PEERLESS Boiler Manual L0308220

User Manual: PEERLESS PEERLESS Boiler Manual PEERLESS Boiler Owner's Manual, PEERLESS Boiler installation guides

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Pinnacle

Gas Boilers

If the information

in this manual

is not

followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.

Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.

WHATTO

DO IFYOU

SMELL

GAS

• Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your building.
• Immediately call your gas supplier from
a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier,
call the fire department.
- Installation

and service

by a qualified installer,
the gas supplier.

must be performed
service

agency or

Installation,
Operation
Maintenance
Manual
p=E_Lr=-ss"
PINNACLE"
mOH

EFFICIENCY

STAINLSSS

_TE_L

BOMLER

3 Sizes

Three

Sizes

27 to

27to80MBHInputModulation

• PI 140

- 46

to 140

MBH

Input

Modulation

• PI 199

- 66

to 199

MBH

Input

Modulation

• 92%

Modulating

Burner

AFUE

Star J Efficient

Natural

MBH Input

92%

AFUE

Available

• PI80

Fully

199

Energy

for Maximum

Efficiency

or LP Gas

Direct

Vent

• Sealed

Combustion

• No Chimney
• Uses

Required

Standard

• ConceTitric

or Vertical

40 PVC

or V1000

Aluminum

PVC

Compact,

- Horizontal

Schedule

Light-Weight

Plastic

Venting

Pipe for

Vent

Kits

Venting

Available

Design

• Installation
Flexibility
• Z_'ro Cl_!aran_?
to Combustibles
• Lightweight

Stainless
• High

Des_n

Steel

Grad<" Stainless

Safe

lbs.)

& Small

Footprint

StPeI

Burner

and

Heat

Exchanger

Operation

• Honeywell
• State

Gas

Valve

oJ:the-Arf

• Spark

and

Control

Venturi

Board

with

System
LED Light

As an ENERGY

STAR"

that thi8 producl

meel_

Partr_er

Peerless

Healer

Ihe ENERGY

STAR

Gas

Valve

Company

has delermined

gwdelin es for energy

efficiency

Indicator

Ignition

Quiet
• As

(75 to 111

Construction

Operation
Quiet

as Most

Home

Comprehensive

Warranty

• One-Year

Parts

• Lin_ited.

12-Year

• See

Below_lbr

& Labor

Warranty

• Burner

Warranty

Environmentally
• Low

• Honeywell

Appliances

• High

on the

Heat

Exchanger

Fan
Limit

Temperature

• 30 PSI Sol-ely

RelieJ

Control
Valve

Description

• Combination
Temperature-Pressure
Gauge
• 3" PVC Screened
Air Intake
Terminal
and

Friendly

Emissions

Exhatlsl

Terminal

• 3" V1000

Aluminunl

• 3" Concemcic
• Ad.]uslable

Outside

PVC Venl
Steel

Venl

Terminalion

Termination

Kit

Kil

Boilt, r Slartd

Pt_erless
l h,cltt'i Company
is pleased
to o[]-er one ql ttle most comprehensive
w_rrrulty
piogranls
in t!2e industry.
T/t(, P{,t,d(,ss
Pitlllacl_h
slttilllt!ss
steel boiler calT_es a fitU oHe yeQr warrcItllt.]
o11 tilt" t,ltlir(" boils'r: Pt!url_'ss
lvJU pttrchase
all _lddiitollQ!
II'(IKI'(UII{t
,
,
tllat ('over.s
Iclbor.lbr r_'l)lat'irlg tcatTanled
parts.lioln
the! 31""sl day thro_lgh th_'.llrst
y('_u qlh'r iHsiclllalion,
prolqctt'd
lh(' it,¢ut(mt!l
r%qi.strilliotl
ccuH is l't'llutled.
111additiotL
Pt'(,d¢'ss
Q[lt!ra o lilniled,
pm rated.
12 yt'(u w(ullmlg
oil tilt? ]l('_lt cxch(mgt'r
ol llu'
PifuItl{'l('

spt?c{]ic
Peerless

I)Oil('E

u,ancmtg.
Heater

[PIPt'

[llld

Pk!tzse
Company

It,ll-year

corlslllt
* 231

('xtetld('(t

Pt'edess
North

Ii_€.lrr(ltlti{'F.

[It*¢ller
Walnut

oil

( onlpany

Street

])Qrt.¢_

a/id

l[ll)ol

Jbr conq_lea,

• Boyertown,

ill(l!]

[lINo

PA 19512

t){'

!'}lH'('_KI.v;t'[I.

Wllis

SllllllIl(lQ]

i.s ilol

il{!()rnttlliolL

It,al'l'glllig

1021

* 610-307-2153

• www.peerless-heater.com
FA9

PI RI _I 0i 75M)
Ps,'_r/,d m LI _

USING THIS MANUAL
A. INSTALLATION SEQUENCE .............

1
1

E. EXTENDED VENT LENGTHS WITH
4" PIPE ............................

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

E CONDENSATE ......................
G. BOILER REMOVAL FROM COMMON

..........

B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION .....................
C. LIQUEFIED PETROLEUM (LP) GAS

2
2

.......

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

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

A. WIRING

...........................

B. ZONED SYSTEM WIRING .............
C. SEQUENCE OF OPERATION ...........

15
17

B. LIGHTING/OPERATING

A. BOILER SUPPLY, RETURN AND
CONTROLS .........................

B. CIRCULATOR SIZING ..................

C. SAFETY RELIEF VALVE ................

D. PIPING FOR ZONED SYSTEMS

..........

E. EXPANSION TANK ....................

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

G. FREEZE PROTECTION

.................

" ........

A. GENERAL ..........................

B. EXHAUST VENT/AIR INLET VENT
LOCATION .........................

C. EXHAUST VENT INSTALLATION

........

D. AIR INLET VENT INSTALLATION

........

6. ELECTRICAL

A. COMPLETING THE INSTALLATION

GAS PIPING

VENTING SYSTEM ...................

PREINSTALLATION
A. ACCESSIBILITY CLEARANCES

......

INSTRUCTIONS

18
. .19

C. CONTROL DESCRIPTIONS .............

D. CHECK-OUT PROCEDURE .............

A. SHUT-DOWN

......................

B. BOILER FAULT CODES ................
C. BOILER FAULT CONDITIONS ...........

22
22

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

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

C. ANNUALLY (BEFORE START OF
HEATING SEASON) ..................

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 safet F during
boiler installation.

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 Peerless Heater Company:

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.

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

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

Read carefully, study these instructions

before beginnin 9 work

This boiler must be installed by a qualified contractor.
The boiler warranty

can be voided if the boiler is not installed, maintained

Boiler can be installed at high altitude
elevations above 7,000 feet.

with no burner

adjustments.

and serviced correctly.
LP equipped

boilers

must not be installed

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/CGA B149 Installation Codes.
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, ANSI/ASME CSD-1.

