PEERLESS SERIES 62 Instruction manual

61/62
Boilers
Installation,
Operation Et
Maintenance
Manual

3-8 90,0 Up to 81.7% AFUE
Natural or LP Gas
Standing Pilot (Steam Only) or Spark Ignition (Hot Water and Steam)
Natural Draft (chimney) Venting
Factory Assembled Sections on Knockdown Boilers
•Reduces Installation Time
Large Water Content
•Ideal for Steam and Large Volume Hot Water Applications
Skim Tapping
•For Cleaning Steam Boilers
Low Profile Design
•Horizontal to Vertical Draft Diverter
•Ideal for Installations with Low Ceilings
Steel Push Nipples
•Provide a Permanent Water Tight Seal Between Sections
•Unaffected by Petroleum and Other Contaminants
Tankless Coils
•For Domestic Hot Water Production on Hot Water Boilers
Deluxe Insulated Enameled Steel Jacket
•Reduces Boiler Heat Loss
•Completely Encloses Gas Valve and Burners
Safety Controls
•Low Water Cut-Offon Steam Boilers
•Flame Roll-Out Shut-OffSwitch
•Blocked Vent Shut-OffSwitch
•Honeywell Operating Controls
•Vent Damper
•Float Type LWCO on Steam Boilers
•Taco 007 Circulator on Packaged Water Boilers
•Tankless Coil for Hot Water Boilers
•Gnmdfos Circulator on Packaged Hot Water Boilers
• Probe Type LWCO on Steam Boilers
Peerless Heater Comparly is pleased to offer one of the most comprehensive warranty programs
icl tile indnstn 1, All Peerless residential cast troll _x_ilers include a fidl one-yea" warranty. A limited.
lifetone warranty is provided.for the cast iron sections ol Peerless residential hot water boilers.
Peerless also provides a limited, ten year warranty ot_ the cast iron sections of its residential steam
boilers. Five and ten year extended warratlties on parts and labor are now available. Pl_'asc consult
Peerl_,ss Heater Company for complete warranty inJbrmation.
PGGRLESS _
CAST IRON BOILERS
Peerless Heater Company * 231 North Walnut Street •Boyertown, PA 19512-1021 •610-3S7-2153 * www.peerless-heater.eom
FAB-61 R1 (3/02 3M)
Printed in US A

pr=-I RLESS o
CAST IRON BOILERS
Series 61
oResidential Gas Boilers
•Packaged or Knockdown
oNatural Draft Venting
oStanding Pilot or
Spark Ignition
QSteam or Hot Water Boilers
oNatural or LP Gas
Water
Steam
QThis large water content boiler
installsindifficultsteam or water
applications.
oAFUE ranges from 76.8%
(standing pilot) to 80.7% (spark
ignition) on steam boilers and
80,3% to 81.7% (spark ignition
only) on water boilers, significantly
exceeding the federal standards
for residential boiler efficiency.
oLow profile design ideal for boiler
installationsinareas with a low
ceiling.
An optional tankless domestic
hot water coil can be installedon
hotwater boilers, insuringample
domestichotwater production.
oProbe or float-type lowwater
cutoff available.
DOE
Heating Capacity
MBH--
Stdg.PilotwlDamper
Seasonal Efficiency
(AFUE)4
Net I=B=R Ratings 3
Steam Steam Water
Sq. Ft. MBH 2MBH 1
225 54 63
304 73 85
4O4 97 113
504 121 140
604 145 168
704 169 196
Spark Ign. wlDamper
Seasonal Efficiency
(AFUE) 4Water Content (GaL)
IA,G.A.
I Input
N MBH Water Steam Water I Steam Water I Steam Water Steam
90 73 72 N/A I 76.8 80.5 I 80.6 8.16 4.80
120 98 97 N/A I77.7 81.7 I 80.7 10.32 5.88
160 130 129 N/A I 77,8 81.3 I 80.6 12.48 6.96
200 I 161 161 N/A I 78.0 81.0 I 80.6 14.64 8.04
240 193 193 N/A I 78.1 80.6 I 80.6 16.80 9.12
280 225 225 N/A I 78.3 80.3 I80.6 18.96 18.20
1 Net I=B=R water ratings based on an allowance of 1.15,
2 Net I=B=R steam ratings based on an allowance of 1.333.
3Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping
systems, etc.
4 Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are based on U.S. Government test. Before purchasing this appliance, read important
information about its estimated annual energy consumptions or energy efficiency rating that is available from your retailer.

