PB Heat Gas Boiler manual

P innacle ® Gas Boilers P eerless ® Stainless Steel Installation, Operation & Maintenance Manual – Do not store or use gasoline or other flammable v apors and liquids in the vicinity of this or any other appliance . – WHA T T O DO IF Y OU SMELL GAS • Do not tr y to light any appliance . • Do not touch any electrical s witch; do not us[...]

USING THIS MANUAL 1 A . INST ALLA TION SEQUENCE . . . . . . . . . . . . .1 B . SPECIAL A TTENTION BO XES . . . . . . . . . . . .1 1. PREINST ALLA TION 2 A . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 B . CODES & REGULA TIONS . . . . . . . . . . . . . . .2 C. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2 D . COMBUSTION AN[...]

1 A. INST ALLA TION SEQUENCE F ollow 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 safety during boiler installation. B. SPECIAL A TTENTION BO XES Through[...]

2 A. GENERAL 1. Pinnacle boilers ar e supplied completely assembled as packaged boilers. The package should be inspected for damage upon receipt and any damage to the unit should be reported to the shipping company and wholesaler . This boiler should be stored in a clean, dry area. 2. Carefully r ead these instructions and be sure to understand the[...]

3 PREINST ALLA TION Do not install this boiler where gasoline or other flammable liquids or v apors are stored or are in use . W ARNING This boiler is certified as an indoor appliance . Do not install this boiler outdoors or locate where it will be exposed to freezing temperatures. W ARNING Figure 1.1: Accessibility Clearances – Floor Standing Un[...]

4 A. GENERAL 1. Pinnacle boilers ar e to be installed in an area with a floor drain or in a suitable drain pan. Do not install any boiler where leaks or r elief valve discharge will cause proper ty damage. 2. This boiler is not intended to suppor t e xter nal piping. All venting and other piping should be suppor ted independently of the boiler . 3.[...]

A. GENERAL 1. The water supply and return piping of this appliance are to be sized according to system r equirements. Do not use piping smaller than the boiler connections. 2. In hydronic systems where sediment may e xist, install a strainer device in the boiler return piping to prevent large particles and pipe scale from entering the boiler heat e[...]

6 9. P ressur e Relief V alve: The boiler pressur e relief valve is factory installed into the right side boiler manifold (inside the jacket). Pipe the discharge of the r elief valve to within 12" of the floor and close to a floor drain. Provide piping that is the same size or larger than the relief valve outlet. 10. Circulator: The boiler cir[...]

7 c. The required flow rate can be calculated based on the design temperature differ ence from the return to the supply of the boiler . F or a PI- T80 with a design temperature differ ence of 20°F the calculation is as follows: d. T able 3.3 shows the pressure drop (in feet of water) for a flow rate which gives a 20°F temperature differ ence for [...]

8 D . SYSTEM PIPING 1. Figur e 3.3 shows a single boiler with two zones. In this application, the P eerless P artner indirect water heater and the single heating zone requir e similar water temperature. 2. Figur e 3.4 shows an additional zone in which baseboard radiation is the heat load. This zone also requir es water temperatures similar to the i[...]

9 Figure 3.3: One Boiler , Primary/Secondary with T wo Zones (Zone Circulator) WA TER PIPING AND CONTROLS[...]

10 Figure 3.4: One Boiler , Primary/Secondary with Three Zones (Zone Circulator) WA TER PIPING AND CONTROLS[...]

11 Figure 3.5: T wo Boilers, Primary/Secondary with F our Zones (Zone Circulator) WA TER PIPING AND CONTROLS[...]

12 Figure 3.6: Three Boilers, P rimary/Secondary with Five Zones (Zone Circulator) WA TER PIPING AND CONTROLS[...]

13 WA TER PIPING AND CONTROLS Figure 3.7: Three Boilers, P rimary/Secondary with Four Zones (Zone V alves)[...]

14 Antifreeze solutions e xpand more than water . F or example, a 50% by volume solution e xpands 4.8% for a 148°F temperature rise while water e xpands about 3% for the same temperature incr ease. Allowance for this expansion must be considered in sizing e xpansion tanks and related components. 4. The flow rate in systems utilizing glycol solutio[...]

15 WA TER PIPING AND CONTROLS Figure 3.8: Boiler in conjunction with a Chilled W ater System Figure 3.9: Boiler Connected to a Heating Coil in a F orced Air System[...]

16 GAS PIPING A . GENERAL 1. All fuel piping to the boiler is to be in accordance with local codes. In the absence of local regulations refer to the National F uel Gas Code, ANSI Z223.1/NFP A 54. 2. Size and install piping to provide a supply of gas sufficient to meet the maximum demand of all appliances supplied by the piping. B. FUEL LINE SIZING [...]

