PeerlessBoilers MI-03, MI-04, MI-05, MI-06, MI-07 Installation Manual

...

MI/MIH

™

Boilers

Series

Gas

Installation, Operation & Maintenance Manual

USING THIS MANUAL 1

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

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

1. PREINSTALLATION 2

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

B. CLEARANCE FROM COMBUSTIBLE

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

C. AIR FOR COMBUSTION AND

VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . .3

D. INSTALLATION SURVEY . . . . . . . . . . . . . . . .6

E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .6

2. BOILER SET-UP 7

3. WATER PIPING AND CONTROLS 8

A. BOILER SUPPLY AND RETURN . . . . . . . . . . .8

B. SAFETY RELIEF VALVE . . . . . . . . . . . . . . . . .9

C. PIPING FOR ZONED SYSTEMS . . . . . . . . .10

D. EXPANSION TANK . . . . . . . . . . . . . . . . . . . .11

E. INDIRECT-FIRED WATER HEATER . . . . . . .11

F. FREEZE PROTECTION . . . . . . . . . . . . . . . . .11

4. VENTING 12

A. INTEGRAL DRAFT HOOD . . . . . . . . . . . . . .12

B. VENT DAMPER INSTALLATION –

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .12

C. VENT PIPING AND CHIMNEY . . . . . . . . . . .13

D. BOILER REMOVAL FROM COMMON

VENTING SYSTEM . . . . . . . . . . . . . . . . . . .14

5. GAS PIPING 15

6. ELECTRICAL 17

A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

B. ZONED SYSTEM WIRING . . . . . . . . . . . . . .17

C. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . .17

D. SEQUENCE OF OPERATION . . . . . . . . . . . .20

7. START-UP PROCEDURES 21

A. COMPLETING THE INSTALLATION . . . . . .21

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

C. ADJUSTMENT OF GAS PRESSURE

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

D. CHECKING BURNER INPUT . . . . . . . . . . . . .24

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

8. TROUBLESHOOTING 26

A. SHUT-DOWN CAUSED BY PILOT OUTAGE,

BLOCKED VENT SHUT-OFF SWITCH OR

FLAME ROLL-OUT SAFETY SHUT-OFF

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

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

9. MAINTENANCE 29

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

B. DAILY (WITH BOILER IN USE) . . . . . . . . . . .30

C. WEEKLY (WITH BOILER IN USE) . . . . . . . . .30

D. MONTHLY (WITH BOILER IN USE) . . . . . . .30

E. ANNUALLY (BEFORE START OF HEATING

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

10. BOILER DIMENSIONS & RATINGS 32

11. REPAIR PARTS 33

A. BASE/COMBUSTIBLE FLOOR PAN . . . . . . .33

B. MANIFOLD, GAS VALVE & PILOT . . . . . . . .34

C. BLOCK/DRAFT HOOD & JACKET . . . . . . . .36

D. CONTROLS/CIRCULATOR/VENT &

DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

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. ACCESSIBILITY CLEARANCES

Install boiler not less than 24″ (610 mm) between the left side, top, and front of the boiler and adjacent wall or other appliance, when access is required for servicing.

B. CLEARANCE FROM COMBUSTIBLE

CONSTRUCTION

The design of this boiler is certified for alcove installation with the following clearances:

1. 6″ (152 mm) between sides and combustible

construction.

2. 24″ (610 mm) between top of jacket and

combustible construction.

3. 6″ (152 mm) between draft hood and combustible

construction.

4. 6″ (152 mm) between vent pipe and combustible

construction.

5. 10″ (254 mm) between rear of jacket and

combustible construction.

PREINSTALLATION

1. PREINSTALLATION

Read carefully, study these instructions before beginning work.

This boiler must be installed by a qualified contractor.

The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly.

The equipment must be installed in accordance with those installation requirements of the authority having jurisdiction or, in the absence of such requirements, to the current edition of the

National Fuel Gas Code

, ANSI

Z223.1/NFPA 54 and/or CAN/CSA B149.1,

Natural Gas and Propane Installation Code

Where required by the authority having jurisdiction, the installation must conform to

American Society of

Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers,

ASME CSD-1.

NOTICE

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is not used for any space heating

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

IMPORTANT

Do not install this boiler on carpeting. Boiler installation on carpeting is a fire hazard. Install this boiler on non-combustible flooring or use a combustible floor pan to install this boiler on other non-carpeted flooring.

