LA TORS[}_8.._

v

HOT DOMESTIC

SUP'PLY

IN[I:C'F:SI FIRED

Wi- TER HEATER

",:. _},

},k: I',"

.', TF{ i;vP Y

S

. - J

>

DRAIN

! F '

! :

I i

L

Figure 12: Typical Piping with Indirect-Fired Water Heater

W! ID);_l_ilil[oIo]B

1,

2.

3.

The boiler is equipped with a draft hood designed to:
a. provide for the ready escape of flue gases from

the boiler in the event of no draft.

b. prevent a backdraft from entering the boiler.

c. control stack draft during operation.
The draft hood must be installed without alteration.

Make certain there are no obstructions to airflow to
the relief opening.

Position draft hood with 1" diameter hole in conical
portion of draft hood (for vent safety shutoff switch)
towards front right corner of boiler. Secure to flue
collector with sheet metal screws. See Figure 13.

The boiler is equipped with a vent safety shutoff
switch. The switch is shipped in a cloth bag attached
to the harness on the exterior of the boiler. Attach
switch to holes in the conical portion of the draft
hood using the screws provided in bag. See
Figure 13.

Vent safety shutoff switch wiring harness must extend
to vent safety shutoff switch without excessive slack.
To adjust harness length, squeeze strain relief bushing
to release from jacket. Adjust harness to proper
length. Reinsert strain relief bushing.

VENT SAFETY

SHUTOFFSCREWSMETALSHEETSWITCH_x

VENT SAFETY '_ /
SHUTOFF SWITCH "_
WlRINC HARNESS_

Figure 13: Draft Hood and Vent Safety Shutoff

Switch Installation

INCORRECT

I

L__,

,{},THEr_

k:_ _]IN,S

APPLIANCE-

CORRECT

Figure 14: Venting Multiple Appliances

10

[e,lqkV4:lL'hlii:,]l:Jh,_felF_qL'_le][_:ilLVJh'q=h,

1.

2.

3.

4.

Do not use one vent damper to control two or more
heating appliances. See Figure 14.

Follow these and the installation instructions included
with the vent damper. Observe the cautions and

warnings that accompany all instructions.

Provide minimum 6 inch clearance between
automatic vent damper and combustible

construction. Increase clearance if required by vent
damper manufacturer's instructions. Provide

adequate space for vent damper access and service.

The automatic vent damper can be mounted directly

onto the draft hood outlet or in vent piping close to

the boiler.
See Figure 15 for installation with vent damper

mounted in vertical position. See Figure 16 for
installation with vent damper mounted in horizontal

position. Mount the unit to avoid excessive heat on
the operator or condensation drips into the operator.

a. Orient the vent damper operator to facilitate

connection of the vent damper harness to
knockout on right side of boiler. See Figure 19.

b. Orient vent damper direction arrow in direction

of vent gas flow. Direction arrow must be visible

from front of boiler.

i,

2.

3.

4,

5,

6.

7.

Install vent piping in accordance with Part 7, Venting
of Equipment, National Fuel Gas Code, ANSI

Z223.1/NFPA 54 or applicable provisions of the local
building codes.

Inspect the existing chimney and lining for structural
soundness, corrosion and perforations. Repair as

necessary.

Install vent pipe to slope upward at least I/4" per
lineal foot between the draft hood outlet and the

chimney.

Before connection of joints, inspect the vent pipe
interior for foreign objects such as tools, equipment,

rags, etc. and remove if present.

Insert vent pipe into but not beyond the inside wall
of the chimney flue.

Do not connect vent connectors serving appliances
vented by natural draft into any portion of
mechanical draft systems operating under positive
pressure.

Support horizontal portions of the venting system to
prevent sagging by use of metal strapping or
equivalent means. Locate supports at no more than

four (4) foot intervals, or in accordance with vent
system manufacturer's installation instructions.

SLOPE UP
A MINIMUM

OF

PER FOOT_

\

AUTOMATIC
VENT

DAMPER_

AS REQUIRED

DRAFT
HOOD

RELIEF
OPENING

\

\

"DRAFT HOOD

OUTLET

Figure 15: Venting with Vent Damper in Vertical Position

11

AUTOMATIC /- VENT TO

SLOPE UP VENT /CHIMNEY

A MINIMUM DAMPER 7
OF 1/4" / [ I

PER FOOT _

NENN

7

O'CLOCK 1 O'CLOCK

POSITION_ , /-- POSITION

VJJ/// s DA',,'PER

HEAT ....-.'_ S OPERATOR

ZONEJ __O0_ECONDENSATION

O'CLOCK J _5 O'CLOCK

POSITION POSITION

DO NOT MOUNT DAMPER

OPERATOR IN SHADED REGION

SECTION A--A

Figure 16: Venting with Vent Damper in Horizontal Position

At the time of removal of an existing boiler, follow these
steps 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, leakage, corrosion and other

deficiencies which could cause an unsafe condition.

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 common venting system.
Turn on any exhaust fans, such as range hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
fireplace dampers.

d,

e.

g.

Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.

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.

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.
Any improper operation of the common venting

system should be corrected so that the installation
conforms with the National Fuel Gas Code, ANSI

Z223.1/NFPA 54. 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 located in
the chapter "Sizing of Category I Venting Systems,"

of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

12

I. Size and install the gas supply piping to provide a

supply of gas sufficient to meet the maximum
demand of all appliances without undue loss of
pressure between the meter and the boiler.
Maximum permissible gas supply pressure to the

boiler is 13.5 inches water column.

2. Determine the volume of gas to be provided to the
boiler Obtain this value by dividing the Btu per hour
rating (on the boiler rating plate) by the heating
value of the gas in Btu per cubic feet. Obtain the
heating value of the gas from the gas supplier. As an
alternative, use Table 1 to obtain the volume of gas
to be provided to the boiler.

Table 1: Input (Cubic Feet Per Hour)

Model Natural Gas

GM-05 228
GM 06 285

GM-07 342
GM-08 399

Natural gas based on I000 Btu/Cubic Foot.

3. Use the value obtained above as the basis for piping
sizing. Size the gas piping in accordance with Table

2. Consult the National Fuel Gas Code for other
sizing options.

Table 2: Capacity of Schedule 40 Pipe

Capacity of Schedule 40 pipe (cu. fl. per hour) with pressure
drop of 0.3 in. and specific gravity of 0.60. No allowance for
an ordinary number of fittings is required.

Pipe _/4_ 1_ 1t/4" 1½"

Length

Feet Pipe Pipe Pipe Pipe

I0 ! 278 I 520 1,050 1,600

20 190 i 350 I 730 I,i00
30 I 152 285 ; 590 890

40 130 ! 245 500 760
50 115 i 215 440 670

60 105 195 400 610

Multipliers to be used with the above table when the
specific gravity of the gas is other than 0.60:

Specific Gravity , . .0,50 0.55 0.60 0.65 0.70

Multiplier ........ 1.10 1.04 1.00 0.962 0.926

4. Connection of boiler to the gas piping system may
be made on the left side or top of the boiler. See
Figure 41 for jacket opening locations.

Use a pipe joint sealing compound that is resistant to

the action of liquefied petroleum gas. A non-resistant

compound may lose sealing ability in the presence of

this gas, resulting in a gas leak and fire or explosion

potential.

5.

6.

7.

