PeerlessBoilers MI-03 Series Installation, Operation & Maintenance Manual
Cast iron, chimney vent, gas fired
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Series
!
WARNING
Attention Installer - Affix
these instructions adjacent
to boiler. Provide model
number and serial number
when seeking information and
support.
Attention Building Owner -
Retain these instructions for
future reference. Contact a
qualified installer, service
agency or gas supplier for all
issues and support.
• Water Boiler
• Cast Iron
• Chimney Vent
• Gas Fired
MI-x
Gas
Boilers
MI-x-03 MI-x-04 MI-x-05 MI-x-06
MI-x-07 MI-x-08 MI-x-09
Installation,Operation
& Maintenance Manual
Read these instructions carefully before installing.
This boiler must only be installed, serviced, or repaired by a qualified
installer, service agency or gas supplier. Improper installation,
adjustment, alteration, service, or maintenance can cause severe
personal injury, death, or substantial property damage. For assistance
or additional information, consult a qualified installer, service agency or
gas supplier.
!
WARNING
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Summary of Contents for PeerlessBoilers MI-03 Series
- Page 1 Series MI-x Boilers MI-x-03 MI-x-04 MI-x-05 MI-x-06 MI-x-07 MI-x-08 MI-x-09 WARNING Attention Installer - Affix these instructions adjacent to boiler. Provide model number and serial number when seeking information and support. Attention Building Owner - Retain these instructions for future reference. Contact a qualified installer, service agency or gas supplier for all issues and support.
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Page 2: Table Of Contents
MI-x Installation, Operating & Service Manual Manual Contents Page 1. Qualified Installer, Service Agency or Gas Supplier Read Before Proceeding ......3 2. -
Page 3: Qualified Installer, Service Agency Or Gas Supplier
Installation, Operating & Service Manual MI-x Qualified Installer, Service Agency or Gas Supplier Read Before Proceeding DANGER DANGER Explosion Hazard. Asphyxiation Hazard, Burn Hazard, Electrical Shock Hazard. • DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this •... -
Page 4: User/Homeowner Read Before Proceeding
MI-x Installation, Operating & Service Manual User/Homeowner Read Before Proceeding WARNING CAUTION Asphyxiation Hazard. Fire Hazard. Burn Hazard. • A qualified installer, service agency or gas Keep children and pets away from hot surfaces supplier should annually inspect boiler. of the boiler including boiler piping, vent piping, and vent terminals. -
Page 5: Specifications
Installation, Operating & Service Manual MI-x Specifications Table 3-1: Ratings Model Number AFUE % Input (MBH) DOE Heating Capacity (MBH) Net AHRI (MBH) MI-x-03 84.0 MI-x-04 84.0 MI-x-05 84.0 MI-x-06 84.0 MI-x-07 84.0 MI-x-08 84.0 MI-x-09 84.0 Input ratings can be used for elevations up to 2,000 ft.Refer to Appendix C, High Altitude Installations, for elevations 2,000 ft. -
Page 6: Locating Boiler
MI-x Installation, Operating & Service Manual Locating Boiler Table 4-1: Corrosive Combustion Contaminants Code Requirements and Sources 1. Installations must conform to requirements of Contaminants to avoid: authority having jurisdiction or, in the Spray cans containing chloro/fluorocarbons (CFC’s) absence of such requirements, to National Fuel Gas Code, ANSI Z223.1/NFPA 54. - Page 7 Installation, Operating & Service Manual MI-x Locating Boiler (continued) Before Removing Existing Boiler 4. Place in operation appliance being inspected. Follow Operating Instructions. See Figure 10- Take pictures and measure and/or mark existing 1. Adjust thermo stat so appliance will operate steam and condensate return piping to ensure continuously.
- Page 8 MI-x Installation, Operating & Service Manual Locating Boiler (continued) WARNING WARNING Adequate combustion and ventilation air must ASSURE THAT THE FRONT AIR DAM is in place be provided to assure proper combustion. and undamaged. A damaged front air dam will negatively affect the performance of this boiler, which can cause serious property damage, personal injury or death.
