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PEERLESS Series 63 - User Manual

PEERLESS Series 63
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63/64
™
Boilers
Series
Gas
Installation,
Operation &
Maintenance
Manual

Table of Contents

Questions and Answers

  • C
    Christian ValdezAug 20, 2025
    Why does the pilot light keep going out on my PEERLESS Boiler?
    • B
      blakerodneyAug 20, 2025
      If the pilot light on your PEERLESS Boiler keeps going out, several factors could be responsible. It might be due to a defective thermocouple or ignition control, in which case replacement is the suggested solution. A heavy draft blowing across the pilot could also be the culprit; redirecting air movement or eliminating the draft may resolve the issue. Other potential causes include a plugged pilot orifice (replace the orifice), a lack of gas (check the manual pilot valve, main gas shut-off valve, and meter valve, or consult your gas company), or a defective thermopilot switch (replace it).
  • S
    stephenshawAug 22, 2025
    What to do if main gas valve will not open on PEERLESS Series 63 (Spark Ignited Pilot)?
    • E
      Erica CampbellAug 22, 2025
      If the main gas valve on your spark ignited pilot PEERLESS Boiler isn't opening, several issues could be at play. First, check the power source with a meter and inspect the fuses. A defective gas valve or ignition control could also be the cause, requiring replacement. Additionally, a low water level in the boiler or system might be triggering the low water cut-off; check for leaks and the feeder. Finally, examine the high and low gas pressure switches, if provided, ensuring the switch settings and manifold gas pressure are correct.
  • J
    Justin ClarkeAug 25, 2025
    What to do if main gas valve will not open on PEERLESS Boiler (Standing Pilot)?
    • B
      Brad AndersenAug 25, 2025
      If the main gas valve on your standing pilot PEERLESS Boiler isn't opening, several issues could be responsible. First, check the power source with a meter and inspect the fuses. A defective gas valve, thermopilot switch, or thermocouple might also be the cause, requiring replacement. If the pilot is out, try relighting it, but be aware there may be a defective pilot valve or relay. Also, check for low water levels in the boiler or system, which could cause the low water cut-off to function; inspect for leaks and check the feeder. Finally, examine the high and low gas pressure switches, if provided, ensuring the switch settings and inlet gas pressure are correct.
  • C
    Christina BrownAug 30, 2025
    What to do if main gas valve opens but no gas flows on PEERLESS Boiler?
    • L
      Leah KiddAug 30, 2025
      If the main gas valve on your PEERLESS Boiler opens but no gas flows, ensure that the manual valve at the gas train and the manual valve at the meter are open. Also, check if the test firing valve, if provided, is closed and open it.
  • R
    Ronald TurnerSep 1, 2025
    Why is my PEERLESS Series 63 system overfilling?
    • S
      Stephen JohnsonSep 1, 2025
      If your PEERLESS Boiler system is overfilling or experiencing excessive make-up water, leaks in the system may be the cause, requiring repair or piping replacement. The expansion tank's charge pressure (if it's a diaphragm or bladder type) might be incorrect, so check and correct it. An air compression tank could be waterlogged, or the diaphragm or bladder in the expansion tank may be defective, necessitating tank replacement. Also, the fill valve might not be working correctly or could be set for too high a cold fill pressure, causing the relief valve to weep; check and replace the fill valve if necessary.
  • Y
    youngwilliamSep 3, 2025
    Why is my PEERLESS Series 63 Boiler (steam) system overfilling or flooding?
    • H
      henryleeSep 3, 2025
      If your PEERLESS Boiler (steam) is overfilling or flooding, it could be due to the new boiler's water content being smaller than the old one; in this case, install a boiler feed system with a receiver tank large enough for condensate. Another possibility is that the boiler water feed rate or pump rate is too fast, causing the water level to collapse; reduce the feed rate. Poor water quality leading to foaming, priming, or surging can also cause this issue, so cleaning the boiler is recommended.
  • P
    patrickgainesSep 5, 2025
    How to fix water hammer on start-up on PEERLESS Series 63 Boiler (Steam Boilers)?
    • J
      John CollinsSep 5, 2025
      If you're experiencing water hammer on start-up with your PEERLESS steam boiler, it could be due to sags in the steam piping or insufficient pitch, requiring correction of the piping condition. Concentric reducers causing condensate pooling could also be the culprit, necessitating piping correction. A drip trap that has failed closed should be replaced. If dry returns are wetted due to a new boiler water line being higher than the old boiler, correct the piping or install a feed system and traps. The absence of a drip line on the back side of a back-pitched motorized valve requires installing a drip line and trap. Finally, uninsulated steam piping can cause excessive condensate loads, so insulate the steam pipes.
  • N
    Nichole ConleySep 9, 2025
    How to fix water hammer on shut-down on PEERLESS Series 63 (Steam Boilers)?
    • R
      Russell GarciaSep 9, 2025
      If you're experiencing water hammer on shut-down with your PEERLESS steam boiler, a close nipple on the Hartford Loop that is too high may be the cause; repipe it to be 2" to 4" (5cm to 10cm) below the water line. Additionally, uninsulated steam piping in the boiler room, while the system piping is insulated, can cause a vacuum condition on shut-down, so insulate the steam pipes.
  • T
    Tonya ParsonsSep 12, 2025
    What causes excessive water level bounce in PEERLESS Boiler (Steam Boilers)?
    • M
      Megan RomeroSep 12, 2025
      If your PEERLESS Boiler (steam) has excessive water level bounce, it could be due to poor water quality causing foaming and surging, so cleaning the boiler is recommended. Incorrect near-boiler piping, such as undersized or incorrectly placed risers, can also cause this issue, so pipe per the manual. Another possibility is that the boiler water feed rate or pump rate is too fast, so reduce the feed rate.
  • A
    Ana KruegerSep 13, 2025
    Why is there no heat or poor heat distribution in the building with my PEERLESS Series 63 (Steam Boilers)?
    • B
      Brianna KennedySep 13, 2025
      If there is no heat or poor heat distribution in the building with your PEERLESS Boiler (steam), the main vents may not be working, and you should replace them, repiping away from the end of lines if needed. Drip traps that have failed closed should be replaced. Radiator traps that have failed open, allowing pressurization of the returns, should also be replaced. Water legs or back slope in return lines to the receiver tank, preventing air from venting out the receiver vent, require piping correction. Finally, if the boiler pressure is too high, causing air vents to lock up or blowing water loop seals, reduce the operating pressure.