Install a sediment trap. See Figure 17. 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 an alternate, the sediment trap may be

located in the boiler vestibule. See Figure 18.

Install a ground joint union ahead of the gas control
assembly to permit servicing of the control. Some

local codes require an additional equipment shutoff
valve when using the combination gas controls. If
your code requires such a valve, a suggested

location is shown in Figure 17 or 18.

Check piping for leaks. Use an approved gas
detector, a non-corrosive leak detection fluid or other

leak detection method. If leaks are found, turn off all
gas flow and repair as necessary.

When checking for leaks, do not use matches,
candles, open flames or other methods that provide a
source of ignition,This can ignite a gas leak,
resulting in fire or explosion,

EQUIPMENT
SHUTOFF

VALVE

JACKET
OROUND

JOINT
UNION __

SEDIMENT

TRAP _
FLOOR

lINE

x

\

I

Figure 17: Gas Connection to Boiler - External

13

8. Disconnect the boiler and its individual shut-off valve
from the gas supply piping system during any
pressure testing of that system at test pressure in
excess of 1/2 psig (3.5 kPa).

Isolate the boiler from the gas supply piping system
by closing its individual service valve during any
pressure testing of the gas supply piping system at
test pressure equal to or less than 1/2 psig (3.5 kPa).

9. Minimum permissible supply pressure for purposes of

input adjustment (Inches Water Column):

_ GM-07

Standing Pilot 4.8 5,5 ........

Intermittent 4.5 4.5 4.6 4.9
Ignition

10. Maximum permissible supply pressure to the boiler
(Inches Water Column):

All models 13.5"

Ec_'UIP'dk N

FiI,' - r_

_])IN r fz

' C/ J

- !

Figure 18: Gas Connection to Boiler - Internal

14

,d

E.']II:lIF--[,._;IC,.I_g

This unit when installed must be electrically grounded in accordance with the requirements of the authority

having jurisdiction or, in the absence of such requirements, with the current edition of the National Electrical
Code, ANSI/NFPA 70.

r;l ITl_JI;] Ib,_[€

I. See Figure 19 for location of wiring and controls, use

Figures 22 and 23 to connect the boiler to a power
supply and the connect components to the boiler.

2. Connect the boiler to a separate, permanently live

electrical supply line with a fused switch.

3. Connect the vent damper harness to the polarized

connector in the boiler vestibule as shown in

Figure 19.

3. Figure 25 shows typical wiring for one or more
circulators.

4. Figure 26 shows typical wiring for zone valves.

Do not power zone valves directly from the boiler
transformer, Doing so will greatly reduce the life of

the transformer. Use a separate transformer sized to
handle the total of all zone valve electrical loads.

:J [e,]I_'{HIJIf_,'llie] -'_Y_[e]L_I=kVl_,l&vj =liVid|I;| h_[€

:l[e|_A!JI_1!!'-_1/ =1;i[H Ij I[*] ;I

1. A zone control is required to operate circulator(s)

when using a low voltage thermostat.

2. Taco Zoning circulator(s) can be used instead of
mounting separate circulator r_lay(s) (Figure 20).

Wire low water cutoff to turn off power to boiler. See
Figure 21 for Hydroleve1550 low water cutoff. Refer to

manufacturer's instructions for other low water cutoffs.

POLARIZED
CONNECTOR

DAMPER

HARNESS

THERMOSTAT

VOLTAGE

POWER SUPPLY

BOX WITH PLATE

MOUNTED TRANSFORMER

Figure 19: Wiring Details

15

.a

[.11[=(M=[q,(;([_f-'1ml('4_i_rmi'

f FROM t

THERMOSTAT --

OR OPERATING

CONTROL

/

TO JUNCTION 115V 60HZ

BOX PINK AND POWER SUPPLY
GREY W_RES.

Figure 20: Taco Zoning Circulator Wiring

I f:J v' E,QIZ

FO HAIN

DISCONNECT S_'vl ICH

t

L2 _/ GXD

A •

/, TO TRAXSFORM P B[ A/,_ ,',!;F

WHFF WIltS [ :': ,'_:[S I _!l}

L2 SHO//'4 {}_J WI_N{] [}/ 1_'

Figure 21: Hydrolovel 550 Low Water Cutoff Wiring

16

- [_iR =iai=[_ d;t [,@',_'_i![(_]

(HOT) ?

TRANSFORMER

120VAC

f_c'Nwww_

24VAC

"- l: •

i i
i i

VENT I i

i i FLAM E

SAFETy i

LIMIT S_TC H CONTROL S_TCH

....

DAMPER STUB HARNESS _ _

Y Y

GAS VALVE t i

!

I

_ _ ,

LADDER LEGEND L_

120 VAC _IRING (LINE) IGNITER L

..... 24 VAC WIRING (LOW) ELEMENT _ENSOR LGROUND

(pILOT

NOTES TUBING)

ALL _RING MUST COMPLY WrTH APPLICABLE CODES,
ORDINANCES AND REGULATIONS

bF ANY OF THE ORIGINAL WIRE AS SUPPLIED _TH THE APPLIANCE
MUST BE REPLACED, IT MUST BE REPLACED WITH WIRE
AS SHOWN OR _TS EQUIVALENT

VENT SAFETy_CGY _( _____ DAMPER PLUG OR VENT DAMPER

SHUTOF_yS_TCH _ OU_ HARNESS (WHEN USED)

=-R ..... ; ; 'I_'_DAMPER STUB HARNESS

_1 _ o I-i

LIMIT i I _ I _ SERVICE FUSED

i i : S_TCH DISCONNECT

I , , ,' , J HOT

I I . ' L _ TOMAN

JUNC TION I I LiI I I , _ _SV 60HZ DSCONNEC

BOX----.._ , I # " I " I _2 _ SWITCH

i J r i ,

40VA i i t L._

7 }1, • ,,,

_! .... •

llllll .....

\

BR ' 2 J'

_ : i I \ THESE,TEMSTOeE

LJllllkr-- 1 T ! SURPUEDBY_NSTALLER

i

i p

_ ' PR',IRR FLA_E

ROLLOUTSWPTCH

WIRE CODE

RED

ORANGE
BK BLACK
BR BROWN
W WHITE
GY GREY

GRGYW GREE_GREYWMrTE STRIPE
Pl PINK

pR PURPLE

PILO T

[

CONNECTION DIAGRAM LEGEND

24 VAC SiZE IB AWG TYPE CL2X WIPE

........ 120 VAC SIZE 14 AWG TYPE TW TgFN WIRE

......... 24 VAC SIZE 16 18 AWC TYPE TW/TFFN OR CL2X WiRE

HONEYWELL PILOT WIRING

Figure 22: Connection and Schematic Diagram, intermittent Ignition

1.

2.

3.

4.

5.

Thermostat calls for heat.

Limit senses boiler water temperature. Prevents
operation until water temperature falls approximately
15°F below the cut-out temperature.

Automatic vent damper (if used) opens. Damper
must be in open position when appliance main
burner(s) is operating.

Gas valve energizes.

a. Igniter on.
b. Pilot gas on, igniting pilot.

Pilot flame detected.

a. Igniter off.

b. Main gas on, igniting main burners.

Note: If pilot flame is not detected within 30 seconds,
the igniter is turned off for 30 seconds, and then turned
back on. If the pilot is not detected within 30 seconds,
the igniter and pilot gas are turned off for 5 minutes.
The sequence then resumes at Step 4a.

