Pinnacle. Peerless. Stainless Steel. Gas Boilers Rev 2. Installation, Operation & Maintenance Manual WARNING WHAT TO DO IF YOU SMELL GAS

Transcription

1 Peerless Stainless Steel Pinnacle Gas Boilers Rev 2 WARNING 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. WHAT TO DO IF YOU 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. As an ENERGY STAR Partner, PB Heat, LLC has determined that this product meets the ENERGY STAR guidelines for energy efficiency. Installation, Operation & Maintenance Manual

2 TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 1 A. INSTALLATION SEQUENCE B. SPECIAL ATTENTION BOXES PREINSTALLATION 2 A. GENERAL B. CODES & REGULATIONS C. ACCESSIBILITY CLEARANCES D. COMBUSTION AND VENTILATION AIR....3 E. PLANNING THE LAYOUT BOILER SET-UP 4 A. GENERAL B. WALL HUNG BOILERS C. FLOOR MOUNTED BOILERS WATER PIPING AND CONTROLS 5 A. GENERAL B. OPERATING PARAMETERS C. SYSTEM COMPONENTS D. SYSTEM PIPING E. FREEZE PROTECTION F. SPECIAL APPLICATIONS GAS PIPING 15 A. GENERAL B. FUEL LINE SIZING C. GAS SUPPLY PIPING INSTALLATION D. GAS SUPPLY PIPING OPERATION E. MAIN GAS VALVE OPERATION VENTING, INTAKE AIR & CONDENSATE 18 A. GENERAL B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE AIR PIPE C. EXHAUST VENT / AIR INTAKE PIPE LOCATION D. EXHAUST VENT AND INTAKE AIR PIPE SIZING E. EXHAUST VENT AND AIR INLET PIPE INSTALLATION F. EXHAUST TAPPING FOR VENT SAMPLE G. CONDENSATE DRAIN INSTALLATION H. BOILER REMOVAL FROM COMMON VENTING SYSTEM ELECTRICAL 25 A. WIRING B. SEQUENCE OF OPERATION C. SAFETY INTERLOCKS D. CONTROL FUNCTIONS E. HEATING CURVE START-UP PROCEDURES 33 A. COMPLETING THE INSTALLATION B. LIGHTING/OPERATING PROCEDURES C. CHECK-OUT PROCEDURE TROUBLESHOOTING 37 A. BOILER ERROR CODES B. BOILER FAULT CODES MAINTENANCE 39 A. GENERAL (WITH BOILER IN USE) B. WEEKLY (WITH BOILER IN USE) C. ANNUALLY (BEFORE START OF HEATING SEASON) D. CONDENSATE CLEANING INSTRUCTIONS E. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS BOILER DIMENSIONS & RATINGS 42 A. BOILER DIMENSIONS REPAIR PARTS 46 APPENDIX A. STARTUP COMBUSTION RECORD 50

3 USING THIS MANUAL USING THIS MANUAL A. INSTALLATION SEQUENCE Follow the installation instructions provided in this manual in the order shown. The order of these instructions has been set in order to provide the installer with a logical sequence of steps that will minimize potential interferences and maximize safety during boiler installation. B. SPECIAL ATTENTION BOXES Throughout this manual you will see special attention boxes intended to supplement the instructions and make special notice of potential hazards. These categories mean, in the judgment of PB Heat, LLC: DANGER Indicates a condition or hazard which will cause severe personal injury, death or major property damage. WARNING Indicates a condition or hazard which may cause severe personal injury, death or major property damage. CAUTION Indicates a condition or hazard which will or can cause minor personal injury or property damage. NOTICE Indicates special attention is needed, but not directly related to potential personal injury or property damage. 1

4 PREINSTALLATION 1. PREINSTALLATION A. GENERAL 1. Pinnacle boilers are supplied completely assembled as packaged boilers. The package should be inspected for damage upon receipt and any damage to the unit should be reported to the shipping company and wholesaler. This boiler should be stored in a clean, dry area. 2. Carefully read these instructions and be sure to understand the function of all connections prior to beginning installation. Contact your PB Heat, LLC Representative for help in answering questions. 3. This boiler must be installed by a qualified contractor. The boiler warranty may be voided if the boiler is not installed correctly. 4. A hot water boiler installed above radiation or as required by the Authority having jurisdiction, must be provided with a low water fuel cut-off device either as part of the boiler or at the time of installation. 5. This boiler can be installed at high altitudes above 5,000 feet with no burner adjustments. This applies to boilers equipped for firing natural gas or liquefied petroleum (LP) gas. B. CODES & REGULATIONS 1. Installation and repairs are to be performed in strict accordance with the requirements of state and local regulating agencies and codes dealing with boiler and gas appliance installation. 2. In the absence of local requirements the following should be followed. a. ASME Boiler and Pressure Vessel Code, Section IV - "Heating Boilers" b. ASME Boiler and Pressure Vessel Code, Section VI - Recommended Rules for the Care and Operation of Heating Boilers" WARNING Liquefied Petroleum (LP) Gas or Propane is heavier than air and, in the event of a leak, may collect in low areas such as basements or floor drains. The gas may then ignite resulting in a fire or explosion. c. ANSI Z223.1/NFPA 54 - "National Fuel Gas Code" d. ANSI/NFPA 70 - "National Electrical Code" e. ANSI/NFPA "Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances" 3. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. **Please read if installing in Massachusetts** Massachusetts requires manufacturers of Side Wall Vented boilers to provide the following information from the Massachusetts code: A hard wired carbon monoxide detector with an alarm and battery back-up must be installed on the floor level where the gas equipment is to be installed AND on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. Detector(s) must be installed by qualified licensed professionals. APPROVED CARBON MONOXIDE DETECTORS: Each carbon monoxide detector shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS. EXEMPTIONS The to the requirements listed above: The above requirements do not apply if the exhaust vent termination is seven (7) feet or more above finished grade in the area of the venting, including but not limited to decks and porches. The above requirements do not apply to a boiler installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. boiler installation manual, vent manufacturer's installation manual, and this supplement shall remain with the boiler at the completion of the installation. See latest edition of Massachusetts Code 248 CMR for complete verbage and also for additional (non-vent related) requirements (248 CMR is available online). If your installation is NOT in Massachusetts, please see your authority of jurisdiction for requirements that may be in effect in your area. In the absence of such requirements, follow the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. 2

