PEERLESS Pinnacle PI-399 Installation And Operation Manual

Download

Page 1

Pinnacle

Gas Boilers PI-399 Rev 2

Peerless

Stainless Steel

Installation, Operation & Maintenance Manual

– 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.

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.

WARNING

Page 2

TABLE OF CONTENTS

USING THIS MANUAL 1

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

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

1. PREINSTALLATION 2

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

B. CODES & REGULATIONS . . . . . . . . . . . . . . .2

C. ACCESSIBILITY CLEARANCES . . . . . . . . . . .3

D. COMBUSTION AND VENTILATION AIR . . . .3

E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .3

2. BOILER SET-UP 4

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3. WATER PIPING AND CONTROLS 5

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

B. OPERATING PARAMETERS . . . . . . . . . . . . . .5

C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .5

D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . . .8

E. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .8

F. SPECIAL APPLICATIONS . . . . . . . . . . . . . . . .8

4. GAS PIPING 15

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .15

B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . .15

C. GAS SUPPLY PIPING INSTALLATION . . . . .15

D. GAS SUPPLY PIPING – OPERATION . . . . . .16

E. MAIN GAS VALVE – OPERATION . . . . . . . .17

5. VENTING, INTAKE AIR & CONDENSATE 18

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .18

B. APPROVED MATERIALS FOR EXHAUST

VENT AND INTAKE AIR PIPE . . . . . . . . . . .18

C. EXHAUST VENT / AIR INTAKE PIPE

LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . .18

D. EXHAUST VENT AND INTAKE AIR PIPE

SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

E. EXHAUST VENT AND AIR INTAKE PIPE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .20

F. EXHAUST TAPPING FOR VENT

SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

G. CONDENSATE DRAIN INSTALLATION . . . .23

H. BOILER REMOVAL FROM COMMON

VENTING SYSTEM . . . . . . . . . . . . . . . . . . .23

6. ELECTRICAL 24

A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

B. SEQUENCE OF OPERATION . . . . . . . . . . . .25

C. SAFETY INTERLOCKS . . . . . . . . . . . . . . . . .27

D. CONTROL FUNCTIONS . . . . . . . . . . . . . . . .28

E. HEATING CURVE . . . . . . . . . . . . . . . . . . . . .30

7. START-UP PROCEDURES 32

A. COMPLETING THE INSTALLATION . . . . . . .32

B. LIGHTING/OPERATING PROCEDURES . . . .33

C. CHECK-OUT PROCEDURE . . . . . . . . . . . . . .34

8. TROUBLESHOOTING 36

A. BOILER ERROR CODES . . . . . . . . . . . . . . . .36

B. BOILER FAULT CODES . . . . . . . . . . . . . . . .36

9. MAINTENANCE 38

A. GENERAL (WITH BOILER IN USE) . . . . . . .39

B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .39

C. ANNUALLY (BEFORE START OF

HEATING SEASON) . . . . . . . . . . . . . . . . . . .39

D. CONDENSATE CLEANING

INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .39

E. COMBUSTION CHAMBER COIL CLEANING

INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .40

10. BOILER DIMENSIONS & RATINGS 41

A. BOILER DIMENSIONS . . . . . . . . . . . . . . . . .41

11. REPAIR PARTS 44

APPENDIX A. STARTUP COMBUSTION RECORD 46

TABLE OF CONTENTS

Page 3

A. INSTALLATION SEQUENCE

Follow the installation instructions provided in this manual in the order shown. The order of these instructions has been set in order to provide the installer with a logical sequence of steps that will minimize potential interferences and maximize safety during boiler installation.

B. SPECIAL ATTENTION BOXES

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:

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

NOTICE

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

CAUTION

DANGER

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

USING THIS MANUAL

Indicates a condition or hazard which may cause severe personal injury, death or major property damage.

WARNING

Page 4

A. GENERAL

1. Pinnacle boilers are supplied completely assembled as packaged boilers. The package should be inspected for damage upon receipt and any damage to the unit should be reported to the shipping company and wholesaler. This boiler should be stored in a clean, dry area.

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. The boiler warranty may be voided if the boiler is not installed correctly.

4. A hot water boiler installed above radiation or as required by the Authority having jurisdiction, must be provided with a low water fuel cut-off device either as part of the boiler or at the time of installation.

5. This boiler can be installed at high altitudes above 5,000 feet elevation with no burner adjustments. This applies to boilers firing natural gas or liquefied petroleum (LP) gas.

B. CODES & REGULATIONS

1. Installation and repairs are to be performed in strict accordance with the requirements of state and local regulating agencies and codes dealing with boiler and gas appliance installation.

2. In the absence of local requirements the following should be followed.

a. ASME Boiler and Pressure Vessel Code, Section

IV - "Heating Boilers"

b. ASME Boiler and Pressure Vessel Code, Section

VI - Recommended Rules for the Care and Operation of Heating Boilers"

c. ANSI Z223.1/NFPA 54 - "National Fuel Gas Code"

d. ANSI/NFPA 70 - "National Electrical Code"

e. ANSI/NFPA 211 - "Chimneys, Fireplaces, Vents

and Solid Fuel Burning Appliances"

3. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

**Please read if installing in Massachusetts** Massachusetts requires manufacturers of Side Wall Vented boilers to provide the following information from the Massachusetts code:

A hard wired carbon monoxide detector with an alarm and battery back-up must be installed on the floor level where the gas equipment is to be installed AND on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment.

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

Detector(s) must be installed by qualified licensed professionals.

APPROVED CARBON MONOXIDE DETECTORS: Each carbon monoxide detector shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

EXEMPTIONS to the requirements listed above:

The above requirements do not apply if the exhaust vent termination is seven (7) feet or more above finished grade in the area of the venting, including but not limited to decks and porches.

The above requirements do not apply to a boiler installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

The boiler installation manual, vent manufacturer's installation manual, and this supplement shall remain with the boiler at the completion of the installation.

See latest edition of Massachusetts Code 248 CMR for complete verbage and also for additional (non-vent related) requirements (248 CMR is available online).

If your installation is NOT in Massachusetts, please see your authority of jurisdiction for requirements that may be in effect in your area. In the absence of such requirements, follow the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

PREINSTALLATION

1. PREINSTALLATION

Liquefied Petroleum (LP) Gas or Propane is heavier than air and, in the event of a leak, may collect in low areas such as basements or floor drains. The gas may then ignite resulting in a fire or explosion.

WARNING

Page 5

C. ACCESSIBILITY CLEARANCES

1. The Pinnacle boiler is certified for closet installations with zero clearance to combustible construction. In addition, it is design certified for use on combustible floors.

2. Refer to Figure 1.1 for the recommended clearance to allow for reasonable access to the boiler. Local codes or special conditions may require greater clearances.

D. COMBUSTION AND VENTILATION AIR

1. The Pinnacle boiler is designed only for operation with combustion air piped from outside (sealed combustion). PVC pipe must be supplied between the air intake connection at the rear of the boiler and an outside wall or roof.

2. No additional combustion or ventilation air is required for this appliance.

3. Refer to Section 5 of this manual, Venting, for specific instructions for piping combustion air.

E. PLANNING THE LAYOUT

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

2. The following sections of this manual should be reviewed for consideration of limitations with respect to:

a. Water Piping: Section 3 b. Fuel Piping: Section 4 c. Venting: Section 5 d. Air Intake Piping: Section 5 e. Condensate Removal: Section 5 f. Electrical Wiring: Section 6

PREINSTALLATION

Do not install this boiler where gasoline or other flammable liquids or vapors are stored or are in use.

WARNING

This boiler is certified as an indoor appliance. Do not install this boiler outdoors or locate it where it will be exposed to freezing temperatures.

WARNING

Figure 1.1

Do not install this boiler on carpeting.

DANGER

Page 6

A. GENERAL

1. Pinnacle boilers are to be installed in an area with a floor drain or in a suitable drain pan. Do not install any boiler where leaks or relief valve discharge will cause property damage.

2. This boiler is not intended to support external piping. All venting and other piping should be supported independently of the boiler.

3. Install this boiler level to prevent condensate from backing up inside the boiler.

4. An optional boiler stand is available for Pinnacle boilers. Two part number 91439 boiler stands are required for the PI-399.

2. BOILER SET-UP

BOILER SET-UP

This boiler must be installed level to prevent condensate from backing up inside the boiler.

CAUTION

Page 7

A. GENERAL

1. The water supply and return piping of this appliance are to be sized according to system requirements. Do not use piping smaller than the boiler connections.

2. In hydronic systems where sediment may exist, install a strainer device in the boiler return piping to prevent large particles and pipe scale from entering the boiler heat exchanger coil. Use a large mesh screen in the strainer.

3. 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 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. This is to keep the appliance from operating in the event of a system leak or other condition in which water is not flowing through the heat exchanger.

2. Table 3.1 shows minimum water flow rates for the Pinnacle PI-399 Boiler. If a glycol solution is to be used, contact the factory for minimum flow rates.

C. SYSTEM COMPONENTS

1. Figure 3.1 shows the symbol key for piping diagrams in this section. The following are brief descriptions of system components.

2. Pressure/Temperature Gauge: A combination pressure/temperature gauge is provided with each Pinnacle boiler to be mounted in the piping from the boiler supply to the system. Most local codes require this gauge.

3. Air Elimination: Any closed loop hydronic system in which the Pinnacle boiler is installed must have an air elimination device. As the system water is heated, dissolved oxygen and carbon dioxide will separate from the liquid. An air elimination device (such as a TACO 430 Series Air Scoop with automatic air vent) is required to remove the dissolved gasses from the system preventing corrosion in the piping system and eliminating system noise.