7 Sizes 9-15 Sections 320 to 560 MBH Input 80% Combustion Efficiency
Natural or LP Gas
Standing Pilot or Spark Ignition
Natural Draft (chimney) Venting
Factory Assembled Sp/it Block Sections on Knockdown Boilers
•For Ease of Handling
Large Water Content
•Ideal for Steam and Large Volume Hot Water Jobs
Skim Tapping
•For Cleaning Steam Boilers
Low Profile Design
•Horizontal to Vertical Draft Diverter
•Idealfor Installatiolis with Low Ceilings
Steel Push Nipples
•Provide a Permal_ent Water Tight Seal Between S_ctioris
•Unaffected by Petroleum arid Other Cor_tamiTlalltS
Tankless Coils
•For Domestic Hot Water Production o_ Hot Water Boilers
Deluxe Insulated Enameled Steel Jacket
•Reduces Boiler Heat Loss
•Completely Encloses Gas Valve and Burners
Safety Controls
•Low Water Ctlt Q[l'orl Steam Boil_'rs
•HoT_eywell Operating Co_ltrols
•Mar_ltal Reset High Limit Corltrol (12-15 Section)
•Float Type LWCO orl Steam Boilers
•Tcxl_lcless Coiljor Hol Watcr Boilers
•Moclultxtillg Fi1_rlg Systems (12 15 S<:cliorl}
• F_'I _rid IRI Colltrol S!]slerTls (12 15 Sectioll)
• Prot)t> "I_upe I.WCO o11 Sle(lfll Boilers
_ll lilt" il_(lll._lr'!]. ./Ill I_'_'r'l( '.,_.s ('ollilll_'r('i(¢l _'cl.'q/ _rt)ll I)oih>l_ _ll_'h_(l_ >(I /illl. oil(' ! (>_'lr" tl,_ls't(_ll[ 1. A
lilliilt>(I. It'll !]('(1I II'_llltll_l[/ I)ll I]l(" _'tl._l il'oll ._('t'l_oll._ i.'_ [)l()l'l_ll'_ [i_t (ill (Ollllll<'F('i_ll 11(>I I_ll('I _lll([
,'_l_>(llll I?l_il(>I'_. I+'il'( ' _lll_'l [I'll I I>tlr ('._l_'tl_l(>_l ll'_l_'ltlllll_'_ I)ll l_(It l_ (lll_l I_l!)ol (It't' /loll' ttl'(li[(l!)_('. CAST IRON BOILERS
!'lt>(_._;( ' €'otl.'_ll/I I>_'('t'l_ '.'q_ I h'_ll_'t ( "olllt)_lltt].[O_" _'Oml)lt'f_" it,t_r_t_i_l!] ir!]Oi rIl(llioll.
Peerless Heater Company •231 North Walnut Street *Boyertown. PA 19512 1021 • 610 367-2153 - www.peerless-heater.com
FAB 6_7t9 02 :_,%

pGr=-RLESS o
CAST IRON BOILERS
Series 62
oSemi-Commercial Gas Boiler
• Packaged or Knockdown
oNatural Draft Venting
o320 to 560 MBH Input
oSteam or Hot Water Boilers
oNatural or LP Gas
Steam
Water
oThe large water content of this
knockdown or completely packaged
boiler makes it ideal for difficult steam
or water applications.
oAvailable in standing pilot or spark
ignition.
oCombustion efficiency meets the
80% ASHRAE 90.1 minimum as
required by the federal standards for
commercial boilers.
OHorizontal to vertical draft hood
and aluminized steel flue collector
provide a low boiler profile to allow
installation in areas with low
clearance.
r_ An optional tankless hot water coil
can be installed on water boilers,
insuring ample domestic hot water
production.
o Probe or float-type low water cutoff
available.
I=B=R Water
Gross Output Net I=B=R Combustion Content
MBH Ratings 3 Efficiency 4 (Gallons)
Model Input Steam Steam Water
Number MBH Water Steam Sq. Ft. MBH2MBH 1Water Steam Water Steam
62-09 320.0 256 256 800 192 223 80.0 80.0 21.12 11.28
62-10 360.0 288 288 900 216 250 80.0 80.0 23.18 12.36
62-11 400.0 320 320 1000 240 278 80.0 80.0 25,34 13.44
62-12 440,0 352 352 1100 264 306 80.0 80.0 27.50 14.52
62-13 480.0 384 384 1200 288 334 80.0 80.0 29.66 15.60
62o14 520.0 416 416 1300 312 362 80.0 80.0 31.82 16.68
1 Net I=B=R water ratings based on an allowance 011.15.
2 Net I=B=R steam ratings based on an allowance of 1.333.
3 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation,
extensive piping systems, etc
4 Combustion efficiency determined in accordance with ANSf Z21 13, Gas-Fired Low-Pressure Steam and Hot Water Boilers

I
J
K
L
M
N
O
P
Q
R
m
Boiler
Model
Number
62-09
62-10
62-11
62-12
62-13
62-14
62-15
Steam Water
3/4" Pressure Gauge* Limit Control (Models 09-11)
3/4,, N/A Operating Control (Models 12-15)
3/4" N/A Limit Control (Models 12-15)
V2" N/A Temperature-Pressure Gauge
V2" Gauge Glass and Low Water Cutoff N/A
2" Return Return
3/4" Secondary Probe Low Water Cut-Off N/A
3/4" Safety Relief Valve Safety Relief Valve
1V2" Skim Tapping N/A
¾" Primary Probe Low Water Cut-Off N/A
3o4-
L£_'T SID_ £RON_ RIGH TSIDE
• Pressure gauge, operating control and I_mitcontrol on Models 62 12 to 62 15
Jacket Right of Distance Rear of Distance ,..
Jacketto Betw. Two Jacketto Flue Between !Rt. Sup.& C_uetOy
Width Depth Top to Fir. c/I of Flue Flue c/l's c/I of Flue Size Tappings Tap. Inter. Chimney
"A .... B.... C.... D.... D1.... E.... F.... G.... GI"
39V2" 30V4" 35" 14" 11%#' 4%s" 2-6" 333/." N/A 9" 9" x 20'
43%" 30V4" 35" 15" 13_V_6" 4%8" 2-7" 37%" N/A 9" 9" x 20'
47_¾_' 30V4" 35" 16" 15_3/lS" 4%4' 2-7" 42V16" N/A 9" 9" x 20'
52" 30V4" 35" 18" 15_%#' 6_/_6" 2-8" 46V4" 21_/_6" 10" 10" x20'
56Ys" 30V4" 35" 19" 18V_6" 6Vls" 2-8" 50%" 253/16" 10" 10" x 20'
60%6" 30_/4" 35" 20VI4' 20¾e" 6V_6" 2-8" 54%6" 25z/_6" 10" 10" x 20'
64W_6" 30V4" 35" 22W' 203Ae" 6%6" 2-8" 58"A_" 29s/_6"10" 10" x 20'

