PEERLESS Boiler Manual L0308192

User Manual: PEERLESS PEERLESS Boiler Manual PEERLESS Boiler Owner's Manual, PEERLESS Boiler installation guides

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61/62
Boilers

Installation,
Operation
Maintenance
Manual

90,0

3-8

Natural

to 81.7%

AFUE

or LP Gas

Standing

Pilot

(Steam

Natural

Draft

Factory

Assembled

• Reduces

Large

or Spark

Ignition

(Hot

Water

and

Steam)

Venting

Sections

Installation

Water

Only)

(chimney)

Knockdown

Boilers

Time

Content

• Ideal for Steam

Skim

and

Large

Volume

Hot

Water

Applications

Tapping

• For Cleaning

Low

Profile

Steam

Boilers

Design

• Horizontal
to Vertical
• Ideal for Installations

Steel

Push

Draft Diverter
with Low Ceilings

Nipples

• Provide
a Permanent
Water Tight Seal Between
• Unaffected
by Petroleum
and Other Contaminants

Tankless

Coils

• For Domestic

Deluxe

Sections

Hot Water

Insulated

Production

on Hot Water

Enameled

• Reduces
Boiler Heat
• Completely
Encloses

Loss
Gas

Steel

Valve

Safety
Controls
• Low Water Cut-Offon
Steam
• Flame Roll-Out Shut-OffSwitch
• Blocked
Vent Shut-OffSwitch

and

Boilers

Jacket

Burners

Boilers

• Honeywell

Operating

Controls

• Vent Damper
• Float

Type

• Taco

007

• Tankless
• Gnmdfos
• Probe

LWCO

on Steam

Circulator

Peerless

Five and ten year
Heater
Company
Heater

Company

extended
warratlties
for complete
warranty
* 231

North

Walnut

on parts
and
inJbrmation.
Street

labor

• Boyertown,

Type

are now

Water

Boilers

Coil for Hot Water Boilers
Circulator
on Packaged
Hot Water
LWCO

on Steam

Peerless
Heater
Comparly
is pleased
to offer one of the most comprehensive
warranty
programs
icl tile indnstn 1, All Peerless
residential
cast troll _x_ilers include
a fidl one-yea"
warranty.
A limited.
lifetone
warranty
is provided.for
the cast iron sections
ol Peerless
residential
hot water
boilers.
Peerless
also provides
a limited,
ten year warranty
ot_ the cast iron sections
of its residential
steam
boilers.
Peerl_,ss

Boilers

on Packaged

available.

19512-1021

Pl_'asc

•

610-3S7-2153

Boilers

PGGRLESS
CAST

IRON

BOILERS

consult

* www.peerless-heater.eom
FAB-61 R1 (3/02 3M)
Printed in US A

pr=-I RLESS

Series

o Residential Gas Boilers
• Packaged or Knockdown

CAST

o Natural Draft Venting
o Standing Pilot or
Spark Ignition
Q Steam or Hot Water Boilers
o Natural or LP Gas

IRON BOILERS

Q This large water content boiler
installs in difficultsteam or water
applications.
o AFUE ranges from 76.8%
(standing pilot) to 80.7% (spark
ignition) on steam boilers and
80,3% to 81.7% (spark ignition
only) on water boilers, significantly
exceeding the federal standards
for residential boiler efficiency.
o Low profile design ideal for boiler
installationsin areas with a low
ceiling.
An optional tankless domestic
hot water coil can be installed on
hot water boilers, insuringample
domestic hot water production.
o Probe or float-type low water
cutoff available.

Steam

Water

DOE
Heating Capacity
MBH-I
I
N

Net I=B=R Ratings 3

Stdg. PilotwlDamper Spark Ign. wlDamper
Seasonal Efficiency Seasonal Efficiency
(AFUE)4
(AFUE) 4

Water Content
(GaL)

A,G.A.
Input
MBH

Water

Steam

Steam
Sq. Ft.

Steam
MBH 2

Water
MBH 1

Water

Steam

Water

Steam

Water

Steam

225

N/A

76.8

80.5

80.6

8.16

4.80

120

304

N/A

77.7

81.7

80.7

10.32

5.88

160

130

129

4O4

113

N/A

77,8

81.3

80.6

12.48

6.96

161

504

121

140

N/A

78.0

81.0

80.6

14.64

8.04

240

193

604

145

168

N/A

78.1

80.6

16.80

9.12

280

225

704

169

196

N/A

78.3

80.3

80.6

18.96

18.20

200

1 Net I=B=R water ratings based on an allowance of 1.15,
2 Net I=B=R steam ratings based on an allowance of 1.333.
3 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping
systems, etc.
4 Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are based on U.S. Government test. Before purchasing this appliance, read important
information about its estimated annual energy consumptions or energy efficiency rating that is available from your retailer.

9-15

7 Sizes

Natural

Sections

560

MBH

Input

80%

Combustion

Efficiency

or LP Gas

Standing

Pilot

or Spark

Natural

Draft

Factory

Assembled

• For Ease

Large

Ignition

(chimney)

Venting

Sp/it

Block

Sections

Knockdown

Boilers

of Handling

Water

Content

• Ideal for Steam

Skim

320

and

Large

Volume

Hot Water

Jobs

Tapping

• For Cleaning

Low

Profile

Boilers

Design

• Horizontal

to Vertical

• Idealfor

Steel

Steam

Draft

Installatiolis

Push

• Provide

Diverter

with

Low

Ceilings

Nipples

a Permal_ent

• Unaffected

Water

by Petroleum

Tankless

Tight

Seal

arid Other

Between

S_ctioris

Cor_tamiTlalltS

Coils

• For Domestic
Deluxe

Hot Water

Insulated

• Reduces

Boiler

• Completely
Safety

Production

o_ Hot Water

Enameled
Heat

Steel

Boilers

Jacket

Loss

Encloses

Gas

Valve

and

Burners

Controls

• Low

Water

Ctlt Q[l'orl

Steam

Boil_'rs
• HoT_eywell
Operating
Co_ltrols
• Mar_ltal Reset High Limit Corltrol (12-15
• Float Type LWCO orl Steam Boilers

•
•
•
•

_ll lilt"

il_(lll._lr'!].

lilliilt>(I.

,'_l_>(llll

It'll

!]('(1I

I?l_il(>I'_.

!'lt>(_._;( ' €'otl.'_ll/I
Peerless

Heater

./Ill I_'_'r'l(

'.,_.s ('ollilll_'r('i(¢l

II'_llltll_l[/

I+'il'( ' _lll_'l

I)ll

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il'oll

I I>tlr ('._l_'tl_l(>_l

I>_'('t'l_ '.'q_ I h'_ll_'t
Company

I]l("

( "olllt)_lltt].[O_"

• 231

North

I)oih>l_

._('t'l_oll._

ll'_l_'ltlllll_'_
_'Oml)lt'f_"

Walnut

Street

Tcxl_lcless Coiljor Hol Watcr Boilers
Moclultxtillg Fi1_rlg Systems
(12 15 S<:cliorl}
F_'I _rid IRI Colltrol S!]slerTls (12 15 Sectioll)
Prot)t> "I_upe I.WCO o11 Sle(lfll Boilers

_ll_'h_(l_ > (I /illl.

i.'_ [)l()l'l_ll'_

I)ll

Section)

[i_t

l_(It l_ (lll_l

it,t_r_t_i_l!]
* Boyertown.

