PEERLESS Pinnacle PI-399 Installation And Operation Manual

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

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

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

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

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

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

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

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 =

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

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