PEERLESS Pinnacle PO-70, Pinnacle PO-70A, Pinnacle PO-84, Pinnacle PO-84A, Pinnacle Installation, Operation & Maintenance Manual

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Pinnacle

Boilers

Peerless

Oil

Installation, Operation & Maintenance Manual

As an ENERGY STAR®Partner, PB Heat, LLC has determined that this product meets the ENERGY STAR

guidelines for energy efficiency.

Page 2

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 . . . . . . . . . . .2

D. COMBUSTION & VENTILATION AIR . . . . . . .2

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

2. BOILER SET-UP 4

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

3. VENTING, INLET AIR & CONDENSATE 5

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

B. APPROVED MATERIALS FOR EXHAUST

VENT AND INLET AIR PIPING . . . . . . . . . . . .5

C. EXHAUST VENT/INLET AIR LOCATION . . . .5

D. CONCENTRIC VENTING SYSTEM . . . . . . . .6

E. EXHAUST VENT AND AIR INLET PIPE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .6

F. STANDARD VENT KITS . . . . . . . . . . . . . . . . .7

G. CONDENSATE . . . . . . . . . . . . . . . . . . . . . . . .8

4. WATER PIPING 10

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .10

B. SYSTEM COMPONENTS . . . . . . . . . . . . . . .10

C. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .12

D. FREEZE PROTECTION . . . . . . . . . . . . . . . . .12

E. SPECIAL APPLICATIONS . . . . . . . . . . . . . . .18

5. OIL BURNER INSTALLATION 20

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .20

B. BURNER INSTALLATION . . . . . . . . . . . . . . .20

6. ELECTRICAL & CONTROLS 21

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .21

B. BURNER WIRING . . . . . . . . . . . . . . . . . . . . .21

C. BOILER WIRING . . . . . . . . . . . . . . . . . . . . . .21

D. CONTROL TERMS . . . . . . . . . . . . . . . . . . . .22

E. SEQUENCE OF OPERATION . . . . . . . . . . . .23

F. BOILER SAFETY INTERLOCKS . . . . . . . . . .24

G. BOILER TEMPERATURE CONTROL

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .24

H. CONTROL MODES . . . . . . . . . . . . . . . . . . . .24

I. USER INTERFACE . . . . . . . . . . . . . . . . . . . .24

J. CONTROL ACCESS LEVELS . . . . . . . . . . . .25

K. TROUBLESHOOTING . . . . . . . . . . . . . . . . . .27

L. POC TECHNICAL DATA . . . . . . . . . . . . . . . .28

7. START-UP PROCEDURE 30

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .30

B. FILL THE SYSTEM WITH WATER . . . . . . . .30

C. CHECK THE ELECTRIC CIRCUITS . . . . . . . .30

D. PRIME THE FUEL UNIT . . . . . . . . . . . . . . . .30

E. SET COMBUSTION . . . . . . . . . . . . . . . . . . .30

F. CHECK BOILER FUNCTION . . . . . . . . . . . . . .31

8. TROUBLESHOOTING 32

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .32

9. MAINTENANCE 34

A. GENERAL MAINTENANCE (WITH BOILER

IN USE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

B. ANNUAL MAINTENANCE (BEFORE THE

START OF HEATING SEASON) . . . . . . . . . .34

10. BOILER DIMENSIONS & RATINGS 37

A. BOILER DIMENSIONS . . . . . . . . . . . . . . . . .37

B. BOILER RATINGS . . . . . . . . . . . . . . . . . . . . .37

11. REPAIR PARTS & OPTIONAL ACCESSORIES 38

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 special attention boxes are provided to supplement the instructions and make special notice of potential hazards. The definition of each of these categories, in the judgement of PB Heat, LLC are as follows:

USING THIS MANUAL

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.

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

WARNING

USING THIS MANUAL

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A. GENERAL

1. Pinnacle Oil boilers are supplied factory assembled with pressure vessel, base, and jacket panels. A trim box containing the relief valve, drain valve, temperature / pressure gauge and associated pipe fittings is included in the crate.

2. The burner, acoustic shroud and venting are shipped separately for field assembly. The POC control is shipped separately for maximum flexibility.

3. The package should be carefully inspected for damage upon receipt and any damage to the unit should be reported to the shipping company and wholesale distributor.

4. The boiler should be stored in a clean, dry location.

5. Carefully read these instructions and be sure to understand the functions of all mechanical and electrical connections before beginning the installation. Contact your PB Heat, LLC representative for help in answering questions.

6. This boiler must be installed by a qualified contractor. The boiler warranty may be voided if the boiler is not installed correctly.

7. This boiler may be installed at high altitudes above 5,000 feet elevation. Consult burner manual (included) for burner requirements.

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 appliance installation.

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

a) ASME Boiler & Pressure Vessel Code, Section IV –

Heating Boilers

b) ASME Boiler & Pressure Vessel Code, Section VI –

Recommended Rules for the Care and Operation of Heating Boilers.

c) ANSI/NFPA 70 – National Electrical Code

d) NFPA 31 – Standard for the Installation of Oil-

Burning Equipment.

e) ANSI/NFPA 211 – Chimneys, Fireplaces, Vents

and Solid Fuel Burning Appliances.

3. Where required by the authority having jurisdiction, the installation of this equipment must comply with ANSI/ASME CSD-1 – Standard for Controls and Safety Devices for Automatically Fired Boilers.