(ill

oil('

! (>_'lr" tl,_ls't(_ll[

( Ollllll<'F('i_ll

I_l!)ol

1. A

11(>I I_ll('I

(It't' /loll'

_lll([

ttl'(li[(l!)_('.

CAST

IRON

BOILERS

ir!]Oi rIl(llioll.
PA

19512

1021

• 610

367-2153

- www.peerless-heater.com
FAB

6_7 t9 02 :_,%

pGr=-RLESS o

Series
o Semi-Commercial

62
Gas Boiler

• Packaged or Knockdown

o
o
o
o

CAST IRON BOILERS

Natural Draft Venting
320 to 560 MBH Input
Steam or Hot Water Boilers
Natural or LP Gas

o The large water content of this
knockdown or completely packaged
boiler makes it ideal for difficult steam
or water applications.
o Available in standing pilot or spark
ignition.
o Combustion efficiency meets the
80% ASHRAE 90.1 minimum as
required by the federal standards for
commercial boilers.

Steam

Horizontal to vertical draft hood
and aluminized steel flue collector
provide a low boiler profile to allow
installation in areas with low
clearance.

r_ An optional tankless hot water coil
can be installed on water boilers,
insuring ample domestic hot water
production.
o Probe or float-type
available.

low water cutoff

Water

I=B=R
Gross Output
MBH

Net I=B=R
Ratings 3

Combustion
Efficiency 4

Water
Content
(Gallons)

Model
Number

Input
MBH

Water

Steam

Steam
Sq. Ft.

Steam
MBH 2

Water
MBH 1

Water

Steam

Water

Steam

62-09

320.0

256

800

192

223

80.0

21.12

11.28

62-10

360.0

288

900

216

250

80.0

23.18

12.36

62-11

400.0

320

1000

240

278

80.0

25,34

13.44

62-12

440,0

352

1100

264

306

80.0

27.50

14.52

62-13

480.0

384

1200

288

334

80.0

29.66

15.60

62o14

520.0

416

1300

312

362

80.0

31.82

16.68

1 Net I=B=R water ratings based on an allowance 011.15.
2 Net I=B=R steam ratings based on an allowance of 1.333.
3 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent
extensive piping systems, etc
4 Combustion efficiency determined in accordance with ANSf Z21 13, Gas-Fired Low-Pressure Steam and Hot Water Boilers

system operation,

Steam

Water

3/4"

Pressure Gauge*

3/4,,

N/A

3/4"

N/A

V2"

N/A

V2"

Gauge Glass and Low Water Cutoff

N/A
Return

Limit Control (Models 09-11)
Operating

Control (Models 12-15)

Limit Control (Models 12-15)
Temperature-Pressure

Gauge

Return

3/4"

Secondary Probe Low Water Cut-Off

N/A

3/4"

Safety Relief Valve

1V2"

Skim Tapping

N/A

¾"

Primary Probe Low Water Cut-Off

N/A

3o4L£_'T

SID_

£RON_

• Pressure gauge, operating

RIGH T SIDE

control and I_mitcontrol on Models 62 12 to 62 15

m
Jacket

Right of

Distance

Rear of

Top to Fir.
C ....

Jacketto
c/I
of Flue
D ....

Betw.
Two
Flue c/l's
D1 ....

Jacketto
c/I
of Flue
E....

Flue
Size
F ....

30V4"

35"

14"

11%#'

4%s"

2-6"

333/."

30V4"

35"

15"

13_V_6"

4%8"

2-7"

37%"

47_¾_'

30V4"

35"

16"

15_3/lS"

4%4'

2-7"

52"

30V4"

35"

18"

15_%#'

6_/_6
"

2-8"

62-13

56 Ys"

30V4"

35"

19"

18V_6"

6Vls"

62-14

60%6"

30_/4"

35"

20VI4'

20¾e"

6V_6"

62-15

64W_6"

30V4"

35"

22W'

203Ae"

6%6"

Boiler
Model
Number

Width
"A ....

Depth
B ....

62-09

39 V2"

62-10

43%"

62-11
62-12

Distance

Between
Tappings
G....

!Rt.
Tap.Sup.&
Inter.
GI"

C_uetOy

Chimney

N/A

9" x 20'

N/A

9" x 20'

42V16"

N/A

9" x 20'

46V4"

21_/_6"

10"

10" x 20'

2-8"

50%"

253/16"

10"

10" x 20'

2-8"

54%6"

25z/_6"

10"

10" x 20'

2-8"

58"A_"

29s/_6"

10"

10" x 20'

STEAM

WATER

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

Steam

Boiler
Model
Number

No. Supply Outlets

62-09

3 _=

1V4"

62-10

11/4"

62-11

1V2"

62-12

62-13

62-14

31/2'`

62-15

31/2"

Size of Outlets

Boiler
Model
Number

Htr. No.
X-1020
GPM

62-09

4,75

62-10

5.00

62-11

Header Supply

3V2"

1V2"

31/2''

1V2"
1W'
,

Htr. No.
X-1021
GPM

Htr. No.
X-1022
GPM

5.25

6.25

6.5

62-12

5.50

6.75

7.0

62-13

5.50

7.00

7.5

62-14

5.75

7.25

8.5

62-15

5.75

7.25

9.0

Water healer ratings in GPM are based on intermittent
CAUTION:

demand40

Equalizer Size

° to 140 _ F rise with 200 ° F bOiler water

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

1V2"

SERIES 62 BOILER SPECS
_-_-_

LlJl-J_vd_id

• Cast Iron Sections--Factory
Tested and
Assembled with Steel Push Nipples
• Deluxe Insulated Enameled Steel Jacket

Approx. Shipping
Boiler
Model
Number

• Drain Valve
• Horizontal to Vertical Draft Diverter

62-09

I Length

57"

Width

31"

! Height

391/2"

Wts. (Ibs.)

1080

1088

1105

1108

1170

1178

1195

1203

1265

1273

1290

1298

1420

1428

1445

1453

1520

1528

1545

1553

1620

1628

1645

1653

1720

1728

1745

1753

• End Cleanout
I

• Manual Reset Limit (62-12 to 62-15)
62-10

• Standing Pilot or Spark Ignition

61"

• Automatic Reset Limit
62-11

Water

62-12

Gauge

Steam

66"

62-13

• Pressure Gauge

62-14

• Low Water Cutoff - Probe or Float

31"

74"
I

391/2`'

!
]

391/2"

]
!

391/2"

31"

J
I

31"

78"

391/2"

• Gauge Glass

31"

70"

J
I

• 15 PSI Safety Valve

3t"
I

• 30 PSI Safety Relief Valve
• Temperature-Pressure

I
J

391/2''

]
I

• Skim Tapping
62-15

82"

31"

391/2"

nnam

• HSP-2 Honeywell ignition System
• 50 PSI Safety Relief Valve - Water Boilers
• Insurance Controls
• I.R.I.
,F.M.
• Ignition Systems
• HSP-2
• E1-M
• E1-E
• Modulating Firing Systems
• MFSC
• Mod-U-Pak (12-15 Section)

PEERLESSHEATERCO.