I_,! If_,T0(H:(.,'_"]I:] I! / li'd [H I d_'l; f'_1L_
[_ :_

[Igl

The following are the recommended
minimum
accessibility clearances between boiler and adjacent wall
or other appliances.
1. 16" from right side or left side of boiler.
2. 15" from top of boiler.
3. 4" from front of boiler.
4. Provide clearance for annual inspection
and condensate connections.

of vent pipe

! [oll J=1;I 1:1DI "J :ili ;(o] I :l I hV_ll._lliC-r__

The following LP requirements from the Uniform
Mechanical Code, section 304.6, may be in effect in
your geographic area:
"Liquefied petroleum gas burning appliances shall
not be installed in a pit, basement or similar location
where heavier-than-air gas might collect. Appliances
so fueled shall not be installed in an above-grade
under-floor space or basement unless such location
is provided with an approved means for removal of
unburned gas."
Jill Ih_l.'lllf:lll/:_l/[O]L_l

The design of this boiler is certified for closet installation
with the following clearances:
I.

0" from left side, right side, rear, top, bottom,
and combustible construction.

2. O" from vent pipe and combustible

front

construction.

3. This boiler is design certified for use on combustible
floors.

Do not install this boiler on carpeting. Boiler
installation on carpeting is a fire hazard.

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.

F.'lll;iVJ:li'

For new and existing installations, a Water Installation
Survey is available from Peerless Heater Company. 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 Peerless
representative.
:11 I'J IL_ _ I L_Ib_[€'l i / -"I = I I/;V.'o]ll

Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring. Review
limitations on vent pipe, vent terminal, and air inlet pipe
locations in Section 5, Venting.

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

1. Place boiler on a level surface (Note: An optional
boiler stand is available. Contact your Peerless
Dish-ibutor. )
2.

Locate boiler to allow for ease of vent pipe
installation and heating system piping.

Boiler must be set on a levei surface so condensate
does not back up inside the boiler.
3.

Install boiler in an area with a floor drain or install in
a suitable drain pan.

Size the supply and return to suit the system. Refer
to Figure I. Refer also to the I-B=R Installation
Guide No. 2000 and the Peerless Water Survey for
additional guidance during water piping installation.
2.

The boiler incorporates a pressure switch in the
Outlet Manifold. This switch will not let the boiler
operate without a minimum of 10 PSI on system.

Refer to Figure ] for suggested controls and
components location in the near boiler piping.

In older hydronic systems where sediment may exist,
install a basket strainer to prevent particles from
returning to boiler.

Install this boiler so that the gas
components are protected from
spraying, etc.) during appliance
service {circulator replacement,
control replacements, etc.)

If this boiler and distribution
system is used in
conjunction
with a refrigeration
system, i_Jipe the
chilled medium
in parallel with the boiler and install
the proper valve to prevent the chilled medium
from
entering
the boiler

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.

If the boiler is installed above radiation level, provide
a low water cutoff device at the time of boiler
installation.

ignition system
water {dripping,
operation and
condensate trap,

All piping must be properly supported. See Figure 1.

SYSTEM
SYSTEM

I_
_VltCH

_ I_ BACK rL_,4

pREVeNTER

_ I_) LOW pRESSURE
_ I_ EXPANSION

FIED

._.
(15

t _I)Alll
VEtlT (Mi rco bubbler
Etimtnltol"
Recmer_led)
_ (_)
F_jt_
(_ _RGE
& BALANCE
VALVE
• _
_

DRAIN

NQIqI_L}

CD_N

T&_

_
_IU_R

Air
_UP=PLY__

E:o_JST
rl/KET

¢OL_

VALVE

TEMPERATURE

I pRESSURE

GAEE
_l_ONt

tITE_$U

I_PLIEOBYC_ITRACTOR

CONNECT

_OILER

SUPPLY

I_IT

CONNECT

BOILER

_.L pe._= _U=T E

RETURN

_m_lU.V

COLD

_ttW'a_T[It

NOTE: I_I

U_R CONNECTIONS

ARE I I/i"
LEfT

Figure

Supply

and Return

Near Boiler Piping

_I_

N_T
VI{W

:! [e.]l:T_eJW'_'ll[e]H _'t[rAh_[€
The boiler heat
which must be
Using the chart
boiler model is
PI-80
PI-140
PI 199

exchanger does have a pressure drop
allowed for in determining circulator sizing
in Figure 2, the pressure drop for each
as follows:
-- 8 feet of head at 8 GPM flow rate
- 11 feet of head at 14 GPM flow rate
18 feet of head at 19.9 GPM flow rate

Refer to Figure 2 for recommended

circulator sizing.

[-*'_ .[_'_1==ill5"dlzf=ll!l=l= kVl_,NAvJ
The safety relief valve is factory insta[led into the right
side boiler manifold.

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.

2120-

F
R
I
C
T
I
O
N

1918171615141312-

F
E
E
T

11109
8
7

H
E
A
D

6
5
4
3
2
1
n

IIIIIIII

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
FLOW IN GALLONS PER MINUTE
TACO P/N

Figure 2:

THE RECOMMENDED

Circulator

Sizing

GRUNDFOS

P/N

PI-80

007(1)

15-42 F SPD-2

P1-140

0010(1)

26-64 F

P1-199

0011 (1)

26-96 F

CIRCULATORS

ARE BASED ON 1 GPM PER 10,000 BTU/HR

W/20 ° At

DJ I;JI;,]l_[cl I;[e):_(e]K_l:_D][_A'd_liil:lL'd<
I.

See Figures 3 and 4 for basic zoned system layouts.

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

FROM

TO SYSTEM
ZONE
5

ZONE
2

ZONE
1

SYSTEM
ZONE
2

ZONE
5

ZONE
VALVES

D_z

ET_
Z

BALANCING
VALVES

(3-

CONNECT TO
BOILER
SUPPLY

Figure 3:

Zone Piping

with

ZONE
2

ZONE
1

ZONE
RCULATORS

CONNECT
TO BOILER
SUPPLY

Zone

Piping

CONNECT TO
BOILER
RETURN

FROM SYSTEM

ZONE
1

FLOW
CONTROL/
VALVES _"

Figure

with

Zone Valves

TO SYSTEM
ZONE
5

Circulators

CONNECT TO
BOILER
RETURN

ZONE
2

ZONE
5

:_"m
I=:t::l::P:,l:_
I;,I:{oleeI:T_J/[O]_
i.

Consult the tank manufacturer's instructions for
specific information relating to tank installation. Size
the expansion tank for the required system volume
and capacity.

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. Boiler system requires 12 PSI minimum.

Refer back to Figure 1 for typical expansion
I_

For new or existing systems that must be freezeprotected:

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.

tank piping.

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.

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

Antifreeze solutions expand
example, a 50% by volume
in volume for a temperature
180 ° E while water expands
temperature rise. Allowance
expansion in system design.

For more information, consult the Peerless Water
Installation Survey and the antifreeze manufacturer.