4. Expansion Tank: An expansion tank (such as a Bell & Gossett Series HFT) is required to provide room for expansion of the heating medium (water or glycol solution). Consult the expansion tank manufacturer's instructions for specific information regarding installation. The expansion tank is to be sized for the required system volume and capacity. In addition, be sure that the expansion tank is sized based on the proper heating medium. Glycol solutions may expand more than water for a similar temperature rise.

5. Y-Type Strainer: In older systems where a significant amount of sediment may be present, it may be necessary to install a Y-type strainer. The strainer should be checked often and cleaned during the first few months of operation to assure that sediment does not reach the heat exchanger and clog the passages. Use a large mesh screen in the strainer.

6. Flow Control Valve: Flow control valves such as the TACO Flo-Chek or Bell & Gossett Flo-Control™ are used to prevent gravity circulation by incorporating a check valve with a weighted disc.

7. Pressure Reducing Valve: A pressure reducing valve, such as the Bell & Gossett B-38 or a TACO #329, is used in a hydronic system to automatically feed water to the system whenever pressure in the system drops below the pressure setting of the valve. These valves should not be used on glycol systems unless close supervision of the glycol solution is practiced.

8. Back Flow Preventer: A back flow preventer (check valve) is required by some jurisdictions to prevent the hydronic system water from backing up into the city water supply. This is especially important on systems in which glycol solution is used as the heating medium.

3. WATER PIPING AND CONTROLS

WATER PIPING AND CONTROLS

Table 3.1 – Minimum Flow Rate and Water Volume

Boiler Model

Total Water

Volume-Gallon (Liter)

Minimum Flow

Rate-GPM (LPM)

PI-399 1.30 (4.92) 20 (75.7)

Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems. Unlike automotive antifreeze, solutions for hydronic applications contain corrosion inhibitors that will protect system components from premature failure due to corrosion.

CAUTION

Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems. Ethylene glycol is toxic and may cause an environmental hazard if a leak or spill occurs.

WARNING

Page 8

9. Pressure Relief Valve: The boiler pressure relief valve is factory installed into the right side boiler manifold (inside the jacket). Pipe the discharge of the relief valve to within 12" of the floor and close to a floor drain. Provide piping that is the same size or larger than the relief valve outlet.

10. Circulator: The boiler circulator is to be sized to overcome the pressure drop of the system while providing the flow required by the boiler.

a. 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.

b. The circulator should be sized based on the net

output of the boiler. Table 3.2 shows the Boiler Output as reported to the Hydronics Institute division of GAMA.

c. 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-399 with a design temperature difference of 20°F the calculation is as follows:

WATER PIPING AND CONTROLS

Table 3.2 – Boiler Inputs and Outputs

Boiler Model

Boiler Input

(Btu/hr [kW])

Gross Output

(Btu/hr [kW])

PI-399 399,000 (116.9) 379,000 (111.1)

Figure 3.1: Piping Symbol Key

Pipe the discharge of the relief valve as close as possible to the floor and away from high traffic areas. Pipe the discharge to a floor drain. Failure to do so may result in personal injury and/or property damage.

CAUTION

Output 379,000

= = 37.9 GPM

ΔT x 500 20 x 500

Required Flow =

Page 9

d. Table 3.3 shows the pressure drop (in feet of

water) for a flow rate which gives a 20°F temperature difference for the PI-399 boiler.

e. The boiler pressure drop for various flow rates

can be determined by using Figure 3.2, the Pinnacle Circulator Sizing Graph.

f. Table 3.4 gives the recommended circulators for

a boiler on a secondary loop with water as the heating medium.

The recommended circulators are based on water using primary secondary piping with the boilers on a secondary loop.

g. Special consideration must be given if anti-freeze

is to be used as a heating medium. Propylene glycol has a higher viscosity than water therefore the system pressure drop will be higher.

11. Indirect Water Heater: An indirect water heater should be piped in a dedicated zone. It consists of a water tank that is heated by boiler water passing through an internal coil. Examples of indirect water heating are shown in the System Piping subsection of this Section.

WATER PIPING AND CONTROLS

Table 3.3 – Flow Rate and Pressure Drop

Boiler Model

Flow Rate

(GPM [LPM])

Pressure Drop

(Feet [meters])

PI-399 37.9 (143.5) 17.9 (5.46)

Table 3.4 – Recommended Circulators

Boiler Model

TACO

Circulator

Bell & Gosset

Circulator

Grundfos

Circulator

PI-399 1400-50

PL-130

UP43-70

Figure 3.2: Pinnacle Circulator Sizing Graph

The circulator sizing given is for primary/secondary installations only. The system circulators must be sized based on the flow and pressure drop requirements of the system.

NOTICE

The P825 Control gives the DHW Circulator priority over the Boiler Circulator. The DHW Circulator should also be sized per 10a. through g.

NOTICE

Page 10

D. SYSTEM PIPING

1. Figure 3.3 shows a single boiler with one heating zone and a Peerless Partner indirect water heater.

2. Figure 3.4 shows a single boiler with an additional zone in which baseboard radiation is the heat load.

3. Figure 3.5 shows diverter tees used in combination with conventional hydronic radiators on an additional zone. A second boiler is also added to the system. Notice that the boilers are piped in parallel on the secondary loop. It is important that the common headers are sized to match the system piping. Smaller headers may result in flow fluctuations through the boilers.

4. Figure 3.6 shows a system in which several different types of loads and multiple boilers are shown. This system illustrates how different temperature zones can be supplied from the same source by mixing down the temperature using a three way mixing valve. Radiant flooring typically requires much lower temperatures than baseboard radiation and indirect water heating. Notice that a third boiler is included in this system.

5. Figure 3.7 shows zone valves used in place of zone circulators. Notice that this system utilizes reverse return piping which makes it easier to balance the system. If the heating zones are very different in length, the balancing valves on the return side of each loop are required.

E. FREEZE PROTECTION

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

3. The antifreeze solution should be tested at least once per year and as recommended by the antifreeze manufacturer.

4. Antifreeze solutions expand more than water. For example, a 50% by volume solution expands 4.8% for a 148°F temperature rise while water expands about 3% for the same temperature increase. Allowance for this expansion must be considered in sizing expansion tanks and related components.

5. The flow rate in systems utilizing glycol solution should be increased compared with a water system to compensate for increased heating capacity.

6. Due to increased flow rate and fluid viscosity the circulator head requirement will increase. Contact the pump manufacturer to correctly size the circulator for a particular application based on the glycol concentration and heating requirements.

7. A strainer, sediment trap, or some other means for cleaning the piping system must be provided. It should be located in the return line upstream of the boiler and must be cleaned frequently during the initial operation of the system. Glycol solution is likely to remove mill scale from new pipe in new installations.

8. Glycol solution is expensive and leaks should be avoided. Weld or solder joints should be used where possible and threaded joints should be avoided. Make up water should not be added to the system automatically when a glycol solution is used. Adding make-up water may significantly dilute the system.

9. Check local regulations to see if systems containing glycol solutions must include a back-flow preventer or require that the glycol system be isolated from the water supply.

10. Do not use galvanized pipe in glycol systems.

11. Use water that is low in mineral content and make sure there are no petroleum products in the solution.

12. Mix solution at room temperature.

13. Do not use a chromate treatment.

14. Do not use glycol solution in a system that may reach temperatures above 250°F.

15. Refer to Technical Topics, #2a published by the Hydronics Institute Division of GAMA for further glycol system considerations.

F. 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.

b. Install a flow control valve (spring check valve) to

prevent gravity flow through the boiler.

c. See Figure 3.8 for recommended system piping.

2. For boilers connected to heating coils in a forced air system where they may be exposed to chilled air circulation, install flow control valves or other automatic means to prevent gravity circulation of the boiler water during cooling cycles. See Figure 3.9 for illustration.

WATER PIPING AND CONTROLS

Page 11

Figure 3.3: One Boiler, Primary/Secondary with one heating zone and a Peerless Partner (Zone Circulators)

WATER PIPING AND CONTROLS

Page 12

Figure 3.4: One Boiler, Primary/Secondary with two heating zones and a Peerless Partner (Zone Circulators)

WATER PIPING AND CONTROLS

Page 13

Figure 3.5: Two Boilers, Primary/Secondary with Four Zones (Zone Circulator)

WATER PIPING AND CONTROLS

Page 14

Figure 3.6: Three Boilers, Primary/Secondary with Five Zones (Zone Circulator)

WATER PIPING AND CONTROLS

Page 15

WATER PIPING AND CONTROLS

Figure 3.7: Three Boilers, Primary/Secondary with Four Zones (Zone Valves)

Page 16

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 17

GAS PIPING

A . GENERAL

1. All fuel piping to the boiler is to be in accordance with local codes. In the absence of local regulations refer to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

2. Size and install piping to provide a supply of gas sufficient to meet the maximum demand of all appliances supplied by the piping.

B. FUEL LINE SIZING

1. The rate of gas to be provided to the boiler can be determined by the following:

Obtain the gas heating value from the gas supplier.

2. As an alternative use Table 4.1 which uses typical heating values for natural gas and liquefied petroleum (LP) gas.

3. Table 4.2 shows the maximum flow capacity of several pipe sizes based on 0.3" of pressure drop.

a. The values shown are based on a gas specific

gravity of 0.60 (Typical for natural gas).

b. Multiply the capacities listed by the factors

indicated in Table 4.3 for gas with a specific gravity other than 0.60 to obtain the corrected capacity.

4. The gas piping to the boiler must be a minimum of 1-1/4" pipe. The boiler is supplied with a 1-1/4" NPT x 1" NPT bell reducer. Do not remove the reducer.

