PEERLESS SERIES TC, Installation, Operation & Maintenance Manual

Page 1: ...TC Gas Off Boilers Installation Operation Maintenance Manual pr r I_Lr SS CAST IRON BOILERS ...

Page 2: ...nkless Coils For Domestic Hot Water on Sleam and Hot Waler Boilers Insulated Enameled Steel Jacket Reduce_ Boiler Heat Loss Short Individual Draw Rods Simplify Assembly Reduce Slmss Burner Mortaring Plate with lllsulation Block 30 PSIASME Saj e__ Relie Valve Water Boilers 15 PSI ASME Side Outlet Safe_ Valve Steam Boilers LWCO on Packaged Boilers Wide Variety of Tcmkless Heater Options Assembled Se...

Page 3: ... flexible _raphite port connectors and short individual draw rods simpli_ installation Front and rear flame observation ports aid burner setup All Series TC boilers are available with a slandard built in cast iron flue collector with integral damper and a burner mountin_ plate with insulation block Steel an_ le floor rails and ceramic fiber rope seal between seclions are also standard Series TC bo...

Page 4: ...0 072 _ _ R84 GO _ 2 C20B _ I JB10072 _ _ R84GO I 2 20131 _ g20 1O 1 RIB I GO z 2 L2 DBll JB2_tB 2 RIOIGO l 3 101 2 JB20 10 l RIO I GO t 3 C O 2 B20 202 RlO I GO t 30 _ 2 1B20 20 _ RIB2GO _ 5 3 0 _ 2 JB20213 _ R102GO 5 _0B l B20 30l RIO2GO 5 3 0B JB20 O RI0 O t 5 40A 2 5 JB30 0 t RI_2 D 5 4 A 3 I _303Bl I Gordon Plait Model NO HP R8G _ _ R82 O t _4 RB 2 G r R82 G 1 _4 R84 fl R84 G 1 R_B 1 G_ R101 ...

Page 5: ... MBH MBH 2 013 675 783 3 646 875 1 014 4 538 1 089 1 246 5 458 1 310 1 477 6 358 1 526 1 709 7 221 1 733 1 941 8 079 1 939 2 172 8 942 2 146 2 403 9 804 2 353 2 636 10 667 2 560 2 867 11 525 2 766 3 098 12 392 2 974 3 330 13 250 3 180 3 562 14 113 3 387 3 793 14 975 3 594 4 025 Water Content Gal Ream Water 103 8 123 4 125 8 150 3 14L8 177 2 169 8 204 1 lgl 8 231 0 213 8 257 9 235 8 284 8 257 8 311...

Page 6: ...61 150 169 158 177 166 191 183 199 191 Optional Package Base Dimenslo 91sA_ 104 112_A_ 120 128 _ 136 144_A_ 157 165z _ 173_ _ 181_ _ 189 197z _ 211 219 e Furnace Len _h 23_A_ 31 d 39_Ae _ 47 e_ 55 _ 63 e 71SAd 79 _ 87 e 95 6 111_ 1e 119_ze 127 e 135_Ao Boiler Ler_h 33 41 49 57 65 73 81 8g 97 105 113 121 129 137 145 5reamUpla_eLocatlonS _ D E F 12 20 12 16 12 24 12 32 12V_ 40 20 40 20 24 24 20V2 24...

Page 7: ... 6 THRU 9 SECT E t0 THRU 18 SECT Steam Plpin_ Sizes No of Sections 4 S o 7 8 10 11 18 Risers A I 8 l c 5 J 5 I 5 S S 5 5 5 Header D s 5 6 8 Return Gravity 2V2 2 4 4 Conn _umped _E R 21 2 2_ 4 4 ump Dlsch Pipe I 1 1 G Manual and automatic water feed connection Pump dischar_e size based on 15 PSI steam pressure and 20 PSI feed pump discharge pressure and feed valve In boller connection Pipe size red...

Page 8: ... draw IO0 F average lemperature rise Peerless_ Partner_ Indirect Fired Water Heater Standard Equipment Hi h Grade 316L StainlessSteel Tank Enclosed Thermostat Well Malntenance FreePlastlcJacket Adjustable Honeywell Control 2 Polyurethane Foam Insulation T PRelief Valve Cupronickel Fin TubeHeat Exchanger Modern Ooil Design MinimalSS t_l Temperatum Los Rapid RecoveO Rate Easy Installation Long Lasti...