6. Call for heat ends.
a. Pilot and main gas off, extinguishing pilot and

main burners.

b. Automatic vent damper (if used) closes.

17

[.II _ [r4"a_al

(HOT)

fRANSFORMER

ltSVAC

24VAC

II
II

VENT I I FLAME

SAFETY

H T FF OPERATING _ ROLLOUT

UMIT S_U ITOH CONTROL SWITCH

I

DAMPER STUB HARNESS _ I

L_DDER LEGEND

115 VAC WIRING (LINE)

- 24 VAC WIRING (LO_)

i i
i

_mAP

THERMOCOUPLE

NOT[SH -

ALL WIRING MUST COMPLY WITH APPLICABLE CODES,
©_D_NANCES AND REGULATIONS

.F AN_ OF Trl_ ORIGINAL WiRE AS SUPPLIED WITH THE APPLIANCE
MUST _E RFPLACED :T MUST BE REPLACED WITH _RE
AS SHOWN OR ITS FCUIVALENT

?

VENT

SAFETY

S_TC H

Ou

OR VENT DAMPER

HARNESS

SER_CE FUSED ]

S_TCH DISCONNECT

TO MAIN

I15V-60HZ DISCONNECT

S_TCH I

I

OPERATING CONTROl.

SUPPLIED BY INSTALLER

I
I

L
I

WIRE CODE [

RE D

ORANGE

BK BLACK
BR BROWN

_y WHITE

OREY

GY W GREY/WHITE STRIPE

GR GREEN

PI PINK
pR PURPLE

PILOT

PR PR FLAME

_ ROLLOUTS_,_ TCH

[ BR THERMOCOL

CONNECTION DLAGRAM LEGEND

24 VAC SEZE 18 AWG T_PE CL2X WIRE

115 VAC SIZE 14 AW0 TYPE TW TFFN _RE

_-- 24 VAC SIZE 16 18 AWG TYpE TW/TFFN OR CL2X WIRE

Figure 23: Connection and Schematic Diagram, Standing Pilot

1.

2.

3.

4.

5.

Thermostat calls for heat.

Limit senses boiler water temperature. Prevents
operation until water temperature falls approximately
15°F below the cut-out temperature.

Automatic vent damper opens.

Gas valve energizes.
Pilot flame detected by thermocouple. Main gas on,

igniting main burners.

Note: if pilot flame is not detected, main and pilot
gas are automatically turned off. Pilot must be
manually relit. See Figure 36 for Lighting

Instructions.

6. Call for heat ends.
a. Main gas off, extinguishing main burners.

b. Automatic vent damper closes.

18

START

TRIAL

FOR J

IGNITION

MAIN L

BURNER
OPERATION

I APPLY24 VAC I

TO APPLIANCE

L THERMOSTAT J

CALLS FOR HEAT

,p,

I_LA_c_S'_A'_NO'._YES

INTERNAL CHECK OKAY? [

I

_YES

• PILOT VALVE OPENS I

m

• IGNITER POWERED

I

[ uo

IS SENSED DURING
TRIAL FOR IGNITION?

YES

• IGNITER OFF |

l

• MAIN VALVE OPENS

J

• WAIT FOR FLAME SIGNAL

TO DISAPPEAR

• PILOT VALVE/IGNITER

REMAIN OFF

"1

• PILOT VALVE CLOSES /

• IGNITER OFF

/

I FIVE-MINUTE RETRY IDELAY

J,

END

I FLAME SIGNAL LOST?

_NO

I THERMOSTAT CALL FOR I

HEAT ENDS

I"'A'NANOPIL VALVESCLOSEI

I

• MAIN AND PILOT VALVES CLOSE I

I

FLAME LOST MORE THAN Ni NO

y--

FIVE TIMES IN ONE
CALL FOR HEAT?

I YES

Z_ IGNITER WILL TURN OFF ABOUT 30 SECONDS INTO THE TRIAL FOR IGNITION.

IF THE PILOT FLAME HAS NOT LIT, IT WILL TORN BACK ON FOR THE FINAL
30 SECONDS OF THE 90 SECOND TRIAL FOR IGNmON. THE PILOT VALVE
WILL BE ENERGIZED DURING THE ENTIRE TRIAL FOR IGNITION. THIS IS
NORMAL OPERATION FOR THIS GAS IGNITION SYSTEM.

Figure 24: System Operating Sequence

19

II 5V/6OHZ

TO MAIN

DISCONNECT

SWITCH

TO BOILER

JUNCTION BOX

PINK & GREY

_RES

L2

LI (HOT)

t F

ZONE

CIRCULATOR

L#

L

ZONE I

THERMOSTAT

24V O

ZONE 2

CIRCULATOR

ZONE 2

THERMOSTAT

24V (_)

I

FIELD
INSTALLED

R845A

RELAY

L_ND

-- - LINE VOLTAGE
LOW VOLTAGE

Figure 25: Circulator Wiring

115V/60HZ --L1 (HOT)

TO MAIN L2

DISCONNECT

SWITCH

f

I
I

I
I

I I FIELD

I INSTALLED
I JUMPER

I

I I

! I

t I.... I-

I I I I I

._ _$__ I__ I....... ____I__

I I I I I

I F J I I r j

I I I I I

©i ©

I

ZONE 1 I ZONE 2

THERMOSTAT I THERMOSTAT

24V I 24V

f-

I

?----r ..... ?

R R R R

I I

ZONE 3 ZONE 4

THERMOSTAT I THERMOSTAT

24V I Z4V

TO BO+LE

JUNCTION

PINK & GF

WIRES

CIRCULATOR __+

FIELD MOUNTED

TRANSFORMER

24V 4OVA

4, ._-

NOTES."
1 ALL WIRING MUST COMPLY WITH APPLICABLE CODES, ORDINANCES

AND REGULATIONS.

2 IF CODES PERMtT, VBO43E AND VBO43F MAY BE USED

INTERCHANGEABLY WHEN _RED AS SHOWN.

3 DO NOT USE BOILER TRANB_-ORMER TO POWER ZONE VALVES

LggE_

-- - LINE VOLTAGE

.... LOW VOLTAGE

Figure 26: Zone Valve Wiring

2O

P"_I Kit =lkH=1;_.'_,

This section is in regard to requirements of the ASME

CSD 1 1998 Code. Controls and Safety Devices for
Automatically Fired Boilers, which may be in effect in
your area Any omissions or discrepancies that may exist

between these instructions and the CSD-1 code itself,
the code itself takes precedence. The CSD-I Code may

be ordered by calling 1-800-THE-ASME.

I I/2 ¢ROSS_

BUSHING

(MANUAL RESET)

I I/2 × 1

& I × 3/_.

:t! [e,_",le]IbV_,q;tl[el: I:l::[eleJl;t:;l_VAl::iL'qilK

The Series GM is CSA certified to ANSI Z21.13 and as
such meets all CSD-I Part CF requirements for

combustion side controls for units under 400,000 btuh
input. No other combustion side controls are required to

meet CSD-I.

Figure 27: CSD Piping, Using Cross Fitting

_ [e,_...'.lm]I:]±!;tEe4rilJ ;,l=[e).llll,l:lLV_l:l_/l_

CSD-I requires the following waterside controls to be

installed with the boiler:

1. Manual reset low water cut-off (LWCO), such as
Hydrolevel 550SV Probe (29028)

2. Manual reset high limit, such as Honeywell
L4006E1117 (50536).

Install these controls in the supply piping. Figures 27-29
show typical piping using a probe style low water cut-off.

