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61 / 62 Boilers Installation , Operation Et Maintenance Manual
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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 PGGRLESS _ 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 CAST IRON BOILERS 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 . 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
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Series 61 pr = - I RLESS o o Residential Gas Boilers • Packaged or Knockdown o Natural Draft Venting o Standing Pilot or CAST IRON BOILERS Spark Ignition Q Steam or Hot Water Boilers o Natural or LP Gas Q This large water content boilerer installsin difficultsteam or wat 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 Steam 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 domesticd hot water coil can be installe on hot water boilers , insuringample domestic hot water production . o Probe or float - type low water cutoff available . Water DOE Stdg . PilotwlDamper Spark Ign . wlDamper Water Content Seasonal Efficiency Seasonal Efficiency Heating Capacity MBH - - Net I = B = R Ratings 3 ( AFUE ) 4 ( AFUE ) 4 ( GaL ) I A , G . A . Steam Steam Water I Input N MBH Water Steam Sq . Ft . MBH 2 MBH 1 Water I Steam Water I Steam Water Steam 90 73 72 225 54 63 N / A I 76.8 80.5 I 80.6 8.16 4.80 120 98 97 304 73 85 N / A I 77.7 81.7 I 80.7 10.32 5.88 160 130 129 4O4 97 113 N / A I 77,8 81.3 I 80.6 12.48 6.96 200 I 161 161 504 121 140 N / A I 78.0 81.0 I 80.6 14.64 8.04 604 145 168 240 193 193 N / A I 78.1 80.6 I 80.6 16.80 9.12 280 225 225 704 169 196 N / A I 78.3 80.3 I 80.6 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 . 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 .
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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 : _ , %
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Series 62 pGr = - RLESS o o Semi - Commercial Gas Boiler • Packaged or Knockdown o Natural Draft Venting o 320 to 560 MBH Input CAST IRON BOILERS o Steam or Hot Water Boilers o 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 Steam required by the federal standards for commercial boilers . O 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 low water cutoff available . Water 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 . MBH 2 MBH 1 Water 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
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Steam Water I 3 / 4 " Pressure Gauge * Limit Control ( Models 09 - 11 ) J 3 / 4 , , N / A Operating Control ( Models 12 - 15 ) K 3 / 4 " N / A Limit Control ( Models 12 - 15 ) L V2 " N / A Temperature - Pressure Gauge M V2 " Gauge Glass and Low Water Cutoff N / A N 2 " Return Return O 3 / 4 " Secondary Probe Low Water Cut - Off N / A P 3 / 4 " Safety Relief Valve Safety Relief Valve Q 1V2 " Skim Tapping N / A R ¾ " Primary Probe Low Water Cut - Off N / A 3o4 - L £ _ ' T SID _ £ RON _ RIGH T SIDE • Pressure gauge , operating control and I _ mitcontrol on Models 62 12 to 62 15 m Jacket Right of Distance Rear of Distance , . . Boiler Jacketto Betw . Two Jacketto Flue Between ! Rt . Sup . & C _ uetOy Model Width Depth Top to Fir . c / I of Flue Flue c / l's c / I of Flue Size Tappings Tap . Inter . Chimney Number " A . . . . B . . . . C . . . . D . . . . D1 . . . . E . . . . F . . . . G . . . . GI " 62 - 09 39 V2 " 30V4 " 35 " 14 " 11 % # ' 4 % s " 2 - 6 " 333 / . " N / A 9 " 9 " x 20 ' 62 - 10 43 % " 30V4 " 35 " 15 " 13 _ V _ 6 " 4 % 8 " 2 - 7 " 37 % " N / A 9 " 9 " x 20 ' 62 - 11 47 _ ¾ _ ' 30V4 " 35 " 16 " 15 _ 3 / lS " 4 % 4 ' 2 - 7 " 42V16 " N / A 9 " 9 " x 20 ' 62 - 12 52 " 30V4 " 35 " 18 " 15 _ % # ' 6 _ / _ 6 " 2 - 8 " 46V4 " 21 _ / _ 6 " 10 " 10 " x 20 ' 62 - 13 56 Ys " 30V4 " 35 " 19 " 18V _ 6 " 6Vls " 2 - 8 " 50 % " 253 / 16 " 10 " 10 " x 20 ' 62 - 14 60 % 6 " 30 _ / 4 " 35 " 20VI4 ' 20 ¾ e " 6V _ 6 " 2 - 8 " 54 % 6 " 25z / _ 6 " 10 " 10 " x 20 ' 62 - 15 64W _ 6 " 30V4 " 35 " 22W ' 203Ae " 6 % 6 " 2 - 8 " 58 " A _ " 29s / _ 6 " 10 " 10 " x 20 '
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STEAM WATER , , i t t " L NOTE : Provide Tee , Nipple and Cap Fittings below water line to assist in cleaning or draining . Boiler Steam Model Number Size of Outlets No . Supply Outlets Header Supply Equalizer Size 62 - 09 2 2 " 3 _ = 1V4 " 62 - 10 2 2 " 3 " 11 / 4 " 62 - 11 2 2 " 3 " 1V2 " 62 - 12 3 2 " 3V2 " 1V2 " 62 - 13 3 31 / 2 ' ' 1V2 " 62 - 14 3 2 " 31 / 2 ' ` 1W ' 62 - 15 3 2 " 31 / 2 " , 1V2 " Boiler Htr . No . Htr . No . Htr . No . Model X - 1020 X - 1021 X - 1022 Number GPM GPM GPM 62 - 09 4,75 62 - 10 5.00 m 62 - 11 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 demand40 ° to 140 _ F rise with 200 ° F bOiler water CAUTION : Water mixing valve should always be installed in the hot water supply to prevent injury ,
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SERIES 62 BOILER SPECS _ - _ - _ LlJl - J _ vd _ id • Cast Iron Sections - - Factory Tested and Approx . Shipping Wts . ( Ibs . ) Assembled with Steel Push Nipples Boiler Model • Deluxe Insulated Enameled Steel Jacket Number I Length I Width ! Height I W S WP SP • Drain Valve I I I ! • Horizontal to Vertical Draft Diverter 62 - 09 I 57 " 31 " I 391 / 2 " I 1080 I 1088 1105 1108 • End Cleanout I I I I • Manual Reset Limit ( 62 - 12 to 62 - 15 ) 62 - 10 I 61 " 3t " J 391 / 2 " J 1170 I 1178 1195 1203 • Standing Pilot or Spark Ignition I I I I • Automatic Reset Limit 62 - 11 I 66 " 31 " I 391 / 2 ` ' ! 1265 I 1273 1290 1298 Water I I I ] • 30 PSI Safety Relief Valve 62 - 12 I 70 " 31 " I 391 / 2 " ] 1420 I 1428 1445 1453 • Temperature - Pressure Gauge I I I ! Steam 62 - 13 I 74 " 31 " I 391 / 2 " I 1520 I 1528 1545 1553 • 15 PSI Safety Valve I I I J • Pressure Gauge • Gauge Glass 62 - 14 I 78 " 31 " I 391 / 2 ' ' ] 1620 I 1628 1645 1653 • Low Water Cutoff - Probe or Float I I I I • Skim Tapping 62 - 15 I 82 " 31 " I 391 / 2 " I 1720 1 1728 1745 1753 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 : 231 North Walnut Street 62 - 09 - STDG / SPRK - WP - N Boyertown , PA 19512 - 1021 Phone : 610 - 367 - 2153 • FAX : 610 - 369 - 3284 Series Sects . Natural Gas ( Substitute www . peerless - heater . com Standing Pilot or " LP " for LP Gas ) Spark Ignition W = Water Knockdown WP = Water Package S = Steam Knockdown SP = Steam Package HI Division ASME garNa of gama CUT - 62 F _ 7 ( 3 / 03 - 1M ) , Printed in U SA . _ 003 Peedess Heater Company
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Readcarefullybeforebeginningwork . It witlsavetime . Studythe includeddrawings . The equipmentshallbe installedin accordancewith thoseinstallationrequirementsof the 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 , backandfrontof theboilerand adjacentwall or otherappliance , whenaccessis requiredfor servicing . B - CLEARANCEFROMCOMBUSTIBLECONSTRUCTION 1 . Thedesignofthisbelieriscertifiedforthefollowingclearancefsromcombustibcleonstruction : MODELS62 - 12thru62 - 15 MODELS61 - 03thru61 - 08 ; 62 - 09thru 62 - 11 18 " fromrear 24 " fromsidesand rear 6 " from rightand left sides 55 " fromtopueconnector 6 " fromfl 30 " fromtop - frontalcove 6 " fromflue connector 6 " fromsteam andhotwater pipes 6 " from steamandhot waterpipes 2 . CAUTION : This boileris NOTDESIGNCERTIFIEDforinstallationon carpetingor combustibleflooring . C - AIR FORCOMBUSTIONANDVENTILATION 1 . Be certainadequatefacilitiesare availableto provideairfor satisfactorycombustionandventilation . 2 . AppliancesLocatedin UnconfinedSpaces : a . Installationsin unconfinedspaceswith conventionacl onstructionand large areas : thesupplyof air for combustionandventilationcanusually beconsideredadequate , 3 , AppliancesLocatedonConfinedSpaces : If allair for combustionand ventilationis to comefromwithinthebuilding : two openingsshallbe providedwithone openingcommencingwithin 12inchesof thetop andone openingwithin12inchesof the bottomof theenclosure . Theseopeningsshall notbe locatedcloserthan 3 inches fromeitherthe topor bottomof the enclosureand shallbeopen intoareascommunicatingfreely 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 within12inchesof thetop and oneopeningcommencingwithin12inchesof the bottomof theenclosure . Theseopeningsshall notbe located closerthan 3 inchesfromeitherthe top or bottomof theenclosureandshallcomreunicatdeirectlyor 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 thefull areaof the openingsto whichtheyconnect . c . The upperopeningsare essentialfor maintenanceof propercirculationofair withthe boilerroomand reasonableambienttemperatureinorder 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 . Whenboileris removedfromthe crate , carefulinspectionshouldbe madeandthecarrier notifiedof anydamagefound . 4 . Providea good levelfoundation . 5 . Placethe boileronthe foundationnearand in properpositionwith relationto the chimney , andas centralizedwith respectto the heatingsystemas practical , 6 . The openingsin thebasesides are providedfor admittingsecondaryair and mustneverbeclosed . 7 . Removeiackettop andattach drafthoodto fluecollectorwithtwo # 10x 1 / 2 " sheetmetalscrewsprovided . Replacejackettop . 8 . The burnersare installedin the boiler . Theyare securedin placefor shipmentbywoodstripewiradto the Burnermixingtube . Cut thewiresand removethewood strips . 9 . The gasmanifoldandocntrolassemblyare madeup gastight , completelyfactoryassembledand installedas integralcomponentsof thebase assembly . See Figure12 .
