PB Heat MI manual

MI/MIH Boilers Series Gas Installation, Operation & Maintenance Manual[...]

USING THIS MANUAL 1 A . INST ALLA TION SEQUENCE . . . . . . . . . . . . .1 B . SPECIAL A TTENTION BO XES . . . . . . . . . . . .1 1. PREINST ALLA TION 2 A . ACCESSIBILITY CLEARANCES . . . . . . . . . . .2 B . CLEARANCE FROM COMBUSTIBLE CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . .2 C. AIR FOR COMBUSTION AND VENTILA TION . . . . . . . . .[...]

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. ACCESSIBILITY CLEARANCES Install boiler not less than 24 ″ (610 mm) between the left side, top, and front of the boiler and adjacent wall or other appliance, when access is requir ed for ser vicing. B. CLEARANCE FROM COMBUSTIBLE CONSTRUCTION The design of this boiler is cer tified for alcove installation with the following clearances: 1. 6 ?[...]

3 where: I other = Input of appliances other than fan assisted in Btu/hr ACH = air change per hour (per cent of the volume of the space e xchanged per hour , expr essed as a decimal) F or fan assisted appliances, calculate the required volume of air using the following equation: I fan = Input of the fan assisted appliances in Btu/hr Note: These cal[...]

4 ii. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free ar ea of 1 in 2 per 2000 Btu/hr (22 cm 2 per 2000 W) of total rated input for all appliances in the space. See Figur e 1.5. b. One P er manent Opening Method: Provide one permanent opening beginning within 12 inches (305 mm) of the top of th[...]

5 c. Each of the appliances ser ved shall be interlocked to the mechanical air supply to prevent main burner operation when the mechanical air supply system is not in operation. d. In buildings wher e the combustion air is provided by the mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the re[...]

6 BOILER SET -UP 1. Provide a sound, level foundation. Locate boiler as near to the chimney or outside wall as possible and centralized with respect to the heating system. 2. Locate boiler in front of installation position before removing crate. 3. If using combustible floor pan, position pan on foundation or flooring. 4. Separate the wood shipping[...]

7 A. BOILER SUPPL Y AND RETURN 1. Size the supply and return to suit the system. A typical piping arrangement is shown in Figure 3.1. Refer also to the I=B=R Guide - Residential Hydronic Heating Installation/Design and the PB Heat W ater Sur vey for additional guidance during water piping installation. 2. Return Piping: Pipe the drain valve to a te[...]

8 6. Install this boiler so that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and ser vice (circulator r eplacement, condensate trap, control replacements, etc.). 7. If this boiler and distribution system is used in conjunction with a refrigeration system, pipe the chilled medium [...]

9 C. PIPING FOR ZONED SYSTEMS 1. See Figur es 3.5 and 3.6 for basic zoned system layouts. 2. Run each zone pipe down then up to zone to prevent air accumulation in piping. 3. If requir ed, provide means to isolate and drain each zone separately . WA TER PIPING AND CONTROLS Figure 3.5: Zone Piping with Zone V alves Figure 3.6: Zone Piping with Circu[...]

10 D . EXP ANSION T ANK 1. Consult the tank manufacturer ’s instructions for specific information relating to tank installation. Size the e xpansion tank for the required system volume and capacity . See T able 10.2 in Section 10 for boiler water content. 2. Expansion tanks are available with built-in fill valves and check valves for reducing sup[...]

11 A. INTEGRAL DRAFT HOOD 1. The MI/MIH boiler is equipped with a built-in draft hood. This device is designed to: a. provide for the r eady escape of flue gases from the boiler in the event of no draft. b. prevent a backdraft from entering the boiler . c. control stack draft during operation. These tasks are accomplished without the e xtra height [...]

12 Figure 4.2: V enting with V ent Damper in V ertical Position Figure 4.3: V enting with V ent Damper in Horizontal P osition C. VENT PIPING AND CHIMNEY 1. Install vent piping in accordance with V enting of Equipment par t of the National F uel Gas Code , ANSI Z223.1/NFP A 54, sections 7.2, 7.3 or 7.4 of CAN/CSA B149.1, Natural Gas and P ropane In[...]

D . BOILER REMO V AL FROM COMMON VENTING SYSTEM At the time of r emoval 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 venti[...]

14 1. 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 pressur e between the meter and the boiler . 2. Determine the volume of gas to be provided to the boiler in cubic feet per hour . T o obtain this value, divide the Btu per hour rating (on the boiler r[...]