See CSD-1 code for requirements when using a float
i_pe low water cut-off.

No valves are allowed between these controls and the
boiler supply connection.

Low water cut-off must be positioned higher than the
top of the boiler. See figure 30 for wiring details. Follow

all instructions furnished by the control manufacturers.

Figure 28: CSD Piping, Vertical Using Tee's

I. Modular Boilers

a. CSD-1 requires a manual reset low water cut-off

and manual reset high limit to control the

modular boiler system. The individual boiler
modules are not required to have a low water
cut-off or manual reset high limit.

b. To be considered a modular boiler system, the

individual boiler modules are not allowed to be
isolated from the main headers and controls with

stop valves.

2. Multiple Boilers
CSD-I requires a manual reset low water cut-off and

manual reset high limit on each individual boiler.

For more information on modular and multiple boiler
systems, see Peerless Flex-Heat manual or contact

Peerless Heater company.

HQN£ Y_LL L4006[

OMIT (MANUAl. R(_T)

Figure 29: CSD Piping, Horizontal

H_X _NG

550 SV

L'/_O (MANUAL RESET)

MAINTAIN 2" M4NIMUM
CL[ARANC_ TO 0RAFT
HO00. 4" "_ERTICAL

CL[ARANC_ BELOW

R(U(F _NING

21

[r_ _-.t,_[o_e_ll_l::[olUJld=l,'_l=l;kn_ [_]_

Note the following elec'aical requirements per CSD-I
Section CE-II0(a):

"A disconnecting means capable of being locked in
the open position shall be installed at an accessible

location at the boiler so that the boiler can be
disconnected from all sources of potential. This

disconnecting means shall be an integral part of the
boiler or adjacent to it."

"A manually operated remote shutdown switch or
circuit breaker shall be located just outside the boiler
room door and marked for easy identification.
Consideration should be given to the type and
location of the switch to safeguard against

tampering. Ifthe boiler room door is on the building
exterior, the switch should be located just inside the
door. If there is more than one door to the boiler

room, there should be a switch located at each

door."

"The emergency shutdown switch or circuit breaker
must disconnect all power to the burner controls."

TO BOILER

GROUND

SCREW

115V-6OHZ

TO MAIN

DISCONNECT SWITCH

(HOT) I

TO _ANSFORMER BLACK AND WHITE

WIRES. REPLACES L1 AND L2 SHOWN

ON BOILER WIRING DIAGRAM.

L%o"Oc%bA %SE'O

m

HONEYWELLUMIT

L4006E --_

115V-6OHZ

ALARM CIRCUIT

(WHEN REQUIRED)

Figure 30: CSD Low Water Cut-Off/Limit Wiring

22

V±_o] _vfl_ IH_ilIIIL'I[e,.ImiI-"I_ IIL_[,."_1ir±lIIIIV_I€[o] i

].

2.

3.

4_

5.

6.

7.

Confirm that all water, gas and electridty are
turned off.

Inspect the boiler combustion chamber for foreign
objects and remove if present,

Check physical condition of burners and pilot. Make
certain that there are no unusual bends or

perforations in the burners or pilot. Replace
components if necessary.

Veri_ that water piping, venting, gas piping and
electrical wiring and components are installed
properly. Refer back to previous sections of these
instructtuns as well as equipment manufacturer's
instructions as necessary.

Fill the boiler and system with water, making certain
to vent all air from all points in the system. To check

water level in the system, open and close each vent
in the system. Water should exit from each vent when

it is opened.

The pressure reducing valve on the fill line will
typically allow the system to be filled and pressurized
to 12 psi. Consult the valve and expansion tank
manufacturer for more specific information.

Check joints and fittings throughout the system for
leaks. If leaks are found, drain the system and repair

as required.

8. Connect a manometer to 1/8 NPT tapping provided
on the manifold. See Figures 31 and 32.

9. Confirm that the gas supply pressure to the boiler is
above the minimum and below the maximum values

for the gas being used. See the end of Section 5 for
these values. If a supply pressure check is required,

isolate the boiler and gas valve before performing the

pressure check. If the supply pressure is too high or
too low, contact the gas supplier,

I0. Turn on electricily and gas to boiler

11. Light the boiler by following the Lighting/Operating
Instructions label mounted to the jacket panel. The

initial ignition may require several tries as the piping

is purged of air.

12. Use the sequence descriptions in Figures 22, 23 and
24 in Section 6 (Electrical) to follow light-off and
shutdown sequences and to assist in diagnosing

problems. If the boiler does not function properly,
consult Section 9, Troubleshooting.

13. The gas manifold and control assembly provided
with this boiler meet with all criteria regarding safe
lighting and performance as specified in ANSI

Z21.13, Gas-Fired Low Pressure Steam and Hot

Water Boilers. The gas manifold and control

assembly are made of gas-tight, completely factory
assembled and installed components of the base

assembly. See Figure 31 and 32.

23

MAIN
BURNER

A

r GAS

VALVE /- PILOT

GAg _

MANIFOLD PILOT TUBING

SECTION A-A

Figure 31: Gas, Valve, Manifold and Burner Assembly, GM-05/06 (Standing Pilot shown, Intermittent

ignition similar)

MAIN
BURNER

GAS
VALVE

S PILOT

_ PILOT TUBING

SECTION A A

TEST TAPPING J

L__GAS MANIFOLD

ORIFICE SPUD

Figure 32: Gas. Valve, Manifold and Burner Assembly, GM-07/08 (Intermittent ignition)

]r : T

F: '-4 iRE

PRESSURE REGULATOR
ADJUSTblENT (UNDER CAP
SCREW) --

\ P i C'f '

*, T "id /

I)l )[ ,[ IUSTMENT

_lu F, k' ' AP SCREW)

Figure 33: Valve Tapping and Adjustment Screw

Locations, Intermittent ignition

24

OUTLET
PRESSURE

rAP

z" WIRING

J FL ,MINA[ S

INLET I_ I_ OUTLET

/

THERbIS(t()UP i //
COrINg(}: ON z

Figure 34: Valve Tapping and Adjustment Screw

Locations, Standing Pilot

FOR YOUR SAFETY READ BEFORE OPERATING

I WARNING: If you do not follow these instructions exactly, a fire or explosion may result

I

causing property damage, personal injury, or loss of life

I

A. This appliance is equipped with an ignition device

which automatically lights the pilot, Do not try to

light the pilot by hand.

• If you cannot reach your gas supplier, call the fire
department

B.

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 OF 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,

Use only your hand to slide the gas control switch.

Never use tools, If the switch will not slide by hand,
don't try to repair it, call a qualified service
technician Force or attempted repair may result in a
fire or explosion,

D, 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

1. STOP! Read the safety information above on this
label.

5. If the gas valve is not visible, remove control access
panel.

2.

3.

4.

Set the thermostat to the 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.

/-GAS CONTROL

SWITCH

OUTLET _II _IIINLET

6. If the gas control switch is not in the "OFF" position,
slide the switch to "OFF".

7. Wait five (5) minutes to clear out any gas. If you
then smell gas, STOP! Follow "B" in the safety

information above this label. Ifyou don't smell gas,

go to the next step.