Page 9: ...TION 9 D JACKET INSTALLATION 10 E CONTROL TAPPING LOCATION 13 E CONTROL LOCATIONS 13 G INSTALLATION OF WATER COLUMN PIPING 14 H SAFETY RELIEF VALVE INSTALLATION 14 A FACTORY ASSEMBLED SECTIONS 8 PACKAGED BOILERS 4 B ASSEMBLY OF KNOCKED DOWN BOILERS 4 C BURNER MOUNTING PLATE INSTALLATION 6 D REAR OBSERVATION PORT INSTALLATION 6 E FLUE BOX INSTALLATION 7 E CLEANOUT COVER INSTALLATION 7 G BURNER MOUN...

Page 10: ...special attention boxes intended to supplement the insh_uctions and make special notice of potential hazards These categories mean in the judgment of the Peerless Heater Company Indicates a condition or hazard which will cause severe personal injury death or major property damage Indicates a condition or hazard which may potentially cause severe personal injury death or major property damage Indic...

Page 11: ...r and 48 in front of the boiler is recommended for serviceability The minimum clearance to combustible materials based on ANSI NFPA 31 Table 4 4 11 Clearances to Combustible Materials is as follows 2 I Sides 6 2 Rear of Jacket 6 3 Front of Boiler 24 4 Top of Jacket 6 5 Vent Chimney Flue Box 18 Vent System Inspection a Inspect the existing chimney or vent system Make sure it is in good condition b ...

Page 12: ...ng or a fire resulting in severe personal injury or death 1 2 Provide adequate air for combustion and ventilation Unless boiler room construction and natural air infiltration supply all necessary combustion air provide an outside air opening or duct The free cross sectional area of the opening or duct shall meet or exceed i square inch per 4000 Btuh input for all installed appliances At altitudes ...

Page 13: ...ase angles and the straps from the draw rods to angle base after the boiler is in place Leave the boiler on the angle iron base The lifting lugs on assembled blocks of sections must be removed for the boiler to accept its jacket 4 Remove left side jacket panels and check that the cleanout covers are secure and gas tight tll __ ff __ d I_ e I OTeIdN ID_ _ DIol_ _ Tl o 1IF J_ Section Assembly 1 Dril...

Page 14: ...er Left Step 5 Upper Right Step 6 Lower Left 25 ft Ibs 25 ft Ibs 25 ft lbs 10 ft Ibs 50 ft Ibs 50 ft lbs Step 7 Lower Right 50 ft Ibs Step 8 Upper Right 75 ft Ibs Step 9 Lower Left 75 ft Ibs Step i0 Lower Right 75 ft Ibs 9 Step 11 Upper Left 30 ft Ibs Step 12 UpperRight 125 ft Ibs Step 13 Lower Left 125 ft Ibs Step 14 Lower Right 125 ft Ibs Step 15 Upper Right 125 ft Ibs Step 16 Upper Left 40 ft I...

Page 15: ...out on the top left side Place the burner mounting plate over the block and force the block inward until the studs extend far enough through holes in the burner mounting plate to accept the nuts Tighten the nuts Use a long drill awl or other such tool for form holes through the insulation block for four 1 4 machine screws Install the i 4 x 5 machine screws through the holes in burner mounting plat...

Page 16: ...he grooves at the top and bottom of the cleanout cover openings between the sections to insure an air tight seal when the covers are installed Cleanout cover hex nuts should be set at 15 Ibs torque Use Hi Temp silicone caulk around the cleanout covers to seal air tight Most large burners require support from the floor See Burner Manufacturer s Manual for such specifications if needed 1 2 3 4 Remov...

Page 17: ...f vaporization at 212 F 970 BTU Ibm 2 Minimum feedwater pump flow is based on 2 times evaporation rate 3 Condensate receiver capacities are based on 20 minute steam cycle Chaa shows actual capo ity and not gross receiver volume 3 The front section has 3 tappings at the base for installation of 3 close nipples and 3 caps Removal of caps allows flushing of sediment from boiler These recommendations ...

Page 18: ...and evenly Gasket should not be visible after tightening Table 4A Parts List Item Quantity Stock Code Description I 6 __ 7656 Coupling 4 2 1 7657 Coupling 5 3 I 7658 Tee 4 x 4 x 5 4 2 7659 Tee 4 8 i I 7663 Lube 4 5 oz Clean the heater flange to remove any dirt or rust Install the 7 16 x 1 1 2 studs in the screw seats around heater opening Place the heater gasket over the studs and install the heat...

Page 19: ...Assemble left rear post to back panel Align lower holes of right and left posts with lower channel holes and join with 10 washer head sheet metal screws Install panel B2 with sheet metal screws CHECK VALVE 8 _r_R UlaPLy 4 5 Upper Channels 4 Through 7 Section Boilers Boilers from 4 through 7 sections have one piece upper channels These are installed and attached to the top of front and back panels ...