STEAM WATER
, , i
t t "L
Boiler
Model
Number
62-09
62-10
62-11
62-12
62-13
62-14
62-15
NOTE: Provide Tee, Nipple and Cap Fittings below water line to assist in cleaning or draining.
Steam
No. Supply Outlets
2
2
2
3
3
3
3
Size of Outlets
2"
2"
2"
2"
2"
2"
Header Supply
3 _=
3"
3"
3V2"
31/2''
31/2'`
31/2" ,
Equalizer Size
1V4"
11/4"
1V2"
1V2"
1V2"
1W'
1V2"
Boiler
Model
Number
62-09
62-10
62-11
62-12
62-13
62-14
62-15
Htr. No.
X-1020
GPM
4,75
5.00
5.25
5.50
5.50
5.75
5.75
Htr. No. Htr. No.
X-1021 X-1022
GPM GPM
6.25
6.75
7.00
7.25
7.25
m
6.5
7.0
7.5
8.5
9.0
*Water healer ratings in GPM are based on intermittent demand40 °to 140_ Frise with 200 °FbOiler water
CAUTION: Water mixing valve should always be installed in the hot water supply to prevent injury,

SERIES 62 BOILER SPECS
_-_-_ LlJl-J_vd_id
• Cast Iron Sections--Factory Tested and
Assembled with Steel Push Nipples
•Deluxe Insulated Enameled Steel Jacket
• Drain Valve
• Horizontal to Vertical Draft Diverter
•End Cleanout
• Manual Reset Limit (62-12 to 62-15)
• Standing Pilot or Spark Ignition
• Automatic Reset Limit
Water
• 30 PSI Safety Relief Valve
• Temperature-Pressure Gauge
Steam
•15 PSI Safety Valve
• Pressure Gauge
• Gauge Glass
• Low Water Cutoff - Probe or Float
• Skim Tapping
• HSP-2 Honeywell ignitionSystem
• 50 PSI Safety Relief Valve - Water Boilers
• Insurance Controls
•I.R.I.
,F.M.
• Ignition Systems
• HSP-2
• E1-M
• E1-E
• Modulating Firing Systems
• MFSC
• Mod-U-Pak (12-15 Section)
Approx. Shipping Wts. (Ibs.)
Boiler
Model
Number ILength IWidth !Height IW S
I II!
62-09 I57" 31" I 391/2" I 1080 I1088
I I I I
62-10 I 61" 3t" J391/2" J1170 I 1178
I I I I
62-11 I 66" 31" I 391/2`' ! 1265 I 1273
I I I ]
62-12 I 70" 31" I 391/2" ]1420 I 1428
I II!
62-13 I 74" 31" I 391/2" I 1520 I 1528
I IIJ
62-14 I 78" 31" I 391/2'' ] 1620 I 1628
I I I I
62-15 I 82" 31" I391/2" I 1720 1 1728
WP SP
1105 1108
1195 1203
1290 1298
1445 1453
1545 1553
1645 1653
1745 1753
nnam
Example:
62 - 09 - STDG/SPRK - WP - N
Series Sects. Natural Gas (Substitute
Standing Pilot or "LP" for LP Gas)
Spark Ignition W = Water Knockdown
WP = Water Package
S = Steam Knockdown
SP = Steam Package
PEERLESSHEATERCO.
231 North Walnut Street
Boyertown, PA 19512-1021
Phone: [phone] • FAX: [phone]
www.peerless-heater.com
HI Division ASME garNa
of gama
CUT-62 F_7(3/03-1M), Printed in U SA. _003 Peedess Heater Company

