Pinnacle. Peerless. Stainless Steel. Gas Boilers. Installation, Operation & Maintenance Manual WARNING WHAT TO DO IF YOU SMELL GAS

Peerless Stainless Steel Pinnacle Gas Boilers WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
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Peerless Stainless Steel Pinnacle Gas Boilers WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor s phone. Follow the gas supplier s instructions. If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier. As an ENERGY STAR Partner, PB Heat, LLC has determined that this product meets the ENERGY STAR guidelines for energy efficiency. Installation, Operation & Maintenance Manual TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 1 A. INSTALLATION SEQUENCE B. SPECIAL ATTENTION BOXES PREINSTALLATION 2 A. GENERAL B. CODES & REGULATIONS C. ACCESSIBILITY CLEARANCES D. COMBUSTION AND VENTILATION AIR....2 E. PLANNING THE LAYOUT BOILER SET-UP 4 A. GENERAL B. WALL HUNG BOILERS C. FLOOR MOUNTED BOILERS WATER PIPING AND CONTROLS 5 A. GENERAL B. OPERATING PARAMETERS C. SYSTEM COMPONENTS D. SYSTEM PIPING E. FREEZE PROTECTION F. SPECIAL APPLICATIONS GAS PIPING 16 A. GENERAL B. FUEL LINE SIZING C. GAS SUPPLY PIPING INSTALLATION D. GAS SUPPLY PIPING OPERATION E. MAIN GAS VALVE OPERATION VENTING, INLET AIR & CONDENSATE 19 A. GENERAL B. APPROVED MATERIALS FOR EXHAUST VENT AND INLET AIR PIPE C. EXHAUST VENT / AIR INLET PIPE LOCATION D. EXHAUST VENT AND INLET AIR PIPE SIZING E. EXHAUST VENT AND AIR INLET PIPE INSTALLATION F. EXHAUST TAPPING FOR VENT SAMPLE G. CONDENSATE DRAIN INSTALLATION H. BOILER REMOVAL FROM COMMON VENTING SYSTEM ELECTRICAL 26 A. WIRING B. SEQUENCE OF OPERATION C. SAFETY INTERLOCKS D. CONTROL FUNCTIONS START-UP PROCEDURES 30 A. COMPLETING THE INSTALLATION B. LIGHTING/OPERATING INSTRUCTIONS...31 C. CHECK-OUT PROCEDURE TROUBLESHOOTING 33 A. SHUT-DOWN B. BOILER FAULT CODES MAINTENANCE 35 A. GENERAL (WITH BOILER IN USE) B. WEEKLY (WITH BOILER IN USE) C. ANNUALLY (BEFORE START OF HEATING SEASON) BOILER DIMENSIONS & RATINGS 36 A. BOILER DIMENSIONS REPAIR PARTS 39 APPENDIX A. WHAT S NEW WITH THE P125 CONTROL BOARD 41 A. ADVANTAGES OF THE P125 CONTROL BOARD B. P125 CONTROL BOARD QUICK REFERENCE C. P125 CONTROL BOARD VS. WHA CONTROL BOARD COMPARISON USING THIS MANUAL USING THIS MANUAL A. INSTALLATION SEQUENCE 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 safety during boiler installation. B. SPECIAL ATTENTION BOXES Throughout this manual you will see special attention boxes intended to supplement the instructions and make special notice of potential hazards. These categories mean, in the judgment of PB Heat, LLC: DANGER Indicates a condition or hazard which will cause severe personal injury, death or major property damage. WARNING Indicates a condition or hazard which may cause severe personal injury, death or major property damage. CAUTION Indicates a condition or hazard which will or can cause minor personal injury or property damage. NOTICE Indicates special attention is needed, but not directly related to potential personal injury or property damage. 1 PREINSTALLATION 1. PREINSTALLATION A. GENERAL 1. Pinnacle boilers are 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 read these instructions and be sure to understand the function of all connections prior to beginning installation. Contact your PB Heat, LLC Representative for help in answering questions. 3. This boiler must be installed by a qualified contractor. The boiler warranty may be voided if the boiler is not installed correctly. 4. A hot water boiler installed above radiation or as required by the Authority having jurisdiction, must be provided with a low water fuel cut-off device either as part of the boiler or at the time of installation. 5. This boiler can be installed at high altitudes above 5,000 feet elevation with no burner adjustments. For boilers equipped for firing liquefied petroleum (LP) gas at elevations above 7,000 feet contact the factory. B. CODES & REGULATIONS 1. Installation and repairs are to be performed in strict accordance with the requirements of state and local regulating agencies and codes dealing with boiler and gas appliance installation. 2. In the absence of local requirements the following should be followed. a. ASME Boiler and Pressure Vessel Code, Section IV - Heating Boilers b. ASME Boiler and Pressure Vessel Code, Section VI - Recommended Rules for the Care and Operation of Heating Boilers WARNING Liquefied Petroleum (LP) Gas or Propane is heavier than air and, in the event of a leak, may collect in low areas such as basements or floor drains. The gas may then ignite resulting in a fire or explosion. C. ACCESSIBILITY CLEARANCES 1. The Pinnacle boiler is certified for closet installations with zero clearance to combustible construction. In addition, it is design certified for use on combustible floors. 