I1_,_
ID]I ;t:[kl I_ = I;t :1D]iTA_I'-_I
/ :1:!1 : I=Lr-'_nl
=1:
If the boiler is to be used in conjunction with an indirectfired water heater, refer to Figure 4 for typical piping.
Follow the instructions provided by the water heater
manufacturer. Pipe the water heater as a separate zone.

FROM
BOILER
SUPPLY

more than water. For
solution expands 4.8%
increase from 32 ° F to
3% with the same
must be made for this

SUPPLY TO
SYSTEM

[3RETURN FROM
SYSTEM
BALANCING
VALVE

INDIRECT-FIRED
WATER HEATER

f
HOT DOMESTIC
WATER SUPPLY

TO
BOILER
RETURN

SUPPLY
TO TANK

BALANCING
VALVE
COLD DOMESTIC
WATER SUPPLY

Figure 5:

Typical

Piping with

Indirect-Fired

Water

Heater

Size and install the gas supply piping properly in
order to provide a supply of gas sufficient to meet
the maximum demand without exceeding a pressure
drop greater than .5" W.C. between the meter and
the boiler.
2.

Determine the volume of gas to be provided to the
boiler in cubic feet per hour. To obtain this value,
divide the Btu per hour rating (on the boiler rating
label) by the heating value of the gas in Btu per
cubic feet. Obtain the heating value of the gas from
the gas supplier. As an alternative, use Table 1 or 2
on the next page to obtain the volume of gas to be
provided to the boiler.
Use the value obtained above as the basis for piping
sizing. Size the gas piping in accordance with Table 3
for natural gas. Consult the National Fuel Gas Code
ANSI Z223.5/NFPA 54 and/or CAN/CGA B149 for
other sizing options and LP gas pipe sizes.

Locate the drop pipe adjacent
the boiler.

to, but not in front of

Install a sediment trap. See Figure 6. Locate a tee in
the drop pipe at same elevation as the gas inlet
connection to the boiler. Extend the drop pipe to a
pipe cap.

Install a ground joint union ahead of the gas control
assembly to permit servicing of the control. Install a
service valve as shown in Figure 6.

Use a pipe joint sealing compound that is resistant to
the action of liquefied petroleum gas. A non-resistant
compound may lose sealing ability in the presence of
this gas, resulting in a gas leak and fire or explosion
potential.
7.

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

I
_

SERVICE VALVE---J_"-_

JACKET

O.J. UNION _

SEDIMENT TRAP
FLOOR

Figure

LINE_

Gas Connection

to Boiler

Disconnect the boiler and its individual shut-off valve
from the gas supply piping system during any
pressure testing of that system at test pressure in
excess of i/2 psig (3.5 kPa). Remove the mounting
screws of the flanged gas connection on the gas
valve, and disconnect flange from valve.

Do not subject the gas valve to more than 112 psi
pressure. Doing so may damage the valve.
Isolate the boiler from the gas supply piping system
by closing its individual service valve during any
pressure testing of the gas supply piping system at
test pressure equal to or less than 1/2 psig (3.5 kPa).
10. Check for proper supply pressures to boiler at
sediment trap location. Remove pipe cap and
provide fittings as required. Minimum permissible
supply pressure (Inches Water Column):
Natural Gas
3.7"
LP Gas
3.7"
Maximum permissible supply pressure to the boiler
(Inches Water Column):
Natural Gas
13.5"
LP Gas
13.5"

necessar_

11. Maintain a minimum distance of 10 feet between a
gas pressure regulator and boiler.
When checking for leaks, do not use matches,
candles, open flames or other methods that provide a
source of ignition. This can ignite a gas leak,
resulting in fire or explosion.
8.

The gas piping connection to the boiler must be a
minimum of 3/4 pipe size. Boiler is provided with a
3/4 x I/2 pipe reducer. Do not remove the reducer.

12. Gas line must be properly purged of air to allow for
normal main burner ignition.

Table

Natural

Gas

Model

Input
(Cubic Ft/Hr)

PI-80
Pb140
PI 199

80
140
199

Based on 1000 Btu/Cubic

Table

LP Gas

Model

Input
(Cubic Ft/Hr)

PI-80
PI-140
PI-199

32
56
79

Based on 2500

Table

Ft.

Blu/Cubic

Ft.

Pipe Capacity

Capacity of pipe of different diameters and lengths in cu. ft. per
hour with pressure drop of 0.3 in. and specific gravity of 0.60.
No allowance for an ordinary number of fiVdngs is required.
I

Pipe
Length
Feet

Pipe

10
20
30
40
50
60

278
190
152
130
115
105

3/'4"*

I
i

1¼"

1½"

Pipe

1,050
730
590
500
440
400

1,600
1,100
890

520
350
285
245
215
195

i
J

760
670
610

Multipliers to be used wi_ the above _b_ when the
specific gravity of me gas is other than 0.60:
Specific Gravity
Multiplier ........

. . .0.5
1.10

0.55
1.04

0.60
1.00

0.65
0.962

0.70
0.926

r,_1 [€-I=b,_
I =h_±_.
Install vent system in accordance with these
instructions and with Part 7, V_'nting of Equipment,
National Fuel Gas Code, ANSI Z223.1/NFPA 54,
CAN/CGA B149, or applicable provisions of the local
building codes•
2.

Boiler is a direct vent appliance.
listed as Category IV.

Determine air inlet vent location
a Provide I foot clearance between bottom of vent
and ground level and normal snow lines.

Refer to venting diagrams (Figures 7 through 12) for
typical sidewall and vertical vent/air inlet piping.
a. Maintain distances between air inlet, vent. and
exhaust vent as indicated in Figures 7, 8, and 11.
Do not space the air inlet vent and exhaust vent
greater than 6 feet apart•

The boiler vent is

rA |vivhl ;t ii ,,

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

c. When sidewall venting multiple VI000 vent kits
refer to instructions provided with vent kit.

For minimum and maximum
to Table 4,

Use only 3" PVC, CPVC, or ABS solid schedule 40
or 80 material for exhaust vent, 4" PVC, CPVC, or
ABS solid schedule 40 or 80 pipe is also approved
under special conditions; see Section E, Extended
Vent Lengths with 4" Pipe, in this section for details,
FOAM CORE PIPING IS NOT APPROVED•

Vent connection is located on rear of boiler and is
marked "exhaust outlet".

Alljoints must be properly cleaned, primed, and
cemented, Use only approved cement and primer for
PVC, CPVC and ABS materials. Cement must
conform to ASTM D-2564 (PVC) or D2235 (ABS).

Remove all burrs and debris from joints and fittings.

Horizontal lengths must slope back to boiler
connection not less than 1/4" per foot to allow
codensate to flow back to boiler•

A screened 3" straight coupling is provided with
boiler for use as a vent termination• Optional vent
terminations approved for use with the Pinnacle
boiler are 3" concentric KGAVT0601CVT Vent Kit
and V1000 Vent Kit. Both are available from a
Peerless Distributor.

Vent piping must be supported at 4 ft. intervals to
prevent sagging. The boiler is not intended as a
support means for vent.

Flue gases will condense as they exit the vent
termination. This condensate can freeze on exterior
building surfaces which may cause discoloration of
these surfaces.

