PEERLESS Boiler Manual L0308192

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

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Boilers

Installation,

Operation Et

Maintenance

Manual

3-8 90,0 Up to 81.7% AFUE

Natural or LP Gas

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

Natural Draft (chimney) Venting

Factory Assembled Sections on Knockdown Boilers

•Reduces Installation Time

Large Water Content

•Ideal for Steam and Large Volume Hot Water Applications

Skim Tapping

•For Cleaning Steam Boilers

Low Profile Design

•Horizontal to Vertical Draft Diverter

•Ideal for Installations with Low Ceilings

Steel Push Nipples

•Provide a Permanent Water Tight Seal Between Sections

•Unaffected by Petroleum and Other Contaminants

Tankless Coils

•For Domestic Hot Water Production on Hot Water Boilers

Deluxe Insulated Enameled Steel Jacket

•Reduces Boiler Heat Loss

•Completely Encloses Gas Valve and Burners

Safety Controls

•Low Water Cut-Offon Steam Boilers

•Flame Roll-Out Shut-OffSwitch

•Blocked Vent Shut-OffSwitch

•Honeywell Operating Controls

•Vent Damper

•Float Type LWCO on Steam Boilers

•Taco 007 Circulator on Packaged Water Boilers

•Tankless Coil for Hot Water Boilers

•Gnmdfos Circulator on Packaged Hot Water Boilers

• Probe Type LWCO on Steam Boilers

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

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

lifetone warranty is provided.for the cast iron sections ol Peerless residential hot water boilers.

Peerless also provides a limited, ten year warranty ot_ the cast iron sections of its residential steam

boilers. Five and ten year extended warratlties on parts and labor are now available. Pl_'asc consult

Peerl_,ss Heater Company for complete warranty inJbrmation.

PGGRLESS _

CAST IRON BOILERS

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

FAB-61 R1 (3/02 3M)

Printed in US A

pr=-I RLESS o

CAST IRON BOILERS

Series 61

oResidential Gas Boilers

•Packaged or Knockdown

oNatural Draft Venting

oStanding Pilot or

Spark Ignition

QSteam or Hot Water Boilers

oNatural or LP Gas

Water

Steam

QThis large water content boiler

installsin difficultsteam or water

applications.

oAFUE 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.

oLow 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.

oProbe or float-type low water

cutoff available.

DOE

Heating Capacity

MBH--

Stdg.PilotwlDamper

Seasonal Efficiency

(AFUE)4

Net I=B=R Ratings 3

Steam Steam Water

Sq. Ft. MBH 2MBH 1

225 54 63

304 73 85

4O4 97 113

504 121 140

604 145 168

704 169 196

Spark Ign. wlDamper

Seasonal Efficiency

(AFUE) 4

Water Content

(GaL)

IA,G.A.

I Input

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

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

120 98 97 N/A I77.7 81.7 I 80.7 10.32 5.88

160 130 129 N/A I 77,8 81.3 I 80.6 12.48 6.96

200 I 161 161 N/A I 78.0 81.0 I 80.6 14.64 8.04

240 193 193 N/A I 78.1 80.6 I 80.6 16.80 9.12

280 225 225 N/A I 78.3 80.3 I80.6 18.96 18.20

1 Net I=B=R water ratings based on an allowance of 1.15,

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

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

systems, etc.

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

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

7 Sizes 9-15 Sections 320 to 560 MBH Input 80% Combustion Efficiency

Natural or LP Gas

Standing Pilot or Spark Ignition

Natural Draft (chimney) Venting

Factory Assembled Sp/it Block Sections on Knockdown Boilers

•For Ease of Handling

Large Water Content

•Ideal for Steam and Large Volume Hot Water Jobs

Skim Tapping

•For Cleaning Steam Boilers

Low Profile Design

•Horizontal to Vertical Draft Diverter

•Idealfor Installatiolis with Low Ceilings

Steel Push Nipples

•Provide a Permal_ent Water Tight Seal Between S_ctioris

•Unaffected by Petroleum arid Other Cor_tamiTlalltS

Tankless Coils

•For Domestic Hot Water Production o_ Hot Water Boilers

Deluxe Insulated Enameled Steel Jacket

•Reduces Boiler Heat Loss

•Completely Encloses Gas Valve and Burners

Safety Controls

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

•HoT_eywell Operating Co_ltrols

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

•Float Type LWCO orl Steam Boilers

•Tcxl_lcless Coiljor Hol Watcr Boilers

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

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

• Prot)t> "I_upe I.WCO o11 Sle(lfll Boilers

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

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

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

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

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

FAB 6_7t9 02 :_,%

pGr=-RLESS o

CAST IRON BOILERS

Series 62

oSemi-Commercial Gas Boiler

• Packaged or Knockdown

oNatural Draft Venting

o320 to 560 MBH Input

oSteam or Hot Water Boilers

oNatural or LP Gas

Steam

Water

oThe large water content of this

knockdown or completely packaged

boiler makes it ideal for difficult steam

or water applications.

oAvailable in standing pilot or spark

ignition.

oCombustion efficiency meets the

80% ASHRAE 90.1 minimum as

required by the federal standards for

commercial boilers.

OHorizontal to vertical draft hood

and aluminized steel flue collector

provide a low boiler profile to allow

installation in areas with low

clearance.

r_ An optional tankless hot water coil

can be installed on water boilers,

insuring ample domestic hot water

production.

o Probe or float-type low water cutoff

available.

I=B=R Water

Gross Output Net I=B=R Combustion Content

MBH Ratings 3 Efficiency 4 (Gallons)

Model Input Steam Steam Water

Number MBH Water Steam Sq. Ft. MBH2MBH 1Water Steam Water Steam

62-09 320.0 256 256 800 192 223 80.0 80.0 21.12 11.28

62-10 360.0 288 288 900 216 250 80.0 80.0 23.18 12.36

62-11 400.0 320 320 1000 240 278 80.0 80.0 25,34 13.44

62-12 440,0 352 352 1100 264 306 80.0 80.0 27.50 14.52

62-13 480.0 384 384 1200 288 334 80.0 80.0 29.66 15.60

62o14 520.0 416 416 1300 312 362 80.0 80.0 31.82 16.68

1 Net I=B=R water ratings based on an allowance 011.15.

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

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

extensive piping systems, etc

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

I

J

K

L

M

N

O

P

Q

R

m

Boiler

Model

Number

62-09

62-10

62-11

62-12

62-13

62-14

62-15

Steam Water

3/4" Pressure Gauge* Limit Control (Models 09-11)

3/4,, N/A Operating Control (Models 12-15)

3/4" N/A Limit Control (Models 12-15)

V2" N/A Temperature-Pressure Gauge

V2" Gauge Glass and Low Water Cutoff N/A

2" Return Return

3/4" Secondary Probe Low Water Cut-Off N/A

3/4" Safety Relief Valve Safety Relief Valve

1V2" Skim Tapping N/A

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

3o4-

L£_'T SID_ £RON_ RIGH TSIDE

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

Jacket Right of Distance Rear of Distance ,..

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

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

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

39 V2" 30V4" 35" 14" 11%#' 4%s" 2-6" 333/." N/A 9" 9" x 20'

43%" 30V4" 35" 15" 13_V_6" 4%8" 2-7" 37%" N/A 9" 9" x 20'

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

52" 30V4" 35" 18" 15_%#' 6_/_6" 2-8" 46V4" 21_/_6" 10" 10" x20'

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

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

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

STEAM WATER

, , i

t t "L

Boiler

Model

Number

62-09

62-10

62-11

62-12

62-13

62-14

62-15

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

Steam

No. Supply Outlets

2

2

2

3

3

3

3

Size of Outlets

2"

2"

2"

2"

2"

2"

Header Supply

3 _=

3"

3"

3V2"

31/2''

31/2'`

31/2" ,

Equalizer Size

1V4"

11/4"

1V2"

1V2"

1V2"

1W'

1V2"

Boiler

Model

Number

62-09

62-10

62-11

62-12

62-13

62-14

62-15

Htr. No.

X-1020

GPM

4,75

5.00

5.25

5.50

5.50

5.75

5.75

Htr. No. Htr. No.

X-1021 X-1022

GPM GPM

6.25

6.75

7.00

7.25

7.25

m

6.5

7.0

7.5

8.5

9.0

*Water healer ratings in GPM are based on intermittent demand40 °to 140_ Frise with 200 °FbOiler water

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

SERIES 62 BOILER SPECS

_-_-_ LlJl-J_vd_id

• Cast Iron Sections--Factory Tested and

Assembled with Steel Push Nipples

•Deluxe Insulated Enameled Steel Jacket

• Drain Valve

• Horizontal to Vertical Draft Diverter

•End Cleanout

• Manual Reset Limit (62-12 to 62-15)

• Standing Pilot or Spark Ignition

• Automatic Reset Limit

Water

• 30 PSI Safety Relief Valve

• Temperature-Pressure Gauge

Steam

•15 PSI Safety Valve

• Pressure Gauge

• Gauge Glass

• Low Water Cutoff - Probe or Float

• Skim Tapping

• HSP-2 Honeywell 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)

Approx. Shipping Wts. (Ibs.)

Boiler

Model

Number ILength IWidth !Height IW S

I II!

62-09 I57" 31" I 391/2" I 1080 I1088

I I I I

62-10 I 61" 3t" J391/2" J1170 I 1178

I I I I

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

I I I ]

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

I II!

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

I IIJ

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

I I I I

62-15 I 82" 31" I391/2" I 1720 1 1728

WP SP

1105 1108

1195 1203

1290 1298

1445 1453

1545 1553

1645 1653

1745 1753

nnam

Example:

62 - 09 - STDG/SPRK - WP - N

Series Sects. Natural Gas (Substitute

Standing Pilot or "LP" for LP Gas)

Spark Ignition W = Water Knockdown

WP = Water Package

S = Steam Knockdown

SP = Steam Package

PEERLESSHEATERCO.

231 North Walnut Street

Boyertown, PA 19512-1021

Phone: 610-367-2153 • FAX: 610-369-3284

www.peerless-heater.com

HI Division ASME garNa

of gama

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

Readcarefullybeforebeginningwork.It witlsavetime.Studythe includeddrawings.

Theequipmentshallbe installedin accordancewith thoseinstallationrequirementsofthe authorityhavingjurisdictionor, in theabsenceof such

requirements,to thecurrenteditionof the NationalFuelGas CodeZ223.1/NFPA54.

Whererequiredbythe authorityhavingjurisdiction,theinstallationmustconformto the standardforControlsand SafetyDevicesfor AutomaticallyFired

Boilers,ANSI/ASMECSD-I.

A-ACCESSIBILITY CLEARANCES

1. Toprovidefor reasonableconditionsof accessibility,the followingminimumclearancesare recommended.

a. 24" betweenthesides, top,back andfront of theboilerand adjacentwall or otherappliance,when accessis requiredfor servicing.