15 T able 5.4: P ipe Capacity Capacity of pipe of different diameters and lengths in cubic feet per hour [cubic meter per hour] with a pressur e drop of 0.3 inches of water (75 P a) and specific gravity of 0.60. No allowance for an ordinary number of fittings is required. T able 5.1: MI Boiler – Natural Gas T able 5.2: MI Boiler – LP Gas T able[...]

A. WIRING 1. See Figur e 6.1 for location of wiring and controls. Use Figur es 6.2 and 6.3 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. Connect the vent damper harness to the damper motor as shown in Figur e 6.1.[...]

17 D . SEQUENCE OF OPERA TION 1. Standing Pilot (See F igure 6.2 above) a. The vent damper is continuously power ed. On a call for heat, limit relay R is energized, which energizes: ● the circulator (when used) through contact R1, and ● the vent damper operator through contact R2, provided that the high-limit switch is closed. The vent damper o[...]

18 ELECTRICAL 2. Inter mittent Ignition (see Figur e 6.3 above) a. The vent damper is continuously power ed. On a call for heat, limit relay R is energized, which energizes: ● the circulator (when used) through contact R1, and ● the vent damper operator through contact R2, provided that the high-limit aquastat switch is closed. The damper opera[...]

19 Figure 6.4: Intermittent Ignition System Operating Sequence ELECTRICAL[...]

ELECTRICAL Figure 6.5: Zone Wiring with Zone V alves Figure 6.6: Zone Wiring with Circulators 20[...]

A. COMPLETING THE INST ALLA TION 1. Confirm that all water , gas and electricity are turned off. 2. Inspect the boiler combustion chamber for foreign objects and remove if pr esent. 3. Check physical condition of burners and pilot. Make cer tain that ther e are no unusual bends or perforations in the bur ners or pilot. Replace components if necessa[...]

22 Figure 7.1: Gas V alve, Manifold and Burner Assembly – Standing Pilot (Continuous Ignition) Figure 7.2: Gas V alve, Manifold and Burner Assembly – Intermittent Ignition Figure 7.3: V alve T apping and Adjustment Screw Locations ST ART -UP PROCEDURES[...]

23 ST ART -UP PROCEDURES Figure 7.4: Operating Instructions[...]

24 Figure 7.5: Lighting Instructions ST ART -UP PROCEDURES H24V VR8200/VR8300 9177R If you cannot reach your gas supplier , call the fire department. C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or[...]

B. CONTROL DESCRIPTIONS See Figur e 6.1 in Section 6 (Electrical) for locations of these devices. 1. FLAME ROLL-OUT SAFETY SHUT -OFF SWIT CH (FLAME ROLL-OUT SWIT CH) – A ther mally activated switch located between the first burner from the left and the manifold bracket. The flame roll-out safety shut-off switch will sense e xcessive temperature c[...]

26 E. CHECKING BURNER INPUT 1. Refer to rating label mounted on the jacket top panel to obtain the rated BTU per hour input. In no case shall the input to the boiler e xceed the value shown on the rating label. 2. Check input by use of the following formulas (PB Heat, LLC suggests reading meter for 2 Cu. Ft.): U.S. Customary Units Input (BTU/Hr .)=[...]

27 b. Intermittent Ignition System: i) T ur n gas supply off. ii) Set thermostat or controller above room temperature to call for heat. W atch for igniter glow at pilot burner . iii) Igniter will continue to glow for 30 seconds, de-energize for 30 seconds, then re-energize and glow for another 30 seconds. It will then de-energize for 5 minutes befo[...]

A. SHUT -DOWN CAUSED B Y PIL OT OUT AGE, BL OCKED VENT SHUT - OFF SWITCH OR FLAME ROLL - OUT SAFETY SHUT - OFF SWITCH In the event of a shut-down caused by a pilot outage, action of the blocked vent shut-off switch or flame roll- out safety shut-off switch effecting a shut-down of the main burners: a. Refer to the Lighting/Operating Instructions in[...]

29 TROUBLESHOOTING T able 8.1: Boiler T roubleshooting Guide PROBLEM POSSIBLE C AUSES CORRECTIVE A CTIONS 1. No power . 2. Limit (Aquastat) not working. 3. Flame rollout switch open. 4. Blocked vent switch open. 5. Gas off at boiler gas valve. 6. Gas off e xternal to boiler . 7. Plugged orifice spuds. 8. Defective gas valve. 9. Improper wiring. 10.[...]