Determine

exhaust vent location,

a. Vent is approved
constr_ction.

for 0" clearance

Provide 3 feet clearance above any forced air
inlet within 10 feet.

Provide 1 foot clearance below, I foot beside, or
1 foot above any door, window, or gravity air
inlet into any building•

Provide I foot clearance between bottom of vent
terminal and ground level and normal snow lines•

Provide 4 feet horizontal clearance from, and in
no case above or below, unless a 4 foot
horizontal distance is maintained, from electric
meters, gas meters, regulators and relief
equipment.
Do not locate vent terminal over public walkways
where condensate could create a nuisance or
hazard.

vent pipe lengths refer

to combustible

When sidewall venting multiple 3" concentric vent
kits, the vent kits must remain in a horizontal
plane and placed no closer than 8" center to
center• Also refer to instructions provided with
vent kit.

When adjacent to a public walkway, locate vent
terminal at least 7 feet above grade.

Do not locate directly under roof overhangs
prevent icicles from forming.

Provide 3 foot clearance from inside corner of
adjacent walls•

ivl _ _lih_[€]
i].

f-'ll;t
I.

h_llllitill_ll

Ih_t-'tP-1!l!-'_l

For minimum and maximum
Table 4.

/ [l]_

Table

pipe length rpfer to

Minimum/Maximum

Vent

Length

Total Combined
**Equivalent
Length of 3 _
Exhaust Vent Plus 3 _ Air Inlet Vent
Boiler

Use same
vent

Air inlet pipe connections is located in the rear of
boiler and is marked "air inlet" Connection is a slip
fit. No sealant is required.

material

as noted

in Section

C for exhaust

All joints and fittings are to be assembled
instructions for vent pipe in Section C.

Model
All

*Minimum

Length

*Maximum

16 feet

Length

85 feet

*Lengths are the combined
vent and air inlet vent.

added lengths of the exhaust

**Include equivalent length
3" 90 degree elbow =
3" 45 degree elbow 3" concenlric vent kit =
3" air inlet tee =
3" VI000 vent kit =

of fittings as
5 equivalent
3 equivalent
3 equivalent
0 feet
0 feet

as per

A screened inlet air tee is provided
used as an outside termination.

with boiler, to be

Provide same suport means as noted for exhaust
vent in Section C.

follows:
feet
feet
feet

Refer to Venting Diagram Figures 7 through
and Vertical Venting arangements.

12 for Sidewall

DIAGRAMS

FOR SIDEWALL

VENTING

T_E {VERTICAL_

EXTERIOR
WALL

COUPLING

TEE (VErtiCAL)

FRONTeLEVAT_N
qMULTIPLeVENTS)

EXTERIOR
WALL

1" MIN.

BOILER

INTAKE
BOILER

1" MIN,

_12"_

EXHAUST

....

STRAIGHT

ST_mHT

OT&P

CcuPUNG

--.

3" EXHAUST

_j===_
_"TS_EWW

INTAKE

R_"T _OZ ViEW
SlDEE_EVAXl0N

**IMPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
1/4" per foot back to the boiler (to allow drainage of
condensate).

Figure 7:

Figure 8:

3" Sidewall Vent with
Coupling (Exhaust)

Tee (Intake)

3 _ Sidewall Vent with
Coupling (Exhaust)

Tee (Intake)

EXTERIOR
WALL

BOILER
BOILER
--IMFOR_ANT
MUST

INTAKE
3"
OT&P

VI000
VENT KIT

coupu_

OT&P

ST_,aHr
¢_pu,o

EXHA

_NTAKE

WE FACI_

LEG
Up**

US T

"_r--_INTAKE

eX_XUST
OUTLET
EXHAUST

RIGHT

RIGHT SIDE ViEW

SIDE

V_EW

**IMPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
i/4" per foot back to the boiler (to allow drainage of
condensate).

**IMPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
1/4" per foot back to the boiler (to allow drainage of
condensate).

Figure 9:

Figure

3 _ Sidewall

Vent with

VlOOO Kit

10:3 _ Sidewall Vent with 3 _ Concentric
Vent Kit (KGAVT06OICVT)

DIAGRAMS
STRAIGHT

FOR VERTICAL

VENTING

COUPLING

24"
MIN.

MAINTAIN12", (18" FOR CANADA),_
MINIMUMCLEARANCEABOVE
NORMAL SNOW LINES.

MAINTAIN 12_, (18" FOR CANADA),_
I

"",

DO NOT EXTEND MORE THAN
24" ABOVE ROOF LINE.

BO/LER

BOILER
m

3,,

INTAKE
O T&P

fNTAKE

STRA_HT
OT&P
COUPUNG

STRAIGHT
COUpLiNG

r J

EXHAUST
ex_ust

OUTU_T

RIGHT S_DE _IEW

1 1: 3" Roof Vent with Tee (Intake)
Coupling (Exhaust)

EXHAUST

R_HT SlOE VIEW

*'_[MPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
1/4" per foot back to the boiler (to allow drainage of
condensate).
Figure

_TL_r

**IMPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
1/4" per foot back to the boiler (to allow drainage of
condensate).
Figure

12: 3"" Roof Vent with 3" Concentric
Vent Kit (KGAVTO6OICVT)

:lq

-'_lll :_ l *] :i e] LvA:ib,_llllq:lL_LcJlIbl_i_ji/'Ev-m;JI;J:
The connection of air inlet vent and exhaust vent at
boiler must remain 3" and each vent must extend
from boiler a minimum of 15 equivalent feet before
transitioning to 4" vent
2.

The maximum length shown in Table 4 can be
increased by using 4" PVC, CPVC, or ABS solid
schedule 40 or 80 pipe.

Use a 4" x 3" reducing coupling to transition to
4" vent•

The maximum combined *equivalent length of 4"
air inlet vent plus 4" exhaust vent must not exceed
125 feet•
*

I;4

At the time of removal of an existing boiler, follow these
steps with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation:
a. Seal any unused openings
system•

Use the same pipe sizes for air inlet vent and
exhaust vent.

To use the VI000 Vent Kit or 3" Concentric Vent Kit
transition 4" pipe to 3" pipe at exit point of building.

[ _o) L_Iu_] :IL'_
l+,."f'.*_l
II
I.

This boiler is a high efficiency unit that produces
condensate.

The rear of the boiler has a plastic hose for
connection of a 5/8" size plastic tubing.

Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.

Insofar as is practical, close all building doors and
windows and all doors belween the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building• Turn on any clothes dryers and any
appliance not connected to common venting system.
Turn on any exhaust fans, such as range hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan+ Close
fireplace dampers.

d+ Place in operation the appliance being inspected•
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously•
e.

Test for spillage at the draft hood relief opening after
5 minutes of main burner operation• Use the flame
of a match or candle, or smoke from a cigarette,
cigar, or pipe.

After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas-burning appliance to their previous
conditions of use.