C. ACCESSIBILITY CLEARANCES

1. The Pinnacle Oil boiler is design certified for closet installations with zero clearance to combustible construction. In addition, it is certified for use on combustible floors provided the boiler is not installed on carpeting.

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

D. COMBUSTION & VENTILATION AIR

1. The Pinnacle Oil boiler is designed for several options for combustion air and venting.

a) Concentric Sidewall Venting

b) Concentric Vertical Chimney Venting

c) Single Wall Vertical Chimney Venting using the

chimney as a chase for inlet air.

d) Concentric Vertical Roof Venting

2. The concentric venting options are designed for operation with combustion air piped from the outside (sealed combustion). For these options, no additional ventilation air is required.

PREINSTALLATION

1. PREINSTALLATION

This appliance must be supplied with adequate combustion air to properly burn the fuel. Failure to supply an adequate air supply will result in incomplete combustion resulting in sooting and carbon monoxide emission. This may result in severe personal injury, death or major property damage.

WARNING

DANGER

Do not install this boiler on carpeting.

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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. Review the following sections of this manual for consideration of the limitations with respect to:

a) Venting: Section 3

b) Air Intake Piping: Section 3

c) Condensate Removal: Section 3

d) Water Piping: Section 4

e) Oil Burner & Fuel Piping: Section 5

f) Electric and Controls: Section 6

PREINSTALLATION

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

WARNING

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

WARNING

Service Clearances

Designation Description Dimension

“A” Burner Swing Clearance (Left or Right) 16" [406 mm]

“B” Jet/Acoustic Shroud Removal Clearance 13" [330 mm]

“C” Vent/Air Intake Sampling Clearance 12" [305 mm]

“D” Control Panel Access Clearance 24" [610 mm]

Figure 1.1: Recommended Service Clearances

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A. GENERAL

1. Pinnacle Oil boilers are to be installed in either 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. Provide a level foundation, located as close as practicable to the center of the heating system.

4. After removing the boiler from the packaging and setting it on its foundation, open the burner swing door on the top of the boiler and make sure the jet inserts are seated properly in the combustion chamber. Refer to the repair parts in Section 11 to identify these parts. Close the burner swing door before continuing.

5. Install the boiler level to prevent condensation from blocking the vent system.

BOILER SET-UP

2. BOILER SET-UP

Be sure that any packing material that is in the combustion chamber to protect the Jet Inserts is removed before firing the appliance. Failure to do this may result in minor personal injury or property damage.

CAUTION

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A. GENERAL

1. All venting and air inlet piping is to be installed in accordance with local building codes, NFPA 31 and these instructions.

2. This appliance may be vented in any one of the following three ways. Examples of these systems are detailed in this section.

a) Concentric Sidewall Venting

b) Concentric Vertical Chimney Venting

c) Single Wall Vertical Chimney Venting using the

chimney as a chase for inlet air

d) Concentric Vertical Roof Venting

B. APPROVED MATERIALS FOR EXHAUST

VENT AND INLET AIR PIPING

1. The venting system for this boiler has been approved under UL-726 for use with this boiler. No substitutions are to be made for this material.

2. The venting components shown in Table 3.2 and the venting kits shown in Figures 3.2 through 3.5 are to be purchased separately from your distributor. Questions regarding the proper vent material are to be directed to your PB Heat, LLC representative.

C. EXHAUST VENT/INLET AIR LOCATION

1. The concentric vent piping for this boiler is approved for zero clearance to combustible construction.

2. The Pinnacle Oil boiler, like all high efficiency products, is likely to produce a visible vapor plume due to condensation. Surfaces near the vent termination will likely be coated with condensation.

3. Care must be taken to locate the exhaust vent where the exhaust gas, vapor plume, and condensation do not cause a hazard or nuisance. For example, do not locate the exhaust vent termination under a deck where, under certain conditions, it could form a coating of ice causing a hazard or reduce the life of the deck materials.

4. Sidewall Vent System a) Sidewall vented products are susceptible to wind

conditions that can effect combustion. To minimize the effects of wind, the exhaust and air inlet terminations must penetrate the same wall or vertical surface. In addition, the length of the exhaust and air inlet pipes must be roughly equivalent.

b) Condensation from a sidewall vented appliance

may cause paint and other surface coatings to deteriorate. In addition, soot stains may appear on surrounding surfaces if the boiler is not properly maintained.

c) If the boiler is used to heat potable (tap) water, the

boiler will operate year round. The effects of hot gases and odors must be taken into consideration during the summer months.

d) See Figure 3.1 for an illustration of clearances for

location of exit terminals for direct-vent, sidewall venting systems.

e) The boiler vent system shall terminate at least 3

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

f) Provide a minimum of 1 foot (300 mm) distance

from any door, operable window, or gravity air inlet into any building.

g) Do not locate the exhaust termination directly

under an operable window.

h) Provide a minimum of 1 foot (300 mm) clearance

from the bottom of the exhaust termination above the expected snow accumulation level. Snow removal may be necessary to maintain clearance.

i) Provide 4 feet horizontal clearance from electrical

meters, gas meters, air conditioning condensers or other external equipment. In no case shall the exit terminal be above or below the aforementioned equipment unless a 4 foot horizontal distance is maintained.

j) Do not locate the exit termination over public

walkways where condensate could drip or freeze, causing a hazard or nuisance.

k) When the exhaust termination is adjacent to a

public walkway, it is to be located at least 7 feet (2100 mm) above grade.

l) Do not locate exhaust termination directly under

roof overhangs to prevent icicles from forming.

m) Provide 3 feet (0.9 m) clearance from the inside

corner of adjacent walls.