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D - SE'I - rlNG UP BOILER - UNASSEMBLED UNITS I - - ASSEMBLEDBLOCKS 1 - - The boilersectionsandbase , Models61 - 03thru61 - 07arefactoryassembledR . emoveshippingskidfromtheboilerbase . If boilerisa 61 - 08 , or62 - 09thru62 - 15beginassemblyasnotedin PartII " SplitBlockAssembly " . 2 - - Providea goodlevelfoundationT , he Boilershouldbe locatedasneartothechimneyandcentralizedwithrespecttotheheatingsystemas possible . 3 - - Open controlbox . Removecontroland manifoldassembly , Referto Figure6 andattachmanifoldto boilerwithfour V4 - 20x 1 " machinescrews and nutsprovided . Figures43thru 45show thestandardcontrolassembliesusedon Models61 - 08thru 62 - 15 . 4 Openfluecollectorcarton . Removefluecollectorand Hi Tempropeandlay ropeontop of boileragainstbead provided . SeeFigure7 . 5 - - Place fluecollectoron topof ropeand attachto boilerwithtwo1 / 4 " - 20studs , washersandhex nutsprovided , throughfluecollectorbrackets intothetapped lugs providedontopof theboilerend sections . Drawboltsdownsnugly . SeeFigure8 , 6 - - Attach cast ironclean - outplate10clean - outopeningon leftside of the boiler . Thisplate , HiTempropeand mountinghardwaremaybefoundin thecontrolboxreferred1opreviously . 7 - - Remove the burnersfromthecontrolboxand install . Installeachburnerby slippingtheopeninginthe venturioverthe orificespud . Insertthe pin on thebottomof theburnerintothe holeprovidedin theflange onthe basebackplate . SeeFigure9 . The Burnerswith pilotsattachedmust be installedas follows : Note : Hookbolt is providedon models62 - 11through62 - 15 . ModelNo . No . Pilots Location of Pilot 61 - 03 1 Between2nd and 3rd BurnerfromLeft 61 - 04 1 Between4th and5th BurnerfromLeft 61 - 05 1 Between4th and5th BurnerfromLeft 61 - 06 1 Between4th and 51hBurnerfromLeft 61 - 07 1 Between4th and 5thBurnerfromLeft 61 - 08 2 Between4th and5th Burnerfrom Leftand4th and5thfrom Right 62 - 09 2 Between4th and5th BurnerfromLeft and4th and5thfrom Right 62 - 10 2 Between4th and 5thBurnerfromLeft and4th and5thfrom Right 62 - 11 2 Between4th and5th Burnerfrom Leftand4th and 5thfrom Right 62 - 12 2 Between4th and 5thBurnerfromLeft and4th and 5thfrom Right 62 - 13 2 Between4th and 5thBurnerfromLeft and41hand5thfrom Right 62 - 14 2 Between41hand5th BurnerfromLeft and6th and7thfrom Right 62 - 15 2 Between6th and7th BurnerfromLeft and6th and7thfrom Right 8 . . - Removepilot tubingfromcontrolboxand installbetweengas valveandpilot . Referto figures43 through45 . 9 - - If boileris to incorporatea tanklessheaterfordomestichot water , installinopeningprovidedin the rightside of the boiler . Sixmountingbolts 3 / 8 " 16 x3 / 4 are rovldedBe sure rubber asketi I ( - ) p " • g " s betweencoverplateandtheboier , 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 ° Fcancausesevereburnsinstantlyor deathfromscalds , 2
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I : ' ROC _ " OUR lr FOR STACKING PALLtr'rq II - - SPLITBLOCKASSEMBLY 1 - - Boiler sectionsfor Models61 - 08,62 - 09thru 62 - 15are shippedintwo parts . Removeskidfromeach blockof sections . 2 - - Place each blockof sectionsonthe stackedskids . See Fig . A . Be certainto removethesmall blocksonthetop skid . See Fig . B , 3 - - To clean nippleportsand removeprotectivecoating , usea wire brushandmineralspiritsor 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 of burrs . 6 - - Apply a thin coatof PeerlessNippleSealerto the ropegroove . Press5 / 8 " Dia . ropeintothegroove . The nipplesealer actsas an adhesiveto holdthe ropein placeuntil thesecgonsare drawnup . 7 - - Arrange both blocksso that protrudingnippleentersthe open port . Caremustbetakento keepnipplesstraightand blocksaligned . 8 - - Insert drawrodsthroughthe nippleports . Make certainthat the3 / 4 " drawrod is usedonthe 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 " fromthe 6V4 " threadedend . Inserttherod throughthe lugs oneachendsectionand tightenthehex nutshandtight . 12 - - Attach3 / 8 " Dia . ropeto basebackplateby layingropeacross topof backplateflange and in ropegrooveon eachendof backplate . Usenipple sealerto hold ropein place . Referto figures9 & 12 . Attachbase backplate by meansof V4 " - 20x lr / 2 " machinescrewsandnutsfurnished . The base backplateis attachedto backof boiler . SeeFigure8 . Be certainthatthe flange portionof plate is towardsthe insideof the boiler . Note : hook boltis providedonmodels 62 - 11through62 - 15only . 13 - - Install pressuregage , drain valve , water supplylinewith shutoffvalve , and meansto ventair . Plugunusedtappings . 14 - - Fill boilerwith water , ventingairas water levelrises . Pressurizeboilerto 75 - 85 psig . Do notexceed85 psig . 15 - - Verify pressureis maintained . Checkalljointsand fittingsfor leaks . 16 - - Drain boiler . Removepressuregage , drain valve , watersupplyand air vent . ContinuewithStep2 underD - 1 . E - JACKET ASSEMBLY A . Wrap - AroundRearJacketPanelStylefor Models61 - 03thru 61 - 06 Thisstylejacket designincorporatesa BackJacketPanelaspart of eachRightand Left SideJacketPanel . TheBack JacketPanelis formedwhena portion of each SidePanelis 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 blockandalignthe slotsof the mountingbrackets , ( atbottomof jacketpanel ) , withthe 1 / 4 - 20x 1 " studs . Attachjacketpanel to boilersectionwithtwo ( 2 ) 1 / 4 " nutsandwashers . SeeFigureI . 3 . Placethe Left SidePanelalongleft side of boiler blockand attachto boilersectionin samemanneras performedfor RightSidePanel . 4 . Bendat theperforationsof the Right SidePanelto form halfof 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 .