17 2. Install a sediment trap as shown in Figur e 4.1. Be sure to allow clearance from the floor for r emoval of the pipe cap. 3. Install a ground joint union between the sediment trap and the boiler to allow ser vice of the appliance. 4. Install a ser vice valve as shown in F igure 4.1 to allow the gas supply to be interrupted for ser vice. 5. Mai[...]

18 3. T o check the gas supply pr essure on the gas valve: a. T urn off the power at the ser vice switch. b. T ur n off the gas shutoff valve. c. Using a flat screwdriver , tur n the screw inside the inlet pressur e tap fitting (see figure 4.4 and 4.5) one turn counterclockwise. d. Attach the manometer tube to the pr essure tap fitting. e. Open the[...]

19 A. GENERAL 1. Install the boiler venting system in accordance with these instructions and with the National F uel Gas Code, ANSI Z223.1/NFP A 54, CAN/CGA B149, and/or applicable provisions of local building codes. 2. This boiler is a direct vent appliance and is listed as a Category IV appliance with Under writers L aboratories, Inc. B. APPRO VE[...]

20 VENTING , INLET AIR AND CONDENSA TE D . EXHA UST VENT AND INT AKE AIR PIPE SIZING 1. F or the PI- T50 and PI- T80 Boilers the e xhaust vent and air intake pipes should be 2" Schedule 40 or 80. 2. F or the PI-80, PI-140, PI-199 the exhaust vent and air intake pipes should be 3" Schedule 40 or 80. 3. The total combined equivalent length [...]

21 4. The minimum combined equivalent length is 16 equivalent feet. 5. The maximum combined equivalent length can be e xtended by increasing the diameter of the vent pipe. However , the transitions should begin a minimum of 15 equivalent feet from the boiler . a. T ransitions should always be made in ver tical sections of pipe to prevent the conden[...]

22 VENTING , INLET AIR AND CONDENSA TE Figure 5.3: PI-80, PI-140, and PI-199 Sidewall V enting with 3" Pipe (Exhaust T ermination at Higher Elevation than Air Intak e). Figure 5.5: PI-80, PI-140, PI-199 Sidewall V enting with 3" P ipe (Air Intake and Exhaust on the same Elevation). Figure 5.4: PI- T50 & PI- T80 Sidewall V enting with [...]

23 VENTING , INLET AIR AND CONDENSA TE Figure 5.7: PI-80, PI-140, PI-199 Sidewall V enting with 3" P ipe (3" V ent Kit). Figure 5.9: PI-80, PI-140, PI-199 Sidewall V enting with 3" P ipe (Concentric V ent Kit). Figure 5.10: PI- T50 & PI- T80 Sidewall V enting with 2" P ipe (Concentric V ent Kit). All exhaust vent pipes m ust[...]

24 VENTING , INLET AIR AND CONDENSA TE Figure 5.11: PI-80, PI-140, PI-199 V ertical V enting with 3" Pipe. Figure 5.13: PI-80, PI-140, PI-199 V ertical V enting with 3" Pipe (Concentric V ent Kit). Figure 5.12: PI- T50 & PI- T80 V ertical V enting with 2" P ipe. Figure 5.14: PI- T50 & PI- T80 V ertical V enting with 2" P[...]

25 F . EXHAUST T APPING FOR VENT SAMPLE T o obtain a combustion sample a hole must be drilled in the e xhaust vent pipe just above the first elbow at the outlet of the boiler . a. Drill a 21/64" diameter hole in the vent pipe just above the first elbow . b. T ap the hole with a 1/8" NPT P ipe T ap. c. T ake combustion samples through the [...]

26 ELECTRICAL Install all electrical wiring in accordance with the National Electrical Code, ANSI/NFP A 70, and local requir ements. A. WIRING 1. Refer to Figur es 6.1 for connecting the power supply to the boiler . 2. Connect boiler to a 110 volt, single phase, 60 hertz electrical supply line with a fused disconnect switch. The boiler is fused for[...]

27 ELECTRICAL e) The main gas valve is then energized to allow gas to mix with the combustion air . f) If the main flame is not detected in 5 seconds, the gas valve closes and the combustion fan goes into post-purge. Other wise, the combustion fan stays at the ignition speed for the length of the flame stabilization period. (10 to 25 seconds). g) A[...]

28 C. SAFETY INTERL OCKS 1. Low W ater Pr essure Limit Switch: This boiler is intended to operate at pressur es exceeding 10 psig. If the water pressur e drops to below 10 psig, there is a water pressur e limit switch that inter rupts boiler operation and displays the message "PR0" on the interface unit. The combustion air fan completes a[...]