Readcarefullybeforebeginningwork.It witlsavetime.Studythe includeddrawings.
Theequipmentshallbe installedin accordancewith thoseinstallationrequirementsofthe authorityhavingjurisdictionor, in theabsenceof such
requirements,to thecurrenteditionof the NationalFuelGasCodeZ223.1/NFPA54.
Whererequiredbythe authorityhavingjurisdiction,theinstallationmustconformtothe standardforControlsandSafetyDevicesfor AutomaticallyFired
Boilers,ANSI/ASMECSD-I.
A-ACCESSIBILITY CLEARANCES
1. Toprovideforreasonableconditionsofaccessibility,the followingminimumclearancesarerecommended.
a. 24"betweenthesides,top,backandfrontof theboilerand adjacentwallor otherappliance,whenaccessis requiredfor servicing.
B- CLEARANCEFROMCOMBUSTIBLECONSTRUCTION
1. Thedesignofthisbelieriscertifiedforthefollowingclearancesfromcombustibleconstruction:
MODELS61-03thru61-08;62-09thru62-11
18"fromrear
6"from rightand leftsides
30"fromtop- frontalcove
6"fromflue connector
6"from steamandhot waterpipes
MODELS62-12thru62-15
24"fromsidesand rear
55"fromtop
6"fromflueconnector
6"fromsteamandhotwaterpipes
2. CAUTION:This boileris NOTDESIGNCERTIFIEDforinstallationon carpetingor combustibleflooring.
C-AIR FORCOMBUSTIONANDVENTILATION
1. Becertainadequatefacilitiesareavailableto provideairfor satisfactorycombustionandventilation.
2. AppliancesLocatedin UnconfinedSpaces:
a. Installationsin unconfinedspaceswith conventionalconstructionand largeareas:thesupplyof airfor combustionandventilationcanusually
beconsideredadequate,
3, AppliancesLocatedonConfinedSpaces:
Ifallair forcombustionandventilationistocomefromwithinthebuilding:twoopeningsshallbe providedwithone openingcommencingwithin
12inchesof thetop andone openingwithin12inchesofthe bottomof theenclosure.Theseopeningsshall notbe locatedcloserthan3 inches
fromeitherthe topor bottomofthe enclosureand shallbeopenintoareascommunicatingfreelywiththeoutdoors,Theareaof eachopening
shallbe equaltoone squareinchper 1000BTU/HRof totalinput ratingofall applianceswithinthe enclosure,witha minimumof100square
inchesforeachopemng,
Ifallair forcombustionandventilationistocomefrom outsidethebuilding:twoopeningsshallbe providedwithone openingcommencing
within12inchesofthetop and oneopeningcommencingwithin12inchesofthe bottomoftheenclosure.Theseopeningsshall notbe located
closerthan 3 inchesfromeitherthe top or bottomoftheenclosureandshallcomreunicatedirectlyor by ductswith theoutdoors.Theareaof
eachopeningshallbeequalto onesquareinchper4000BTU/HRof totalinputrating.Ifductsareusedto conveythe air,verticalductsrequire
areasofonesquareinchper4000 BTU/HR:horizontalductsrequireone squareinchper2000BTU/HR,Ductsshallhavethe samecross
sectionalareaas thefull areaofthe openingsto whichtheyconnect.
c. Theupperopeningsareessentialformaintenanceof propercirculationofairwiththe boilerroomandreasonableambienttemperatureinorder
tomaintainpropercontroltemperatures.
D - SETTING UP BOILER -PACKAGEDUNITS
1. A PackagedBoiler isfactoryassembledbeforebeingcrated.Allcontrolsand accessoriesnecessaryfor operationof the boilerareattachedand
electricallywired.
2. Thedraft hoodis packedin a separatecarton.
3. Whenboileris removedfromthe crate,carefulinspectionshouldbe madeandthecarriernotifiedofanydamagefound.
4. Provideagoodlevelfoundation.
5. Placethe boileronthe foundationnearand inproperpositionwith relationtothe chimney,andascentralizedwith respecttothe heatingsystemas
practical,
6. Theopeningsin thebasesidesareprovidedfor admittingsecondaryairand mustneverbeclosed.
7. Removeiackettop andattachdrafthoodto fluecollectorwithtwo #10x 1/2"sheetmetalscrewsprovided.Replacejackettop.
8. The burnersareinstalledin the boiler.Theyaresecuredin placefor shipmentbywoodstripewiradtothe Burnermixingtube.Cutthewiresand
removethewood strips.
9. The gasmanifoldandocntrolassemblyaremadeup gastight,completelyfactoryassembledand installedasintegralcomponentsof thebase
assembly.See Figure12.

D - SE'I-rlNG UP BOILER - UNASSEMBLED UNITS
I-- ASSEMBLEDBLOCKS
1--The boilersectionsandbase,Models61-03thru61-07arefactoryassembled.Removeshippingskidfromtheboilerbase.If boilerisa61-08,
or62-09thru62-15beginassemblyasnotedin PartII "SplitBlockAssembly".
2--Providea goodlevelfoundation,The Boilershouldbe locatedasneartothechimneyandcentralizedwithrespecttotheheatingsystemas
possible.
3--Open controlbox.Removecontroland manifoldassembly,Referto Figure6 andattachmanifoldto boilerwithfourV4-20x 1"machinescrews
andnutsprovided.Figures43thru45showthestandardcontrolassembliesusedon Models61-08thru62-15.
4 Openfluecollectorcarton.Removefluecollectorand HiTempropeandlay ropeontop ofboileragainstbeadprovided.SeeFigure7.
5--Place fluecollectoron topof ropeand attachto boilerwithtwo1/4"-20studs,washersandhex nutsprovided,throughfluecollectorbrackets
intothetappedlugsprovidedontopof theboilerendsections.Drawboltsdownsnugly.SeeFigure8,
6--Attach castironclean-outplate10clean-outopeningon leftsideofthe boiler.Thisplate,HiTempropeand mountinghardwaremaybefoundin
thecontrolboxreferred1opreviously.
7--Removethe burnersfromthecontrolboxand install.Installeachburnerbyslippingtheopeninginthe venturioverthe orificespud.Insertthe
pinon thebottomof theburnerintothe holeprovidedin theflangeonthe basebackplate.SeeFigure9.TheBurnerswith pilotsattachedmust
be installedas follows:Note:Hookbolt isprovidedon models62-11through62-15.
ModelNo. No.Pilots
61-03 1
61-04 1
61-05 1
61-06 1
61-07 1
61-08 2
62-09 2
62-10 2
62-11 2
62-12 2
62-13 2
62-14 2
62-15 2
Location of Pilot
Between2nd and3rdBurnerfromLeft
Between4th and5th BurnerfromLeft
Between4th and5th BurnerfromLeft
Between4th and 51hBurnerfromLeft
Between4th and 5thBurnerfromLeft
Between4th and5th Burnerfrom Leftand4th and5thfrom Right
Between4th and5th BurnerfromLeft and4th and5thfrom Right
Between4th and 5thBurnerfromLeft and4th and5thfrom Right
Between4th and5th Burnerfrom Leftand4th and 5thfrom Right
Between4th and 5thBurnerfromLeft and4th and 5thfrom Right
Between4th and 5thBurnerfromLeft and41hand5thfrom Right
Between41hand5th BurnerfromLeft and6th and7thfrom Right
Between6th and7th BurnerfromLeft and6th and7thfrom Right
8..-Removepilottubingfromcontrolboxandinstallbetweengas valveandpilot.Referto figures43 through45.
9--If boileris toincorporatea tanklessheaterfordomestichot water,installinopeningprovidedin the rightsideofthe boiler.Sixmountingbolts
3/8"16 x3/4 are rovldedBesurerubber asketi I
( - ) p " • g "sbetweencoverplateandtheboier, Ifboiler doesnot incorporatea fanklessheater,a
blankcoverplateis providedwithrubbergasketand bolts.One3/4"pipeopeningisprovidedin 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