5 PREINSTALLATION C. ACCESSIBILITY CLEARANCES 1. The Pinnacle boiler is certified for closet installations with zero clearance to combustible construction. In addition, it is design certified for use on combustible floors. 2. Refer to Figure 1.1 for the recommended clearance to allow for reasonable access to the boiler. Local codes or special conditions may require greater clearances. D. COMBUSTION AND VENTILATION AIR 1. The Pinnacle boiler is designed only for operation with combustion air piped from outside (sealed combustion). PVC pipe must be supplied between the air intake connection at the rear of the boiler and an outside wall or roof. 2. No additional combustion or ventilation air is required for this appliance. DANGER Do not install this boiler on carpeting. 3. Refer to Section 5 of this manual, Venting, for specific instructions for piping combustion air. E. PLANNING THE LAYOUT 1. Prepare sketches and notes showing the layout of the boiler installation to minimize the possibility of interferences with new or existing equipment, piping, venting and wiring. 2. The following sections of this manual should be reviewed for consideration of limitations with respect to: a. Water Piping: Section 3 b. Fuel Piping: Section 4 c. Venting: Section 5 d. Air Intake Piping: Section 5 e. Condensate Removal: Section 5 f. Electrical Wiring: Section 6 WARNING This boiler is certified as an indoor appliance. Do not install this boiler outdoors or locate where it will be exposed to freezing temperatures. WARNING Do not install this boiler where gasoline or other flammable liquids or vapors are stored or are in use. Figure 1.1: Accessibility Clearances Floor Standing Units Figure 1.2: Accessibility Clearances Wall Hung Units 3

6 BOILER SET-UP 2. BOILER SET-UP A. GENERAL 1. Pinnacle boilers are to be installed in an area with a floor drain or in a suitable drain pan. Do not install any boiler where leaks or relief valve discharge will cause property damage. 2. This boiler is not intended to support external piping. All venting and other piping should be supported independently of the boiler. 3. Install this boiler level to prevent condensate from backing up inside the boiler. CAUTION This boiler is must be installed level to prevent condensate from backing up inside the boiler. B. WALL HUNG BOILERS 1. The PI-T50 and PI-T80 Boilers are provided with slots for wall mounting and feet for floor mounting. Refer to Figure 10.1 in this manual for dimensions & locations. 3. Use a minimum of 1/4" threaded fasteners for supporting the boiler. Do not mount the boiler to wall board only. WARNING Make sure the boiler is adequately supported. Do not install this boiler on drywall unless adequately supported by wall studs. 4. Be sure to adequately support the boiler while installing external piping. Be sure to pipe condensate to a suitable drain or condensate pump. C. FLOOR MOUNTED BOILERS 1. PI-80, PI-140, and PI-199 boilers are designed for floor mounting. The PI-80 can be wall mounted using the optional boiler stand available through your PB Heat, LLC distributor (Part Number 91439). 2. The boiler stand may used for floor mounting of the PI-140 and PI-199 boilers. 2. If wall mounted, the boiler must be attached to a wall that provides adequate support for the boiler. 4