Example:
62 Series

09 -

STDG/SPRK

Sects.
Standing Pilot or
Spark Ignition

WP -

N
Natural Gas (Substitute

"LP" for LP Gas)
W = Water Knockdown

231 North Walnut Street
Boyertown, PA 19512-1021
Phone: 610-367-2153 • FAX: 610-369-3284
www.peerless-heater.com

WP = Water Package
S = Steam Knockdown
SP = Steam Package
HI Division
of gama

CUT-62

F_7(3/03-1M),

Printed in U SA.

ASME

garNa

_003

Peedess Heater Company

Read carefullybeforebeginningwork.It witlsavetime.Studythe includeddrawings.
The equipmentshallbe installedin accordancewith thoseinstallationrequirementsof the authorityhavingjurisdictionor, in the absenceof such
requirements,to the current editionof the NationalFuelGas Code Z223.1/NFPA54.
Whererequiredbythe authorityhavingjurisdiction,the installationmustconformto the standardforControlsand SafetyDevicesfor AutomaticallyFired
Boilers,ANSI/ASMECSD-I.
A - ACCESSIBILITY CLEARANCES
1. Toprovidefor reasonableconditionsof accessibility,the followingminimumclearancesare recommended.
a. 24" betweenthe sides, top,back andfront of the boilerand adjacentwall or otherappliance,when accessis requiredfor servicing.

B - CLEARANCEFROMCOMBUSTIBLECONSTRUCTION
1. Thedesignofthisbelieriscertifiedforthefollowingclearances
fromcombustible
construction:

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

MODELS62-12thru62-15

18"from rear
6"from rightand left sides
30" from top- front alcove
6"from flue connector
6"from steamandhot waterpipes

24" from sidesand rear
55" from top
6"from flue connector
6"from steam andhot water pipes

CAUTION:This boileris NOTDESIGNCERTIFIEDforinstallationon carpetingor combustibleflooring.

C -AIR FORCOMBUSTIONANDVENTILATION
1. Be certain adequatefacilitiesare availableto provideair for satisfactorycombustionandventilation.
2.

AppliancesLocatedin UnconfinedSpaces:
a.

Installationsin unconfinedspaceswith conventionalconstructionand large areas:the supply of air for combustionandventilationcan usually
be consideredadequate,

3, AppliancesLocatedon ConfinedSpaces:
If all air for combustionand ventilationis to comefrom withinthe building:two openingsshallbe providedwithone openingcommencingwithin
12 inchesof the top andone openingwithin12 inches of the bottomof the enclosure.Theseopeningsshall not be locatedcloserthan 3 inches
from eitherthe top or bottomof the enclosureand shallbe open into areas communicatingfreely withthe outdoors,The area of eachopening
shallbe equalto one squareinch per 1000BTU/HRof total input ratingof all applianceswithinthe enclosure,witha minimumof 100square
inchesfor eachopemng,
If all air for combustionand ventilationis to comefrom outsidethe building:two openingsshallbe providedwithone openingcommencing
within12 inches of the top and oneopeningcommencingwithin12 inches of the bottomof the enclosure.Theseopeningsshall not be located
closerthan 3 inchesfrom eitherthe top or bottomof the enclosureandshallcomreunicate
directlyor by ductswith the outdoors.The area of
eachopeningshall be equalto onesquareinch per 4000 BTU/HRof total inputrating.If ductsare usedto conveythe air, verticalducts require
areas of onesquareinch per4000 BTU/HR:horizontalducts requireone squareinchper 2000 BTU/HR,Ductsshallhavethe samecross
sectionalarea as the full area of the openingsto whichthey connect.
c.

The upperopeningsare essentialfor maintenanceof propercirculationofair withthe boilerroomand reasonableambienttemperaturein order
to maintainpropercontroltemperatures.
D - SETTING UP BOILER - PACKAGED UNITS

1. A PackagedBoiler is factoryassembledbeforebeingcrated.All controlsand accessoriesnecessaryfor operationof the boilerare attachedand
electricallywired.
2. The draft hoodis packedin a separatecarton.
3. When boileris removedfrom the crate,careful inspectionshouldbe made andthe carrier notifiedof any damagefound.
4.

Providea good levelfoundation.

Placethe boileron the foundationnearand in proper positionwith relationto the chimney,andas centralizedwith respectto the heatingsystemas
practical,

6. The openingsin the basesides are providedfor admittingsecondaryair and mustneverbe closed.
7.

Removeiackettop andattach draft hoodto flue collectorwithtwo #10x 1/2"sheetmetalscrewsprovided.Replacejacket top.

8. The burnersare installedin the boiler.Theyare securedin placefor shipmentbywoodstripewiradto the Burnermixing tube.Cut the wiresand
removethe wood strips.
9. The gas manifoldandocntrol assemblyare madeup gas tight,completelyfactoryassembledand installedas integralcomponentsof the base
assembly.See Figure12.

D - SE'I-rlNG UP BOILER - UNASSEMBLED UNITS
I-- ASSEMBLEDBLOCKS
1--The boilersectionsandbase,Models61-03thru61-07arefactoryassembled.Removeshippingskidfromthe boilerbase.If boilerisa 61-08,
or 62-09thru62-15beginassemblyas notedin PartII "SplitBlockAssembly".
2--Providea goodlevelfoundation,
The Boilershouldbe locatedas neartothechimneyandcentralizedwithrespecttothe heatingsystemas
possible.
3--Open control box.Removecontroland manifoldassembly,Referto Figure6 andattachmanifoldto boilerwithfour V4-20x 1"machinescrews
and nuts provided.Figures43 thru 45 show the standardcontrolassembliesusedon Models61-08thru 62-15.
4 Openflue collectorcarton.Removeflue collectorand Hi Temprope andlay rope on top of boileragainstbead provided.SeeFigure7.
5--Place flue collectoron top of ropeand attachto boilerwithtwo1/4"-20studs,washersandhex nutsprovided,throughflue collectorbrackets
into the tapped lugs providedon top of the boilerend sections.Drawbolts downsnugly.SeeFigure8,
6--Attach cast ironclean-outplate10clean-outopeningon leftside of the boiler.This plate, HiTempropeand mountinghardwaremay be foundin
the control box referred1opreviously.
7--Remove the burnersfrom the control boxand install.Installeachburner by slippingthe openinginthe venturioverthe orificespud.Insertthe
pin on the bottomof the burner intothe hole providedin the flange on the baseback plate.SeeFigure9.The Burnerswith pilotsattachedmust
be installedas follows:Note: Hookbolt is providedon models62-11through62-15.
ModelNo.