I:'ROC_"OUR lr FOR STACKING PALLtr'rq
II-- SPLITBLOCKASSEMBLY
1--Boiler sectionsfor Models61-08,62-09thru 62-15areshippedintwoparts.Removeskidfromeach blockofsections.
2--Place each blockofsectionsonthe stackedskids.See Fig.A. Becertainto removethesmallblocksonthetop skid.See Fig.B,
3--To clean nippleportsand removeprotectivecoating,useawirebrushandmineralspiritsor lacquerthinner.Makecertainthereareno burrs
aroundthe outsideedgeof the ports.
4--Spread a thincoatof PeerlessNippleSealerin the nippleports,NEVERON NIPPLES.
5--Insert the pushnipples,withthe chamferededgeout. Makecertaintheyarecleanand freeofburrs.
6--Apply athin coatof PeerlessNippleSealerto the ropegroove.Press5/8"Dia. ropeintothegroove.Thenipplesealeractsas an adhesiveto
holdthe ropein placeuntilthesecgonsaredrawnup.
7--Arrange bothblocksso that protrudingnippleentersthe openport.Caremustbetakento keepnipplesstraightandblocksaligned.
8--Insert drawrodsthroughthe nippleports.Makecertainthat the3/4"drawrodis usedonthe largenipple.Payparticularattentiontothe
placementof the drawwashers.See Fig.A.
9--Before startingdraw,oil thethreadsand betweenthe nutsandwashers.
10--Tightenthe hexnutsanddraw boilerevenlyuntilthe smallpadsoneach sectionjusttouch.
11--After boilerisdrawn,removethedraw rodsandcut5" fromthe 6V4" threadedend.Inserttherodthroughthe lugsoneachendsectionand
tightenthehex nutshandtight.
12--Attach3/8"Dia.ropeto basebackplateby layingropeacrosstopofbackplateflangeand in ropegrooveon eachendofbackplate.Usenipple
sealerto hold ropeinplace.Refertofigures9& 12.Attachbasebackplate bymeansof V4"-20x lr/2" machinescrewsandnutsfurnished.
Thebase backplateisattachedtobackof boiler.SeeFigure8.Becertainthatthe flangeportionofplate istowardsthe insideof the boiler.
Note: hook boltisprovidedonmodels62-11through62-15only.
13--Install pressuregage,drainvalve,watersupplylinewith shutoffvalve,and meansto ventair.Plugunusedtappings.
14--Fill boilerwith water,ventingairas waterlevelrises.Pressurizeboilerto75-85psig.Do notexceed85 psig.
15--Verifypressureis maintained.Checkalljointsand fittingsfor leaks.
16--Drainboiler.Removepressuregage,drainvalve,watersupplyand airvent.ContinuewithStep2 underD-1.
E-JACKET ASSEMBLY
A.Wrap-AroundRearJacketPanelStylefor Models61-03thru61-06
Thisstylejacket designincorporatesa BackJacketPanelaspart of eachRightand Left SideJacketPanel.TheBackJacketPanelis formedwhena
portionofeachSidePanelis bentatperforationsto rearof boile_:
I, Inserttwo (2) 1/4-20x 1"studs intappedholesat bottomof RightEndSection.SeeFiguret.
2. Placethe RightSide Panelalongright sideof boilerblockandalignthe slotsofthe mountingbrackets,(atbottomofjacketpanel),withthe 1/4-20x
1"studs.Attachjacketpaneltoboilersectionwithtwo (2)1/4"nutsandwashers.SeeFigureI.
3. Placethe Left SidePanelalongleftsideof boilerblockand attachto boilersectionin samemanneras performedfor RightSidePanel.
4. Bendat theperforationsofthe RightSidePaneltoform halfofthe BackJacketPanel.Dothe sameat perforationsofthe LeftSidePanel.Atthe
centerjointoverlapofthe BackPanel,attachpanelswiththree (3)#10x 1/2"sheetmetalscrews.See Figure2.
Positionthe InnerFrontPanelbetweenthe Leftand RightSide Panels.Alignthe two(2)mountingholes,on eachsideflangeofthe InnerFront
Panel,with the clearanceholesin eachSide Panelandattachwith four(4)#10x 1/2"sheetmetalscrews.See Figure4.