WARNING

Do not install this boiler on combustible flooring unless it is installed on a special combustible floor pan provided by PB Heat, LLC. Boiler installation on combustible flooring without the special pan is a fire hazard.

To order combustible floor pan, use the 5-digit stock codes listed in Table 11.1 of this manual.

WARNING

C. AIR FOR COMBUSTION AND

VENTILATION

1. Adequate combustion air and ventilation air must be provided for this appliance in accordance with the section of the National Fuel Gas Code entitled, “Air for Combustion and Ventilation” or applicable provisions of the local building code. Subsections 2 through 8 as follows are based on the National Fuel Gas Code requirements.

2. Required Combustion Air Volume:

The total required volume of indoor air is to be the sum of the required volumes for all appliances located within the space. Rooms communicating directly with the space in which the appliances are installed and through combustion air openings sized as indicated in Subsection 3 are considered part of the required volume. The required volume of indoor air is to be determined by one of two methods.

a. Standard Method: The minimum required

volume of indoor air (room volume) shall be 50 cubic feet per 1000 BTU/Hr (4.8 m

/kW). This method is to be used if the air infiltration rate is unknown or if the rate of air infiltration is known to be greater than 0.6 air changes per hour. As an option, this method may be used if the air infiltration rate is known to be between 0.6 and

0.4 air changes per hour. If the air infiltration rate is known to be below 0.4 then the Known Air Infiltration Rate Method must be used. If the building in which this appliance is to be installed is unusually tight, PB Heat recommends that the air infiltration rate be determined.

b. Known Air Infiltration Rate Method: Where

the air infiltration rate of a structure is known, the minimum required volume of indoor air for appliances other than fan assisted and for the Series MI™ Boiler shall be determined as follows:

where:

other

= Input of appliances other than fan

assisted in Btu/hr

ACH = air change per hour (percent of the

volume of the space exchanged per hour, expressed as a decimal)

For fan assisted appliances, calculate the required volume of air using the following equation:

fan

= Input of the fan assisted appliances in

Btu/hr

Note: These calculations are not to be used for

infiltration rates greater than 0.60 ACH.

3. Indoor Air Opening Size and Location:

Openings connecting indoor spaces shall be sized and located as follows:

a. Combining spaces on the same floor:

Provide two permanent openings communicating with additional spaces that have a minimum free area of 1 in

per 1000 Btu/hr (22 cm2per 1000 W) of the total input rating of all gas fired equipment but not less than 100 in

(645 cm2). One opening is to begin within 12 inches (305 mm) from the top of the space and the other is to begin within 12 inches (305 mm) from the floor. The minimum dimension of either of these openings shall be 3 inches (76 mm). See Figure

1.1 for an illustration of this arrangement.

b. Combining spaces on different floors:

Provide one or more permanent openings communicating with additional spaces that have a total minimum free area of 2 in

per 1000

Btu/hr (44 cm

per 1000 W) of total input rating of all equipment. See Figure 1.2 for an illustration of this arrangement.

PREINSTALLATION

15 ft

fan

ACH 1000

Btu

Required Volume

fan

⎛ ⎜ ⎝

⎛

⎜

⎝

Figure 1.1: Air Openings – All Air from Indoors

on the Same Floor

Figure 1.2: Air Openings – All Air from Indoors

on Different Floors

21 ft

other

ACH 1000

Btu

Required Volume

other

⎛ ⎜ ⎝

⎛

⎜

⎝

4. Outdoor Combustion Air: Outdoor combustion air is to be provided through one or two permanent openings. The minimum dimension of these air openings is 3 inches (76 mm).

a. Two Permanent Opening Method: Provide

two permanent openings. One opening is to begin within 12 inches (305 mm) of the top of the space and the other is to begin within 12 inches (305 mm) of the floor. The openings are to communicate directly or by ducts with the outdoors or with spaces that freely communicate with the outdoors. The size of the openings shall be determined as follows:

i. Where communicating directly or through

vertical ducts with the outdoors each opening shall have a minimum free area of 1 in

per

4000 Btu/hr (22 cm

per 4000 W) of total input rating for all equipment in the space. See Figure 1.3 for openings directly communicating with the outdoors or Figure

1.4 for openings connected by ducts to the outdoors.

ii. Where communicating with the outdoors

through horizontal ducts, each opening shall have a minimum free area of 1 in

per 2000

Btu/hr (22 cm

per 2000 W) of total rated input for all appliances in the space. See Figure 1.5.

b. One Permanent Opening Method: Provide

one permanent opening beginning within 12 inches (305 mm) of the top of the space. The opening shall communicate directly with the outdoors, communicate through a vertical or horizontal duct, or communicate with a space that freely communicates with the outdoors. The opening shall have a minimum free area of 1 in

per 3000 Btu/hr of total rated input for all appliances in the space and not less than the sum of the cross-sectional areas of all vent connectors in the space. The gas-fired equipment shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance. See Figure 1.6 for this arrangement.