5. Size and install the gas supply piping for no more than 0.5 inches of water pressure drop between the gas regulator and the boiler.

C. GAS SUPPLY PIPING INSTALLATION

1. Do not install any piping directly over or in front of the boiler. Locate the drop pipe adjacent to the boiler.

4. GAS PIPING

Boiler Input Rate

Gas Heating Value

Input Rate

(

)

(

Btu

)

(

Btu

)

Boiler

Model

PI-399

Gas Input Rate* (ft³/hr)

Natural Gas

399

LP Gas

160

*Natural gas input rates are based on 1000 Btu/ft³, LP input

rates are based on 2500 Btu/ft³.

Table 4.2: Maximum Capacity of Pipe (CFH) for a

Pressure Drop of 0.3" of Water

Table 4.3: Maximum Capacity Correction Factors

for Specific Gravity other than 0.60

Specific Gravity

0.50 0.55 0.60 0.65 0.70 0.75

Correction Factor

1.10 1.04 1.00 0.96 0.93 0.90

Specific Gravity

0.80 0.85 0.90 1.00 1.10 1.20

Correction Factor

0.87 0.84 0.82 0.78 0.74 0.71

Specific Gravity

1.30 1.40 1.50 1.60 1.70 1.80

Correction Factor

0.68 0.66 0.63 0.61 0.59 0.58

Table 4.1: Gas Input Rates

Pipe

Length

(Feet)

1-1/4"

NPT Pipe

1-1/2"

NPT Pipe

2" NPT

Pipe

2-1/2"

NPT Pipe

10 1,050 1,600 3,050 4,800

20 730 1,100 2,100 3,300

30 590 890 1,650 2,700

40 500 760 1,450 2,300

50 440 670 1,270 2,000

60 400 610 1,150 1,850

70 350 560 1,050 1,700

90 320 490 930 1,500

100 305 460 870 1,400

150 250 380 710 1,130

The values are based on a specific gravity of 0.60 (typical for natural gas). See table 4.3 for capacity correction factors for gases with other specific gravities.

Page 18

2. Install a sediment trap as shown in Figure 4.1. Be sure to allow clearance from the floor for removal of the pipe cap.

3. Install a ground joint union between the sediment trap and the boiler to allow service of the appliance.

4. Install a service valve as shown in Figure 4.1 to allow the gas supply to be interrupted for service.

5. Maintain a minimum distance of 10 feet between the gas pressure regulator and the boiler.

6. Check all gas piping for leaks prior to placing the boiler in operation. Use an approved gas detector, non-corrosive leak detection fluid, or other leak detection method. If leaks are found, turn off all gas flow and repair as necessary.

7. Figure 11.1 shows the gas shutoff valve (item 8) for the Pinnacle Boiler. This valve is to be used in addition to the gas service valve shown in Figure 4.1.

D. GAS SUPPLY PIPING - OPERATION

1. The gas line must be properly purged of air to allow boiler to operate. Failure to do so may result in burner ignition problems.

2. Table 4.4 shows the maximum and minimum supply pressure to the boiler.

a. Gas pressure below the minimum pressure may

result in burner ignition problems.

b. Gas pressure above the maximum may result in

damage to the gas valve.

3. To check the gas supply pressure on the gas valve:

a. Turn off the power at the service switch.

b. Turn off the gas shutoff valve.

c. Using a flat screwdriver, turn the screw inside the

intake pressure tap fitting (see Figure 4.2) one turn counterclockwise.

d. 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.

GAS PIPING

Use a pipe joint sealing compound that is resistant to liquefied petroleum gas. A non-resistant compound may lose sealing ability in the presence of this gas, resulting in a gas leak. Gas leaks may potentially cause an explosion or fire.

WARNING

When checking for leaks, do not use matches, candles, open flames or other methods that provide an ignition source. This may ignite a gas leak resulting in a fire or explosion.

WARNING

Figure 4.1: Gas Supply Piping – Sediment Trap

Figure 4.2: Gas Valve/Venturi PI-399

Do not adjust the throttle screw without monitoring the carbon dioxide (CO²) and carbon monoxide (CO) in the vent pipe. Vent CO emissions above 400 ppm are in excess of most safety standards.

WARNING

Do not subject the gas valve to more than 1/2 psi (13.5" W.C.) of pressure. Doing so may damage the gas valve.

CAUTION

Page 19

g. Turn off the boiler and gas shutoff valve

h. Remove the manometer tube from the pressure

tap fitting and turn the screw to close the internal valve.

i. Turn on the gas shutoff valve and boiler service

switch.

4. All gas piping must be leak tested prior to placing the boiler in operation.

a. If the leak test pressure requirement is higher

than the maximum intake pressure noted in Table 4.4, the boiler must be isolated from the gas supply piping system.

b. If the gas valve is exposed to pressures exceeding

13.5" of water, the gas valve must be replaced.

5. Install the boiler such that the gas ignition system components are protected from water (dripping, spraying, rain, etc) during operation and service (circulator replacement, condensate trap cleanout, and control replacement, etc).

E. MAIN GAS VALVE - OPERATION

1. Figure 4.2 shows an illustration of the gas valve/venturi assembly for the Pinnacle PI-399.

a. The throttle screw on the valve should not be

adjusted without a means to measure carbon monoxide (CO) and carbon dioxide (CO²) emissions.

b. Turning the throttle screw clockwise will decrease

the gas flow (decreasing CO²) and turning it counterclockwise will increase the gas flow (increasing CO²).

c. The recommended CO²settings are given in

Table 4.5. In no case should the boiler be allowed to operate with CO emissions in excess of 150 ppm.

2. Refer to Section 5, Venting for information on obtaining vent samples from this boiler.

GAS PIPING

Gas

Type

Fuel Pressure (inches of water)

Minimum Maximum

Natural 3.5 13.5

LP 3.5 13.5

Table 4.4: Maximum and Minimum Fuel Pressure

Gas Type

Firing

Rate

Vent CO

Natural

Low 8-1/2% to 9-1/2% < 50 ppm

High 8-1/2% to 9-1/2% < 100 ppm

Low 9-1/2% to 10-1/2% < 50 ppm

High 9-1/2% to 10-1/2% < 100 ppm

Table 4.5: Recommended Vent CO²Settings

Do not adjust the throttle screw without monitoring the carbon dioxide (CO²) and carbon monoxide (CO) in the vent pipe. Vent CO emissions above 400 ppm are in excess of most safety standards.

WARNING

Page 20

A. GENERAL

1. Install the boiler venting system in accordance with these instructions and with the 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.

B. APPROVED MATERIALS FOR EXHAUST

VENT AND INTAKE AIR PIPE

1. Use only Non Foam Core venting material. The following materials are approved for use as vent pipe for this boiler:

a. Non Foam Core PVC (Polyvinyl Chloride) Pipe

conforming to ASTM D-1785.

b. Non Foam Core CPVC (Chlorinated Polyvinyl

Chloride) Pipe conforming to ASTM D-1785.

Non Foam Core ABS (Acrylonitrile-ButadieneStyrene) Pipe conforming to ASTM D3965. .

2. Cellular foam core piping may be used on air intake piping only. Never use cellular foam core material for exhaust piping.

C. EXHAUST VENT / AIR INTAKE PIPE

LOCATION

1. Determine exhaust vent location: a. The vent piping for this boiler is approved for

zero clearance to combustible construction.

b. See Figure 5.1 for an illustration of clearances for

location of exit terminals of direct-vent venting systems.

c. This boiler vent system shall terminate at least 3

feet (0.9 m) above any forced air intake located within 10 ft (3 m). Note: this does not apply to the combustion air intake of a direct-vent appliance.

d. Provide a minimum of 1 foot distance from any

door, operable window, or gravity intake into any building.

e. Provide a minimum of 1 foot clearance from the

bottom of the exit terminal above the expected snow accumulation level. Snow removal may be necessary to maintain clearance.

f. Provide 4 feet horizontal clearance from electrical

meters, gas meters, gas regulators, and relief equipment. In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained.

g. Do not locate the exit terminal over public

walkways where condensate could drip and/or freeze and create a nuisance or hazard.

h. When adjacent to a public walkway, locate exit

terminal at least 7 feet above grade.

i. Do not locate the exit termination directly under

roof overhangs to prevent icicles from forming.

j. Provide 3 feet clearance from the inside corner

of adjacent walls.

2. Determine air intake pipe location. a. Provide 1 foot clearance from the bottom of the

air intake pipe and the level of maximum snow accumulation. Snow removal may be necessary to maintain clearances.

b. Do not locate air intake pipe in a parking area

where machinery may damage the pipe.

c. Maximum distance between air intake and

exhaust vent is 6 feet (1.8 m). Minimum distance between exhaust vent and air intake on single Pinnacle is 8" (0.2 m) center-to-center. Minimum distance between vents and intake on multiple Pinnacles is 8" (0.2 m) center-to-center. See Figure 5.2.

VENTING, INTAKE AIR AND CONDENSATE

5. VENTING, INTAKE AIR AND CONDENSATE

This vent system will operate with a positive pressure in the pipe. Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure.

WARNING

Follow these venting instructions carefully. Failure to do so may result in severe personal injury, death, or substantial property damage.

WARNING

Do not use Foam Core Pipe in any portion of the exhaust piping from this boiler. Use of Foam Core Pipe may result in severe personal injury, death, or substantial property damage.