2. Refer to Figure 1.1 and Figure 1.2 for the recommended clearance to allow for reasonable access to the boiler. Local codes or special conditions may require greater clearances. D. COMBUSTION AND VENTILATION AIR 1. The Pinnacle boiler is designed only for operation with combustion air piped from outside (sealed combustion). PVC pipe must be supplied between the air inlet connection at the rear of the boiler through an outside wall. 2. No additional combustion or ventilation air is required for this appliance. DANGER Do not install this boiler on carpeting. 3. Refer to Section 5 of this manual, Venting, for specific instructions for piping combustion air. E. PLANNING THE LAYOUT 1. Prepare sketches and notes showing the layout of the boiler installation to minimize the possibility of interferences with new or existing equipment, piping, venting and wiring. 2. The following sections of this manual should be reviewed for consideration of limitations with respect to: a. Water Piping: Section 3 b. Fuel Piping: Section 4 c. Venting: Section 5 d. Air Intake Piping: Section 5 e. Condensate Removal: Section 5 f. Electrical Wiring: Section 6 c. ANSI Z223.1/NFPA 54 - National Fuel Gas Code d. ANSI/NFPA 70 - National Electrical Code e. ANSI/NFPA Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances 3. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. 2 PREINSTALLATION WARNING This boiler is certified as an indoor appliance. Do not install this boiler outdoors or locate where it will be exposed to freezing temperatures. WARNING Do not install this boiler where gasoline or other flammable liquids or vapors are stored or are in use. Figure 1.1: Accessibility Clearances Floor Standing Units Figure 1.2: Accessibility Clearances Wall Hung Units 3 BOILER SET-UP 2. BOILER SET-UP A. GENERAL 1. Pinnacle boilers are to be installed in an area with a floor drain or in a suitable drain pan. Do not install any boiler where leaks or relief valve discharge will cause property damage. 2. This boiler is not intended to support external piping. All venting and other piping should be supported independently of the boiler. 3. Install this boiler level to prevent condensate from backing up inside the boiler. CAUTION This boiler is must be installed level to prevent condensate from backing up inside the boiler. B. WALL HUNG BOILERS 1. The PI-T50 and PI-T80 Boilers are provided with slots for wall mounting and feet for floor mounting. Refer to Figure 10.1 in this manual for dimensions & locations. 3. Use a minimum of 1/4 threaded fasteners for supporting the boiler. Do not mount the boiler to wall board only. WARNING Make sure the boiler is adequately supported. Do not install this boiler on drywall unless adequately supported by wall studs. 4. Be sure to adequately support the boiler while installing external piping. Be sure to pipe condensate to a suitable drain or condensate pump. C. FLOOR MOUNTED BOILERS 1. PI-80, PI-140, and PI-199 boilers are designed for floor mounting. The PI-80 can be wall mounted using the optional boiler stand available through your PB Heat, LLC distributor (Part Number 91439). 2. The boiler stand may used for floor mounting of the PI-140 and PI-199 boilers. 2. If wall mounted, the boiler must be attached to a wall that provides adequate support for the boiler. 4 WATER PIPING AND CONTROLS 3. WATER PIPING AND CONTROLS A. GENERAL 1. The water supply and return piping of this appliance are to be sized according to system requirements. Do not use piping smaller than the boiler connections. 2. In hydronic systems where sediment may exist, install a strainer device in the boiler return piping to prevent large particles and pipe scale from entering the boiler heat exchanger coil. Use a large mesh screen in the strainer. 3. 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 cleaning, control replacement, etc.). B. OPERATING PARAMETERS 1. The Pinnacle boiler is designed to operate in a closed loop hydronic system at approximately 15 psi. A pressure limit in the boiler header will prevent the unit from operating if the pressure drops below 10 psi. This is to keep the appliance from operating in the event of a system leak or other condition in which water is not flowing through the heat exchanger. 2. Table 3.1 shows minimum water flow rates for Pinnacle boilers. If a glycol solution is to be used, contact the factory for minimum flow rates. Table 3.1 Minimum Flow Rate and Water Volume Boiler Model Total Water Volume-Gallon (Liter) C. SYSTEM COMPONENTS Minimum Flow Rate-GPM (LPM) PI-T (1.89) 2 (7.6) PI-T (2.40) 4 (15.2) PI (2.40) 4 (15.2) PI (3.50) 6 (22.7) PI (4.26) 8 (30.3) 1. Figure 3.1 shows the symbol key for piping diagrams in this section. The following are brief descriptions of system components. 