PREINSTALLATION

Figure 1.4: Air Openings – All Air from Outdoors

through Vertical Ducts

Figure 1.5: Air Openings – All Air from Outdoors

through Horizontal Ducts

Figure 1.6: Air Openings – All Air from Outdoors

through One Opening

Figure 1.3: Air Openings – All Air Directly from

Outdoors

5. Combination Indoor and Outdoor Combustion Air: If the required volume of indoor air exceeds the available indoor air volume, outdoor air openings or ducts may be used to supplement the available indoor air provided:

a. The size and location of the indoor openings

comply with Subsection 3.

b. The outdoor openings are to be located in

accordance with Subsection 4.

c. The size of the outdoor openings are to be sized

as follows:

where:

req

= minimum area of outdoor openings.

full

= full size of outdoor openings calculated

in accordance with Subsection 4.

avail

= available indoor air volume

req

= required indoor air volume

6. Engineered Installations:

Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and dilution air and shall be approved by the authority having jurisdiction.

7. Mechanical Combustion Air Supply:

a. In installations where all combustion air is

provided by a mechanical air supply system, the combustion air shall be supplied from the outdoors at the minimum rate of 0.35 ft

/min per

1000 Btu/hr (0.034 m

/min per 1000 W) of the

total rated input of all appliances in the space.

b. In installations where exhaust fans are installed,

additional air shall be provided to replace the exhaust air.

c. Each of the appliances served shall be

interlocked to the mechanical air supply to prevent main burner operation when the mechanical air supply system is not in operation.

d. In buildings where the combustion air is provided

by the mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the required ventilation air.

8. Louvers & Grills:

a. The required size of openings for combustion,

ventilation, and dilution air shall be based on the net free area of each opening.

i. Where the free area through a louver or grille

is known, it shall be used in calculating the opening size required to provide the free area specified.

ii. Where the free area through a louver or grille

is not known, it shall be assumed that wooden louvers will have 25% free area and metal louvers and grilles will have 75% free area.

iii. Nonmotorized dampers shall be fixed in the

open position.

b. Motorized dampers shall be interlocked with the

equipment so that they are proven in the full open position prior to ignition and during operation of the main burner.

i. The interlock shall prevent the main burner

from igniting if the damper fails to open during burner startup.

ii. The interlock shall shut down the burner if

the damper closes during burner operation.

9. Combustion Air Ducts

a. Ducts shall be constructed of galvanized steel or

an equivalent corrosion- resistant material.

b. Ducts shall terminate in an unobstructed space,

allowing free movement of combustion air to the appliances.

c. Ducts shall serve a single space.

d. Ducts shall not serve both upper and lower

combustion air openings where both such openings are used. The separation between ducts serving upper and lower combustion air openings shall be maintained to the source of combustion air.

e. Ducts shall not be screened where terminating in

an attic space.

f. Horizontal upper combustion air ducts shall not

slope downward toward the source of the combustion air.

g. The remaining space surrounding a chimney liner,

gas vent, special gas vent, or plastic piping installed within a masonry, metal, or factory built chimney shall not be used to supply combustion air.

h. Combustion air intake openings located on the

exterior of buildings shall have the lowest side of the combustion air intake opening at least 12 inches (305 mm) above grade.

avail

1 –

req

= A

full

⎛ ⎜ ⎝

⎛

⎜

⎝

Liquefied Petroleum (LP) is heavier than air and may collect or “pool” in a low area in the event of a leak from defective equipment. This gas may then ignite, resulting in a fire or explosion.

WARNING

PREINSTALLATION

D. INSTALLATION SURVEY

For new and existing installations, a Water Installation Survey is available from PB Heat, LLC. The survey will provide information on how a hot water boiler works with your specific system and will provide an overview of hot water system operation in general.

You can also use this survey to locate system problems which will have to be corrected. To obtain copies of the Water Installation Survey, contact your PB Heat representative or download it from PeerlessBoilers.com.