No. Pilots

Location of Pilot

61-03

Between2nd and 3rd Burnerfrom Left

61-04

Between4th and5th Burnerfrom Left

61-05

Between4th and5th Burnerfrom Left

61-06

Between4th and 51hBurnerfrom Left

61-07

Between4th and 5th Burnerfrom Left

61-08

Between4th and5th Burnerfrom Leftand4th and5th from Right

62-09

Between4th and5th Burnerfrom Left and4th and5th from Right

62-10

Between4th and 5th Burnerfrom Left and4th and5th from Right

62-11

Between4th and5th Burnerfrom Leftand4th and 5thfrom Right

62-12

Between4th and 5th Burnerfrom Left and4th and 5thfrom Right

62-13

Between4th and 5th Burnerfrom Left and41hand5th from Right

62-14

Between41hand5th Burnerfrom Left and6th and7th from Right

62-15

Between6th and7th Burnerfrom Left and6th and7th from Right

8..-Removepilot tubingfrom controlbox and installbetweengas valveandpilot. Referto figures43 through45.
9--If boileris to incorporatea tanklessheaterfordomestichot water,installinopeningprovidedin the rightside of the boiler.Six mountingbolts
I Ifboiler doesnot incorporatea fanklessheater,a
(3/8"-16 x 3/4 ) are provldedBe
" • sure rubbergasket i"s betweencoverplateandthe boier,
blank coverplateis providedwithrubbergasketand bolts.One 3/4" pipeopeningis providedin the platefor the operatingand/orlimit control.
This 3/4"tappingis alsousedfor the pressuregaugeon the steamboiler,
10--For suggestedpipingto fanklessheaterreferto Figure23.
DANGER:Installmixingvalvein hot watersupply piping.Watertemperatureover 125°Fcan causesevere burnsinstantlyor death from scalds,

I:'ROC_"OUR lr

FOR STACKING PALLtr'rq

II-- SPLITBLOCKASSEMBLY
1--Boiler sectionsfor Models61-08,62-09thru 62-15are shippedin two parts. Removeskidfrom each blockof sections.
2--Place each blockof sectionson the stackedskids.See Fig.A. Be certainto removethe small blockson the top skid.See Fig.B,
3--To clean nippleportsand removeprotectivecoating, use a wire brush andmineralspiritsor lacquerthinner.Makecertainthereare no burrs
aroundthe outsideedgeof the ports.
4--Spread a thin coat of PeerlessNippleSealer in the nippleports, NEVERON NIPPLES.
5--Insert the push nipples,withthe chamferededge out. Makecertain they are clean and free of burrs.
6--Apply a thin coat of PeerlessNippleSealerto the rope groove.Press5/8"Dia. rope into the groove.The nipplesealer actsas an adhesiveto
hold the rope in place until the secgonsare drawnup.
7--Arrange both blocksso that protrudingnippleentersthe open port. Caremustbe takento keepnipplesstraightand blocksaligned.
8--Insert drawrodsthroughthe nippleports. Make certainthat the 3/4" drawrod is usedon the large nipple.Pay particularattentionto the
placementof the drawwashers.See Fig.A.
9--Before startingdraw,oil the threadsand betweenthe nuts andwashers.
10--Tighten the hex nuts anddraw boilerevenly untilthe small padson each sectionjust touch.
11--After boiler is drawn, removethe draw rodsand cut 5" from the 6V4" threadedend.Insert the rod throughthe lugs oneachendsectionand
tighten the hex nuts handtight.
12--Attach 3/8" Dia.rope to baseback plateby layingropeacross top of back plateflange and in rope grooveon eachendof back plate.Usenipple
sealerto hold ropein place.Referto figures 9 & 12. Attachbase backplate by meansof V4"-20x lr/2" machinescrewsandnuts furnished.
The base back plateis attachedto back of boiler.SeeFigure8. Be certain thatthe flange portionof plate is towardsthe insideof the boiler.
Note: hook bolt is providedon models 62-11through 62-15only.
13--Install pressuregage,drain valve,water supply linewith shutoffvalve,and meansto vent air. Plugunusedtappings.
14--Fill boilerwith water,ventingair as water levelrises. Pressurizeboilerto 75-85 psig.Do not exceed85 psig.
15--Verify pressureis maintained.Checkall jointsand fittingsfor leaks.
16--Drain boiler.Removepressuregage, drain valve,watersupply and air vent.ContinuewithStep2 underD-1.
E - JACKET ASSEMBLY
A. Wrap-AroundRearJacket PanelStyle for Models61-03thru 61-06
Thisstylejacket designincorporatesa BackJacket Panelaspart of eachRightand Left SideJacket Panel.TheBack JacketPanelis formedwhen a
portion of each Side Panelis bent atperforationsto rearof boile_:
I,

Inserttwo (2) 1/4-20x 1"studs intapped holesat bottomof RightEndSection.SeeFigure t.

Placethe RightSide Panelalong right sideof boiler blockandalign the slotsof the mountingbrackets,(atbottomof jacket panel),withthe 1/4-20x
1"studs.Attachjacket panel to boilersectionwithtwo (2) 1/4" nuts andwashers.SeeFigureI.

Placethe Left Side Panelalongleft side of boiler blockand attachto boilersectionin samemanneras performedfor RightSide Panel.

Bendat the perforationsof the Right Side Panelto form half of the BackJacket Panel.Dothe sameat perforationsof the LeftSide Panel.At the
centerjoint overlapof the Back Panel,attach panelswiththree (3) #10x 1/2"sheetmetalscrews.See Figure2.
Positionthe InnerFrontPanelbetweenthe Leftand RightSide Panels.Align the two (2) mountingholes,on eachsideflangeof the InnerFront
Panel,with the clearanceholes in eachSide Paneland attachwith four (4) #10x 1/2"sheetmetalscrews.See Figure4.

6. Place
theSecondary
AirCover
Door
atbottom
ofInner
Front
Panel.
Thetopbend
oftheCover
Door
slips
over
thetopreverse
bend
atcutout
opening
oftheinner
Front
Panel.
Refer
toFigure
11.
7. Atlach
Draft
Hood
toFlue
Collector
with
two(2)#10
x1/2"sheet
metal
screws.
Refer
toFigure
10.
8. Attach
theLower
Front
Panel
tothebottom
tront
oftheLeft
andRight
Side
Panels
with
two(2)#10
x 1"sheet
meta_
screws.
See
Figure
4.
9. Position
TopJacket
Panel
sotheflanges
overlap
Side
Jacket
Panels
and
airlouvers
areatthefront
oftheboiler.
Secure
withsix(6)#10
x 1/2"
sheet
metal
screws.
SeeFigure
4.
10.Attach
theClean
OutCover
Plate
Panel
over
opemng
inLeft
Side
Jacket
Panet,
with
four(4)#10
x 1/2"
jacket
screws.
SeeFigure
4
11.Themanila
envelope
that
contains
theInstallation
Manual
also
contains
theboiler
rating
label,
clearance
tocombustibles
plate,
Lighting/Operating
instruction
plate
orlabel
and
wiring
diagram
label.
SeaFigure
5forlocation
ofplates
andlabels.
Attach
plates
with
#6x3/8"
screws
provided.
12.Position
theRemovable
Front
Panel
inplace
bysliding
thePanel
under
thefront
flange
oftheTopPanel
andthen
down
until
itrests
onLower
Front
Panel.
B. IndividualBackJacket PanelStyle for Models61-07thru 62-t5
Thisjacket style has a separateBackJacketPanelthatis attachedto individualRightand LeftSide Panels.
1. AttachSide Panelsper instructionsin #1 thru 3 above.SeeFigure 1.
2. Positionthe BackJacket Panelon the inside of the Left and RightPanelflangesand attachwithsix (6) #10x !/2" sheetmetalscrews.SeeFigure3.
3. Follow instructionsaboveper #5 thru 12for assemblyof remainingjacket panels.

