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PEERLESS Stainless Steel Gas Boilers Installation, Operation & Maintenance Manual

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See also: Installation, Operation & Maintenance Manual
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. CONDENSATE ..... . .18 USING THIS MANUAL G. BOILER REMOVAL FROM COMMON A. INSTALLATION SEQUENCE ... . .1 VENTING SYSTEM .

  • 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 Read carefully, study these instructions before beginning work. This boiler must be installed by a qualified contractor. The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly. Boiler can be installed at high altitude with no burner adjustments. LP equipped boilers must not be installed at elevations above 7,000 feet.

  • Page 5: Boiler Set-Up

    BOILER SET-UP 2. BOILER SET-UP 1. Place boiler on a level surface. (Note: An optional boiler stand is available. Contact your Peerless Distributor.) 2. Locate boiler to allow for ease of vent pipe installation and heating system piping. WARNING Boiler must be set on a level surface so condensate does not back up inside the boiler.

  • Page 6: Water Piping And Controls

    WATER PIPING AND CONTROLS 3. WATER PIPING AND CONTROLS 2. For boilers connected to heating coils in a forced air A. GENERAL system where they may be exposed to chilled air circulation, install flow control valves or other 1. The Pinnacle boiler is a coil type boiler that requires automatic means to prevent gravity circulation of the adequate flow through the boiler for acceptable boiler water during cooling cycles.

  • Page 7: System Components

    WATER PIPING AND CONTROLS b. We can determine the required flow based on the E. SYSTEM COMPONENTS design temperature difference and the "Net I=B=R Output." For this example we will use a 1. Pressure/Temperature Gauge: A combination 20° temperature rise. The calculation is as pressure/temperature gauge is provided with the unit follows: to be mounted in the piping from the boiler supply to...

  • Page 8: Freeze Protection

    WATER PIPING AND CONTROLS Pinnacle Circulator Sizing Graph PI-80 PI-140 PI-199 Flow Rate (GPM) Figure 3.2 2. Zone Valves: Figure 3.7 shows a system in which 1. Glycol in hydronic applications is specially zone valves are used in place of zone circulators. formulated for this purpose.
  • Page 9 WATER PIPING AND CONTROLS...
  • Page 10 WATER PIPING AND CONTROLS...
  • Page 11 WATER PIPING AND CONTROLS...
  • Page 12 WATER PIPING AND CONTROLS...
  • Page 13 WATER PIPING AND CONTROLS...

  • Page 14: Gas Piping

    GAS PIPING 4. GAS PIPING 1. Size and install the gas supply piping properly in order to provide a supply of gas sufficient to meet the maximum demand without exceeding a pressure drop greater than .5″ W.C. between the meter and the boiler.
  • Page 15 GAS PIPING Table 4.1: Natural Gas Input Model (Cubic Ft/Hr) PI-80 PI-140 PI-199 Based on 1000 Btu/Cubic Ft. Table 4.2: LP Gas Input Model (Cubic Ft/Hr) PI-80 PI-140 PI-199 Based on 2500 Btu/Cubic Ft. Table 4.3: Pipe Capacity Capacity of pipe of different diameters and lengths in cu. ft. per hour with pressure drop of 0.3 in.

  • Page 16: Venting

    VENTING 5. VENTING 2. Determine air inlet vent location. A. GENERAL a. Provide 1 foot clearance between bottom of vent Install vent system in accordance with these and ground level and normal snow lines. instructions and with Part 7, Venting of Equipment, 3.

  • Page 17: Air Inlet Vent Installation

    VENTING D . AIR INLET VENT INSTALLATION Table 5.1: Minimum/Maximum Vent Length 1. For minimum and maximum pipe length refer to ″ ″ Total Combined **Equivalent Length of 3 Table 5.1. ″ ″ Exhaust Vent Plus 3 Air Inlet Vent Boiler 2.
  • Page 18 VENTING DIAGRAMS FOR SIDEWALL VENTING STRAIGHT COUPLING TEE (VERTICAL) TEE (VERTICAL) FRONT ELEVATION (MULTIPLE VENTS) EXTERIOR WALL 1" MIN. BOILER EXHAUST 12" MINIMUM INTAKE STRAIGHT 3" 3" COUPLING 3" T & P INTAKE EXHAUST REFER TO MANUAL FOR PROPER CLEARANCES EXHAUST OUTLET GROUND LEVEL RIGHT SIDE VIEW...
  • Page 19 VENTING DIAGRAMS FOR VERTICAL VENTING **IMPORTANT NOTE: All vent pipes must be glued, properly **IMPORTANT NOTE: All vent pipes must be glued, properly supported, and the exhaust must be pitched minimum of a supported, and the exhaust must be pitched minimum of a 1/4″...

