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SERIES PSC

PEERLESS SERIES PSC, PSC-03, PSC-04, PSC-05, PSC-06 Installation, Operation & Maintenance Manual

PSC
Installation, Operation
Maintenance
Manual
PEERLESS °
CAST IRON BOILERS
TABLE OF CONTENTS
1°
2,
3.
4.
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. LIQUEFIED PETROLEUM (LP) GAS ....... 2
D. INSTALLATION SURVEY ............... 2
E. PLANNING THE LAYOUT ............... 2
BOILER SET-UP 3
WATER PIPING AND CONTROLS 4
A. BOILER SUPPLY AND RETURN .......... 4
B. SAFETY RELIEF VALVE ................ 5
C. PIPING FOR ZONED SYSTEMS .......... 6
D. EXPANSION TANK .................... 7
E. INDIRECT-FIRED WATER HEATER ........ 7
E FREEZE PROTECTION ................. 7
VENTING, VENTILATION AND AIR INLET 8
A. GENERAL ........................... 8
B. PEERLESS WALL THIMBLE ............. 8
C. ROOF TERMINATION ................. 10
D. VENT PIPE INSTALLATION ............ 11
E. AIR INLET PIPE INSTALLATION ......... 11
E AIR FOR VENTILATION ............... 12
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM ................... 12
6. ELECTRICAL 15
A. WIRING ........................... 15
B. ZONED SYSTEM WIRING ............. 15
C. CONTROLS ........................ 15
D. SEQUENCE OF OPERATION ........... 16
7. START-UP PROCEDURES 19
A. COMPLETING THE INSTALLATION ...... 19
B. CONTROL DESCRIPTIONS ............. 22
C. ADJUSTMENT OF GAS PRESSURE
REGULATOR ....................... 22
D. CHECKING BURNER INPUT ............ 22
E. CHECK-OUT PROCEDURE ............. 23
8. TROUBLESHOOTING 24
A. SHUT-DOWN CAUSED BY PILOT OUTAGE,
PRESSURE SWITCH OR FLAME ROLL-OUT
SAFETY SHUT-OFF SWITCH ........... 24
B. TROUBLESHOOTING GUIDES .......... 24
C. MEASURING SUCTION PRESSURE ...... 24
9. MAINTENANCE 28
A. GENERAL .......................... 28
B. DAILY (WITH BOILER IN USE) .......... 28
C. WEEKLY (WITH BOILER IN USE) ........ 28
D. MONTHLY (WITH BOILER IN USE) ....... 28
E. ANNUALLY (BEFORE START OF HEATING
SEASON) .......................... 29
10. BOILER DIMENSIONS 8 RATINGS 31
11. REPAIR PARTS
33
5. GAS PIPING 13
USING THIS MANUAL
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Follow the installation instructions provided in this
manual 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 sMet_ during
boiler installation.
Indicates a condition or hazard which will cause severe personal injury, death or major property
damage.
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Throughout this manual you wil! 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 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.
1. PREINSTALLATION
Read carefully study th_se instructions before beginning \vork
This boiler must be installed by a qualified contractor The boiler warranty can be voided if the boiler is not instal}ed, 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. f/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, ANSI/ASME CSD-1.
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 right side, front and combustible
cotlstruction
2. ]2" between top of jacket and combustible construction
3. 1"" between left side, rear and combustible
construction,
4. 2" between vent pipe and combustible construction.
5. 0" between wall thimble and combustible construction
6. This boiler is design certified for use on combustible flooring
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The following LP requirements from the Uniform Mechanical Code, section 304.6, may be in effect in
your geographic area:
"Liquefied petToleum 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."
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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.
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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.
Prepare sketches and notes of the layout to minimize the possibility of interferences with new or existing equipment, piping, venting and wiring. Review Limitations on vent pipe, vent terminal, and air inlet pipe
locations and ventilation air requirements in Section 4.
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.