-,_

RIGHT SIDE PANEL

J
ONEPIECERIGHT
SIDEANDREAR
PANEL

ONE PIECE LEFT
SIDE AND REAR
PANEL

1/4" WASHER
1/4" NUT

SIDE PANEL ATFACHMENT
FIGURE 1

REAR VIEW WRAPPER
STYLE JACKET
(61-03THRU
61-06)
FIGURE 2
LEFT
SIDEPANEL

RIGHT
SIDE
PANEL

REAR VIEW OF BACK PANEL
(61-07 THRU 62-15)
FIGURE 3

BACK PANEL

JACKET ASSEMBLY
FIGURE 4

RATINGLABEL
,
,

LIGHTING/OPERATING
INSTRUCTIONSLABEL
(61-63 THRU 62-11)

LIGHTING
INSTRUCTIONSPLATE

(62-12 THRU 62-15)

#,
•

" WIRING

CLEARANCETO
COMBUSTIBLESPLATE

/jJ

REMOVABLEFRONT PANEL
(INSIDE VIEW)

AGENCY

CITYOFNEWYORK
MEAPLATE
(WHENREQUIRED)

DIAGRAM LABEL

INNER FRONT PANEL

LABEL & PLATE LOCATIONS
FIGURE 5

FIGURE 6
FRONT BOILER VIEW

FIGURE 7
FRONT TOP BOILER VIEW

T_6"_

!_UNC

_BASE

NUT

& WASHER

BACK

PLATE
BURNER
HOOK

MANIFOLD-_
BOLT _'w

FIGURE 9
HOOK BOLT ASSEMBLY

FIGURE 10
FLUE COLLECTOR/DRAFT

FIGURE8
REAR BOILERVIEW

HOOD

.f,
H

FIGURE 11
SIDE VIEW OF INNER FRONT
AND COVER DOOR

-"IGURE 12
TOP CUT VIEW OF MANIFOLD
BURNER AND BASE BACK PLATE

F - VENTING
A. General
1--For connectionto gasvents or chimneys,vent installationshall be in accordancewith Part7, Ventingof Equipment,of the currenteditionof the
NationalFuelGas Code,ANSIZ223.1/NFPA54,or applicableprovisionsof the localbuildingcodes.
2--Draft: Sufficientdraft mustbe availableforremovalof productsof combustion.If draftis not adequate,spillageof the productsof combustion
will occurat the bottomoutletof the draft hood. Ifsuch a conditionshouldexistcheck the flue and chimneyto determinecauseof insufficient
draft.It is also importantthat ampleair is availablein the boiler roomto facilitatedraft.
3--Vent connectorshouldslope upwardat least 1/4"per lineal footbetweenthe draft hood outletandthe chimney.
4--Flue or vent connectormustbe insertedinto but not beyondthe insidewall of the chimneyflue.
5--Vent connectorsservingappliancesventedby naturaldraft shallnot be connectedinto any portionof mechanicaldraft systemsoperating
underpositivepressure.
6--Horizontal portionsof the ventingsystemsshall be supportedto preventsaggingby use of metalstrappingor equivalentmeans andbe located
at no morethan 12 ft. intervals.
7--When an existing boileris removedfrom a commonventingsystem,the commonventingsystemis likelyto be too large forproper ventingof
the appliancesremainingconnectedto it.
At the time of removalof an existingboiler,the followingsteps shall be followedwith eachapplianceremainingconnectedto the common
ventingsystemplacedin operation,whilethe otherappliancesremainingconnectedto the commonventingsystemare not inoperation.
a.Seal any unusedopeningin the commonventingsystem.
b.Visuallyinspectthe ventingsystemfor propersize and horizontalpitchand determinethereis no blockageor restriction,leakage,corrosion
and otherdeficiencieswhichcouldcausean unsafecondition.
c.Insofaras is practical,closeall buildingdoorsand windowsand all doors betweenthe spacein whichthe appliancesremainingconnected
to the commonventingsystemare locatedandotherspacesof the building.Turnon any clothesdryersandany appliancenot connectedto
the commonventingsystem.Turnon any exhaustfans,such as rangehoodsand bathroomexhausts,so they will operate at maximum
speed. Donot operatea summerexhaustfan.Close fireplacedampers.
d.Place in operationthe appliancebeing inspected.Followthe lightinginstructions.Adjustthermostatso appliancewill operatecontinuously.
e.Testfor spillageat the draft hood reliefopeningafter 5 minutes of mainburner operation.Usethe flameof a match or candle, or smokefrom
a cigarette,cigar or pipe.
f. After it has beendeterminedthat eachapplianceremainingconnectedto the commonventingsystemproperlyvents whentested as
outlined above,returndoors,windows,exhaustfans,fireplacedampersandany othergas-burningapplianceto their previousconditionsof
use.
g.Any improperoperationof the commonventingsystemshouldbe correctedso the installationconformswith the currenteditionof the
NationalFuel GasCode,ANSIZ223.1/NFPA54.When resizingany portionof the commonventingsystem,the commonventing system
should be resizedto approachminimumsize as determinedusing the appropriatetableslocatedin the chapter"Sizingof CategoryI Venting
Systems",inthe currenteditionof the NationalFuelGas Code,ANSIZ223.1/NFPA54.
8--Single WallTypeVentPipeshouldbe furnishedbetweenthe draft hood andchimney.If the vent connectorshallbe located in or pass througha
cold area,the ventconnectorshall be of listed double-wallTypeB or L material.

B,VentDamperInstallation
1 Ventdampers are providedon models61-03through 61-08as standardequipment.
2--Unpack the vent damperandfollowthese instructionsandthe installationinstructionsin the vent dampercarton.Observethe cautionsand
warmngthat accompanyall instructions.Do not modifyvent damperor boilerdraft hood
3--The vent dampercan be mounteddirectlyonto the drafthood outletcollar,or in the vent pipingclose to the boiler.Seefigures14 and 15, Be
sure directionof flow arrow locatedon dampercollar,is pointingawayfrom draft hoodcollar and damperpositionindicatoris visibleafter
installation,For installationwithdampermountedin the horizontalposition,mountthe damperas shownin figure 15 to avoid excessiveheat
and possiblecondensationdrips on the damperoperatingcontrol.
4--Do not use onevent damperto controltwo or moreheatingappliances.Seefigure 13.
5 Makecertain thatthe minimumclearancesprovidedinthe vent dampermanufacturersinstructionsare maintainedandthatadequatespaceis
providedfor damperaccessand service.
6--A wiring harnessis packedwiththe vent damperwith plug inconnectionsat eachendof the harness.Connectsmallerendinto dampermotor
receptacleand connectotherendto boileraquastatrelay_imit(on waterboilermodelsequippedan L8148Eor L8124Elimitcontrol),or boiler
junctionbox (onsteam boilermodels),
7--Damper mustbe in the open positionwhen appliancemainburnersare operating.