B - CLEARANCEFROMCOMBUSTIBLECONSTRUCTION

1. Thedesignofthisbelieriscertifiedforthefollowingclearancesfromcombustibleconstruction:

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

18"fromrear

6"from rightand left sides

30" fromtop- front alcove

6"fromflue connector

6"from steamandhot waterpipes

MODELS62-12thru62-15

24" fromsidesand rear

55" fromtop

6"fromflueconnector

6"fromsteam andhotwater pipes

2. CAUTION:This boileris NOTDESIGNCERTIFIEDforinstallationon carpetingor combustibleflooring.

C -AIR FORCOMBUSTIONANDVENTILATION

1. Be certainadequatefacilitiesare availableto provideairfor satisfactorycombustionandventilation.

2. AppliancesLocatedin UnconfinedSpaces:

a. Installationsin unconfinedspaceswith conventionalconstructionand largeareas:thesupplyof airfor combustionandventilationcan usually

beconsideredadequate,

3, AppliancesLocatedonConfinedSpaces:

If allair for combustionand ventilationis to comefromwithinthebuilding:two openingsshallbe providedwithone openingcommencingwithin

12inchesof thetop andone openingwithin12 inchesof the bottomof theenclosure.Theseopeningsshall notbe locatedcloserthan 3 inches

fromeitherthe topor bottomof the enclosureand shallbe openintoareascommunicatingfreely withtheoutdoors,The areaof eachopening

shallbe equalto one squareinch per 1000BTU/HRof totalinput ratingof all applianceswithinthe enclosure,witha minimumof 100square

inchesfor eachopemng,

If allair for combustionand ventilationis to comefrom outsidethebuilding:two openingsshallbe providedwithone openingcommencing

within12 inchesof thetop and oneopeningcommencingwithin12 inchesof the bottomof theenclosure.Theseopeningsshall notbe located

closerthan 3 inchesfromeitherthe top or bottomof theenclosureandshallcomreunicatedirectlyor by ductswith theoutdoors.The areaof

eachopeningshall beequalto onesquareinch per 4000 BTU/HRof totalinputrating.If ductsare usedto conveythe air,verticalductsrequire

areasof onesquareinch per4000 BTU/HR:horizontalductsrequireone squareinchper 2000 BTU/HR,Ductsshallhavethe samecross

sectionalareaas the full area of the openingsto whichtheyconnect.

c. Theupperopeningsare essentialfor maintenanceof propercirculationofairwiththe boilerroomand reasonableambienttemperatureinorder

to maintainpropercontroltemperatures.

D - SETTING UP BOILER -PACKAGEDUNITS

1. A PackagedBoiler is factoryassembledbeforebeingcrated.Allcontrolsand accessoriesnecessaryfor operationof the boilerare attachedand

electricallywired.

2. Thedraft hoodis packedin a separatecarton.

3. When boileris removedfromthe crate,carefulinspectionshouldbe made andthecarrier notifiedof any damagefound.

4. Providea goodlevelfoundation.

5. Placethe boileron the foundationnearand in properpositionwith relationtothe chimney,andas centralizedwith respecttothe heatingsystemas

practical,

6. The openingsin thebasesides are providedfor admittingsecondaryair and mustneverbe closed.

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

8. The burnersare installedin the boiler.Theyare securedin placefor shipmentbywoodstripewiradto the Burnermixingtube.Cut thewiresand

removethewood strips.

9. The gas manifoldandocntrolassemblyare madeup gas tight,completelyfactoryassembledand installedas integralcomponentsof thebase

assembly.See Figure12.

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

I-- ASSEMBLEDBLOCKS

1--The boilersectionsandbase,Models61-03thru61-07arefactoryassembled.Removeshippingskidfromtheboilerbase.If boilerisa61-08,

or62-09thru62-15beginassemblyas notedin PartII "SplitBlockAssembly".

2--Providea goodlevelfoundation,The Boilershouldbe locatedasneartothechimneyandcentralizedwithrespecttotheheatingsystemas

possible.

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

and nutsprovided.Figures43 thru45 show thestandardcontrolassembliesusedon Models61-08thru 62-15.

4 Openflue collectorcarton.Removeflue collectorand Hi Tempropeandlay rope ontop of boileragainstbeadprovided.SeeFigure7.

5--Place fluecollectoron topof ropeand attachto boilerwithtwo1/4"-20studs,washersandhex nutsprovided,throughfluecollectorbrackets

into thetapped lugs providedontopof theboilerend sections.Drawbolts downsnugly.SeeFigure8,

6--Attach cast ironclean-outplate10clean-outopeningon leftside of the boiler.This plate, HiTempropeand mountinghardwaremay befoundin

thecontrolbox referred1opreviously.

7--Remove the burnersfromthecontrolboxand install.Installeachburnerby slippingtheopeninginthe venturioverthe orificespud.Insertthe

pin on thebottomof theburnerintothe holeprovidedin theflangeon the basebackplate.SeeFigure9.The Burnerswith pilotsattachedmust

be installedas follows:Note:Hookbolt isprovidedon models62-11through62-15.

ModelNo. No.Pilots

61-03 1

61-04 1

61-05 1

61-06 1

61-07 1

61-08 2

62-09 2

62-10 2

62-11 2

62-12 2

62-13 2

62-14 2

62-15 2

Location of Pilot

Between2nd and 3rd BurnerfromLeft

Between4th and5th BurnerfromLeft

Between4th and5th BurnerfromLeft

Between4th and 51hBurnerfromLeft

Between4th and 5thBurnerfromLeft

Between4th and5th Burnerfrom Leftand4th and5thfrom Right

Between4th and5th BurnerfromLeft and4th and5thfrom Right

Between4th and 5thBurnerfromLeft and4th and5thfrom Right

Between4th and5th Burnerfrom Leftand4th and 5thfrom Right

Between4th and 5thBurnerfromLeft and4th and 5thfrom Right

Between4th and 5thBurnerfromLeft and41hand5thfrom Right

Between41hand5th BurnerfromLeft and6th and7thfrom Right

Between6th and7th BurnerfromLeft and6th and7thfrom Right

8..-Removepilot tubingfromcontrolbox and installbetweengas valveandpilot. Referto figures43 through45.

9--If boileris to incorporatea tanklessheaterfordomestichot water,installinopeningprovidedin the rightside of the boiler.Six mountingbolts

3/8"16 x3/4 are rovldedBe sure rubber asketi I

( - ) p " • g "sbetweencoverplateandtheboier, Ifboiler doesnot incorporatea fanklessheater,a

blankcoverplateis providedwithrubbergasketand bolts.One3/4"pipeopeningis providedin the platefor the operatingand/orlimit control.

This 3/4"tappingis alsousedfor the pressuregaugeonthe steamboiler,

10--For suggestedpipingto fanklessheaterreferto Figure23.

DANGER:Installmixingvalveinhotwatersupplypiping.Watertemperatureover 125°Fcan causesevereburnsinstantlyor deathfromscalds,

2

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

II-- SPLITBLOCKASSEMBLY

1--Boiler sectionsfor Models61-08,62-09thru 62-15are shippedintwo parts. Removeskidfrom each blockof sections.

2--Place each blockof sectionson the stackedskids.See Fig.A. Becertainto removethesmall blocksonthetop skid.See Fig.B,

3--To clean nippleportsand removeprotectivecoating, usea wire brush andmineralspiritsor lacquerthinner.Makecertainthereare no burrs

aroundthe outsideedgeof the ports.

4--Spread a thincoatof PeerlessNippleSealerin the nippleports, NEVERON NIPPLES.

5--Insert the push nipples,withthe chamferededge out. Makecertaintheyare cleanand free ofburrs.

6--Apply a thin coatof PeerlessNippleSealerto the ropegroove.Press5/8"Dia. ropeinto thegroove.Thenipplesealeractsas an adhesiveto

holdthe ropein placeuntil thesecgonsare drawnup.

7--Arrange both blocksso that protrudingnippleentersthe openport.Caremustbe takento keepnipplesstraightand blocksaligned.

8--Insert drawrodsthroughthe nippleports.Make certainthat the3/4"drawrod is usedon the large nipple.Pay particularattentionto the

placementof the drawwashers.See Fig.A.

9--Before startingdraw,oil thethreadsand betweenthe nutsandwashers.

10--Tightenthe hexnutsanddraw boilerevenlyuntilthe small padsoneach sectionjust touch.

11--After boiler is drawn,removethedraw rodsand cut 5" from the 6V4" threadedend.Inserttherod throughthe lugs oneachendsectionand

tightenthehex nutshandtight.

12--Attach3/8"Dia.ropeto baseback plateby layingropeacross topof back plateflange and in ropegrooveon eachendof backplate.Usenipple

sealerto hold ropein place.Referto figures9 & 12.Attachbase backplate by meansof V4"-20x lr/2" machinescrewsandnutsfurnished.

The base back plateis attachedto back of boiler.SeeFigure8. Be certainthatthe flange portionof plate istowardsthe insideof the boiler.

Note: hook bolt isprovidedonmodels 62-11through62-15only.

13--Install pressuregage,drain valve,water supplylinewith shutoffvalve,and meansto ventair.Plugunusedtappings.

14--Fill boilerwith water,ventingair as water levelrises.Pressurizeboilerto 75-85 psig.Do notexceed85 psig.

15--Verify pressureis maintained.Checkall jointsand fittingsfor leaks.

16--Drain boiler.Removepressuregage,drain valve,watersupplyand airvent.ContinuewithStep2 underD-1.

E-JACKET ASSEMBLY

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

Thisstylejacket designincorporatesa BackJacketPanelaspart of eachRightand Left SideJacketPanel.TheBackJacketPanelis formedwhena

portion of each Side Panelis bent atperforationsto rearof boile_:

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

2. Placethe RightSide Panelalong right sideof boiler blockandalign the slotsof the mountingbrackets,(atbottomof jacketpanel),withthe 1/4-20x

1"studs.Attachjacket panel to boilersectionwithtwo (2) 1/4"nutsandwashers.SeeFigureI.

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

4. Bendat theperforationsof the Right SidePanelto form half of the BackJacketPanel.Dothe sameat perforationsof the LeftSidePanel.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 clearanceholesin eachSide Paneland attachwith four(4) #10x 1/2"sheetmetalscrews.See Figure4.

6. PlacetheSecondaryAirCoverDooratbottomofInnerFrontPanel.ThetopbendoftheCoverDoorslipsoverthetopreversebendatcutout

openingoftheinnerFrontPanel.RefertoFigure11.

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

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

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

metalscrews.SeeFigure4.

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

11.ThemanilaenvelopethatcontainstheInstallationManualalsocontainstheboilerratinglabel,clearancetocombustiblesplate,Lighting/Operating

instructionplateorlabelandwiringdiagramlabel.SeaFigure5forlocationofplatesandlabels.Attachplateswith#6x3/8"screwsprovided.

12.PositiontheRemovableFrontPanelinplacebyslidingthePanelunderthefrontflangeoftheTopPanelandthendownuntilitrestsonLowerFront

Panel.

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

Thisjacketstyle hasa separateBackJacketPanelthatis attachedto individualRightand LeftSidePanels.

1. AttachSide Panelsper instructionsin #1thru 3 above.SeeFigure 1.

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

3. Followinstructionsaboveper #5thru 12for assemblyof remainingjacket panels.

SIDE PANEL ATFACHMENT

FIGURE 1

-,_ RIGHT SIDE PANEL

ONEPIECERIGHT

SIDEANDREAR

PANEL

1/4" WASHER

1/4" NUT

J

J

ONE PIECE LEFT

SIDE AND REAR

PANEL

REAR VIEW WRAPPER

STYLE JACKET

(61-03THRU 61-06)

FIGURE 2

LEFTSIDEPANEL

RIGHT

SIDE

PANEL

REAR VIEW OF BACK PANEL

(61-07 THRU 62-15)

FIGURE 3

BACKPANEL

4

JACKET ASSEMBLY

FIGURE 4

/

/

#,

,LIGHTING/OPERATING

,INSTRUCTIONSLABEL

(61-63 THRU 62-11)

"WIRING

_J

/jJ DIAGRAM LABEL

RATINGLABEL

LIGHTING

INSTRUCTIONSPLATE

(62-12 THRU 62-15)

CITYOFNEWYORK

•MEAPLATE

(WHENREQUIRED)

CLEARANCETO

COMBUSTIBLESPLATE

REMOVABLEFRONTPANEL

(INSIDE VIEW) INNER FRONTPANEL

AGENCY LABEL & PLATE LOCATIONS

FIGURE 5

FIGURE 6

FRONT BOILER VIEW

FIGURE 7

FRONT TOP BOILER VIEW

T_6"- !_UNC NUT & WASHER

_BASE BACK_

-- PLATE

BURNER MANIFOLD-_

HOOK BOLT _'w

FIGURE 9

HOOK BOLT ASSEMBLY

FIGURE8

REAR BOILERVIEW

FIGURE 10

FLUE COLLECTOR/DRAFT HOOD

.f,

H

FIGURE 11

SIDE VIEW OF INNER FRONT

AND COVER DOOR

-"IGURE 12

TOP CUT VIEW OF MANIFOLD

BURNER AND BASE BACK PLATE

6

F- VENTING

A.General

1--For connectionto gasventsor chimneys,ventinstallationshall bein accordancewith Part7, Ventingof Equipment,of thecurrenteditionof the

NationalFuelGas Code,ANSIZ223.1/NFPA54,orapplicableprovisionsof the localbuildingcodes.