Slope condensate tubing down and away from boiler
into a drain pan or condensate neutralizing filter.
Condensate has a low PH level; check with local
codes or ordinances before connecting to drain.
g.
4+

Do not expose condensate
temprature.

line to freezing

5. Use only plastic tubing as a condensate

drain line.

To allow for proper drainage on large horizontal
runs, a second line vent may be required and tubing
size may need to increase to i".

A condensate
below drain•

removal pump is required

if boiler is

venting

Equivalent Length of 4" Piping:
4" 90 degree elbow - 3 feet
4" 45 degree elbow - I foot
4" air inlet tee = 0 feet

in the common

Any improper operation of the common venting
system should be corrected so that the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CGA B149. When
resizing any portion of the common venting system,
the common venting system should be resized to
approach minimum size as determined using the
appropriate tables located in the Chapter "Sizing of
Category I Venting Systems" of the National Fuel
Gas Code, ANSI Z223.J/NFPA 54.

Install
allelectrical
wiringinaccordance
withtheNational

Electrical Code and local requirements.

This unit when installed must be electrically grounded in accordance with the requirements of the authority
having jurisdiction or, in the absence of such requirements, with the current edition of the National Electrical
Code, ANSI/NFPA 70.

r_,11i_A_il;th_[=
Refer to Figures 13 and 14 for power supply
connection to boiler. Use #14 AWG size wire.

The Building System Ground must be inspected by a
qualified Electrician.

2. Connect boiler to a separate, permanently live
electrical supply line with a fused switch. 120 volts,
60 HZ, 15 amp service.
The boiler electrical connection
side of unit.

Wires in the electrical J Box have been labeled at the
factory. Do not remove labels.

Connect the supply line (HOT) wire to the black wire
and supply line (GROUND) to the white wire. Boiler
control board is polarity sensitive. If polairty is
reversed, boiler control will not sense main burner
flame.

Connect building service ground (green wire), and
boiler ground (green wire) to green ground screw
located in boiler J Box.
GP.J:EN

For connection to system circulator and room
thermostat refer to Figures 13 and 14. Thermostat
anticipator setting is 0.56 amp.

The boiler control board and factory wiring are
shown in Figure 17.

is located on the left

4. The boiler is supplied with a burner service switch.
When refering to Figures 13 and 14, wire the burner
service switch in the (HOT) line to boiler.
5.

:m _[e]L'_l::le]t*.."b'd.,.']lll::l_'JI
|vA_il;th,_[{
See Figure 15 for typical wiring with zone valves. See
Figure 16 for typical wiring with zone circulators. When
wiring a zoned heating system, follow all applicable
codes, ordinances and regulations.

Do not power zone valves directly from the boiler
transformer. Doing so will greatly reduce the life of
the transformer. Use a separate transformer sized to
handle the total of all zone valve electrical loads.

(GROUNO)

WHITE
DRY

PUMP

RED

RELAy

BLACK

RED

(NOT

USED)

NORMALLY OPEN
THERHO_I'AT
CONNECTION

NORMALLY
OPEN
_ERHOSTAT
CONNECTION

GRAY

O G_

WH_E

(NEUTRAL)
•
BLACK

(HOT)
GREEN

GREEN

(GROUNO)•

_
GROUND

SCREW
ELECTRICAL
SWITCH
JUNCTION
120V
60 HZ

BOX

Figure

13: Connection

Wiring

SCREW
ELECTR[CAL
SW_CH
JUNCtiON
120V
60 HZ

with

BOX

GROUND

Circulator

Relay

Figure

14: Connection
Wiring
Circulator
Relay

without

120V-60HZ
TO MAIN
DISCONNECT
SWITCH

1T_ANSFORMER
(HOT)

i
I r
iIr

120/24V--60HZ
[

(_THERMOBTA(_V
I I
j I
I
I
I
I

I
I
I

40VA_

I
JUNCllON
BOX

I
I
J

I
I

I
]
J

I I
I I
J I
I
I
I
I
I
I
4

I
I
I

Y
Y

J
TO THERMOSTAT
CONNECTIONGRAY raRES
LOCATED IN
BOILER JUNCTION
BOX

I
I
I
I

]

ZONE

I
J

I
I
I

R
--

NOT£_
ALL WlRING MUST COMPLY
WITH
ORDINANCES,
AND REGULATIONS

Figure

15: Zone Wiring

with

APPLICABLE

I
I

CODES,

Zone Valves

120V-60HZ
TO MAIN
DISCONNECT
SWITCH

THERMOSTAT,

2€V

{_
/
/

TO THERMOSTAT
CONNECTION GRAY
BOILER

JUNCTION

.....

BOX

_
LOW VOLTAGE
LINE VOLTAGE

ZONE

"/_

ZONE

NOTE:
ALL WIRING MUST COMPLY WITH
ORDINANCES,
AND REGULATIONS

Figure

16: Zone Wiring

with

I
I
I

I
J

LOW VOLTAGE
LINE VOLTAGE

H-V8043E

I
I

VALVE

Circulators

APPLICABLE

CODES,

'_CULATOR

ZONE

/- SWITCHING RELAY
H-R845A
OR
W/R-829A-845

=ilit::[_ i+_[o,7'iTili

THERM[] DISC

TEMP.

SWITC_

210

DEGREE

WATER PRESSURE
SWITCH
ECO WATER/ HIGH LIMIT
INLET
PROBE

TEMP

120

t20 VAC
CDNBUSTION
BLOWER

GAS

VAC

LINE
_II_T
1_0 VAC

VALVE
SPARK {]LIT V

FLAME

ROD

PRESSURE SWITCH
PROVE AIR

Figure

17: Boiler Control

Board Factory

When power is first applied to the control, the
control will initially run through a self-diagnostic
routine, and then go into its operating mode. The
green LED light will pulse in a dim to bright
sequence indicating a normal operating mode. If
there is no call for heat, the control will go into the
idle state.

If the thermostat is calling for heat, the control will
apply power to the circulator pump. If the control
determines the appliance water temperature is below
the temperature dial set point value less the
switching differential, the control will initiate a
heating cycle.

pUMP

Wiring

.[ ."]:loll J:1L_[I.] = [o] :11o]'] :1t#,.31/ [m]i

CIRC.

The control then performs selected system diagnostic
checks. If all checks are successfully passed, a 5
second pre-purge cycle is initiated (blower on max
speed).
When the pre-purge period is complete, power is
applied to the spark ignitor for a 6 second trial for
ignition. If a flame is not verified during the trial-forignition, the gas valve is immediately closed, and the
control will return to step 2. If after three trials a
flame is not verified, the control will go into lockout
mode. If a flame is confirmed, the control enters the
heating mode.

When water temperature reaches the temperature
dial set point plus i0 ° F (or if the thermostat call-forheat is satisfied), the gas valve is closed and the
control enters a 4 second post-purge (blower on max
speed). NOTE: IF THE THERMOSTAT IS STILL
CALLING FOR HEAT, THE CIRCULATOR PUMP
WILL CONTINUE TO RUN UNTIL THE
THERMOSTAT CALL FOR HEAT IS SATISFIED.

