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PEERLESS Stainless Steel Gas Boilers Installation, Operation & Maintenance Manual

Stainless steel gas boilers
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Peerless
Stainless Steel
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.
®
Pinnacle
Gas Boilers
I n s t a l l a t i o n ,
O p e r a t i o n &
M a i n t e n a n c e
M a n u a l
®
®
E
S
As an
NERGY
TAR
Partner, PB Heat, LLC has
E
S
determined that this product meets the
NERGY
TAR
guidelines for energy efficiency.
®

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Summary of Contents for PEERLESS Stainless Steel Gas Boilers

  • Page 1 Peerless ® Pinnacle ® Stainless Steel 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.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS F. EXHAUST TAPPING FOR VENT USING THIS MANUAL SAMPLE ......25 A.

  • Page 3: Using This Manual

    USING THIS MANUAL USING THIS MANUAL A. INSTALLATION SEQUENCE DANGER Follow the installation instructions provided in this Indicates a condition or hazard which will cause manual in the order shown. The order of these severe personal injury, death or major property instructions has been set in order to provide the installer damage.

  • Page 4: Preinstallation

    PREINSTALLATION 1. PREINSTALLATION A. GENERAL C. LIQUIFIED PETROLEUM (LP) GAS The following LP requirements from the Uniform 1. Pinnacle boilers are supplied completely assembled Mechanical Code, section 304.6, may be in effect in as packaged boilers. The package should be your geographical area: inspected for damage upon receipt and any damage "Liquefied petroleum gas-burning appliances shall...
  • Page 5 PREINSTALLATION WARNING WARNING This boiler is certified as an indoor appliance. Do not Do not install this boiler where gasoline or other install this boiler outdoors or locate where it will be flammable liquids or vapors are stored or are in use. exposed to freezing temperatures.

  • Page 6: Boiler Set-Up

    BOILER SET-UP 2. BOILER SET-UP 3. Use a minimum of 1/4" Threaded fasteners for A. GENERAL supporting the boiler. Do not mount the boiler to wall board only. 1. Pinnacle boilers are to be installed in an area with a floor drain or in a suitable drain pan.

  • Page 7: Water Piping And Controls

    WATER PIPING AND CONTROLS 3. WATER PIPING AND CONTROLS 4. Expansion Tank: An expansion tank (such as a Bell & A. GENERAL Gossett Series HFT) is required to provide room for expansion of the heating medium (water or glycol 1. The water supply and return piping of this appliance solution).
  • Page 8 WATER PIPING AND CONTROLS Figure 3.1: Piping Symbol Key 9. Pressure Relief Valve: The boiler pressure relief valve b. The circulator should be sized based on the net is factory installed into the right side boiler manifold output of the boiler. The Table 3.2 shows the (inside the jacket).
  • Page 9 WATER PIPING AND CONTROLS c. The required flow rate can be calculated based g. Special consideration must be given if anti-freeze is on the design temperature difference from the to be used as a heating medium. Propylene glycol return to the supply of the boiler. For a PI-T80 has a higher viscosity than water therefore the with a design temperature difference of 20°F the system pressure drop will be higher.

  • Page 10: System Piping

    WATER PIPING AND CONTROLS Figure 3.2: Pinnacle Curculator Sizing Graph PI-T50 PI-T80/80 PI-140 PI-199 Flow Rate (GPM) D. SYSTEM PIPING E. FREEZE PROTECTION 1. Figure 3.3 shows a single boiler with two zones. In 1. Glycol for hydronic applications is specially this application, the Peerless Partner indirect water formulated for this purpose.
  • Page 11 WATER PIPING AND CONTROLS...
  • Page 12 WATER PIPING AND CONTROLS...
  • Page 13 WATER PIPING AND CONTROLS...
  • Page 14 WATER PIPING AND CONTROLS...
  • Page 15 WATER PIPING AND CONTROLS...

  • Page 16: Special Applications

    WATER PIPING AND CONTROLS Antifreeze solutions expand more than water. For example, a 9. Do not use galvanized pipe in glycol systems. 50% by volume solution expands 4.8% for a 148°F 10. Use water that is low in mineral content and make temperature rise while water expands about 3% for the same sure there are no petroleum products in the solution.
  • Page 17 WATER PIPING AND CONTROLS Figure 3.8: Boiler in conjunction with a Chilled Water System Figure 3.9: Boiler Connected to a Heating Coil in a Forced Air System...

  • Page 18: Gas Piping

    GAS PIPING 4. GAS PIPING Table 4.2: Maximum Capacity of Pipe (CFH) for a A . GENERAL Pressure Drop of 0.3" of Water 1. All fuel piping to the boiler is to be in accordance Pipe 1-1/4" 1-1/2" with local codes. In the absence of local regulations Length 3/4"...