2--Draft: Sufficientdraft mustbe availableforremovalof productsof combustion.If draftis notadequate,spillageof the productsof combustion

will occurat the bottomoutletof the draft hood.Ifsuch a conditionshouldexistcheck theflue and chimneyto determinecauseof insufficient

draft.It is also importantthat ampleairis availablein theboiler roomto facilitatedraft.

3--Vent connectorshouldslope upwardat least 1/4"per lineal footbetweenthe drafthood outletandthechimney.

4--Flue orvent connectormustbe insertedinto butnot beyondtheinsidewall of the chimneyflue.

5--Vent connectorsservingappliancesventedby naturaldraft shallnot beconnectedinto anyportionof mechanicaldraftsystemsoperating

underpositivepressure.

6--Horizontal portionsof theventingsystemsshall be supportedto preventsaggingby use of metalstrappingor equivalentmeansandbe located

at no morethan 12 ft. intervals.

7--When anexistingboileris removedfrom a commonventingsystem,thecommonventingsystemis likelyto be too large forproperventingof

theappliancesremainingconnectedto it.

At thetime of removalof anexistingboiler,thefollowingstepsshall be followedwith eachapplianceremainingconnectedto the common

ventingsystemplacedin operation,whilethe otherappliancesremainingconnectedto thecommonventingsystemare not inoperation.

a.Sealany unusedopeningin thecommonventingsystem.

b.Visuallyinspectthe ventingsystemfor propersize and horizontalpitchand determinethereisno blockageor restriction,leakage,corrosion

and otherdeficiencieswhichcouldcausean unsafecondition.

c.Insofaras is practical,closeall buildingdoorsand windowsand alldoorsbetweenthespacein whichtheappliancesremainingconnected

to thecommonventingsystemare locatedandotherspacesof the building.Turnon any clothesdryersandany appliancenotconnectedto

the commonventingsystem.Turnon any exhaustfans,suchas rangehoodsand bathroomexhausts,so theywilloperateat maximum

speed.Donot operatea summerexhaustfan.Close fireplacedampers.

d.Placein operationtheappliancebeing inspected.Followthe lightinginstructions.Adjustthermostatso appliancewill operatecontinuously.

e.Testfor spillageat the drafthood reliefopeningafter 5 minutes of mainburneroperation.Usethe flameof a match orcandle, orsmokefrom

a cigarette,cigar orpipe.

f. After it hasbeendeterminedthat eachapplianceremainingconnectedto thecommonventingsystemproperlyventswhentested as

outlinedabove,returndoors,windows,exhaustfans,fireplacedampersandany othergas-burningapplianceto their previousconditionsof

use.

g.Anyimproperoperationof thecommonventingsystemshouldbe correctedso theinstallationconformswith thecurrenteditionof the

NationalFuel GasCode,ANSIZ223.1/NFPA54.Whenresizingany portionof the commonventingsystem,the commonventing system

should beresizedto approachminimumsize as determinedusingtheappropriatetableslocatedin the chapter"Sizingof CategoryI Venting

Systems",inthe currenteditionof theNationalFuelGas Code,ANSIZ223.1/NFPA54.

8--Single WallTypeVentPipeshouldbefurnishedbetweenthedrafthood andchimney.If theventconnectorshallbe locatedin orpassthrougha

cold area,the ventconnectorshall be of listed double-wallTypeB or L material.

B,VentDamperInstallation

1 Ventdampersare providedon models61-03through61-08as standardequipment.

2--Unpack thevent damperandfollowthese instructionsandthe installationinstructionsin theventdampercarton.Observethecautionsand

warmngthat accompanyall instructions.Do notmodifyventdamperor boilerdrafthood

3--The ventdampercanbe mounteddirectlyonto the drafthood outletcollar,or in theventpipingclose to the boiler.Seefigures14 and 15, Be

sure directionof flow arrowlocatedon dampercollar,is pointingawayfromdraft hoodcollarand damperpositionindicatoris visibleafter

installation,Forinstallationwithdampermountedin the horizontalposition,mountthe damperas shownin figure15to avoidexcessiveheat

and possiblecondensationdrips on the damperoperatingcontrol.

4--Do not useoneventdamperto controltwo or moreheatingappliances.Seefigure 13.

5 Makecertainthatthe minimumclearancesprovidedinthe ventdampermanufacturersinstructionsare maintainedandthatadequatespaceis

providedfor damperaccessand service.

6--A wiring harnessis packedwiththe ventdamperwith pluginconnectionsat eachendof theharness.Connectsmallerendintodampermotor

receptacleand connectotherendto boileraquastatrelay_imit(on waterboilermodelsequippedanL8148Eor L8124Elimitcontrol),orboiler

junctionbox (onsteam boilermodels),

7--Damper mustbe in theopen positionwhenappliancemainburnersare operating.

OTHERHEATING

APPLIANCE

I[_ OTHER

HEATING

APPLIANCE

INCORRECT CORRECT

Figure13:VentingMultipleAppliances

8

SLOPE UP

A MINIMUM

OF 1/4"

PER FOOT -m

VENT

DAMPER

AS REQUIRED

DRAFT HOOD

OUTLET

Figure14:VentingwithVentDamperinVerticalPosition

/- VENT TO

SLOPE UP VENT /CHIMNEY

A MINIMUM DAMPER

oF1/4" "7F" 1

PER FOOT_ 11 O'CLOCK

r_

1 O'CLOCK

POSITION

OPERATOR

-CONDENSATION

ZONE

7 O'CLOCK 5 O'CLOCK

POSITION 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 loopis recommendedto be usedonall steam

boilers.Also referto PeerlessSteamSurvey.

3--The reliefvalveand popsafetyvalveshallbe installedby usingthe 3/4"x 3"nippleand 3/4"elbowsuppliedwith theboiler.Referto illustrations

located inSection R - "Ratings,Tappingsand DimensionalData".LargeNPT sizevalvesmaybe installedin supplypiping.

NOTE: IFTHIS BOILERANDDISTRIBUTIONSYSTEMIS USEDIN CONJUNCTIONWITHA REFRIGERATIONSYSTEM.THECHILLED

MEDIUMSHALLBE PIPEDIN PARALLELWITHTHE BOILERAND THEPROPERVALVEAPPLIEDTO PREVENTTHECHILLED

MEDIUMFROMENTERINGTHE BOILER.A DRAWINGILLUSTRATINGTHIS HOOK-UPIS PROWDEDINFIGURE18.

WHENTHEBOILERIS CONNECTEDTOHEATINGCOILSLOCATEDINAIR HANDLINGUNITWHERETHEYMAYBE EXPOSED

TO REFRIGERATEDAIR CIRCULATION,THE BOILERPIPINGSYSTEMMUSTBE EQUIPPEDWITHFLOWCONTROLVALVESOR

OTHERAUTOMATICMEANSTO PREVENTGRAVITYCIRCULATIONOFTHEBOILERWATERDURINGTHECOOLINGCYCLE.

CAUTION:PIPETHEDISCHARGEOFRELIEFVALVETO PREVENTINJURYINTHE EVENTOF PRESSURERELIEE SUGGEST

DISCHARGETOBE PIPEDTODRAIN.PIPEFULLSIZE OFOUTLET.

H - GAS PIPING

1--Gas supplypipingis to be sizedand installedproperlyinorder to providesupplyof gas sufficientto meet themaximumdemandwithoutundue

lossof pressurebetweenthe meterandthe boiler.

2_onsult the followingtablefor propersizing of gaspiping for variouslengthsand diameters.

CAPACITYOF PIPEOF DIFFERENTDIAMETERSAND LENGTHSINCU. FT PERHOURWITHPRESSUREDROPOF 0.3 IN.AND

SPECIFICGRAVITYOF0.60. NOALLOWANCEFORAN ORDINARYNUMBEROF FITTINGSIS REQUIRED,

PipeLength 3/4" 1" 11h"11/2"

Feet Pipe Pipe Pipe Pipe

10 278 520 1,050 1,600

20 190 350 730 1,100

30 152 285 590 890

40 130 245 500 760

50 115 215 440 670

60 105 195 400 610

MULTIPLIERSTO BEUSEDWITH ABOVETABLE,WHENTHE SPECIFICGRAVITYOFTHEGAS IS OTHERTHAN0.60

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,butnotin frontof theboiler.

4--Locate a tee in thedrop pipeat sameelevationas thegasinlet connectionto the boiler.Extendthe droppipeto a pipecap asshownin Figure

19to forma sedimenttrap.

5--Install a groundjoint unionaheadof the gas controlassemblyto permitservicingof the equipment.See Figure19.Somelocalcodesrequirean

additionalshut-offvalve.Ifyour coderequiressucha valve,a suggestedlocationis shownin Figure19.

6_OTE: Wheninstallingboiler besure a pipecompoundresistanttotheactionof liquefiedpetroleumis used.

7--Check pipingfor leaks.Alwayscheck leakswitha waterandsoapsolutionor equal.DONOTUSE A FLAMEFORCHECKINGGASLEAKS,

8--The boilerandits individualshut-offvalvemustbe disconnectedfrom the gas supplypipingsystemduringany pressuretestingof that system

at test pressuresin excessof r/2psig (3.5kPa),

The boiler mustbe isolatedfromthe gassupplypipingsystembyclosing its individualmanualshut-offvalveduringany pressuretestingof the

gassupplypipingsystemat test pressureequalto or lessthan V2psig (3.5kPa).

10

Table1: SteamHeader,Risersand EqualizerSizing

L---RETURN

SUGGESTEDPIPING

t t

ETURN

NOTE:Thereturnfrom systemshouldalwaysenterequalizer

throughHartfordLoop,approximately2"- 4" below

normalwaterline.

Steamheadershouldbe 24" rain.aboveboilernormal

waterline.

Figure16: SteamSupplyand ReturnPiping

Model No.Supply Size of Header Equalizer

No. Outlets Outlets Supply Size

6t-03 1 2" -- 1114"

61-04 1 2" -- 11/4"

61-05 1 2" -- lr_"

61-06 2 2" 21_" 11_"

61-07 2 2" 2+/2" 11_"

61-08 2 2" 3" 11_"

62-09 2 2" 3" 11_"

62-10 2 2" 3" 1!_"

62-11 2 2" 3" 1_"

62-12 3 2" 31_" 11_"

62-13 3 2" 31_" 11_"

62-14 3 2" 31_" tl_"

62-15 3 2" 31_" 11_"

STEAM BOILER

SUGGESTEDPIPING

HOT WATERBOILER

_TOP • w_STt ¥_LV[ (Nomwl_eJrY O_J_W_

Cu_{D _to _ [xF_l_,_ TANK

_ S_T_II_ESS v,_Tl_ ;_'_1_ is _ _Fw°_ ;4(ATW4G<

Figure 17: Hot Water Supply and Return Piping

11

Figure18: ParallelHook-UpwithWaterChiller

J

SERVICE

_JACKET

G.J. UNION

SEDIMENT TRAP

_./FLOOR LINE

Figure19:GasConnectionto Boiler

Figure20:GravityHotWater

Figure22: SteamW/FloatLWCO

Figure21: ForcedHotWater

.HIGH TEMPERATURE

HOT WATER _.

MIXEO

WATER

MIXER

HEATER

"rAPPING

12 Figure23:SuggestedPipingForTanklessHeater

A

c

©o ©

F_

1/2 TAPPINGS

TO MOUNT

9 1/4 LONG

GAUGE GLASS

FROM PROBE

L.WC.O. CARTON

L_ I_

RIGHT SIDE PANEL

Figure24:Steam:PrimaryProbeLWCO,HydrolevelCG400P

THRU

i1_11 _.

