PEERLESS MI SERIES, MIH SERIES, MI-03, MI-04, MI-05 Installation, Operation & Maintenance Manual

MI/MIH

Boilers

Installation,

Operation
Maintenance

Manual

Pr=-EI_LESS _

CAST IRON BOILERS

MI Model Available for Natural or LP Gas

• Standit_g Pilot (3 9 sectior_) with 8(7_ AFUE

• [-Ioneywell SmartValve ® Intermittent Ignition (3-9 section)

with 82% AFUE

MIH Mid-E._f_ency Model Available in 3-6 Sections

for Natural Gas

• Honeywell SmartValve ®Intermittent Ignition with 83% AFUE

• Qualifies for Utility Company Energy Rebates in Some Areas

Natural Draft (Chimney) Venting
Low Profile Design

• Internal Horizontal to Vertical Draft Diverter

• Ideal for Ir_stallations with Low Ceilings

Steel Push Nipples

• Provici( _ a Permar_ent _Vct_'r 7"(c)hl Seed Between Sections

• Unaffected by PetroIcum alzd Oilier Contaminants

Deluxe Insulated Enameled Steel Jacket

• Reduces Boiler Heat Loss

• Completely Encloses Gas Valve and Burners

Safety Controls

• Vent Safety ShutoffSwitch

• Flame Rollout Safety ShutoffSwitch

• Standing Pilot or Honeywell SmartValve _

Intermittent Ignition

• Honeywell Operating Controls

• Taco Circulator

• Elec. Operated Automatic Vent Damper

• Grundfos Circulator

• 50 PSI Safety Relief Valve

• Non-Combustible Floor Pan

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/'/(,cLs(_ co¢l._tdt ['(,('rli,ss [ ](,_ll(,_ (2)m[J(lll{/ ]OF Coltll)l(.lt, it)(iFK(llll!j it!]orlnaliorL

Peerless Heater Company * 231 North Walnut Street * Boyertown. PA 19512 1021 * 610 367 2153 * www,peerless-heater.eom

FAB MI l_l {3/02 5M)