8. Slide the gas control switch to "ON".

9. Replace control access panel, if applicable.

10. Turn on all electric power to the appliance.

11. Set the thermostat to desired setting.

12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Appliance" and call

your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1, Set the thermostat to lowest setting. 4. Slide the gas control switch to "OFF".

2. Turn off all electric power to the appliance if service 5. Replace control access panel, if applicable.
is to be performed.

3. If the gas valve is notvisible, remove the control
access panel, sv9501/sv96019348

Figure 35: Operating Instructions

25

FOR YOUR SAFETY READ BEFORE LIGHTING

I WARNING: If you do not follow these instructions exactly, a fire or explosion may I

result causing property damage, personal injury or loss of life. I

A. This appliance has a pilot which must be lighted by

hand. When lighting the pilot, follow these Instruc-
tions exactly.

B. BEFORE OPERATING smell 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.

• If you cannot reach your gas supplier, call the

fire department.

C. Use only your hand to push in or turn the gas con-

trol knob. Never use tools. If the knob will not push
in or turn by hand, don't try to repair It, call a quail-
fled service technician. Force or attempted repair
may result in a fire or explosion.

O.

Do not use this appliance if any part has been under
water. Immediately call a qualified service techni-

cian to inspect the appliance and to replace any part
of the control system and any gas control which

has been under water.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above on this
label.

2. Set the thermostat to lowest setting.

3. Turn off ell electric power to the appliance.

4. If the gas valve is not visible, remove control access
panel.

5. If the gas control knob is not in the "OFF" position,
turn the knob clockwise F_ to "OFF."

RED RESET BuI-rON

Gas Control Knob
(shown in =OFF"

8. Find pilot--follow metal tube _n
from gas valve. The pilot Is

between two burner tubes.

Pilot Burner

9. Turn the gas control knob counterclockwlse f'_to

"PILOT."

10. 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, I_peat
steps 5 through 10.

GAS

INLET

• If button does not pop up when released, stop
and Immediately call your service technician or

gas supplier.

• If the pilot will not stay lit after several tries,
turn the gas control knob to "OFF" and call

your service technician or gas supplier.

6. Walt 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.

7. Remove the pilot access panel, if supplied, located
below and behind the gas valve directly above burn-

er tubes

11. Replace pilot access panel, if applicable.

12. Turn gas control knob counterclockwise

to "ON."

13. Replace control access panel, if applicable.

14. Turn on all electric power to the appliance.

15. Set thermostat to desired setting.

_TO TURN OFF GAS TO APPLIANCE _

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance If service
is to be performed.

3. If the gas valve is not vlslble, remove control access
panel.

4. Turn the gas control knob clockwise F'_ to "OFF."

5. Replace control access panel, if applicable.

H24V VR8200 9177R

Figure 36: Lighting Instructions

26

I:]q [e[o)l,_i d;{el I Ie):_'_ed;t I_ | [o]L'_:

See Figure 37 for locations of these devices.

1. FLAME ROLLOUT SAFETY SHUTOFF SWITCH
A thermally activated switch located above the

burners on the inner front jacket panel The flame
rollout safety shutoff switch will sense excessive
temperature caused by continued flame rollout and
shut down main burner gas. This is a non-recycling
switch that must be replaced once activated.

2.

VENT SAFETY SHUTOFF SWITCH A thermally
activated, manually resetable switch located on the

draft hood. If venting system becomes partially or
totally blocked, the vent safety shutoff switch will

sense excessive temperature caused by flue products
exiting the draft hood relief opening and shut down
main burner gas.

lel [q-'l=(_][41L:[ctl:]lJ;t_l=l.'t IIL'_I:,LIII

3.

LIMIT - A thermally activated, manually adjustable
switch located in the upper right side of boiler
vestibule. The limit senses supply water temperature
and will shut down main burner gas if the supply
water exceeds the preset temperature limit. This is a
recycling switch that will automatically reset when
the supply water falls below the preset temperature.

4.

LOW WATER CUT-OFF (FOR GRAVITY SYSTEMS

OR HOT WATER BOILERS INSTALLED ABOVE

RADIATION LEVEL) - A level-sensing device (float
or probe) located in supply piping near the boiler. If
water level in the system drops below the control's
position, it will shut down main burner gas. The

conhol will automatically reset once the water level
rises above its position.

2.

3.

4,

To adjust gas pressure, turn adjusting screw of gas
pressure regulator counterclockwise to decrease
pressure, clockwise to increase pressure. Refer to

Figure 33 and 34 for location of gas pressure
regulator, Replace the cap screw when adjustment is
complete,

In no case should the final manifold pressure vary

more than +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 spuds.

When adjustment is complete, turn off boiler, gas

flow and eleclricily to boiler Remove manometer

connection from valve and plug tapping with plug
provided. Turn utilities back on and resume

checkout.

1. Refer to rating label mounted on the jacket top panel
to obtain the rated BTU per hour input. In no case

shall the input to the boiler exceed the value shown

on the rating label.

2. Check input by use of the following formula
(Peerless suggests reading meter for 2 Cu.Ft.):

BTU/Hr. Input-3600 x F x H

T

3600 - Seconds per hour

F - Cubic Feet of Gas Registered on Meter

H - Heat Value of Gas in BTU/Cubic Feet

T - Time in Seconds the Meter is Read

3. As an alternative, use Table 3. Use the heating value
provided by gas supplier. Use a stopwatch to record
the time it takes for 2 cubic feet of gas to pass
through the meter. Read across and down to

determine rate.

I, Using the manometer setup installed in part 8A, set

manifold pressure.

3 VENT DAMPER

VENT SAFETY SHUTOFF SWITCH
SAFETY RELIEF VALVE

JRE PRESSURE GAGE

LIMIT

GAS VALVE

FLAME ROLLOUT SWITCH

PILOT (NOT SHOWN)

Figure 37: Control Locations

27

Table 3: Meter Conversion - Natural Gas

Burner inputs in Btu!hr for various meter timings and
heat values. (Tables based on 2 cubic feet of gas through
meter).

Time that Heat Value of Gas

meter is (Btu/cubic foot)

read (sec)

25
30
35
40
45

50
55
60
65

70
75

80

85
90
95

I00
I05

110
115
120
125

1000

288000
240000
205714

180000
160000
144000
130909

120000
110769
102857

96000
90000
84706
80000

75789
72000
68571
65455
62609
60000

57600

1025 1050

295200 302400
246000 252000
210857 216000

184500 189000

164000 168000
147600 151200
134182 137455

123000 126000
113538 116308

105429 108000

98400 100800
92250 94500

86824 88941
82000 84000

77684 79579
73800 75600

70286 72000
67091 68727
64174 65739
61500 63000
59040 60480

I_q [0_:I:[_][_o1111 I'] ;{o1_1:11]lJ.'t

1. After starting the boiler, be certain all controls are
working properly. Check to be sure that the limit will

shut off the boiler in the event of excessive water
temperature. This can be done by lowering the limit

setting until the main burners shut down. When
proper limit function is confirmed, return the dial to

its previous setting.

2. To check operation of the ignition system safely

shut-off features:
a. Standing Pilot:

i) Turn the gas control knob counterclockwise

to "PILOT". The main burner should go out

and the pilot should remain lit.

ii) Extinguish the pilot flame. Pilot gas flow

should stop within 2-1/2 minutes. Complete
shutdown is proven since the safely shut-off

valve has stopped main and pilot gas flow.

iii) Reset the boiler by following Lighting

Instructions.