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Page 9: Preparing Boiler
Installation, Operating & Service Manual MI-x Preparing Boiler 4. Remove all boiler hold-down fasteners. DANGER 5. Tilt the boiler to one side and slide a wooden slat Use precautions and appropriate rigging under the two raised feet. apparatus when moving heavy objects. 6. - Page 10 MI-x Installation, Operating & Service Manual Venting (continued) 2. Install vent piping. E. Do not connect boiler into a chimney flue servicing an open fireplace or other solid fuel A. See Figure 3-4 for vent sizes and locations. appliance. See Figure 4-2 for clearances. Prior to boiler installation, inspect chimney B.
- Page 11 Installation, Operating & Service Manual MI-x Venting (continued) 4. Install vent termination (masonry chimney and DANGER single wall metal pipe). Inspect existing chimney before installing A. Termination shall extend at least 5 ft. boiler. Look for corrosion holes. Failure to clean in vertical height above highest connected chimney or replace corroded pipe or tile lining appliance vent outlet.
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Page 12: Water Piping
MI-x Installation, Operating & Service Manual Venting (continued) Roof Slope Heights (H) Roof Slope Flat to 6/12 Over 6/12 to 7/12 1.25 Over 7/12 to 8/12 Over 8/12 to 9/12 Over 9/12 to 10/12 Over 10/12 to 11/12 3.25 Over 11/12 to 12/12 Over 12/12 to 14/12 Over 14/12 to 16/12 Over 16/12 to 18/12... - Page 13 Installation, Operating & Service Manual MI-x Water Piping (continued) 4. Connect system supply and return piping to boiler. Refer to Figures 7-1, 7-2, and 7-3. Also consult Residential Hydronic Heating Installation and Design I=B=R Guide. Maintain minimum ½ inch clearance from hot water piping to combustible materials.
- Page 14 MI-x Installation, Operating & Service Manual Water Piping (continued) MI8104R2 112380-02 - 6/24...
- Page 15 Installation, Operating & Service Manual MI-x Water Piping (continued) MI8104R2 112380-02 - 6/24...
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Page 16: Gas Piping
MI-x Installation, Operating & Service Manual Gas Piping DANGER Explosion Hazard. 1. Size gas piping. Design system to provide Do not use matches, candles, open flames, or adequate gas supply to boiler. Consider these other ignition sources to check for leaks. Failure factors: to comply could result in severe personal injury, A. -
Page 17: Electrical
Installation, Operating & Service Manual MI-x Electrical WARNING DANGER Electrical Shock Hazard. Electrical Shock Hazard. Wiring errors can cause improper or dangerous • Disconnect electrical supply before installing or operation. Verify proper operation after performing maintenance. installation. • Electrical power may be supplied from more than one circuit. - Page 18 MI-x Installation, Operating & Service Manual Electrical (continued) Figure 9-1: Wiring Connection Diagram MI8104R2 112380-02 - 6/24...
- Page 19 Installation, Operating & Service Manual MI-x Electrical (continued) Figure 9-2: Schematic Ladder Diagram MI8104R2 112380-02 - 6/24...
- Page 20 MI-x Installation, Operating & Service Manual Electrical (continued) Figure 9-3: Wiring Schematic, Zone Valves Figure 9-4: Wiring Schematic, Zone Circulators MI8104R2 112380-02 - 6/24...
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Page 21: System Start-Up And Checkout
Installation, Operating & Service Manual MI-x System Start-up and Checkout H. Allow water to flow through system until DANGER discharge from hose is bubble free for 30 Explosion Hazard. seconds. Do not use matches, candles, open flames, or Open zone valve or start circulator to second other ignition sources to check for leaks. - Page 22 MI-x Installation, Operating & Service Manual System Start-up and Checkout (continued) Figure 10-1: Operating Instructions MI8104R2 112380-02 - 6/24...
- Page 23 Installation, Operating & Service Manual MI-x System Start-up and Checkout (continued) 9. Check pilot burner flame. WARNING Natural Gas Only. Pilot produces single flame. Explosion Hazard. Flame should be steady medium hard blue Ensure inlet pressure tapping is fully closed enveloping 3/8 to 1/2 inch of igniter-sensor tip.