7 WATER PIPING AND CONTROLS 3. WATER PIPING AND CONTROLS A. GENERAL 1. The water supply and return piping of this appliance are to be sized according to system requirements. Do not use piping smaller than the boiler connections. 2. In hydronic systems where sediment may exist, install a strainer device in the boiler return piping to prevent large particles and pipe scale from entering the boiler heat exchanger coil. Use a large mesh screen in the strainer. 3. 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 cleaning, control replacement, etc.). B. OPERATING PARAMETERS 1. The Pinnacle boiler is designed to operate in a closed loop hydronic system at approximately 15 psi. A pressure limit in the boiler header will prevent the unit from operating if the pressure drops below 10 psi. This is to keep the appliance from operating in the event of a system leak or other condition in which water is not flowing through the heat exchanger. 2. Table 3.1 shows minimum water flow rates for Pinnacle boilers. If a glycol solution is to be used, contact the factory for minimum flow rates. Table 3.1 Minimum Flow Rate and Water Volume Boiler Model Total Water Volume-Gallon (Liter) C. SYSTEM COMPONENTS Minimum Flow Rate-GPM (LPM) PI-T (1.89) 2 (7.6) PI-T (2.40) 4 (15.2) PI (2.40) 4 (15.2) PI (3.50) 6 (22.7) PI (4.26) 8 (30.3) 1. Figure 3.1 shows the symbol key for piping diagrams in this section. The following are brief descriptions of system components. 2. Pressure/Temperature Gauge: A combination pressure/temperature gauge is provided with each Pinnacle boiler to be mounted in the piping from the boiler supply to the system. Most local codes require this gauge. 3. Air Elimination: Any closed loop hydronic system in which the Pinnacle boiler is installed must have an air elimination device. As the system water is heated, dissolved oxygen and carbon dioxide will separate from the liquid. An air elimination device (such as a TACO 430 Series Air Scoop with automatic air vent) is required to remove the dissolved gasses from the system preventing corrosion in the piping system and eliminating system noise. 4. Expansion Tank: An expansion tank (such as a Bell & Gossett Series HFT) is required to provide room for expansion of the heating medium (water or glycol solution). Consult the expansion tank manufacturer's instructions for specific information regarding installation. The expansion tank is to be sized for the required system volume and capacity. In addition, be sure that the expansion tank is sized based on the proper heating medium. Glycol solutions may expand more than water for a similar temperature rise. CAUTION Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems. Unlike automotive antifreeze, solutions for hydronic applications contain corrosion inhibitors that will protect system components from premature failure due to corrosion. WARNING Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems. Ethylene glycol is toxic and may cause an environmental hazard if a leak or spill occurs. 5. Y-Type Strainer: In older systems where a significant amount of sediment may be present, it may be necessary to install a Y-type strainer. The strainer should be checked often and cleaned during the first few months of operation to assure that sediment does not reach the heat exchanger and clog the passages. Use a large mesh screen in the strainer. 6. Flow Control Valve: Flow control valves such as the TACO Flo-Chek or Bell & Gossett Flo-Control are used to prevent gravity circulation by incorporating a check valve with a weighted disc. 7. Pressure Reducing Valve: A pressure reducing valve, such as the Bell & Gossett B-38 or a TACO #329, is used in a hydronic system to automatically feed water to the system whenever pressure in the system drops below the pressure setting of the valve. These valves should not be used on glycol systems unless close supervision of the glycol solution is practiced. 8. Back Flow Preventer: A back flow preventer (check valve) is required by some jurisdictions to prevent the hydronic system water from backing up into the city water supply. This is especially important on systems in which glycol solution is used as the heating medium. 5

8 WATER PIPING AND CONTROLS Figure 3.1: Piping Symbol Key 9. Pressure Relief Valve: The boiler pressure relief valve is factory installed into the right side boiler manifold (inside the jacket). Pipe the discharge of the relief valve to within 12" of the floor and close to a floor drain. Provide piping that is the same size or larger than the relief valve outlet. CAUTION Pipe the discharge of the relief valve as close as possible to the floor and away from high traffic areas. Pipe the discharge to a floor drain. Failure to do so may result in personal injury and/or property damage. 10. Circulator: The boiler circulator is to be sized to overcome the pressure drop of the system while providing the flow required by the boiler. a. If the boiler is piped in a secondary loop of a primary/secondary heating system, the circulator will need only to overcome the resistance of the boiler and any fittings in that loop. Table 3.2 Boiler Inputs and Outputs Boiler Model Boiler Input (Btu/hr [kw]) Net I=B=R Output (Btu/hr [kw]) PI-T50 50,000 (14.7) 40,000 (11.7) PI-T80 80,000 (23.4) 64,000 (18.8) PI-80 80,000 (23.4) 64,000 (18.8) PI ,000 (41.0) 112,000 (32.8) PI ,000 (58.3) 159,000 (46.6) c. The required flow rate can be calculated based on the design temperature difference from the return to the supply of the boiler. For a PI-T80 with a design temperature difference of 20 F the calculation is as follows: Required Flow = Output 64,000 = = 6.4 GPM ΔT x x 500 b. The circulator should be sized based on the net output of the boiler. The Table 3.2 shows the Boiler Output as reported to the Hydronics Institute division of GAMA. These values are based on a pickup factor of