2. BOILER SET-UP
1 Provide a sound, level foundation Locate boiler as
near to the chimney or outside wal! as possible and centralized with respect to the heating system
2 Locate boiler in front of installation position before
removing crate
4 Separate the wood shipping pallet ff()m the boiler
base by removing two (2) hold down bolts at each
end of the boiler base
5. Move boiler into final position.
3. WATER PIPING AND CONTROLS
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]. Size the supply and return to suit the system. A
typical piping arrangement is shown in Figure i. Refer also to the Hydronics Institute Residential Hydronic Heating 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.
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 right section Pipe the return to the inlet
connection of the circulator
3
4.
5.
Supply Piping:
a Pipe the supply to the I I 2 NPT supply tapping
at the top of the boiler.
b Provide clearance to venting system
(see Section 4)
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 Survey
If desired, install the circulator in the alternate location shown in Figure I. Consult the Peerless
Water Survey for more information on circulator
location
AIR VENT_
AIR ELIMINATOR _
-- SAFETY RELIEF
VALVE
)_-ALTERNATE
CIRCULATOR
LOCATION
SUPPLY
COLD
WA1ER
NLL
SHUTOFF
VALVE VALVE" REDUCING VALVE
VALVE
_-EXPANStON TANK
0
o
©
TO DRAIN
RE_JRN
CIRCULATOR
DRAIN VALVE
Figure 1: Supply and Return Piping
6. 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.).
7. 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 illust_ating this hook- up is provided in Figure 2.
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 control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.
9. 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.
WATER
THREE WAY VALVE
Figure 2: Parallel Hook-up with Water Chiller
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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 3.
3. For air elimination at the safety relief valve tapping,
install valve and piping as shown in Figure 4.
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.
SAFETY RELIEF
SUPPLY VALV E
NIPPLE
Figure 3: Safety Relief Valve Hook-Up Installation
with Air Elimination in System Piping
TO AIR
ELIMINATION
DEVICE
SUPPLY I-3/4" TEE
SAFETY r5/4" X 6" RELIEF NIPPLE
VALVE_-._I_
_3/4" x 2"
NIPPLE
Figure 4: Safety Relief Valve Hook-Up with
Air Elimination
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1. See Figures 5 and 6 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 ZONE ZONE
5 2 1
I
ZONE
VALVES _z
I
_Z
J
_Z
CONNECT
TO
SUPPLY
FROM SYSTEM
ZONE ZONE ZONE
1 2 5
BALANCING
VALVES
CONNECT TO
RETURN
(CIRCULATOR INLET)
tl
Figure 5: Zone Piping with Zone Valves
TO SYSTEM
ZONE ZONE ZONE
5 2 !
FROM SYSTEM
ZONE ZONE ZONE
1 2 5
FLOW
CONTROL
VALVES
! I .11
CONNECT
TO
SUPPLY
ZONE
CONNECT TO
TAPPING
±
Figure 6: Zone Piping with Circulators
6
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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 c) in Section 10 for bof]¢,_
water capacity
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
necessary.
Refer back to Figure i for typical expansion tank piping.
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If the boiler is to be used in conjunction with an indirect- fired water heater, refer to Figure 7 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:
2.
3.
4+
Glycol in hydronic applications is specially
formulated for this purpose. It includes inhibitors which prevent the glvcol from attacking metallic system components Make certain that the system fluid is checked for the correct gtycol concentration
and inhibitor level.
The antifreeze solution should be tested at least once
a year and as recommended by the antifreeze
manufacturer.
Antifreeze solutions expand more than water. For
example, a 80% by volume solution expands 4.8%
in volume for a temperature increase from 32°F to
180°F, 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
SAFETy
RELIEF
VALVE
TO DRAIN
BALANCING
VALVE
O SYSTEM
{_ O CIRCULATOR
©
DRAIN
VALV [
ZONE VALVES
INDIRECT-FIRED
WATER HEAER
SUPPLy
TO TANK
i /
BALANONG
VALVE
SUPPLY TO
SYSTEM
q RETURN FROM
SYSTEM
HOT DOMESTIC
_WATER SUPPLy
COLD DOMESTIC
WAIER SUPPLY
Figure 7: Typical Piping with Indirect-Fired Water Heater
4. VENTING
Install vent system 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.
This vent system will operate with a positive pressure in the vent pipe. Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure.
Flue gases will condense as they exit the vent termination. This condensate can freeze on exterior
building surfaces which may cause discoloration of these surfaces.