Page 20: ...LEFT REAR POST LH1 LH3 LH4 SUPPORT BRACKETS RIGHT REAR POST B2 CHANNELS T3 T4 T5 T6 T7 3E UPPER RH3 T1 RH4 RH5 F1 BASE ANGLES NOT INCLUDED WITH JACKET Figure 12 Jacket Assembly 11 ...

Page 21: ... 8 E Std Washer Table 5A Jacket Schedule Top Side Cartons Jacket Front Back Carton _ Left Side Front Panels Back Panels _ Top Panels Panels Right Side Panels _ _ C3 Chrome Knob The front and back carton which consists of one 1 each of the above listed items is the same for all size boilers Hardware Bag 23 10 x 1 2 Slot Hex Washer Head 8M Screws Zinc Plated 21 1 4 20 x 1 2 Slot Rd Head Machine Scre...

Page 22: ...7 i Water Column Bottom Water Column Bottom 1 1 2 r Inspection Tapping Top 8 3 4 Tankless Heater O _ra_ng Tankless Heater Operating Control Located in Heater Control Located in Heater Mounting Plate Mounting Plate Figure 13 Tapping Locations I_ e 0 t_ l Te g 0I _IID L_ Figure 14 shows the suggested location of limit and operating controls MANUAL RESET HIGH OPERATING CONTROL STEAM PRESSURE GUAGE St...

Page 23: ...s located in the 3 tapping at the top of the rear section for both steam and water boilers Water and steam b irn cartons contain relief valves and fittings Relief valve discharge piping must be piped to avoid exposure of persons to hot liquid or vapor see Figure 15 Never install any type of valve between the boiler and the relief valve SUPPORT DISCHARGE PIPING SO AS TO AVOID STRAIN ON VALVE BODY R...

Page 24: ...stem components due to liming and oxygen corrosion 2 If the system requires antifreeze use only antifreeze designed for hydronic systems These contain inhibitors to prevent corrosion of the boiler and system components Do not use ethylene glycol or automotive antifreezes Make sure the antifreeze supplier can provide periodic inhibitor check service If automatic fill is used the system will have to...

Page 25: ...im valve run to a point of safe discharge 7 8 Close all valves to the system Provide a means of continuous fresh water to the boiler for the cleaning process Open the skim valve Fill the boiler until water begins to flow out of the valve 9 Use common washing soda such as Arm and Hammer Super Washing Soda Mix the soda with water in a 10 quart pail and pour into the boiler through the safety valve t...

Page 26: ...ally 3 Do not use ethylene glycol antifreeze in a boiler system 4 Be certain that the boiler and system are refilled before returning to service Follow the instructions in this manual and the burner instructions to operate Before servicing the boiler Turn off all electrical power to the boiler Close the Gas Service Valve and Oil Shut Off Valve Allow the boiler to cool if it has been operating Labe...

Page 27: ...sible allow the boiler to cool nautrally before adding water If an excessive loss of water occurs check for a leak in the piping and correct th problem Excessive make up water will cause corrosion and damage to the boiler STEAM BOILERS Do not place cold boilers in service on a hot steam line or severe damage may occur to boiler and piping Keep cold boilers valved off line fire until boiler reaches...

Page 28: ...Co _ J t 3 D 11 19_ 17 36 34 _ 35 9 15 35 39 34 5 4 29 1 28 2 27 21 13B 41 40 37 _ I I 1 38 24 25 20 o_ _oe _ _ __ _ _ 5 _ _ _o _cr c_ _3 _ CJ _ _t Q m m g D_ g_ _ t_ ...

Page 29: ... Mounting Plate Assembly I0 i 4 GPR10 1 76025 Burner Mounting Plate Assembly 10 i 4 STD 76024 Burner Mounting Plate Assembly 12 1 2 76022 Burner Mountinq Plate Hardware I 7653 21 Burner Insulating B oek 76029 Burner Insulating Block Hardware 7720 22 Observation Glass Only 7648 23 Observation Glass Gasket 7650 24 Observation Glass Gaskel 7649 25 i Observation Glass Retainer 7651 26 Observation Cove...

Page 30: ...for future reference TO THE OWNER This boiler should be inspected annually by a Qualified Service Agency member HI Division ASME of gama PEERLESS CAST IRON BOILERS PEERLESS HEATER COMPANY 231 NORTH WALNUT STREET BOYERTOWN PA 19512 1021 PHONE 610 367 2153 www peerless heate_com THE PREFERRED HEATING CHOICE 2002 Peerless Heater Company TC8001 R1 10 02 1M Printed in U S A ...