Summary

Using This Manual

A. Instruction Manuals

Explains the manual's structure and division into four basic sections.

B. Special Attention Boxes

Details the types of hazard warnings used throughout the manual.

Preinstallation

A. General

Provides general information and requirements for boiler installation.

B. Codes & Regulations

Outlines codes and standards that must be followed during installation.

C. Accessibility Clearances

Recommends clearances for servicing the boiler and its components.

D. Clearances From Combustible Construction

Specifies required clearances from combustible materials for safe installation.

E. Air for Combustion and Ventilation

Details requirements for providing adequate combustion and ventilation air.

F. Installation Survey

Suggests conducting surveys for new and existing installations for planning.

G. Planning the Layout

Advises on preparing sketches and notes for installation layout planning.

Boiler Placement & Assembly

A. Packaged Boiler

Instructions for handling and placing packaged boilers.

B. Knockdown Boilers - Split Block Assembly Models 64-07 to 64-12

Step-by-step guide for assembling split block knockdown boilers.

C. Knockdown Boilers: Assembled Blocks

Instructions for assembling pre-assembled blocks of knockdown boilers.

D. Knockdown Boilers: Control & Manifold Assembly

Guidance on assembling the control and manifold components.

E. Knockdown Boilers: Flue Collector Assembly

Steps for assembling the flue collector and related parts.

F. Knockdown Boiler: Hydrostatic Testing

Procedure for performing a hydrostatic test to check for leaks.

G. Knockdown Boiler: Assemble Jacket

Instructions for attaching the boiler jacket panels.

Venting

A. Chimney or Vent

Guidelines for inspecting and connecting to chimneys or vents.

B. Automatic Vent Damper Installation - General

Instructions for installing automatic vent dampers.

C. Boiler Removal From Common Venting System

Procedure for safely removing a boiler from a shared venting system.

Boiler Piping

A. Water Boiler Piping - Single Boiler

Details on piping a single water boiler system.

B. Water Boiler Piping - Multiple Boilers

Guidance for piping multiple water boilers.

C. Steam Boiler Piping - Single Boilers

Details on piping a single steam boiler system.

D. Steam Boiler Indirect Water Heater Piping

Instructions for piping steam boilers with indirect water heaters.

E. Steam Boiler Piping - Multiple Boilers

Guidance for piping multiple steam boilers.

Fuel Piping

A. Installation

Requirements for installing gas fuel piping.

B. Operation

Operational considerations for fuel piping systems.

Controls & Trim

A. Water Boiler Controls & Trim

Installation and function of controls for water boilers.

B. Steam Boiler Controls & Trim

Installation and function of controls for steam boilers.

Electrical

A. Connect Supply Wiring

Guidelines for connecting the main electrical supply to the boiler.

B. Mount Remaining Controls

Instructions for mounting various control components.

C. Install Control Wiring

Steps for wiring the control system components.

D. Wiring Diagram Index

A guide to finding specific wiring diagrams for different models.

Boiler Operation

A. System Inspection

Pre-operation checks for the boiler and system.

B1. Fill the Boiler (Water Boilers)

Procedure for filling water boilers and venting air.

B2. Fill the Boiler (Steam Boilers)

Procedure for filling steam boilers to the correct water line.

C. Study Lighting Instructions

Emphasizes reviewing lighting instructions before starting the boiler.

D. Run Pilot Check-Out

Steps to verify the pilot ignition system is functioning correctly.

E. Check Main Burner System

Verifies main burner ignition, gas pressure, and flame characteristics.

F. Check Boiler Controls

Tests the functionality of limit and safety controls.

G. Purge Air From the System (Water Boilers Only)

Instructions for removing air from water heating systems.

H. Check the System Pressure (Water Boilers Only)

Monitors system pressure during operation for anomalies.

I. Clean the Boiler (Steam Boilers Only)

Procedure for cleaning steam boilers to remove impurities.

J. To Shut Down the Boiler

Steps for safely shutting down the boiler for service or storage.

Maintenance

A. General

General guidelines and precautions for boiler maintenance.

B. Daily Maintenance (With Boiler Operating)

Routine daily checks to ensure proper boiler operation.

C. Weekly Maintenance (With Boiler Operating)

Weekly checks, including flushing low-water cut-offs.

D. Monthly Maintenance (With Boiler Operating)

Monthly checks, including safety relief valve and limit controls.

E. Annual Maintenance (Before Start of Heating Season)

Comprehensive annual inspection and cleaning for optimal performance.

F. As Required Maintenance

Maintenance tasks performed based on system conditions or recommendations.

Troubleshooting - Service Tips

Boiler Dimensions & Ratings

Repair Parts

PEERLESS Series 63 Specifications

General IconGeneral
BrandPEERLESS
ModelSeries 63
CategoryBoiler
LanguageEnglish

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