Pnnled _n U S A

USING THIS MANUAL 1

A. INSTALLATION SEQUENCE ............. 1

B. SPECIAL ATTENTION BOXES ........... 1

1. PREINSTALLATION 2

A. ACCESSIBILITY CLEARANCES .......... 2

B. CLEARANCE FROM COMBUSTIBLE

CONSTRUCTION ..................... 2

C. AIR FOR COMBUSTION AND

VENTILATION ....................... 2

D. LIQUEFIED PETROLEUM (LP) GAS ....... 4

E. INSTALLATION SURVEY ............... 4

E PLANNING THE LAYOUT ............... 4

7. START-UP PROCEDURES 20

A. COMPLETING THE INSTALLATION ...... 20

B. CONTROL DESCRIPTIONS ............. 24

C. ADJUSTMENT OF GAS PRESSURE

REGULATOR ....................... 24

D. ADJUSTMENT OF PILOT GAS FLOW .... 24

E. CHECKING BURNER INPUT ............ 24

E CHECK-OUT PROCEDURE ............. 25

8. TROUBLESHOOTING 26

A. SHUT-DOWN CAUSED BY PILOT OUTAGE,

BLOCKED VENT SHUT-OFF SWITCH OR

FLAME ROLL-OUT SAFETY SHUT-OFF

SWITCH ........................... 26

B. TROUBLESHOOTING GUIDES .......... 26

A. BOILER SUPPLY AND RETURN .......... 6

B. SAFETY RELIEF VALVE ................ 7

C. PIPING FOR ZONED SYSTEMS .......... 8

D. EXPANSION TANK .................... 9

E. INDIRECT-FIRED WATER HEATER ........ 9

E FREEZE PROTECTION ................. 9

A. INTEGRAL DRAFT HOOD ............. !0

B. VENT DAMPER INSTALLATION -

GENERAL .......................... 10

C. VENT PIPING AND CHIMNEY .......... 11

D. BOILER REMOVAL FROM COMMON

VENTING SYSTEM ................... 12

A. GENERAL .......................... 29

B. DAILY (WITH BOILER IN USE) .......... 29

C. WEEKLY (WITH BOILER IN USE) ........ 29

D. MONTHLY (WITH BOILER IN USE) ....... 29

E. ANNUALLY (BEFORE START OF HEATING

SEASON) .......................... 30

10. BOILER DIMENSIONS _ _TINGS 31

A. BASE/COMBUSTIBLE FLOOR PAN ....... 32

B. MANIFOLD/GAS TRAIN ............... 34

C. BLOCK/DRAFT HOOD ................ 36

D. JACKET ........................... 38

E. CONTROLS/CIRCULATOR/VENT

DAMPER .......................... 40

A. WIRING ........................... 15

B. ZONED SYSTEM WIRING ............. 15

C. CONTROLS ........................ 15

D. SEQUENCE OF OPERATION ........... 16

Follow thetnsta[lattoninstructionspro',,'_dedill this

manual m the order shown The order ot these
mstructLons has been set m order to provide the installer

with a logical sequence ol steps that wdl mulmllze

potenhal interferences and maximize safety, during

boiler mstallatLon

Indicates a condition or hazard which will cause
severe personal injury, death or major property

damage.

Throughout thLs manual you will see speoal attenuon

boxes intended to supplement the mstmct=ons and make
speoal nohce of potenhal hazards These categories
mean m the judgment of Peerless Heater Company

indicates a condition or hazard which may cause

severe personal injury, death or major property
damage.

Indmates a condition or hazard which will or can
cause minor personal injury or property damage.

indicates special attention is needed, but not directly
related to potential personal injury or property
damage.

1.!B INS

Read carefully, study these msh-uchons before beginning work

This bo,le_ must be installed by a quahfled con_ac_or
The bonler warranty can be voided _t the boder Is not installed, maintained and serviced correctly

The equipment must be installed m accordance with those installation requirements of the authority having
jurisdiction or, in the absence of such requirements, to the current edition of the National Fuel Gas Code, ANSI

Z223.1/NFPA 54.
Where requtred by the authority having jurisdiction, the installation must conform to American Society of

Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, ASME CSD-I.

r_*wr:_o,[o.]:[.."[.."]I:]I ! / ik'd_a,]l :f;1 :_r_*l_[q _

Install boiler not less than 24" between the left slde. top,
and tront ot the boiler and adjacent wall or other

apphance, when access is reqmred for servicing

The design of ths boiler _scertffled for alcove mstallatlon
wlth the following clearances

I 6" between s,des and combustible construction

2 24" between top of jacket and combushble

construction

3 6" between draft hood and combustible

COl_ls_uctlon

4 6" between vent pipe and combustLble construction
5 10" between rear of ]acket and combushble

consiluctlon

Do not install this boiler on combusttble flooring

unless it is installed on a special combustible floor
pan provided by Peerless Heater Company. Boiler

installation on combustible flooring without the
special pan is a fire hazard.

To order combustible floor pan, use the 5-digit stock
codes listed in Section 11A of this manual.

Do not install this boiler on carpeting. Boiler
installation on carpeting asa fire hazard. Install this
boder on non.combustible flooring or use a

combustible floor pan to install thts boder on other

non-carpeted flooring.

2

Prowde adequate facflltnes for combustlon and

vent]lahon a_r unaccordance w_th Sechon 5 3. ALrfor

Combustion and Ventilation Nanonal Fuel Gas

Code ANSI -7223 1/NFPA 54, or apphcable

prows_ons of the local budding code Subsechons 2

through 6 below are based on National Fuel Gas

Code ANSI Z223 1!NFPA 54 requnrements

DehnltlOnS

Unconfined Space: a space whose volume usnot

less than fifty (50) cubnc feet per 1000 Btu/hr of the

total input rahng of all apphances installed Jnthat

space Rooms commumeatmg dnrectly w_th the space

m which the apphances are installed, through

opemngs not furmshed w_th doors, are considered

part of the unconfined space

Unusually Tight Construction: Constmchon

where

Walls and cenlmgs exposed to the outsMe
atmosphere have a continuous water vapor

retarder wlth a rating of i perm or less wLth
openings gasketed or sealed, and

b Weatherstnppmg has been added on openable

windows and doors, and

CaulkLng or sealants are supphed to areas such
as joints around window and door frames.
between sole plates and floors, between wall-
ceflmg joints, between wall panels, at
penetratlons for plumbing, electrical and gas
hnes, and at other openings

2

3 Appliances Located in Unconfined Spaces:

For installations in unconfined spaces with other
than unusually tight construction, the supply of air
for combustion and ventilation can usually be
considered adequate.