9 WATER PIPING AND CONTROLS d. Table 3.3 shows the pressure drop (in feet of water) for a flow rate which gives a 20 F temperature difference for each boiler model. Table 3.3 Flow Rate and Pressure Drop Boiler Model Flow Rate (GPM [LPM]) Pressure Drop (Feet [meters]) PI-T (15.1) 4.5 (1.22) PI-T (24.2) 5.0 (1.52) PI (24.2) 5.0 (1.52) PI (42.4) 8.0 (2.44) PI (60.2) 13.0 (4.02) e. The boiler pressure drop for various flow rates can be determined by using Figure 3.2, the Pinnacle Circulator Sizing Graph. f. Table 3.4 gives the recommended circulators for a boiler on a secondary loop with water as the heating medium. Table 3.4 Recommended Circulators Boiler Model TACO Circulator Grundfos Circulator PI-T UPS 15-58FC SPD-1 PI-T UPS 15-58FC SPD-2 PI UPS 15-58FC SPD-2 PI UPS 15-58FC SPD-3 PI UP 26-64F g. Special consideration must be given if anti-freeze is to be used as a heating medium. Propylene glycol has a higher viscosity than water; therefore the system pressure drop will be higher. 11. Indirect Water Heater: An indirect water heater should be piped in a dedicated zone. It consists of a water tank that is heated by boiler water passing through an internal coil. Examples of indirect water heating are shown in the System Piping subsection of this Section. D. SYSTEM PIPING NOTICE The circulator sizing given is for primary/secondary installations only. The system circulators must be sized based on the flow and pressure drop requirements of the system. NOTICE When using the domestic hot water priority function, the domestic circulator must be piped directly to the boiler. Also, the circulator must be sized to exceed the minimum flow rate of the boiler. Failure to follow these instructions will cause the system to operate incorrectly and may cause premature failure of the appliance. Figure 3.2: Pinnacle Circulator Sizing Graph Pressure Drop (Feet of Head) Pinnacle Circulator Sizing Graph PI-T PI-T80/ PI PI Flow Rate (GPM) 7

10 WATER PIPING AND CONTROLS 1. Figure 3.3 shows a single boiler with one heating zone and a Peerless Partner indirect water heater. 2. Figure 3.4 shows a single boiler with an additional zone in which baseboard radiation is the heat load. NOTICE When applying multiple boilers, a sequencing control such as the tekmar 265 or the Heat Timer Mini-Mod, should be used. These controls provide control for boiler temperature and domestic circulator operation. 3. Figure 3.5 shows diverter tees used in combination with conventional hydronic radiators on an additional zone. A second boiler is also added to the system. Notice that the boilers are piped in parallel on the secondary loop. It is important that the common headers are sized to match the system piping. Smaller headers may result in flow fluctuations through the boilers. 4. Figure 3.6 shows a system in which several different types of loads and multiple boilers are shown. This system illustrates how different temperature zones can be supplied from the same source by mixing down the temperature using a three way mixing valve. Radiant flooring typically requires much lower temperatures than baseboard radiation and indirect water heating. Notice that a third boiler is included in this system. 5. Figure 3.7 shows zone valves used in place of zone circulators. Notice that this system utilizes reverse return piping which makes it easier to balance the system. If the heating zones are very different in length, the balancing valves on the return side of each loop are required. E. FREEZE PROTECTION 1. Glycol for hydronic applications is specially formulated for this purpose. It includes inhibitors which prevent the glycol from attacking metallic system components. Make certain that the system fluid is checked for the correct glycol concentration and inhibitor level. 2. Use only inhibited propylene glycol solutions of up to 50% by volume. Ethylene glycol is toxic and can chemically attack gaskets and seals used in hydronic systems. 3. The antifreeze solution should be tested at least once per year and as recommended by the antifreeze manufacturer. Antifreeze solutions expand more than water. For example, a 50% by volume solution expands 4.8% for a 148 F temperature rise while water expands about 3% for the same temperature increase. Allowance for this expansion must be considered in sizing expansion tanks and related components. 4. The flow rate in systems utilizing glycol solution should be increased compared with a water system to compensate for increased heating capacity. 5. Due to increased flow rate and fluid viscosity the circulator head requirement will increase. Contact the pump manufacturer to correctly size the circulator for a particular application based on the glycol concentration and heating requirements. 6. A strainer, sediment trap, or some other means for cleaning the piping system must be provided. It should be located in the return line upstream of the boiler and must be cleaned frequently during the initial operation of the system. Glycol solution is likely to remove mill scale from new pipe in new installations. 7. Glycol solution is expensive and leaks should be avoided. Weld or solder joints should be used where possible and threaded joints should be avoided. Make up water should not be added to the system automatically when a glycol solution is used. Adding make-up water may significantly dilute the system. 8. Check local regulations to see if systems containing glycol solutions must include a back-flow preventer or require that the glycol system be isolated from the water supply. 9. Do not use galvanized pipe in glycol systems. 10. Use water that is low in mineral content and make sure there are no petroleum products in the solution. 11. Mix solution at room temperature. 12. Do not use a chromate treatment. 13. Do not use glycol solution in a system that may reach temperatures above 250 F. 14. Refer to Technical Topics, #2a published by the Hydronics Institute Division of GAMA for further glycol system considerations. F. SPECIAL APPLICATIONS 1. If the boiler is used in conjunction with a chilled medium system, pipe the chiller in a separate secondary loop. a. Assure that the boiler circulator is disabled during chiller operation so chilled water does not enter the boiler. b. Install a flow control valve (spring check valve) to prevent gravity flow through the boiler. c. See figure 3.8 for recommended system piping. 2. For boilers connected to heating coils in a forced air system where they may be exposed to chilled air circulation, install flow control valves or other automatic means to prevent gravity circulation of the boiler water during cooling cycles. See figure 3.9 for illustration. 8

11 WATER PIPING AND CONTROLS Figure 3.3: One Boiler, Primary/Secondary with one heating zone and a Peerless Partner (Zone Circulators) 9