I[_

OTHER
HEATING
APPLIANCE

HEATING
OTHER
APPLIANCE

INCORRECT

CORRECT

Figure13:VentingMultipleAppliances

SLOPE UP
A MINIMUM
OF 1/4"
PER FOOT

-m

VENT
DAMPER
AS REQUIRED

DRAFT HOOD
OUTLET

Figure14:Ventingwith VentDamperin VerticalPosition

SLOPE UP
A MINIMUM

VENT
DAMPER

oF1/4"

/- VENT TO
/CHIMNEY

"7F" 1

PER FOOT_

1 O'CLOCK
POSITION

11 O'CLOCK

OPERATOR
-CONDENSATION
ZONE

r_
7 O'CLOCK
POSITION

5 O'CLOCK
POSITION

DO NOT MOUNT DAMPER
OPERATOR IN SHADED REGION
SECTION A-A

Figure15:VentingwithVentDamperin HorizontalPosition

G - PIPING
1--Hot Water:
a.The recommendedpipinghook-upis shownin Figure17.Also referto PeerlessWaterSurvey.
2--Steam:
a.The recommendedpipinghook-upis shownin Figure16. Pleasenotethat a Hartfordreturn loop is recommendedto be usedon all steam
boilers.Also referto PeerlessSteam Survey.
3--The reliefvalveand popsafetyvalveshallbe installedby usingthe 3/4"x 3"nippleand 3/4"elbow suppliedwith the boiler.Referto illustrations
located inSection R - "Ratings,Tappingsand DimensionalData".LargeNPT sizevalvesmay be installedin supplypiping.
NOTE: IF THIS BOILERAND DISTRIBUTIONSYSTEMIS USEDIN CONJUNCTIONWITHA REFRIGERATION
SYSTEM.THE CHILLED
MEDIUMSHALLBE PIPEDIN PARALLELWITHTHE BOILERAND THE PROPERVALVEAPPLIEDTO PREVENTTHE CHILLED
MEDIUMFROMENTERINGTHE BOILER.A DRAWINGILLUSTRATING
THIS HOOK-UPIS PROWDEDIN FIGURE18.
WHENTHE BOILERIS CONNECTEDTO HEATINGCOILS LOCATEDIN AIR HANDLINGUNITWHERETHEYMAYBE EXPOSED
TO REFRIGERATED
AIR CIRCULATION,
THE BOILERPIPINGSYSTEMMUSTBE EQUIPPEDWITHFLOWCONTROLVALVESOR
OTHERAUTOMATICMEANSTO PREVENTGRAVITYCIRCULATIONOF THE BOILERWATERDURINGTHE COOLINGCYCLE.
CAUTION:PIPETHE DISCHARGEOF RELIEFVALVETO PREVENTINJURYIN THE EVENTOF PRESSURERELIEE SUGGEST
DISCHARGETO BE PIPEDTO DRAIN.PIPEFULLSIZE OF OUTLET.
H - GAS PIPING
1--Gas supply pipingis to be sizedand installedproperlyinorder to providesupplyof gas sufficientto meet the maximumdemandwithoutundue
lossof pressurebetweenthe meterandthe boiler.
2_onsult the followingtablefor propersizing of gas piping for variouslengthsand diameters.
CAPACITYOF PIPEOF DIFFERENTDIAMETERSAND LENGTHSIN CU. FT PERHOURWITHPRESSUREDROPOF 0.3 IN.AND
SPECIFICGRAVITYOF 0.60. NO ALLOWANCEFORAN ORDINARYNUMBEROF FITTINGSIS REQUIRED,
Pipe Length
Feet

3/4"
Pipe

1"
Pipe

11h"
Pipe

11/2"
Pipe

278

520

1,050

1,600

190

350

730

1,100

152

285

590

890

130

245

500

760

115

215

440

670

105

195

400

610

MULTIPLIERSTO BEUSEDWITH ABOVETABLE,WHENTHE SPECIFICGRAVITYOF THE GAS IS OTHERTHAN 0.60
SpecificGravity

0.5

0.55

0.60

0.65

0.70

Multiplier

1.10

1.04

1.00

0.962

0.926

3.-Locate the droppipe adjacentto, but not in front of the boiler.
4--Locate a tee in the drop pipe at sameelevationas the gas inlet connectionto the boiler.Extendthe drop pipe to a pipe cap asshown in Figure
19 to form a sedimenttrap.
5--Install a groundjoint unionaheadof the gas controlassemblyto permitservicingof the equipment.See Figure19. Somelocalcodesrequirean
additionalshut-offvalve.If your coderequiressucha valve,a suggestedlocationis shownin Figure19.
6_OTE:

When installing
boiler be sure a pipe compoundresistantto the actionof liquefiedpetroleumis used.

7--Check pipingfor leaks.Alwayscheck leakswitha waterandsoapsolutionor equal.DO NOTUSE A FLAMEFORCHECKINGGAS LEAKS,
8--The boilerandits individualshut-offvalvemustbe disconnectedfrom the gas supply pipingsystemduringany pressuretestingof that system
at test pressuresin excessof r/2psig (3.5kPa),
The boiler mustbe isolatedfrom the gas supplypipingsystembyclosing its individualmanualshut-offvalveduringany pressuretestingof the
gas supply pipingsystemat test pressureequalto or lessthan V2psig (3.5kPa).

Table1: SteamHeader,Risersand EqualizerSizing
Model

No. Supply

Size of

Header

Equalizer

No.

Outlets

Supply

Size

6t-03

1114"

61-04

11/4"

61-05

lr_"

61-06

21_"

11_"

61-07

2+/2"

11_"

61-08

11_"

62-09

11_"

62-10

1!_"

62-11

1_"

62-12

31_"

11_"

62-13

31_"

11_"

62-14

31_"

tl_"

62-15

31_"

11_"

SUGGESTED
PIPING
STEAM BOILER

L---RETURN
_TOP • w_STt
Cu_{D
_to _

¥_LV[
(Nomwl_eJrY O_J_W_
[xF_l_,_
TANK

t
<
ETURN

NOTE:Thereturnfrom systemshouldalwaysenterequalizer
through HartfordLoop,approximately2"- 4" below
normalwaterline.

S_T_II_ESS

v,_Tl_

;_'_1_

is _

SUGGESTED
PIPING
HOT WATERBOILER

Steam headershouldbe 24" rain.aboveboilernormal
waterline.

Figure16: SteamSupplyand ReturnPiping

Figure 17: Hot Water Supply and Return Piping

_Fw°_ ;4(ATW4G

SERVICE

_JACKET
G.J. UNION

SEDIMENT

TRAP

J
_./FLOOR

LINE

Figure18: ParallelHook-UpwithWater Chiller
Figure19:Gas Connectionto Boiler

Figure20: GravityHotWater

Figure21: ForcedHotWater

.HIGH TEMPERATURE
HOT

WATER

MIXEO

HEATER

"rAPPING

WATER
MIXER

Figure22: SteamW/FloatLWCO

Figure23: SuggestedPipingForTanklessHeater

F_
A

THRU
i1_11

1/2
TO

9 1/4
LONG
GAUGE GLASS
FROM PROBE
L.WC.O.
CARTON

o
L_

TAPPINGS
MOUNT

I_
Figure21A

RIGHT

SIDE

PANEL

Figure24: Steam:PrimaryProbeLWCO,HydrolevelCG400P
IMPORTANT
1. InspectProbeElectrodeannuallyfor scaleandbuild-upand clean if necessary.
2. Forpropermaintenance,
recommended
waterfeeder applications
andoperation,referto the Hydrolevel
ProbeLWCOInstallation
Instructions.