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6 . PlactheeSecondAairrCyoveDrooartbottoomfInneFrronPtanTelh . etopbenodftheCoveDroosrliposvethr etopreversbeenadtcuot ut openionfgtheinneFrronPtaneRle . fetorFigur1e1 . 7 . AtlacDhraHftootdoFluCeollecwtoitrhtwo ( 2 ) # 10x1 / 2s " heemtetsacl rewRse . fetorFigu1re0 . 8 . AttacthheLowFerronPtanteolthebottotmronotftheLefatndRighStidPeanewlsithtwo ( 2 ) # 10x1 " sheemtetsac _ rewSse . eFigu4re . 9 . PositiToonpJackPeat nseoltheflangoevserlSapidJeackPetanealnsdairlouvearrseatthefronotftheboileSre . cuwreithsix ( 6 ) # 10x1 / 2s " heet metsacl rewSse . eFigu4re . 10 . AttacthheCleaOnuCt ovPerlatPeanoevl eorpeminngLefSt idJeackPeat newti , thfou ( r4 ) # 10x1 / 2ja " ckesct rewSse . eFigu4re 11 . ThemanielanvelothpaectontaitnhseInstallaMtioannuaalsl ocontatinhseboilerartinlgabecll , earantocceombustpiblaleteLs , ighting / Operating instructpiolantoerlabealndwirindgiagralambeSl . eaFigu5reforlocatioofnplateasndlabeAlst . tacphlatewsith # 6x3 / 8s " crewpsrovided . 12 . PosititohneRemovaFbrolenPtanienlplacbeyslidinthgePanuenl dethrefronfltangoeftheTopPanaenl dthednowunntiitlrestosnLowFerront 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 BackJacketPanelonthe insideof theLeft and RightPanelflangesand attachwithsix ( 6 ) # 10x ! / 2 " sheetmetalscrews . SeeFigure3 . 3 . Followinstructionsaboveper # 5thru 12for assemblyof remainingjacketpanels . - , _ RIGHT SIDE PANEL J ONEPIECERIGHT SIDEANDREAR ONE PIECE LEFT PANEL SIDE AND REAR PANEL J 1 / 4 " WASHER 1 / 4 " NUT SIDE PANEL ATFACHMENT REAR VIEW WRAPPER FIGURE 1 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
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JACKET ASSEMBLY FIGURE 4 RATINGLABEL , LIGHTING / OPERATING , INSTRUCTIONSLABEL ( 61 - 63 THRU 62 - 11 ) / LIGHTING / INSTRUCTIONSPLATE ( 62 - 12 THRU 62 - 15 ) # , CITYOFNEWYORK • MEAPLATE ( WHENREQUIRED ) " WIRING CLEARANCETO COMBUSTIBLESPLATE _ J / jJ DIAGRAM LABEL REMOVABLEFRONTPANEL INNER FRONTPANEL ( INSIDE VIEW ) AGENCY LABEL & PLATE LOCATIONS FIGURE 5
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FIGURE 6 FIGURE 7 FRONT BOILER VIEW FRONT TOP BOILER VIEW T _ 6 " - ! _ UNC NUT & WASHER _ _ BASE BACK - - PLATE BURNER MANIFOLD - _ HOOK BOLT _ ' w FIGURE 9 HOOK BOLT ASSEMBLY FIGURE 10 FIGURE8 REAR BOILERVIEW FLUE COLLECTOR / DRAFT HOOD . f , H FIGURE 11 - " IGURE 12 SIDE VIEW OF INNER FRONT TOP CUT VIEW OF MANIFOLD AND COVER DOOR BURNER AND BASE BACK PLATE 6
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F - VENTING A . General 1 - - For connectionto gasventsor chimneys , ventinstallationshall bein accordancewith Part7 , Ventingof Equipment , of thecurrenteditionof the NationalFuelGas Code , ANSIZ223 . 1 / NFPA54o , rapplicableprovisionsof the localbuildingcodes . 2 - - Draft : Sufficientdraft mustbeavailableforremovalof productsof combustion . If draftis notadequate , spillageof the productsof combustion will occurat the bottomoutletof the drafthood . Ifsucha conditionshouldexistchecktheflueand chimneyto determinecauseof insufficient draft . It is also importantthat ampleairis availablein theboiler roomto facilitatedraft . 3 - - Vent connectorshouldslope upwardat least1 / 4 " per lineal footbetweenthe drafthood outletandthechimney . 4 - - Flue orvent connectormustbe insertedinto butnot beyondtheinsidewall of the chimneyflue . 5 - - Vent connectorsservingappliancesventedby naturaldraftshallnot beconnectedintoanyportionof mechanicaldraftsystemsoperating underpositivepressure . 6 - - Horizontal portionsof theventingsystemsshall besupportedto preventsaggingby useof metalstrappingor equivalentmeansandbe located at no morethan 12ft . intervals . 7 - - When anexistingboileris removedfrom a commonventingsystem , thecommonventingsystemis likelyto betoo large forproperventingof theappliancesremainingconnectedto it . At thetime of removalof anexistingboiler , thefollowingstepsshall befollowedwith eachapplianceremainingconnectedto the common ventingsystemplacedin operation , whilethe otherappliancesremainingconnectedto thecommonventingsystemare not inoperation . a . Sealanyunusedopeningin thecommonventingsystem . b . Visuallyinspectthe ventingsystemfor propersize and horizontalpitchand determinethereis no blockageor restriction , leakage , corrosion and otherdeficiencieswhichcouldcausean unsafecondition . c . Insofaras is practical , closeall buildingdoorsand windowsand alldoorsbetweenthespacein whichtheappliancesremainingconnected to thecommonventingsystemare locatedandotherspacesof the building . Turnon anyclothesdryersandanyappliancenotconnectedto the commonventingsystem . Turnon anyexhaustfans , 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 reliefopeningafter5 minutesof mainburneroperation . Usethe flameof a match orcandle , orsmokefrom a cigarette , cigar orpipe . f . Afterit hasbeendeterminedthat eachapplianceremainingconnectedto thecommonventingsystemproperlyventswhentested as outlinedabove , returndoors , windows , exhaustfans , fireplacedampersandanyothergas - burningapplianceto their previousconditionsof use . g . Anyimproperoperationof thecommonventingsystemshouldbe correctedso theinstallationconformswith thecurrenteditionof the NationalFuel GasCode , ANSIZ223 . 1 / NFPA54W . henresizinganyportionof 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 theventconnectorshallbelocated in orpassthrougha cold area , the ventconnectorshall beof listed double - wallTypeB or L material .
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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 . Seefigures14and 15 , Be sure directionof flow arrowlocatedondampercollar , is pointingawayfromdraft hoodcollarand damperpositionindicatoris visibleafter installation , Forinstallationwithdampermountedin the horizontalposition , mountthe damperas shownin figure15to avoidexcessiveheat and possiblecondensationdrips onthe damperoperatingcontrol . 4 - - Do not useoneventdamperto controltwo or moreheatingappliances . Seefigure 13 . 5 Makecertainthatthe minimumclearancesprovidedinthe ventdampermanufacturersinstructionsare maintainedandthatadequatespaceis providedfor damperaccessand service . 6 - - A wiringharnessis packedwiththe ventdamperwith pluginconnectionsat eachendof theharness . Connectsmallerendintodampermotor receptacleand connectotherendto boileraquastatrelay _ imit ( on waterboilermodelsequippedanL8148Eor L8124Elimitcontrol ) , orboiler junctionbox ( onsteam boilermodels ) , 7 - - Damper mustbe in theopen positionwhenappliancemainburnersare operating . I [ _ OTHER HOETAHTEIRNG HEATING APPLIANCE APPLIANCE INCORRECT CORRECT Figure13 : VentingMultipleAppliances 8
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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 1 O'CLOCK PER FOOT _ 11 O'CLOCK POSITION OPERATOR - CONDENSATION ZONE r _ 7 O'CLOCK 5 O'CLOCK POSITION POSITION DO NOT MOUNT DAMPER OPERATOR IN SHADED REGION SECTION A - A Figure15 : VentingwithVentDamperin HorizontalPosition
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G - PIPING 1 - - Hot Water : a . The recommendedpipinghook - upis shownin Figure17 . Also referto PeerlessWaterSurvey . 2 - - Steam : a . The recommendedpipinghook - upis shownin Figure16 . Pleasenotethat a Hartfordreturnloopis 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 DimensionaDl ata " . LargeNPTsizevalvesmaybe installedin supplypiping . NOTE : IFTHIS BOILERANDDISTRIBUTIONSYSTEMIS USEDINCONJUNCTIONWITHA REFRIGERATIONSYSTEM . THECHILLED MEDIUMSHALLBE PIPEDIN PARALLELWITHTHEBOILERAND THEPROPERVALVEAPPLIEDTO PREVENTTHECHILLED MEDIUMFROMENTERINGTHE BOILER . A DRAWINGILLUSTRATINGTHIS HOOK - UPIS PROWDEDINFIGURE18 . WHENTHEBOILERIS CONNECTEDTOHEATINGCOILSLOCATEDINAIR HANDLINGUNITWHERETHEYMAYBE EXPOSED TO REFRIGERATEDAIR CIRCULATIONT , HE 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 gassufficientto 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 , WHENTHESPECIFICGRAVITYOFTHEGASIS 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 , butnotin frontof theboiler . 4 - - Locate a tee in thedroppipeat sameelevationas thegasinlet connectionto the boiler . Extendthe droppipeto a pipecapasshownin Figure 19to forma sedimenttrap . 5 - - Install a groundjoint unionaheadof the gascontrolassemblyto permitservicingof the equipment . See Figure19 . Somelocalcodesrequirean additionalshut - offvalve . Ifyour coderequiressucha valve , a suggestedlocationis shownin Figure19 . 6 _ OTE : Wheninstallinbgoiler besure a pipecompoundresistantto theactionof liquefiedpetroleumis used . 7 - - Check pipingfor leaks . Alwayscheckleakswitha waterandsoapsolutionor equal . DONOTUSE A FLAMEFORCHECKINGGASLEAKS , 8 - - The boilerandits individualshut - offvalvemustbedisconnectedfromthe gassupplypipingsystemduringanypressuretestingof that system at test pressuresin excessof r / 2psig ( 3.5kPa ) , The boiler mustbeisolatedfromthe gassupplypipingsystembyclosingits individualmanualshut - offvalveduringanypressuretestingof the gassupplypipingsystemat testpressureequalto or lessthan V2psig ( 3.5kPa ) . 10