  • Page 19: Gas Supply Piping - Operation

    GAS PIPING 2. Install a sediment trap as shown in Figure 4.1. Be 5. Maintain a minimum distance of 10 feet between the sure to allow clearance from the floor for removal of gas pressure regulator and the boiler. the pipe cap. 6.

  • Page 20: Main Gas Valve - Operation

    GAS PIPING Table 4.4: Maximum and Minimum Fuel Pressure WARNING Pressure (inches of water) Do not adjust the throttle screw without monitoring Type Minimum Maximum the carbon dioxide (CO ² ) and carbon monoxide (CO) Natural 13.5 in the vent pipe. Vent CO emissions above 400 ppm are in excess of most safety standards.

  • Page 21: Venting, Inlet Air & Condensate

    VENTING, INLET AIR AND CONDENSATE 5. VENTING, INLET AIR AND CONDENSATE A. GENERAL C. EXHAUST VENT / AIR INLET PIPE LOCATION 1. Install the boiler venting system in accordance with these instructions and with the National Fuel Gas 1. Determine exhaust vent location: Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, a.

  • Page 22: Exhaust Vent And Inlet Air Pipe Sizing

    VENTING, INLET AIR AND CONDENSATE Figure 5.1: Location of exit terminals of mechanical draft and direct-vent venting systems. (Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002). Further, if the inlet air pipe has two 90° elbows, D. EXHAUST VENT AND INLET AIR PIPE one 45°...

  • Page 23: Exhaust Vent And Air Inlet Pipe Installation

    VENTING, INLET AIR AND CONDENSATE b. Use a 3" x 2" reducing coupling to transition from 7. All piping must be fully supported. Use pipe hangers the PI-T50 and PI-T80 boiler connections to a 3" at a minimum of 4 foot intervals to prevent sagging vent.
  • Page 24 VENTING, INLET AIR AND CONDENSATE Figure 5.2: PI-80, PI-140, and PI-199 Sidewall Figure 5.4: PI-80, PI-140, PI-199 Sidewall Venting Venting with 3" Pipe (Air Inlet at Higher with 3" Pipe (Air Inlet and Exhaust on Elevation than Exhaust Termination). the same Elevation). Figure 5.3: PI-T50 &...
  • Page 25 VENTING, INLET AIR AND CONDENSATE Figure 5.6: PI-80, PI-140, PI-199 Sidewall Venting Figure 5.8: PI-80, PI-140, PI-199 Sidewall Venting with 3" Pipe (V1000 Vent Kit). with 3" Pipe (Concentric Vent Kit). Figure 5.7: PI-T50 & PI-T80 Sidewall Venting with Figure 5.9: PI-T50 & PI-T80 Sidewall Venting with 2"...
  • Page 26 VENTING, INLET AIR AND CONDENSATE Figure 5.10: PI-80, PI-140, PI-199 Vertical Figure 5.12: PI-80, PI-140, PI-199 Vertical Venting with 3" Pipe. Venting with 3" Pipe (Concentric Vent Kit). Figure 5.11: PI-T50 & PI-T80 Vertical Venting Figure 5.13: PI-T50 & PI-T80 Vertical Venting with 2"...

  • Page 27: Exhaust Tapping For Vent Sample

    VENTING, INLET AIR AND CONDENSATE EXHAUST TAPPING FOR VENT SAMPLE H. BOILER REMOVAL FROM COMMON VENTING SYSTEM To obtain a combustion sample a hole must be drilled in the exhaust vent pipe just above the first elbow at the 1. At the time of removal of an existing boiler from a outlet of the boiler.

  • Page 28: Electrical

    ELECTRICAL 6. ELECTRICAL Install all electrical wiring in accordance with the National c) An example of this wiring using a Honeywell R845A Electrical Code, ANSI/NFPA 70, and local requirements. relay is shown in Figure 6.2 NOTICE 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...
  • Page 29 ELECTRICAL e) The main gas valve is then energized to allow h) As the supply temperature approaches the set gas to mix with the combustion air. point, the combustion control will reduce the input rate. The supply temperature will continue f) If the main flame is not detected in 5 seconds, to climb to about 7°F above the boiler set point the gas valve closes and the combustion fan goes...