•

LEFT

I';AhlD

OPPOSITE

F3 TI

Figure 25: Steam: Gauge/Pressuretrols Piping Arrangement

t[[

Figure26: Steam:Gauge/Pressuretrols
AlternatePipingArrangement
13

I - CONTROLS
l--Steam:
a.For proper }ocationof controlsand accessoriesreferto SectionR "Ratings,TappingLocationsandDimensionalData".
b.The McDonnell& Miller #67PE-2LWCOis furnishedas a standardwith all steamboilers.The HydrolevelCG 400-PPrimaryProbeLWCOis
optional.This control providesa lg minuteon cyciefollowedby a 90 secondoff cycle.This featureallowsthe waterlevelinboilerto settleso
that the probe can sensea true waterlevel.
c.The HydrolevelCG 550-P ProbeLWCOmay be usedin combinationwith a PrimaryFloat LWCOand is to be mountedinthe secondary
probe location.
1. The CG550PLWCOincorporatesa 10 minuteon cyclefollowedbya 90 secondoff cycle.
d. Whena 67PE-2Float LWCOis supplied,the pressuretroland brasssiphonare mountedon top of the 67PE-2.Thisis standardformodels
61-03thru 62-1t. Referto figure 22. The 67PE-2is providedwith fittingsto attachdirectlyto tappingsA and B,as shownin figure 24.The
20q 05-10gaugeglassset is installedas part of the 67PE-2quickhook up fittings.
e.When a HydrolevelCG400-PPrimaryProbeLWCOis supplied,the pressuretrol,brasssiphonand gaugeare mountedasshown infigure
24. The fittings requiredfor mountingthesethreecomponentsare found inthe ProbeLWCOCartonand the SteamTrimCarton.
A longergaugeglassw/rods, (22-162-10carton), are requiredfor usewith the HydrolevelCG-400-Pprobe.Two1/2"x 3" nipples,two 1/2"
couplers,longergaugeglassw/rodsand gaugevalvesare mountedintoTappingsA andC as shown infigure 24. For PackagedBoilers,
theseparts are suppliesin the Misc.PartsCarton,locatedin boilercrate. ForKnockdownBoilers,use the gaugevalvesfound in20-105-10
WaterGaugeCarton,whichis packedin the SteamTrimCarton.Thelongergaugeglassw/rodsandfittings are in PrimaryProbeLWCO
Carton.
NOTE:REFERTO FIGURE25 AND26 FOR MOUNTINGOF DUALPRESSURETROLS,FOR MODELS62-12THRU62-15
CAUTION:If using chemicaladditivesto preventfoamingand surging,such as "Squick",watchthe gaugeglassandshut down boilerif water
disappearsfrom glass.Thencyclethe boilera fewtimes until the waterstabilizes.
2--Hot Water:
a.For proper locationof controlsand accessoriesreferto SectionR "Ratings,TappingLocationsand DimensionalData".
NOTE:A HOTWATERBOILERINSTALLEDABOVERADIATIONLEVELMUST BE PROVIDEDWITHA LOWWATERCUTOFFDEVICE
EITHERAS A PARTOF THE BOILEROR ATTHETIME OF BOILERINSTALLATION.
b.When a probe LWCOis provided,installprobeLWCOin supply piping.
Supply Piping (left or right).
Note:This mountingmethoddoesnot requirea probewitha timed on/offfeature.
1. Instal_a 2" x 10" inch or longer nipple in the boiler supply tapping. Install a 2" x 2" x 3/4"
tee on the nipple. See figure 27.
TO SYSTEM

__
2

X 10

]

2,,x
I,P"

TEE

NIPPLE _

RO
' Eo

Figure27: ProbeLWCOLocationfor HotWaterBoiler

2. Install the remainderof the boilersupply piping.Pipesizemay be reducedas required.Referto low
watercut off manufacturer'sinstructionsfor installationandmaintenanceprocedures.

Do not install a probe low water cut off in the boiler primary or secondary probe tapping unless the
low water cut off is equipped with a timed on and off feature. The cycled off time will allow the probe
low water cut off to sense the true water level in the boiler and eliminate a false reading caused from
sensing a foaming or surging water condition. Failure to use a timed low water cut off could result in
a failed heat exchanger.
14

3--Specific details regardingthe installationof the variouscontrolsare givenin the controlsheetsattached.
4--In the eventof a controlfailurethe replacementshallbe identicalwiththe originalequipment.
5_n certain modelsa separatepilot switchmustbe used.The switchshallbe mountedon the left sideof the inner frontjacket panel.Usethe
two Ys"holes provided,if holesare not provided,drill accordinglyas shownin Figure45.
6--For Models61-08,62-09thru 62-16the sparkignitioncontrolbox whensupplied,mustbe mountedon the outerleft side jacketpanel asshown
in Figure43. Ifadditionalspark ignitioncontrol box is supplied,this mustbe mountedto the outerrightsidejacket panel.
7--For Models61-03thru 61-07the spark ignitioncontrol and mountingbracket,whensupplied,can be mountedto the rightor left outerjacket
panelas requiredfor easeof wiring.
8--This boilermay be suppliedwithsafetylimitsin additionto the high limitaquastatand pressuretrol.The followingis a descriptionof theselimits
and howthey work in conjunctionwith the safe operationof the boiler.
a. FLAMEROLL-OUTSAFETYSHUTOFF SWITCH--For Models61-03thru 61-08ONLY,this is a thermallyactivatedswitchthat is located
on the burneraccesscoverplate.The flameroll-outsafetyshutoft switchwill senseexcessivetemperaturecaused bycontinuedflame rollout and shut down mainburnergas.This is a non-recyclingswitchthat mustbe replacedonceit has beenactivatedandthe causeof the
roll-outeliminated.
b. VENTSAFETYSHUT OFF SWITCH--ForModels61-03thru 61-08ONLY,this is a thermallyactivated,manuallyresetableswitch,located
inthe draft hood reliefopening.If ventingsystembecomespartiallyor totally blocked,the vent safetyshut off switchwill senseexcessive
temperaturecaused byflue productsexitingthe draft hood reliefopeningandshut downmainburner gas.
NOTE:REFERTO SECTIONQ FOR INSTRUCTIONSWHENBOILERIS SHUTDOWNBY THE ACTIVATIONOF EITHEROFTHE ABOVE
SWITCHES.
9--Water & SteamModels62-12lhru 62-15are suppliedwith2 limitcontrols.The manualreset limitmustbe setfor a highercut out pointthanthe
operatinglimitcontrol.If aThermostatis usedas an operatingcontrol,it shouldbe usedin additionto and not in lieuof the operatinglimit
control.
NOTE:THISBOILERSHALLBE INSTALLEDSO THATTHE GAS IGNITIONSYSTEMCOMPONENTSARE PROTECTEDFROMWATER
(DRIPPING,SPRAYING,ETC.)DURINGAPPLIANCEOPERATIONAND SERVICE(CIRCULATORREPLACEMENT,
CONDENSATE
TRAP,CONTROLREPLACEMENTS,ETC.).
J - WIRING
NOTE:]HIS UNITWHENINSTALLED
MUSTBEELEC'rI_AU.YGROUNDED
INACCORDANCE
WI]HTHEREQUIREMENTS
OF]HEAU_
HAVING
JURISDIC'I]ON
OR,INTHEABSENCE
OF SUCHREQUIREMENTS,
wm.ITHECURRENT
EDmONOF]HE NATIONAL
ELECTRICAL
CODE,ANS_FPANO.70,
IFANEXTERNAL
ELECTRICAL
SOURCE
ISUI1L_D.
1--All electricalwiring shallbe donein accordancewithThe NationalElectricCode ANSI/NFPA70and local requirements.
2--For recommendedwiringof controls,referto Figures28 thru 42. SeeFigures20, 21,22 and 24 for locationof wiringand controls.
3--A lengthof 150° C lowvoltagewire is provided.
4--The boilershouldbe connectedby a separate,permanentlyliveelectricalsupplyline witha fused switch.
5--ThermostatAnticipatorSettings:(note:settingsmay need to be adjustedup or downfrom set pointsnotedbelow)
a. Set to .4 ampwhen a 8222A-1002IsolationRelayis applied.
b. NI othersystems,match anticipatorsettingto amp load of 24 voltcontrolcircuit.
NOTE:Singlepole switchesincludingthoseof safetycontrolsor protectivedevicesshall not be wired ina groundedline.
CAUTION:LABELALLWIRESPRIORTO DISCONNECTION
WHENSERVICINGCONTROLS.WIRINGERRORSCANCAUSEIMPROPERAND
DANGEROUSOPERATION.VERIFYPROPEROPERATIONAFTERSERVICING.