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Table1 : SteamHeader , Risersand EqualizerSizing 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 _ " SUGGESTEDPIPING STEAM BOILER L - - - RETURN _ TOP • w _ STt ¥ _ LV [ ( Nomwl _ eJrY O _ J _ W _ Cu _ { D _ to _ [ xF _ l _ , _ TANK t t < _ S _ T _ II _ ESS v , _ Tl _ ; _ ' _ 1 _ is _ _ Fw ° _ ; 4 ( ATW4G ETURN SUGGESTEDPIPING HOT WATERBOILER NOTE : Thereturnfrom systemshouldalwaysenterequalizer throughHartfordLoop , approximately2 " - 4 " below normalwaterline . Steamheadershouldbe24 " rain . aboveboilernormal waterline . Figure16 : SteamSupplyand ReturnPiping Figure 17 : Hot Water Supply and Return Piping 11
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SERVICE _ JACKET G . J . UNION SEDIMENT TRAP J _ . / FLOOR LINE Figure18 : ParallelHook - UpwithWaterChiller Figure19 : GasConnectionto Boiler Figure20 : GravityHotWater Figure21 : ForcedHotWater . HIGH TEMPERATURE HEATER HOT WATER _ . MIXEO " rAPPING WATER MIXER Figure22 : SteamW / FloatLWCO 12 Figure23 : SuggestedPipingForTanklessHeater
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F _ A THRU i1 _ 11 _ . 1 / 2 TAPPINGS TO MOUNT 9 1 / 4 LONG GAUGE GLASS c FROM PROBE L . WC . O . CARTON © o © I I L _ I _ Figure21A RIGHT SIDE PANEL Figure24 : Steam : PrimaryProbeLWCO , HydrolevelCG400P IMPORTANT 1 . InspectProbeElectrodeannuallyfor scaleandbuild - upand cleanif necessary . 2 . Forpropermaintenancer , ecommendewdaterfeeder applicationasndoperation , referto theHydrolevePlrobeLWCOInstallationInstructions . • ° LEFT I ' ; AhlD OPPOSITE F3 TI Figure 25 : Steam : Gauge / Pressuretrols Piping Arrangement t [ [ Figure26 : Steam : Gauge / PressuretrolAslternatePipingArrangement 13
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I - CONTROLS l - - Steam : a . Forproper } ocationof controlsand accessoriesreferto SectionR " Ratings , TappingLocationsandDimensionaDl ata " . b . The McDonnell & Miller # 67PE - 2LWCOis furnishedas a standardwith all steamboilers . The HydroleveCl G400 - PPrimaryProbeLWCOis optional . This controlprovidesa lg minuteon cyciefollowedby a 90secondoffcycle.Thisfeatureallowsthe waterlevelinboilerto settleso that theprobe cansensea true waterlevel . c . The HydrolevelCG550 - P ProbeLWCOmaybeusedin combinationwith a PrimaryFloat LWCOand is to bemountedinthe secondary probe location . 1 . The CG550PLWCOincorporatesa 10minuteon cyclefollowedbya 90secondoff cycle . d . Whena 67PE - 2Float LWCOis supplied , the pressuretroland brasssiphonare mountedontop of the 67PE - 2 . Thisis standardformodels 61 - 03thru 62 - 1t . Referto figure22 . The 67PE - 2is providedwith 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 HydroleveCl G - 400 - Pprobe . Two1 / 2 " x 3 " nipples , two 1 / 2 " couplers , longergaugeglassw / rodsand gaugevalvesare mountedintoTappingsA andC as showninfigure24 . ForPackagedBoilers , 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 FORMOUNTINGOFDUALPRESSURETROLSF , OR MODELS62 - 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 DimensionaDl ata " . NOTE : A HOTWATERBOILERINSTALLEDABOVERADIATIONLEVELMUST BE PROVIDEDWITHA 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 _ Figure27 : ProbeLWCOLocationfor HotWaterBoiler RO ' Eo 2 . Installtheremainderof 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
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3 - - Specific detailsregardingthe installationof the variouscontrolsare givenin the controlsheetsattached . 4 - - In theeventof a controlfailurethe replacementshallbe identicalwiththeoriginalequipment . 5 _ n certainmodelsa separatepilot switchmustbe used . The switchshallbe mountedonthe left sideof the inner frontjacketpanel . Usethe two Ys " holesprovided , if holesare not provided , drill accordinglyas shownin Figure45 . 6 - - For Models61 - 08,62 - 09thru 62 - 16the sparkignitioncontrolboxwhensupplied , mustbe mountedon theouterleft side jacketpanel asshown in Figure43 . Ifadditionalspark ignitioncontrolboxis supplied , this mustbemountedto the outerrightsidejacketpanel . 7 - - For Models61 - 03thru 61 - 07thespark ignitioncontroland mountingbracket , whensupplied , canbe mountedto the rightor left outerjacket panelas requiredfor easeof wiring . 8 - - This boilermaybesuppliedwithsafetylimitsin additionto the highlimitaquastatand pressuretrolT . he 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 . VENTSAFETYSHUT OFFSWITCH - - ForModels61 - 03thru 61 - 08ONLY , this is a thermallyactivated , manuallyresetableswitch , located inthe drafthood reliefopening . If ventingsystembecomespartiallyortotallyblocked , thevent safetyshutoff switchwill senseexcessive temperaturecaused byflueproductsexitingthe drafthood reliefopeningandshut downmainburnergas . NOTE : REFERTOSECTIONQ FORINSTRUCTIONSWHENBOILERIS SHUTDOWNBY THEACTIVATIONOFEITHEROFTHEABOVE SWITCHES . 9 - - Water & SteamModels62 - 12lhru 62 - 15are suppliedwith2 limitcontrols . The manualreset limitmustbe setfor a highercut out pointthanthe operatinglimitcontrol . If aThermostatis usedas an operatingcontrol , it shouldbeusedin additionto and not in lieuof the operatinglimit control . NOTE : THISBOILERSHALLBE INSTALLEDSO THATTHEGASIGNITIONSYSTEMCOMPONENTSARE PROTECTEDFROMWATER ( DRIPPING , SPRAYING , ETC . ) DURINGAPPLIANCEOPERATIONAND SERVICE ( CIRCULATORREPLACEMENTC , ONDENSATE TRAP , CONTROLREPLACEMENTSE , TC . ) . J - WIRING NOTE : ] HIS UNITWHENINSTALLEMDUSTBEELEC'rI _ AU . YGROUNDEDINACCORDANCWEI ] HTHEREQUIREMENTOSF ] HEAU _ HAVING JURISDIC'I ] OONR , INTHEABSENCEOFSUCHREQUIREMENTwSm , . ITHECURRENTEDmONOF ] HE NATIONAELLECTRICACLODEA , NS _ FPANO . 70 , IFANEXTERNAELLECTRICASLOURCEISUI1L _ D . 1 - - All electricalwiringshallbe donein accordancewithThe NationalElectricCodeANSI / NFPA70and local requirements . 2 - - For recommendedwiringof controls , referto Figures28 thru 42 . SeeFigures20,21,22 and 24for locationof wiringand controls . 3 - - A lengthof 150 ° C lowvoltagewire is provided . 4 - - The boilershouldbeconnectedby a separate , permanentlyliveelectricalsupplyline witha fused switch . 5 - - ThermostatAnticipatorSettings : ( note : settingsmayneed to be adjustedupor 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 DANGEROUSOPERATIONV . ERIFYPROPEROPERATIONAFTERSERVICING . K - STARTING BOILER 1 - - Refer to INSTRUCTIONSFOROPERATIONandthe lighting / aperatinglabelwhichis mountedtojacketpanel . 2 - - The boilerand itsgasconnectionmustbe leaktested beforeplacingthe boilerin operation . Checkgasconnectionswithsoap solution . 15
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L1 - ADJUSTMENT TO GAS PRESSURE REGULATOR 1 - - Set manifoldpressureasfo _ lowsfor variousgases . a . Natural Gas . . . . . . . . . . . . . . . . 31 / 2 " WaterColumn b , LiquefiedPetroleumGas . . . . . . . . . . . . . . . . 10 " WaterColumn 2 - - To adjustgaspressure , turn adjustingscrewof gaspressureregulator , outto decreasepressure , turn in to increasepressure , Referto control sheetssuppliedwith boilerfor locationof gas pressureregulator • 3 - - In no caseshouldthe finalmanifoldpressurevarymorethan plusor minus03 incheswatercolumnfromtheabovespecifiedpressures • Any necessarymajorchangesinthe flowshouldbemadeby 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 FIXEDORIFICELOCATEDINTHEGASTRAINANDIS NOT ADJUSTABLE • L2 - ADJUSTMENTOF PILOTGASFLOWWITHMR8200AND MR8300COMBINATIONGASVALVES To maximizethermocouplelife , particularlyonnaturalgasinstallationswith gassupplypressuresabove9 " W , C . , reducethepilot gasflow . 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 flameextinguishesT • hen increasethe pilotflow just to thepointthatthegasvalveholds in whenrelightingthe pilot persteps9 and 10of LightingInstructionsonpage 25 ( turnscrewno morethana 1 / 8turn ) . NOTICE : THE FIRSTFEWTURNSOFTHEADJUSTMENTSCREWMAYNOT CAUSEANYCHANGEINTHEPILOTFLOW . SUBSEQUENT PARTIALTURNSOFTHE ADJUSTMENTSCREWMAYHAVEA GREATIMPACTON PILOTFLOW . 4 - - Turn on electricpowerto the appliance . 5 - - Turn Gas ControlKnob to " On " positionper the LightingInstructionsonpage 25 . 6 - - Verify pilot remainslit aftershutdownfroma boiler " ON " cycleof at leasttenminutes , If pilot extinguishesf , ollowLightingInstructionsonpage25 and again slightlyincreasepilotflow . 7 - - Make a fina _ slightincreaseinthe sizeofthe pilot to ensuresufficientpilot signalunderalloperatingconditions , justto thepointthat youobserve a slight increasein thesizeof theflame ( nomore thanan 1 / 8turn ) . 8 - - Replace adjustmentcapscrewandobservationcover door • M - BURNERINPUT 1 - - Refer to ratinglabelmountedon thejacketinner - frontpanelto obtainthe requiredBTUper hourinput • In nocaseshallthe 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
