PEERLESS SERIES PSC Instruction manual

PSC
Installation,
Operation
Maintenance
Manual
PEERLESS °
CAST IRON BOILERS

4 Sizes 3-6 Sections 70.0 to 175.0 MBH CSA Input 83% AFUE
Natural or LP Gas
Sealed Combustion, Direct Vent
•Ideal Where the Chimney is Inadequate or Unavailable
•Uses Outside Air For Combustion
• 4" Galvanized or Aluminum Approved For Combustion Air Inlet Piping
•Combustion Air Inlet From Either Side of Boiler
•Uses 3" AL29-4C Stainless Steel Vent Pipe For "Through the Wall" Venting
Applications
Unique Wall Thimble For "Thru the Wall" Venting
• Concentric Design For Combustion Air Inlet and Exhaust
• Requires Only One Hole in Outside Wall
•Exhaust Gases Heat Incoming Combustion Air to Prevent Freezing
of Air Inlet
Steel Push Nipples
• Provide a Permanent Water Tight Seal Between Sections
• Unaffected by Petroleum and Other Contaminants
Deluxe Insulated Enameled Steel Jacket
•Reduces Boiler Heat Loss
•Completely Encloses Gas Valve, Burners
and Air Inlet Box
Safety Controls
•Flame Roll-Out Shut-OffSwitch
•Differential Pressure Switch
_SraartValve is a registered trademark oj'Honeywell Corporation.
•Honeywell Operating Controls
•Honeywell SmortValve ® Intermittent Ignition
•Taco 007 Circulator
• Non-Combustible Floor Pan
• Wall Thimble with Stainless Steel Vent Cap and
Screened Vent Termination
•30 PSI Safety Relief Valve
•Grundfos Circulator
•AL29-4C Stainless Steel Venting Components
•50 PSI Safety Relief Valve
Peerless Heater Company is pleased to offer one of the most comprehensive warranty pro_lrams in
the industry. All Peerless residential cast iron boilers include a full one-year warranty. A limited,
lifetime warranty is provided for tile cast iron sectior_s of Peerless residential hot water boilers.
Peerless also provides a limitc, d, ten-year warranty on the cast iron sections of its residential steam
boilers. Five and ten year extended warranties on parts and labor are now available. Please consult
Peerless Heater CorrqgoJly for complete warranty information.
pGERLESS ®
CAST IRON BOILERS
Peerless Heater Company • 231 North Walnut Street •Boyertow_, PA I9512-1021 • 610-367-2153 •www.peerless-heater.com
FAB PSC (11/02-5M)
Printed in U.S.A

TABLE OF CONTENTS
1°
2,
3.
4.
USING THIS MANUAL 1
A. INSTALLATION SEQUENCE ............. 1
B. SPECIAL ATTENTION BOXES ........... 1
PREINSTALLATION 2
A. ACCESSIBILITY CLEARANCES .......... 2
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION ..................... 2
C. LIQUEFIED PETROLEUM (LP) GAS ....... 2
D. INSTALLATION SURVEY ............... 2
E. PLANNING THE LAYOUT ............... 2
BOILER SET-UP 3
WATER PIPING AND CONTROLS 4
A. BOILER SUPPLY AND RETURN .......... 4
B. SAFETY RELIEF VALVE ................ 5
C. PIPING FOR ZONED SYSTEMS .......... 6
D. EXPANSION TANK .................... 7
E. INDIRECT-FIRED WATER HEATER ........ 7
E FREEZE PROTECTION ................. 7
VENTING, VENTILATION AND
AIR INLET 8
A. GENERAL ........................... 8
B. PEERLESS WALL THIMBLE ............. 8
C. ROOF TERMINATION ................. 10
D. VENT PIPE INSTALLATION ............ 11
E. AIR INLET PIPE INSTALLATION ......... 11
E AIR FOR VENTILATION ............... 12
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM ................... 12
6. ELECTRICAL 15
A. WIRING ........................... 15
B. ZONED SYSTEM WIRING ............. 15
C. CONTROLS ........................ 15
D. SEQUENCE OF OPERATION ........... 16
7. START-UP PROCEDURES 19
A. COMPLETING THE INSTALLATION ...... 19
B. CONTROL DESCRIPTIONS ............. 22
C. ADJUSTMENT OF GAS PRESSURE
REGULATOR ....................... 22
D. CHECKING BURNER INPUT ............ 22
E. CHECK-OUT PROCEDURE ............. 23
8. TROUBLESHOOTING 24
A. SHUT-DOWN CAUSED BY PILOT OUTAGE,
PRESSURE SWITCH OR FLAME ROLL-OUT
SAFETY SHUT-OFF SWITCH ........... 24
B. TROUBLESHOOTING GUIDES .......... 24
C. MEASURING SUCTION PRESSURE ...... 24
9. MAINTENANCE 28
A. GENERAL .......................... 28
B. DAILY (WITH BOILER IN USE) .......... 28
C. WEEKLY (WITH BOILER IN USE) ........ 28
D. MONTHLY (WITH BOILER IN USE) ....... 28
E. ANNUALLY (BEFORE START OF HEATING
SEASON) .......................... 29
10. BOILER DIMENSIONS 8RATINGS 31
11. REPAIR PARTS 33
5. GAS PIPING 13