4. Unusually Tight Construction:

For equipment located in buildings of unusually tight
construction as defined on the previous page,
provide air for combustion and ventilation using the

methods described in 5a or 5b below.

5. Appliances Located in Confined Spaces:

a. All air from inside the building: Provide two

permanent openings communicating directly with
an additional room or rooms of sufficient volume

so that the combined volume of all spaces meets
the criteria for an unconfined space. Use the total

input of all gas utilization equipment installed in

the combined space in making this
determination.

Size each opening with a minimum free area of
one square inch per 1000 Btu/hr. of the total

rating of all gas utilization equipment in the

confined space, but not less than I00 square
inches. Begin with one opening 12 inches from

the top, and begin the other opening within 12
inches of the bottom of the enclosure. See Figure

1. Provide air openings with minimum
dimensions not less than three (3) inches.

b. All air from outside the building. Connect the

confined space with the outdoors in accordance
with methods i) or ii) below. Provide air openings

with minimum dimensions not less than three (3)
inches. Where ducts are used, make certain that
they are the same cross-sectional area as the free
area of the openings to which they connect.

Provide two permanent openings, one
commencing within 12 inches of the top and
one commencing within 12 inches of the

bottom of the enclosure. Connect the

openings directly or by duets, with the
outdoors or spaces (crawl or attic) that freely

communicate with the outdoors.

Where directly communicating with the

outdoors (see Figure 2) or where
communicating to the outdoors through
vertical ducts (see Figure 3), size each
opening with a minimum free area of one (I)
square inch per 4000 Btu/hr. of total rating of
all equipment in the enclosure.

i ?

I

12" max

TWO AIR OPENINGS:

Minimum

Free Area Each -

1 in2per 1000 Btuh

at Least 100 in2

BUILDING

Must communicatefreely

withoutdoors

Must notbeunder

negativepressure

12" max

Figure 1: Air Openings - All Air from Indoors

TWO AIR OPENINGS:

Minimum

Free Area Each -

1 in_per 4000 Btuh

Figure 2: Air Openings - All Air Directly from

Outdoors

Figure 3: Air Openings - All Air from Outdoors

through Vertical Ducts

6.

:_ IIL_l_uf±lUHff±_ugl[e]L_l[_'q_|J;kVJ_k

7.

Where communicating with the outdoors

through horizontal ducts, size each opening

with a minimum free area of one (1) square

inch per 2000 Btu/hr of total input rating of

all equipment in the enclosure. See Figure 4.

ii) Where the equipment has clearances of at

least one (1) inch from the sides and back
and six (6) inches from the front of the
appliance, the code allows one permanent
opening, commencing within 12 inches of
the top of the enclosure. Connect the
opening directly with the outdoors or through

a vertical or horizontal duct to the outdoors
or spaces (crawl or attic) that freely

communicate with the outdoors. Size the
opening with a minimum free area of one

square inch per 3000 Btu!hr. of the total
input rating of all equipment in the enclosure,

and not less than the sum of the areas of all
vent connectors in the confined space.

In calculating free area of an opening, take into
account the blocking affect of louvers, grilles and

screens. Do not use screens smaller than i/4" mesh.
If the free area is known, use this value in calculating

the size of the opening required. If it is not known,
assume that wood louvers provide 20-25% free area,

and metal louvers and grilles provide 60-75% free
area.

Remove sources of hydrocarbons (bleaches,
cleaners, chemicals, sprays, paint removers, fabric

softeners, etc.) from the boiler area. The vapors
generated by these substances can contaminate the
combustion air and contribute to shortened

boiler/vent system life.

