PEERLESS Boiler Manual L0308220

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

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Pinnacle T"

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 must be performed

by a qualified installer, service agency or

the gas supplier.

Installation,

Operation

Maintenance

Manual

p=E_Lr=-ss"

PINNACLE"

mOH EFFICIENCY STAINLSSS _TE_L BOMLER

3 Sizes 27 to 199 MBH Input 92% AFUE

Three Sizes Available

•PI80 27to80MBHInputModulation

•PI 140 -46 to 140 MBH Input Modulation

•PI 199 -66 to 199 MBH Input Modulation

Fully Modulating Burner for Maximum Efficiency

• 92% AFUE Energy Star JEfficient

Natural or LP Gas

Direct Vent

• Sealed Combustion

• No Chimney Required -Horizontal or Vertical Venting

• Uses Standard Schedule 40 PVC Plastic Pipe for Venting

•ConceTitric PVC or V1000 Aluminum Vent Kits Available

Compact, Light-Weight Design

• Installation Flexibility

•Z_'ro Cl_!aran_? to Combustibles

• Lightweight Des_n (75 to 111 lbs.) & Small Footprint

Stainless Steel Construction

•High Grad<" Stainless StPeI Burner and Heat Exchanger

Safe Operation

• Honeywell Gas Valve and Venturi System

• State oJ:the-Arf Control Board with LED Light Indicator

•Spark Ignition

Quiet Operation

• As Quiet as Most Home Appliances

Comprehensive Warranty

• One-Year Parts & Labor Warranty

•Lin_ited. 12-Year Warranty on the Heat Exchanger

• See Below_lbr Warranty Description

Environmentally Friendly

•Low Emissions

As an ENERGY STAR" Partr_er Peerless Healer Company has delermined

that thi8 producl meel_ Ihe ENERGY STAR gwdelin es for energy efficiency

•Honeywell Gas Valve

• Burner Fan

•High Limit Temperature Control

• 30 PSI Sol-ely RelieJ Valve

• Combination Temperature-Pressure Gauge

• 3" PVC Screened Air Intake Terminal and

Exhatlsl Terminal

• 3" V1000 Aluminunl Outside Venl Termination Kit

•3" Concemcic PVC Venl Terminalion Kil

• Ad.]uslable Steel 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

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Peerless Heater Company *231 North Walnut Street •Boyertown, PA 19512 1021 *610-307-2153 • www.peerless-heater.com

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USING THIS MANUAL 1

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

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

PREINSTALLATION

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

B. CLEARANCE FROM COMBUSTIBLE

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

C. LIQUEFIED PETROLEUM (LP) GAS ....... 2

D. INSTALLATION SURVEY ............... 2

E. PLANNING THE LAYOUT ............... 2

A. BOILER SUPPLY, RETURN AND

CONTROLS ......................... 4

B. CIRCULATOR SIZING .................. 5

C. SAFETY RELIEF VALVE ................ 5

D. PIPING FOR ZONED SYSTEMS .......... 6

E. EXPANSION TANK .................... 7

E INDIRECT-FIRED WATER HEATER ........ 7

G. FREEZE PROTECTION ................. 7

4, GAS PIPING " ........

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

B. EXHAUST VENT/AIR INLET VENT

LOCATION ......................... 10

C. EXHAUST VENT INSTALLATION ........ 10

D. AIR INLET VENT INSTALLATION ........ 11

E. EXTENDED VENT LENGTHS WITH

4" PIPE ............................ 14

E CONDENSATE ...................... 14

G. BOILER REMOVAL FROM COMMON

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

6. ELECTRICAL

A. WIRING ........................... 15

B. ZONED SYSTEM WIRING ............. 15

C. SEQUENCE OF OPERATION ........... 17

A. COMPLETING THE INSTALLATION ...... 18

B. LIGHTING/OPERATING INSTRUCTIONS . .19

C. CONTROL DESCRIPTIONS ............. 20

D. CHECK-OUT PROCEDURE ............. 20

A. SHUT-DOWN ...................... 21

B. BOILER FAULT CODES ................ 22

C. BOILER FAULT CONDITIONS ........... 22

A. GENERAL (WITH BOILER IN USE) ....... 24

B. WEEKLY (WITH BOILER IN USE) ........ 24

C. ANNUALLY (BEFORE START OF

HEATING SEASON) .................. 24

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.