VENTING, INLET AIR & CONDENSATE

3. VENTING, INLET AIR & CONDENSATE

DANGER

This vent system operates under a positive pressure. Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure. Failure to comply will result in severe personal injury, death or major property damage.

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D. CONCENTRIC VENTING SYSTEM

1. The concentric venting system used with this appliance consists of an inner pipe constructed of polypropylene or stainless steel and an outer pipe made of aluminum.

2. The inner pipe provides a path for the exhaust gases to exit the boiler to the outdoors while space between the pipes allows outdoor air to be conveyed to the boiler.

3. The minimum vent length is 14 equivalent feet for models PO-70 and PO-84 and 25 feet for models PO-70A and PO-84A. This minimum length is required to obtain the efficiency rating of this product. The maximum vent length is 80 equivalent feet. Since the air inlet pipe is integral to the vent, the same minimum and maximum vent lengths apply.

4. The following chart gives equivalent lengths for several common venting components.

E. EXHAUST VENT AND AIR INLET PIPE

INSTALLATION

1. Only polypropylene vent material supplied by PB Heat, LLC is to be used with this appliance.

2. Horizontal lengths of vent pipe must slope towards the boiler at a pitch not less than 1/4" per foot (20 mm per meter) to allow condensate to drain from the vent pipe into the boiler. 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 this low point to provide drainage.

3. All piping must be fully supported. Use pipe hangers at a minimum of 4 foot (1.2 meter) intervals to prevent sagging of the vent pipe where condensate may form.

4. Do not use the boiler to support any piping. All piping is to be supported externally.

VENTING, INLET AIR & CONDENSATE

Fitting Description Equivalent Length

Elbow, 90° 5

Cleanout Tee 5

Elbow, 45° 3

Vertical Vent Termination 0

Sidewall Vent Termination 0

Figure 3.1: Location of Exit Terminals of Mechanical Draft and Direct-Venting Systems

Page 9

F. STANDARD VENT KITS

1. Common Vent Kit (54044): The common vent kit is required for each Pinnacle Oil Boiler. This includes:

a) (54000) Concentric Sample Port Adapter

b) (54001) Concentric Clean-out Tee

c) (54006) Adjustable Length Vent Pipe - 19-1/2"

Max.

d) (54002) Concentric 90° Support Elbow

e) (54048) Vent Pipe Support

2. Concentric Sidewall Vent Kit (54045): A concentric sidewall vent kit is used for boilers that are vented through a building wall. This type of installation is shown in Figure 3.2. This kit includes:

a) (54029) Concentric Sidewall Termination

b) (54003) Concentric 90° Elbow

c) (54007) Concentric Wall Plate

Additional vent pipe and fittings may be required to complete the installation. Refer to the component list for vent pipe in Table 3.2.

3. Concentric Vertical Chimney Vent Kit (54047): A concentric vertical chimney vent kit is used to pipe both the exhaust vent and the inlet air through an existing chimney. An example of this type of installation is shown in Figure 3.3. This kit includes:

a) (54012) Aluminum Shaft Cover Assembly

b) (54015) Vertical Vent Termination

Additional concentric vent pipe components may be required to complete the installation. Refer to the component list for vent pipe in Table 3.2.

4. Single Wall Vertical Chimney Vent Kit (54046): A single wall vertical chimney vent kit is used to pipe the exhaust vent through an existing chimney while drawing the inlet air down through the chimney around the exhaust vent pipe. An example of this type of installation is shown in Figure 3.4. This kit includes:

a) (54036) Stainless Steel End Pipe

b) (54013) Aluminum Shaft Cover

Additional vent pipe components may be required to complete the installation. Refer to the component list for vent pipe in Table 3.2.

VENTING, INLET AIR & CONDENSATE

Figure 3.2: Sidewall Venting

Figure 3.3: Concentric Vertical Chimney Venting

Page 10

5. Concentric Vertical Roof Vent Kit (54049): The concentric vertical roof vent kit is used without a chimney to vent through the building roof. This type of installation is shown in Figure 3.5. Additional concentric vent pipe components may be required to complete the installation. Refer to the component list for vent pipe in Table 3.2.

G. CONDENSATE

1. The disposal of all condensate into public sewage systems is to be in accordance with local codes and regulations. In the absence of such codes, follow these instructions.

2. The condensate from oil-fired condensing appliances may have a pH value as low as 2. Some local codes require the use of neutralization equipment to treat the condensate.

3. A condensate neutralizer (91438), available from your distributor is recommended to reduce the acidity of the condensate before it is piped to a drain.

4. This appliance must be fitted with a condensate trap to prevent flue gas leakage.

5. Figure 3.6 shows a simple condensate trap that can be utilized with this equipment. A 3/4" Female NPT x 3/4" O.D. Barb Adapter is used to attach a 3/4" ID PVC (Tygon) Hose.