- Page 24 MI-x Installation, Operating & Service Manual System Start-up and Checkout (continued) 13. Check gas input rate to boiler. A. When checking rate, ensure all other appliances connected to same meter as boiler are off. B. Input ratings shown on boiler rating label can be used for elevations up to 2,000 ft.
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Page 25: Operation
Installation, Operating & Service Manual MI-x Operation 1. See Hydrolevel 4200 Series HydroStat manual for details regarding 4200 control operation. 2. Boiler Sequence of Operation. A. When thermostat calls for heat, control starts system circulator if water temperature is above 125ºF. - Page 26 MI-x Installation, Operating & Service Manual Operation (continued) TEMP LWCO ECONOMY IGNITION LIMITS V-PWR V-SW FLAME ACTIVE HI TEMP ACTIVE ACTIVE TARGET SPILL VENT VENT PILOT SWITCH, DAMPER DAMPER FLAME ROLL-OUT POWER SWITCH SWITCH CALL 30 IGNITION BLINKS IF TEST / MENU ATTEMPTS IN HEAT DAMPER...
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Page 27: Before Leaving Jobsite
Installation, Operating & Service Manual MI-x Before Leaving Jobsite Before Leaving Jobsite: Checked CO alarm installed Boiler and system filled with water Performed gas leak test Checked pilot burner flame Checked main burner flames Checked gas input rate ... -
Page 28: Service And Maintenance
MI-x Installation, Operating & Service Manual Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen. - Page 29 Installation, Operating & Service Manual MI-x Service and Maintenance (continued) WARNING This boiler should be serviced by a qualified installer, service agency, or gas supplier. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. •...
- Page 30 MI-x Installation, Operating & Service Manual Service and Maintenance (continued) 6. Inspect Temperature/Pressure Gauge. 4. Clean Main Burners and Combustion Chamber. A. Water temperature needle should move with A. To remove burners for cleaning, changing variation in water temperature. orifices, or repairs: i.
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Page 31: How It Works
Installation, Operating & Service Manual MI-x How It Works Economy thermal targeting feature saves fuel by adjusting boiler water temperature based on heating demand. Thermal pre-purge feature saves fuel by delaying burner start when residual heat is available in boiler. When thermostat calls for heat, control module starts system circulator, checks safety limits, and activates vent damper. - Page 32 MI-x Installation, Operating & Service Manual How It Works (continued) Rear of Boiler (On rear of boiler) MI8104R2 112380-02 - 6/24...
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Page 33: Troubleshooting
Installation, Operating & Service Manual MI-x Troubleshooting 1. Before Troubleshooting. When using troubleshooting tables, keep in mind: A. Troubleshooting should be completed by a professional heating technician. B. Before seeking technical assistance, the servicing technician should have a electrical meter and gas pressure gauge available for use. - Page 34 MI-x Installation, Operating & Service Manual Troubleshooting (continued) 2. See Troubleshooting Tables 15-2 and 15-3. See also troubleshooting information in HydroStat 4200 manual. Table 5-2: Troubleshooting Chart (1 of 2) Condition Recommended Corrective Action No “dot” at bottom-right corner of No call for heat.
- Page 35 Installation, Operating & Service Manual MI-x Troubleshooting (continued) Table 5-2: Troubleshooting Chart (2 of 2) Condition Recommended Corrective Action Can you hear sparking at pilot, or sparking at control with ignition wire disconnected? Display will show the ignition trial number. - If there is not spark noise, replace the control.
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Page 36: Service Parts
MI-x Installation, Operating & Service Manual Service Parts Service parts are available from your local PB Heat, LLC distributor or from Parts To Your Door at 1 (610) 916-5380 (www.partstoyourdoor.com). Part Number [Quantity] Key No. Description MI-x-03 MI-x-04 MI-x-05 MI-x-06 MI-x-07 MI-x-08 MI-x-09... - Page 37 Installation, Operating & Service Manual MI-x Service Parts (continued) Part Number [Quantity] Description MI-x-03 MI-x-04 MI-x-05 MI-x-06 MI-x-07 MI-x-08 MI-x-09 Base Assembly Base Wrapper Base Tray Burner Tray Base Side Insulation Base Rear Insulation (Nat Gas) (Nat Gas) (Nat Gas) (Nat Gas) (Nat Gas) (Nat Gas)
- Page 38 MI-x Installation, Operating & Service Manual Service Parts (continued) Natural Gas Only Part Number [Quantity] Description MI-x-03 MI-x-04 MI-x-05 MI-x-06 MI-x-07 MI-x-08 MI-x-09 Gas Valve, Natural Gas, 1/2 in. X 1/2 in. MIX026 [1] VR8204C3007 Gas Valve, Natural Gas, 3/4 in. X 3/4 in. MIX027 [1] VR8304P4496 Gas Valve, LP, 1/2 in.