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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 _ TUB _ AP , NES $ _ ADC , CR LEr _ ND LINE VOLTAGE LO _ VOLTAGE H V88 _ X _ _ X Figure28 HONEYWELL 24V STANDING PILOT - STEAM OR GRAVITY HOTWATER Models62 - 09thru 62 - 11 / r _ ' f _ Figure29 17
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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 ilrl IAODER tECENO : IN _ VOLTAGE _ OW VOL _ SE Figure30 HONEYWELL SPARK IGNITION ( HSP ) - FORCED HOTWATER w / DAMPER Models61 - 03thru 61 - 07 4 _ OJTJL _ Z4 _ ' / ? v " . . . . . . . . . _ : _ - 4 , _ ) _ . . . . . . . . . _ . . t . . . . . . . . . . . . . _ . . . . _ , , _ l _ . _ J _ . . . _ . . L . . , . . . _ . . , i i i _ _ , i i ii i 1 _ ! _ / _ , , • w Figure31 18
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HONEYWELL SPARK IGNITION ( HSP ) - FORCED HOTWATER w / COIL AND DAMPER Models61 - 03thru61 - 07 _ - - _ . . . . . _ - rr'ccc _ . . . . . _ ' - . . . . - I @ _ - * . . . . . , . . . . . . . . . . . . I * 1 @ i . . . . L . . . . . . . . . . . . _ w . . . . . . L I i _ I L . . . . . . _ _ ' . . iJ _ _ J z - _ _ . , qt _ • , i _ - - - = _ _ = _ _ - _ 2 • _ x - _ _ + J . . . . - - L _ IN _ _ , rAG _ _ tt 14 _ rY _ TW . . . . . . . . IC _ _ SiZE 16 _ BO'C STA , * I , _ O W , RI _ 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 ; • . . . . I LOW WAEP , Cu _ - Orr _ L ME _ 3LtC _ JT I I I COt _ TFIO _ S _ ' _ _ _ _ lii ' 1 SmEi HARNESS _ Il I Z : i % \ flING HIN SSu iFILO : _ RNER _ , I C _ BL _ _ I , , _ BL _ A if i _ x 7039 _ i _ I I _ PIRLCO _ T DBUrRoN [ R - - LINE VOtTACE VAL ' , _ - - . . . . . . . . . . _ ppkor GAS . _ L _ LO _ iigAIN LO . . W . . . . V . . I . _ . . I . A . . _ " Z [ 15 A " " C 51R _ D £ D " R < L _ . , _ , , R _ - - J _ _ ' - - 1 - - - - - - VAL , , _ , _ 5 V ; * L _ H VRll _ < 14 ¢ OL . . . . LOW VOLT , _ GtS " IZE 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 _ TQUIVALENI BE FIEPL # * CE _ IT IdUST I _ REPLACED1 , 41H11411A [ _ _ H _ ) l _ ldt ITS E Figure33 19
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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
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WIRING APPLICATION OF HYDROLEVEL PROBE LOW WATERCUTOFFS Models550P , 650PandCG550P Referto SectionI - Controlsof this manualfor mountinglocationandinstructions . 115V - 60HZ L2 L1 ( HOT ) £ - - I1 _ - 115V - 60HZ L ALARM CIRCUIT TO L2 ON ( WHEN REQ'D ) WIRING DIAGRAM _ , sTO L1 ON WIRING DIAGRAM NOTES : ALL WIRING MUST COMPLY W ! TH APPLIANCE CCDE3 , ORDINANCES , AND REGULATIONS ( _ ) PLACE JUMPER Figure 36 : Wiringof ProbeLWCO 21
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The followingwiringdiagrams , figures37thru 42 , arefor use witha HydrolevelCG400 - PProbeLWCO HONEYWELL 24V STANDING PILOT - STEAM w / DAMPER AND HYDROLEVEL PROBE LWCO Models61 - 03thru61 - 08 C _ , INEC _ _ A _ AU _ H _ ESS r F R _ SCON _ J _ T I : F _ ¢ _ _ kL S _ S _ TC _ - - L1O I ( H I I I I r - - mANSF _ 4OVA PROBE _ E C _ I _ t - - - I x - - - _ I r ] , L / _ , , i _ _ _ w w / _ _ vat . s - - - - , = - _ - - _ < Zz _ r _ 1 ion . _ o _ _ _ = 1 / CAS VAL _ _ S - - - _ - _ XS RLOT metC _ ( ol + i i _ 61 - 0 _ ) - _ - - - % - - - _ - x - - UN £ " , _ . TA _ Sa21E14 AW _ _ TW tF , E _ - _ N _ _ _ _ ALL I _ IRING MUST COMPly _ n _ APP ' , JOm _ - - _ _ LOw t @ - T _ NIl 1 _ / 2 A _ 4 _ _ UMI11 _ RF _ IF " ANy OF _ O _ dG _ NALI _ R _ AS _ JPPU _ _ _ P4 _ PI _ AN _ E _ MUST _ REPtJ _ C _ O , IT 141SJT BE R _ PLl _ ll _ _ l113t llIRE AS SitO _ I 4OR I / ' 3 _ CAJIVALD _ T . Figure37 HONEYWELL 24V STANDING PILOT - STEAM AND HYDROLEVEL PROBE LWCO Models62 - 09Thru62 - 11 L GND F . . . . . . . J _ ] I r - - ' @ - _ + . . . . I I I I I cR I L _ co OP _ R , _ T _ G LIMIT CONTROL . . . . . . . . . . _ _ N _ _ _ 4 G _ S VALES V88A I I I I HYO _ OLEV _ L LADDER OAGIIAW G NB CO _ TRC _ U _ E V0LrAG £ EXI [ R _ AL ' _ I _ ING V88 _ 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 _ : Figure38 22
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HONEYWELL SPARK IGNITION ( HSP ) - STEAM w / DAMPER AND HYDROLEVEL PROBE LWCO Models61 - 03thru61 - 07 CO _ EClrO _ I _ AGRAM MRE HARNESS T _ N _ FORME _ ! i i ] ilZSS ] 24V / . . . . . . . . . . . . _ 1 . T , E , . O _ , , T L . . . . . . . I _ , % • _ , , - - - , _ - - - . 1 _ . . . . . . . . ; g Fo _ , _ " p . . . . . . . @ . . . . . . . < _ _ rRS L W ¢ O u _ m _ _ LL TRAN _ C _ M ( R " l _ * , OVA , m . . . . . . _ F : . . . . . . . . . ® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : VEN ] _ AMpE _ ? IGNIIE R - - UN _ VOL ; ACE INERNAL _ IRING HY'OROLEVEL CONNECTION = ACRa _ LEGE _ ! ) WBK _ P _ LOT BURN [ r UV m I ¢ _ IIlON k _ , _ N _ NG CABLE . . . . . LOW _ IDL _ CE INT _ RNA L _ 4RING : O = . . = J _ t _ . V / F = V LOW VOLI ' _ CE _ ZE _ 6 _ , WG aO _ STRa _ C _ D V4RE - - - - LOW VOLIACE _ ZE 16 / 2 AWG pO _ ' _ ERLIM _ TEO nRE G * _ S vaU _ ALL _ NG MUST COMPLY _ APPUCA _ E CODEg G _ V _ LVE PROECnVE SIgnALING CIK'CUIt CABLE 105 _ 3 ORDNANCES AND _ [ _ UL _ T _ OnS O I _ 1 _ O N COnTr . . lgR _ IN ; * L 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 _ ) CROdND LE ^ 0 _ E SIZE t6 AWC _ 00 ' , 3 _ TRAND _ D ' MI _ E Figure39 HONEYWELL SPARK IGNITION ( HSP - 2 ) - STEAM w / DAMPER AND HYDROLEVEL PROBE LWCO Model61 - 08only r . . - - - ¢ [ - fir i , , I i * - n m " _ m _ _ _ I [ ' " % v _ v _ e _ s v , _ u _ PROT _ CTNES _ O _ O _ t C _ t £ I _ _ o _ Figure40 23
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HONEYWELL SPARK IGNITION ( HSP - 1 ) - w / DUAL 24V MAIN GAS VALVESAND HYDROLEVEL PROBE LWCO Models62 - 09thru62 - 15 IRANsrO _ E _ _ OV ( HOt ) . . . . . . . . . . T . . i _ 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 ( H ° T ) IRI 2RI 2 _ T _ AN _ ' 0l _ ER rIIIC0 _ NECT _ i I I I _ V I r _ _ _ _ . , . _ . . . . . . . i IC'WITER I v • _ f I ; t : . - _ - - _ - . < p2e - - pr _ A _ ' _ T _ V _ V / PV PV icN _ o _ _ wco OG _ G LMIT _ C ( I I I . + , 1 / _ \ \ m ; j , , - ' _ iPi _ - - G _ S VALVES | | HYr ) NOLfV [ L I t _ - - LINGVOLTAGE E _ IERNAL , _ RINe _ I - - _ , , , . . < , . , ° % y , , , . , , , , , _ : , , . , ? , , , o . . . , . < . , W _ - _ ] _ C2 _ 5 ION'T'ON CONISOL I _ P , ' _ INAL _ ) GRoUNO LEAOIRE _ ll { 16 J _ 200C STRANDED IRE Figure42 24
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BOILERESQUIPPEWDITHCONSTANBTURNINPGILOT HONEYWELL GAS VALVELIGHTING INSTRUCTIONS NOTEC : HECKWATERLINEOFSTEAMBOILERO , RBECERTAISNYSTEMISFULL FORWATERBOILERB , EFOREPROCEEDINWGITHTHESEINSTRUCTIONS . 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 • Ifyou cannot reachyour gas supplier , callthe fire department . lighting thepilot , follow these instructions exactly . C , Use only your hand to push in or turn the gas control knob . B . BEFORE OPERATINGsmell all around theappliance area for 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 gas . Be sure to smell next to the floor because some gas is heavier thanair and will settleon the floor . attempted repair mayresult in a fireor explosion , WHATTO DO IFYOU SMELL GAS D , Do not usethis applianceif any part hasbeenunderwater . • Do not try to light any appliance . Immediatelcyall a qualifiedservicetechnicianto inspectthe e Do not touch any electric switch ; do not use any phone in applianceandtoreplaceanypartofthecontrosl ystemandany your building . gascontrolwhichhasbeenunderwater . • Immediately call your gas supplier from a neighbor's phone . Followthe gas supplier's instructions . LIGHTING INSTRUCTIONS 1 . STOP ! Read the safety information above on this page . 10 . Pushinredresetbuttonallthewayandholdin.Immediatellyight the pilotwitha match . Continueto holdthe resetbuttonin for 2 . Set the thermostat to lowest setting . aboutone ( 1 ) minuteafterthe pilotis lit . Releasebuttonandit 3 . Turn off all electric power to the appliance . will popbackup , Pilot shouldremainlit . If it goesout , repeat steps5 through10 . 4 . If the gas valve is not visible , removecontrol access panel . • If buttondoesnot pop upwhenreleased , stopand immedi - 5 . If the gascontrol knobis not inthe " OFF " position , turn the knob atelycallyourservicetechnicianorgassupplier . clockwise _ to " OFF . " • If the pilot will not stay lit after severaltries , turn the gas controlknobto " OFFandcallyourservicetechnicianor gas 6 . Wait five ( 5 ) minutesto clear out any gas . Then smell for gas , supplier . 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 11 . Replacepilotaccesspanel , if applicable . gas , go to the nextstep . 12 . Turnthegascontrolknobcounterclockwise _ to = ON . " 7 . Remove the pilotaccess panel , if supplied , located below and behind the gas valve directly above burner tubes . 13 . Replacecontrolaccesspanel , ifapplicable . 8 . Find pilot followmetaltube from gas valve . The pilot is 14 . Turnonallelectricpowerto theappliance . betweentwoburnertubes . 15 . Setthe thermostatot desiredsetting . 9 . Turnthegascontrolknobcounterclockwise _ to " PILOT " Ga * Cont , _ l Knob ( - _ n , , _ " OFF " Rtd Reset 8ulto * P ° " " ' ) _ S tNL [ T S _ E _ Ew 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