ELECTRICAL 4. Error Codes: The LED Display will display error codes if the boiler is in a temporary fault condition. T able 8.1 shows Error Codes and descriptions. In some cases, if the temporary fault is not cor rected within 60 seconds the controller will go into a F ault Code. 5. F ault Codes: A F ault Code indicates the controller is locked-out[...]

30 A. COMPLETING THE INST ALLA TION 1. Confirm that all water , gas and electricity are turned off. 2. V erify that water piping, venting, gas piping and electrical wiring and components are installed properly and where applicable in accordance with manufacturers' instructions. Be sur e that the boiler is installed in accordance with this manu[...]

31 B. LIGHTING AND OPERA TING PROCEDURES ST ART -UP PROCEDURES FOR YOUR SAFETY READ BEFORE OPERATING OPERATING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE A. This appliance does not ha ve a pilot. It is equipped with an ignition de vice which automatically lights the burner . Do not try to light the burner by hand. B. BEFORE OPERA TING smell all arou[...]

32 C. CHECK - OUT PROCEDURE 1. After star ting the boiler , be cer tain that all controls are working properly . Check to be sure that the boiler will shut down when the water temperature reaches the control board set point. 2. T o check operation of the ignition system safety shut- off features: a) T urn off gas supply . b) Set thermostat or contr[...]

33 A. BOILER ERROR 1. When an error condition occurs the controller will display an error code on the display module. 2. These error codes and several suggested cor rective actions are included in T able 8.1. 3. In the case of E00, E13, and E14 this error , if uncorrected, will go into a fault condition as described is P aragraph B. B. BOILER F AUL[...]

34 F ault Code Description Corrective Action F00 High Limit Exceeded. 1. Check circulation pump operation. 2. Assure that ther e is adequate flow through the boiler by accessing the status menu and confirming that there is less than a 50°F rise from the return thermistor to the supply thermistor . 3. If gray thermostat wires are being used, discon[...]

35 A. GENERAL (WITH BOILER IN USE) General boiler obser vation can be perfor med by the owner . If any potential problems are found, a qualified installer or ser vice technician/agency must be notified. 1. Remove any combustible materials, gasoline and other flammable liquids and substances that generate flammable vapors from the area wher e the bo[...]

36 d. Disconnect the white, red, blue, and black connection from the Mole x on the combustion blower . (Refer to Control W iring Schematic, Figure 6.3.) This will cause the fan to run at 100% which will then blow out any sediment that has accumulated in the condensate line. (This process should only take a few minutes.) e. The unit should now be re[...]

37 e. Reset thermostats (IMPORT ANT : MAKE SURE EXHAUST VENT IS NO L ONGER BL OCKED!) f. T urn the Pinnacle back on** and observe condensate flow . g. Reconnect the condensate piping to the outside connection. **NOTE: When firing the boiler the first few times you may experience some fluttering of the gas burner that may result in a flame lockout. [...]

38 A. BOILER DIMENSIONS 1. Figur e 10.1 shows the dimensions of the PI- T50 and PI- T80. 10. BOILER DIMENSIONS & RA TINGS BOILER DIMENSIONS & RA TINGS Figure 10.1: PI- T50/PI- T80 Dimensions[...]

39 2. Figur e 10.2 shows the dimensions of the PI-80, PI-140 and PI-199. BOILER DIMENSIONS & RA TINGS Figure 10.2: PI-80/PI-140/PI-199 Dimensions[...]

40 Boiler Model Input Btu/hr DOE Heating Capacity³ Btu/hr Net I=B=R Rating¹ ’ ² Btu/hr Seasonal Efficiency³ AFUE % Shipping W eight Lbs. PI- T50 18,000 to 50,000 16,000 to 46,000 40,000 92 58 PI- T80 19,000 to 80,000 17,000 to 74,000 64,000 92 58 PI-80 27,000 to 80,000 25,000 to 74,000 64,000 92 75 PI-140 46,000 to 140,000 43,000 to 129,000 1[...]

41 REP AIR P ARTS 11. REP AIR P ARTS[...]

42 REP AIR P ARTS[...]

43 A. ADV ANT AGES OF THE P125 CONTROL BOARD 1. T emperature displays in F ahrenheit or Celsius. 2. Improved troubleshooting by status display of: a. Actual Supply and Return T emperatures b. Flame Signal c. F an Speed 3. Ser vice Mode allows installers to manually control the firing rate for easy set up. 4. Available Softwar e that allows the inst[...]

44 C. P125 CONTROL BO ARD VS. WHA CONTROL BOARD COMP ARISON Figure A.2: Comparative Control Board Sequence of Operation WHA T’S NEW WITH THE P125 CONTROL BOARD[...]

P innacle ® Gas Boilers P eerless ® Stainless Steel Installation, Operation & Maintenance Manual TO THE INST ALLER: 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. PI8008 R11 (9/06-5M) Printed in U .S.A . ©[...]