- Page 39 Installation, Operating & Service Manual MI-x Service Parts (continued) Part Number [Quantity] Key No. Description MI-x-03 MI-x-04 MI-x-05 MI-x-06 MI-x-07 MI-x-08 MI-x-09 Boiler Control (Gas) Hydrolevel 4200, w/ sensor MIX045 [1] 24 VAC Transformer 40VA MIX046 [1] Limit Sensor 12 inches long MIX047 [1] MI8104R2 112380-02 - 6/24...
- Page 40 MI-x Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description MI-x-03 MI-x-04 MI-x-05 MI-x-06 MI-x-07 MI-x-08 MI-x-09 Jacket Set MX048 [1] MX049 [1] MX050 [1] MX051 [1] MX052 [1] MX053 [1] MX054 [1] MI8104R2 112380-02 - 6/24...
- Page 41 Installation, Operating & Service Manual MI-x Service Parts (continued) Part Number [Quantity] Key No. Description MI-x-03 MI-x-04 MI-x-05 MI-x-06 MI-x-07 MI-x-08 MI-x-09 Manifold, Water Relief/Temp-Press Gauge MX055 [1] Temperature/Pressure Gauge MX056 [1] Safety Valve, 30 PSI MX057 [1] Drain Valve Obtain Locally (3/4 in.
- Page 42 MI-x Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Key No. Description MI-x-03 MI-x-04 MI-x-05 MI-x-06 MI-x-07 MI-x-08 MI-x-09 Power Supply Harness MIX058 [1] Main Control Harness MIX060 [1] Gas Conversion Kits*: Part Number [Quantity] Key No. Description MI-x-03 MI-x-04 MI-x-05 MI-x-06 MI-x-07 MI-x-08 MI-x-09 Not Shown...
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Page 43: Appendix A Combination Refrigeration/Heating System
Installation, Operating & Service Manual MI-x Appendix A Combination Refrigeration/ Heating System 1. If boiler is used in connection with refrigeration 2. If boiler is connected to heating coils located in systems, boiler must be installed with chilled air handling units where they may be exposed to medium piped in parallel with the heating boiler refrigerated air, boiler piping must be equipped using appropriate valves to prevent chilled... -
Page 44: Appendix B Water Quality And Boiler Additives
MI-x Installation, Operating & Service Manual Appendix B Water Quality and Boiler Additives Other non-metallic tubing is equipped with an The heat exchanger used in this boiler is made from oxygen barrier to prevent migration of oxygen cast-iron. Once filled with water, it will be subjected into water. -
Page 45: Appendix C High Altitude Installations
Installation, Operating & Service Manual MI-x Appendix C High Altitude Installations Conversion kits are required for installations above 5,400 ft. WARNING Asphyxiation Hazard. Proper operation of boiler depends upon use of correct burner orifice and blocked vent switch for fuel and altitude at which boiler is installed. -
Page 46: Service Record
MI-x Installation, Operating & Service Manual SERVICE RECORD DATE SERVICE PERFORMED MI8104R2 112380-02 - 6/24... - Page 47 Installation, Operating & Service Manual MI-x SERVICE RECORD DATE SERVICE PERFORMED MI8104R2 112380-02 - 6/24...
- Page 48 Installation, Operating & Service Manual MI-x Series MI-x Boilers MI-x-03 MI-x-04 MI-x-05 MI-x-06 MI-x-07 MI-x-08 MI-x-09 Installation, Operation & Maintenance Manual TO THE INSTALLER: 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.
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