6. If the condensate outlet of the Pinnacle boiler is below the drain level, a condensate pump must be used.

7. All piping for the condensate drain should be corrosion resistant material such as PVC or polypropylene. Do not use galvanized, aluminized, or materials containing copper (such as brass or bronze) for pipe or fittings.

VENTING, INLET AIR & CONDENSATE

Figure 3.4: Single Wall Vertical Chimney Venting

Figure 3.5: Concentric Vertical Roof Venting

Page 11

VENTING, INLET AIR & CONDENSATE

Figure 3.6: Condensate Trap & Neutralization

Table 3.2: Vent Pipe Component List

Stock

Code

Description

54017 Concentric Vent Pipe 19" Long

54018 Concentric Vent Pipe 39" Long

54006

Adjustable Length Concentric Vent Pipe - 19-1/2" Maximum Length

54005

Adjustable Length Concentric Vent Pipe - 39" Maximum Length

54003 90° Concentric Elbow

54062 Wall Clamp for Concentric Vent Pipe

54063 Universal Lead Tile for Vertical Vent Termination

54064 Flat Roof Flashing for Vertical Vent Termination

54024 9" Polypropylene Vent Pipe

54025 19" Polypropylene Vent Pipe

54026 39" Polypropylene Vent Pipe

54027 78" Polypropylene Vent Pipe

54023 90° Polypropylene Elbow

54058 45° Polypropylene Elbow

Page 12

A. GENERAL

1. All boiler piping is to be installed in accordance with local building codes and these instructions.

2. This appliance is to be installed so that the electrical components of the burner and ignition system are protected from water (dripping, spraying, etc.) during operation and service. Service includes circulator replacement, condensate system cleaning, control replacement and other general maintenance procedures.

B. SYSTEM COMPONENTS

Figure 4.1 shows the symbol key for piping diagrams in this section. The following are brief descriptions of system components.

1. Pressure/Temperature Gauge: A combination pressure/temperature gauge is provided with the unit to be mounted in the piping from the boiler supply to the system. Installation of this gauge is required by most local codes.

WATER PIPING

4. WATER PIPING

Figure 4.1

Page 13

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

3. 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 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 for the proper heating medium. Glycol solutions may expand more than water for a given temperature rise.

4. Y-Type Strainer: In older heating 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 and cleaned often in the first few months of operation to assure that sediment does not build up in the heat exchanger.

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

6. Pressure Reducing Valve: A pressure reducing valve such as the Bell & Gossett B-38 or 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 in glycol solution systems unless the glycol concentration is closely monitored.

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

8. Pressure Relief Valve: A pressure relief valve is supplied with each boiler for installation in the supply piping. Figure 4.2 shows the installation of the pressure relief valve and the temperature/pressure gauge. The relief valve discharge is to be piped within 12” (305mm) of the floor and close to a floor drain. Provide piping that is the same size or larger than the relief valve outlet.

9. Isolation Valve: Isolation valves are intended to provide a positive shut-off for isolating sections of system piping. Ball valves and gate valves are examples of valves for this purpose. These types of valves are not intended for throttling flow.

10. Balancing Valve: Balancing valves are intended to throttle water flow. Examples of this type of valve are globe and needle valves.

11. Zone Valve: Zone valves are electronically activated valves intended for use with zone thermostats to provide heat only in the zone in which it is required.

12. Differential Bypass Valve: A differential bypass valve is used to allow minimum circulation in a system employing zone valves if all the zone valves close before the circulator stops. This prevents the circulator from “dead heading.”

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

WATER PIPING

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 the system components from premature failure due to corrosion.

CAUTION

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

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

Figure 4.2

Valves which automatically feed water under low water conditions can allow leaks to go unnoticed. This may allow large amounts of fresh water to be added to the system resulting in scaling in the boiler heat exchanger or dilution of glycol solutions.

NOTICE

Page 14

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. In the case of the Pinnacle Oil boiler, the pressure drop through the boiler is nearly negligible.

b) The circulator should be sized based on the boiler

net output. The boiler “Net I=B=R Output” for each Pinnacle Oil Model is listed in the chart below. This value includes a piping pickup factor of 1.15.

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 PO-50 with a design water temperature rise of 20°F the calculation is as follows:

d) The pressure drop of the system then determines

the circulator that should be used.

e) Special consideration must be given if propylene

glycol solution is to be used as a heating medium.

- Propylene glycol has a higher viscosity than water; therefore the system pressure drop will be higher.

- Propylene glycol has a lower heating capacity than water and therefore requires a higher flow rate (14% for a 50% glycol solution) to transfer heat similar to water.

14. Indirect Water Heater: An indirect water heater, such as the Peerless Partner, should be piped into a dedicated zone. It consists of a water tank that is heated by boiler water passing through an internal coil.

C. SYSTEM PIPING

1. Figure 4.3: This illustration shows a single Pinnacle Oil Boiler, a Peerless Partner Indirect Water Heater, and a single heating zone.

a) The standard POC #1 control will accept separate

inputs for heating and hot water. This will allow the heating zone to be supplied with a variable temperature depending on outdoor temperature (outdoor reset) while the domestic hot water zone will have a pre-designated set point. A complete description of this control will be given in Section 6 of this manual, Electrical & Controls. Note: Outdoor reset operation requires an optional Outdoor Sensor (54034).

b) By upgrading to the POC #2 control (54031), the

boiler may give domestic hot water full priority over the heat load.