  • Page 20: Extended Vent Lengths With

    VENTING E. EXTENDED VENT LENGTHS WITH 4″ ″ PIPE G. BOILER REMOVAL FROM COMMON VENTING SYSTEM 1. The connection of air inlet vent and exhaust vent at At the time of removal of an existing boiler, follow these boiler must remain 3″ and each vent must extend steps with each appliance remaining connected to the from boiler a minimum of 15 equivalent feet before common venting system placed in operation, while the...

  • Page 21: Electrical

    ELECTRICAL 6. ELECTRICAL Install all electrical wiring in accordance with the National Electrical Code and local requirements. 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 National Electrical Code, ANSI/NFPA 70 .
  • Page 22 ELECTRICAL Figure 6.3:Zone Wiring with Zone Valves Figure 6.4:Zone Wiring with Circulators...

  • Page 23: Sequence Of Operation

    ELECTRICAL Figure 6.5:Boiler Control Board Factory Wiring 5. When water temperature reaches the temperature C. SEQUENCE OF OPERATION dial set point plus 10° F (or if the thermostat call-for- heat is satisfied), the gas valve is closed and the 1. When power is first applied to the control, the control enters a 4 second post-purge (blower on max control will initially run through a self-diagnostic speed).

  • Page 24: Start-Up Procedures

    START-UP PROCEDURES 7. START-UP PROCEDURES 8. Adjust set point temperature and differential settings A. COMPLETING THE INSTALLATION as follows: 1. Confirm that all water, gas and electricity are a. Temperature Adjustment: A potentiometer turned off. located on the control board is used to adjust the set point temperature on the boiler appliance.

  • Page 25: Lighting/Operating Instructions

    START-UP PROCEDURES B. LIGHTING/OPERATING INSTRUCTIONS 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 26: Control Descriptions

    START-UP PROCEDURES b. Set thermostat or controller above room C. CONTROL DESCRIPTIONS temperature to call for heat. See Figure 11.1 for location of these devices. c. Ignition sequence should try 3 times before going 1. SUPPLY WATER TEMPERATURE THERMISTOR – into lockout mode.

  • Page 27: Troubleshooting

    TROUBLESHOOTING 8. TROUBLESHOOTING DANGER A. SHUT-DOWN In the event of a shut-down caused by thermodisc When servicing or replacing items that communicate temperature switch, water pressure switch or high limit with the boiler water, be certain that: switch effecting a shut-down of the main burner and There is no pressure on the boiler.

  • Page 28: Boiler Fault Codes

    TROUBLESHOOTING d. Check that the flame rod is connected, and also B. BOILER FAULT CODES that the flame rod is clean. When a fault condition occurs, the control board goes to a LOCKOUT mode. When in the LOCKOUT mode, the e.
  • Page 29 TROUBLESHOOTING 7. Air Pressure Switch Fault Stuck Open – 8 PULSES 10.Gas Valve NOT Connected – 11 PULSES If the control senses the blower pressure switch is not If the controller detects that the gas valve is not closed during the pre-purge cycle, the control will connected it will go into the lockout state.

  • Page 30: 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 31: Boiler Dimensions & Ratings

    BOILER DIMENSIONS & RATINGS 10. BOILER DIMENSIONS & RATINGS PI-80 PI-140/PI-199 Figure 10.1: Boiler Dimensions...
  • Page 32 BOILER DIMENSIONS & RATINGS Table 10.1: Pinnacle ® Connection Sizes Boiler Supply/Return Air Inlet Vent/ Model Connection Connection Exhaust Size ″ ″ ″ 1-1/4 ® Table 10.2: Pinnacle Boiler Ratings PINNACLE ® BOILER RATINGS Net I=B=R Boiler Heating Ratings Seasonal Model Input Capacity...

  • Page 33: Repair Parts

    REPAIR PARTS 11. REPAIR PARTS REPAIR PARTS ® PINNACLE GAS BOILER Repair parts are available from your installer or by contacting Peerless Boilers, New Berlinville, PA 19545-0447. Refer to Table 11.1 and Figure 11.1 to assist in ordering parts. Note: Remember to include boiler model number and serial number when ordering parts. Figure 11.1: Repair Parts Location Diagram (See Next Page for Ordering Information)
  • Page 34 REPAIR PARTS Table 11.1: Repair Parts Stock Code Item Description PI-80 PI-140 PI-199 91425 Blower 91423 91424 Transformer 91413 91413 91413 91406 Control Board 91404 91405 Gas Valve 91426 91426 91426 J/Box — — — 91422 Supply/Return Water Temperature Thermistor 91422 91422 Water Pressure Switch...
  • Page 35 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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