6. PlacetheSecondaryAirCoverDooratbottomofInnerFrontPanel.ThetopbendoftheCoverDoorslipsoverthetopreversebendatcutout
openingoftheinnerFrontPanel.RefertoFigure11.
7. AtlachDraftHoodtoFlueCollectorwithtwo(2)#10x1/2"sheetmetalscrews.RefertoFigure10.
8. AttachtheLowerFrontPaneltothebottomtrontoftheLeftandRightSidePanelswithtwo(2)#10x1"sheetmeta_screws.SeeFigure4.
9. PositionTopJacketPanelsotheflangesoverlapSideJacketPanelsandairlouversareatthefrontoftheboiler.Securewithsix(6)#10x1/2"sheet
metalscrews.SeeFigure4.
10.AttachtheCleanOutCoverPlatePaneloveropemnginLeftSideJacketPanet,withfour(4)#10x1/2"jacketscrews.SeeFigure4
11.ThemanilaenvelopethatcontainstheInstallationManualalsocontainstheboilerratinglabel,clearancetocombustiblesplate,Lighting/Operating
instructionplateorlabelandwiringdiagramlabel.SeaFigure5forlocationofplatesandlabels.Attachplateswith#6x3/8"screwsprovided.
12.PositiontheRemovableFrontPanelinplacebyslidingthePanelunderthefrontflangeoftheTopPanelandthendownuntilitrestsonLowerFront
Panel.
B.IndividualBackJacket PanelStyle for Models61-07thru 62-t5
ThisjacketstylehasaseparateBackJacketPanelthatis attachedtoindividualRightand LeftSidePanels.
1. AttachSide Panelsper instructionsin #1thru3 above.SeeFigure1.
2. Positionthe BackJacketPanelonthe insideoftheLeft andRightPanelflangesand attachwithsix(6) #10x !/2" sheetmetalscrews.SeeFigure3.
3. Followinstructionsaboveper#5thru 12for assemblyof remainingjacketpanels.
SIDE PANEL ATFACHMENT
FIGURE 1
-,_ RIGHT SIDEPANEL
ONEPIECERIGHT
SIDEANDREAR
PANEL
1/4" WASHER
1/4" NUT
J
J
ONEPIECELEFT
SIDEAND REAR
PANEL
REAR VIEW WRAPPER
STYLE JACKET
(61-03THRU 61-06)
FIGURE 2
LEFTSIDEPANEL
RIGHT
SIDE
PANEL
REAR VIEW OF BACK PANEL
(61-07 THRU 62-15)
FIGURE 3
BACKPANEL
4

JACKET ASSEMBLY
FIGURE 4
/
/
#,
,LIGHTING/OPERATING
,INSTRUCTIONSLABEL
(61-63 THRU 62-11)
"WIRING
_J
/jJ DIAGRAMLABEL
RATINGLABEL
LIGHTING
INSTRUCTIONSPLATE
(62-12 THRU 62-15)
CITYOFNEWYORK
•MEAPLATE
(WHENREQUIRED)
CLEARANCETO
COMBUSTIBLESPLATE
REMOVABLEFRONTPANEL
(INSIDEVIEW) INNERFRONTPANEL
AGENCY LABEL & PLATE LOCATIONS
FIGURE 5

FIGURE 6
FRONT BOILER VIEW FIGURE 7
FRONT TOP BOILER VIEW
T_6"- !_UNC NUT & WASHER
_BASE BACK_
-- PLATE
BURNER MANIFOLD-_
HOOK BOLT _'w
FIGURE 9
HOOK BOLT ASSEMBLY
FIGURE8
REAR BOILERVIEW FIGURE 10 FLUE COLLECTOR/DRAFT HOOD
.f,
H
FIGURE 11
SIDE VIEW OF INNER FRONT
AND COVER DOOR
-"IGURE 12
TOP CUT VIEW OF MANIFOLD
BURNER AND BASE BACK PLATE
6

