PEERLESS Pinnacle PO-70, Pinnacle PO-70A, Pinnacle PO-84, Pinnacle PO-84A, Pinnacle Installation, Operation & Maintenance Manual
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.
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
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 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
1
USING THIS MANUAL
2
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.
3
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
4
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
5
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.
6
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
7
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
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.
8
VENTING, INLET AIR & CONDENSATE
Figure 3.4: Single Wall Vertical Chimney Venting
Figure 3.5: Concentric Vertical Roof Venting
9
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
10
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
11
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
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