WARNING

Page 21

VENTING, INTAKE AIR AND CONDENSATE

D. EXHAUST VENT AND INTAKE AIR PIPE

SIZING

1. For the PI-399 Boilers the exhaust vent and air intake pipes should be 4" Schedule 40 or 80.

2. The total combined equivalent length of exhaust vent and intake air pipe should not exceed 85 feet.

a. The equivalent length of elbows, tees, and other

fittings are listed in Table 5.1.

b. For example: If the exhaust vent has two 90°

elbows and 10 feet of PVC pipe we will calculate:

Exhaust Vent Pipe Equivalent Length = (2x3)+10=16 feet

Further, if the intake air pipe has two 90° elbows, one 45° elbow and 10 feet of PVC pipe, the following calculation applies:

Air Intake Pipe Equivalent Length = (2x3)+1+10=17 feet

Finally, the combined vent length is found by:

Total Combined Equivalent Length = 16+17=33 feet

Therefore, the total combined equivalent length is 33 feet which is below the maximum of 85 feet.

c. The intake air pipe and the exhaust vent are

intended to penetrate the same wall or roof of the building.

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).

Fitting Description

Equivalent Length

4" Vent 6" Vent

Elbow, 90°, Short Radius 3 3

Elbow, 90°, Long Radius 2 2

Elbow, 45°, Short Radius 1 1

Coupling 0 0

Air Intake Tee 0 0

Stainless Steel Vent Kit, 4" 1 2

Concentric Vent Kit 3 3

Table 5.1: Fitting Equivalent Length Table 4" or 6"

Figure 5.2: Multiple Pinnacle Vent Spacing

Page 22

d. Effort should be made to keep a minimum

difference in equivalent length between the air intake pipe and the exhaust vent.

3. The minimum combined equivalent length is 16 equivalent feet.

4. The maximum combined equivalent length can be extended by increasing the diameter of the vent pipe. However, the transitions to a larger size should begin 15 equivalent feet from the boiler.

a. Transitions should always be made in vertical

sections of pipe to prevent the condensate from pooling in the vent pipe.

b. Use a 4" x 6" reducing coupling to transition from

the PI-399 boiler connections to 6" vent.

c. The maximum equivalent length for the

increased diameter vent pipes is 125 feet.

d. If the transition occurs at a distance greater than

15 equivalent feet from the boiler, the maximum equivalent length will be reduced. See Table 5.2.

E. EXHAUST VENT AND AIR INTAKE PIPE

INSTALLATION

1. On the PI-399 the 4" exhaust vent connection is located on the rear of the boiler and the air intake is higher and toward the left side when the boiler is viewed from the front. See Figure 10.1. The air intake connection is intended for a slip fit. No sealant or adhesive is required.

2. Use only solid PVC, CPVC, or ABS schedule 40 or 80 pipe. FOAM CORE PIPING IS NOT APPROVED.

3. Remove all burrs and debris from joints and fittings.

4. All joints must be properly cleaned, primed, and cemented. Use only cement and primer approved for use with the pipe material. Cement must conform to ASTM D2564 for PVC or CPVC pipe and ASTM D2235 for ABS pipe.

5. Horizontal lengths of exhaust vent must slope back towards the boiler not less than ¼" per foot to allow condensate to drain from the vent pipe. If the vent pipe must be piped around an obstacle that causes a low point in the pipe, a drain pipe must be connected to allow condensate to drain.

6. All piping must be fully supported. Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form.

7. Do not use the boiler to support any piping.

8. A screened straight coupling is provided with the boiler for use as an outside exhaust termination.

9. A screened intake air tee is provided with the boiler to be used as an outside intake termination.

10. An optional stainless steel intake air/exhaust vent termination (91401) is available from your PB Heat, LLC distributor for use with Pinnacle Boilers.

11. Refer to Figure 5.3 to 5.5 for sidewall venting and Figure 5.6 for vertical venting. Refer to Figure 5.7 for sidewall venting below grade.

F. EXHAUST TAPPING FOR VENT SAMPLE

To obtain a combustion sample a hole must be drilled in the exhaust vent pipe just above the first elbow at the outlet of the boiler.

a. Drill a 21/64" diameter hole in the vent pipe just

above the first elbow.

b. Tap the hole with a 1/8" NPT Pipe Tap.

c. Take combustion samples through the tapped

hole.

d. Thread a standard 1/8" NPT Pipe Plug into the

hole.

VENTING, INTAKE AIR AND CONDENSATE

All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into the living space.

WARNING

Transition

Point

(ft from

boiler)

TEL of

Standard 4"

Vent Pipe (ft)

TEL of

Oversized 6"

Vent Pipe (ft)

Maximum TEL of all

Vent Pipe (ft)

15 30 95 125

20 40 77-1/2 117-1/2

25 50 60-1/2 110-1/2

30 60 43 103

35 70 26 96

40 80 8-1/2 88-1/2

None 85 0 85

Table 5.2: Maximum Equivalent Vent Length for

Oversized Vent Pipe

TEL = Total Equivalent Length

Page 23

VENTING, INTAKE AIR AND CONDENSATE

Figure 5.3: PI-399 Sidewall Venting with 4" Pipe (Exhaust Termination at Higher Elevation than Air

Intake).

Figure 5.4: PI-399 Sidewall Venting with 4" Pipe (Air Intake and Exhaust on the same Elevation).

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.

WARNING

Page 24

VENTING, INTAKE AIR AND CONDENSATE

Figure 5.5: PI-399 Sidewall Venting with 4" Pipe (Stainless Steel Vent Kit).

Figure 5.6: PI-399 Vertical Venting with 4" Pipe.

WARNING

Page 25

G. CONDENSATE DRAIN INSTALLATION

1. This boiler is a high efficiency unit that produces condensate. The condensate must be drained from the unit.

2. The hose under the unit is a condensate trap which prevents products of combustion from exiting the boiler through the condensate drain.

3. The black plastic 3/4" NPT fitting at the left side of the boiler is intended for connection to plastic piping. Do not block vent hole at the top of the fitting.

4. Slope the condensate drain piping down away from the unit into a floor drain or condensate pump.

Check with local codes or ordinances to determine if the condensate must first be neutralized before running it to a drain.

5. Do not route the condensate piping through unheated spaces that may reach freezing temperatures.

6. Use only plastic piping for the condensate drain line. Metal pipes will corrode and cause blockage of the condensate drain.

7. To allow for proper drainage on large horizontal runs, a second line vent may be required and the required tubing size may increase to 1" I.D.

8. A condensate removal pump is required if the boiler is below the drain.

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.

a. Seal any unused openings in the common

venting system.

b. Visually inspect the venting system for proper size

and horizontal pitch. Verify there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition.

c. Where practical, close all building doors and

windows, including interior doors between the space in which the appliances that remain connected to the common venting system are located and other areas of the building.

d. Turn on any clothes dryers and any appliance

not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhaust fans, at their maximum speed. (Do not operate a summer exhaust fan).

e. Close fireplace dampers.

f. Place the appliance being inspected in operation.

Follow the lighting instructions and adjust the thermostat so that the appliance operates continuously.

g. Test for spillage at the draft hood relief opening

after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

h. After it has been determined that each appliance

remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.

i. Any improper operation of the common venting

system should be corrected so that the installation conforms with the National Fuel Gas

Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA B149.

j. The common venting system should be resized to

approach the minimum size determined by using the appropriate tables located in the National

Fuel Gas Code, ANSI Z223.1/NFPA 54, "Sizing of Category I Venting."

VENTING, INTAKE AIR AND CONDENSATE

Figure 5.7: Sidewall Venting Below Grade

Make sure the condensate drain piping is below the level of the boiler to prevent condensate from filling up the combustion chamber and damaging the boiler.

CAUTION

Page 26

ELECTRICAL

Install all electrical wiring in accordance with the National Electrical Code, ANSI/NFPA 70, and local requirements.

A. WIRING

1. Refer to Figure 6.1 for connecting the power supply to the boiler.

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.

3. The boiler electrical connection is located on the left side of the boiler in the junction box which houses the service switch.

6. ELECTRICAL

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.

NOTICE

Figure 6.1: Wiring Connections to Boiler Junction Box

Page 27

ELECTRICAL

4. Wire the burner service switch in the hot line to the boiler as shown in Figure 6.1.

5. Make sure to maintain correct polarity on the incoming power supply wires. If polarity is reversed, the boiler control will not sense the main burner flame.

6. Connect the ground wire from the incoming power supply to the green ground screw in the junction box. Also, the boiler ground should be connected to this screw.

7. Figure 6.1 shows connections to boiler circulator.

a) The maximum current load for the circulator

circuit is 4.0 amperes.

b) For loads greater than 4.0 amps, isolate the

circulator using a switching relay.

c) An example of this wiring using a Honeywell

R845A relay is shown in Figure 6.2

8. The thermostat connections are shown in Figure 6.1 or 6.2. The setting for the thermostat anticipator is

0.56 amps.

9. The boiler control board is shown in Figure 6.3.

10. Factory wiring of all controls and safety devices are shown in Figure 6.4.

B. SEQUENCE OF OPERATION

1. System Power-Up: a) When power is first applied to the boiler, the

control will initially run through a self-diagnostic routine. The interface unit shows the system supply temperature.

b) Next, it will power the combustion air fan for a 10

second purge cycle.

c) Finally the combustion air shuts down and if there

is no call for heat the control board enters a standby mode.

2. Heating Cycle: a) When the thermostat calls for heat (closing the

contact between the two gray [TSTAT] wires) and the boiler control senses a supply temperature lower than the set point by more than the differential, the boiler initiates a heating cycle.

b) The control then powers the combustion air fan

at the speed prescribed for the particular boiler model and performs a 6 second pre-purge of the combustion chamber.

c) 0.5 second before the pre-purge is complete

power is applied to the spark igniter.