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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 - • If youcannotreachyour gassupplier , call thefire department . matically lights the pilot . Do not try to light the pilot by hand . C . Useonly yourhandto pushin or turn the gas controlknob . B . BEFORE OPERATINGsmell all around the appliance area for Neveruse tools . Ifthe knobwill not pushin orturn by hand , gas . Be sure to smell next to the floor because some gas is don'ttryto repairit , callaqualifiedservicetechnicianF . orceor heavier than air and will settle on the floor . attemptedrepairmayresultina fireor explosion . WHATTO DO IFYOU SMELL GAS D , Do not use this applianceif anypart has beenunderwater . • Do not try to light anyappliance . Immediateclyall a qualifiedservicetechnicianto inspectthe • Do not touch any electric switch ; do not use any phone in applianceandto replaceanypartof thecontrosl ystemandany your building . gascontrolwhichhasbeenunderwater . • Immediately call your gas supplier from a neighbor's phone . Followthe gas supplier's instructions . OPERATING INSTRUCTIONS 1 . STOP ! Readthe safetyinformatioanboveonthispage . 7 . Waitfive ( 5 ) minutesto clearoutany gas . Thensmellfor gas , includingnearthe floor . If you smellgas , STOP ! Follow = B " in 2 . Setthethermostatto lowestsetting . thesafetyinformationaboveonthispage . Ifyoudon'tsmellgas , 3 . Turnoffallelectricpowertothe appliance . gotothe nextstep , 4 . This appliance is equippedwith an ignitiondevice which auto - 8 . Turnthegascontrolknobcounterclockwise _ to " ON . " matically lights the pilot . De not try to light the pilotby hand . 9 . Replacecontrolaccesspanel , if applicable , 5 . If the gas valve is not visible , removecontrol access panel . 10 . Turnonallelectricpowerto the appliance . 6 . Ifthe gas control knobis not inthe " OFF position , turn the knob 11 . Setthethermostatto desiredsetting . dcokwise f - 4 to " OFF " 12 . If theappliancewill notoperate , followtheinstruction " sToTurn Off GasTo Appliancea " ndcall yourservicetechnicianor gas supplier . Gas Conlrol Knob positio _ n ) H _ H VOLTAC , _ 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 ifservice is to be per - formed . 5 . Replacecontrol access panel , if applicable . 3 . If the gas valve is not visible , remove control accesspanel . 26
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Refetro Figure43withthefollowinginstructions BOILERS EQUIPPED WITH ELECTRIC IGNITION AND DUAL GAS VALVE LIGHTING INSTRUCTIONS NOTE : CHECKWATERLINEOF STEAMBOILER , ORBE 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 • Immediatelycall your gas supplier from a neighbor's phone , must be lighted by hand , and an ignition devicewhich automat - Followthe gas supplier'sinstructions . ically lights the main pilot . Light only the secondary pilot by • If youcannot reachyour gas supplier , call thefire department , hand followingthese instructionsexactly . C . Useonlyyour handto pushin orturn the gas controlknob . B . BEFOREOPERATINGsmell all around the appliance area for Neverusetools . If the knobwill notpush in or turn by hand , gas . Be sure to smell next to the floor because some gas is don'ttryto repairit , calla qualifiedservicetechnicianF . orceor heavierthan air and will settle on the floor . attemptedrepairmayresultinafire orexplosion . WHATTO DO IFYOU SMELL GAS B . Do not usethis applianceif any part has beenunderwater . • Do not try to light anyappliance . Immediatelcyall a qualifiedservicetechnicianto inspectthe • Do not touch any electric switch ; do not use any phone in applianceandto replaceanypartofthecontrolsystemandany yourbuilding . gascontrowl hichhasbeenunderwater . LIGHTING INSTRUCTIONS 1 . STOP ! Readthesafetyinformationaboveonthispage . Svff _ , 2 . Setthethermostatto lowestsetting . R * * d Rese + 3 . Turnoffallelectricpowerto theappliance . 4 . Ifthe gascontroal ssemblyis notvisible , removecontroal ccess panel . Referto controlassemblyonfollowingpage . 9 . Turnthepiloct ockhandlecounterclockwise _ to " ON . " 5 . If themanualshut - offleverandpilotcockarenotinthe " OFF " 10 . Pushin redresetbuttonon pilotvalveall the wayandholdin . positiont , urnbothclockwise _ - 4 to " OFF . " Immediatelylight the pilot witha match . Continueto holdthe resetbuttonin for aboutone ( 1 ) minuteafterthe pilot is lit . Pil © _ Cock { 5how _ in " ofF * Releasebuttonandit will popbackup . Pilotshouldremainlit . If Man _ al S _ tu - _ 0ll _ osd _ on ) it goesout , repeatsteps5through10 . Lever ( s _ o , n ; , - o [ r - • If resetbuttondoesnotpopupwhenreleaseds , topandimme - diatelycallyourservicetechnicianor gassupplier . • Ifthepilotwillnotstaylit afterseveratlries , turnthe piloct ock handleto " OFF " andcallyourservicetechnicianorgas supplier . 11 . Replacepilotaccesspanel , if applicable . 6 . Wait five ( 5 ) minutes to clear out any gas . If you smell gas , 12 . Turnrnanualshut - offlevercountercleckwi _ se to " ON . " STOP ! Follow " B " in the safety informationabove on this page . Ifyou don'tsmell gas , goto the nextstep . 13 . Replacecontrolaccesspanel , if applicable . 14 . Turnonallelectricpowerto theappliance . 7 . Removethe pilotaccesspanel , if supplied , locatedbelowand 15 . Setthermostatto desiredsetting . behindthegasvalvedirectlyaboveburnertubes . 16 . Iftheappliancewi [ Inotoperate , followthe instruction " sToTurn 8 . Findsecondarypilot - - followmetaltubefromgasvalve . Pilotis Off GasTo Appliance " andcall yourservicetechnicianor gas betweentwoburnertubes . supplier . TO TURN OFF GAS TO APPLIANCE 1 . Set the thermostat to lowest setting . 4 . Turnthe pilot cock and the manual shut - off lever clockwise to " OFF 2 . Turnoff all electric power to the applianceif service is to be per - formed . 5 . Replacecontroalccesspanel , ifapplicable . 3 . If thegascontrolassemblyis notvisibler , emovecontroal ccess panel . 27
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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 I / 4 " TEST PILOT GAS VALVE 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
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Refetro Figure44withthefollowinginstructions BOILERS EQUIPPED WITH ELECTRIC IGNITION AND A COMBINATION GAS VALVE OPERATING INSTRUCTIONS NOTE : CHECKWATERLINEOF STEAMBOILER , ORBE 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 . C . A . Thisapplianceis equippedwithanignitiondevicewhichauto - Use only your hand to push in or turn the gas control knob . maticallylightsthepilots . Donot fryto lightthepilotsby hand . 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 B . BEFOREOPERATINGsmellallaroundthe applianceareafor attempted repair may result in a fire or explosion . gas . Be sureto smellnextto the floorbecausesomegas is heavierthanairandwill settleonthe floor . D , Do not use thisapplianceif any part hasbeenunderwater . Immediatelycall a qualifiedservicetechnicianto inspectthe WHATTODOIFYOUSMELLGAS applianceandto replaceanypartof thecontrolsystemandany • Donottryto lightanyappliance . gascontrowl hichhasbeenunderwater . • Donottouchanyelectricswitch ; donotuseanyphonein yourbuilding . • Immediatelycallyour gassupplierfroma neighbor'sphone . Followthegassupplier'sinstructions . • Ifyoucannotreachyourgassupplierc , allthefiredepartment . OPERATING INSTRUCTIONS 1 . STOP ! Readthe safety informationabove on this page . 7 . Wait five ( 5 ) minutes to clear out any gas . Then smell for gas , includingnear the floor . If you smell gas , STOP ! Follow " B " inthe 2 . Setthethermostatto lowesst etting . safety informationabove on this page . If you don't smell gas , go 3 . Turnoffallelectricpowerto theappliance . to the nextstep . 8 . Turnthe gas control knob and pitotcock counterclockwise 4 . Thisapplianceis equippedwithan ignitiondevicewhichauto - to " ON . " maticallylightsthepilots . Donot tryto lightthepilotsbyhand . 9 . Replace controlaccess panel , if applicable . 5 . If the gas valveis not visible , removecontrolaccesspanel . Referto controlassemblyonfollowingpage . 10 . Turn on all electric power to the appliance . 6 . If thegascontrolknobandpilotcockarenotinthe " OFF " 11 . Set the thermostat to desired setting . positiont , urnbothclockwise _ to " OFF . " , , , , , 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 . Setthethermostattolowesstetting . 4 . Turnthegascontrolknobandpilotcockclockwis _ e - 4 2 . Turnoffallelectricpowetrotheapplianciefserviceistobeper - to " OFF . " formed . 3 . Ifthegasvalveisnotvisibler , emovecontrolaccesspanel . 5 . Replacecontrolaccesspanel , ifapplicable . 29