Indicates a condition or hazard which will cause

severe personal injury, death or major property

damage.

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 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 and serviced correctly.

Boiler can be installed at high altitude with no burner adjustments. LP equipped boilers must not be installed at

elevations above 7,000 feet.

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_[_ :_

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 of vent pipe

and condensate connections.

[Igl ! [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 F.'lll;iVJ:li'

The design of this boiler is certified for closet installation

with the following clearances:

I. 0" from left side, right side, rear, top, bottom, front

and combustible construction.

2. O" from vent pipe and combustible construction.

3. This boiler is design certified for use on combustible

floors.

:11 I'J IL_ _IL_Ib_[€'l i /-"I= I I/;V.'o]ll

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.

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.

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.

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 ignition system

components are protected from water {dripping,

spraying, etc.) during appliance operation and

service {circulator replacement, condensate trap,

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.

All piping must be properly supported. See Figure 1.

SYSTEM

_ (_F_jt_(_) _RGE & BALANCE VALVE _UP=PLY__

_ I_ BACK rL_,4 pREVeNTER ._.

_ I_) LOW pRESSURE FIED (15 _ NQIqI_L}

_ I_ EXPANSION T&_

t _I)Alll VEtlT (Mi rco bubbler Air

Etimtnltol" Recmer_led)

• _ DRAIN VALVE

_ TEMPERATURE I pRESSURE GAEE

tITE_$U I_PLIEOBYC_ITRACTOR CONNECT TO _OILER SUPPLY I_IT

SYSTEM F_ I_

_VltCH

CD_N _

E:o_JST E

_ rl/KET

CONNECT TO BOILER RETURN COLD

_.L pe._= _U=T E _m_lU.V _ttW'a_T[It

_IU_R HO

¢OL_

_l_ONt

NOTE: I_I U_R CONNECTIONS

ARE I I/i" N_T

LEfT _I_ VI{W

Figure 1: Supply and Return Near Boiler Piping

:! [e.]l:T_eJW'_'ll[e]H _'t[rAh_[€

The boiler heat exchanger does have a pressure drop

which must be allowed for in determining circulator sizing

Using the chart in Figure 2, the pressure drop for each

boiler model is as follows:

PI-80 -- 8 feet of head at 8 GPM flow rate

PI-140 - 11 feet of head at 14 GPM flow rate

PI 199 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.

21-

20-

19-

18-

17-

16-

15-

14-

13-

12-

11-

10-

n , ,n n n

1 23 45 678910 11 12 13 14 15 16 17 18 19 20 21 22 23

FLOW IN GALLONS PER MINUTE

PI-80

P1-140

P1-199

IIIIIIII

TACO P/N GRUNDFOS P/N

007(1) 15-42 F SPD-2

0010(1) 26-64 F

0011 (1) 26-96 F

1) THE RECOMMENDED CIRCULATORS ARE BASED ON 1 GPM PER 10,000 BTU/HR W/20 ° At

Figure 2: Circulator Sizing

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.

2. If required, provide means to isolate and drain each

zone separately

ZONE

VALVES

TO SYSTEM

ZONE ZONE ZONE

521

D_z

ET_Z (3-

CONNECT TO

BOILER

SUPPLY

FROM SYSTEM

ZONE ZONE ZONE

1 2 5

BALANCING

VALVES

-, I I

CONNECT TO

BOILER

RETURN

Figure 3: Zone Piping with Zone Valves

TO SYSTEM

ZONE ZONE ZONE

5 2 1

FROM SYSTEM

ZONE ZONE ZONE

1 2 5

FLOW

CONTROL/

VALVES _" ZONE

RCULATORS

CONNECT

TO BOILER

SUPPLY

CONNECT TO

BOILER

RETURN

Figure 4: Zone Piping with Circulators

:_"mI=: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.

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. Boiler system requires 12 PSI minimum.

Refer back to Figure 1 for typical expansion tank piping.

I_ 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 indirect-

fired 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.

For new or existing systems that must be freeze-

protected:

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.

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 more than water. For

example, a 50% by volume solution expands 4.8%

in volume for a temperature increase from 32 ° F to

180 ° E while water expands 3% with the same

temperature rise. Allowance must be made for this

expansion in system design.

For more information, consult the Peerless Water

Installation Survey and the antifreeze manufacturer.

