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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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Related Manuals for PEERLESS Gas Boiler
Summary of Contents for PEERLESS Gas Boiler
- Page 1 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 ® ® As an NERGY Partner, PB Heat, LLC has ® determined that this product meets the NERGY guidelines for energy efficiency.
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Page 2: Table Of Contents
A. SHUT-DOWN ......33 B. BOILER FAULT CODES ....33 9. -
Page 3: Using This Manual
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: USING THIS MANUAL DANGER Indicates a condition or hazard which will cause severe personal injury, death or major property damage. -
Page 4: Preinstallation
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. - Page 5 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. Figure 1.1: Accessibility Clearances – Floor Standing Units Figure 1.2: Accessibility Clearances – Wall Hung Units...
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Page 6: Boiler Set-Up
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. -
Page 7: Water Piping And Controls
(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. - Page 8 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.
- Page 9 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: Output Required Flow = ∆...
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Page 10: System Piping
WATER PIPING AND CONTROLS Figure 3.2: Pinnacle Circulator Sizing Graph 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. - 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...
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Page 16: Special Applications
Hydronics Institute Division of GAMA for further glycol system considerations. SPECIAL APPLICATIONS 1. If the boiler is used in conjunction with a chilled medium system, pipe the chiller in a separate secondary loop. a. Assure that the boiler circulator is disabled during chiller operation so chilled water does not enter the boiler. - 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...
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Page 18: Gas Piping
2. Size and install piping to provide a supply of gas sufficient to meet the maximum demand of all appliances supplied by the piping. FUEL LINE SIZING 1. The rate of gas to be provided to the boiler can be determined by the following: Boiler Input Rate ft ³... -
Page 19: Gas Supply Piping - Operation
This may ignite a gas leak resulting in a fire or explosion. 7. Figure 4.2 and 4.3 are illustrations of the gas shutoff valve for the Pinnacle Boiler. This valve is to be used in addition to the gas service valve shown in Figure 4.1. -
Page 20: Main Gas Valve - Operation
Attach the manometer tube to the pressure tap fitting. e. Open the gas shutoff valve and start the boiler. f. Read and record the gas pressure while the boiler is firing. g. Turn off the boiler and gas shutoff valve h. -
Page 21: Venting, Inlet Air & Condensate
National Fuel Gas Code, ANSI Z223.1/NFPA 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 Underwriters Laboratories, Inc. -
Page 22: Exhaust Vent And Intake 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). Figure 5.2: Multiple Pinnacle Vent Spacing D. EXHAUST VENT AND INTAKE AIR PIPE SIZING 1. -
Page 23: Exhaust Vent And Air Intake Pipe Installation
1. On the PI-T50 and PI-T80 the 2" exhaust vent connection is located on the top, right side of the boiler and the air intake is on the top, left side. See Figure 10.1. The air intake connection is intended for a slip fit. - Page 24 Elevation). WARNING All exhaust vent pipes must be glued, properly supported, and pitched at a minimum of ¼" per foot back to the boiler. Failure to do so may result in severe personal injury, death, or substantial property damage.
- Page 25 2" Pipe (Concentric Vent Kit). WARNING All exhaust vent pipes must be glued, properly supported, and pitched at a minimum of ¼" per foot back to the boiler. Failure to do so may result in severe personal injury, death, or substantial property damage.
- Page 26 VENTING, INLET AIR AND CONDENSATE Figure 5.11: PI-80, PI-140, PI-199 Vertical Venting with 3" Pipe. Figure 5.12: PI-T50 & PI-T80 Vertical Venting with 2" Pipe. Figure 5.13: PI-80, PI-140, PI-199 Vertical Venting with 3" Pipe (Concentric Vent Kit). Figure 5.14: PI-T50 &...