2. Figure 4.4: This diagram shows an additional zone in which baseboard radiation is the heat load. Baseboard radiation can be operated using the outdoor reset function to maximize the boiler efficiency.

3. Figure 4.5: This figure shows diverter tees used in combination with conventional hydronic radiators on an additional zone.

a) Also, a second boiler is shown piped in parallel

with the first. It is important that the common headers are sized to match the system piping. Smaller headers may result in flow fluctuations through the boilers.

b) An upgrade to the POC #3 control (54032) allows

a second boiler with a POC #1 conrol to act as a second stage, firing only when the first boiler fails to meet the load demand.

4. Figure 4.6: This illustration shows two boilers piped in parallel feeding a primary/secondary system with 5 zones using zone circulators. In this configuration, the supply water temperatures become increasingly cooler when all zones are calling. Therefore, the hottest and smallest zones should be piped closest to the boiler for best results.

5. Figure 4.7: This illustration shows a system in which zone valves are used in place of zone circulators. Notice that this system utilizes reverse return piping (where the first zone supplied is the last zone on the return), which makes it easier to balance the system. If the heating loops are very different in length, balancing valves, shown on the return side of each loop, are required.

D. FREEZE PROTECTION

1. Propylene glycol for hydronic heat transfer 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 concentration and inhibitor level.

2. Do not used galvanized pipe in systems using propylene glycol solutions.

3. Use water low in mineral content and make sure there is no petroleum based solution in the mixture.

4. Make sure the heating system is clean.

5. Mix propylene glycol solution at room temperature.

6. Do not use a chromate treatment.

7. Do not use automotive type glycol. Use an inhibited propylene glycol specifically formulated for hydronic heat transfer.

WATER PIPING

Do not use more than 50% propylene glycol.This provides freeze protection to -28°F. Higher concentrations will inhibit heat transfer and reduce the system flow rate.

NOTICE

Output 56,000

= = 5.6 GPM

(

T x 500) 20 x 500

Required Flow =

Boiler Model

Boiler Input

Net I=B=R

Output (Btu/hr)(gph) (Btu/hr)

PO-70 & PO-70A

0.50 70,000 56,000

PO-84 & PO-84A

0.60 84,000 67,000

Page 15

Figure 4.3: One Boiler with Two Zones using Zone Circulators

WATER PIPING

Page 16

WATER PIPING

Figure 4.4: One Boiler with Three Zones using Zone Circulators

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WATER PIPING

Figure 4.5: Two Boilers with Four Zones using Zone Circulators

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WATER PIPING

Figure 4.6: Two Boilers with Five Primary/Secondary Zones using Zone Circulators

Page 19

WATER PIPING

Figure 4.7: Two Boilers with Five Reverse Return Zones using Zone Valves

Page 20

8. Propylene glycol solution is expensive and is more prone to leaks than water. Use welded or sweat joints where possible to minimize leaks. Where threaded joints must be used, inspect them regularly for leaks.

9. The propylene glycol solution must be checked at least once per year as recommended by the propylene glycol supplier. It includes a corrosion inhibitor that can diminish over time causing the solution to become corrosive.

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

E. SPECIAL APPLICATIONS

1. Boilers used in conjunction with a chiller. a) If the boiler is used in conjunction with a chilled

water system, pipe the chiller in a separate parallel loop.

b) Assure that the boiler circulator is disabled during

chiller operation so chilled water does not enter the boiler.

c) Install a flow control valve (spring check) to

prevent gravity flow through the boiler.

d) See figure 4.8 for recommended system piping.

2. Boilers connected to heating coils in a forced air system: a) If the heating coil is exposed to chilled air

circulation, install flow control valves or other automatic means to prevent gravity circulation of the water during cooling cycles.

b) See figure 4.9 for recommended system piping.

Figure 4.8: Boiler in conjunction with a Chilled Water System

WATER PIPING

Page 21

Figure 4.9: Boiler Connected to a Heating Coil in a Forced Air System

WATER PIPING

Page 22

A. GENERAL

1. The oil burner for this appliance is supplied separately but must be as specified for this equipment. At the time of this printing, the following burners are Listed in accordance with UL-726, Oil Fired Boiler Assemblies:

a) Beckett AFG

b) Heat Wise Pioneer I (Not Yet Available)

2. Check for concealed damage to the burner or controls when it is unpacked. If concealed damage is found, notify the carrier and/or wholesale distributor at once.

3. Install the burner in accordance with instructions given in this section and with those provided by the burner manufacturer.

B. BURNER INSTALLATION

1. The burner is supplied with a mounting flange fixed in position to provide the proper insertion depth.

2. Be sure that a high temperature gasket is installed between the burner mounting flange and the combustion chamber cover plate.

3. Care must be taken when routing the oil lines so they do not interfere with opening and closing the combustion chamber cover plate. Flexible oil lines may be installed to allow opening the cover plate for servicing.

4. Oil Burner Specifications: The following charts indicate the nozzle specification, fuel pressure and initial air settings for firing the burner. Final adjustments shall be made using combustion analysis equipment and a smoke spot tester.

5. Refer to Section 7, Start-Up Procedure, for information on proper CO²and smoke levels.

OIL BURNER INSTALLATION

5. OIL BURNER INSTALLATION

DANGER

This appliance is intended for use with Commercial Standard #2 Oil fuel as specified in ASTM D396. Use with other fuels, including gasoline and crankcase oil, will void the appliance warranty.