  • Page 30: Safety Interlocks

    ELECTRICAL Table 6.1: Program Functions C. SAFETY INTERLOCKS Alternating 1. Low Water Pressure Limit Switch: This boiler is Display intended to operate at pressures exceeding 10 psig. If Description Character Allowable Range the water pressure drops to below 10 psig, there is a water pressure limit switch that interrupts boiler 50°F to 201°F Supply Set Point...
  • Page 31 ELECTRICAL 4. Error Codes: The LED Display will display error codes e. To exit the Service Mode, press the S1/- or S2/+ if the boiler is in a temporary fault condition. Table 8.1 keys simultaneously. shows Error Codes and descriptions. In some cases, if the temporary fault is not corrected within 60 seconds 8.

  • Page 32: Start-Up Procedures

    START-UP PROCEDURES 7. START-UP PROCEDURES c) The set point may be adjusted by using the S1/- A. COMPLETING THE INSTALLATION (to decrease) or S2/+ (to increase) keys on the display module. 1. Confirm that all water, gas and electricity are turned off.

  • Page 33: Lighting/Operating Instructions

    START-UP PROCEDURES B. LIGHTING AND OPERATING PROCEDURES FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result, causing property damage, personal injury or loss of life. • A. This appliance does not have a pilot. It is equipped If you cannot reach your gas supplier, call the with an ignition device which automatically lights the fire department.

  • Page 34: Check-Out Procedure

    START-UP PROCEDURES 4. Low Water Cut-Off (if used) - Consult the C. CHECK-OUT PROCEDURE manufacturer's instructions for the low water cut-off operational check procedure. 1. After starting the boiler, be certain that all controls are working properly. Check to be sure that the 5.

  • Page 35: Troubleshooting

    TROUBLESHOOTING 8. TROUBLESHOOTING A. BOILER ERROR DANGER 1. When an error condition occurs the controller will When servicing or replacing components that are in display an error code on the display module. direct contact with the boiler water, be certain that: There is no pressure in the boiler.
  • Page 36 TROUBLESHOOTING Table 8.2: P125 Control Board Fault Codes Fault Code Description Corrective Action 1. Check circulation pump operation. 2. Assure that there is adequate flow through the boiler by accessing the High Limit Exceeded. status menu and assuring that there is less than a 50°F rise from the return thermistor to the supply thermistor.

  • Page 37: Maintenance

    MAINTENANCE 9. MAINTENANCE d. Release the try lever and allow the valve to close. A. GENERAL (WITH BOILER IN USE) If the valve leaks, operate the lever two or three General boiler observation can be performed by the times to clear the valve seat of foreign matter. It owner.

  • Page 38: Boiler Dimensions & Ratings

    BOILER DIMENSIONS & RATINGS 10. BOILER DIMENSIONS & RATINGS A. BOILER DIMENSIONS 1. Figure 10.1 shows the dimensions of the PI-T50 and PI-T80. Figure 10.1: PI-T50/PI-T80 Dimensions...
  • Page 39 BOILER DIMENSIONS & RATINGS 2. Figure 10.2 shows the dimensions of the PI-80, PI-140 and PI-199. Figure 10.2: PI-80/PI-140/PI-199 Dimensions...
  • Page 40 BOILER DIMENSIONS & RATINGS Table 10.1: Boiler Ratings DOE Heating Net I=B=R Seasonal Shipping Boiler Input Btu/hr Capacity³ Rating¹ ’ ² Efficiency³ Weight Model Btu/hr Btu/hr AFUE % Lbs. PI-T50 18,000 to 50,000 16,000 to 46,000 40,000 PI-T80 19,000 to 80,000 17,000 to 74,000 64,000 PI-80...

  • Page 41: Repair Parts

    REPAIR PARTS 11. REPAIR PARTS...
  • Page 42 REPAIR PARTS...

  • Page 43: Appendix A. What's New With The P125 Control Board

    WHAT’S NEW WITH THE P125 CONTROL BOARD APPENDIX A. WHAT’S NEW WITH THE P125 CONTROL BOARD A. ADVANTAGES OF THE P125 CONTROL B. P125 CONTROL BOARD QUICK BOARD REFERENCE 1. Temperature displays in Fahrenheit or Celsius. 1. Press and hold the S3 “Program” key to make changes to: 2.

  • Page 44: P125 Control Board Vs. Wha Control Board Comparison

    WHAT’S NEW WITH THE P125 CONTROL BOARD C. P125 CONTROL BOARD VS. WHA CONTROL BOARD COMPARISON Figure A.2: Comparative Control Board Sequence of Operation...
  • Page 45 NOTES...
  • Page 46 NOTES...
  • Page 47 Peerless ® Pinnacle ® Stainless Steel Gas Boilers I n s t a l l a t i o n , O p e r a t i o n & M a i n t e n a n c e M a n u a l TO T H E I N S TA L L E R : This manual is the property of the owner and must...

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