I

I

Figure21A

IMPORTANT

1. InspectProbeElectrodeannuallyfor scaleandbuild-upand cleanif necessary.

2. Forpropermaintenance,recommendedwaterfeeder applicationsandoperation,referto theHydrolevelProbeLWCOInstallationInstructions.

• °

LEFT I';AhlD OPPOSITE

F3 TI

Figure 25: Steam: Gauge/Pressuretrols Piping Arrangement

t[[

Figure26:Steam:Gauge/PressuretrolsAlternatePipingArrangement

13

Figure27:ProbeLWCOLocationfor HotWaterBoiler

I - CONTROLS

l--Steam:

a.Forproper }ocationof controlsand accessoriesreferto SectionR "Ratings,TappingLocationsandDimensionalData".

b.TheMcDonnell& Miller#67PE-2LWCOisfurnishedas a standardwith all steamboilers.The HydrolevelCG400-PPrimaryProbeLWCOis

optional.This controlprovidesa lg minuteon cyciefollowedby a 90secondoffcycle.Thisfeatureallowsthe waterlevelinboilerto settleso

that theprobe cansensea true waterlevel.

c.The HydrolevelCG550-P ProbeLWCOmaybe usedin combinationwith a PrimaryFloatLWCOand isto be mountedinthe secondary

probe location.

1. TheCG550PLWCOincorporatesa 10minuteon cyclefollowedbya 90 secondoff cycle.

d. Whena 67PE-2Float LWCOis supplied,the pressuretroland brasssiphonare mountedontop of the 67PE-2.Thisisstandardformodels

61-03thru 62-1t. Referto figure22.The 67PE-2isprovidedwith fittingsto attachdirectlyto tappingsA and B,as shownin figure24.The

20q 05-10gaugeglassset is installedas part of the67PE-2quickhook upfittings.

e.Whena HydrolevelCG400-PPrimaryProbeLWCOis supplied,the pressuretrol,brasssiphonand gaugeare mountedasshowninfigure

24.The fittingsrequiredfor mountingthesethreecomponentsare foundinthe ProbeLWCOCartonand theSteamTrimCarton.

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 showninfigure24.For PackagedBoilers,

theseparts are suppliesin the Misc.PartsCarton,locatedin boilercrate.ForKnockdownBoilers,usethegaugevalvesfoundin20-105-10

WaterGaugeCarton,whichis packedin the SteamTrimCarton.Thelongergaugeglassw/rodsandfittingsare in PrimaryProbeLWCO

Carton.

NOTE:REFERTO FIGURE25 AND26 FOR MOUNTINGOFDUALPRESSURETROLS,FORMODELS62-12THRU62-15

CAUTION:If usingchemicaladditivesto preventfoamingand surging,suchas "Squick",watchthe gaugeglassandshutdownboilerif water

disappearsfrom glass.Thencyclethe boilera fewtimesuntil the waterstabilizes.

2--Hot Water:

a.Forproperlocationof controlsand accessoriesreferto SectionR "Ratings,TappingLocationsand DimensionalData".

NOTE:A HOTWATERBOILERINSTALLEDABOVERADIATIONLEVELMUST BEPROVIDEDWITHA LOWWATERCUTOFFDEVICE

EITHERAS A PARTOF THEBOILERORATTHETIMEOFBOILERINSTALLATION.

b.Whena probe LWCOis provided,installprobeLWCOin supplypiping.

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

2 X 10 ] I,P" TEE

NIPPLE _

RO Eo'

2. Install theremainderof the boilersupplypiping.Pipesizemaybe reducedasrequired.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--Specificdetailsregardingthe installationof the variouscontrolsare givenin the controlsheetsattached.

4--In the eventof a controlfailurethe replacementshallbe identicalwiththeoriginalequipment.

5_n certain modelsa separatepilot switchmustbe used.The switchshallbe mountedonthe left sideof the inner frontjacket panel.Usethe

two Ys"holesprovided,if holesare not provided,drill accordinglyas shownin Figure45.

6--For Models61-08,62-09thru 62-16the sparkignitioncontrolboxwhensupplied,mustbe mountedon the outerleft side jacketpanel asshown

in Figure43. Ifadditionalspark ignitioncontrolbox issupplied,this mustbemountedto the outerrightsidejacket panel.

7--For Models61-03thru 61-07thespark ignitioncontroland mountingbracket,whensupplied,can be mountedto the rightor left outerjacket

panelas requiredfor easeof wiring.

8--This boilermaybe suppliedwithsafetylimitsin additionto the highlimitaquastatand pressuretrol.The followingis a descriptionof theselimits

and howtheyworkin conjunctionwith thesafe operationof theboiler.

a. FLAMEROLL-OUTSAFETYSHUTOFFSWITCH--For Models61-03thru 61-08ONLY,this is a thermallyactivatedswitchthat is located

onthe burneraccesscoverplate.The flameroll-outsafetyshutoft switchwill senseexcessivetemperaturecaused bycontinuedflame roll-

outand shutdownmainburnergas.This is a non-recyclingswitchthat mustbereplacedonceit hasbeenactivatedandthe causeof the

roll-outeliminated.

b. VENTSAFETYSHUTOFFSWITCH--ForModels61-03thru 61-08ONLY,this is a thermallyactivated,manuallyresetableswitch,located

inthe drafthood reliefopening.If ventingsystembecomespartiallyortotallyblocked,thevent safetyshutoff switchwill senseexcessive

temperaturecausedbyflueproductsexitingthe drafthoodreliefopeningandshut downmainburnergas.

NOTE:REFERTOSECTIONQ FOR INSTRUCTIONSWHENBOILERIS SHUTDOWNBY THE ACTIVATIONOF EITHEROFTHEABOVE

SWITCHES.

9--Water & SteamModels62-12lhru 62-15are suppliedwith2 limitcontrols.Themanualreset 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 GASIGNITIONSYSTEMCOMPONENTSARE PROTECTEDFROMWATER

(DRIPPING,SPRAYING,ETC.)DURINGAPPLIANCEOPERATIONANDSERVICE(CIRCULATORREPLACEMENT,CONDENSATE

TRAP,CONTROLREPLACEMENTS,ETC.).

J-WIRING

NOTE:]HIS UNITWHENINSTALLEDMUSTBEELEC'rI_AU.YGROUNDEDINACCORDANCEWI]HTHEREQUIREMENTSOF]HEAU_ HAVING

JURISDIC'I]ONOR,INTHEABSENCEOFSUCHREQUIREMENTS,wm.ITHECURRENTEDmONOF]HE NATIONALELECTRICALCODE,ANS_FPANO.70,

IFANEXTERNALELECTRICALSOURCEISUI1L_D.

1--All electricalwiringshallbe donein accordancewithThe NationalElectricCodeANSI/NFPA70and local requirements.

2--For recommendedwiringof controls,referto Figures28 thru42.SeeFigures20,21,22 and 24 for locationof wiringand controls.

3--A lengthof 150° C lowvoltagewireis provided.

4--The boilershouldbe connectedby a separate,permanentlyliveelectricalsupplyline witha fused switch.

5--ThermostatAnticipatorSettings:(note:settingsmayneed to be adjustedup or downfromset pointsnotedbelow)

a. Setto .4 ampwhena 8222A-1002IsolationRelayis applied.

b. NI othersystems,match anticipatorsettingto amp loadof 24 voltcontrolcircuit.

NOTE:Singlepole switchesincludingthoseof safetycontrolsor protectivedevicesshall notbewired ina groundedline.

CAUTION:LABELALLWIRESPRIORTO DISCONNECTIONWHENSERVICINGCONTROLS.WIRINGERRORSCANCAUSEIMPROPERAND

DANGEROUSOPERATION.VERIFYPROPEROPERATIONAFTERSERVICING.

K - STARTING BOILER

1--Refer to INSTRUCTIONSFOROPERATIONandthe lighting/aperatinglabelwhichis mountedtojacketpanel.

2--The boilerand itsgas connectionmustbe leaktested beforeplacingthe boilerin operation.Checkgasconnectionswithsoap solution.

15

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,outto decreasepressure,turnin to increasepressure,Referto control

sheetssuppliedwith boilerfor locationof gas pressureregulator•

3--In no caseshouldthe finalmanifoldpressurevarymorethan plusor minus03 incheswatercolumnfromtheabovespecifiedpressures•Any

necessarymajorchangesinthe flowshouldbe madeby changingthe sizeof the burnerorifice.

MinimumPermissibleSupplyPressurefor Purposeof Input Adjustment.... 5.0" W.C.NaturalGas 11.0" W.C LiquefiedPetroleumGas

MaximumPermissibleSupplyPressureto the Boiler .................. 13.5" W.C.NaturalGas 13.5" W.C LiquefiedPetroleumGas

NOTE: MINIMUMRATEAS SHOWNONTHE RATINGPLATE!S OBTAINEDBY A FIXEDORIFICELOCATEDIN THEGASTRAINAND IS NOT

ADJUSTABLE•

L2 -ADJUSTMENTOF PILOTGASFLOWWITHMR8200AND MR8300COMBINATIONGASVALVES

To maximizethermocouplelife,particularlyon naturalgasinstallationswith gassupplypressuresabove9" W,C.,reducethepilot gas flow.

WARNING:TURNOFFALL ELECTRICPOWERTOTHEAPPLIANCE.TURNGASCONTROLKNOBTO "PILOT'POSITION•

1--Locate and removethe pilotadjustmentcapscrew,whichis adjacenttothepilottube connectionontopof gasvalve.

2--Remove pilot observationcoverdoor.SeeFigure11.

3--Turn the pilot adjustmentscrewclockwiseuntilthe pilot flameextinguishes•Then increasethe pilotflow just to the pointthatthegas valveholds

in whenrelightingthe pilot persteps9 and 10of LightingInstructionsonpage 25 (turnscrewno morethana 1/8turn).

NOTICE:THE FIRSTFEWTURNSOFTHEADJUSTMENTSCREWMAYNOT CAUSEANYCHANGEINTHE PILOTFLOW.SUBSEQUENT

PARTIALTURNSOFTHE ADJUSTMENTSCREWMAYHAVEA GREATIMPACTON PILOTFLOW.

4--Turn on electricpowerto the appliance.

5--Turn Gas ControlKnob to "On"positionper the LightingInstructionson page 25.

6--Verify pilot remainslit aftershutdownfroma boiler"ON"cycleof at least tenminutes,If pilot extinguishes,followLightingInstructionson page25

and again slightlyincreasepilotflow.

7--Make a fina_slightincreaseinthe sizeofthe pilot to ensuresufficientpilot signal underalloperatingconditions,justto the pointthat youobserve

a slight increasein thesizeof theflame (nomore thanan 1/8turn).

8--Replace adjustmentcap screwandobservationcover door•

M-BURNERINPUT

1--Refer to ratinglabelmountedon thejacket inner-frontpanelto obtainthe requiredBTUper hour input•In no case shallthe inputto theboiler

exceedthat shownonthe ratinglabel.

2--Check input by useof thefollowingformula:Suggestreadingmeterfor2 Cu.Ft.

_Q0 x F x H_ BTU/Hr.Input

T

3600 -- Secondsper hour

F -- Cu.Ft.GasRegisteredonMeter

H -- HeatValueof Gas inBTU/Cu.Fb

T-- TimeinSecondsof Meteris Read

NUMBER OF ORIFICE SPUDS REQUIRED

MODELNUMBER-- 61-03 61-04 61-05 61-06 61-07 61-08 62-09 62-10 62-11 62-12 62-13 62-14 62-15

ORIFICESPUDS-- 4 6 8 10 12 14 16 18 20 22 24 26 28

• k

16

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

Models61-03thru61-08

2_v 7

I

TST_ _LA¥ COIL

I F

_ ml I

R _ RELAY II I

_ADC,CR LEr_ND

LINE VOLTAGE

LO_ VOLTAGE

_TUB _AP,NES$

X_ _X

H V88_

Figure28

HONEYWELL 24V STANDING PILOT -STEAM OR GRAVITY HOTWATER

Models62-09thru 62-11

/r_'f_

Figure29

17

HONEYWELL SPARK IGNITION (HSP) - GRAVITY OR STEAM w/DAMPER, FLOATLWCO AND ISOLATION RELAY

Models61-03thru61-07

-- ?