Since the burner on this appliance is located at the top of the appliance in a down-fired configuration, disconnecting the oil lines while the burner door is closed will allow oil to drip into the combustion chamber.To avoid this, install the burner with flexible oil lines and only disconnect the lines after the combustion chamber cover plate is swung open.

NOTICE

Boiler Model

Danfoss Nozzle

Specification

Pump Pressure

(psig)

Air Damper

Setting

PO-70 & PO-70A

0.45 gph 60° AS 130 1.5

PO-84 & PO-84A

0.55 gph 60° AS 130 2.5

This combustion equipment must be installed by qualified service person who is responsible for the correct installation and adjustment of this equipment. Failure to comply with this may cause a condition which may cause severe personal injury, death, or major property damage.

WARNING

Table 5.1: Beckett Burner Specification

Page 23

A. GENERAL

1. This appliance is to be wired in accordance with local codes and regulations as defined by the Authority having jurisdiction. In the absence of such local codes, it shall be wired in accordance with the latest edition of the National Electrical Code, ANSI/NFPA 70.

B. BURNER WIRING

1. Burners intended for use with this boiler will come equipped with a wiring harness that terminates in a quick-disconnect style connector that mates with the connector supplied with the boiler.

2. If the burner supplied does not have such a harness and connector, contact your boiler/burner supplier and/or your PB Heat, LLC representative.

3. Refer to the wiring diagram shown in Figure 6.1 for reference and further details.

C. BOILER WIRING

1. To open the boiler control panel the two screws at the top of the upper front panel must be removed. The burner cover must be removed to access these screws.

2. Figure 6.2 shows the customer connections to the boiler control terminals. All customer connections are to be made to the labeled screw terminations in the electrical control panel.

ELECTRICAL & CONTROLS

6. ELECTRICAL & CONTROLS

The wiring diagrams in this manual are for general reference only and apply only to the appliance as it is specified from the factory which includes a burner primary control and a boiler temperature control (POC#1, POC#2, or POC#3).

WARNING

Do not bypass the wiring harness provided with this boiler or burner. Failure to apply the correct harness can result in severe personal injury, death or substantial property damage.

WARNING

Figure 6.1: Boiler Wiring Diagram

Page 24

D. CONTROL TERMS

To describe the operation of this appliance, there are several terms that must be defined. The following is a short glossary of terms.

1. Parallel Piping: In parallel piping applications the boiler outlet goes directly to the system. In these cases, only one sensor, the boiler supply sensor, is required to control the boiler target temperature.

2. Primary/Secondary Piping: In primary/secondary piping applications, the system supply temperature may be lower than the boiler outlet temperature. An additional sensor (54033) is required to control the boiler based on the system supply, while the boiler supply sensor continues to limit the boiler target based on the programmed values.

3. Setpoint demand: A setpoint demand is a fixed target temperature that is programmed into the control by the installer. For example, if the system requires 180°F water when a call for heat is initiated, the control targets that temperature.

4. Outdoor Reset: Outdoor reset describes a system where the boiler target temperature is calculated based on outdoor temperature. As the outdoor temperature increases, the system requirement decreases. This allows the boiler to operate at a lower, more efficient temperature.

5. Reset Override: Reset override occurs when a boiler is operating on an outdoor reset temperature and a setpoint demand is introduced. Reset override changes the target temperature to the setpoint target, overriding the outdoor reset temperature.

6. Domestic Hot Water Priority: Domestic hot water (DHW) priority is when a system uses reset override and controls circulators to provide a higher temperature water to a DHW tank while preventing this high temperature water from circulating to the heating zones. To provide control of the DHW circulator the POC #2 (54031) or POC #3 (54032) is required.

7. Boiler Differential: In order to operate a boiler without frequent cycling on and off a boiler differential is used. All POC controls work on an automatic differential that will change between 2°F and 42°F based on the system response. The differential is split across the target temperature. For example, if the target temperature is 160°F and the differential is at 10°F, the boiler will shut down at 165°F and turn on at 155°F.

ELECTRICAL & CONTROLS

Figure 6.2: Customer Electrical Connections

Figure 6.3: Parallel Piping

Figure 6.6: Boiler Differential

Figure 6.4: Primary/Secondary Piping

Figure 6.5: Outdoor Reset Ratio

(Boiler Design - Boiler Start)

(Outdoor Start - Outdoor Design)

Boiler Target = Boiler Start + RR (Outdoor Start - Actual Outdoor)

RR =

Page 25

ELECTRICAL & CONTROLS

E. SEQUENCE OF OPERATION

1. System Power-up: a) When power is first applied the control turns on all

segments in the display for 2 seconds.

b) Next, the software version is displayed for 2

seconds.

c) Finally the control enters the normal operating

mode.

2. Heating Cycle: a) On a call for heat (or DHW), the boiler runs

according to the control modes listed in Section 6H.

b) The boiler continues to run until either the call for

heat (or DHW) is satisfied or the boiler reaches the target temperature plus half of the differential.

c) When the boiler turns off, a 2 minute post-purge

(air evacuation of the combustion chamber) is initiated.

d) If the boiler cycles off on temperature, it will allow

the temperature to drop to the target temperature minus half of the differential before cycling back on.

e) When the boiler satisfies the load, the control will

go into a standby mode and the target temperature is displayed as “- - -“.