I_ff±!_l_ll_[dl|ll:lt_VLelll

Liquefied Petroleum (LP) is heavier than air and may

collect or "pool" in a low area in the event of a leak
from defective equipment.This gas may then ignite,

resulting in a fire or explosion. See the instructions
below.

ii-i ..

12"maxl [ i 1--

, _t [jT TWO AIR OPENINGS: |

) 1' Minimum l

Free Area Each =

in_per 2000 Btuh !

_ min

?

12"max

Figure 4: Air Openings - All Air from Outdoors

through Horizontal Ducts

For new and existing installations, a Water Installation
Survey is available from Peerless Heater Company. The

survey will provide information on how a hot water
boiler works with your specific system and will provide

an overview of hot water system operation in general.

You can also use this survey to locate system problems

which will have to be corrected. To obtain copies of the

Water Installation Survey, contact your Peerless

representative.

Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring.

I IJ ! [o|lJ :l ;i I:ll]'.J :Eld:{o] ! ::[IILVA|_[€-r_,_..

The following LP requirements from the Uniform
Mechanical Code, section 304.6, may be in effect in

your geographic area:

"Liquefied peh'oleum gas-burning appliances shall
not be installed in a pit, basement or similar location

where heavier-than-air gas might collect. Appliances

so fueled shall not be installed in an above-grade
under-floor space or basement unless such location

is provided with an approved means for removal of
unburned gas."

l_.]llF'4T_'i:i_IrJ_

2

3

Provide a sound, level foundahon Locate boiler as
near to the chmney or outside v_ali as possLble and

cennahzed v_Jth respect to the heahng system

Locate boiler [n front of installation pos[hon before
_movll_g crate

If using combushble floor pan, poslhon pan on
foundat,on or flooring

4 Separate the wood shppmg pallet from the boiler

base by removing two (2) hold-down bolts at each
end of the boder base

5 Move boder into hnal poslhon If using combustLble

floor pan, install boder on pan as outhned ,n the
instructions included wlth the pan

3. WATER PIPING AND CONTROLS

"-I [:{=]ll_;l[.-llJ'J_Jl_'m_,]l_ll] I;l:i[IJ;|k'

1. Size the supply and return to suit the system. A

t_pical piping arrangement is shown in Figure 5.
Refer also to the I-B-R Installation Guide No. 200

and the Peerless Water Survey for additional
guidance during water piping installation.

2. Return Piping:
a. For boilers equipped with a factory mounted

circulator, pipe the return to the inlet connection
of the circulator.

b. For boilers equipped with a separate, unmounted

circulator, pipe the outlet connection of the
circulator to a tee, provided with a drain valve, at
the 1-1/4 NPT return tapping near the bottom of
the left section. Pipe the return to the inlet

connection of the circulator.

3

4.

5.

Supply Piping:
Pipe the supply to the I i/2 NPT supply tapping at

the top and rear of the boiler.

When system return water temperature will be below

130°E pipe the boiler with a bypass arrangement to
blend the system return and hot supply to obtain at
least 130°F entering the boiler. For more information
on bypass piping, consult the Peerless Water Survey.

If desired, install the circulator in the alternate
location shown in Figure 5. Consult the Peerless
Water Survey for more information on circulator

location.

COLD

WATER

FILL

VAL VE

DRAIN

VAI VE J

TO

DRAIN

l

i

,7

Figure 5: Supply and Return Piping

6. 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,
control replacements, etc )

7. If this boiler and distribution system is used in
conjunction with a refrigeration system, pipe the
chilled medium in parallel with the boiler and install
the proper valve to prevent the chilled medium from

entering the boiler. A drawing illustrating this hook-
up is provided in Figure 6

8. When the boiler is connected to heating coils located

in air handling units where they may be exposed to

refrigerated air circulation, install flow control valves

or other automatic means to prevent gravity

circulation of the boiler water during the cooling

cycle.

9. If this boiler is installed above radiation level,

provide a low water cutoff device, either as a part of

the boiler or at the time of boiler installation.