2. Pressure/Temperature Gauge: A combination pressure/temperature gauge is provided with each Pinnacle boiler to be mounted in the piping from the boiler supply to the system. Most local codes require this gauge. 3. Air Elimination: Any closed loop hydronic system in which the Pinnacle boiler is installed must have an air elimination device. As the system water is heated, dissolved oxygen and carbon dioxide will separate from the liquid. An air elimination device (such as a TACO 430 Series Air Scoop with automatic air vent) is required to remove the dissolved gasses from the system preventing corrosion in the piping system and eliminating system noise. 4. Expansion Tank: An expansion tank (such as a Bell & Gossett Series HFT) is required to provide room for expansion of the heating medium (water or glycol solution). Consult the expansion tank manufacturer's instructions for specific information regarding installation. The expansion tank is to be sized for the required system volume and capacity. In addition, be sure that the expansion tank is sized based on the proper heating medium. Glycol solutions may expand more than water for a similar temperature rise. CAUTION Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems. Unlike automotive antifreeze, solutions for hydronic applications contain corrosion inhibitors that will protect system components from premature failure due to corrosion. WARNING Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems. Ethylene glycol is toxic and may cause an environmental hazard if a leak or spill occurs. 5. Y-Type Strainer: In older systems where a significant amount of sediment may be present, it may be necessary to install a Y-type strainer. The strainer should be checked often and cleaned during the first few months of operation to assure that sediment does not reach the heat exchanger and clog the passages. Use a large mesh screen in the strainer. 6. Flow Control Valve: Flow control valves such as the TACO Flo-Chek or Bell & Gossett Flo-Control are used to prevent gravity circulation by incorporating a check valve with a weighted disc. 7. Pressure Reducing Valve: A pressure reducing valve, such as the Bell & Gossett B-38 or a TACO #329, is used in a hydronic system to automatically feed water to the system whenever pressure in the system drops below the pressure setting of the valve. These valves should not be used on glycol systems unless close supervision of the glycol solution is practiced. 8. Back Flow Preventer: A back flow preventer (check valve) is required by some jurisdictions to prevent the hydronic system water from backing up into the city water supply. This is especially important on systems in which glycol solution is used as the heating medium. 5 WATER PIPING AND CONTROLS Figure 3.1: Piping Symbol Key 9. Pressure Relief Valve: The boiler pressure relief valve is factory installed into the right side boiler manifold (inside the jacket). Pipe the discharge of the relief 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. CAUTION Pipe the discharge of the relief valve as close as possible to the floor and away from high traffic areas. Pipe the discharge to a floor drain. Failure to do so may result in personal injury and/or property damage. 10. Circulator: The boiler circulator is to be sized to overcome the pressure drop of the system while providing the flow required by the boiler. a. If the boiler is piped in a secondary loop of a primary/secondary heating system, the circulator will need only to overcome the resistance of the boiler and any fittings in that loop. b. The circulator should be sized based on the net output of the boiler. The Table 3.2 shows the Boiler Output as reported to the Hydronics Institute division of GAMA. These values are based on a pickup factor of Table 3.2 Boiler Inputs and Outputs Boiler Model Boiler Input (Btu/hr [kw]) Net I=B=R Output (Btu/hr [kw]) PI-T50 50,000 (14.7) 40,000 (11.7) PI-T80 80,000 (23.4) 64,000 (18.8) PI-80 80,000 (23.4) 64,000 (18.8) PI ,000 (41.0) 112,000 (32.8) PI ,000 (58.3) 159,000 (46.6) 6 WATER PIPING AND CONTROLS c. The required flow rate can be calculated based on the design temperature difference from the return to the supply of the boiler. For a PI-T80 with a design temperature difference of 20 F the calculation is as follows: Required Flow = Output 64,000 = = 6.4 GPM T x x 500 d. Table 3.3 shows the pressure drop (in feet of water) for a flow rate which gives a 20 F temperature difference for each boiler model. g. Special consideration must be given if anti-freeze is to be used as a heating medium. Propylene glycol has a higher viscosity than water therefore the system pressure drop will be higher. 