28

iv) Observe boiler operation through one

complete cycle.

b. Intermittent Ignition System:

i) Turn gas supply off.

ii) Set thermostat or controller above room

temperature to call for heat. Watch for igniter
glow at pilot burner.

iii) Igniter will continue to glow for 30 seconds,

de-energize for 30 seconds, then re-energize
and glow for another 30 seconds. It will then
de energize for 5 minutes before restarting

the sequence.

iv) Turn gas supply on.

v) Reset the boiler and control by following

Operating Instructions.

vi) Observe boiler operation through one

complete cycle.

3.

4.

5.

6.

7.

8.

9.

10.

Low Water Cut-Off (if used) - Consult the
manufacturer's instructions for the low water cut-off

operational check procedure.

Check the system to make sure there are no leaks or

overfilling problems which might cause excessive
make-up water to be added. Make-up water causes
liming in the boiler and brings in oxygen. Oxygen
can cause severe damage to the boiler though

oxygen corrosion pitting.

Check the expansion tank and automatic fill valve (if
used) to confirm that they are operating correctly. If
either of these components causes high pressure in
the system, the boiler relief valve will weep or open,
allowing fresh water to enter the system.

Do not allow the system controls to subject the boiler
to excessively low water temperatures, which would
cause condensation of flue gases and corrosion of
the boiler. Operate the boiler at a temperature above
130°E Adjust the boiler limit as required to maintain
boiler temperature above this level.

Check the general condition of the system including
piping support, joints, etc. Check cleanliness of the
radiators, baseboard units and!or convectors. Clean
them to the extent possible. If radiators do not heat
evenly, vent any remaining air from them.

Review operation and User's Information Manual
with end-user

Complete the Warranty Card and submit it to
Peerless Heater Company.

Hang the Installation, Operation and Maintenance
Manual and User's Information Manual in an

accessible position near the boiler.

Intheeventofashut-downcausedbyapilotoutage,
actionoftheventsafelyshutoffswitchorflamerollout
safelyshutoffswitcheffectingashut-downofthemain

burners:

a. RefertotheLighting/OperatingInstructionsin

Figures35and36toproperlyturnoffthegastothe
boiler.

b. Turnoffallelectricpowertotheboiler.
c Callaqualifiedheatingserviceagencyorlocalgas

companyandhavethecauseoftheshut-down
investigatedandcorrected.

d. RefertoLighting/OperatingInstructionstore-start

boiler.

I:l! I / ;{olll :tII :{.'l :[olo;I / IL_[€-I[_lll ID]@

Use Table 4 to assist in determining causes and

providing corrective actions to boiler problems. Refer

also to Figure 38 to troubleshoot the Intermittent Ignition

System Control. These guides must be used only by

qualified service technicians. These individuals must
follow all applicable codes and regulations in repair of
any boiler problems.

When servicing or replacing items that communicate
with the boiler water, be certain that:

• There is no pressure on the boiler.

• The boiler is not hot.

• The power is off.

When servicing the gas valve or pilot, be certain that:

• The gas is off.

• The electricity is off.

Do not use this appliance if any part has been under

water. Improper or dangerous operation may result.

Immediately call a qualified service technician to
inspect the boiler and to replace any part of the

control system and any gas control which has been

under water.

Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.

Should overheating occur or the gas supply fail to
shut off, do not turn off or disconnect the electrical
supply to the pump. This may aggravate the problem
and increase the likelihood of boiler damage. Instead,
shut off the gas supply at a location external to the
appliance.

29

Table 4: Boiler Troubleshooting Guide

Burners not functioning

1 No power.

2 Limit (aquastat) not working

3 Flame rollout switch open.
4 Blocked vent switch open

5 Gas oft at boiler gas valve.

6 Gas off external to boiler.
7 Plugged orifice spuds.

8. Defective gas valve.

9. Improper wiring.

10 Vent damper malfunctioning.

Burners will not shut 1 Defective gas valve.

down.

Flashback or burning
at orifice spuds.

Delayed ignition

Excessive condensation in
vent.

Boiler not heating

properly.

Fumes or gas odors

2. Short circuit.

1. Manifold gas pressure too low.

2. Improperly sized/drilled orifice spuds.

3. Leaking gas valve.

4. Burrs on orifice.

5. Low supply gas pressure.

6 Excessive downdraft or draft problems in

boiler room.

I. Insufficient pilot flame.

2. Pilot burner/orifice clogged.

3. Overfiring

4. Misaligned burners or pilot.

5. Draft problem in boiler room.

I. Underftring.

2. Limit (aquastat} set too low.

3. Vent pipe too long.

4. Inadequate chimney or venting system.

I. Underfiring.

2 Limit set too low.
3, Air in system.

4 Circulator malfunctioning.

5. Circulation system dogged.

6. Incorrect thermostat heat anticipator setting.

1 Leaks in gas piping or fittings.

2 Leaks in gas service line or meter.
3 Obstructed chimney.
4 Obstructed flueways or vent.

5. Undersized chimney or vent, high draft loss
in vent.

6. Draft problem in boiler room.

7. OverfiPng.
8 Vent damper malfunctioning.

1 Check line voltage wiring and fuses.

2. Check wiring and contacts, relay, temperature
setting. Clean and adjust as necessary

3. Replace switch. Locate cause and correct

4 Reset blocked vent switch Locate cause and correct,
5 Start boiler using Lighting/Operating

Instructions.

6. Check any gas valves in the line

7. Check, clean and re-install.

8. Use Figure 38 to troubleshoot intermittent
ignition gas valve. Replace if necessary.

9. Check and correct in accordance with wiring

diagrams in Section 6.

10. Refer to vent damper manufacturer's instructions
Replace if necessary.

1. Use Figure 38 to troubleshoot intermittent

ignition gas valve. Replace if necessary

2. Check and correct wiring,

1. Adjust to proper pressure

2. Install correct spuds.

3, Replace valve.

4. Remove bun's.

5. Contact gas supplier if natural gas. Adjust
regulator if LP gas.

6. Check air supply, ventilation and venting system.

1 Increase pilot gas flow

2. Clean pilot burner and orifice

3. Reduce rate to input on rating label

4. Realign burners or pilot.

5. Check air supply, ventilation and venting
system.

I. Increase rate to input on rating label.

2. Reset limit (aquastat) to higher setting.

3. Reposgion boiler to reduce length.

4. Check chimney and venting recommendations.

i. Increase rate to input on rating label

2. Reset limit (aquastat) to higher setting.

3. Vent air from all points in system.

4. Check circulator, replace if necessary.

5. Shut down and cool boiler, drain and flush
system.

6. Adjust heat anticipator.

1. Locate and repair or replace.

2. Shut down boiler and notify gas provider.

3. Check, repair and/or clean chimney.

4. Clean flueways or vent and remove obstructions

5. Check National Fuel Gas Code and vent
manufacturer's recommendations.

6. Check air supply, ventilation and venting system.

7. Reduce rate to input on rating label.

8. Refer to vent damper manufacturer's instructions.

Replace if necessary.