USING THIS MANUAL
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Follow the installation instructions provided in this
manual in the order shown. The order of these
instructions has been set in order to provide the installer
with a logical sequence of steps that will minimize
potential interferences and maximize sMet_ during
boiler installation.
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
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Throughout this manual you wil! see special attention
boxes intended to supplement the instructions and make
special notice of potential hazards These categories
mean, in the judgment of Peerless Heater Company:
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
Indicates a condition or hazard which will or can
cause minor personal injury or property damage,
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.

1. PREINSTALLATION
Read carefully study th_se instructions before beginning \vork
This boiler must be installed by a qualified contractor
The boiler warranty can be voided if the boiler is not instal}ed, maintained and serviced correctly.
The equipment must be installed in accordance with those installation requirements of the authority having
jurisdiction or, in the absence of such requirements, to the current edition of the National Fuel Gas Code, ANSI
Z223. f/NFPA 54.
Where required by the authority having jurisdiction, the installation must conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
Install boiler not less than 24" between the left side, top.
and front of the boiler and adjacent wall or other
appliance, when access is required for servicing.
The design of this boiler is certified for closet installation
with the following clearances:
1. 6" between right side, front and combustible
cotlstruction
2. ]2" between top of jacket and combustible
construction
3. 1"" between left side, rear and combustible
construction,
4. 2" between vent pipe and combustible construction.
5. 0" between wall thimble and combustible
construction
6. This boiler is design certified for use on combustible
flooring
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The following LP requirements from the Uniform
Mechanical Code, section 304.6, may be in effect in
your geographic area:
"Liquefied petToleum gas-burning appliances shall
not be installed in a pit. basement or similar location
where heavier-than air gas might collect. Appliances
so fueled shall not be installed in an above-grade
under-floor space or basement unless such location
is provided with an approved means for removal of
unburned gas."
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For new and existing installations, a Water Installation
Survey is available from Peerless Heater Company. The
survey will provide information on how a hot water
boiler works with your specific system and will provide
an overview of hot water system operation in general.
You can also use this survey to locate system problems
which will have to be corrected. To obtain copies of the
Water Installation Survey, contact your Peerless
representative.
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Do not install this boiler on carpeting. Boiler
installation on carpeting is a fire hazard. Install this
boiler on non-combustible flooring or use a
combustible floor pan to install this boiler on other
non-carpeted flooring.
Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring. Review
Limitations on vent pipe, vent terminal, and air inlet pipe
locations and ventilation air requirements in Section 4.
Liquefied Petroleum (LP) is heavier than air and may
collect or "pool" in a low area in the event of a leak
from defective equipment. This gas may then ignite,
resulting in a fire or explosion. See the instructions
below.

2. BOILER SET-UP
1 Provide a sound, level foundation Locate boiler as
near to the chimney or outside wal! as possible and
centralized with respect to the heating system
2 Locate boiler in front of installation position before
removing crate
4 Separate the wood shipping pallet ff()m the boiler
base by removing two (2) hold down bolts at each
end of the boiler base
5. Move boiler into final position.