K - STARTING BOILER
1--Refer to INSTRUCTIONSFOROPERATIONandthe lighting/aperatinglabel whichis mountedtojacket panel.
2--The boilerand its gas connection
mustbe leaktested beforeplacingthe boilerin operation.Checkgas connectionswithsoap solution.

L1 - ADJUSTMENT TO GAS PRESSURE REGULATOR
1--Set manifoldpressureasfo_lowsfor variousgases.
a. Natural Gas................

31/2"WaterColumn

b, LiquefiedPetroleumGas ................

10" WaterColumn

2--To adjustgas pressure,turn adjustingscrewof gas pressureregulator,out to decreasepressure,turn in to increasepressure,Referto control
sheetssuppliedwith boilerfor locationof gas pressureregulator•
3--In no case shouldthe finalmanifoldpressurevary morethan plusor minus03 incheswatercolumnfrom the abovespecifiedpressures•Any
necessarymajorchangesinthe flowshouldbe made by changingthe sizeof the burnerorifice.
MinimumPermissibleSupplyPressurefor Purposeof Input Adjustment....

5.0" W.C.NaturalGas

11.0" W.C LiquefiedPetroleum
Gas

MaximumPermissibleSupplyPressureto the Boiler ..................

13.5" W.C.NaturalGas

13.5" W.C LiquefiedPetroleum
Gas

NOTE: MINIMUMRATEAS SHOWNONTHE RATINGPLATE!S OBTAINEDBY A FIXEDORIFICELOCATEDIN THE GASTRAINAND IS NOT
ADJUSTABLE•

L2 - ADJUSTMENTOF PILOTGASFLOWWITHMR8200AND MR8300COMBINATIONGASVALVES
To maximizethermocouplelife,particularlyon naturalgas installationswith gas supplypressuresabove9" W,C.,reducethe pilot gas flow.
WARNING:TURNOFF ALL ELECTRICPOWERTO THE APPLIANCE.TURNGAS CONTROLKNOBTO "PILOT'POSITION•
1--Locate and removethe pilotadjustmentcap screw,whichis adjacenttothe pilottube connection
on topof gas valve.
2--Remove pilot observationcoverdoor.SeeFigure11.
3--Turn the pilot adjustmentscrew clockwiseuntilthe pilot flameextinguishes•Then increasethe pilotflow just to the pointthatthe gas valveholds
in when relightingthe pilot persteps 9 and 10 of LightingInstructionson page 25 (turnscrewno morethana 1/8turn).
NOTICE:THE FIRSTFEWTURNSOF THE ADJUSTMENTSCREWMAYNOT CAUSEANYCHANGEIN THE PILOTFLOW.SUBSEQUENT
PARTIALTURNSOF THE ADJUSTMENTSCREWMAYHAVEA GREATIMPACTON PILOTFLOW.
4--Turn on electricpowerto the appliance.
5--Turn Gas ControlKnob to "On"positionper the LightingInstructionson page 25.
6--Verify pilot remainslit after shutdownfrom a boiler"ON"cycleof at least ten minutes,If pilot extinguishes,followLightingInstructionson page25
and again slightlyincreasepilotflow.
7--Make a fina_slightincreaseinthe sizeofthe pilot to ensuresufficientpilot signal underall operatingconditions,justto the pointthat you observe
a slight increasein the sizeof the flame (nomore thanan 1/8turn).
8--Replace adjustmentcap screw andobservationcover door•

M-BURNERINPUT
1--Refer to rating labelmountedon the jacket inner-frontpanelto obtainthe requiredBTU per hour input•In no case shallthe inputto the boiler
exceedthat shownon the rating label.
2--Check input by use of thefollowingformula:Suggestreadingmeterfor2 Cu.Ft.
_Q0 x F x H _ BTU/Hr.Input
T
3600
F
H
T

-----

Secondsper hour
Cu.Ft.Gas RegisteredonMeter
HeatValueof Gas in BTU/Cu.Fb
Timein Secondsof Meteris Read

NUMBER OF ORIFICE SPUDS REQUIRED
MODELNUMBER-ORIFICESPUDS--

61-03
4

61-04 61-05
6
8

61-06
10

61-07
12

61-08
14

62-09 62-10
16
18

62-11 62-12
20
22

62-13
24

62-14 62-15
26
28

•

HONEYWELL 24V STANDING PILOT - STEAM w/DAMPER, FLOAT LWCO AND ISOLATION RELAY
Models61-03 thru61-08

2_v
TST_

_LA¥

7
I

COIL

_
R _ RELAY

ml
II

_ADC,CR LEr_ND

I
I

_TUB _AP,NES$

LINE VOLTAGE
LO_ VOLTAGE
H V88_
X_

Figure28

HONEYWELL 24V STANDING PILOT - STEAM OR GRAVITY HOT WATER
Models62-09 thru 62-11

Figure29

r_'f_

HONEYWELL SPARK IGNITION (HSP) - GRAVITY OR STEAM w/DAMPER, FLOAT LWCO AND ISOLATION RELAY
Models61-03thru61-07

TRANSFORME_
120V

_J_J_J

I
TSTAI

F_ELA_" COIL

_R L

I I

SpARK

ilrl

IAODER tECENO
:IN_ VOLTAGE
_OW VOL_SE

Figure30

HONEYWELL SPARK IGNITION (HSP) - FORCED HOT WATER w/DAMPER
Models61-03thru 61-07

4_OJTJL_
Z4_

?v"

.........

_)_ ...........................
_t
_.

,, _l_._ J

-4,

_. ..........
_L,._

•

,
i

, ,

Figure31
18

i ii

HONEYWELL SPARK IGNITION (HSP) - FORCED HOT WATER w/COIL AND DAMPER
Models61-03thru61-07

_--_ ..... _-rr'ccc_..... _'-.... -

I@_

i....
L ............

_w......

LI i _

.....

............

I
L ......

....

_---=

__=__-_2

L_IN__,rAG_

_tt

14 _

rY_

........

IC_

SiZE 16 _

BO'C

__'..iJ__J

•

z-__.,qt_

•

__+J

TW
STA,*I,_O

W,RI_

Figure32

HONEYWELL SPARK IGNITION (HSP-2) - GRAVITY OR STEAM w/DAMPER, FLOAT LWCO AND ISOLATION RELAY
Model61-08only

OPERAnNG CO_IFtOL O_
120V_60HZ

....

r_ERUOS_I

ISOLAtiON_[tAY

<.o.
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