10. Indirect Water Heater: An indirect water heater should be piped in a dedicated zone. It consists of a water tank that is heated by boiler water passing through an internal coil. Examples of indirect water heating are shown in the System Piping subsection of this Section. Table 3.3 Flow Rate and Pressure Drop Boiler Model Flow Rate (GPM [LPM]) Pressure Drop (Feet [meters]) PI-T (15.1) 4.5 (1.22) PI-T (24.2) 5.0 (1.52) PI (24.2) 5.0 (1.52) PI (42.4) 8.0 (2.44) PI (60.2) 13.0 (4.02) e. The boiler pressure drop for various flow rates can be determined by using Figure 3.2, the Pinnacle Circulator Sizing Graph. f. Table 3.4 gives the recommended circulators for a boiler on a secondary loop with water as the heating medium. Table 3.4 Recommended Circulators Boiler Model TACO Circulator Grundfos Circulator PI-T UPS 15-58FC SPD-1 PI-T UPS 15-58FC SPD-2 PI UPS 15-58FC SPD-2 PI UPS 15-58FC SPD-3 PI UP 26-64F NOTICE The circulator sizing given is for primary/secondary installations only. The system circulators must be sized based on the flow and pressure drop requirements of the system. 7 WATER PIPING AND CONTROLS Figure 3.2: Pinnacle Circulator Sizing Graph Pressure Drop (Feet of Head) PI-T PI-T80/ PI PI Flow Rate (GPM) D. SYSTEM PIPING 1. Figure 3.3 shows a single boiler with two zones. In this application, the Peerless Partner indirect water heater and the single heating zone require similar water temperature. 2. Figure 3.4 shows an additional zone in which baseboard radiation is the heat load. This zone also requires water temperatures similar to the indirect water heater. 3. Figure 3.5 shows diverter tees used in combination with conventional hydronic radiators on an additional zone. A second boiler is also added to the system. Notice that the boilers are piped in parallel on the secondary loop. It is important that the common headers are sized to match the system piping. Smaller headers may result in flow fluctuations through the boilers. E. FREEZE PROTECTION 1. Glycol for hydronic applications is specially formulated for this purpose. It includes inhibitors which prevent the glycol from attacking metallic system components. Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level. 2. Use only inhibited propylene glycol solutions of up to 50% by volume. Ethylene glycol is toxic and can chemically attack gaskets and seals used in hydronic systems. 3. The antifreeze solution should be tested at least once per year and as recommended by the antifreeze manufacturer. 4. Figure 3.6 shows a system in which several different types of loads and multiple boilers are shown. This system illustrates how different temperature zones can be supplied from the same source by mixing down the temperature using a three way mixing valve. Radiant flooring typically requires much lower temperatures than baseboard radiation and indirect water heating. Notice that a third boiler is included in this system. 5. Figure 3.7 shows zone valves used in place of zone circulators. Notice that this system utilizes reverse return piping which makes it easier to balance the system. If the heating zones are very different in length, the balancing valves on the return side of each loop are required. 8 WATER PIPING AND CONTROLS Figure 3.3: One Boiler, Primary/Secondary with Two Zones (Zone Circulator) 9 WATER PIPING AND CONTROLS Figure 3.4: One Boiler, Primary/Secondary with Three Zones (Zone Circulator) 10 WATER PIPING AND CONTROLS Figure 3.5: Two Boilers, Primary/Secondary with Four Zones (Zone Circulator) 11 WATER PIPING AND CONTROLS Figure 3.6: Three Boilers, Primary/Secondary with Five Zones (Zone Circulator) 12 WATER PIPING AND CONTROLS Figure 3.7: Three Boilers, Primary/Secondary with Four Zones (Zone Valves) 13 WATER PIPING AND CONTROLS Antifreeze solutions expand more than water. For example, a 50% by volume solution expands 4.8% for a 148 F temperature rise while water expands about 3% for the same temperature increase. Allowance for this expansion must be considered in sizing expansion tanks and related components. 4. The flow rate in systems utilizing glycol solution should be increased compared with a water system to compensate for increased heating capacity. 5. Due to increased flow rate and fluid viscosity the circulator head requirement will increase. Contact the pump manufacturer to correctly size the circulator for a particular application based on the glycol concentration and heating requirements. 6. A strainer, sediment trap, or some other means
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