F- VENTING
A.General
1--For connectionto gasventsor chimneys,ventinstallationshall bein accordancewith Part7,VentingofEquipment,ofthecurrenteditionof the
NationalFuelGasCode,ANSIZ223.1/NFPA54,orapplicableprovisionsofthe localbuildingcodes.
2--Draft: Sufficientdraft mustbeavailableforremovalofproductsof combustion.If draftis notadequate,spillageofthe productsof combustion
will occuratthe bottomoutletofthe drafthood.Ifsucha conditionshouldexistchecktheflueand chimneytodeterminecauseof insufficient
draft.It isalso importantthat ampleairis availablein theboilerroomtofacilitatedraft.
3--Vent connectorshouldslope upwardat least1/4"perlinealfootbetweenthe drafthoodoutletandthechimney.
4--Flue orvent connectormustbe insertedinto butnot beyondtheinsidewallofthe chimneyflue.
5--Vent connectorsservingappliancesventedbynaturaldraftshallnot beconnectedintoanyportionofmechanicaldraftsystemsoperating
underpositivepressure.
6--Horizontalportionsoftheventingsystemsshallbesupportedtopreventsaggingbyuseof metalstrappingor equivalentmeansandbe located
atno morethan12ft.intervals.
7--When anexistingboilerisremovedfrom a commonventingsystem,thecommonventingsystemis likelytobetoo largeforproperventingof
theappliancesremainingconnectedto it.
Atthetime of removalof anexistingboiler,thefollowingstepsshall befollowedwith eachapplianceremainingconnectedtothe common
ventingsystemplacedin operation,whilethe otherappliancesremainingconnectedtothecommonventingsystemare not inoperation.
a.Sealanyunusedopeningin thecommonventingsystem.
b.Visuallyinspectthe ventingsystemfor propersize andhorizontalpitchand determinethereisno blockageor restriction,leakage,corrosion
andotherdeficiencieswhichcouldcausean unsafecondition.
c.Insofarasis practical,closeall buildingdoorsand windowsand alldoorsbetweenthespacein whichtheappliancesremainingconnected
to thecommonventingsystemarelocatedandotherspacesofthe building.Turnon anyclothesdryersandanyappliancenotconnectedto
the commonventingsystem.Turnon anyexhaustfans,suchas rangehoodsandbathroomexhausts,so theywilloperateatmaximum
speed.Donot operateasummerexhaustfan.Close fireplacedampers.
d.Placein operationtheappliancebeinginspected.Followthe lightinginstructions.Adjustthermostatso appliancewill operatecontinuously.
e.Testfor spillageatthe drafthoodreliefopeningafter5minutesofmainburneroperation.Usethe flameofamatchorcandle,orsmokefrom
a cigarette,cigar orpipe.
f. Afterit hasbeendeterminedthateachapplianceremainingconnectedtothecommonventingsystemproperlyventswhentestedas
outlinedabove,returndoors,windows,exhaustfans,fireplacedampersandanyothergas-burningappliancetotheirpreviousconditionsof
use.
g.Anyimproperoperationofthecommonventingsystemshouldbe correctedsotheinstallationconformswith thecurrenteditionof the
NationalFuel GasCode,ANSIZ223.1/NFPA54.Whenresizinganyportionofthe commonventingsystem,the commonventingsystem
shouldberesizedtoapproachminimumsize as determinedusingtheappropriatetableslocatedin the chapter"Sizingof CategoryI Venting
Systems",inthe currenteditionof theNationalFuelGasCode,ANSIZ223.1/NFPA54.
8--Single WallTypeVentPipeshouldbefurnishedbetweenthedrafthoodandchimney.If theventconnectorshallbelocatedin orpassthrougha
coldarea,the ventconnectorshallbeoflisteddouble-wallTypeB or Lmaterial.

B,VentDamperInstallation
1 Ventdampersareprovidedon models61-03through61-08asstandardequipment.
2--Unpack thevent damperandfollowthese instructionsandthe installationinstructionsintheventdampercarton.Observethecautionsand
warmngthat accompanyall instructions.Do notmodifyventdamperor boilerdrafthood
3--The ventdampercanbe mounteddirectlyontothe drafthoodoutletcollar,or in theventpipingclosetothe boiler.Seefigures14and 15,Be
suredirectionofflow arrowlocatedondampercollar,ispointingawayfromdraft hoodcollarand damperpositionindicatorisvisibleafter
installation,Forinstallationwithdampermountedin the horizontalposition,mountthe damperasshownin figure15toavoidexcessiveheat
and possiblecondensationdrips onthe damperoperatingcontrol.
4--Do not useoneventdamperto controltwo or moreheatingappliances.Seefigure 13.
5 Makecertainthatthe minimumclearancesprovidedinthe ventdampermanufacturersinstructionsaremaintainedandthatadequatespaceis
providedfordamperaccessandservice.
6--A wiringharnessis packedwiththe ventdamperwith pluginconnectionsat eachendof theharness.Connectsmallerendintodampermotor
receptacleand connectotherendto boileraquastatrelay_imit(onwaterboilermodelsequippedanL8148Eor L8124Elimitcontrol),orboiler
junctionbox (onsteamboilermodels),
7--Damper mustbe in theopenpositionwhenappliancemainburnersareoperating.
OTHERHEATING
APPLIANCE
I[_ OTHER
HEATING
APPLIANCE
INCORRECT CORRECT
Figure13:VentingMultipleAppliances
8

SLOPE UP
A MINIMUM
OF 1/4"
PER FOOT -m
VENT
DAMPER
AS REQUIRED
DRAFT HOOD
OUTLET
Figure14:VentingwithVentDamperinVerticalPosition
/- VENT TO
SLOPE UP VENT /CHIMNEY
A MINIMUM DAMPER
oF1/4" "7F" 1
PER FOOT_ 11 O'CLOCK
r_
1 O'CLOCK
POSITION
OPERATOR
-CONDENSATION
ZONE
7 O'CLOCK 5 O'CLOCK
POSITION POSITION
DO NOT MOUNT DAMPER
OPERATOR IN SHADED REGION
SECTION A-A
Figure15:VentingwithVentDamperin HorizontalPosition