3. WATER PIPING AND CONTROLS
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]. Size the supply and return to suit the system. A
typical piping arrangement is shown in Figure i.
Refer also to the Hydronics Institute Residential
Hydronic Heating Guide 2000 and the Peerless
Water Survey for additional guidance during water
piping installation.
2 Return Piping:
a. For boilers equipped with a factory-mounted
circulator, pipe the return to the inlet connection
of the circulator.
b For boilers equipped with a separate, unmounted
circulator, pipe the outlet connection of the
circulator to a tee, provided with a drain valve, at
the 1-1/4 NPT return tapping near the bottom of
the right section Pipe the return to the inlet
connection of the circulator
3
4.
5.
Supply Piping:
a Pipe the supply to the I I 2 NPT supply tapping
at the top of the boiler.
b Provide clearance to venting system
(see Section 4)
When system return water temperature will be below
130°F, pipe the boiler with a bypass arrangement to
blend the system return and hot supply to obtain at
least 130°F entering the boiler. For more information
on bypass piping, consult the Peerless Water Survey
If desired, install the circulator in the alternate
location shown in Figure I. Consult the Peerless
Water Survey for more information on circulator
location
AIR VENT_
AIR ELIMINATOR _
-- SAFETY
RELIEF
VALVE
)_-ALTERNATE
CIRCULATOR
LOCATION
SUPPLY
COLD
WA1ER
NLL
SHUTOFF
VALVE VALVE" REDUCING VALVE
VALVE
_-EXPANStON TANK
0
o
©
TO DRAIN RE_JRN
CIRCULATOR
DRAIN
VALVE
Figure 1: Supply and Return Piping

6. Install this boiler so that the gas ignition system
components are protected from water (dripping,
spraying, etc.) during appliance operation and
service (circulator replacement, condensate trap,
control replacements, etc.).
7. If this boiler and distribution system is used in
conjunction with a refrigeration system, pipe the
chilled medium in parallel with the boiler and install
the proper valve to prevent the chilled medium from
entering the boiler. A drawing illust_ating this hook-
up is provided in Figure 2.
8. When the boiler is connected to heating coils located
in air handling units where they may be exposed to
refrigerated air circulation, install flow control valves
or other automatic means to prevent gravity
circulation of the boiler water during the cooling
cycle.
9. If this boiler is installed above radiation level,
provide a low water cutoff device, either as a part of
the boiler or at the time of boiler installation.
WATER THREE WAY
VALVE
Figure 2: Parallel Hook-up with Water Chiller
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1. Locate safety relief valve and fittings in bag
assembly.
2. If air elimination is not required at the safety relief
valve tapping, install valve and piping as shown in
Figure 3.
3. For air elimination at the safety relief valve tapping,
install valve and piping as shown in Figure 4.
Pipe the discharge of safety relief valve to prevent
injury in the event of pressure relief. Pipe the
discharge to a drain. Provide piping that is the same
size as the safety relief valve outlet.
SAFETY
RELIEF
SUPPLY VALV E
NIPPLE
Figure 3: Safety Relief Valve Hook-Up Installation
with Air Elimination in System Piping
TO AIR
ELIMINATION
DEVICE
SUPPLY I-3/4" TEE
SAFETY r5/4" X 6"
RELIEF NIPPLE
VALVE_-._I_ _3/4" x2"
NIPPLE
Figure 4: Safety Relief Valve Hook-Up with
Air Elimination

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1. See Figures 5 and 6 for basic zoned system layouts.
2. Run each zone pipe down then up to zone to
prevent air accumulation in piping.
3. If required, provide means to isolate and drain each
zone separately.
TO SYSTEM
ZONE ZONE ZONE
5 2 1
I
ZONE
VALVES _z
I
_Z
J
_Z
CONNECT
TO
SUPPLY
FROM SYSTEM
ZONE ZONE ZONE
1 2 5
BALANCING
VALVES
CONNECT TO
RETURN
(CIRCULATOR INLET)
tl
Figure 5: Zone Piping with Zone Valves
TO SYSTEM
ZONE ZONE ZONE
5 2 !
FROM SYSTEM
ZONE ZONE ZONE
1 2 5
FLOW
CONTROL
VALVES
! I .11
CONNECT
TO
SUPPLY
ZONE
CONNECT TO
TAPPING
±
Figure 6: Zone Piping with Circulators
6