TRANSFORME_

120V

_J_J_J

I

TSTAI F_ELA_" COIL

_R L I I SpARK

IAODER tECENO

:IN_ VOLTAGE

_OW VOL_SE

ilrl

Figure30

HONEYWELL SPARK IGNITION (HSP) -FORCED HOTWATER w/DAMPER

Models61-03thru 61-07

4_OJTJL_

Z4_

'/?v"

......... _ : _ -4,

_)_ ..........................._t _. _ ,, _l_._ _L,._J _. ..........

,i i i

_ _ ,

_/_ , ,

• w

i i ii i1_ !

Figure31

18

HONEYWELL SPARK IGNITION (HSP) - FORCED HOTWATER w/COIL AND DAMPER

Models61-03thru61-07

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

I

i....

L............ _w...... L I i _I

....

_---= __=__-_2

-- L_IN__,rAG_ _tt 14 _rY_ TW

........ IC_ _ SiZE 16 _ BO'C STA,*I,_O W,RI_

I@_ -* ..... , ............

* 1

@

L...... __'..iJ__J z-__.,qt_ •

, i

•_x- __+J

Figure32

HONEYWELL SPARK IGNITION (HSP-2) - GRAVITY OR STEAM w/DAMPER, FLOATLWCO AND ISOLATIONRELAY

Model61-08only

OPERAnNG CO_IFtOL O_

120V_60HZ r_ERUOS_I ISOLAtiON_[tAY H-RB222A IC,0_

TRANSFORMER

.... <.o.<t!, ; • ....

ILOW WAEP, Cu_-Orr

_ L ME _3LtC_JT

I I I COt_TFIO_S

_'_ _ _ _lii ' 1

SmEi HARNESS_ Il I Z: i %\ flING HIN SS ui FILO:_RNER _, I C_BL_ _ I , , _BL_ A

_RC_ D roif i_ x 7039 _ i _ II PILOT BURN[R

--.......... _ppkor GAS._ L _LO_ iigAIN LOW VI_IA_ "Z[ 15 A" "C51R_D£D "R<.............. L_.,_,, R _-- _--1-- -- --J_'

-- LINE VOtTACE VAL',_

VAL ,,_,_5 V;*L_ H VRll_<14

¢OL .... LOW VOLT,_Gt"SIZE 16/'2 A_ POll UkilErl FIRE

pROIE_TI_ _I_JNALqN__II!_ULT ¢_E IflS'C

_ROUND LEAEitI4N_IZ_ If Al_f__<1" C SIRAN_I] II_ll[

MORES ALL _4111N8HUST CC_4mty141H I_PLIOABLE _(:(YES 0RDINAN_[_ #*bid RECNLAllI:_t5

In ANY I Ill( ilCINAL _I4N[AS _PPU[I_ li4]H [HE _P_IANg[ MU_T

BE FIEPL#*CE_IT IdUST I_ REPLACED 1,41H11411[A_ _H_)l_ldt ITS EQUIVALENI

Figure33

19

HONEYWELL SPARK IGNITION (HSP-1) - w/DUAL 24V MAIN GAS VALVES

Models62-09thru 62-15

_j m

1[................

i i ;

i i

_,L W_ _ _,V___ _T_ _ICA_[ COOlS. C,_O_',_ES. A_ _1'_ A_IC,_S,

Figure34

HONEYWELL SPARK IGNITION (HSP-1) -w/DUAL 120V MAIN GAS VALVES

Models62-09Thru62-15

........"F

............ [ '! ....... "

_ _, _D ,_ ,¢_,_ ._=_.p_,x _L_._. *,.,_ _0_ T_pL_;T _

NOTES=

=

Figure35

2O

WIRING APPLICATION OF HYDROLEVEL PROBE LOW WATERCUTOFFS

Models550P,650PandCG550P

Referto SectionI - Controlsof this manualfor mountinglocationandinstructions.

115V-60HZ

L2 L1 (HOT)

£

L

TO L2 ON

WIRING DIAGRAM _,

--I1_- 115V-60HZ

ALARM CIRCUIT

(WHEN REQ'D)

sTO L1 ON WIRING DIAGRAM

NOTES:

ALL WIRING MUST COMPLY W!TH APPLIANCE CCDE3,

ORDINANCES, AND REGULATIONS

(_) PLACE JUMPER

Figure 36:Wiringof ProbeLWCO

21

The followingwiringdiagrams,figures37thru 42, arefor use witha HydrolevelCG400-PProbeLWCO

HONEYWELL 24V STANDING PILOT- STEAM w/DAMPER AND HYDROLEVEL PROBE LWCO

Models61-03thru61-08

_SCON_J_T

S_TC _ -- L1

(HO

mANSF_

4OVA

PROBE

_E C_I_t -- -

r],

-- UN£ ",_.TA_ Sa21E14 AW_ _TW tF, E

-- __ LOw t@-T_ NIl 1_/2 A_4_ _UMI11_ RF_

C_,INEC_ _A_AU

_H_ESS

r F R

I:F _¢ _ _kL S_

I

I I I I r--

Ix---_

I

L/_, ,

i___w w/ _ _ vat.s

----,=-_-- _<Zz_r_ 1 ion._o___ =1

CAS VAL_ _S---_-_XS

(ol+i i_ 61-0_)

ALL I_IRING MUST COMPly _n_ APP',JOm_

IF" ANy OF _O_dG_NALI_R_ AS _JPPU_ _ _ P4_PI_AN_E

MUST _REPtJ_C_O, IT 141JST BE R_PLl_ll_ _l113t llIRE AS SitO_I_4OR I/'3 _CAJIVALD_T.

/

RLOT metC_

-_---%---_- x

_-_N____

Figure37

HONEYWELL 24V STANDING PILOT-STEAM AND HYDROLEVEL PROBE LWCO

Models62-09Thru62-11

HYO_OLEV_L

CO_TRC_

CONNECTION DIAGRAU LEC,_NO

-- UN£ vo_r,_c_ _Z_ i,, _,wc WP[ _w ,_

LOW VO_IAC_ _zt _/2 ,_w_; pO_R UMIT[D rIFle

_OTE¢_V_ _ON_.LING ¢l_tCulr CABLE IO_:

I I

I I

V88_

I I

I I cR

L_co OP_R,_T_G LIMIT

CONTROL

L

F ....... J_ ]

I r--'@-_+ ....

I

I

.....

..... __N___ 4

G_S VALES

V88A

LADDER OAGIIAW G NB

U_E V0LrAG£ EXI[R_AL '_I_ING

GND

Figure38

22

HONEYWELL SPARK IGNITION (HSP) - STEAM w/DAMPER AND HYDROLEVEL PROBE LWCO

Models61-03thru61-07

CO_EClrO_ I_AGRAM

MRE HARNESS

! i i]ilZSS]

............ _1 . T,E,.O_,,T L....... I_,%

TRAN_C_M( R "l _

*,OVA

HY'OROLEVEL CONNECTION =ACRa_ LEGE_ ! )WBK _ P_LOT BURN[r

mI¢_IIlON k _,_N_NG CABLE

LOW VOLI'_CE _ZE _6 _,WG aO_ STRa_C_D V4RE

---- LOW VOLIACE _ZE 16/2 AWG pO_'_ERLIM_TEO nRE G*_S vaU_

PROECnVE SIgnALING CIK'CUIt CABLE 105_3

OI_1_O N COnTr.. lgR_IN;*L

_) CROdND LE^0_E SIZE t6 AWC _00',3 _TRAND_D 'MI_E

T_N_FORME _

24V

/

•_,,---,_---.1_........ ;g Fo _ ,_ "p....... @.......

<_ _rRS

LW¢O u_m_ _LL

,m

...... _F: ......... ® ....................................

: VEN] _AMpE_? IGNIIE R

-- UN_ VOL;ACE INERNAL _IRING

UV

..... LOW_IDL_CE INT_RNA L _4RING :O=..=J_t _ .V/F=V

ALL _NG MUST COMPLY _ APPUCA_E CODEg G_ V_LVE

ORDNANCES AND _[_UL_T_OnS

rr AN_ OF THE oN6mNAL _E AS _PPLIED _'_TH THE A_IANCE

_USJ 8( r_EpLA¢£D tT _lUgT _ RfPL_Cf_ _TH WIRE AS SHO_IN OR FTS [oUWAI_NT

Figure39

HONEYWELL SPARK IGNITION (HSP-2) -STEAM w/DAMPER AND HYDROLEVEL PROBE LWCO

Model61-08only

PROT_CTNES_ O_O_t C_t£ I_

-fir

,,

Ii*-n m"_ m_ __

I[' "%

e_s v,_u_

r..--- ¢[

i

v_v_

_o_

Figure40

23

HONEYWELL SPARK IGNITION (HSP-1) -w/DUAL 24V MAIN GAS VALVESAND HYDROLEVEL PROBE LWCO

Models62-09thru62-15

............Ti(HOt)

IRANsrO_E_

_OV

_J3LLLt_ o,o

_'Iv i

I I

....

VAL_

-- LING VOtT;_C[ EXT_F_N_L_e,NG

Figure41

HONEYWELL SPARK IGNITION (HSP-1) -w/DUAL 120V MAIN GAS VALVES AND HYDROLEVEL PROBE LWCO

Models62-09thru62-15

CONNCC_ON DIACP,_U

rIIIC0_NECT _i I I I

v• _ f I

.+,1 /_ \\ m ;j

- ' _ iiP_-- G_S VALVES

HYr)NOLfV[L I t _

,,,..<,.,°%,,.,,y,,,,_,:,.,?,,,o,< ,..... W _-_ ]

ION'T'ON CONISOL I_P,'_INAL

_) GRoUNO LEAOIRE _ll{ 16 J_ 200C STRANDED IRE

(H°T) IRI 2RI 2_

T_AN_'0l_ ER

_V I

r_ ___.,._ .......

iIC'WITER I

;t :.- _ --_ - .<p2e

-- pr_A _'_T _V _V/PV PV icN_o_

_wco OG _G LMIT _C (

III

,,

| |

-- LING VOLTAGE E_IERNAL ,_RINe _I-- _

_C2_5

Figure42

24

BOILERSEQUIPPEDWITHCONSTANTBURNINGPILOT

HONEYWELL GAS VALVELIGHTING INSTRUCTIONS

NOTE:CHECKWATERLINEOFSTEAMBOILER,ORBECERTAINSYSTEMISFULL

FORWATERBOILER,BEFOREPROCEEDINGWITHTHESEINSTRUCTIONS.

FOR YOUR SAFETY READ BEFORE LIGHTING

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

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

A, This appliance has a pilot whichmust be lighted by hand.When

lighting thepilot, follow these instructions exactly.

B. BEFORE OPERATINGsmell all around theappliance area for

gas. Be sure to smell next to the floor because some gas is

heavier thanair and will settleon the floor.

WHATTO DO IFYOU SMELL GAS

• Do not try to light any appliance.

e Do not touch any electric switch; do not use any phone in

your building.

• Immediately call your gas supplier from a neighbor's phone.

Followthe gas supplier's instructions.

C,

D,

• Ifyou cannot reachyour gas supplier,callthe fire department.

Use only your hand to push in or turn the gas control knob.

Never use tools. If the knob will not push in or turn by hand,

don't try to repair it, call a qualified service technician.Force or

attempted repair mayresult in a fireor explosion,

Do not usethis applianceif any part hasbeenunderwater.