FROM

BOILER

SUPPLY

BOILER

RETURN

BALANCING

VALVE

[3-

BALANCING

VALVE

SUPPLY

TO TANK

INDIRECT-FIRED

WATER HEATER

SUPPLY TO

SYSTEM

RETURN FROM

SYSTEM

HOT DOMESTIC

WATER SUPPLY

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.

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 to, but not in front of

the boiler.

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

necessar_

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.

SERVICE VALVE---J_"-_

O.J. UNION _

SEDIMENT TRAP

FLOOR LINE_

_ JACKET

Figure 6: Gas Connection to Boiler

9. 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"

11. Maintain a minimum distance of 10 feet between a

gas pressure regulator and boiler.

12. Gas line must be properly purged of air to allow for

normal main burner ignition.

Table 1: Natural Gas

Model Input

(Cubic Ft/Hr)

PI-80 80

Pb140 140

PI 199 199

Based on 1000 Btu/Cubic Ft.

Table 2: LP Gas

Model Input

(Cubic Ft/Hr)

PI-80 32

PI-140 56

PI-199 79

Based on 2500 Blu/Cubic Ft.

Table 3: 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.

Pipe

Length

Feet

3/'4"*

Pipe

1# 1¼" 1½"

IPipe Pipe Pipe

10 278 520 I 1,050

20 190 i 350 730

30 152 285 590

40 130 245 500

50 115 215 440

60 105 195 400

Multipliers to be used wi_ the above _b_ when the

specific gravity of me gas is other than 0.60:

Specific Gravity . . .0.5 0.55 0.60 0.65

Multiplier ........ 1.10 1.04 1.00 0.962

1,600

1,100

890

760

i 670

J 610

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. The boiler vent is

listed as Category IV.

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.

2 Determine air inlet vent location

a Provide I foot clearance between bottom of vent

and ground level and normal snow lines.

3 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•

b. 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.

c. When sidewall venting multiple VI000 vent kits

refer to instructions provided with vent kit.

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.

i. Determine exhaust vent location,

a. Vent is approved for 0" clearance to combustible

constr_ction.

b. 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.

When adjacent to a public walkway, locate vent

terminal at least 7 feet above grade.

Do not locate directly under roof overhangs to

prevent icicles from forming.

Provide 3 foot clearance from inside corner of

adjacent walls•

For minimum and maximum vent pipe lengths refer

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.

ivl _ _lih_[€]

i]. f-'ll;t h_llllitill_ll Ih_t-'tP-1!l!-'_l / [l]_

I. For minimum and maximum pipe length rpfer to

Table 4.

2 Use same material as noted in Section C for exhaust

vent

3 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.

4. All joints and fittings are to be assembled as per

instructions for vent pipe in Section C.

5 A screened inlet air tee is provided with boiler, to be

used as an outside termination.

6. Provide same suport means as noted for exhaust

vent in Section C.

Table 4: Minimum/Maximum Vent Length

Total Combined **Equivalent Length of 3 _

Exhaust Vent Plus 3 _ Air Inlet Vent

Boiler

Model *Minimum Length *Maximum Length

All 16 feet 85 feet

*Lengths are the combined added lengths of the exhaust

vent and air inlet vent.

**Include equivalent length of fittings as follows:

3" 90 degree elbow = 5 equivalent feet

3" 45 degree elbow - 3 equivalent feet

3" concenlric vent kit = 3 equivalent feet

3" air inlet tee = 0 feet

3" VI000 vent kit = 0 feet

Refer to Venting Diagram Figures 7 through 12 for Sidewall

and Vertical Venting arangements.

DIAGRAMS FOR SIDEWALL VENTING

BOILER

OT&P

_j===_

_"TS_EWW

EXTERIOR

WALL

ST_mHT

CcuPUNG --. --

1" MIN.