G - PIPING
1--Hot Water:
a.The recommendedpipinghook-upis shownin Figure17.Alsoreferto PeerlessWaterSurvey.
2--Steam:
a.Therecommendedpipinghook-upis showninFigure16.Pleasenotethat a Hartfordreturnloopis recommendedtobe usedonall steam
boilers.Alsoreferto PeerlessSteamSurvey.
3--The reliefvalveand popsafetyvalveshallbe installedbyusingthe 3/4"x 3"nippleand 3/4"elbowsuppliedwith theboiler.Referto illustrations
locatedinSectionR-"Ratings,Tappingsand DimensionalData".LargeNPTsizevalvesmaybe installedin supplypiping.
NOTE: IFTHIS BOILERANDDISTRIBUTIONSYSTEMIS USEDINCONJUNCTIONWITHA REFRIGERATIONSYSTEM.THECHILLED
MEDIUMSHALLBEPIPEDIN PARALLELWITHTHEBOILERANDTHEPROPERVALVEAPPLIEDTO PREVENTTHECHILLED
MEDIUMFROMENTERINGTHE BOILER.A DRAWINGILLUSTRATINGTHIS HOOK-UPIS PROWDEDINFIGURE18.
WHENTHEBOILERISCONNECTEDTOHEATINGCOILSLOCATEDINAIR HANDLINGUNITWHERETHEYMAYBE EXPOSED
TO REFRIGERATEDAIR CIRCULATION,THE BOILERPIPINGSYSTEMMUSTBE EQUIPPEDWITHFLOWCONTROLVALVESOR
OTHERAUTOMATICMEANSTO PREVENTGRAVITYCIRCULATIONOFTHEBOILERWATERDURINGTHECOOLINGCYCLE.
CAUTION:PIPETHEDISCHARGEOFRELIEFVALVETO PREVENTINJURYINTHE EVENTOF PRESSURERELIEE SUGGEST
DISCHARGETOBEPIPEDTODRAIN.PIPEFULLSIZEOFOUTLET.
H - GAS PIPING
1--Gas supplypipingistobe sizedand installedproperlyinordertoprovidesupplyof gassufficienttomeetthemaximumdemandwithoutundue
lossofpressurebetweenthe meterandthe boiler.
2_onsult the followingtablefor propersizingofgaspiping for variouslengthsand diameters.
CAPACITYOF PIPEOF DIFFERENTDIAMETERSANDLENGTHSINCU.FT PERHOURWITHPRESSUREDROPOF 0.3 IN.AND
SPECIFICGRAVITYOF0.60. NOALLOWANCEFORAN ORDINARYNUMBEROF FITTINGSISREQUIRED,
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 BEUSEDWITHABOVETABLE,WHENTHESPECIFICGRAVITYOFTHEGASISOTHERTHAN0.60
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 atee in thedroppipeat sameelevationas thegasinletconnectiontothe boiler.Extendthe droppipetoa pipecapasshownin Figure
19to forma sedimenttrap.
5--Install a groundjoint unionaheadofthe gascontrolassemblyto permitservicingofthe equipment.See Figure19.Somelocalcodesrequirean
additionalshut-offvalve.Ifyour coderequiressucha valve,a suggestedlocationis shownin Figure19.
6_OTE: Wheninstallingboilerbesureapipecompoundresistanttotheactionof liquefiedpetroleumis used.
7--Check pipingfor leaks.Alwayscheckleakswitha waterandsoapsolutionor equal.DONOTUSEA FLAMEFORCHECKINGGASLEAKS,
8--The boilerandits individualshut-offvalvemustbedisconnectedfromthe gassupplypipingsystemduringanypressuretestingofthat system
attest pressuresin excessof r/2psig (3.5kPa),
Theboiler mustbeisolatedfromthe gassupplypipingsystembyclosingits individualmanualshut-offvalveduringanypressuretestingofthe
gassupplypipingsystemat testpressureequalto or lessthanV2psig(3.5kPa).
10

Table1: SteamHeader,Risersand EqualizerSizing
L---RETURN
SUGGESTEDPIPING
t t
ETURN
NOTE:Thereturnfrom systemshouldalwaysenterequalizer
throughHartfordLoop,approximately2"- 4" below
normalwaterline.
Steamheadershouldbe24" rain.aboveboilernormal
waterline.
Figure16:SteamSupplyand ReturnPiping
Model No.Supply Sizeof Header Equalizer
No. Outlets Outlets Supply Size
6t-03 1 2" -- 1114"
61-04 1 2" -- 11/4"
61-05 1 2" -- lr_"
61-06 2 2" 21_" 11_"
61-07 2 2" 2+/2" 11_"
61-08 2 2" 3" 11_"
62-09 2 2" 3" 11_"
62-10 2 2" 3" 1!_"
62-11 2 2" 3" 1_"
62-12 3 2" 31_" 11_"
62-13 3 2" 31_" 11_"
62-14 3 2" 31_" tl_"
62-15 3 2" 31_" 11_"
STEAM BOILER
SUGGESTEDPIPING
HOT WATERBOILER
_TOP • w_STt ¥_LV[ (Nomwl_eJrY O_J_W_
Cu_{D _to _ [xF_l_,_ TANK
_ S_T_II_ESS v,_Tl_ ;_'_1_ is _ _Fw°_ ;4(ATW4G<
Figure 17: Hot Water Supply and Return Piping
11

Figure18: ParallelHook-UpwithWaterChiller
J
SERVICE
_JACKET
G.J. UNION
SEDIMENT TRAP
_./FLOOR LINE
Figure19:GasConnectiontoBoiler
Figure20:GravityHotWater
Figure22: SteamW/FloatLWCO
Figure21: ForcedHotWater
.HIGH TEMPERATURE
HOT WATER _.
MIXEO
WATER
MIXER
HEATER
"rAPPING
12 Figure23:SuggestedPipingForTanklessHeater