30 Figure 8.1: Intermittent Ignition System T roubleshooting Sequence TROUBLESHOOTING[...]

31 MAINTENANCE 9. MAINTENANCE W ARNING Product Saf ety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fiber s (RCF). Airborne RCF , when inhaled, have been classified b y the International Agency for Resear ch on Cancer (IARC), as a possible carcinogen to humans. After the RCF materials h[...]

A. GENERAL 1. Disconnect this boiler from the gas supply piping during any pressur e testing of the gas system. 2. Check pipes adjacent to cold walls or in unheated spaces. Insulate and tape them if necessary to be sure they can ’t freeze up. Keeping the water moving at all times will reduce the likelihood of fr eezing. See Section 3 for glycol i[...]

33 E. ANNUALL Y (BEFORE ST ART OF HEA TING SEASON) 1. Check flueways and burners for cleanliness and clean if necessary . Use the following procedure if cleaning is requir ed: a. Refer to the Lighting/Operating Instructions in Figur es 7.4 and 7.5 to properly tur n off the gas to the boiler . b. T ur n off all electrical power to the boiler . c. Re[...]

BOILER DIMENSIONS & RA TINGS 10. BOILER DIMENSIONS & RA TINGS T able 10.2: Series MI/MIH Boiler Ratings 1 Net I=B=R water ratings based on an allowance of 1.15. 2 Consult factory before selecting a boiler for installations having unusual piping and pickup requir ements, such as intermittent system operation, extensive piping systems, etc. 3[...]

35 REP AIR P ARTS REP AIR P ARTS SERIES MI/MIH GAS BOILER Repair par ts are available from your installer or by contacting PB Heat, LLC, New Berlinville, P A 19545-0447. Use the figures and tables on pages 34-40 to assist in ordering par ts. Note: Remember to include boiler model number and serial number when ordering par ts. 11. REP AIR P ARTS T a[...]

REP AIR P ARTS 36 T able 11.2: Manifold/Gas T rain (MI – Standing Pilot) *F or elevations over 2,000 feet above sea level contact PB Heat, LLC. Item No . Description P art Selection Information MI-03 MI-04 MI-05 MI-06 MI-07 MI-08 MI-09 5 Steel Burner Specify quantity 51537 51537 51537 51537 51537 51537 51537 6 Steel Burner w/ Pilot Clip 1 per boi[...]

*F or elevations over 2,000 feet above sea level contact PB Heat, LLC. *F or elevations over 2,000 feet above sea level contact PB Heat, LLC. 37 REP AIR P ARTS T able 11.3a: Manifold/Gas T rain (MI – Intermittent Ignition) T able 11.3b: Manifold/Gas T rain (MIH – Intermittent Ignition) Figure 11.3b: Gas V alve and Pilot – Intermittent Ignitio[...]

REP AIR P ARTS 38 Figure 11.4: Block/Draft Hood T able 11.4a: Block/Draft Hood 12 13 14 Block Assembly Flue Collector/Draft Hood Flue Collector Blanket Seal Item No . Description 90419 90510 50866 90425 90516 50866 90424 90515 50866 90423 90514 50866 90422 90513 50866 90421 90512 50866 90420 90511 50866 Specify length P art Selection Information MI[...]

39 REP AIR P ARTS Figure 11.5: Jacket T able 11.5: Jacket Item No . Description P art Selection Information MI/MIH -03 MI/MIH -04 MI/MIH -05 MI/MIH -06 M I -07 M I -08 M I -09 16 Jacket Assembly Complete jacket* with insulation and screws 90445 90446 90447 90448 90449 90450 90451 16 16 16 16 16 16 *Complete Jacket Consists of: Left Side P anel Righ[...]

REP AIR P ARTS T able 11.6: Controls/Circulator/V ent Damper 40 Figure 11.6: Controls/Circulator/V ent Damper Item No . Description MI/MIH -03 MI/MIH -04 MI/MIH -05 MI/MIH -06 M I -07 M I -08 M I -09 23 Honeywell L8148E1182 Limit w/ ³⁄₄ ″ W ell* 51689 51689 51689 51689 51689 51689 51689 24 T emperature- Pressur e Gauge 51774 51774 51774 5177[...]

MI/MIH Boilers Series Gas 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. MI8038 R9 (10/05-10M) Printed in U .S.A. ©2005 PB HEA T , LLC PO BOX 4[...]