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1. Consult the tank manufacturer's instructions for
specific information relating to tank installation Size
the expansion tank for the required system volume
and capacity See Table c) in Section 10 for bof]¢,_
water capacity
2. Expansion tanks are available with built in fill valves
and check valves for reducing supply water pressure
and maintaining minimum system pressure. Check
the design features of the tank and provide valves as
necessary.
Refer back to Figure i for typical expansion tank piping.
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If the boiler is to be used in conjunction with an indirect-
fired water heater, refer to Figure 7 for typical piping
Follow the instructions provided by the water heater
manufacturer. Pipe the water heater as a separate zone.
For new or existing systems that must be freeze-
protected:
2.
3.
4+
Glycol in hydronic applications is specially
formulated for this purpose. It includes inhibitors
which prevent the glvcol from attacking metallic
system components Make certain that the system
fluid is checked for the correct gtycol concentration
and inhibitor level.
The antifreeze solution should be tested at least once
a year and as recommended by the antifreeze
manufacturer.
Antifreeze solutions expand more than water. For
example, a 80% by volume solution expands 4.8%
in volume for a temperature increase from 32°F to
180°F, while water expands 3% with the same
temperature rise. Allowance must be made for this
expansion in system design.
For more information, consult the Peerless Water
Installation Survey and the antifreeze manufacturer
SAFETy
RELIEF
VALVE
TO DRAIN
BALANCING
VALVE
OSYSTEM
{_ OCIRCULATOR
©DRAIN
VALV [
ZONE VALVES
INDIRECT-FIRED
WATER HEAER
SUPPLy
TO TANK
i/
BALANONG
VALVE
SUPPLY TO
SYSTEM
q RETURN FROM
SYSTEM
HOT DOMESTIC
_WATER SUPPLy
COLD DOMESTIC
WAIER SUPPLY
Figure 7: Typical Piping with Indirect-Fired Water Heater

4. VENTING
Install vent system in accordance with Part 7, Venting of
Equipment, National Fuel Gas Code, ANSI Z223,1/NFPA
54 or applicable provisions of the local building codes.
This vent system will operate with a positive
pressure in the vent pipe. Do not connect vent
connectors serving appliances vented by natural
draft into any portion of mechanical draft systems
operating under positive pressure.
Flue gases will condense as they exit the vent
termination. This condensate can freeze on exterior
building surfaces which may cause discoloration of
these surfaces.
1 Determine vent cap (terminal) location.
a Must be within the maximum and minimum vent
and air intake lengths shown in Tables 1 and 2.
b Maximum wall thickness for the 1%1/2" long
Peerless Wall Thimble (standard)is I 1-I/2".
Maximum wall thickness for the optional 28"
long thimble is 20".
CProvide 2" clearance between vent pipe and
combustible construction No clearance is
required between Thimble and combustible
construction
d. Provide 3 feet clearance above any forced air
inlet within I0 feet.
e. Provide 1 foot clearance below. 1 foot beside, or
1 foot above any door, window, or gravity air
inlet into any building
Provide 1 foot clearance between bottom of vent
terminal and ground level and normal snow
lines.
g.
h.
Provide 4 feet horizontal clearance from. and in
no case above or below, unless a 4 foot
horizontal distance is maintained, from electric
meters, gas meters, regulators and relief
equipment.
Do not locate vent terminal over public walkways
where condensate could createa nuisance or
hazard.
i.
j.
When adjacent to a public walkway, locate vent
terminal at least 7 feet above grade
Do not locate directly under roof overhangs to
prevent icicles from forming
2. Cut a 5-]/8" square hole in sidewall to allow Peerless
Wall Thimble to go through
3. Insert Thimble from inside wall with 4" diameter air
inlet connection facing down. Extend Thimble 3-I/2"
past outside wall surface. The cut-out opening of
thimble is pointed down.
COLLAR
INSIDE THIMBLE CAP
/
3" DIA CLAMP /
PEERLESS WALL THIMBLE
3" DIA CLAMP
!
OUTSIDE 3" DIA
VENT PIPE
VENT CAP
Figure 8: Peerless Wall Thimble