1 Determine vent cap (terminal) location.
a Must be within the maximum and minimum vent
and air intake lengths shown in Tables 1 and 2.
b Maximum wall thickness for the 1%1/2" long
Peerless Wall Thimble (standard)is I 1-I/2". Maximum wall thickness for the optional 28"
long thimble is 20".
C
Provide 2" clearance between vent pipe and combustible construction No clearance is
required between Thimble and combustible construction
d. Provide 3 feet clearance above any forced air
inlet within I0 feet.
e. Provide 1 foot clearance below. 1 foot beside, or
1 foot above any door, window, or gravity air
inlet into any building
Provide 1 foot clearance between bottom of vent terminal and ground level and normal snow
lines.
g.
h.
Provide 4 feet horizontal clearance from. and in no case above or below, unless a 4 foot horizontal distance is maintained, from electric
meters, gas meters, regulators and relief
equipment.
Do not locate vent terminal over public walkways
where condensate could createa nuisance or
hazard.
i.
j.
When adjacent to a public walkway, locate vent terminal at least 7 feet above grade
Do not locate directly under roof overhangs to prevent icicles from forming
2. Cut a 5-]/8" square hole in sidewall to allow Peerless Wall Thimble to go through
3. Insert Thimble from inside wall with 4" diameter air inlet connection facing down. Extend Thimble 3-I/2"
past outside wall surface. The cut-out opening of thimble is pointed down.
COLLAR
INSIDE THIMBLE CAP
/
3" DIA CLAMP /
PEERLESS WALL THIMBLE
3" DIA CLAMP
!
OUTSIDE 3" DIA
VENT PIPE
VENT CAP
Figure 8: Peerless Wall Thimble
4.
5.
6.
7.
8.
Use a nqinimum 2-1/2" foot piece of 3" diameter
AL29 4C stainless steel vent pipe fol insertion
through Wall Thimble. See Vvnt Pipe section below for vent pipe requirements
Slide Stainless Steei Collar over vent pipe and slide 3" diameter hose clamp and collar to vent pipe
Insert pipe with collar through Outside Vent Cap and slide 3" diameter hose clamp and collar to vent pipe.
Leave at least 2" of vent pipe protruding beyond face of Vent Cap and secure hose clamp and collar
to vent pipe.
Place Outside Vent Cap over Wall Thimble with air
openings in Vent Cap facing down. Secure Cap to Thimble with #10 sheet metal screws
9. Place 3' diameter hose clamp over pipe protruding through inside of Wall Thimble
10. Place Inside Thimble Cap and Collar onto Wall Thimble. Access hose clamp through 4" diameter collar on bottom of Thimble and secure hose clamp over collar and vent pipe as per step 7 above.
1 1 Secure Inside Thimble cap to Wall Thimble with # 10
screws Seal Thimble Cap perimeter with silicone
12 Seal all openings between Wall and Thimble and
around the 3- diameter stainless steel vent pipe that protrudes through hlside and outside of Wall
Thimble
13 Add any bracing that may be needed to support Wall
Thimble on inside of wall structure.
14, Secure Outside Vent Cap to exterior wall with four
#]0 sheet metal screws provided.
15 Attach Z-Flex #2SVSTPF03 terminal to protruding
vent pipe Refer to Figure 9. To attach to HEATFAB pipe. insert into pipe end and fold over tabs to secure Otherwise, silicone terminal to vent pipe.
VENT PIPE MALE END
(SEAL VENT _///
FOLLOWING VENT PEERLESS// /
MANUFACTURER'S WALL THIMBLE /, r_/
INSTRUCTIONS) _ _/
\
VEN
OR
_. TO 4" DIA I_j
FAN ADAPTER f SILICONE AIR BOX
CONNECTION _//'
/
OUTSIDE
2 _ MIN
f SILICONE
02-SVSTPXOS
AIR iNLET TERMIN ATION OPENINGS
_EXTERIOR WALL
• ,,' 11 L
ALTERNATE LEFT /SIDE AIR BOX
CONNECTION
_- BOILER
--4" DIA AIR 80X CONNECTION
Figure 9: Side Wall Venting System
9
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