When post-purge is complete, the control enters the
idle state while continuing to monitor temperature
and the state of other system devices. If a call-forheat is received, the control will automatically return
to step 2 and repeat the entire operating cycle.
During
detects
devices
on the

the idle state and heat state, if the control
an improper operating condition for external
such as the high-limit switch, the green LED
control will flash an error code sequence.

During the call for heat the boiler control board will
continually
monitor
the return and supply water
temps in relation to the temperature
dial set point
and the differential
switch setting. The control board
will use this input to modulate
the blower speed. The
blower coupled
with the gas valve venturi system will
modulate
the premix air/gas input to the burner. The
gas valve and venturi system provide
the optimum
gas/air ratio through
the full burner
modulation.

l,_ll [iI* ] lviI:l I ::l / IL'_
[ci i l I= IIb.'ff.-'lI'_I ! i!'_l / 1*] i
1.

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

2. Verify that water piping, venting, gas piping and
electrical wiring and components are installed
properly. Refer back to previous sections of these
instructions as well as equipment manufacturer's
instructions as necessary.
3.

Fill the boiler and system with water, making certain
to vent all air from all points in the system. To check
water level in the system, open and close each vent
in the system. Water should exit from each vent
when it is opened.

and differential settings

Temperature Adjustment: A potentiometer
located on the control board is used to adjust the
set point temperature on the boiler appliance.
This can be set between 70 and 210 degrees.

Temperature Differential Adjustment: A "DIP"
switch is located on the control board.
Depending upon the configuration of the "DIP"
switch, the differential selection is 6, 12, 20, or
30. See the figure below for further detail.

NOTE: the differential adjustment is the value below
the set point, when the burner will fire. (Example:
190 degrees set point, 30 degrees differential, burner
will not fire until return water drops below 160
degrees and will modulate the flame until 200
degrees is reached, then post purge and idle state
will be achieved. If at any point "IT is satisfied, the
cycle will be interrupted by post purge and idle
state.

The pressure reducing valve on the fill line will
typically allow the system to be filled and pressurized
to 12 PSI. Consult the valve and expansion tank
manufacturer for more specific information.

Check joints and fittings throughout the system for
leaks. If leaks are found, drain the system and repair
as required.

Connect a manometer at the sediment trap location.
Refer to Figure 6. Remove pipe cap and provide
fittings as required.

10. Light the boiler by following the Lighting/Operating
Instructions in this section. The initial ignition may
require several tries as the piping is purged of air.

Confirm that the gas supply pressure to the boiler is
above the minimum and below the maximum values
for the gas being used. See the end of Section 4 for
these values. If a supply pressure check is required
isolate the boiler and gas valve before performing
the pressure check. If the supply pressure is too high
or too low, contact the gas supplier.

11. Use the sequence of operation description and
Figure 17 in Section 6 (Electrical) to follow light-off
and shutdown sequences and to assist in diagnosing
problems. If the boiler does not function properly,
consult Section 8, Troubleshooting.

Turn on electricity and gas to boiler. Check to see if
LED light is illuminated on control board.

Differential

Adjust set point temperature
as follows:

Dip Switch

Adjustments

I [of: / i h_[€_Lo]:,1:1:f,_'t/ IL_[€'l IL_I,.i Ii:1 ILO,]li [o]L_F:

FOR YOUR

SAFETY

READ

BEFORE

OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion
result, causing property damage, personal injury or loss of life.
A. This applianca does not have a pilot. It is equipped
with an ignition device which automatically lights the
burner. Do not try to light the burner by hand,

If you cannot reach your gas supplier, call the
fire department.
C,

Use only your hand to turn the gas control knob. Never
use tools. If the handle will not turn by hand, don't try
to repair it, call a qualified service technician. Force or
attempted repair may result in a fire or explosion.

Do not use this appliance if any part has
water. Immediately call a qualified service
inspect the appliance and to replace any
control system and any gas control which
under water,

B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle
on the floor.
WHAT TO DO IF YOU SMELL GAS
•

Do not try to light any appliance.
Do not touch any electric switch; do not use any
phone in your building.

•

may

been under
technician to
part of the
has been

Immediately call your gas supplier from a neighbor's
phone. Follow the gas suppliers' instructions.

OPERATING

INSTRUCTIONS

1. STOP! Read the safety information above.

5. Remove front cover.

2. Set the thermostat to lowest setting.

6. Turn gas shutoff valve clockwise to "off". Handle will be
vertical, do not force.

3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device
which automatically lights the burner. Do not try to light
the burner by hand.
Combination
Gas Control
/

7. Wait five (5) minutes to clear out any gas. If you then
smell gas, STOP! Follow "B" in the safety information
above on this label. If you don't smell gas, go to next
step.
8. Turn gas shutoff valve counterclockwise
Handle will be horizontal

to "on".

9. Install Front Cover.
10. Turn on all electric power to appliance.
11. Set thermostat

12. If the appliance will not operate, follow the instructions
"To Turn Off Gas To Appliance" and call your service
technician or gas suppllier.

Gas Shutoff
Valve

TO TURN

OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.
2.
3.

to desired setting.

Turn off all electric power to the appliance if service is
to be performed.

4. Turn gas shutoff valve clockwise to "off". Handle will be
vertical. Do not force.
5.

Install front cover.

Remove front cover.

[a,,]il[_o] L_IIii;{o] nilI.] :;(.."_o.]
;t I:,inId[o] L__

Set thermostat or controller above room
temperature to call for heat.

Ignition sequence should try 3 times before going
into lockout mode.

Turn gas supply on.

Reset by turning 120V power supply off then on.

Observe
cycle.

See Figure 19 for Location of these devices.
1.

SUPPLY WATER TEMPERATURE THERMISTOR
Senses supply water temperature from boiler Shuts
down main burner gas upon reaching i0 degrees
over control board set point. As supply temperature
falls, boiler ignition will restart.
RETURN WATER TEMPERATURE THERMISTOR Senses return water temperature from system. As
thermistor senses a drop in return water temperature
below the control board set point minus the
differential set point, boiler ignition sequence begins.
WATER HIGH LIMIT SWITCH - Senses supply
water temperature and shuts down main burner gas
upon reaching limit set point. Boiler control will go
into lockout mode upon activation of high limit.
WATER PRESSURE SWITCH - Senses boiler water
system pressure and shuts down main burner gas
when pressure falls to 8 PSI. Boiler contiol will go
into lockout mode upon activation of water pressure
switch.
AIR PRESSURE SWITCH - Senses burner manifold
pressure and prevents ignition sequence activation if
blower is not operating.
THERMODISC TEMPERATURE SWITCH - Senses
combustion chamber outside surface temperature
and shuts down main burner gas upon reaching set
point of 210 ° E Boiler control will go into lockout
mode upon reaching set point. This is a manually
resetable switch.

Ira1 [_:l:[_[_ellli

I:J;{elq=llllJ:!

1. After starting the boiler, be certain all controls are
working properly. Check to be sure that boiler will
shut down on action of water temperature reaching
control board temperature set point.
2.