Figure 6.2

Page 28

ELECTRICAL

Figure 6.3: P825 Control Board with Molex® Connector & Pin Designations

Page 29

d) Once the pre-purge cycle is complete, the fan

speed decreases to the programmed ignition speed.

e) The main gas valve is then energized to allow gas

to mix with the combustion air.

f) If the main flame is not detected in 5 seconds, the

gas valve closes and the combustion fan goes into post-purge. Otherwise, the combustion fan stays at the ignition speed for the length of the flame stabilization period. (10 to 25 seconds).

g) After the flame stabilization period is complete, the

combustion air fan ramps down to its low fire setting. Then the boiler will begin to modulate depending on the supply temperature to maintain the set point temperature.

h) As the supply temperature approaches the set

point, the combustion control will reduce the input rate. The supply temperature will continue to climb to about 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.

j) If an indirect limit is connected between two light

blue (DHW) wires, the boiler will run the same as described in 2.a through i except it will use the Indirect (DHW) setpoint.

C. SAFETY INTERLOCKS

1. Low Water Pressure Limit Switch: This boiler is intended to operate at pressures exceeding 10 psig. If the water pressure drops to below 10 psig, there is a water pressure limit switch that interrupts boiler operation and displays the message "PR0" on the display module. The combustion air fan completes a post-purge in this event. Once the low water pressure condition is corrected the boiler will reinitiate a heating cycle if a call for heat remains.

2. High Water Temperature Limit Switch: The boiler is equipped with a limit switch that will interrupt the heating cycle and execute a post-purge if the water temperature increases to above the limit set point of 210°F.

3. High Flue Temperature Limit Switch: The high flue temperature limit switch will interrupt the heating cycle if it senses flue gas temperatures above 210°F.

ELECTRICAL

Figure 6.4: Component Wiring

Page 30

ELECTRICAL

4. Blocked Vent Pressure Limit Switch: This switch prevents the boiler from operating if the vent pressure exceeds 2 inches water column. This will prevent the boiler from operating if the vent pipe is blocked. The boiler will indicate "FLU" on the display module.

D. CONTROL FUNCTIONS

1. This Pinnacle boiler is equipped with a P825 Control Board. This control board with display module has the following functions:

a. Shows the boiler supply (outlet) water temperature

on the LED Display as default.

b. Allows user to adjust the supply water set point,

the set point differential, and change the display mode between Fahrenheit and Celsius.

c. Provides Error and Fault Codes on the LED

Display.

d. Shows the supply and return temperatures, fan

speed, flame signal (µA), boiler circulator status, boiler set point, total power on hours, boiler on hours, and the number of cycles.

e. Allows manual control of the firing rate using the

Service Mode.

2. Default Display: Under normal operating conditions the default display shows the temperature of the water supply (boiler outlet) to the system. This may be displayed in Fahrenheit or Celsius according to user preferences.

3. Program Functions: By using the S3 "Program" key, the settings shown in Table 6.1 may be programmed.

a. To access the menu, stop any calls for heat. Wait

for blower to stop. Press and hold the S3 "Program" key on the display module.

b. The control will enter the Supply Set Point

selection.

i. The display will alternately show "C" and then

the current set point temperature.

ii. The set point may be adjusted by using the

S1/- (to decrease) or S2/+ (to increase) keys on the display module.

c. Pressing the S3 "Program" key again will advance

to the next adjustable value, Set Point Differential, and the display will alternate between "Ch" and the programmed value:

i. The differential adjustment is the difference

between the temperature that the boiler shuts down (high) and the temperature at which it re-starts (low).

ii. The differential may be set to values between

5°F (3°C) and 30°F (17°C) in 1°F increments.

iii. The boiler will always shut down at a

temperature 7°F (4°C) above the set point. The differential temperature is then applied to this value.

iv. The set point differential may be adjusted by

using the S1/- (to decrease) or S2/+ (to increase) keys on the display module.

d. Pressing the S3 “Program” key again will

advance to the next adjustable value, Indirect (DHW) Set Point:

i. The display will alternate between “dE” and a

numerical value.

ii. If an optional indirect tank sensor is not

installed, this value is not applicable.

iii. If an optional indirect tank sensor (91589) is

installed, the set point may be adjusted by using the S1/- (to decrease) or S2/+ (to increase) keys on the display module.

e. Pressing the S3 "Program" key again will advance

to the next adjustable value. The display will read "dh" and alternate with numerical value. This value is not applicable to the Pinnacle boiler.

f. Finally, by pressing the S3 "Program" key again,

the display will advance to the Measurement Units selection. The display will alternate between "t" and either "F" or "C" depending on the units selected. This value may be changed by using the S1/- or S2/+ keys on the display module.

g. Pressing the S3 "Program" key once more will exit

the program mode and again display the supply temperature.

Table 6.1: Program Functions

Description

Alternating

Display

Character

Allowable

Range

Default

Supply Set Point

50°F to 201°F

(10°C to 94°C)

180°F

Set Point Differential

5°F to 30°F

(3°C to 17°C)

30°F

Indirect (DHW) Set Point

104°F to 158°F

(40°C to 70°C)

119°F

Not Applicable dh N/A 9

Measurement Units

t C or F F

If outdoor reset is used setpoint should be above Boiler Supply Design Temperature, Parameter 9. See Section E. “Heating Curve”

NOTICE

Page 31

ELECTRICAL

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.

5. Fault Codes: A Fault Code indicates the controller is locked-out. Press the S4 "Reset" key to resume operation after repairing the problem. Table 8.2 shows Fault Codes for this control.

6. Status Menu: The status menu, as shown in Table

6.2, allows the installer to display the current boiler supply (outlet) temperature, return (intake temperature), fan speed, flame signal (µA), boiler circulator status, boiler set point, total power on hours, boiler on hours, and the number of cycles.

a. To access this menu press and hold the S4

"Reset" key on the display module for 3 seconds.

b. The display will alternate between "d1" and the

value of the supply temperature.

c. To scroll through the other status codes, simply

press S4 "Reset" key again.

d. To exit this menu, press the S3 "Program" key.

7. Service Mode: The Pinnacle boiler can be operated in Service Mode to allow the installer to manually set the fan speed/input rate of the boiler.

a. To enter service mode, press and hold the S2/+

key and the S3 "Program" key simultaneously.

b. The display will alternately display "SER" and the

fan speed in RPMs ÷ 10. As default, the fan speed will start at the ignition fan speed (this value is listed in Section 10, Dimensions and Ratings, for each boiler size).

c. The fan speed can be adjusted by using the S1/-

key (to decrease speed) or S2/+ key (to increase speed) on the display module.

d. The fan speed will stay in this mode for 10

minutes or until the boiler reaches 7 degrees above the set point temperature.

e. To exit the Service Mode, press the S1/- and

S2/+ keys simultaneously.

8. Installer Menu: The Pinnacle boiler can be programmed to be controlled by an external analog input controlling set point temperature or fan speed. In addition, it can be programmed for a 6 minute step modulation sequence.

a. To enter the installer menu, stop any calls for

heat. Wait for blower to stop. Press and hold the S3 "Program" key and S4 "Reset" key simultaneously for 3 seconds. The display will show a blinking "000."

b. Use the S1/- and S2/+ keys to change the display

to read 825. Press and hold the S3 "Program" key to enter the installer menu. The display will alternate between 1, which represents the Parameter Number, and either 0 or 1, which represents the Function setting.

Table 6.2: Status Menu

Status

Code

Description

d1 Supply (Outlet) Temperature

d2 Return (Intake) Temperature

DHW (Indirect) Demand Status (0 = Open, 1 = Demand) [The DHW (Indirect) Temperature will be displayed if the sensor is attached*]

d4 Not Applicable

d5 Outdoor Temperature**

d6 Fan Speed (rpm ÷ 10) [ex. 200 = 2000 rpm]

d7 Ionization Current (Flame Signal)

Central Heating Circulator Status (0 = Off, 1 = On)*

DHW (Indirect) Circulator Status (0 = Off, 1 = On)*

d10

Bus Comm Status (co = connected, no = not connected)

d11 Central Heating Set Point

d12 Power On Time (Hrs ÷ 1000) [ex. 0.1 = 100 hrs]

d13 Central Heat On Time (Hrs ÷ 1000)

d14 DHW (Indirect) On Time (Hrs ÷ 1000)

d15

Successful Ignition Attempts (Attempts ÷ 1000) [ex. 0.1 = 100 attempts]

Figure 6.5: Display Module

*Optional DHW (Indirect) Tank Sensor (91589) Required

**Only when Outdoor Sensor is connected

Page 32

ELECTRICAL

c. Table 6.3 shows the Parameter numbers and

Functions. Press S3 "Program" to advance through the parameters and use the S1/- and S2/+keys to change the function values. Do not change to

external input without external input device installed! Do not change Parameters 1, 2, 4 or 20!

d. To exit the Installer Menu, press and hold the S4

"Reset" key for 3 seconds.

E. HEATING CURVE

1. Parameters 8, 9, 10 and 11 in the Installer Menu (Table 6.3) define the heating curve for outdoor reset operation. This is applicable only if the outdoor sensor is installed. When this sensor is installed the control will automatically recognize it and begin outdoor reset operation.

2. Parameters 8 and 9 define the design point of the heating curve. The factory defaults are set such that if the outdoor temperature is 5ºF or below, the boiler target temperature will be 180ºF.

3. Parameters 10 and 11 define the “mild weather” reference point of the heating curve. The factory defaults will drop the boiler supply target temperature to 95ºF when the outdoor temperature reaches 68ºF. If the outdoor temperature increases beyond 68ºF the boiler supply target temperature will continue to drop based on the slope of the heating curve.