C HECj VAILVEI

SUPPLY

LINE

LINE

WATER THREE WAY

_HILLER VALVE

Figure 6: Parallel Hook-up with Water Chiller

I:m l-'f!1=:lL'dI;t=l!l=l:l krl±lLvd

i I Locate safety relief valve and fittings in bag

assembly.

2. If air elimination is not required at the safety relief
valve tapping, install valve and piping as shown in
Figure 7.

3. For air elimination at the safety relief valve tapping,
install valve and piping as shown in Figure 8.

SAFETY
RELIEF

VALVE

x6"

NIPPLE

Pipe the discharge of safety relief valve to prevent
injury in the event of pressure relief, Pipe the
discharge to a drain. Provide piping that is the same
size as the safety relief valve outlet.

Figure 7: Safety Relief Valve Hook-Up Installation

with Air Elimination in System Piping

TO AIR

ELIMINATION

DE_CE

SUPPLY TEE

SAFETY X 6 _
RELIEF NIPPLE

VALVE

NIPPLE

TO DRAIN

5/4" STREET

ELBO_

Figure 8: Safety Relief Valve Hook-Up with

Air Elimination

7

loll I'JI_IL'_[_ l;:[e];l v_[o]L'ql:lm]F.._'_"-]Ii :hVj_

1. See Figures 9 and 10 for basic zoned system layouts.

2 Run each zone pipe down then up to zone to

prevent air accumulation in piping

3. If required, provide means to isolate and drain each
zone separately,

TO SYSTEM

ZONE ZONE ZONE

5 2 /

ZONE

VALVES

I

I

TO

SUPPLY

FROM SYSTEbl

BAL _,NCINO

VAi VES m',

CONNECT TO

RETURN

(CIRCULATOR INLET)

ZONE ZONE ZONE

I 2 3

I

I

±

Figure 9: Zone Piping with Zone Valves

TO SYSTEM

ZONE ZONE ZONE

5 2 1

FROM SYSTEM

ZONE ZONE

1 2 3

FLOW

CONTROL _]

VALVES

I-

q

CONNECT

TO

SUPPLY

ZONE

CIRCULATORS

CONNECT TO

RETURN

TAPPING

Figure 10: Zone Piping with Circulators

8

I_ I:l;f:l:_,l: I;J;{e]i:_l,]i[o]_

1. Consult the tank manufacturer's instructions for

specific information relating to tank installation Size
the expansion tank for the required system volume
and capacity. See Table 8 in Section 10 for boiler
water capacity.

2.

Expansion tanks are available with built-in fill valves
and check valves for reducing supply water pressure

and maintaining minimum system pressure. Check
the design features of the tank and provide valves as

necessary.

Refer back to Figure 5 for typical expansion tank piping.

I::m I I£qm]I:| =[o,]iI_ :ll:t ::1e]I_l,__ii =1;t I:I_,__ii ::1

If the boiler is to be used in conjunction with an indirect-
fired water heater, refer to Figure 11 for typical piping.
Follow the instructions provided by the water heater
manufacturer. Pipe the water heater as a separate zone.

For new or existing systems that must be freeze-
protected:

Use only inhibited propylene glycol solutions of up to
50% by volume with water. Ethylene glycol is toxic
and can attack gaskets and seals used in hydronic
systems.

1.

Glycol in 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. The anitfreeze solution should be tested at least once
a year and as recommended by the antifreeze

manufacturer.

3.

4.

Antifreeze solutions expand more than water. For
example, a 50% by volume solution expands 4.8%

in volume for a temperature increase from 32°F to

180°F, while water expands 3% with the same
temperature rise. Allowance must be made for this
expansion in system design.

For more information, consult the Peerless Water

Installation Survey and the antifreeze manufacturer.