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SpAR _ IGNkTEO PLLOT \ \ \ \ \ \ _ N GAS VALVE PILOT COCK _ lLO _ _ T _ VALVE Figure44 : HSP - 2 ControlSystem Model61 - 08 30
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Referto Figure45withthefollowinginstructions BOILERS EQUIPPED WITH CONSTANT BURNING PILOT ( S ) LIGHTING INSTRUCTIONS NOTEC : HECKWATERLINEOFSTEAMBOILERO , RBECERTAINSYSTEMIS FULL FORWATERBOILERB , EFOREPROCEEDINWGITHTHESEINSTRUCTIONS . 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 • Ifyoucannotreachyourgassupplierc , allthefiredepartment . lighting the pilots , follow these instructions exactly . C . Use only your hand to push in or turn the gas control knob . B . BEFORE OPERATINGsmel _ all around the appliance area for Never use tools . If the knob will not push in or turn by hand , gas . Be sure to smell next to the floor because some gas is don't try to repair it , call a qualified service technician . Forceor heavierthan air and will settleon the floor . attempted repair may result in a fire or explosion . WHATTO DO IFYOU SMELL GAS D , Do not use thisapplianceif any part has beenunderwater . • Do not try to light any appliance . Immediatelycall a qualifiedservicetechnicianto inspectthe • Do not touch any electric switch ; do not use any phone in applianceandto replaceanypartofthecontrolsystemandany your building . gascontrowl hichhasbeenunderwater . • Immediately call your gas supplier from a neighbor's phone . Followthe gas supplier's instructions . LIGHTING INSTRUCTIONS 1 . STOP ! Read the safety information above on thispage . 2 . Setthe thermostat to lowest setting . 3 . Turn off all electric power to the appliance . 4 . If the gascontrol assemblyis not visible , removecontrolaccess panel , Vah _ 5 . g the manualshut - off lever and pilot cock are not in the " OFF " 9 . Turnthe pilot cockhandle counterclockwise _ to " ON . " posittuiorbnno , eth , ockwitso " eOFF " , o'o 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 . posi _ ion ) _ 11 . Repeatabovelightingprocedurewith lefthandpilotvalveand lefthandpilot . • Ifeitherbuttondoesnotpopupwhenreleaseds , topand immediatelcyallyourservicetechnicianor gassupplier . • Ifthepilotswill notstaylitafterseveratlries , turnthepilot 6 . Wait five ( 5 ) minutes to clear out any gas . If Nu smell gas , cockhandleto " OFF " andcallyourservicetechnicianor includingnear the floor . If yousmell gas , STOP ! Follow " B " in the gassupplier . safety informationabove on this page . If you don't smell gas , go to the next step . 12 . Replace pilot access panel , if applicable . 13 . Turnmanual shut - off levercountercloekwise _ to " ON . " 7 . Removethe pilot accesspanel , if supplied , locatedbelowand behindthegasvalvedirectlyaboveburnertubes . 14 . Replace controlaccess panel , if applicable . 15 . 8 . Findpilots - - followmetaltubefromeachpilotvalveE . achpilot Turnon all electric power to the appliance . isbetweentwoburnertubes . 16 . Set thermostat to desired setting . TO TURN OFF GAS TO APPLIANCE 1 , Set the thermostat to lowest setting . 4 . Turn the pilot cockand the manual shut - off leverclockwise to " OFF . " 2 . Turnoff all electric power to the appliance ifservice is to be per - formed . 5 . Replace control accesspanel , if applicable . 3 . Ifthegascontroal ssemblyisnotvisible , removecontroalccess panel . 31
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I / 8 " BLEED GAS PI _ ESSURE REGULATOR _ / _ INNER FRONT J , t * CKET PANEL i , , 7 , , _ 2 2 _ 8 F _ LOT - THERMC _ ILOT I / 4 " TEST TAP MAIN SAFETY _ ] ' F _ - P _ 16 _ " T PERMOCOUPLE FLOO R LINE Figure45 : 24 VoltControlSystemw / DualValves Models61 - 08,62 - 09thru 62 - 11 32
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0 - INSTRUCTIONS FOR OPERATION 1 - - The installationisnot completeuntil Ratingand LightingPlatesareon the boilerandthe " UsersInformatioMn anual " and " Installation Instructions " are hung neartheboiler 2 - - System shouldbe maintainedin good repair . Radiators , baseboardunitsand / orconvectorsmustbekeptclean . : _ lf a radiatordoes notheat allover . air hasprobablyaccumulatedandshouldbevented . P - CHECKOUTPROCEDURE 1 - - After startingboiler , becertainall controlsare workingproperlybeforeleavingit unattended , Checkto besure thatthe temperaturelimitcontrol will shutoffthe boilerin theeventof excessivetemperature , by loweringlimitset pointuntil mainburnersshutdown , Returnlimitto desiredset point . 2 _ heck gastightnessof maingasvalvewhenclosedto be certainthereis noleakageto theburners . Checkalljoints periodicallyfor gas teakage . Usesoapsolutionto checkleakage . 3 _ heck the operationof the ignitionsystemsafetyshut - offdeviceusingthefollowingmethod : a . ConstantBurningPilot : Withthegascock knobin the pilotposition , extinguishpilot flameand makecertainthe gasvalveshutsoffgasflow 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 - outis provided , 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 . Turnoffall 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 : - SHOULDOVERHEATINGOCCURORTHEGASSUPPLYFAILTO SHUTOFF , DONOTTURNOFFORDISCONNECTTHE ELECTRICAL SUPPLYTOTHEPUMP , INSTEAD , SHUTOFFTHEGASSUPPLYATA LOCATIONEXTERNALTOTHEAPPLIANCE . DO NOTUSETHISAPPLIANCEIFANY PARTHASBEENUNDERWATER , IMMEDIATELYCALLA QUALIFIEDSERVICETECHNICIANTO INSPECTTHEBOILERANDTOREPLACEANY PARTOFTHECONTROLSYSTEMAND ANY GASCONTROLWHICHAS BEENUNDER WATER . 33
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Cleaning the Series 61162Steam Boiler with Skim Tapping Thefollowingcleaningprocedureshallbe performedbya qualifiedserviceperson . 1 . Cleantheboileras describedbelowno laterthanoneweekaftertheinitialstart up , Cleaningwillbe moreeffectiveiftheboileroperatesa day ortwoto loosensedimentand impuritieisnthesystem . 2 , Theboiler mustbe cleanedto removeanyaccumulatior _ ofoil , grease , sludge , etc . thatmaybeinthesystemT , hesesubstancecsancause foamingand surgingof the boilerwater , producingan unstablewaterline andwatercarryoverto thesystem , WARNING : CLEANINGTHEBOILERREQUIRESTHEUSEOFVERY HOTWATERAND CORROSIVECHEMICALS . USECAREWHEN HANDLINGTO PREVENTiNJURY . 3 . Connecta 11 / 2 " pipenippleand shutoffvalveto 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 theboiler untilwaterbeginsto flow outof the valve . Shutofffill 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 OFTHEGAUGEGLASSORTOALLOWFRESHWATERMAKEUPTO FLOWINTOOFASTT . HISWILLAVOID THE POSSIBILITYOFCAUSINGTHEBOILERSECTIONSTO FRACTURE . 8 . Turn burnersonand allowthe boilerwaterto heat upto just belowsteaming ( 180to 200degreesF ) . Cyclethe burnersto maintaintemperature duringskimming . Do notallowtheboiler 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 , Afterskimmingis complete , closethe skimvalveandturn offthe boiler . 12 . Closethe make - upwatervalveandopen theboilerdrain valve . 13 . Draintheboiler completely . Refillanddrain againoneor two timesto makesure allof the sodahasbeen washedout . 14 . Restorepipingto normal . Pipea nippleand capin theskim valve . 15 . Note : If the gaugeglass becomesdirtyagain , this indicatesmorecontaminantshaveworkedloosein thesystem . Repeatthe cleaningand skimmingprocessas neededto cleanthe system . 34