E. PLANNING THE LAYOUT

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

PREINSTALLATION

BOILER SET-UP

1. Provide a sound, level foundation. Locate boiler as near to the chimney or outside wall as possible and centralized with respect to the heating system.

2. Locate boiler in front of installation position before removing crate.

3. If using combustible floor pan, position pan on foundation or flooring.

4. Separate the wood shipping pallet from the boiler base by removing two (2) hold-down bolts at each end of the boiler base.

5. Move boiler into final position. If using combustible floor pan, install boiler on pan as outlined in the instructions included with the pan.

2. BOILER SET-UP

A. BOILER SUPPLY AND RETURN

1. Size the supply and return to suit the system. A typical piping arrangement is shown in Figure 3.1. Refer also to the I=B=R Guide - Residential Hydronic Heating Installation/Design and the PB Heat Water Survey for additional guidance during water piping installation.

2. Return Piping: Pipe the drain valve to a tee, provided, and the 1-1/4 NPT return tapping near the bottom of the left section. Pipe the return to the tee. Pipe the drain valve nipples and tee to the 1-1/4 NPT return tapping as shown in Figure 3.1.

3. Supply Piping: Pipe the supply to the 1-1/2 NPT supply tapping at the top and rear of the boiler.

4. When system return water temperature will be below 130°F (54°C), pipe the boiler with a bypass arrangement to blend the system return and hot supply to obtain at least 130°F (54°C) entering the boiler. For more information on bypass piping, consult the PB Heat Water Survey.

3. WATER PIPING AND CONTROLS

Figure 3.1: Supply and Return Piping

WATER PIPING AND CONTROLS

6. Install this boiler so that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacements, etc.).

7. If this boiler and distribution system is used in conjunction with a refrigeration system, pipe the chilled medium in parallel with the boiler and install the proper valve to prevent the chilled medium from entering the boiler. A drawing illustrating this hookup is provided in Figure 3.2.

8. When the boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation, install flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

9. If this boiler is installed above radiation level, provide a low water cutoff device, either as a part of the boiler or at the time of boiler installation.

B. SAFETY RELIEF VALVE

1. Locate safety relief valve and fittings in bag assembly.

2. If air elimination is not required at the safety relief valve tapping, install valve and piping as shown in Figure 3.3.

3. For air elimination at the safety relief valve tapping, install valve and piping as shown in Figure 3.4.

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

CAUTION

Figure 3.4: Safety Relief Valve Hook-Up with

Air Elimination

Figure 3.3: Safety Relief Valve Hook-Up

Installation with Air Elimination in System Piping

Figure 3.2: Parallel Hook-Up with Water Chiller

WATER PIPING AND CONTROLS

C. PIPING FOR ZONED SYSTEMS

1. See Figures 3.5 and 3.6 for basic zoned system layouts.

2. Run each zone pipe down then up to zone to prevent air accumulation in piping.

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

WATER PIPING AND CONTROLS

Figure 3.5: Zone Piping with Zone Valves

Figure 3.6: Zone Piping with Circulators

D. EXPANSION TANK

1. Consult the tank manufacturer’s instructions for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity. See Table 10.2 in Section 10 for boiler water content.

2. Expansion tanks are available with built-in fill valves and check valves for reducing supply water pressure and maintaining minimum system pressure. Check the design features of the tank and provide valves as necessary. Refer back to Figure 3.1 for typical expansion tank piping.

E. INDIRECT-FIRED WATER HEATER

If the boiler is to be used in conjunction with an indirectfired water heater, refer to Figure 3.7 for typical piping. Follow the instructions provided by the water heater manufacturer. Pipe the water heater as a separate zone.

F. FREEZE PROTECTION

For new or existing systems that must be freezeprotected:

1. Glycol in hydronic applications is specially formulated for this purpose. It includes inhibitors which prevent the glycol from attacking metallic system components. Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level.

2. The glycol solution should be tested at least once a year and as recommended by the glycol manufacturer.

3. Glycol solutions expand more than water. For example, a 50% by volume solution expands 4.8% in volume for a temperature increase from 32°F (0°C) to 180°F (82°C), while water expands 3% with the same temperature rise. Allowance must be made for this expansion in system design.

4. For more information, consult the PB Heat Water Installation Survey and the glycol manufacturer.

WATER PIPING AND CONTROLS

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

WARNING

Figure 3.7: Typical Piping with Indirect-Fired Water Heater

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