_INTAKE

_12"_

BOILER

3" EXHAUST

R_"T _OZ ViEW

T_E {VERTICAL_ COUPLING TEE (VErtiCAL)

FRONTeLEVAT_N

qMULTIPLeVENTS)

EXTERIOR

WALL

1" MIN, EXHAUST

.... STRAIGHT

_INTAKE

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: 3" Sidewall Vent with Tee (Intake) b

Coupling (Exhaust)

**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 8: 3 _Sidewall Vent with Tee (Intake) 8"

Coupling (Exhaust)

BOILER

OT&P

RIGHT SIDE ViEW

INTAKE3"

coupu_

eX_XUSTOUTLETEXHAUST

EXTERIOR

WALL

VI000

VENT KIT

BOILER

OT&P

RIGHT SIDE V_EW

EXTERIOR

WALL

--IMFOR_ANT _NTAKE LEG

MUST WE FACI_ Up**

"_r--_INTAKE

ST_,aHr EXHA T

¢_pu,o US

**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).

Figure 9: 3 _Sidewall Vent with VlOOO Kit

**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 10:3 _Sidewall Vent with 3 _Concentric

Vent Kit (KGAVT06OICVT)

DIAGRAMS FOR VERTICAL VENTING

STRAIGHT COUPLING

MAINTAIN12", (18" FORCANADA),_

MINIMUMCLEARANCEABOVE

NORMALSNOW LINES.

BO/LER

O T&P

RIGHT S_DE_IEW

3,,

INTAKE

STRA_HT

COUPUNG rJ

EXHAUST

ex_ust OUTU_T

,, 24"

MIN.

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

DO NOT EXTEND MORE THAN

24" ABOVE ROOF LINE.

BOILER

OT&P

R_HT SlOEVIEW

3,,

fNTAKE

STRAIGHT

COUpLiNG

_T _TL_r EXHAUST

*'_[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 1 1: 3" Roof Vent with Tee (Intake) 6'

Coupling (Exhaust)

**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 *] :ie] 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

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•

4. The maximum combined *equivalent length of 4"

air inlet vent plus 4" exhaust vent must not exceed

125 feet•

* Equivalent Length of 4" Piping:

4" 90 degree elbow - 3 feet

4" 45 degree elbow - I foot

4" air inlet tee = 0 feet

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

exhaust vent.

6. To use the VI000 Vent Kit or 3" Concentric Vent Kit

transition 4" pipe to 3" pipe at exit point of building.

I;4 [_o) L_I u_] :IL'_l+,."f'.*_lII

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.

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.

Do not expose condensate line to freezing

temprature.

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 removal pump is required ifboiler is

below drain•

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 in the common venting

system•

b. 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.

C. 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.

f. 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.

g. 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.

InstallallelectricalwiringinaccordancewiththeNational 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_[=

:m _[e]L'_l::le]t*.."b'd.,.']lll::l_'JI|vA_il;th,_[{

Refer to Figures 13 and 14 for power supply

connection to boiler. Use #14 AWG size wire.

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 is located on the left

side of unit.

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.

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.

The Building System Ground must be inspected by a

qualified Electrician.

8. For connection to system circulator and room

thermostat refer to Figures 13 and 14. Thermostat

anticipator setting is 0.56 amp.

9. The boiler control board and factory wiring are

shown in Figure 17.

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.

GP.J:EN (GROUNO)

WHITE

DRY PUMP RELAy

RED RED

NORMALLY OPEN

_ERHOSTAT

CONNECTION

GREEN

BLACK

tj GROUND

SCREW

ELECTRICAL

SWITCH JUNCTION BOX

120V 60 HZ

RED (NOT USED)

NORMALLY OPEN

THERHO_I'AT

CONNECTION

G GRAY

OG_ WH_E __

(NEUTRAL)•BLACK

(HOT)

GREEN --

(GROUNO)•_

GROUND

SCREW

ELECTR[CAL

SW_CH JUNCtiON BOX

120V 60 HZ

Figure 13: Connection Wiring with Circulator Relay Figure 14: Connection Wiring without

Circulator Relay

1T_ANSFORMER

120/24V--60HZ

40VA_

TO THERMOSTAT

CONNECTION-

GRAY raRES

LOCATED IN

BOILER JUNCTION

BOX

LOW VOLTAGE

-- LINE VOLTAGE

120V-60HZ

TO MAIN

DISCONNECT

SWITCH

(HOT) [ I r

iIr

(_THERMOBTA(_V

J I

JUNCllON I

BOX I

I I

j I

]

J R

I I I

J I I

Y ] Y ! ZONE VALVE

_" H-V8043E

R I I I I

J I R I I

I I

RI I

NOT£_

ALL WlRING MUST COMPLY WITH APPLICABLE CODES,

ORDINANCES, AND REGULATIONS

Figure 15: Zone Wiring with Zone Valves

120V-60HZ

TO MAIN

DISCONNECT

SWITCH

TO THERMOSTAT

CONNECTION GRAY

BOILER JUNCTION .....