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R - RATINGST , APPINGLOCATIONSAND DIMENSIONALDATA SERIES 61 , 7 _ , E , , ' D " 2 SUPPLY lAPPING I " F ' . o 1 _ INLET _ " " 5 " _ R _ , _ " A " _ _ ' B ' _ Lz _ ' LEFT SIDE FRONT RIGHT SIDE SERIES 61 TAPPING LOCATIONS Location Size N . RT . Steam Water [ 3 / 4 , , LimitControl PressureGauge " L 1 / 2 , , N / A Theraltimeter M 1 / 2 " N / A Gauge Glassand RoarLowWaterCut - Off N 2 " Return Return O 3 / 4 " N / A SecondaryProbe LowWaterCut - Off P 3 / 4 " ReliefValve SafetyValve Q 1112 . N / A Skim Tapping R 3 / 4 . N / A PrimaryProbeLowWaterCut - Off S 112 " N / A GaugeGlassforPrimaryProbeLWCO * MountGauge using 3 / 4 ' nipple , couple and 3 / 4 " X 1 / 4 " bushingwhena float lowwate cut - offis used . SERIES 61 BOILER RATINGS i DOE SparkIgn , w / Damper i HeatingCapacity SeasonalEfficiency WaterContent MBH ' Net I = B = RRatings _ ( AFUE ) ' Gallons Boiler Steam Steam2 Wate # Model HInput Number MB Water Steam Water Steam Water Steam Sq . Ft . MBH MBH 61o03 90 73 72 225 54 63 80.5 80.6 8,16 4,80 61 - 04 120 98 97 304 73 85 81.7 80.7 10.32 5.88 61 - 05 160 130 129 404 97 113 81.3 80.6 12.48 6.96 61 - 06 200 161 161 504 121 140 81.0 80.6 14.64 8.04 61 - 07 240 193 193 604 145 168 80.6 80.6 16.80 9.12 61 - 08 280 225 225 704 169 196 80.3 80.6 18.96 10.20 SERIES 61 BOILER DIMENSIONS Jacket Rightof Rear of Jacket Jacket Distance Boiler to ctlof to ctlor Flue Between Flueto Toptoor Model Width Flo Flue Flue Size Depth Tappings Chimney Chimney Number " A " " B " " C " " D . . . . E . . . . F " " G " Diameter Size 61 - 03 143 / 4 " i 27V4 " 35 " 73 / B " 39 / 16 " 5 " 5 _ 5 " x 20 ' 61 - 04 18T / 8 " 271 / 4 " 35 " 97 / 16 , , 41116 ' ' 5 " 131 _ " 5 _ 5 " x 20 ' 61 - 05 23 " 27V4 " 35 " 11 _ / 2 " 49 / 16 " 6 " 171A " 6 " 6 " x 20 ' 61 - 06 27V8 " 27v4 " 85 " 139h6 ' , 49h6 " 7 " 213 _ " 7 _ 7 " x 20 ' 61 - 07 31V4 " 27V4 " 35 " 15518 " 6VIe " 8 " 25V2 " 8 " 8 " x 20 ' 61 - 08 353 / 8 " 30V4 " 35 " 17 " he " 61h6 " 8 " 295 / _ ' 8 " 8 " x 20 ' 1 Net I = B = Rwaterratings basedon an allowanceof 1.15 . 2 Net I - B - - R steamratings basedon an allowanceof 1.333 . 3 Consultfactorybeforeselectinga boilerforinstallationhsaving unusualpipingandpickuprequirementss , uchas interm _ ent system operation , extensivepiping systems , etc . 4 HeatingCapacityandAnnual FuelUtilizationEfficiency ( AFUE ) ratingsare basedon U . S . Governmenttest , Beforepurchasingthis appliance , read importantinformationabout its estimatedannualenergyconsumptionosr energyefficiencyratingthat is availablefrom your retailer . 35
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R - RATINGST , APPINGLOCATIONSAND DIMENSIONALDATA SERIES 62 " DI . . . . [ , , 17 _ " E " " G " 2 7 # ' G ' " TL , _ Fr / , , mr , 35 " / , , / I _ LET _ _ . 5 ' ' kff _ r _ N _ ÷ I I VALVE 161 _ _ , _ _ b _ - | J FLOOR LINE _ I - LI _ 4 ! _ ' A ' _ ' _ BI , , _ LYe ' LEFT SIDE FRONT RIGHTSIDE SERIES 62 TAPPING LOCATIONS Location Size N . RT . Steam Water I 3 / 4 . PressureGauge * LimitControl / Models09 - 11 ) J 3 / 4 . N / A OperatingControl ( Models12 - 16 ) K 3 / 4 " N / A LimitControl ( Models12 - 15 ) L 1 / 2 " N / A Theraltimeter M 1 / 2 " N / A Gauge Glass and FloatLow WaterCut - Off N 2 " Return Return O 3 / 4 - N / A SecondaryProbeLowWaterCut - off P 3 / 4 " ReliefValve SafetyValve Q 11 / 2 " N / A SkimTapping R 3 / 4 - N / A PrimaryProbe LowWaterCut - off S 1 / 2 " N / A GaugeGlass for PrimaryProbe LWCO " PressureGauge , Operatingand LimitControlon Models12 - 15 SERIES62 BOILERRATINGS I = B = R Water Net I = B = R Combustion Content GrossOutput i MBH Gallons Ratings Efficiency Boiler Steam Steam Water Model Input Number MBH Water Steam Water Steam Water Steam Sq . Ft , MBH MBH 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 14.52 j 27.60 62 - 13 480.0 384 384 J 29.66 1200 288 334 80.0 80.0 15.60 416 416 62 - 14 520.0 1309 312 362 80.0 80.0 i 3182 16.68 62 - 15 560,0 448 446 1400 336 390 80.0 80.0 17 # 6 j 3398 SERGES62 BOILER DIMENSIONS Jacket Distance Rightof Rearof Flue Distance Betw . Rt . Jacket Distance Jacket Size Boger to c / I of Betw . Tw ¢ to cffof " F " Between Topto Sup . & Tap . Flueto Model Width Floor Flue Depth Flea c / l'e Rue ( Each Tappings Inter . Chimney Chimney Number u A - " B " " C " " D " " G " " Gt " Diameter Size " D1 . . . . E " of 2 ) 62 - 09 39V2 " 301 / 4 " 35 " t4 " 119h6 " 49 / 16 " 6 " 33314 " N / A 9 " 9 " x 20 ' 62 - 10 435 / 8 " 30114 " 35 " 15 " 1311116 " 49 / 1e " 7 " 37 _ / e " N / A 9 " 9 " x 20 ' 62 - 11 4713 / 16 " 301h " 35 " 16 " 15 _ 3h6 " 49116 " 7 " 42V16 " N / A 9 " 9 " x 20 ' 62 - 12 52 " 301 / 4 " 35 " 18 " 151She " 6V16 " 8 " 46V4 " 21V _ 6 " 10 " 10 " x 20 ' 62 - 13 561 / 8 " 30V4 " 35 " 19 " 18V _ e " 6V _ 6 " 8 " 50316 " 253h6 " 10 " 10 " x 20 ' 62 - 14 605h6 " 30V4 " 35 " 20 ' h6 " 20 _ he " 6V _ 6 " 8 " 549h6 " 253h6 " 10 " 10 " x 20 ' 62 - 15 647 / 1s " 30V4 " 35 " 22Ve " 203 / 16 " 61116 " 6 " 58111 " 16 295h6 " I0 " I0 " x 20 ' 36
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S - MAINTENANCE AND INSPECTION 1 - - This boilermustbe disconnectedfromthe gassupplypipingduringanypressuretestingof thesystem . RefertoSectionH - " GAS PIPING " . Note8 for details . 2 - - The gasventusedonthis boi { erisof the horizontalto verticaltype . Thevent andventingsystemshouldbeinspectedthoroughlayt the beginningof eachheatingsystem . 3 - - The areawherethe boileris containedshould beclearand free fromcombustiblematerials , gasolineandotherflammablevaporsand liquids . The boilerarea shouldhaveample airfor combustionandventilationand thereshouldbeno obstructionspreventinga free flow of air 4 - - AI1low watercut - offsshouldbetested and inspectedper manufacturer'sinstructions , anyfloattypesshouldbeflushed ona weeklybasisto removeanysedimentfromthefloat bowl . 5 - - A visualcheckof burnerandpilot flameshouldbe conductedat leastoncea 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 maingasto appliance . b . Removetheflue pipe , drafthood , top jacketpanelsand fluecollector . c . Brushfluewayswithwirebrush . d . Replacefluecollector . Whenreplacingthe fluecollector , be certainthat the sealingropebetweenthe fluecollectorandtop section makesa tightseal to preventleakageof the productsof combustion . e . Replacethetop of jacket , drafthoodand fluepipe . f . Removethejacketclean - outcover plate . See Figure4 . g . Removecast ironcover plateby removingfour ( 4 ) capscrewsat 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 alljacketpanels . m . FollowLighting / OperatingInstructionsforputtingboilerintooperation . 37
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REPAIR PARTS SERIES 61 / 62 GAS BOILERS REPAIR PARTS ARE AVAILABLE FROM 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 . Part No . Item No . Description AdditionalInformation t P - 150 IntermediateSection 50 lb . WorkingPressure 2 P - 151 Left HandEndSection 50 lb . WorkingPressure P - 152 w / CoilOpening 3 RightHandEndSection P - 152C w / Cast ClosedCoil Opening 4 P - 154 TappedIntermediateSection 50 lb . WorkingPressure 12 - EF 5 Push Nipple 1 RequiredPerFlueway 6 64 Push Nipple 1 RequiredPerFlueway 7 5 / 8 " HighTemperatureRope 42 " RequiredPerFlueway 8 P - 162 CompleteBlockAssembly SpecifyBoilerModel 9 P - 161 LeftHandBlockAssembly SpecifyBoilerModel 10 P - 158 RightHandBlockAssembly SpecifyBoilerModel 11 P - 120 DrawRodsw / nutsandwashers SpecifyBoilerModel 12 P - 106 Clean Out CoverPlate 1 / 4 " HighTemperatureRope 44 " RequiredFor P - 106 13 X - 1037 TanklessHeaterFlangew / screws 14 X - 1023 RubberGasket 15 X - 1034 CoverPlatew / screws BaseBack 16 P - 155 SpecifyBoilerModel 17 P - 156 BaseBack SpecifyBoilerModeland Rightor Left Side 18 X - 1009 Draw - UpWasher 2 Required 19 X - 1001 Draw - UpWasher 2 Required 20 P - 4208 3 / 4 " Gas Manifold SpecifyBoilerModel 21 P - 4209 1 " Gas Manifold SpecifyBoilerModel 22 11 / 4 " Gas Manifoldfor 62 - 15 P - 4210 23 X - 4003 OrificeSpud SpecifyQuantify , Typeof Gas , BoilerModelandAltitude 24 Steel Burnerw / pilot bracket SpecifyControlSystem 25 X - 3005 Steel Burner SpecifyQuantity 26 ThrottlingPilot Cock 27 P - 503 FlueCollector Specify BoilerModel 28 P - 504 DraftHood Specify BoilerModel 38
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AdditionalInformation Item No , Part No . Description 29 JacketAssembly Specify BoilerModel TheraltimeterGauge SteamGauge Gauge GlassBet 3 / 4 " DrainCock LightingInstructionPlate SpecifyControlSystem Lighting / OperatinIgnstructionsLabel SpecifyControlSystem HighTemperatureSealingCement SpecifyQuantityof Containers 1 / 2 " Pint Can NippleSealer SpecifyQuantity 1 / 4 " AluminumTubing Specify Quantityin Feet WaterTrim SteamTrimw / LWCO GasValve SpecifyBoilerModel , ControlSystem , Typeof Gas Pilot SpecifyControlSystemandTypeof Gas IgnitionControl SpecifyModel LimitControl SpecifyBoilerModelandControlSystem Gas ControlAssembly SpecifyControlSystem 39
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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 .
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