4.
5.
6.
7.
8.
Use a nqinimum 2-1/2" foot piece of 3" diameter
AL29 4C stainless steel vent pipe fol insertion
through Wall Thimble. See Vvnt Pipe section below
for vent pipe requirements
Slide Stainless Steei Collar over vent pipe and slide
3" diameter hose clamp and collar to vent pipe
Insert pipe with collar through Outside Vent Cap and
slide 3" diameter hose clamp and collar to vent pipe.
Leave at least 2" of vent pipe protruding beyond
face of Vent Cap and secure hose clamp and collar
to vent pipe.
Place Outside Vent Cap over Wall Thimble with air
openings in Vent Cap facing down. Secure Cap to
Thimble with #10 sheet metal screws
9. Place 3' diameter hose clamp over pipe protruding
through inside of Wall Thimble
10. Place Inside Thimble Cap and Collar onto Wall
Thimble. Access hose clamp through 4" diameter
collar on bottom of Thimble and secure hose clamp
over collar and vent pipe as per step 7 above.
1 1 Secure Inside Thimble cap to Wall Thimble with # 10
screws Seal Thimble Cap perimeter with silicone
12 Seal all openings between Wall and Thimble and
around the 3- diameter stainless steel vent pipe that
protrudes through hlside and outside of Wall
Thimble
13 Add any bracing that may be needed to support Wall
Thimble on inside of wall structure.
14, Secure Outside Vent Cap to exterior wall with four
#]0 sheet metal screws provided.
15 Attach Z-Flex #2SVSTPF03 terminal to protruding
vent pipe Refer to Figure 9. To attach to HEATFAB
pipe. insert into pipe end and fold over tabs to
secure Otherwise, silicone terminal to vent pipe.
VENT PIPE MALE END
(SEAL VENT _///
FOLLOWING VENT PEERLESS// /
MANUFACTURER'S WALL THIMBLE /, r_/
INSTRUCTIONS) _ _/
\
VEN
OR
_. TO 4" DIA I_j
FAN ADAPTER f SILICONE AIR BOX
CONNECTION _//'
/
OUTSIDE
2 _ MIN
f SILICONE
02-SVSTPXOS
AIR iNLET TERMIN ATION
OPENINGS
_EXTERIOR WALL
• ,,' 11
L
ALTERNATE LEFT /SIDE AIR BOX
CONNECTION
_- BOILER
--4" DIA AIR 80X
CONNECTION
Figure 9: Side Wall Venting System
9

1.
2.
3.
4.
5.
Vent pipe and air inlet terminations must be within
the maximum and minimum vent and air intake
lengths shown in Tables 1 and 2.
Vent pipe and air inlet pipe must terminate 12"
above expected snow lines Vent pipe must be a
minimum ]2" above and 12" horizontally from air
inlet pipe. See Figure 10
Attach a vent manufacturer's listed rain cap to both
the vent pipe and air inlet pipe.
Provide 2" clearance between vent pipe and
combustible construction. No clearance is required
between air inlet pipe and combustible construction
See vertical venting section in vent manufacturer's
instructions for recommendations for penetration
through roof.
Table 1 :
*Equivalent Length of 3" Diameter
Stainless Steel Vent Pipe
Boiler Model Minimum Vent Length _4aximum Vent Length
PSC-03 S feet 52 feet
PSC 04 8 feet 52 feet
PSC 05 8 feet 45 feet
PSC 06 8 feet 45 feet
Table 2:
*Equivalent Length of 4" Diameter
Aluminum/Galvanized Air Inlet Pipe
Boiler Model Minimum Length Maximum Length
PSC 03 12 feet 70 feet
PSC 04 12 feet 70 feet
PSC-05 12 feet 63 feet
PSC-06 12 fPet 63 feet
*Each 90 ° elbow equals 5 feet of equivalent length.
ATTACH VENT
}MANUFAC]URER S
12" LISTLD RAIN CAP
MIN
1
12"
MIN
3" DIA
VENT PIF
2" MIN
CLEARANCE
(_ FLOOR
FrRESTOP J
SLOPE UP 1/4"
PER FOOT"
HORIZONTAL
DRAIN
FA" []........_
ADAp]ER
_NT PIPE
AZAI_ TLR OR
BOFLERI_ LOCK BAND
ALTERNATE
LEFT SPDE
AIR INLET
PlPE
LOCATIO
_NLET PIPE
(USE GALVANIZED PIPE OR 'O' VENT
W4EN PENE_A]]NG FLOOR & ROOF)
DRAIN TRAP
(FORM 3" DIA
LOOP)
Figure 10: Vertical Venting System
10