4. When the outdoor temperature is above the outdoor design temperature and below the mild weather outdoor reference temperature, the boiler target temperature will vary according to a straight line between the design point and the mild weather reference point. For example, if the outdoor temperature is at 32ºF the boiler target temperature will be 144ºF.

5. Figure 6.5 shows a graph of the heating curve with the default design and mild weather reference points. It also illustrates how the boiler target temperature varies according to outdoor temperature.

6. The heating curve operates only if an outdoor sensor is connected to the boiler. If the outdoor sensor is disconnected, the boiler will revert to standard setpoint operation.

7. Parameter 12 defines the minimum boiler supply target temperature.

• If this temperature is above the mild weather boiler reference temperature, the boiler will continue to target this temperature even if the outdoor temperature exceeds the corresponding value. This may be used for kick space heaters or unit heaters that require a specified minimum water temperature to operate.

• If this temperature is below the mild weather boiler reference temperature, the boiler will continue to target lower temperatures as the outdoor temperature increases by following the slope of the heating curve.

8. Parameter 14 defines the maximum amount of time the DHW (Indirect) Circulator will take priority over the Boiler Circulator. If there is a continuous call for both indirect and space heating, the DHW and Boiler Circulators will alternate, each running for the maximum amount of time or until the call for heat ends.

Table 6.3: Installer Menu

Parameter

No.

Function Range

Default

Value

Programmed

Setting

1 Unavailable N/A de

No Change

Allowed

2 Unavailable N/A 149°F

No Change

Allowed

Domestic Hot Water (Indirect) Temperature Setpoint (Available only if indirect tank sensor is installed)

95°F to 160°F

(35°C to 71°C)

125°F

4 Unavailable N/A 36°F

No Change

Allowed

Domestic Hot Water (Indirect) Temperature Differential (Available only if indirect tank sensor is installed)

1°F to 18°F

(1/2°C to 10°C)

7°F

Indirect Circulator Post Purge Time

0 to 60

minutes0 minutes

Warm Weather Shutdown Temperature

41°F to 122°F (5°C to 50°C)

68°F

Outdoor Design Temperature

-49°F to 32°F

(-45°C to 0°C)

5°F

Boiler Supply Design Temperature

77°F to 201°F

(25°C to 94°C)

180°F

Mild Weather Outdoor Reference Temperature

32°F to 95°F

(0°C to 35°C)

68°F

Mild Weather Boiler Reference Temperature

32°F to 180°F (0°C to 82°C)

95°F

Minimum Boiler Supply Target Temperature

32°F to 180°F (0°C to 82°C)

68°F

Central Heating Circulator

Post Purge Time

0 to 10

minutes0 minutes

Indirect Maximum Run Time

0 to 60

minutes

Bus Address [0 Zone Master, 1-8 Cascade Slave] (Not Available)

0-8 0

Internal/External Control Parameter: 0 = Internal Control; 1 = External Control

0-1 0

External Input Type: 0 = Temperature; 1 = Modulation %

0-1 0

Step Modulation: 0 = Disabled; 1 = Enabled

0-1 0

Boiler Setpoint for Indirect Call for Heat

119°F to 180°F (48°C to 82°C)

180°F

20 Unavailable N/A 1

The outdoor sensor may need to be temporarily disconnected in order to start up or service the boiler during mild weather.

NOTICE

Page 33

ELECTRICAL

Figure 6.6: Central Heating Curve (Factory Defaults)

Figure 6.7: Central Heating Curve (Installer Settings)

Page 34

START-UP PROCEDURES

A. COMPLETING THE INSTALLATION

1. Confirm that all water, gas and electricity are turned off.

2. Verify that water piping, venting, gas piping and electrical wiring and components are installed properly and where applicable in accordance with manufacturers' instructions. Be sure that the boiler is installed in accordance with this manual and good engineering practice.

3. Fill the boiler and system with water, making certain to vent all air from each high point in the system. Open each vent in the system until all air is released and water begins to be discharged, and then close the vent.

4. The pressure reducing valve on the fill line will typically allow the system to be filled and pressurized to 12 PSI. Consult the manufacturer's instructions for operation of the valve and expansion tank.

5. Check joints and fittings throughout the system and repair as required.

6. Connect a manometer at or near the service valve to the boiler.

7. Confirm that the gas supply pressure to the boiler is between the minimum and maximum values for the gas being used. These values can be found in Table

4.4 of Section 4.

8. If a supply pressure check is required, isolate the boiler and gas valve before performing the pressure test. 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.

10. Refer to Section 6, paragraph D, Control Functions for set point and differential settings. To set the heating curve and advanced functions refer to Section 6, paragraph E, Heating Curve.

11. Light the boiler by following the Lighting/Operating instructions in this section. The initial ignition may fail several times before the gas piping is completely purged of air.

12. Use the sequence of operation description and Figure 6.3, Control Board Wiring Schematic to follow light off and shutdown sequences and to assist in diagnosing problems. If the boiler does not function properly, consult Section 8, Troubleshooting.

13. Refer to subsection 7.C. for instructions on setting up the boiler.

7. START-UP PROCEDURES

Page 35

START-UP PROCEDURES

B. LIGHTING AND OPERATING

PROCEDURES

Figure 7.1: Lighting and Operating Instructions

Page 36

START-UP PROCEDURES

C. CHECK-OUT PROCEDURE

After Starting the boiler, be certain that all controls are working properly and that combustion is properly set up.

1. Check to be sure that the boiler will shut down when the supply water temperature reaches the control setpoint.

a) Note the boiler set point setting in the program

menu (Table 6.1) or in the status menu, code d11 (Table 6.2).

b) Manually set the boiler to its highest input by

entering Service Mode (refer to Section 6.D.7) and pressing the S2/+ key until the display values no longer increase.

c) Monitor the boiler temperature on the

temperature gauge (field mounted in the boiler supply piping).

d) The boiler should shut down at 7ºF above the

boiler setpoint. If it does not shut down, contact your PB Heat Representative. (Note that depending on the outdoor reset curve, the boiler may shutdown before the Supply Setpoint is met).

2. Check the combustion readings in the boiler vent pipe.

a) Drill and tap a 1/8" NPT threaded hole in the

boiler vent pipe within 12 inches (305 mm) of the boiler vent connection. (21/64" drill and 1/8" NPT pipe tap are recommended). This is to be used as a combustion test port for the combustion analyzer. See Figure 7.2.

b) Place the probe of a combustion analyzer with

carbon dioxide (CO2) and and carbon monoxide (CO) reading capability (Testo Model 325-M or equivalent) into the combustion test port. See Figure 7.3.

c) Manually set the boiler to its highest input by

entering Service Mode (refer to Section 6.D.7) and pressing the S2/+ key until the display values no longer increase.

i. Verify that the fan speed indicated matches

the high fire fan speed in Table 10.2.

ii. Verify that the CO and CO² emissions are

within the parameters specified in Table 4.5.

d) Manually set the boiler to its lowest input by

pressing the S1/- key until the display values no longer decrease.

i. Verify that the fan speed matches the low

fire fan speed in Table 10.2.

ii. Verify that the CO and CO²emissions are

within the parameters specified in Table 4.5.

e) If the values in either of these instances falls

outside of the parameters set forth in Table 4.5, turn off the unit and contact your PB Heat representative.

Figure 7.2

Figure 7.3

Page 37

f) To exit Service Mode, press the S1/- and S2/+

keys simultaneously and hold them until the display shows the outlet temperature.

g) After removing the analyzer probe from the vent

pipe, insert a stainless steel pipe plug into the test port.

h) Record combustion readings on the “Startup

Combustion Record” Sheet in Appendix A. Record all requested information for ease of follow-up and troubleshooting.

3. To check operation of the ignition system safety shutoff features:

a) Turn off gas supply.

b) Set thermostat or controller above room

temperature to call for heat.

c) The boiler should perform 3 attempts at ignition

before going into lock-out.

d) Turn gas supply on.

e) Reset by pushing S4 "Reset" key.

f) Observe boiler operation through one

complete cycle.

4. 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" after 5 seconds and does not allow the boiler to operate. Close the boiler drain and turn on the automatic fill valve.

5. Low Water Cut-Off (if used) - Consult the manufacturer's instructions for the low water cut-off operational check procedure.

6. Check the system to assure that there are no leaks or overfilling problems which may cause excessive make up water to be added. Make up water may cause liming in the boiler and corrosion in ferrous system parts.

7. Check the expansion tank and automatic fill valve (if used) to confirm that they are operating correctly. If either of these components causes high pressure in the system, the boiler relief valve will weep or open, allowing fresh water to enter the system.

8. Check the condensate drain hose (and pump if installed) and make sure all condensate is being removed from heat exchanger.

9. Review operation with end-user.

10. Complete the Warranty Card and submit it to PB Heat.

11. Hang the Installation, Operation, and Maintenance Manual in an accessible position near the boiler.

START-UP PROCEDURES

Figure 7.4

Page 38

TROUBLESHOOTING

A. BOILER ERROR

1. When an error condition occurs the controller will display an error code on the display module.

2. These error codes and several suggested corrective actions are included in Table 8.1.

3. In the case of E00, E13, and E14 this error, if uncorrected, will go into a fault condition as described in Paragraph B.

B. BOILER FAULT

1. When a fault condition occurs the controller will illuminate the red "fault" indication light and display a fault code in the format "F##" on the display module.

2. Note the fault code and refer to Table 8.2 for an explanation of the fault code along with several suggestions for corrective actions.

3. Press the reset key to clear the fault and resume operation. Be sure to observe the operation of the unit to prevent a recurrence of the fault.