12 WATER PIPING AND CONTROLS Figure 3.4: One Boiler, Primary/Secondary with two heating zones and a Peerless Partner (Zone Circulators) 10

13 WATER PIPING AND CONTROLS Figure 3.5: Two Boilers, Primary/Secondary with Four Zones (Zone Circulator) 11

14 WATER PIPING AND CONTROLS Figure 3.6: Three Boilers, Primary/Secondary with Five Zones (Zone Circulator) 12

15 WATER PIPING AND CONTROLS Figure 3.7: Three Boilers, Primary/Secondary with Four Zones (Zone Valves) 13

16 WATER PIPING AND CONTROLS Figure 3.8: Boiler in conjunction with a Chilled Water System Figure 3.9: Boiler Connected to a Heating Coil in a Forced Air System 14

17 GAS PIPING 4. GAS PIPING A. GENERAL 1. All fuel piping to the boiler is to be in accordance with local codes. In the absence of local regulations refer to the National Fuel Gas Code, ANSI Z223.1/NFPA Size and install piping to provide a supply of gas sufficient to meet the maximum demand of all appliances supplied by the piping. B. FUEL LINE SIZING 1. The rate of gas to be provided to the boiler can be determined by the following: Boiler Input Rate Input Rate ( ft³ / hr ) ( Btu / hr ) = Gas Heating Value ( Btu / ft ³) Obtain the gas heating value from the gas supplier. 2. As an alternative use Table 4.1 which uses typical heating values for natural gas and liquefied petroleum (LP) gas. Table 4.1: Gas Input Rates Boiler Gas Input Rate* (ft³/hr) Model Natural Gas LP Gas PI-T PI-T PI PI PI *Natural gas input rates are based on 1000 Btu/ft³, LP input rates are based on 2500 Btu/ft³. 3. Table 4.2 shows the maximum flow capacity of several pipe sizes based on 0.3" of pressure drop. a. The values shown are based on a gas specific gravity of 0.60 (Typical for natural gas). b. Multiply the capacities listed by the factors indicated in Table 5.3 for gas with a specific gravity other than 0.60 to obtain the corrected capacity. Table 4.2: Maximum Capacity of Pipe (CFH) for a Pressure Drop of 0.3" of Water Pipe Length (Feet) 3/4" NPT Pipe 1" NPT Pipe 1-1/4" NPT Pipe 4. The gas piping to the boiler must be a minimum of 3/4" pipe. The boiler is supplied with a 3/4" NPT x 1/2" NPT bell reducer. Do not remove the reducer. 5. Size and install the gas supply piping for no more than 0.5 inches of water pressure drop between the gas regulator and the boiler. C. GAS SUPPLY PIPING INSTALLATION 1-1/2" NPT Pipe ,050 1, , The values are based on a specific gravity of 0.60 (typical for natural gas). See Table 4.3 for capacity correction factors for gases with other specific gravities. Table 4.3: Maximum Capacity Correction Factors for Specific Gravity other than 0.60 Specific Gravity Correction Factor Specific Gravity Correction Factor Specific Gravity Correction Factor Do not install any piping directly over or in front of the boiler. Locate the drop pipe adjacent to the boiler. 15

18 GAS PIPING 2. Install a sediment trap as shown in Figure 4.1. Be sure to allow clearance from the floor for removal of the pipe cap. WARNING Use a pipe joint sealing compound that is resistant to liquefied petroleum gas. A non-resistant compound may lose sealing ability in the presence of this gas, resulting in a gas leak. Gas leaks may potentially cause an explosion or fire. 3. Install a ground joint union between the sediment trap and the boiler to allow service of the appliance. 4. Install a service valve as shown in Figure 4.1 to allow the gas supply to be interrupted for service. 5. Maintain a minimum distance of 10 feet between the gas pressure regulator and the boiler. 6. Check all gas piping for leaks prior to placing the boiler in operation. Use an approved gas detector, non-corrosive leak detection fluid, or other leak detection method. If leaks are found, turn off all gas flow and repair as necessary. WARNING When checking for leaks, do not use matches, candles, open flames or other methods that provide an ignition source. This may ignite a gas leak resulting in a fire or explosion. 7. Figure 4.2 and 4.3 are illustrations of the gas shutoff valve for the Pinnacle Boiler. This valve is to be used in addition to the gas service valve shown in Figure 4.1. D. GAS SUPPLY PIPING - OPERATION 1. The gas line must be properly purged of air to allow boiler to operate. Failure to do so may result in burner ignition problems. 2. Table 4.4 shows the maximum and minimum supply pressure to the boiler. a. Gas pressure below the minimum pressure may result in burner ignition problems. b. Gas pressure above the maximum may result in damage to the gas valve. CAUTION Do not subject the gas valve to more than 1/2 psi (13.5" W.C.) of pressure. Doing so may damage the gas valve. Figure 4.1: Gas Supply Piping Sediment Trap Figure 4.2: PI-80/PI-140/PI-199 Gas Valve Shut Off Figure 4.3: PI-T50/PI-T80 Gas Valve Shut Off 16