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1.
2.
3.
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4,
For minimum and maximum vent pipe lengths see
Table 1
Use only 3" diameter Heat Fab Saf-T Vent, Z-Flex
Z V_nt, ProTech FasNSeaL or Flex L Star-34 Type
AL2.9-4C stainless steel vent pipe and fittings for
venting of flue gases from the boiler.
Connect vent pipe to boiler by spreading a I/4" bead
of high-temp GE 106 silicone or Silicones Unlimited
$45005 Red around the fan adapter. Attach proper
vent adapter to fan adapter (not applicable, Z-Flex)
Z-Flex vent pipe/fiRing connects directly to fan
adapter, secure to fan adapter using Z-Flex lock band.
See Figure 11.
Attach remaining pipe and fittings per each
manufacturer's vent instructions. Use only the silicone
recommended by vent pipe manufacturers. Maintain
proper clearance to combustible construction - see
Section 1, Preinstallation.
5. a,
b,
Side Wall Venting Only -Horizontal lengths of
the vent pipe shall slope down not less than 1/4"
per foot from the boiler to the vent terminal. If
vent pipe does slope back toward boiler, a
horizontal drain is required as described in 5B and
Figure 10.
Vertical Venting Only -A horizontal drain tee is
required. Slope horizontal lengths ._ not less
than I/4" per foot from the boiler to the vent
terminal. Install drain tee as shown in Figure I0.
Use silicone hose and form a 3" diameter loop
trap with a water seal. Pipe to drain per
local code.
6. Support horizontal l_,ngths of the vent system to
prevent sagging by use of metal strapping or
equivalent means. Locate supports at not more than
four (4) foot intervals
Vertical Venting Only - If there is no solid anchor
point in the system below the roof for supporting
vertical sections of the vent pipe fie Firestop
Support, etc.), a special vent support system will be
required. See vent manufacturer's instructions for
additional information
1.
2.
3.
4.
5.
6.
7.
For maximum air inlet pipe lengths see Table 2
Use only 4" diameter galvanized pipe or 4" diameter
flexible aluminum vent for supplying combustion air to
boiler inlet air box.
Boiler connection can be from either right or left side
of boiler jacket Determine which jacket side air inlet
piping is to be routed and remove the 4-1/2" jacket
knock out.
Attach a 4" diameter 90 degree elbow to top of air
box and connect air inlet piping.
Support air inlet piping using the same methods and
requirements as shown in the previous section for vent
pipe support.
Seal all connections using silicone.
To prevent condensation from forming on exposed
portions of Wall Thimble and 4" diameter air inlet
piping, wrap exposed aleas with insulation.
Z-FLEX
Z-VENT
MALE
Z-FLEX
Z VENT
LOCKING
BAND
SVSLBXO3
HEAT-FAB
SAF-T VENT
PIPE,
MALE END
HEAT-FAB
_ AF-T VENT
7301AMTK
VENT ADAPTER
PROTECH
FABNSEAL
VENT PIPE
MALE END'
FLEX-L
- STAR-34
VENT PIPE
MALE END'
PROTECH FLEX-L
I FASNSEAL _ STAR-54
FSA-PSC/DE 3 SRAPPA3
VENT ADAPTER VENT ADAPTER
1/4" BEAD 1/4" BEAD 1/4" BEAD !/4" BEAD
LREEB E LPER E B
AOA TEBAOAPTERAOA ' R ABA TER
Figure 1 1: Vent Connection to Boiler
11

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1.
2.
Provide air openings for adequate ventilation in
accordance with Section 5.3 Air for Combustion
and Ventilation, of the National F_el Gas Code,
ANSI Z223 INFPA 54. ol applicable provisions of
the local building codes Ventilation is required to
prevent overheating of the controls which greatly
reduces the life of the controls Air inlet piping
provides only combustion air to the boiler See
Section D for Air Inlet Piping requirements
Definition:
Unconfined Space: a space whose volume is not
less than fifty (50) cubic feet per I000 Btu/hr of the
total input rating of all appliances installed in that
space. Rooms communicating directly with the space
in which the appliances are installed, through
openings not furnished with doors, are considered
part of the unconfined space
3. Appliances Located in Unconfined Spaces:
For installations in unconfined spaces, the supply of
air for ventilation can usually be considered
adequate.
Appliances Located in Confined Spaces:
Provide two permanent openings communicating
directly with an additional room or rooms of sufficient
volume so that the combined volume of all spaces meets
the criteria for an unconfined space Use the total input
of all gas utilization equipment installed in the combined
space in making this determination
Size each opening with a minimum free area of one
square inch per I000 Btu/hr. of the total rating of all gas
utilization equipment in the confined space, but not less
than 100 square inches Begin with one opening 12
inches from the top, and begin the other opening within
12 inches of the bottom of the enclosure See Figure 12.
Provide air openings with minimum dimensions not less
than three (3) inches.
TWO AIR OPENINGS:
Minimum
Free Area Each -
1 in 2per 1000 Btuh
at Least 100 in 2
BOILER
12" max
3" min
,L
I 3" min
12" max
Figure 12: Air Openings
At the time of removal of an existing boiler, follow these
steps with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation:
a Seal any unused openings in the common venting
system
b. Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.
C. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on any clothes dryers and any
appliance not connected to common venting system.
Turn on any exhaust fans. such as range hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
fireplace dampers.
d. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame
of a match or candle, or smoke from a cigarette,
cigar, or pipe
After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans. fireplace dampers and
any other gas burning appliance to their previous
conditions of use.
g. Any improper operation of the common venting
system should be corrected so that the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54. When resizing any portion of the
common venting system, the common venting
system should be resized to approach minimum size
as determined using the appropriate tables in Part 11
of the National Fuel Gas Code, ANSI Z223.1/NFPA
54.
12