3O

START

I • TURN OFF GAS SUPPLY

• ASSURE GAS VALVE SWITCH IS
IN "ON" POSITION

• DISCONNECT SYSTEM CONTROL

HARNESS

• SET THERMOSTAT TO CALL
FOR HEAT

CHECK FOR PROPER VOLTAGE NI NO_I

i

AT CONTROL HARNESS (SEE INSET

YJ

A). VOLTAGE SHOULD BE 24V
BETWEEN THERMOSTAT AND
24V COMMON, AND 24V BETWEEN

24V COMMON AND 24V HOT.

YES !

PLUG HARNESS INTO GAS VALVE
CONTROL. WAIT FOR INTERNAL

CHECK DELAY

/

IGNITER WARMS_UP AND NO _ I

IVES I

I e TURN ON GAS SUPPLy _-_

• PILOT BURNER LIGHTS

YES

YES

I

'r

SYSTEM IS OKAy

I

I

CHECK:

• LINE VOLTAGE POWER

• LOW VOLTAGE TRANSFORMER

• LIMIT CONTROLLER

• THERMOSTAT

• WIRING

• VENT DAMPER IS OPEN AND END

SWITCH MAKES

UNPLUG PILOT BURNER CABLE.

I"

MEASURE VOLTAGE AT GAS VALVE
HSI ELEMENT OUTPUT (SEE INSET B)

24V NOMINAL

_ YES

REPLACEIGNITER/FLAME ROD ASSEMBLY I I

I

RECONNECT PILOT BURNER CABLE 1

I

• CHECK THAT PILOT GAS IS FLOWING. I NO]1_._.__]1_'

WAIT TO ASSURE PILOT GAS TUBING

I '

IS PURGED.

_ YES

• M_ESURE VOLTAGE BETWEEN 24V _

HOT AND 24V COMMON LEADS TO GAS

[,

VALVE. MUST MEASURE AT LEAST

19.5 VAC WITH IGNITER POWERED.

SEE INSET A TO IDENTIFY PROPER

LEAD. THtS CHECK MUST BE DONE
WITH THE GAS VALVE CONNECTED

AND IGNITER POWERED.

YES

REPLACEIGNITERJFLAME RODASSEMBLY I

• CHECK THAT PILOT FLAME MAKES
GOOD CONTACT WITH PILOT BURNER

FLAME ROD.

• CHECK FOR GOOD ELECTRICAL
CONNECTION THROUGH THE PILOT
TUBING

• IF BOTH OF THE ABOVE ARE GOOD,
REPLACE IGNITER/FLAME ROD

ASSEMBLY.

CYCLE THERMOSTAT OFF AND BACK ON I

MAIN BURNER LIGHTS

I I

INSET A

END VIEW OF

24 VOLT CONTROL
THERMOSTAT HARNESS

CONNECTOR

VOLTS

24 VOLT 24 VOLT
COMMO

VOLTS HOT

CHECK FOR DAMAGED OR MISSING
TERMENALS IN CONNECTOR

INSET B

• []

REPLACE GAS VALVE I

CABLERECONNECTPILOT BURNER I

REPLACE GAS VALVE I

CHECK TRANSFORMER AND ILINE VOLT SUPPLY

REPLACE GAS VALVE 1

Figure 38: Intermittent Ignition System Troubleshooting Sequence

31

i.

2_

Disconnect this boiler from the gas supply piping
during any pressure testing of the gas system.

Check pipes adjacent to cold walls or in unheated
spaces. Insulate and tape them if necessary to be
sure they can't freeze up. Keeping the water moving
at all times will reduce the likelihood of freezing. See

Section 3 for antifreeze instructions.

3,

4.

If there is considerable foreign matter in the boiler
water, the boiler should be shut down and allowed to
cool, then drained and thoroughly flushed out. Use

the drain valve at the bottom of the return
connection to drain the boiler. Pipe the drain cock to

a suitable drain or containment device if antifreeze is
used. Flush the system to remove remaining matter.

If there is evidence that hard scale has formed on the
internal surfaces, the boiler should be cleaned by

chemical means as prescribed by a qualified water
treatment specialist.

There must not be signs of continuous wetness at the
chimney. If signs of continuous wetness are

observed, a qualified service agency must be
consulted to modify the vent configuration to prevent

the formation of condensate.

Daily boiler observation can be performed by the owner.
If any potential problems are found, a qualified installer

or service technician/agency must be notified.

I,

Remove any combustible materials, gasoline and
other flammable liquids and substances that generate
flammable vapors from the area where the boiler is

contained. Make certain that the boiler area has
ample air for combustion and ventilation and that

there are no obstructions to the free flow of air to
and from the boiler.

2.

3.

Observe general boiler conditions (unusual noises,
vibrations, etc.)

Observe operating temperature and pressure on the
combination gauge located on the left side of the
boiler. Boiler pressure should never be higher than
5 psi below the rating shown on the safety relief
valve (25 psig maximum for a 30 psig rating, 45 psig
maximum for a 50 psig rating). The valve rating can

be found on the top of the safety relief valve (see
Figure 5 for location of the safety relief valve). Boiler

temperature should never be higher than 250 ° E

4. Check for water leaks inboiler and system piping.

5. Smell around the appliance area for gas. If you smell
gas, follow the procedure listed in the
Lighting/Operating Instructions in Section 8.

[4vA_l _ _ [4 li'mLIivli i" i :[o) IH_ :| I LII_.'_ _

1. Flush float type low water cut-off (if used) to remove
sediment from the float bowl as stated in the

manufacturer's instructions.

I iJLVj[o] _/ / :Ik'ii_i_j / i: i :{o] II _-I h_Ill..-1:

1. Check boiler room floor drains for proper
functioning.

2. Check function of the safety relief valve (monthly
unless specified otherwise by manufacturer) by
performing the following test:

a. Check valve piping to determine that it is

properly installed and supported.

b. Check boiler operating temperature and pressure.

c. Lift the try lever on the safety relief valve to the

full open position and hold it for at least five
seconds or until clean water is discharged.

d.

Release the try lever and allow the valve to close.
If the valve leaks, operate the lever two or three
times to clear the valve seat of foreign matter It
may take some time to determine if the valve has
shut completely.

e. If the valve continues to leak, it must be replaced

before the boiler is returned to operation.

fi Check that operating pressure and temperature

have returned to normal.

g. Check again to confirm that valve has closed

completely and is not leaking.

3. Test low-water cut-off (ifused) as described by the

manufacturer.

4. Test limit as described in Section 8E, "Check-Out

Procedure."

5. Test function of gas safety shut-off features as

described by gas valve and ignition control
manufacturer.

6. Cycle the boiler at least once and check operation of

the vent damper.

32

When servicing or replacing components, be
absolutely certain that the following conditions are
met:

• Water, gas and electricity are off.

• The boiler is at room temperature.

• There is no pressure in the boiler.

1. Check flueways and burners for cleanliness and clean
if necessary. Use the following procedure if cleaning
is required:

a. Refer to the Lighting/Operating instructions in

Figures 35 and 36 to properly turn off the gas to
the boiler.

b. Turn off all electrical power to the boiler.

c. Remove burners and brash gas outlet ports

lightly using a soft bristle brush.

d. Remove the vent pipe, automatic vent damper (if

used), draft hood, top jacket panels, flue collector
and flue baffles..

e. Brush flueways with wire brush.