19 GAS PIPING Table 4.4: Maximum and Minimum Fuel Pressure Gas Type Pressure (inches of water) Minimum 3. To check the gas supply pressure on the gas valve: a. Turn off the power at the service switch. b. Turn off the gas shutoff valve. Maximum Natural LP c. Using a flat screwdriver, turn the screw inside the inlet pressure tap fitting (see figure 4.4 and 4.5) one turn counterclockwise. d. Attach the manometer tube to the pressure tap fitting. e. Open the gas shutoff valve and start the boiler. f. Read and record the gas pressure while the boiler is firing. g. Turn off the boiler and gas shutoff valve h. Remove the manometer tube from the pressure tap fitting and turn the screw to close the internal valve. WARNING Do not adjust the throttle screw without monitoring the carbon dioxide (CO ² ) and carbon monoxide (CO) in the vent pipe. Vent CO emissions above 400 ppm are in excess of most safety standards. b. Turning the throttle screw clockwise will decrease the gas flow (decreasing CO ² ) and turning it counterclockwise will increase the gas flow (increasing CO ² ). c. The recommended CO ² settings are given in Table 4.5. In no case should the boiler be allowed to operate with CO emissions in excess of 150 ppm. 2. Refer to Section 5, Venting for information on obtaining vent samples from this boiler. Table 4.5: Recommended Vent CO ² Settings Gas Type Natural LP Firing Rate Vent CO ² Vent CO Low 8-1/2% to 9-1/2% < 50 ppm High 8-1/2% to 9-1/2% < 100 ppm Low 9-1/2% to 10-1/2% < 50 ppm High 9-1/2% to 10-1/2% < 100 ppm i. Turn on the gas shutoff valve and boiler service switch. 4. All gas piping must be leak tested prior to placing the boiler in operation. a. If the leak test pressure requirement is higher than the maximum inlet pressure noted in Table 4.4, the boiler must be isolated from the gas supply piping system. b. If the gas valve is exposed to pressures exceeding 13.5" of water, the gas valve must be replaced. 5. Install the boiler such that the gas ignition system components are protected from water (dripping, spraying, rain, etc) during operation and service (circulator replacement, condensate trap cleanout, and control replacement, etc). E. MAIN GAS VALVE - OPERATION Figure 4.4: Gas Valve/Venturi 1. Figure 4.4 shows an illustration of the gas valve/venturi assembly for the Pinnacle Boiler. a. The throttle screw on these valves should not be adjusted without a means to measure carbon monoxide (CO) and carbon dioxide (CO ² ) emissions. 17

20 VENTING, INLET AIR AND CONDENSATE 5. VENTING, INTAKE AIR AND CONDENSATE A. GENERAL 1. Install the boiler venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, and/or applicable provisions of local building codes. 2. This boiler is a direct vent appliance and is listed as a Category IV appliance with Underwriters Laboratories, Inc. WARNING This vent system will operate with a positive pressure in the pipe. Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft systems operating under positive pressure. WARNING Follow these venting instructions carefully. Failure to do so may result in severe personal injury, death, or substantial property damage. B. APPROVED MATERIALS FOR EXHAUST VENT AND INTAKE AIR PIPE 1. Use only Non Foam Core venting material. The following materials are approved for use as vent pipe for this boiler: a. Non Foam Core PVC (Polyvinyl Chloride) Pipe conforming to ASTM D b. Non Foam Core CPVC (Chlorinated Polyvinyl Chloride) Pipe conforming to ASTM D WARNING Do not use Foam Core Pipe in any portion of the exhaust piping from this boiler. Use of Foam Core Pipe may result in severe personal injury, death, or substantial property damage. c. Non Foam Core ABS (Acrylonitrile-Butadiene- Styrene) Pipe conforming to ASTM D Cellular foam core piping may be used on air intake piping only. Never use cellular foam core material for exhaust piping. C. EXHAUST VENT / AIR INTAKE PIPE LOCATION 1. Determine exhaust vent location: a. The vent piping for this boiler is approved for zero clearance to combustible construction. b. See Figure 5.1 for an illustration of clearances for location of exit terminals of direct-vent venting systems. c. This boiler vent system shall terminate at least 3 feet (0.9 m) above any forced air intake located within 10 ft (3 m). Note: this does not apply to the combustion air intake of a direct-vent appliance. d. Provide a minimum of 1 foot distance from any door, operable window, or gravity intake into any building. e. Provide a minimum of 1 foot clearance from the bottom of the exit terminal above the expected snow accumulation level. Snow removal may be necessary to maintain clearance. f. Provide 4 feet horizontal clearance from electrical meters, gas meters, gas regulators, and relief equipment. In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained. g. Do not locate the exit terminal over public walkways where condensate could drip and/or freeze and create a nuisance or hazard. h. When adjacent to a public walkway, locate exit terminal at least 7 feet above grade. i. Do not locate the exit termination directly under roof overhangs to prevent icicles from forming. j. Provide 3 feet clearance from the inside corner of adjacent walls. WARNING Flue gases will condense as they exit the vent termination. This condensate can freeze on exterior building surfaces which may cause discoloration of the surfaces. 2. Determine air intake pipe location. a. Provide 1 foot clearance from the bottom of the air intake pipe and the level of maximum snow accumulation. Snow removal may be necessary to maintain clearances. b. Do not locate air intake pipe in a parking area where machinery may damage the pipe. c. Maximum distance between air intake and exhaust vent is 6 feet (1.8 m). Minimum distance between exhaust vent and air intake on single Pinnacle is 8" (0.2 m) center-to-center. Minimum distance between vents and intakes on multiple Pinnacles is 8" (0.2 m) center-to-center. See Figure