BOX

_ "/_ '_CULATOR

LOW VOLTAGE

LINE VOLTAGE ZONE #1 ZONE #2 ZONE #3

THERMOSTAT, 2€V

{_ /- SWITCHING RELAY

/H-R845A OR

/W/R-829A-845

NOTE:

ALL WIRING MUST COMPLY WITH APPLICABLE CODES,

ORDINANCES, AND REGULATIONS

Figure 16: Zone Wiring with Circulators

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

INLET TEMP

PROBE

t20 VAC

CDNBUSTION BLOWER

GAS VALVE

FLAME ROD

PRESSURE SWITCH

PROVE AIR

SPARK {]LIT V

_ CIRC. pUMP

THERM[] DISC TEMP. SWITC_ 210 DEGREE

WATER PRESSURE SWITCH

ECO WATER/ HIGH LIMIT

120 VAC

24 VAC

(_ 1_0 VAC

LINE _II_T

Figure 17: Boiler Control Board Factory Wiring

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

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.

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-for-

ignition, 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.

5. When water temperature reaches the temperature

dial set point plus i0 ° F (or if the thermostat call-for-

heat 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-for-

heat is received, the control will automatically return

to step 2 and repeat the entire operating cycle.

During the idle state and heat state, if the control

detects an improper operating condition for external

devices such as the high-limit switch, the green LED

on the 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

Confirm that all water, gas and electricity are

turned off.

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.

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.

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.

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.

8. Adjust set point temperature and differential settings

as follows:

a. 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.

b. 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.

9. Turn on electricity and gas to boiler. Check to see if

LED light is illuminated on control board.

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.

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.

1 2

CK CK

1 2 1 2

Differential Dip Switch Adjustments

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

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion may

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,

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.

•Immediately call your gas supplier from a neighbor's

phone. Follow the gas suppliers' instructions.

If you cannot reach your gas supplier, call the

fire department.

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 been under

water. Immediately call a qualified service technician to

inspect the appliance and to replace any part of the

control system and any gas control which has been

under water,

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

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

Gas Shutoff

Valve

5. Remove front cover.

6. Turn gas shutoff valve clockwise to "off". Handle will be

vertical, do not force.

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 to "on".

Handle will be horizontal

9. Install Front Cover.

10. Turn on all electric power to appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions

"To Turn Off Gas To Appliance" and call your service

technician or gas suppllier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

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

to be performed.

3. Remove front cover.

4. Turn gas shutoff valve clockwise to "off". Handle will be

vertical. Do not force.

5. Install front cover.

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

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.

2. 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.

3. 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.

4. 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 of the ignition system safety

shut-off features:

a. Turn gas supply off.

b. Set thermostat or controller above room

temperature to call for heat.

c Ignition sequence should try 3 times before going

into lockout mode.

d Turn gas supply on.

e. Reset by turning 120V power supply off then on.

f. Observe boiler operation through one complete

cycle.

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 with end-user.

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

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.

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 Instructions, Section 7,

to re-start 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.

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 [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.

Ignition Failure (No Flame) - 4 PULSES

If an ignition failure occurs during the trial-for-

ignition, 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.

b. Verify that the gas supply is turned on.

c. Check for proper connection to the 120VAC

line source.

d. Check that the flame rod is connected, and also

that the flame rod is clean.

e. If items "a" through "d" are correct replace the

Low-Voltage Cable assembly.

4. Open Return Water Temperature Thermistor -

5 PULSES

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°Fthen 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

5. Open Supply Water Temperature Thermistor -

6PULSES

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.

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 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 Gas Valve/Gas Valve Relay Stuck ON 9

PULSES

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.

b. If the problem persists, replace the control board.

9. 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.

10.Gas Valve NOT Connected - 11 PULSES

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, replace the control board

12.RAM Test Failure 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. If the problem persists, replace the control board.

I_T'_ l_l_o_l

IF:llc-1 =h,'_1:1;.r_*1!ilVl_l I/:nn:{o] III =1;| IL_III _--] _

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 (unusual noises,

vibrations, etc.)

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.