To the extent possible, inspect inside of vent pipe

and vent damper for obstructions in flow or vent

damper movement. Remove or replace as

necessary,

g,

Re-install baffles. 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.

h. Re-install the top of the jacket, draft hood, vent

damper (if used) and vent pipe.

i. Connect blocked vent switch wiring harness to

blocked vent switch.

k. Re-install burners.

• ,OLJT[R (ON[

/ DARK _lllE

!'_ rot rR

-, -

d n _T

_'_ [ " " ,h'l,* _ IE,_[Z _-"

-iiii __J I i

L_ JH

Figure 39: Standing Pilot and Main Burner Flame

OUTER CONE IS

/DARK BLUE

IN COLOR_

INNER CONE
BLUE

IN COLOR_.

FLAMES

Figure 40: Intermittent Pilot and Main Burner

Flame

2. inspect entire venting system for corrosion, support
and joint integrity. Repair as necessary.

3. Check the pilot and main burner flame. See Figures
39 and 40. The pilot should provide a steady flame
enveloping 3/8" to I/2" of the flame sensor. If
required, adjust the pilot as stated in the gas valve
manufacturer's instructions. The main burner flame

inner cone should be approximately I-1/2" high and

should have a very sharp, blue color characteristic.

4. Systems with antifreeze. Check for correct
concentration and inhibitor level.

33

INLET

-12 1/2

1 I/2

RELIEF
VALVE

Figure 41: Boiler Views

Table 5: Series GM Boiler Dimensions

_']JlI,II ;_.'][¢J_ n ;[O)III :1:g H I_ I_1_.[,.I [e)_[,

_ Jacket Left of Jacket Front of Jacket ; Vent

Boiler to Centerline of : to Centerline of Top of Jacket to i Connector Water

Model i Width Depth Top to Floor Vent Connector Vent Connector Vent Connector : Size Content

Number 'W' "B .... C" i "D .... E .... F" I "G" (Gallons)

GM-05 19]/4" 253/g" 35V4" ! 93/4" 16V2" 29" _ 7" [ 6.15
GM-06 _ 223,4" 25¾" . 351/4" i _11 a/f" " 16V2" 30" ____ 8" l 7.20

GM-07 26¾" 253/4" 35V," 131/( ' . 16W" 31" _ 9" i 8.25

GM-08 _ 29sA" 253A" 35'A" ! 15" 16'/z" " 31 ;_ '-- 9" - 9.30

Table 6: Series GM Boiler Ratings

Boiler Combustion
Model Input Efficiency 2

Number Mbh %

GM-05 228

GM-06 285

GM-07 342 -- 82.0

GM-08 399 -- 82.0

__;I:t I;_.'l[tl_ g :{O] III =1:| :!:_ i I_[t_

Standing

DOE Net I=B=R Pilot

Heating Ratings Seasonal

Capacity Output Water Efficiency

Mbh I Mbh 2 Mbh 3,g (AFUE)_

187 163 810

231 -- 201 800

-- 280 243 --

-- 327 284 --

Intermittent

Ignition

Seasonal
Efficiency

(AFUE) 1

82.1

81.1

Heating Capacity and Annual Fuel Utihzation Efficiency (AFUE) ratings are based on U S Government test
Output rating and combustion efficiency determined in accordance with ANSI 7.21 13, Gas Rred Low Pressure Steam and Hot Water Boilers.
Net I-B_R water ratings based on an allowance of 115
Consult factory before selecting a boiler for installations having unusual pipin 9 and pickup requirements, such as intermittenl system operation,

extensive piping systems, et¢

34

Repair parts are available from your installer or by contacting Peerless Heater Company,
Boyertown, PA 19512-1021. Use the figures and tables on pages 35-39 to assist in
ordering parts.

Note: Remember to include boiler model number and serial number when ordering parts.

I Base

2 Burner Access Panel

3 Base Blanket Seal

Specify length

50867 50867 50867

Figure 42: Base

35

6

5

Gas Manifold 50712 50713 i 50714 50715
Main Burner Specify quantity 50192 50192 50192 50192

Main Burner w/Pilot Clip 1 per boiler See Table below
Orifice Spud, #40 Natural Gas, 0-2000 ft. 7157 7157 7157 7157

elevation (specify qty)*

*For elevations over 2,000 feet above sea level contact Peerless Heater Company.

Figure 43: Gas Manifold, Orifice Spuds, and Main Burners

I
2
3
4

Honeywell Q314A3505 Pilot
Thermocouple Johnson K15DA-36

Natural Gas

Natural Gas 51688
1 per boiler 50839

Figure 44: Gas Valve and Pilot, Standing Pilot

36

" EP_ I;I =I_±II;I I_7_._;la_"] [_!}1

1

2 i Honeywell SV9601M4167 Gas Valve Natural Gas i 51683
3 Honeywell Q3480BI041 Pilot ! Natural Gas 51295

Figure 45: Gas Valve and Pilot, Intermittent Ignition

8 Block

9 Flue Baffle
10 Flue Collector
II Flue Collector Blanket Seal

Figure 46: Block and Flue Collector

I per flueway

Specify length

91042 91043

90975 i 90976 , 90977 90978
50866 50866 50866 ! 50866

37

/ _I2G::

12 Jacket Assembly

*Complete Jacket Consists of:

12A Left Side Panel
12B Right Side Panel

12C Rear Panel
12D Inner Front Panel

I

12E I Removable Front Panel
12F Lower Front Panel

12G Top Panel

, Complete jacket* with

insulation and screws

Figure 47: Jacket

38

20

I
\

I

: \15

\ 16

13 3/4" Drain Valve*, Conbraco 31-602-04 50517 50517 ! 50517 50517
14 Flame Rollout Safely Shutoff Switch 51587 51587 51587 51587

• 0

15 ! Transformer, 4OVA, Johnson Y65T42-O _ 51040 i 51040 51040 51 40
16 Honeywell L4080B1261 Limit 50539 50539 i 50539 50539

17 Temperature-Pressure Gage (30, 50 psi safety relief valve) 51774 5i774 i 51774 51774

Temperature-Pressure Gage (80, 100 psi .safety relief valve} 55845 i 55845 i 55845 55845

] 50501 ! 50501 i S0801 50501

18 i Safety Relief Valve, 30 psi*

Safety Relief VaLve, 50 psi* 99950 99950 99950 99950

! 99502

Safely Relief Valve, 80 psi* [ 99502 99502 99502

j Safely Relief Valve, 100 psi* 50118 50118 50118 50118

19 Blocked Vent Switch {Vent Safely Shutoff) 51590 51590 51590 51590

20 Draft Hood 90992 90993 90994 90994
21 Automatic Vent Damper 90610 90611 50167 50167

*Available from distributor

Figure 48: Controls, Draft Hood and Automatic Vent Damper

39

Series GM

Gas

Boilers

Installation,
Operation {_

Maintenance
Manual

TO THE INSTALLER:

This manua/ is the property of the owner and must

be affixed near the boiler for future reference.

TO THE OWNER:

This boi/er shou/d be inspected annual/y by a

Qualified Service Agency,

e®@ei

HI Division ASME

of gama

PEERLESS _

CAST IRON BOILERS

PEERLESS HEATER COMPANY

231 NORTH WALNUT STREET • BOYERTOWN, PA 19512 1021 ° PHONE [phone]

vwvw.peerless-heater.com

THE PREFERRED HEATING CHOICE

@2002 Peerless Heater Company GM8065 R4 (11/02-3M)

Printed in U.S.A.