SUPPLY TO

SYSTEM

RETURN FROM

SYSTEM

ZONE VALVES

INDIRECT FIRED

WATER HEATER

HOT DOMESTIC

WATER

SUPPLY

COLD

DOMESTIC _-

WATER SUPPLY

SUPPLY

TO

TANK

J

BALANCING

VALVE

]

BALANCING

VALVE

i I

SYSTEM

CIRCULATOR _

DRAIN

Figure 11: Typical Piping with Indirect-Fired Water Heater

9

Lt/:1_/Jl_[,':t

4; VENTING

|_,!1 h,'_ii::[d; f_,_ II o] ;f_,_;Iil -"[o_o]g

1.

The MIiMIH boiler is equipped with a built in draft
hood This device is designed to:

a provide for the ready escape of flue gases from

the boiler in the event of no draft.

b. prevent a backdraft [Tomentering the boilen

c. control stack draft during operation.

These tasks are accomplished without the extra
height requirements of a separate draft hood.

2.

The draft hood relief opening is the large rectangular
passage at the front of the boiler. Make certain that

there are no obstructions to airflow in front of this
opening.

3.

A vent safety shut off switch is located within the
draft relief opening to shut off the boiler in case of a
blocked vent condition. See Section 7B for details

regarding this device. See Figure 16 in Section 6
(Electrical) for spill switch location.

4.

The vent damper can be mounted directly onto the
round draft hood outlet (vent connector) on top of

the boiler, or in vent piping close to the boiler. See
the Vent Damper Installation Instructions below.

].

2.

3.

4.

Do not use one vent damper to control two or more
heating appliances. See Figure 12.

Follow these and the installation instructions that are
included with the vent damper. Observe the cautions

and warnings that accompany all instructions.

Make certain that minimum clearances provided in
the vent damper manufacturer's instructions are
maintained and that adequate space is available for

damper accessand service.

Orient the damper operator to facilitate connection
of the harness with the vent damper and boiler. Note
flue gas flow arrow on vent damper and orient as
required. For installation with damper mounted in

vertical position, see Figure 13. For installation with
damper mounted in horizontal position, mount the

unit as shown in Figure 14 to avoid excessive heat

on the operator or condensation drips into the
operator.

BOILER

c:::::::_ c:::::::_

c:::=_ c:::::_
c:::::::_ c:::::::_

OTHER

HEATING

&PPLIANCE

INCORRECT

CORRECT

Figure 12: Venting Multiple Appliances

10

_o,,NkVJ:h,_/ uI:JI:,,]h,1[€_V_*l_._I D][o,]-"I hVjh._I_"

1. Install vent piping in accordance with Part 7. Venting
of Equipment, National Fuel Gas Code, ANSI
Z223. I/NFPA 54 or applicable provisions of the local
building codes.

2. Inspect the existing chimney and lining for structural
soundness, corrosion and perforations. Repair as

neces_Fy.

3. Install vent pipe to slope upward at least I/4" per
lineal foot between the draft hood outlet and the

chimney.

4.

5.

6.

7.

Before connection of joints, inspect the vent pipe
interior for foreign objects such as tools, equipment,

rags, etc. and remove if present.

Insert vent pipe into but not beyond the inside wall
of the chimney flue.

Do not connect vent connectors serving appliances
vented by natural draft into any portion of

mechanical draft systems operating under positive

pressure.

Support horizontal portions of the venting system to
prevent sagging by use of metal strapping or
equivalent means. Locate supports at no more than
four (4) foot intervals.

SLOPE uP
A MINIMUM

OF 1/4"
PER FOOT

VENT

DAMP

DRAFT _ _

f¢3

HOOD

RELIEF

flVENT TO

CHIMNEY

SUPPORT
AS REQUIRED,

DRAFT HOOD
OUTLET

Figure 13: Venting with Vent Damper in Vertical Position

SLOPE UP VENT
A MINIMUM DAMPER

OF I/4"
PER FOOT_,,_

_VENT TO

CHIMNEY

11 O'CLOCK i O'CLOCK

POSITION POSITION

!

SUPPORT AS
REQUIRED

r i

HEAT

_CONDENSATION

ZONE

7 O'CLOCK _5 O'CLOCK

POSITION POSIT'ON

DO NOT MOUNT DAMPER

OPERATOR IN SHADED REGION

SECTION A

Figure 14: Venting with Vent Damper in Horizontal Position

11