Immediatelycall a qualifiedservicetechnicianto inspectthe

applianceandtoreplaceanypartofthecontrolsystemandany

gascontrolwhichhasbeenunderwater.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information aboveon this page.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

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

5. If the gas control knobis not inthe "OFF" position,turn the knob

clockwise _ to"OFF."

6. Wait five (5) minutesto clear out any gas. Then smell for gas,

including near the floor. If you then smell gas, STOP! Follow"B*

in the safety information above on this page. If you don't smell

gas, go to the nextstep.

7. Removethe pilotaccess panel, if supplied, located below and

behind the gas valve directly above burner tubes.

10.Pushinredresetbuttonallthewayandholdin.Immediatelylight

the pilotwitha match.Continueto holdthe resetbuttonin for

aboutone(1) minuteafterthe pilotis lit.Releasebuttonandit

will popbackup,Pilot shouldremainlit. If it goesout,repeat

steps5 through10.

• If buttondoesnot pop upwhenreleased,stopand immedi-

atelycallyourservicetechnicianorgassupplier.

• If the pilot will not stay lit after severaltries, turn the gas

controlknobto "OFFandcallyourservicetechnicianor gas

supplier.

11.Replacepilotaccesspanel,if applicable.

12.Turnthegascontrolknobcounterclockwise_ to=ON."

13.Replacecontrolaccesspanel,ifapplicable.

8. Find pilot followmetaltube from gas valve.The pilot is

betweentwoburnertubes.

9. Turnthegascontrolknobcounterclockwise_ to "PILOT"

14.Turnonallelectricpowerto theappliance.

15.Setthe thermostatto desiredsetting.

S_E _Ew

Ga* Cont,_l Knob

(-_n ,,_"OFF" Rtd Reset 8ulto*

P°""') _ S

tNL[T

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting. 4. Turn the gas control knob clockwise _ to "OFE"

2. Turnoff all electric power to the applianceif service is to be per-

formed. 5. Replace control access panel,if applicable.

3. If the gas valve is not visible, removecontrol access panel.

25

BOILERS EQUIPPED WITH ELECTRIC IGNITION AND A COMBINATION GAS VALVE

OPERATING INSTRUCTIONS

NOTE:CHECKWATERLINEOFSTEAMBOILER,OR BE CERTAINSYSTEMIS FULL

FORWATERBOILER,BEFOREPROCEEDINGWITHTHESEINSTRUCTIONS.

FOR YOUR SAFETY READ BEFORE OPERATING

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

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

A. This appliance is equipped with an ignitiondevice which auto-

matically lights the pilot. Do not try to light the pilot by hand.

B. BEFORE OPERATINGsmell 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.

WHATTO DO IFYOU SMELL GAS

•Do not try to light anyappliance.

•Do not touch any electric switch; do not use any phone in

your building.

•Immediately call your gas supplier from a neighbor's phone.

Followthe gas supplier's instructions.

C.

D,

• If you cannotreachyour gassupplier,call thefire department.

Useonly yourhandto pushin or turn the gas controlknob.

Neveruse tools.Ifthe knobwill not pushin orturn by hand,

don'ttryto repairit,callaqualifiedservicetechnician.Forceor

attemptedrepairmayresultina fireor explosion.

Do not use this applianceif anypart has beenunderwater.

Immediatelycall a qualifiedservicetechnicianto inspectthe

applianceandto replaceanypartof thecontrolsystemandany

gascontrolwhichhasbeenunderwater.

OPERATING INSTRUCTIONS

1.STOP!Readthe safetyinformationaboveonthispage.

2. Setthethermostatto lowestsetting.

3. Turnoffallelectricpowertothe appliance.

7.Waitfive (5)minutesto clearoutany gas.Thensmellfor gas,

includingnearthe floor.If you smellgas,STOP!Follow=B"in

thesafetyinformationaboveonthispage.Ifyoudon'tsmellgas,

gotothe nextstep,

4. This appliance is equippedwith an ignitiondevice which auto-

matically lights the pilot.De not try to light the pilotby hand.

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

6. Ifthe gas control knobis not inthe "OFF position, turn the knob

dcokwise f-4 to "OFF"

8.Turnthegascontrolknobcounterclockwise_ to"ON."

9. Replacecontrolaccesspanel,if applicable,

10.Turnonallelectricpowerto the appliance.

11.Setthethermostatto desiredsetting.

12.If theappliancewill notoperate,followtheinstructions"ToTurn

Off GasTo Appliance"andcall yourservicetechnicianor gas

supplier.

H_H VOLTAC,_

Gas Conlrol Knob

position)_

6A5

INLIT

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostatto lowest setting. 4. Turnthe gascontrolknobclockwise F-4 to "OFF:'

2. Turn off all electricpowerto the appliance if service is to be per-

formed. 5. Replacecontrol access panel, if applicable.

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

26

Referto Figure43withthefollowinginstructions

BOILERS EQUIPPED WITH ELECTRIC IGNITION AND DUAL GAS VALVE

LIGHTING INSTRUCTIONS

NOTE:CHECKWATERLINEOF STEAMBOILER,OR BE CERTAINSYSTEMIS FULL

FORWATERBOILER,BEFOREPROCEEDINGWITHTHESEINSTRUCTIONS.

FOR YOUR SAFETY READ BEFORE LIGHTING

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

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

A. This appliance is equipped with both a secondary pilot which

must be lighted by hand, and an ignition devicewhich automat-

ically lights the main pilot. Light only the secondary pilot by

handfollowingthese instructionsexactly.

B. BEFOREOPERATINGsmell all around the appliance area for

gas. Be sure to smell next to the floor because some gas is

heavierthan air and will settle on the floor.

WHATTO DO IFYOU SMELL GAS

• Do not try to light anyappliance.

• Do not touch any electric switch; do not use any phone in

yourbuilding.

C.

B.

•Immediatelycall your gas supplier from a neighbor's phone,

Followthe gas supplier'sinstructions.

• If you cannot reachyour gas supplier,call thefire department,

Useonlyyour handto pushin orturn the gas controlknob.

Neverusetools.If the knobwill notpush in or turn by hand,

don'ttryto repairit,calla qualifiedservicetechnician.Forceor

attemptedrepairmayresultinafire orexplosion.

Do not usethis applianceif any part has beenunderwater.

Immediatelycall a qualifiedservicetechnicianto inspectthe

applianceandto replaceanypartofthecontrolsystemandany

gascontrolwhichhasbeenunderwater.

LIGHTING INSTRUCTIONS

1.STOP!Readthesafetyinformationaboveonthispage.

2. Setthethermostatto lowestsetting.

3. Turnoffallelectricpowerto theappliance.

4. Ifthe gascontrolassemblyis notvisible,removecontrolaccess

panel.Referto controlassemblyonfollowingpage.

5. If themanualshut-offleverandpilotcockarenotinthe "OFF"

position,turnbothclockwise_-4 to"OFF."

Pil©_ Cock

{ 5how_in "ofF*

Man_al S_tu_- 0ll _osd_on)

Lever (s_o,n ;, -o[r-

6. Wait five (5) minutes to clear out any gas. If you smell gas,

STOP! Follow"B"in the safety informationabove on this page.

Ifyou don'tsmell gas, goto the nextstep.

7. Removethe pilotaccesspanel,if supplied,locatedbelowand

behindthegasvalvedirectlyaboveburnertubes.

8. Findsecondarypilot-- followmetaltubefromgasvalve.Pilotis

betweentwoburnertubes.

R**d Rese+

Svff_,

9. Turnthepilotcockhandlecounterclockwise_ to"ON."

10.Pushin redresetbuttonon pilotvalveall the wayandholdin.

Immediatelylight the pilot witha match.Continueto holdthe

resetbuttonin for aboutone (1) minuteafterthe pilot is lit.

Releasebuttonandit will popbackup.Pilotshouldremainlit.If

it goesout,repeatsteps5through10.

• If resetbuttondoesnotpopupwhenreleased,stopandimme-

diatelycallyourservicetechnicianor gassupplier.

• Ifthepilotwillnotstaylit afterseveraltries,turnthe pilotcock

handleto "OFF"andcallyourservicetechnicianorgas

supplier.

11.Replacepilotaccesspanel,if applicable.

12.Turnrnanualshut-offlevercountercleckwise_ to"ON."

13.Replacecontrolaccesspanel,if applicable.

14.Turnonallelectricpowerto theappliance.

15.Setthermostatto desiredsetting.

16.Iftheappliancewi[Inotoperate,followthe instructions"ToTurn

Off GasTo Appliance"andcall yourservicetechnicianor gas

supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turnoff all electric power to the applianceif service is to be per-

formed.

3. If thegascontrolassemblyis notvisible,removecontrolaccess

panel.

4. Turnthe pilot cock and the manual shut-off lever clockwise

to "OFF

5. Replacecontrolaccesspanel,ifapplicable.

27

SIAqK IGNITED pILOT _STO. PILOT

IGNITI

BLEED TUBING

--VENT TO 118*q BLEED TU6E OR TO OUTSIDE

ATMOSPHERE WELL /M3OVE NORMAL _REATHING

LEVEL AS APPLICABLE

PILOT GAS VALVE

I/4" TEST

PILOT

pILOT COCK

MANUAL S:_UT -OFF

VALVE

E_ _THERMOCOUPLE

LEAD

IGNITION CONTROL

BO_

LEFT SIOC JACKET PANEL

Figure43: HSPControlSystemandIgnitionControlBoxLocation

Models62-09thru 62-15

28

Referto Figure44withthefollowinginstructions

BOILERS EQUIPPED WITH ELECTRIC IGNITION AND A COMBINATION GAS VALVE

OPERATING INSTRUCTIONS

NOTE:CHECKWATERLINEOF STEAMBOILER,OR BE CERTAINSYSTEMIS FULL

FORWATERBOILER,BEFOREPROCEEDINGWITHTHESEINSTRUCTIONS.

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, afire or explosion may result

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

A. Thisapplianceis equippedwithanignitiondevicewhichauto-

maticallylightsthepilots.Donot fryto lightthepilotsby hand.

B. BEFOREOPERATINGsmellallaroundthe applianceareafor

gas.Be sureto smellnextto the floorbecausesomegas is

heavierthanairandwill settleonthe floor.

WHATTODOIFYOUSMELLGAS

•Donottryto lightanyappliance.

• Donottouchanyelectricswitch;donotuseanyphonein

yourbuilding.

• Immediatelycallyour gassupplierfroma neighbor'sphone.

Followthegassupplier'sinstructions.

• Ifyoucannotreachyourgassupplier,callthefiredepartment.

C.

D,

Use only your hand to push in or turn the gas control knob.

Never use tools. If the knob will not push in or turn by hand,

don't try to repair it, call a qualified service technician.Force or

attempted repair may result in a fire or explosion.

Do not use thisapplianceif any part hasbeenunderwater.

Immediatelycall a qualifiedservicetechnicianto inspectthe

applianceandto replaceanypartof thecontrolsystemandany

gascontrolwhichhasbeenunderwater.

OPERATING INSTRUCTIONS

1. STOP! Readthe safety informationabove on this page. 7. Wait five (5) minutes to clear out any gas. Then smell for gas,

2. Setthethermostatto lowestsetting.

3. Turnoffallelectricpowerto theappliance.

4. Thisapplianceis equippedwithan ignitiondevicewhichauto-

maticallylightsthepilots.Donot tryto lightthepilotsbyhand.

5. If the gas valveis not visible,removecontrolaccesspanel.

Referto controlassemblyonfollowingpage.

6. If thegascontrolknobandpilotcockarenotinthe"OFF"

position,turnbothclockwise_ to "OFF."

includingnear the floor. Ifyou smell gas, STOP!Follow"B" inthe

safety informationabove on this page. If you don't smell gas,go

to the nextstep.

8. Turnthe gas control knob and pitotcock counterclockwise

to "ON."

9. Replace controlaccess panel, if applicable.

10.Turn on all electric power to the appliance.

11. Set the thermostat to desired setting.

,,,,,c,,, 12. If the appliance willnot operate, follow lhe instructions "ToTurn

"""'°'" Off Gas To Appliance" and call your service technician or gas

Gas Control Knob ............ o.- supplier.