21 VENTING, INTAKE AIR AND CONDENSATE Figure 5.1: Location of exit terminals of mechanical draft and direct-vent venting systems. (Reference: National Fuel Gas Code ANSI Z223.1/NFPA ). Table 5.1: Fitting Equivalent Length Table Fitting Description Equivalent Length 2" Vent 3" Vent 4" Vent Elbow, 90, Short Radius 5' 5' 3' Elbow, 90, Long Radius 4' 4' 2' Elbow, 45, Short Radius 3' 3' 1' Coupling 0' 0' 0' Air Intake Tee 0' 0' 0' Stainless Steel Vent Kit 1' 1' 1' Concentric Vent Kit 3' 3' 3' Figure 5.2: Multiple Pinnacle Vent Spacing Exhaust Vent Pipe Equivalent Length = (2x5)+10=20 feet D. EXHAUST VENT AND INTAKE AIR PIPE SIZING 1. For the PI-T50 and PI-T80 Boilers the exhaust vent and air intake pipes should be 2" Schedule 40 or For the PI-80, PI-140, PI-199 the exhaust vent and air intake pipes should be 3" Schedule 40 or The total combined equivalent length of exhaust vent and intake air pipe should not exceed 85 feet. a. The equivalent length of elbows, tees, and other fittings are listed in Table 5.1. b. For example: If the exhaust vent has two 90 elbows and 10 feet of PVC pipe we will calculate: Further, if the intake air pipe has two 90 elbows, one 45 elbow and 10 feet of PVC pipe, the following calculation applies: Air Intake Pipe Equivalent Length = (2x5)+3+10=23 feet Finally, if a concentric vent kit is used we find: Total Combined Equivalent Length = =46 feet Therefore, the total combined equivalent length is 46 feet which is well below the maximum of 85 feet. c. The intake air pipe and the exhaust vent are intended to penetrate the same wall or roof of the building. 19

22 VENTING, INTAKE AIR AND CONDENSATE d. Effort should be made to keep a minimum difference in equivalent length between the air intake pipe and the exhaust vent. 4. The minimum combined equivalent length is 16 equivalent feet. 5. The maximum combined equivalent length can be extended by increasing the diameter of the vent pipe. However, the transitions should begin a minimum of 15 equivalent feet from the boiler. a. Transitions should always be made in vertical sections of pipe to prevent the condensate from pooling in the vent pipe. b. Use a 3" x 2" reducing coupling to transition from the PI-T50 and PI-T80 boiler connections to a 3" vent. c. Use a 4" x 3" reducing coupling to transition from the PI-80, PI-140, and PI-199 boiler connections to 4" vent. d. The maximum equivalent length for the increased diameter vent pipes is 125 feet. Table 5.2: Maximum Equivalent Vent Length for Oversized Vent Pipe Transition Point (ft from boiler) TEL of Standard 2 or 3 Vent Pipe (ft) TEL of Oversized 3 or 4 Vent Pipe (ft) Maximum TEL of all Vent Pipe (ft) / / / / /2 88-1/2 None TEL = Total Equivalent Length e. If the transition occurs at a distance greater than 15 equivalent feet from the boiler, the maximum equivalent length will be reduced. See Table 5.2. Standard Vent Pipe is 2 and Oversized Vent Pipe is 3 for PI-T50 and PI-T80. Standard Vent Pipe is 3 and Oversized Vent Pipe is 4 for PI- 80 through PI-199. E. EXHAUST VENT AND AIR INTAKE PIPE INSTALLATION 1. On the PI-T50 and PI-T80 the 2" exhaust vent connection is located on the top, right side of the boiler and the air intake is on the top, left side. See Figure The air intake connection is intended for a slip fit. No sealant or adhesive is required. 3. Use only solid PVC, CPVC, or ABS schedule 40 or 80 pipe. FOAM CORE PIPING IS NOT APPROVED. 4. Remove all burrs and debris from joints and fittings. All joints of positive pressure vent systems must be sealed completely to prevent leakage of flue products into the living space. 5. All joints must be properly cleaned, primed, and cemented. Use only cement and primer approved for use with the pipe material. Cement must conform to ASTM D2564 for PVC or CPVC pipe and ASTM D2235 for ABS pipe. 6. Horizontal lengths of exhaust vent must slope back towards the boiler not less than ¼" per foot to allow condensate to drain from the vent pipe. If the vent pipe must be piped around an obstacle that causes a low point in the pipe, a drain pipe must be connected to allow condensate to drain. 7. All piping must be fully supported. Use pipe hangers at a minimum of 4 foot intervals to prevent sagging of the pipe where condensate may form. 8. Do not use the boiler to support any piping. 9. A screened straight coupling is provided with the boiler for use as an outside exhaust termination. 10. A screened intake air tee is provided with the boiler to be used as an outside intake termination. 11. The following are optional intake air/exhaust vent terminations available from your PB Heat, LLC distributor for use with Pinnacle boilers. Table 5.3: Vent Termination Kits Description WARNING Stock Code 2" PVC Concentric Vent Termination Kit " PVC Concentric Vent Termination Kit " Stainless Steel Vent Termination Kit " Stainless Steel Vent Termination Kit " Stainless Steel Vent Termination Kit Refer to Figure 5.3 to 5.10 for sidewall venting and Figures 5.11 to 5.14 for vertical venting. Refer to Figure 5.15 for sidewall venting below grade. 13. Seal penetration openings in building structure around vent pipe and intake air pipe. 2. On the PI-80, PI-140, and PI-199 Boilers the 3 exhaust vent connection is located on the rear of the boiler and the air intake is higher and toward the left side when the boiler is viewed from the front. See Figure The air intake connection is intended for a slip fit. No sealant or adhesive is required. 20