To check operation
shut-off features:
a.

of the ignition system safety

Turn gas supply off.

boiler operation

through one complete

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

Check the system to make sure there are no leaks or
overfilling problems which might cause excessive
make-up water to be added. Make-up water causes
liming in the boiler.

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

Check the general condition of the system including
piping support, joints, etc. Check cleanliness of the
radiators, baseboard units and!or convectors. Clean
them to the extent possible. If radiators do not heat
evenly, vent any remaining air from them.

Review operation

Complete the Warranty Card and submit it to
Peerless Heater Company.

Hang the Installation, Operation and Maintenance
Manual in an accessible position near the boilen

with end-user.

L'W _._]: lilt _t eIolY,_J_
In the event of a shut down caused by thermodisc
temperature switch, water pressure switch or high limit
switch effecting a shut-down of the main burner and
ignition control lockout:
a. Refer to section "C. Boiler Fault Conditions," item 1.,
"Limit String Open," in this section and follow the
procedure to restart the boiler.
b. If control goes into ignition lockout mode again refer
to the Lighting/Operating
Instructions, Section 7, to
properly turn off the gas to the boiler.

When servicing or replacing items that communicate
with the boiler water, be certain that:
• There is no pressure on the boiler.
• The boiler is not hot.
• The power is off.
When servicing all other boiler controls, be certain
that:
• The gas is off.
• The electricity is off.

c. Turn off electric power to the boiler.
d. Call a qualified heating service organization or local
gas company and have the cause of the shut-down
investigated and corrected.
e. Refer to Lighting/Operating
to re-start boiler.

Instructions,

Section

Do not use this appliance if any part has been under
water. Improper or dangerous operation may result.
Immediately call a qualified service technician to
inspect the boiler and to replace any part of the
control system and any gas control which has been
under water.

Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.

Should overheating occur or the gas supply fail to
shut off, do not turn off or disconnect the electrical
supply to the pump.This may aggravate the problem
and increase the likelihood of boiler damage. Instead,
shut off the gas supply at a location external to the
appliance.

:11 I:[o]lll':l:llgL"_llRI

d. Check that the flame rod is connected,
that the flame rod is clean.

[e,[o]e]:l.;

When a fault condition occurs, the control board goes to
a LOCKOUT mode. When in the LOCKOUT mode, the
green LED located on the Control board will flash a fault
code. The number of times of LED flashes ON/OFF will
determine the nature of the fault (see the table below).
To reset the Control from the LOCKOUT state, remove
and re-apply 120VAC line power to the Control board.
D_scfintion

of Fault

# of LED Pulses

Limit String Open
....................
2
Flame Stuck ON ......................
3
Ignition Fault (No Flame) ................
4
Return Water Temperature Thermistor Fault . .5
Supply Water Temperature Thermistor Fault . .6
Air Pressure Switch Fault, Stuck Closed .....
7
Air Pressure Switch Fault, Stuck Open ......
8
Redundant Gas Valve Relay Stuck ON ......
9
Gas Valve Relay Stuck ON ..............
9
Redundant Gas Valve Relay Stuck OFF .... 10
Gas Valve Relay Stuck OFF .............
10
Gas Valve wire disconnected
............
11
ROM Checksum Failure ................
12
RAM Test Failure .....................
13
60 Hz Failure .......................
14
*,e,]llI:{e]lll::l-'t

_'_IlIII|O,[O]L'_ID]II[O]L'q_

1. LIMIT STRING OPEN - 2 PULSES
(Thermodisc Temp Switch, Water Pressure Switch,
High Limit Switch)
If the limit string opens, the control will immediately
remove power to the gas valve, complete a post
purge cycle, and enter lockout mode. To restart the
control, make sure that there is a least 10 PSI in the
water system. Allow boiler water temperature to cool
below control setpoint less the differential, press reset
buflon of thermodisc temperature switch, then
remove and re-apply 120 VAC line power.
2. Flame Stuck ON - 3 PULSES
The current state of the flame may be determined by
looking through the view port on the combustion
chamber. If the flame is stuck ON/OFF then the
flame rod insulator or the connector CN6 may not
be clean, or unplugged.
3.

Ignition Failure (No Flame) - 4 PULSES
If an ignition failure occurs during the trial-forignition, the control will return to the pre-purge state
and attempt another ignition trial. If after three trials
an ignition failure is still occurring, the control will go
into the lockout mode.
a. Check that the gas valve is operating correctly
and the electrical plug is fully connected into the
valve.

c. Check for proper connection to the 120VAC
line source.

If items "a" through "d" are correct replace the
Low-Voltage Cable assembly.

4. Open Return Water Temperature
5 PULSES

Thermistor

The control will sense an open temperature
thermistor If an open thermistor is sensed, the
conttol will go into the lockout state.
a. Verify that the return thermistor wiring is properly
connected to the control.
b.

If the temperature thermistor is in any
environment of less then 0° F then wait for
ambient temperature to rise, or apply heat to
the unit.

If the temperature thermistor is in an
environment of more then 230 ° F then wait for
the temperature to drop below 200 ° F

5. Open Supply Water Temperature
6 PULSES

Thermistor

The control will sense an open temperature
thermistor. If an open thermistor is sensed, the
control will go into the lockout state.
a. Verify that the return thermistor wiring is properly
connected to the control board.
b.

If the temperature thermistor is in an
environment of less then 0 ° F then wait for
ambient temperature to rise, or apply heat to
the unit.

c. If the temperature thermistor is in an
environment of more then 230 ° F then wait for
the temperature to drop below 200 ° F
6. Air Pressure Switch Fault Stuck Closed - 7 PULSES
If the control senses the blower pressure switch is
closed when it is expected to be open, the control
will wait approximately 90 seconds for the fault
condition to clear. If after approximately 90 seconds
the control still senses the blower pressure switch is
closed, the control will go into the lockout state.
a. Verify that the blower motor is operational and
that the 120 VAC power cable is connected to
the blower.
b.

b. Verify that the gas supply is turned on.

and also

Check that the wires are connected to the blower
air pressure switch and that the air pressure
switch is functional. This may require turning the
screw in the center of the air pressure switch I
turn clockwise to correct (initial set-up only).
After any air pressure switch adjustment, you
must cycle the appliance several times to insure
proper operation.

7. Air Pressure Switch Fault Stuck Open

10.Gas Valve NOT Connected

8 PULSES

If the control senses the blower pressure switch is not
closed during the pre-purge cycle, the control will
attempt two additional pre-purge trials. If after three
pre-purge trials the control is still sensing the blower
pressure switch is not closing, the control will enter the
lockout state.
a. Check that the blower motor is off and verify that
the blower air pressure switch is functional. This
may require turning the screw in the center of the
air pressure switch in 1/4 turn counter clockwise to
correct (initial set-up only).
b. After any air pressure switch adjustment, you must
cycle the appliance several times to insure proper
operation.
8. Redundant
PULSES

Gas Valve/Gas Valve Relay Stuck ON

If the controller senses the redundant gas valve or the
gas valve relay is stuck ON it will go into the lockout
state.
a.