Circulator: Displays when a circulator is in operation.

ºF, ºC: Units of Measurement

Burner: Displays when the burner is operating. When the POC #3 Control is used it will display either 1 or 2 to show what stage of the boiler is on.

Pointer: Displays the operation as indicated by the text

Figure 6.7: Control Display

Symbol Description

Page 26

ELECTRICAL & CONTROLS

F. BOILER SAFETY INTERLOCKS

1. High Water Temperature Limit Switch: This boiler has

a maximum operating temperature of 210°F. If the boiler water temperature reaches 210°F, the high temperature limit will interrupt the heating cycle and begin a post-purge. After the temperature drops 10°F, the switch will automatically reset and allow the boiler to reinitiate.

2. High Vent Temperature Limit Switch: The vent system

for this boiler has a maximum temperature limit of 210°F. If the exhaust vent temperature reaches or exceeds 210°F (120°C), the limit will interrupt the heating cycle and initiate a post-purge. The limit will not reset until the red button under the burner hood is pressed.

G. BOILER TEMPERATURE CONTROL

OPTIONS

The Pinnacle Oil boiler is offered with the POC #1 control board as standard. This boiler may be ordered with the POC #2 or POC#3 control upgrades. The features of each of these are as follows:

1. POC #1 Control: This control is factory set for on/off

operation. It can be easily programmed to provide outdoor reset with reset override (requires Outdoor Sensor #54034). This control can be used with an external zone control that controls a DHW circulator for DHW priority. It will provide a fixed setpoint water temperature on a call for DHW.

2. POC #2 Control: This control offers the same

features of POC #1 with the added benefit of a DHW circulator relay to provide full domestic hot water priority without relying on an external zone control.

3. POC #3 Control: This control offers the same

features of POC #2 while allowing a second boiler with a POC #1 control to be added to provide a second stage of heating. If the first boiler does not meet the demand in a reasonable time, the second boiler will be started.

H. CONTROL MODES

The POC control allows 6 modes of operation.

1. Mode 1: This is designed to operate the boiler at a

fixed set point for systems which use parallel piping. Once a heat demand signal is present, the control operates the boiler to maintain a fixed temperature at the boiler outlet. This is the default control mode and requires no additional sensors.

2. Mode 2: This is designed to operate the boiler at a

fixed set point for systems using primary/secondary piping. Once a heat demand is present, the control operates the boiler to maintain a fixed temperature at the system supply. This mode requires an additional system supply sensor (54033).

3. Mode 3: This is designed to operate a parallel-piped

boiler with outdoor reset when a heat demand signal is introduced. This requires an outdoor sensor (54034). A setpoint demand (such as domestic hot

water) will override (reset override) the heat demand and change the target temperature to the setpoint value. For full DHW priority, control of the system and DHW circulators is required. This can be accomplished using the POC #2 or POC#3 control from PB Heat. This can also be accomplished using an external zone relay as shown later in this section.

4. Mode 4: This is designed to operate a primary/ secondary-piped boiler with outdoor reset when a heat demand signal is introduced. This requires an outdoor sensor (54034) in addition to a system supply sensor (54033). A setpoint demand (such as domestic hot water) will override (reset override) the heat demand and change the target temperature to the setpoint value. For full DHW priority, control of the system and DHW circulators is required. This can be accomplished using the POC #2 or POC#3 control from PB Heat. This can also be accomplished using an external zone relay as shown later in this section.

5. Mode 5: Mode 5 is designed for external boiler control for multiple boiler installations. In this case, the POC #1 control is used to provide boiler circulator control only. The staging and sequencing is controlled by the external control. This can be used in a two boiler system to provide 2-stage operation as we will show later in this section.

I. USER INTERFACE

1. The POC controls offer status display of the boiler circulator, burner, and heat or DHW demand.

2. It also displays the boiler supply temperature (°F or °C) as standard while allowing the user to scroll through 6 other temperature displays as well as a display of the overall run time on the boiler.

3. The three push buttons on the face of the POC Controls are labeled “Item”, “i” and “j” are used for selecting and adjusting settings.

4. Menus: All of the selectable items displayed by the control are organized into two menus designated

and . Advanced options in both menus are accessible by switching the Installer/Advanced dip switch located behind the lower control cover.

a) This is the default menu for all three POC

controls and is displayed in the Menu Field above the Number Field when accessing the View menu. Table 6.1 shows the View Menu for the POC controls.

- The first column shows the item field with the default values (where applicable) for the control.

- The next two columns show the access level at which these items are available.

- The fourth column shows the description of the item field and if the item is only available in certain control modes, the modes in which it is shown are listed.

- The fifth column shows the range of values that may be displayed on this screen.

VIEW

ADJUSTVIEW

Page 27

b) To enter the Adjust Menu press the

“Item”, “i” and “j” keys simultaneously for 1 second.

- The Items in this menu allow the installer to set up the control for a particular installation.

- Once in the ADJUST menu, use the “Item” key to scroll through the parameters listed in Table 6.2.

- Use the “i” and “j” keys to change the values. A blank column entitled, “Actual Setting” allows the installer to record the settings for reference.