If overheating occurs or the gas supply fails to shut off, do not turn off electrical power to the circulating pump. This may aggravate the problem and increase the likelihood of boiler damage. Instead, shut off the gas supply to the boiler at the gas service valve.

CAUTION

This appliance has wire function labels on all internal wiring. Observe the position of each wire before removing it. Wiring errors may cause improper and dangerous operation. Verify proper operation after servicing.

CAUTION

DANGER

When servicing or replacing components that are in direct contact with the boiler water, be certain that:

• There is no pressure in the boiler. (Pull the release on the relief valve. Do not depend on the pressure gauge reading).

• The boiler water is not hot

• The electrical power is off

When servicing or replacing any components of this boiler be certain that:

• The gas is off.

• All electrical power is disconnected

WARNING

Do not use this appliance if any part has been under water. 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.

WARNING

Code Description Duration Corrective Action

E03

Installer Menu: Parameter 1 is not set to “de”

Until Corrected

1. Open Installer Menu. See 6. D. 8.

2. Change Parameter 1 to “de.”

3. Close Installer Menu.

E13

Combustion Fan Speed Low. The boiler combustion air fan speed less than 70% of expected.

60 Sec.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

E14

Combustion Fan Speed High. The boiler combustion air fan speed is more than 130% of expected.

60 Sec.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

PRO Water Pressure Switch Open Until Corrected

1. Assure that the system pressure is above 10 psig.

2. Check for leaks in the system piping.

3. Check the switch operation by applying a jumper. (If the switch is not functioning properly replace it.)

FLu Blocked Vent Pressure Switch Open Until Corrected

1. Assure that the vent is not blocked.

2. Check the switch operation by applying a jumper. (If the switch is not functioning properly replace it.)

Table 8.1: P825 Control Board Error Codes

8. TROUBLESHOOTING

Page 39

TROUBLESHOOTING

Fault Code

Description Corrective Action

F00

High Limit Exceeded.

1. Check circulation pump operation.

2. Assure that there is adequate flow through the boiler by accessing the status menu and confirming that there is less than a 50°F rise from the return thermistor to the supply thermistor.

3. If gray thermostat wires are being used, disconnect them and jump them together. If F00 code can be reset check thermostat circuit for short circuit or stray voltage.

4. Check supply temperature reading on LED display. Replace High Limit Switch if supply temperature is below 210°F.

5. Temporarily jump out Water Pressure Switch. If F00 code can be reset check wiring harness and connections. If wiring harness is okay replace Water Pressure Switch.

F01

Vent Temperature Limit Exceeded.

1. Push the red reset button on the switch.

2. Check the flue temperature during operation using a combustion analyzer.

3. Replace the switch if faulty.

F02

Interrupted or Shorted Supply (Outlet) Thermistor.

1. Check the electrical connection to the thermistor on the outlet manifold.

2. Replace thermistor if necessary.

F03

Interrupted or Shorted Return (Intake) Thermistor.

1. Check the electrical connection to the thermistor on the intake manifold.

2. Replace thermistor if necessary.

F05

Supply (Outlet) Temperature exceeded 230°F.

1. Check circulation pump operation.

2. Assure that there is adequate flow through the boiler by accessing the status menu and confirming that there is less than a 50°F rise from the return thermistor to the supply thermistor.

F06

Return (Intake) Temperature exceeded 230°F.

1. Check circulation pump operation.

2. Assure that there is adequate flow through the boiler by accessing the status menu and confirming that there is less than a 50°F rise from the return thermistor to the supply thermistor.

F09

No flame detected – The boiler will make three attempts at ignition before the control goes into this lockout condition.

1. Watch the igniter through the observation window provided.

2. If there is no spark, check the spark electrode for the proper ¼" gap.

3. Remove any corrosion from the spark electrode.

4. If there is a spark but no flame, check the gas supply to the boiler.

5. If there is a flame, check the flame sensor.

F10

Loss of Flame Signal – The boiler will relight 4 times before the control goes into this lockout condition.

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.

4. If the green light doesn't come on or goes off during operation check the flame signal on the status menu.

5. If the signal reads less than 1 microampere, clean the flame sensor.

6. If the sensor continues to read low, replace it.

F11

False Flame Signal – The boiler will lock out if it senses a flame signal when there should be none present.

1. Turn the gas off to the unit at the service valve.

2. If the flame signal is still present replace the igniter.

3. If the flame signal is not present after turning off the gas supply, check the gas valve electrical connection.

4. If there is no power to the gas valve, remove the valve and check for obstruction in the valve seat or replace the gas valve.

5. Turn the gas on at the service valve after corrective action is taken.

F13

Combustion Fan Speed Low – The boiler will lock out if it senses that the fan speed is less than 70% of expected for more than 60 seconds.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

F14

Combustion Fan Speed High – The boiler will lock out if the fan speed is more than 130% of expected for more than 60 seconds.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

F18

Gas Valve Error

1. Make sure the connector is correctly connected to the gas valve.

2. Check the electrical wiring from the valve to the control board.

3. Replace the gas valve.

4. Replace control board.

F30

Watchdog Call factory for further assistance.

F31

Parameter Memory Call factory for further assistance.

F32

Parameter Memory Write Error Call factory for further assistance.

F33

Programming Error Call factory for further assistance.

Neutral Fault – Boiler locks out if it senses a voltage drop or power feedback on the neutral wire.

1. Check for adequate supply voltage.

2. Check for power feedback on the neutral wire.

Table 8.2: P825 Control Board Fault Codes

Page 40

MAINTENANCE

9. MAINTENANCE

WARNING

Product Safety Information

Refractory Ceramic Fiber Product

This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF, when inhaled, have been classified by the International Agency for Research on Cancer (IARC), as a possible carcinogen to humans. After the RCF materials have been exposed to temperatures above 1800°F (980°C), they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans. If particles become airborne during service or repair, inhalation of these particles may be hazardous to your health.

Avoid Breathing Fiber Particulates and Dust

Suppliers of RCF recommend the following precautions be taken when handling these materials:

Precautionary Measures: Provide adequate ventilation. Wear a NIOSH/MSHA approved respirator. Wear long sleeved, loose fitting clothing and gloves to prevent skin contact. Wear eye goggles. Minimize airborne dust prior to handling and removal by water misting the material and avoiding unnecessary disturbance of materials. Wash work clothes separately from others. Rinse washer thoroughly after use. Discard RCF materials by sealing in an airtight plastic bag.

First Aid Procedures: Inhalation: If breathing difficulty or irritation occurs, move to a location with fresh clean air. Seek immediate medical attention if symptoms persist. Skin Contact: Wash affected area gently with a mild soap and warm water. Seek immediate medical attention if irritation persists. Eye Contact: Flush eyes with water for 15 minutes while holding eyelids apart. Do not rub eyes. Seek immediate medical attention if irritation persists. Ingestion: Drink 1 to 2 glasses of water. Do not induce vomiting. Seek immediate medical attention.

Page 41

MAINTENANCE

A. GENERAL (WITH BOILER IN USE)

General boiler observation can be performed by the owner. If any potential problems are found, a qualified installer or service technician/agency must be notified.

1. Remove any combustible materials, gasoline and other flammable liquids and substances that generate flammable vapors from the area where the boiler is contained.

2. Observe general boiler conditions (unusual noises, vibrations, etc.)

3. Observe operating temperature and pressure on the combination gauge located in the supply piping on the left side of the boiler. Boiler pressure should never be higher than 5 psi below the rating shown on the safety relief valve (25 psig maximum for a 30 psig rating). 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.

B. WEEKLY (WITH BOILER IN USE)

1. Flush float-type low-water cut-off (if used) to remove sediment from the float bowl as stated in the manufacturer’s instructions.

C. ANNUALLY (BEFORE START OF

HEATING SEASON)

1. Check boiler room floor drains for proper functioning.

2. Check function of the safety relief valve by performing the following test:

a. Check valve piping to determine that it is

properly installed and supported.

b. Check boiler operating temperature and pressure.

c. Lift the try lever on the safety relief valve to the

full open position and hold it for at least five seconds or until clean water is discharged.

d. Release the try lever and allow the valve to close.

If the valve leaks, operate the lever two or three times to clear the valve seat of foreign matter. It may take some time to determine if the valve has shut completely.

e. If the valve continues to leak, it must be replaced

before the boiler is returned to operation.

f. Check that operating pressure and temperature

have returned to normal.

g. Check again to confirm that valve has closed

completely and is not leaking.

3. Test low-water cut-off (if used) as described by the manufacturer.

4. Test limit as described in Section 7, Part C, “CheckOut Procedure”.

5. Test function of ignition system safety shut-off features as described in Section 7, Part C, “CheckOut Procedure”.

6. Remove the top/front jacket panel and inspect for any foreign debris that may have entered through air intake vent.

7. Inspect burner for deterioration. Replace if necessary.

8. With boiler in operation check that condensate is dripping from condensate tubing. Check for any restriction in condensate drain line.

D. CONDENSATE CLEANING

INSTRUCTIONS

1. Turn the thermostat down or off so the Pinnacle will not cycle and then follow the steps below.

a. Close manual gas shutoff valve.

b. Disconnect the condensate tubing from the

outside connection (not from the Pinnacle) so flow can be observed.

c. Block the air flow in the exhaust by temporarily

plugging the exhaust from the outside vent.

d. Remove boiler service switch plate. Disconnect

two gray thermostat wires from thermostat circuit and jump them together. (Refer to Control Wiring Schematic, Figure 6.1.) This will cause the fan to run at 100% which will then blow out any sediment that has accumulated in the condensate line. (This process should only take a few minutes.)

e. The unit should now be ready to re-start.