--m
5. GAS PIPING
I Size and install the gas supply piping properly in
order to provide a supply of gas sufficient to meet
the maximum demand without undue loss of
pressure between the meter and the boile_
2 Determine the volume of gas to be provided to the
boiler in cubic feet per hour. To obtain this value,
divide the Btu per hour rating (on the boiler rating
plate) by the heating value of the gas in Btu per
cubic feet. Obtain the heating value of the gas from
the gas supplien As an alternative, use Table 3 or 4
on the next page to obtain the volume of gas to be
provided to the boilen
3 Use the value obtained above as the basis for piping
sizing. Size the gas piping in accordance with Table
5. Consult the National Fuel Gas Code for other
sizing options.
4. Locate the drop pipe adjacent to, but not in front of
the boilen
5.
6.
Install a sediment trap. See Figure 13. Locate a tee
in the drop pipe at same elevation as the gas inlet
connection to the boiler. Extend the drop pipe to a
pipe cap.
Install a ground joint union ahead of the gas control
assembly to permit servicing of the control. Some
local codes require an additional service valve when
using the combination gas controls. If your code
requires such a valve, a suggested location is shown
in Figure 13.
Use a pipe joint sealing compound that is resistant to
the action of liquefied petroleum gas. A non-resistant
compound may lose sealing ability in the presence of
this gas, resulting in a gas leak and fire or explosion
potential.
7. Check piping for leaks prior to placing the boiler in
operation.
Use an approved gas detector, a non-corrosive leak
detection fluid or other leak detection method. If
leaks are found, turn off all gas flow and repair as
necessa W,
I _ SERVICE
VALVE
_--_ JACKET
G.J. UNION
I _ SEDIMENT TRAP
_ FLOOR LINE
Figure 13: Gas Connection to Boiler
8, Disconnect the boiler and its individual shut off valve
from the gas supply piping system during any
pressure testing of that system at test pressure in
excess of 1/2 psig (3.5 kPa).
Do not subject the gas valve to more than 1/2 psi
pressure. Doing so may damage the valve.
Isolate the boiler from the gas supply piping system
by closing its individual service valve during any
pressure testing of the gas supply piping system at
test pressure equal to or less than 1/2 psig (35 kPa)
9. Minimum permissible supply pressure for purposes of
input adjustment (Inches Water Column):
Natura! Gas 5.0"
LP Gas l 1.0"
Maximum permissible supply pressure to the boiler
(Inches Water Column):
Natural Gas 13.5"
LP Gas 13.5"
When checking for leaks, do not use matches,
source of ignition. This can ignite a gas leak,
resulting in fire or explosion.
13

KgFgKEc]
Table 3: Natural Gas
Input
Model (Cubic Ft!Hr)
PSC 03 70
PSC 04 105
PSC-05 140
PSC 06 175
Based on I000 Btu'Cubic Ft
Table 4: LP Gas
Input
Model (Cubic Ft!Hr)
PSC 03 28
PSC 04 42
PSC-05 56
PSC 06 70
Based on 2500 BtuiCubic Ft
Table 5: Pipe Capacity
Capacity of pipe of different diameters and lengths in cu. ft. per
hour with pressure drop of 03 in and specific gravity of 0 60
No allowance for an ordinary number of fittings is required
Pipe _14# I" 1I/4# 1112"
Length
Feet Pipe Pipe Pipe Pipe
10 278 520 1,050 1.600
20 190 350 730 I.I00
30 152 285 590 890
40 130 245 500 760
50 115 215 440 670
60 105 195 400 610
Multipliers to be used with the above table when the
specific gravity of the gas is other than 0.60:
Specific Gravity 05 055 0.60 065 0.70
Multiplier 110 1 04 100 0962 0926
14