J. CONTROL ACCESS LEVELS

1. Each POC control has an “Advanced” and “Installer” Access level. These are selectable by the control dip switch.

a) The “Advanced” access level includes all the

settings and displays available in the control.

b) The “Installer” access level includes only the

settings and displays that are required for system setup.

2. To access the control dip switch: a) Remove the snap-on outer cover.

b) Remove the screw and lower cover plate on the

control.

c) The dip switch is located under this panel and

may be switched between “Advanced” and “Installer”. The dip switch is shown in Figure 6.8.

ADJUST

ELECTRICAL & CONTROLS

Item Field

Access Level

Description Range

INSTALLER ADVANCED

• •

Current outdoor air temperature as measured by outdoor sensor. This is the default display for the control.

MODE = 3, 4

-60 to 190°F

(-51 to 88°C)

• •

Target boiler supply is the temperature the control is currently trying to maintain at the boiler or system supply temperature

MODE = 1, 2, 3, 4

---, 35 to 226°F (2 to 108°C)

• •

Current boiler supply water temperature as measured by the boiler supply sensor.

MODE = 2, 4

14 to 266°F

(-10 to 130°C)

• •

Current system supply water temperature as measured by the system supply sensor.

MODE = 1, 3, 5 (Installer Level) MODE = 2, 4 (Advanced Level)

14 to 266°F

(-10 to 130°C)

• •

Current boiler inlet water temperature as measured by the optional boiler inlet sensor. This value will be displayed if the optional boiler return sensor is connected.

MODE = ALL

14 to 266°F

(-10 to 130°C)

•

Current difference in temperature between the boiler supply and the boiler return sensors. This value will be displayed if the optional boiler return sensor is connected.

MODE = ALL

0 to 252°F

(0 to 140°C)

•

The total number of running hours of the boiler since this item was last cleared.

MODE = ALL

0 to 999

Table 6.1: View Menu

Figure 6.8: Control Dip Switch

Page 28

ELECTRICAL & CONTROLS

Item Field

Access Level

Description Range

Actual

Setting

INSTALLER ADVANCED

• •

Sets the operating mode for the control 1, 2, 3, 4 or 5

Default (1)

________

• •

Minimum boiler target temperature during setpoint operation

MODE = 1, 2, 3, 4

OFF, 70 to 220°F

(OFF, 21 to 104°C)

Default (180°F)

________

• •

The outdoor temperature used to calculate the reset ratio and the boiler target temperature.

MODE = 3, 4

35 to 85°F

(2 to 29°C)

Default

(70°F)

________

• •

The design outdoor temperature used to calculate the reset ratio.

MODE = 3, 4

-60 to 32°F

(-51 to 0°C)

Default

(10°F)

________

• •

The starting water temperature used to calculate the reset ratio and the boiler target temperature.

MODE = 3, 4

14 to 266°F

(-10 to 130°C)

Default

(70°F)

________

• •

The design boiler water Temperature used in the reset ratio calculation.

MODE = 3, 4

0 to 252°F

(0 to 140°C)

Default (180°F)

________

•

The maximum boiler water temperature. This maximum supersedes any differential or outdoor reset targets.

120 to 210ºF

(49 to 99ºC)

Default (200°F)

________

•

The minimum temperature allowed for the boiler target temperature.

MODE = 1, 2, 3, 4

OFF, 80 to 180ºF

(27 to 82ºF)

Default

(OFF)

________

•

The differential that the control is to use when it is operating the boiler.

MODE = 1, 2, 3, 4

AUTO, 2 to 42ºF

(1 to 23ºC)

Default

(AU)

________

•

Determines when to stop pump purging.

MODE = ALL

OFF, 0:20 to 9:55

min, ON

Default

(0:20)

________

• •

System warm weather shutdown temperature.

MODE = 3, 4

35 to 100ºF, OFF

(2 to 38ºC)

Default

(70°F)

________

• •

Units of measurement

MODE = ALL

ºF or ºC

Default (°F)

________

Table 6.2: Adjust Menu

Page 29

K. TROUBLESHOOTING

1. Table 6.3 shows Error Codes that may be encountered with the POC series controls.

a) The first column shows error code display screen.

b) The next column shows descriptions of error codes.

c) The last column shows several steps to be taken to

correct the error code.

2. To test control functions, first turn off the service switch on the boiler control bezel. Then, the harness may be disconnected by pushing down on the tab on the side of the harness connector and gently removing the harness.

a) A good quality electrical multimeter capable of

reading 0-300V as a minimum and at least 02,000,000 Ohms is required to test the control.

b) Testing the Sensors: To test the sensors, the actual

temperature at each sensor location must be measured. If a temperature gauge is not mounted in the boiler piping near the sensor to be tested, a good quality digital thermometer with a surface temperature probe is recommended for the best accuracy.

- Measure the temperature at the location of the sensor.

- Measure the resistance through the sensor.

ELECTRICAL & CONTROLS

Service and maintenance must be performed by properly trained and experienced personnel. Failure to comply with this requirement may cause severe personal injury, death or major property damage.

WARNING

Table 6.3: Error Code Menu

Item Field Description Required Action

The control was unable to read an item from its read-only memory (ROM).

Check that all settings in the adjust menu are correct.

The control is no longer able to read the boiler supply sensor due to a short circuit. If the boiler inlet sensor is present and operational, the boiler will continue to operate using the boiler inlet sensor.