Check for short-circuit(s) from the 24VAC and no
continuity between CN4 pins 3 and 4.

If the problem persists, replace the control board.

If the controller detects that the gas valve is not
connected it will go into the lockout state.
Check the connection to the gas valve.
11.ROM Checksum Failure
12 PULSES
If the controller detects that the ROM check has failed
then it will go into a lockout state.
a. Turn the 120V power OFF then ON.
b.

If the problem

persists,

12.RAM Test Failure

replace

the control

board

13 PULSES

If the controller detects that the RAM test failed it will
go into a lockout state.
a. Turn the 120V power OFF then ON.
b.

If the problem persists, replace the control board,

13.60 Hz Failure

14 PULSES

If the generator, inverter, or other power source does
not provide 60Hz, then the power source must be
replaced.
a. If the power source used supplies 60Hz, turn the
120V power OFF then ON.
b.

- 11 PULSES

If the problem

persists, replace the control board.

Redundant Gas Valve/Gas Valve Relay Stuck OFF 10 PULSES
If the controller senses the redundant gas valve or the
gas valve relay is stuck OFF, it will go into a lockout
state.
Replace the control board.

I_T'_ l_l_o_l

IF:llc-1

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I / : nn:{o] III =1;| I L_III _--] _

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

If the valve continues to leak, it must be replaced
before the boiler is returned to operation.

Check that operating pressure and temperature
have returned to normal.

Check again to confirm that valve has closed
completely and is not leaking,

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

Remove any combustible materials, gasoline and
other flammable liquids and substances that generate
flammable vapors from the area where the boiler is
contained.
Observe general boiler conditions
vibrations, etc.)

(unusual noises,

Observe operating temperature and pressure on the
combination gauge located in the supply piping on
the left side of the boiler. Boiler pressure should
never be higher than 5 psi below the rating shown
on the safety relief valve (25 psig maximum for a 30
psig rating). Boiler temperature should never be
higher than 240 ° P

Check for water leaks in boiler and system piping.

Smell around the appliance area for gas. If you smell
gas. follow the procedure listed in the Lighting
Operating Instructions to shut clown appliance in
Section 7, Start-Up Procedure Part B.

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

Test limit as described
Out Procedure".

Test function of ignition system safety shut-off
features as described in Section 7, Part D, "CheckOut Procedure".

in Section 7, Part D, "Check-

• Water, gas and electricity are off.
• The boiler is at room temperature.
• There is no pressure in the boiler.
Remove the top/front jacket panel and inspect for
any foreign debris that may have entered through air
inlet vent.

Inspect burner for deterioration.

With boiler in operation cheek that condensate is
dripping from drain hose. Cheek for any restriction in
condensate drain line.

Check boiler room floor drains for proper
functioning.

Check function of the safety relief valve by
performing the following test:
a. Check valve piping to determine that it is
properly installed and supported.

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

10. Inspect exhaust vent and air inlet vent terminations
for obstructions.

b. Check boiler operating

temperature

Replace if necessary.

and pressure.

c. Lift the t_y lever on the safety relief valve to the
full open position and hold it for at least five
seconds or until clean water is discharged,

by the

The following annual inspection must be performed
by a qualified service technician.
1.

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

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

:!1 ItAtl:l:l[11_'m LIiIlll;l;{o]ll:l;l
lh_l
llj."] :1
1.

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

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PI-80
--1712

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2132

APP'0×

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BOILER

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--1_TS-L_FT

35 _PeeOx --

SIDe vIEv

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_ XH_USt OUtLet

_LIEr
v_v_

I......

i_c_

vi[v

PI-140/PI-199
32_

75 _P_X
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SU_OL

G_S St_PL_

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I
Figure

18: Boiler

_ x_a_JST _UTLE T

con_nsat[
H0_

_
375

Dimensions

Boiler
Model

Supply/Return
Connection

All

Gas
Connection

1 1/4" NPT

Table 5:

Pinnacle"

Boiler

Air Inlet Vent!
Exhaust Size

3/4" NPT

3 t,

Ratings

JI_1_ r:lel I :MIB"-{elI I ;1:_ I :q.*NHI_.(L"e.

Boiler
Modet
Number

DOE
Heating
Capacity
MBH g

Input
MBH

PI-80

PI-140
PI-199

140
199

129
183

I Net I-B-R

Net I=B=R
Ratings
Water
MBH 1,2

:
I

Seasonal
Efficiency
AFUE %

112
159

92
92

water ratings based on an allowance of 1 15

2 Consult factory before selecting a boiler for installations having unusual piping and pickup
requirements,
such as intermittent system operation,
extensive
piping
systems,
etc.
3

Heating
Government

Capacity
t_'st

and

Annual

Fuel

U{ilization

Efficiency

(AFUE)

ratings

are based

US.
HI Division
of qama

REPAIR PARTS
PINNACLE TM GAS BOILER
Repair parts are available from your installer or by contacting Peerless Heater Company,
Boyertown, PA 19512-1021.
Refer to Table 6 and Figure 19 to assist in ordering parts.
Note: Remember

to include boiler model number and serial number when ordering parts.

÷
Figure

19:

Repair

Parts

÷
Location

Diagram

(See

Page

for

Ordering

Information)

i;l :l'./flhl _I
Table

Repair

Parts

Blower

91423

91424

91425

Transformer

91413

Control

91404

91405

91406

Gas Valve

91426

J/Box

Supply/Return

Water Temperature

Water Pressure

Switch

Air Pressure

Board

I
{ Relief Valve

l High

! Thermodisc

Thermistor

Switch

91422

!
_

91422

91427

91428

91428
i

91430

Limit Water Temperature
Temperature

91410

Switch

91429

91430
9i410

! Spark Electrode

13
14

' Main Burner (burner
Flame Sensor

i
i

91410
9i429

91411
not vlslbie in view)

91430
]

91429

91422

91407
91412

_
|

91411

91408
91412

91409
91412

Peerless

Pinnacle T"

Stainless

Gas Boilers

Steel

Installation,
Operation
Maintenance

Manual
TO THE

INSTALLER:

This manual
is the property
of the owner and must
be affixed
near the boiler for future reference.
TO THE

OWNER:

This

boiler

Qualified

should
Service

inspected

annually

Agency.

CONTROLS

HIDivision
otgama

ASME

Pr=-BRLB$S"
PINNACLE"
m

PEERLESS

m_m_r

sv_amJ_s

=rmaL

HEATER

COMPANY

231 NORTH WALNUT STREET • BOYERTOWN, PA 19512-1021 • PHONE 610-367-2153
www.peedess-heate_ corn
THE

Peerless

Heater

Company

PREFERRED

NU'lrINO

CHOICE

PI8008 R4 (1/03-2M)
Printed in U.S.A.

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Page Layout                     : SinglePage
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Producer                        : Goby Monitor Application version 3, 2, 1, 4
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PEERLESS Boiler Manual L0308220

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