(shownin "OFF ....... --_

TO TURN OFF GAS TO APPLIANCE

t. Setthethermostattolowestsetting. 4. Turnthegascontrolknobandpilotcockclockwise_-4

2.Turnoffallelectricpowertotheapplianceifserviceistobeper- to"OFF."

formed.

3. Ifthegasvalveisnotvisible,removecontrolaccesspanel. 5. Replacecontrolaccesspanel,ifapplicable.

29

SpAR_ IGNkTEO PLLOT

_N GAS VALVE

\\\\\\

_ lLO__T _ VALVE

PILOT COCK

Figure44:HSP-2 ControlSystem

Model61-08

30

Referto Figure45withthefollowinginstructions

BOILERS EQUIPPED WITH CONSTANT BURNING PILOT(S)

LIGHTING INSTRUCTIONS

NOTE:CHECKWATERLINEOFSTEAMBOILER,ORBECERTAINSYSTEMIS FULL

FORWATERBOILER,BEFOREPROCEEDINGWITHTHESEINSTRUCTIONS.

FOR YOUR SAFETY READ BEFORE LIGHTING

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

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

A. This appliance has pilots which must be lighted by hand.When

lighting the pilots, follow these instructions exactly.

B. BEFORE OPERATINGsmel_all around the appliance area for

gas. Be sure to smell next to the floor because some gas is

heavierthan air and will settleon the floor.

WHATTO DO IFYOU 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.

Followthe gas supplier's instructions.

C.

D,

• Ifyoucannotreachyourgassupplier,callthefiredepartment.

Use only your hand to push in or turn the gas control knob.

Never use tools. If the knob will not push in or turn by hand,

don't try to repair it, call a qualifiedservice technician. Forceor

attempted repair may result in a fire or explosion.

Do not use thisapplianceif any part has beenunderwater.

Immediatelycall a qualifiedservicetechnicianto inspectthe

applianceandto replaceanypartofthecontrolsystemandany

gascontrolwhichhasbeenunderwater.

LIGHTING INSTRUCTIONS

1. STOP!Read the safety informationabove on thispage.

2. Setthe thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. If the gas control assemblyis not visible, removecontrolaccess

panel,

5. g the manualshut-off lever and pilot cock are not in the "OFF"

position,turnbothe,ockwiseto"OFF" ,o'o

posi_ion)_

6.Wait five (5) minutes to clear out any gas. If Nu smell gas,

includingnear the floor. If you smell gas, STOP!Follow"B"in the

safety informationaboveon this page.If you don't smell gas, go

to the next step.

Vah_

9. Turnthe pilot cockhandle counterclockwise _ to "ON."

10. Push inred reset buttonon right hand pilot valve all theway and

hold in. Immediately light the right hand pilot with a match.

Continueto holdthe resetbutton in forabout one (1)minuteafter

the pilot is lit. Release button and it will pop back up, Pilot

should remain lit. If it goes out, repeat steps 5 through10.

11. Repeatabovelightingprocedurewith lefthandpilotvalveand

lefthandpilot.

• Ifeitherbuttondoesnotpopupwhenreleased,stopand

immediatelycallyourservicetechnicianor gassupplier.

• Ifthepilotswill notstaylitafterseveraltries,turnthepilot

cockhandleto "OFF"andcallyourservicetechnicianor

gassupplier.

12. Replace pilot access panel, if applicable.

7. Removethe pilot accesspanel,if supplied,locatedbelowand

behindthegasvalvedirectlyaboveburnertubes.

8. Findpilots-- followmetaltubefromeachpilotvalve.Eachpilot

isbetweentwoburnertubes.

13.

14.

15.

16.

Turnmanual shut-off levercountercloekwise _ to"ON."

Replace controlaccess panel,if applicable.

Turnon all electric power to the appliance.

Set thermostat to desired setting.

TO TURN OFF GAS TO APPLIANCE

1, Set the thermostat to lowest setting.

2. Turnoff all electric power to the appliance ifservice is to be per-

formed.

3. Ifthegascontrolassemblyisnotvisible,removecontrolaccess

panel.

4. Turn the pilot cockand the manual shut-off leverclockwise

to"OFF."

5. Replace control accesspanel, ifapplicable.

31

I/8"BLEED

GAS PI_ESSURE REGULATOR

_/_INNER FRONT J,t*CKET PANEL

16_"

i,, 7,,

_2 2 _8 F_LOT

- THERMC_ILOT

I/4" TEST

TAP

MAIN SAFETY _ ]'F_- P_

T PERMOCOUPLE

FLOO R LINE

Figure45:24 VoltControlSystemw/DualValves

Models61-08,62-09thru 62-11

32

0- INSTRUCTIONS FOR OPERATION

1--The installationisnot completeuntil Ratingand LightingPlatesareon the boilerandthe"UsersInformationManual"and "Installation

Instructions"are hung neartheboiler

2--System shouldbe maintainedin good repair.Radiators,baseboardunitsand/orconvectorsmustbe keptclean.

:_lf a radiatordoes notheat allover.air hasprobablyaccumulatedandshouldbe vented.

P- CHECKOUTPROCEDURE

1--After startingboiler,becertainall controlsare workingproperlybeforeleavingit unattended,Checkto be sure thatthe temperaturelimitcontrol

will shut offthe boilerin theeventof excessivetemperature,by loweringlimitset pointuntil mainburnersshutdown,Returnlimitto desiredset

point.

2_heck gas tightnessof maingas valvewhenclosedto be certainthereis no leakageto theburners.Checkall joints periodicallyfor gas

teakage.Usesoapsolutionto check leakage.

3_heck the operationof the ignitionsystemsafetyshut-offdeviceusingthefollowingmethod:

a. ConstantBurningPilot:With thegas cock knobin the pilotposition,extinguishpilot flameand makecertainthe gasvalveshutsoff gasflow

to thepilot withintwo (2) minutes,Torelight follow"LightingInstructions".

b. SparkIgnitionSystems:Withthe unitoperating,turn off thegasat the inletshut-offvalveupstreamfromtheboiler.The unitwill spark

attemptto relight.If pilot lock-outisprovided,thespark willstopwithin ninety(90)seconds,To relightfollow"OperatingInstructions".

Q-SHUT-DOWN CAUSED BY PILOT OUTAGE, VENT SAFETY SHUT OFF SWITCH OR FLAME ROLL-OUT SAFETY SHUT OFF

SWITCH

1--1nthe eventof a shut-downcausedby a pilotoutage,actionof the ventsafetyshutoffswitchorflame roll-outsafetyshut-offswitcheffectinga

shut-downof themain burners:

a. Turnoff all electricpowerto the boiler.

b. Referto "Lightingor OperatingInstructions"andturn gascock knobto "off" position.

c. Call a qualifiedheatingserviceorganizationor localgascompanyand havethe causeof the shut-downinvestigatedand corrected.

d. Referto "Lightingor OperatingInstructions"to re-startboiler.

-NOTE:-

SHOULDOVERHEATINGOCCURORTHE GASSUPPLYFAILTO SHUTOFF,DONOTTURNOFFORDISCONNECTTHE ELECTRICAL

SUPPLYTOTHEPUMP,INSTEAD,SHUTOFFTHE GASSUPPLYATA LOCATIONEXTERNALTOTHEAPPLIANCE.

DO NOTUSETHISAPPLIANCEIFANY PARTHASBEENUNDERWATER,IMMEDIATELYCALLA QUALIFIEDSERVICETECHNICIANTO

INSPECTTHEBOILERANDTOREPLACEANY PARTOFTHECONTROLSYSTEMANDANY GAS CONTROLWHICHAS BEENUNDER

WATER.

33

Cleaning the Series 61162Steam Boiler with Skim Tapping

Thefollowingcleaningprocedureshallbe performedbyaqualifiedserviceperson.

1. Cleantheboileras describedbelownolaterthanoneweekaftertheinitialstart up,Cleaningwillbe moreeffectiveiftheboileroperatesa day

ortwoto loosensedimentand impuritiesinthesystem.

2, Theboiler mustbe cleanedto removeanyaccumulatior_ofoil, grease,sludge,etc.thatmaybeinthesystem,Thesesubstancescancause

foamingand surgingof the boilerwater,producingan unstablewaterline andwatercarryoverto thesystem,

WARNING:CLEANINGTHEBOILERREQUIRESTHEUSEOFVERY HOTWATERANDCORROSIVECHEMICALS.USECAREWHEN

HANDLINGTO PREVENTiNJURY.

3. Connecta 11/2"pipe nippleand shutoff valveto skim tapping.

4. Connecta 11/2"drain lineoff of the skimvalve,runto a pointof safedischarge.

5. Closeall valvesto the system.Providea meansof continuousfresh waterto theboilerfor the cleaningprocess.

6. Openthe skimvalve.Fill the boiler untilwaterbeginsto flow outof the valve.Shutoff fill valve.

7. Usecommonwashingsoda(suchas Arm and HammerSuperWashingSoda).Mixthesoda withwaterin a 10quartpailand pourintothe

boilerthroughthe safetyvalvetapping.Mixa proportionof one(1) poundof washingsodafor each800squarefeetEDRnet boilerrating.

CAUTION:DO NOTLEAVETHEBOILERUNATFENDEDWHILEFIRING.TAKEGREATCARENOTTO ALLOWTHEWATERLEVELTO

DROPBELOWTHEBOT[OM OFTHE GAUGEGLASSORTOALLOWFRESHWATERMAKEUPTO FLOWINTOOFAST.THISWILLAVOID

THE POSSIBILITYOFCAUSINGTHEBOILERSECTIONSTO FRACTURE.

8. Turn burnerson and allowthe boilerwaterto heat up to just below steaming(180 to 200degreesF). Cyclethe burnersto maintaintemperature

duringskimming.Do notallowthe boiler to steam.Steamingmixesup thecontaminantsinthe waterinsteadof floatingthemat the surface.

9. Openthemake-upwatervalveto continuouslyfeed waterto the boiler.Allowwaterto flow outof theskimtapping.

10. Continueskimmingthe boileruntilthe waterflowingfromthe skimtappingflowsclear.Thiswill takesometime,possiblyseveralhoursfora dirty

system.

11, After skimmingis complete,closethe skimvalveandturn off the boiler.

12. Closethe make-upwatervalveandopen theboilerdrain valve.

13. Draintheboiler completely.Refillanddrain againoneor two timesto makesure allof the sodahas beenwashedout.

14. Restorepipingto normal.Pipea nippleand capin theskim valve.

15. Note: If the gaugeglass becomesdirtyagain,this indicatesmorecontaminantshaveworkedloosein thesystem.Repeatthe cleaningand

skimmingprocessas neededto cleanthe system.

34

R - RATINGS,TAPPINGLOCATIONSAND DIMENSIONALDATA

SERIES 61 ,7_,E,,

'D" 2SUPPLY lAPPING I "F'

. o

1_ INLET_ "" 5" _ R

_,_"A"_ _' B' _ Lz_'

LEFT SIDE FRONT RIGHT SIDE

Location

[

L

M

N

O

P

Q

R

S

SizeN.RT.

3/4,,

1/2,,

1/2"

2"

3/4"

3/4"

1112.

3/4.

112"

SERIES 61 TAPPING LOCATIONS

Steam

PressureGauge"

N/A

GaugeGlassand RoarLowWaterCut-Off

Return

SecondaryProbe LowWaterCut-Off

SafetyValve

Skim Tapping

PrimaryProbeLowWaterCut-Off

GaugeGlassforPrimaryProbeLWCO

Water

LimitControl

Theraltimeter

N/A

Return

N/A

ReliefValve

N/A

N/A

N/A

*MountGauge using 3/4' nipple,couple and 3/4" X 1/4" bushingwhena float lowwate cut-offis used.