6. ELECTRICAL
Install all electrical wiring in accordance with the National Electrical Code and local requirements
This unit when installed must be electrically grounded in accordance with the requirements of the authority
having jurisdiction or, in the absence of such requirements, with the current edition of the National Electrical
Code, ANSI/NFPA 70.
r_'l WJl;i h_[€
]. See Figure 14 for location of wiring and controls.
Use Figure 15 to connect the boiler to a power
supply and to connect components to the boiler,
2. Connect the boiler by a separate, permanently live
electrical supply line with a fused switch.
3. Adjust the thermostat heat anticipator to 0.2 Amp.
:]1 W[e)L_I:IB]k"5"_"]ll:lL'JI_IiIil:|l_[C
See Figure 17 for typical wiring with zone valves. See
Figure 18 for typical wiring with zone circulators. When
wiring a zoned heating system, follow all applicable
codes, ordinances and regulations
I. For proper location of controls and accessories refer
to Figure 14
2. See the attached control sheets for specific details
regarding the installation of the various controls.
3. This boiler is supplied with safety devices in addition
to the limit. For a description of these devices and
how they work to ensure the safe operation of the
boiler, see Section 7.
4. If the circulator is mounted in the supply piping,
provide longer wiring harness as required.
Do not power zone valves directly from the boiler
transformer. Doing so will greatly reduce the life of
the transformer. Use a separate transformer sized to
handle the total of all zone valve electrical loads.
TO LINE VOLTAGE THERMOSTAT
POWER SUPPLY_
LIMIT CONTROL
PRESSURE
GAUGE
PRESSURE
SWITCH
GAS
ER RELAY
CENTER
RELAY
FLAME ROLLOUT SWITCH
Figure 14: Wiring, Controls and Safety Devices
15

_)T[S:l) ALL _IRINI_ MU_T COIdPLy U_T]@AP_IJ_ I_0_ _AN_ _#ID REQI3LAT_D{_
_, IT MUST _ r_':t_ClJ_ _1_ _E _ _.
_:_IL
P_MARY W
T
(PILOT
-- l_ov _I_NG _NG )
24V W_
Figure 15: Wiring and Connection Diagram
[)]II _::[.llJ ::10[_] : [el :lt]'] :_'_:_1i [ill _
1. Thermostat calls for heat, energizes R8285 Control
Relay (CR).
2. R8285 Control Relay (CR) energizes circulaton
3. Limit senses boiler water temperature. Prevents
boiler operation until water temperature falls
approximately 15°F below the cut-out temperature.
4. Limit energizes Fan and R4222 Isolation Relay (IR).
5. Negative pressure induced by fan switches Pressure
Switch, continuing power through c[osed R4222
contacts (IR 1) and flame roll-out switch.
6. Gas valve energizes.
a. Igniter on.
b. Pilot gas on, igniting pilot.
7 Pilot flame detected.
a. Igniter off.
b. Main gas on, igniting main burners.
Note: If pilot flame is not detected within 30 seconds,
the igniter is turned off for 30 seconds, and then turned
back on for another 30 seconds. If the pilot remains
undetected in this second ignition period, the igniter and
pilot are turned off for 5 minutes. The sequence then
resumes at Step 6a.
8. Call for heat ends.
a. Pilot and main gas off, extinguishing pilot and
main burners.
b. Fan and circulator off.
16

START
TRIAL
FOR
IGNITION
MAIN
BURNER
OPERATION
IAPPLY 24 VAC ITO APPLIANCE
LTBE°M°STATJ
CALLS FOR HEAT
"<
_r
IFLAME SIGNAL _• WAlT FOR FLAME SIGNAL
DETECTED? I Y l TO DISAPPEAR
•PILOT VALVE/IGNITER
_NO REMAIN OFF
I NO
INTERNAL CHECK OKAY? I
I
J_YES
• PILOT VALVE OPENS
• IGNITER POWERED
PILOTLIGHTSAND FLAME NO •
I D RIN PILOT VALVE CLOSES
YES
• IGNITER OFF J
•MAIN VALVE OPENS
END
ILAME SIGNAL LOST?
ITHERMOSTAT CALL FOR I
HEAT ENDS
•MAIN AND PILOT VALVES CLOSE
t
•MAIN AND PILOT VALVES CLOSE I
I
FLAME LOST MORE THAN I NO
B
FIVE TIMES IN ONE p--
CALL FOR HEAT?
J IYESl
IGNITER WILL TURN OFF ABOUT 30 SECONDS INTO THE TRIAL FOR IGNITION,
IF THE PILOT FLAME HAS NOT LIT, IT WILL TURN BACK ON FOR THE FINAL
30 SECONDS OF THE 90 SECOND TRIAL FOR IGNITION. THE PILOT VALVE
WILL BE ENERGIZED DURING THE ENTIRE TRIAL FOR IGNITION. THIS IS
NORMAL OPERATION FOR THIS GAS IGNITION SYSTEM.
IIVE-MINUTE RETRY 1DELAY
Figure 16: Ignition System Operating Sequence
17