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Page 27: Exhaust Tapping For Vent Sample
VENTING, INLET AIR AND CONDENSATE H. BOILER REMOVAL FROM COMMON VENTING SYSTEM 1. At the time of removal of an existing boiler from a common venting system, follow these steps with each appliance that remains connected. These steps are to be completed while all components which remain connected to the common venting system are not in operation. -
Page 28: Electrical
Figure 6.1: Wiring Connections to Boiler Junction Box 2. Connect boiler to a 110 volt, single phase, 60 hertz electrical supply line with a fused disconnect switch. The boiler is fused for a load of 6.3 amperes. - Page 29 7°F above the boiler set point before it cycles off. i) The differential is applied from this point. For example if the boiler set point is at 180°F with a 10°F differential, the supply temperature will reach 187°F before shutting down. It will not re-start until the supply temperature drops below 177°F.
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Page 30: Safety Interlocks
4. Blocked Vent Pressure Limit Switch: This switch prevents the boiler from operating if the vent pressure exceeds 2 inches of water column. This will prevent the boiler from operating if the vent pipe is blocked. D. CONTROL FUNCTIONS 1. This Pinnacle boiler is equipped with a P125 Control Board. - Page 31 4. Error Codes: The LED Display will display error codes if the boiler is in a temporary fault condition. Table 8.1 shows Error Codes and descriptions. In some cases, if the temporary fault is not corrected within 60 seconds the controller will go into a Fault Code.
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Page 32: Start-Up Procedures
If the supply pressure is too high or too low, contact the fuel gas supplier. 9. Turn on electricity and gas to the boiler. Check to see if the LED display is lit. The combustion air fan will begin a 5 second purge cycle and then the control will go into Standby Mode. -
Page 33: For Your Safety Read Before Operating
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 with an ignition device which automatically lights the burner. -
Page 34: Check-Out Procedure
Reset by pushing S4 "Reset" key. f) Observe boiler operation through one complete cycle. 3. Turn off the automatic fill to the boiler and drain some water to drop the system pressure below 10 psig. Verify that the display module reads "PRO"... -
Page 35: Troubleshooting
Improper or dangerous operation may result. Contact a qualified service technician immediately to inspect the boiler and to repair or replace any part of the boiler which has been under water. This appliance has wire function labels on all internal wiring. -
Page 36: Corrective Action
1. Check the gas pressure to the gas valve while the unit is in operation. 2. Assure that the flame is stable when lit. 3. Check to see if the green light on the display module is out while the boiler is running. -
Page 37: Maintenance
Boiler temperature should never be higher than 240° F. 4. Check for water leaks in boiler and system piping. 5. Smell around the appliance area for gas. If you smell gas, follow the procedure listed in the Lighting Operating Instructions to shut down appliance in Section 7, Start-Up Procedure Part B. -
Page 38: Combustion Chamber Coil Cleaning Instructions
SURE EXHAUST VENT IS NO LONGER BLOCKED!) b. Open the manual gas shutoff valve and reset the thermostats. c. Observe the boiler function to make sure you see a condensate flow. d. If you do not observe a condensate flow, repeat the above procedure. - Page 39 Failure to do so may result in severe personal injury or death. **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.
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Page 40: 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 41 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 42 66,000 to 199,000 Net I=B=R ratings are based on an allowance of 1.15. Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc. Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are based on U.S. Government Testing.
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Page 43: Repair Parts
REPAIR PARTS 11. REPAIR PARTS... - Page 44 REPAIR PARTS...
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Page 45: Appendix A. What's New With The P125 Control Board
“Service Mode.” Press S1/- or S2/+ to change the fan speed. (Note: The service mode will cause the boiler to run even if there is no call for heat. The limits will, however, shut down the unit if the temperature exceeds the set point. -
Page 46: 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 47 Peerless Stainless Steel HI Division ASME of gama PB HEAT, LLC P .O. BOX 447 • NEW BERLINVILLE, PA 19545-0447 ©2006 WEB-3 ® Pinnacle Gas Boilers I n s t a l l a t i o n , O p e r a t i o n &...
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