SERIES 61 BOILER RATINGS

i DOE

HeatingCapacity WaterContent

MBH' Net I=B=RRatings_Gallons

Boiler

Model Input

Number MBH Water Steam

90 73 72

120 98 97

160 130 129

200 161 161

240 193 193

280 225 225

Steam Steam2Wate#

Sq.Ft. MBH MBH

225 54 63

304 73 85

404 97 113

504 121 140

604 145 168

704 169 196

61o03

61-04

61-05

61-06

61-07

61-08

SparkIgn,w/Damper i

SeasonalEfficiency

(AFUE)'

Water Steam Water

80.5 80.6 8,16

81.7 80.7 10.32

81.3 80.6 12.48

81.0 80.6 14.64

80.6 80.6 16.80

80.3 80.6 18.96

Steam

4,80

5.88

6.96

8.04

9.12

10.20

Boiler

Model Width

Number "A"

61-03 143/4"

61-04 18T/8"

61-05 23"

61-06 27V8"

61-07 31V4"

61-08 353/8"

Jacket

Depth

"B"

i 27V4"

271/4"

27V4"

27v4"

27V4"

30V4"

Topto

Floor

"C"

35"

35"

35"

85"

35"

35"

SERIES 61 BOILER DIMENSIONS

Rightof Rear of

Jacket Jacket

to ctlof to ctlor Flue

Flue Flue Size

"D.... E.... F"

73/B" 39/16" 5"

97/16,, 41116' ' 5"

11_/2" 49/16" 6"

139h6,'49h6" 7"

15518" 6VIe" 8"

17"he" 61h6" 8"

Distance

Between

Tappings

"G"

131_"

171A"

213_"

25V2"

295/_'

Flueto

Chimney

Diameter

5 _

5 _

6"

7 _

8"

8"

Chimney

Size

5"x 20'

5" x20'

6" x20'

7" x20'

8"x 20'

8"x 20'

1 Net I=B=Rwater ratingsbased on an allowanceof 1.15.

2 Net I-B--R steam ratingsbased on an allowanceof 1.333.

3 Consultfactorybeforeselectinga boiler forinstallationshaving unusualpipingandpickuprequirements,suchas interm_ent system

operation,extensivepiping systems,etc.

4 HeatingCapacityandAnnual FuelUtilizationEfficiency(AFUE)ratingsare basedon U.S.Governmenttest,Beforepurchasingthis

appliance,read importantinformationabout its estimatedannualenergyconsumptionsor energyefficiencyratingthat is availablefrom

your retailer.

35

R - RATINGS,TAPPINGLOCATIONSAND DIMENSIONALDATA

SERIES 62

N_ ÷

FLOOR LINE_I-LI_4!

LEFT SIDE

,,mr,

35"

"DI.... [ ,, 17_"E"

"G" 2 7

#'G'" TL,_ Fr

/

/ ,,/ I_LET_ _ .5' 'kff_ r_

I I VALVE 161_ _ ,_ _b_ -|

J

_'A'_' _ BI,, _ LYe'

FRONT RIGHT SIDE

Location

I

J

K

L

M

N

O

P

Q

R

S

SizeN.RT.

3/4.

3/4.

3/4"

1/2"

1/2"

2"

3/4-

3/4"

11/2"

3/4-

1/2"

SERIES 62 TAPPING LOCATIONS

Steam

PressureGauge*

N/A

N/A

N/A

Gauge Glass and FloatLow WaterCut-Off

Return

SecondaryProbeLowWaterCut-off

SafetyValve

SkimTapping

PrimaryProbe LowWaterCut-off

GaugeGlass for PrimaryProbe LWCO

"PressureGauge, Operatingand LimitControlon Models12-15

Water

LimitControl/Models09-11)

OperatingControl(Models12-16)

LimitControl(Models12-15)

Theraltimeter

N/A

Return

N/A

ReliefValve

N/A

N/A

N/A

Boiler

Model Input

Number MBH

62-09 320.0

62-10 360.0

62-11 400.0

62-12 440.0

62-13 480.0

62-14 520.0

62-15 560,0

I=B=R

GrossOutput

MBH

Water Steam

256 256

288 288

320 320

352 352

384 384

416 416

448 446

SERIES62 BOILERRATINGS

Net I=B=R

Ratings

Steam Steam Water

Sq.Ft, MBH MBH

800 192 223

900 216 250

1000 240 278

1100 264 306

1200 288 334

1309 312 362

1400 336 390

Combustion

Efficiency

Water Steam

80.0 80.0

80.0 80.0

80.0 80.0

80.0 80.0

80.0 80.0

80.0 80.0

80.0 80.0

i

Water

21.12

23.18

25.34

j27.60

J 29.66

i3182

j 3398

Water

Content

Gallons

Steam

11.28

12.36

13.44

14.52

15.60

16.68

17#6

Boger

Model

Number

62-09

62-10

62-11

62-12

62-13

62-14

62-15

Width

uA-

39V2"

435/8"

4713/16"

52"

561/8"

605h6"

647/1s"

Jacket

Depth

"B"

301/4"

30114"

301h"

301/4"

30V4"

30V4"

30V4"

Topto

SERGES62 BOILER DIMENSIONS

Rightof Rearof Flue

Jacket Distance Jacket Size

to c/I of Betw.Tw¢ to cffof "F"

Floor Flue

"C" "D"

35" t4"

35" 15"

35" 16"

35" 18"

35" 19"

35" 20'h6"

35" 22Ve"

Distance

Between

Flea c/l'e Rue (Each Tappings

"D1.... E" of 2) "G"

119h6" 49/16" 6" 33314"

1311116" 49/1e" 7" 37_/e"

15_3h6" 49116" 7" 42V16"

151She" 6V16" 8" 46V4"

18V_e" 6V_6" 8" 50316"

20_he" 6V_6" 8" 549h6"

203/16" 61116" 6" 5811116"

Distance

Betw.Rt.

Sup.&Tap. Flueto

Inter. Chimney Chimney

"Gt" Diameter Size

N/A 9" 9" x 20'

N/A 9" 9" x 20'

N/A 9" 9" x 20'

21V_6" 10" 10" x20'

253h6" 10" 10" x 20'

253h6" 10" 10"x20'

295h6" I0" I0" x20'

36

S - MAINTENANCE AND INSPECTION

1--This boilermustbe disconnectedfromthe gas supplypipingduringanypressuretestingof thesystem.RefertoSectionH - "GAS PIPING".

Note8 for details.

2--The gasventusedonthis boi{erisofthe horizontalto verticaltype.Thevent andventingsystemshouldbeinspectedthoroughlyat the

beginningof eachheatingsystem.

3--The areawherethe boileriscontainedshould beclearand free fromcombustiblematerials,gasolineandotherflammablevaporsand liquids.

The boilerarea shouldhaveample air for combustionandventilationand thereshouldbe no obstructionspreventinga free flow of air

4--AI1low watercut-offsshouldbetested and inspectedper manufacturer'sinstructions,any floattypesshouldbeflushed ona weeklybasisto

removeanysedimentfromthefloat bowl.

5--A visualcheck of burnerandpilot flameshouldbe conductedat least oncea year.Theflame interconeshouldbeapproximately11/2inches

high andshouldhavea very sharp,bfuecolorcharacteristic.SeeFigurebelow.

m w

f

f

/\

/\

\/

\ J

f

6--At the beginningofeach heatingseason,fluewaysandburnersshouldbecheckedforcleanlinessand cleanedifnecessary.Followingprocedure

wouldapplyif cleaningis required.

a. Turnoft allelectricalpowerto boilerbeforebeginningcleaningoperation.FollowLighting/OperatingInstructionsfor shuttingoff

maingas to appliance.

b. Removetheflue pipe,drafthood,top jacketpanelsand flue collector.

c. Brushfluewayswithwirebrush.

d. Replaceflue collector.Whenreplacingthe flue collector,be certainthat the sealingropebetweenthe fluecollectorandtop section

makesa tight seal to preventleakageof the productsof combustion.

e. Replacethetop of jacket,draft hoodand flue pipe.

f. Removethejacketclean-outcover plate.See Figure4.

g. Removecast ironcover plateby removingfour (4)cap screwsat thecornersof theplate.

h. Brushtubeswith wire brush.

i. Replacecoverplates.MakesureHi Tempropegasketis in place.

j. Removefrontjacketpanel (Figure4), and burneraccesscoverdoor (Figure11).

k. Removeburnersandbrushgasoutletports lightlyusingsoft bristlebrush.

I. Replaceburners(SeeFigure12)and alljacket panels.

m. FollowLighting/OperatingInstructionsforputtingboilerinto operation.

37

REPAIR PARTS

SERIES 61/62 GAS BOILERS

REPAIR PARTS ARE AVAILABLEFROM YOUR INSTALLER OR BY CONTACTING

PEERLESS HEATER COMPANY,BOYERTOWN,PA 19512-0855

NOTE: REMEMBER TO INCLUDE BOILER MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS.

Item No. Description AdditionalInformation

tIntermediateSection

2 Left HandEndSection

3RightHandEndSection

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

Part No.

P-150

P-151

P-152

P-152C

P-154

12-EF

64

P-162

P-161

P-158

P-120

P-106

X-1037

X-1023

X-1034

P-155

P-156

X-1009

X-1001

P-4208

P-4209

P-4210

X-4003

X-3005

P-503

P-504

TappedIntermediateSection

Push Nipple

Push Nipple

5/8"HighTemperatureRope

CompleteBlockAssembly

LeftHandBlockAssembly

RightHandBlockAssembly

DrawRodsw/nutsandwashers

Clean Out CoverPlate

1/4"HighTemperatureRope

TanklessHeaterFlangew/screws

RubberGasket

CoverPlatew/screws

BaseBack

BaseBack

Draw-UpWasher

Draw-UpWasher

3/4"Gas Manifold

1" Gas Manifold

11/4"Gas Manifoldfor 62-15

OrificeSpud

Steel Burnerw/pilot bracket

Steel Burner

ThrottlingPilot Cock

FlueCollector

DraftHood

50 lb.WorkingPressure

50 lb.WorkingPressure

w/CoilOpening

w/Cast ClosedCoil Opening

50 lb.WorkingPressure

1 RequiredPerFlueway

1 RequiredPerFlueway

42" RequiredPerFlueway

SpecifyBoilerModel

SpecifyBoilerModel

SpecifyBoilerModel

SpecifyBoilerModel

44"RequiredFor P-106

SpecifyBoilerModel

SpecifyBoilerModeland Rightor Left Side

2 Required

2 Required

SpecifyBoilerModel

SpecifyBoilerModel

SpecifyQuantify,Typeof Gas,BoilerModelandAltitude

SpecifyControlSystem

SpecifyQuantity

Specify BoilerModel

Specify BoilerModel

38

Item No, Part No. Description

29 JacketAssembly

TheraltimeterGauge

SteamGauge

Gauge GlassBet

3/4"DrainCock

LightingInstructionPlate

Lighting/OperatingInstructionsLabel

HighTemperatureSealingCement

1/2"Pint Can NippleSealer

1/4"AluminumTubing

WaterTrim

SteamTrimw/LWCO

GasValve

Pilot

IgnitionControl

LimitControl

Gas ControlAssembly

AdditionalInformation

Specify BoilerModel

SpecifyControlSystem

SpecifyControlSystem

SpecifyQuantityof Containers

SpecifyQuantity

Specify Quantityin Feet

SpecifyBoilerModel,ControlSystem,Typeof Gas

SpecifyControlSystemandTypeof Gas

SpecifyModel

SpecifyBoilerModelandControlSystem

SpecifyControlSystem

39

Series 61/62

Gas Boilers

Installation,

Operation Et

Maintenance

Manual

TO THE INSTALLER:

This manual is the property of the owner and must

be affixed near the boiler for future reference.

TO THE OWNER:

This boiler should be inspected annually by a

Qualified Service Agency.

HI Division ASME

af gama

PEERLESS BOILERS

www.peerless-heater.com

@2003 Peerless Heater Company P8207 R23 (3/03-2,5M)

Printed in U.SA.