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

1. Flush float-type low-water cut-off {if used) to remove

sediment from the float bowl as stated in the

manufacturer's instructions.

The following annual inspection must be performed

by a qualified service technician.

1. Check boiler room floor drains for proper

functioning.

2, 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.

b. Check boiler operating temperature 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,

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,

3. Test low-water cut-off (if used) as described by the

manufacturer.

4. Test limit as described in Section 7, Part D, "Check-

Out Procedure".

5 Test function of ignition system safety shut-off

features as described in Section 7, Part D, "Check-

Out Procedure".

When servicing or replacing components, be

absolutely certain that the following conditions are

met:

•Water, gas and electricity are off.

•The boiler is at room temperature.

•There is no pressure in the boiler.

6. Remove the top/front jacket panel and inspect for

any foreign debris that may have entered through air

inlet vent.

Inspect burner for deterioration. Replace if necessary.

With boiler in operation cheek that condensate is

dripping from drain hose. Cheek for any restriction in

condensate drain line.

9. 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.

Leaks in the vent system will cause products of

combustion to enter structure (vent system operates

under positive pressure),

I_o]]ll_l=]l_,_l:::l_[-,,.'][=]_ _![[_='_ _]

PI-80

--1712 aPP_OX -- --_ _ 3e_

4 _ APe_OX --

eXMAUST DUTL_r

2132 APP'0× _

II '°'

BOILER gDILER

RE tU_C_ SU_PPtL_

--1_TS--

L_FT SIDe vIEv

35 _PeeOx -- _q

_LIEr

v_v_

_ XH_USt OUtLet

0_S _UPPL_o

•e_ox _-- _0 x

_p_l w_v

I...... ]-

i_c_ vi[v

PI-140/PI-199

eLBI

AP_OX _XH_US_ _UTLET

'_S SU_OL --_

LErr S_D[ V_V

32_

75 _P_X

2t3 f

,3!8

_Pp_x

_EL_Er

V_V£

Figure 18: Boiler Dimensions

_x_a_JST _UTLET

G_S St_PL_

SVltC_ eoo--

_kl[r

VALV_

i ,

[Nk£T _

/con_nsat[ _

H0_ 375

Boiler Supply/Return

Model Connection

All 1 1/4" NPT

Gas

Connection

3/4" NPT

Air Inlet Vent!

Exhaust Size

3 t,

Table 5: Pinnacle" Boiler Ratings

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

DOE Net I=B=R

Boiler Heating Ratings Seasonal

Modet Input Capacity Water Efficiency

Number MBH MBHg MBH 1,2 AFUE %

PI-80 80 74 64 92

PI-140 140 129 :112 92

PI-199 199 183 I 159 92

I Net I-B-R 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 Capacity and Annual Fuel U{ilization Efficiency (AFUE) ratings are based on US.

Government t_'st 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 Next Page for Ordering Information)

i;l :l'./flhl _I

Table 6: Repair Parts

I Blower 91423 91424 91425

2 Transformer

3 Control Board

4 Gas Valve

5 J/Box

6 Supply/Return Water Temperature Thermistor

7 Water Pressure Switch

8 Air Pressure Switch

9 { Relief Valve

10 High Limit Water Temperature Switch

I 1 ! Thermodisc Temperature Switch

91413 91413

91404 91405

91426 91426

91422 _ 91422

91427 i 91427

91428 91428

91430 91430

91410 ' 9i410 ]

91429 91429

91413

91406

91426

91422

91427

91428

91430

91410

9i429

. ÷

!2 ! Spark Electrode 91411 91411 91411

13 ' Main Burner (burner not vlslbie in view) i 91407 _ 91408 91409

14 Flame Sensor i 91412 | 91412 91412

Peerless Pinnacle T"

Stainless Steel Gas Boilers

Installation,

Operation f_

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 should be inspected annually by a

Qualified Service Agency.

CONTROLS

HIDivision ASME

otgama

Pr=-BRLB$S"

PINNACLE"

m m_m_r sv_amJ_s =rmaL m

PEERLESS HEATER COMPANY

231 NORTH WALNUT STREET •BOYERTOWN, PA 19512-1021 • PHONE 610-367-2153

www.peedess-heate_ corn

THE PREFERRED NU'lrINO CHOICE

Printed in U.S.A.

PEERLESS Boiler Manual L0308220

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