The following annual inspection must be performed by a qualified service technician.

CAUTION

When servicing or replacing components, be absolutely certain that the following conditions are met:

• Water, gas and electricity are off.

• The boiler is at room temperature.

• There is no pressure in the boiler.

DANGER

Page 42

MAINTENANCE

2. Before re-starting the Pinnacle follow the steps below:

a. Reconnect the gray wires and unblock the vent.

(IMPORTANT: MAKE 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.

3. If the problem is not corrected at this point, it is possible that there is a material deposit problem. Follow the Coil Cleaning Instructions (Section E) included in this section to dissolve deposits and clean condensate line.

E. COMBUSTION CHAMBER COIL

CLEANING INSTRUCTIONS

Before beginning this procedure, you must have on hand the following items:

– a nylon or brass brush (not steel)

– "Rydlyme" (recommended for best results)

(available online www.rydlyme.com) or "CLR" (available at most hardware stores)

1. Shut the boiler down and access the heat exchanger using the following steps:

a. Close the manual gas shutoff valve and wait for

the unit to be cool to the touch.

b. Disconnect the condensate piping from the outside

connections (not from the Pinnacle side) so the flow can be observed.

c. Remove four screws on the 1/2" NPT connector

at the gas valve intake and disconnect the gas valve electrical connector.

d. Remove the six 10 mm nuts from the burner

plate assembly. Disconnect wire leads to the spark igniter and flame sensor. Disconnect two Molex plugs from blower motor.

e. Pull the entire burner plate towards you to access

the heat exchanger coils.

2. Using a spray bottle filled with the recommended product "Rydlyme" or "CLR", spray liberally on the coils, making sure the solution penetrates and funnels down through the condensate hose. If the condensate hose is blocked, let the chemical penetrate for at least 15 minutes or until it drains.

3. Use the nylon or brass brush (do not use steel) and scrub coils to remove any buildup, then vacuum the debris from the coils.

4. Spray coils with clear water, making sure to confine the spray to the area being cleaned (try to avoid wetting the back ceramic wall of the unit). Flush the combustion chamber with fresh water. At this point, the Pinnacle should be ready to power back up.

5. Reinstall the burner plate assembly using the following steps:

a. Inspect the inside of the heat exchanger for dirt

and debris.

b. Install the burner plate assembly and replace the

six 10 mm nuts.

c. Reconnect the wire leads to the spark igniter,

flame sensor and gas valve. (Be sure that the spark igniter is connected to the lead with the large insulated connection boot.) Reconnect two Molex plugs on blower motor.

d. Replace the four screws for the 1/2" NPT

connector on the gas valve. Turn the gas supply on. (IMPORTANT: CHECK FOR GAS

LEAKS USING A SOAP SOLUTION.)

e. Reset thermostats. (IMPORTANT: BE SURE

THAT THE VENT CONNECTION IS NOT BLOCKED.)

f. Turn the power to the Pinnacle on. Observe the

display module to assure proper operation.

g. Initiate a call for heat** and observe the

condensate flow.

h. Reconnect the condensate piping to the drain

connection.

**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. This is normal and will require you to recycle the unit until this clears up. This is caused by water still present in the combustion chamber.

6. Inspect exhaust vent and air intake vents for proper support and joint integrity. Repair as necessary. Refer to Section 5, VENTING.

7. Inspect exhaust vent and air intake vent terminations for obstructions.

It is extremely important to make sure the exhaust vent is not longer blocked. Failure to do so may result in personal injury or death.

DANGER

It is extremely important that you check for leaks when reconnecting the gas valve and make sure the exhaust vent is no longer blocked. Failure to do so may result in severe personal injury or death.

DANGER

Leaks in the vent system will cause products of combustion to enter structure (vent system operates under positive pressure).

WARNING

Page 43

BOILER DIMENSIONS & RATINGS

A. BOILER DIMENSIONS

1. Figure 10.1 shows the dimensions of the PI-399.

10. BOILER DIMENSIONS & RATINGS

Figure 10.1: PI-399 Dimensions

Page 44

BOILER DIMENSIONS & RATINGS

Peerless Pinnacle

Model

Number

Input, MBH

Gross

Output,

MBH

Net I=B=R

Ratings

Water¹

’

²,

MBH

Thermal

Efficiency,

Combustion

Efficiency,

Min Max

PI-399 100 399 379 330 93.4 95.1

Shipping

Weight,

252

Boiler Model

Fan Speed – RPM

High Fire Ignition Low Fire

PI-399 7700 3000 1900

Table 10.1: Boiler Ratings

Table 10.2: Combustion Air Fan Speed

1. Net I=B=R ratings are based on an allowance of 1.15.

2. Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

Note: These values are subject to change without notice.

Page 45

This page intentionally left blank.

Page 46

REPAIR PARTS

11. REPAIR PARTS

Repair parts are available from your installer or by contacting PB Heat, LLC, 131 S. Church, Bally, PA

19503. Use the Figures and Tables on Pages 44-45 to assist in ordering parts.

Note: Remember to include boiler model number and serial number when ordering parts.

Figure 11.1: Pinnacle P399 Repair Parts

Page 47

REPAIR PARTS

Item

No.

Description

Stock

Code

1 Retainer Clip (Flue Limit) N/A

2 1/8 ID Tube – Black PVC N/A

3 Flue Limit Switch 91429

4 Temperature Sensor 91532

5 Water Pressure Limit Switch 91609

6 Water Temperature Limit Switch 91410

7 Gas Piping Assembly (Includes 8, 9 & 10) 91584

8 Gas Valve Adapter Plate 91585

9 Gas Valve Combination 91541

10 Swirl Plate 91544

11 Relief Valve 91430

12 Nipple – 3/4 NPT x 3 N/A

13 Elbow – Brass 3/4 NPT N/A

14 Gasket – Blower Outlet 91547

15 Premix Channel 91549

16 Gasket – Flame Sensor / Ignitor 91491

17 Electrode Spark 91550

18 Screw M4-070 x 8 mm Phil Rd Hd N/A

19 Flame Sensor 91551

20 Screw M5 x 22 mm Torx T25 N/A

21 Gasket – Burner Intake 91552

22 Burner Element 70 mm Dia x 560 mm 91556

23 Nut Hex M6 N/A

24 Burner Door 91557

25 Refractory Burner Door 91558

26 Screw M4 x 8 mm Skt Hd Cap 2.5 mm N/A

27 Washer M4 Flat N/A

28 Target Wall Ceramic 91432

29 Screw M5 x 14 mm Skt Hd Cap 4 mm N/A

30 Blower Comb 91563

Table 11.1

Item

No.

Description

Stock

Code

31 Spring Clamp N/A

32 Condensate Hose 91576

33 Nipple - 3/4 NPT Black PVC N/A

34 Tee – 3/4 NPT Black PVC N/A

35 Vent Plug – 3/4 NPT Black PVC N/A

36 Clamp – Condensate Tee N/A

37 Screw #8 x 1/2" Self Tapping Phil Rd Hd N/A

38 Jacket – ABS Plastic N/A

39 Cover – ABS Plastic N/A

40 Blocked Vent Pressure Limit Switch 91498

42 Tubing 3/16" ID PVC 91508

43 Hose Barb S.S. 1/4 IDT x 10-32 N/A

44 O-Ring 007 N/A

45 Nut Hex 10-32 S.S. N/A

46 Screw 1/4-20 x 3/4" Phil Rd Hd N/A

47 Mounting Panel – Control Board N/A

48 Control Board w/ Fuse PI-399 91569

49 Low Voltage Wiring Harness (Not Shown) 91578

50 9 Pin Wiring Harness (Not Shown) 91580

51 5 Pin Wiring Harness (Not Shown) 91579

52 Spare Fuse N/A

53 Clips – Control Board N/A

54 Display Module 91461

55 Terminal Box 91603

56 Leveling Foot 91561

57 Latch Assembly 91560

58 Leveling Foot Socket N/A

59 Exhaust Coupling N/A

60 Exhaust Stub – 4" SCH 40 PVC x 4" LG N/A

Page 48

STARTUP COMBUSTION RECORD

APPENDIX A. STARTUP COMBUSTION

RECORD

Contact:

Company Name:

Address:

Phone Number:

Fax Number:

Email Address:

Jobsite Data

Job Name:

Jobsite Address:

Boiler Data

Boiler Model: Boiler Serial No.:

Manufacture Date: Startup Date:

Gas Pressure

Intake Gas Pressure

(in. w.c.):

Intake Gas Pressure

Drop at Startup:

High Fire Outlet Gas

Pressure (in. w.c.):

Low Fire Outlet Gas

Pressure (in. w.c.):

Combustion Readings

Flame Signal

High Fire (µA):

Flame Signal

Low Fire (µA):

CO²High Fire (%): CO²Low Fire (%):

CO High Fire (ppm): CO Low Fire (ppm):

Fan Speed High Fire: Fan Speed Low Fire:

Excess Air

High Fire (%):

Excess Air

Low Fire (%):

Exhaust Temperature

High Fire (°F):

Exhaust Temperature

Low Fire (°F):

System Information

Water Pressure: Condensate Line Size:

Vent Length

(Total Equivalent Feet):

Vent Diameter:

Peerless®Pinnacle®Startup Combustion Record

Page 49

NOTES

Page 50

NOTES

Page 51

Pinnacle

Peerless

Stainless Steel

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.

PI8128 R1 (12/08-1.5M)

Printed in U.S.A.

MH27745

CONTROLS

PB HEAT, LLC

131 S. CHURCH STREET • BALLY, PA 19503

PeerlessBoilers.com

Gas Boilers PI-399 Rev 2

ASME