23 VENTING, INTAKE AIR AND CONDENSATE Figure 5.3: PI-80, PI-140, and PI-199 Sidewall Venting with 3" Pipe (Exhaust Termination at Higher Elevation than Air Intake). Figure 5.5: PI-80, PI-140, PI-199 Sidewall Venting with 3" Pipe (Air Intake and Exhaust on the same Elevation). Figure 5.4: PI-T50 & PI-T80 Sidewall Venting with 2" Pipe (Exhaust Termination at Higher Elevation than Air Intake). Figure 5.6: PI-T50 & PI-T80 Sidewall Venting with 2" Pipe (Air Intake and Exhaust on the same Elevation). WARNING All exhaust vent pipes must be glued, properly supported, and pitched at a minimum of ¼" per foot back to the boiler. Failure to do so may result in severe personal injury, death, or substantial property damage. 21

24 VENTING, INTAKE AIR AND CONDENSATE Figure 5.7: PI-80, PI-140, PI-199 Sidewall Venting with 3" Pipe (3" Vent Kit). Figure 5.9: PI-80, PI-140, PI-199 Sidewall Venting with 3" Pipe (Concentric Vent Kit). Figure 5.8: PI-T50 & PI-T80 Sidewall Venting with 2" Pipe (2" Vent Kit). Figure 5.10: PI-T50 & PI-T80 Sidewall Venting with 2" Pipe (Concentric Vent Kit). WARNING All exhaust vent pipes must be glued, properly supported, and pitched at a minimum of ¼" per foot back to the boiler. Failure to do so may result in severe personal injury, death, or substantial property damage. 22

25 VENTING, INTAKE AIR AND CONDENSATE Figure 5.11: PI-80, PI-140, PI-199 Vertical Venting with 3" Pipe. Figure 5.13: PI-80, PI-140, PI-199 Vertical Venting with 3" Pipe (Concentric Vent Kit). Figure 5.12: PI-T50 & PI-T80 Vertical Venting with 2" Pipe. Figure 5.14: PI-T50 & PI-T80 Vertical Venting with 2" Pipe (Concentric Vent Kit). 23

26 VENTING, INTAKE AIR AND CONDENSATE 7. To allow for proper drainage on large horizontal runs, a second line vent may be required and the required tubing size may increase to 1" I.D. 8. A condensate removal pump is required if the boiler is below the drain. H. BOILER REMOVAL FROM COMMON VENTING SYSTEM Figure 5.15: Sidewall Venting Below Grade F. EXHAUST TAPPING FOR VENT SAMPLE To obtain a combustion sample a hole must be drilled in the exhaust vent pipe just above the first elbow at the outlet of the boiler. a. Drill a 21/64" diameter hole in the vent pipe just above the first elbow. b. Tap the hole with a 1/8" NPT Pipe Tap. c. Take combustion samples through the tapped hole. d. Thread a standard 1/8" NPT Pipe Plug into the hole. CAUTION Make sure the condensate drain piping is below the level of the boiler to prevent condensate from filling up the combustion chamber and damaging the boiler. G. CONDENSATE DRAIN INSTALLATION 1. This boiler is a high efficiency unit that produces condensate. The condensate must be drained from the unit. 2. The hose under the unit is a condensate trap which prevents products of combustion from exiting the boiler through the condensate drain. 3. The black plastic 3/4" NPT fitting at the left side of the boiler is intended for connection to plastic piping. Do not block vent hole at the top of the fitting. 4. Slope the condensate drain piping down away from the unit into a floor drain or condensate pump. Check with local codes or ordinances to determine if the condensate must first be neutralized before running it to a drain. 5. Do not route the condensate piping through unheated spaces that may reach freezing temperatures. 6. Use only plastic piping for the condensate drain line. Metal pipes will corrode and cause blockage of the condensate drain. 1. At the time of removal of an existing boiler from a common venting system, follow these steps with each appliance that remains connected. These steps are to be completed while all components which remain 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. Verify there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition. c. Where practical, close all building doors and windows, including interior doors between the space in which the appliances that remain connected to the common venting system are located and other areas of the building. d. Turn on any clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhaust fans, at their maximum speed. (Do not operate a summer exhaust fan). e. Close fireplace dampers. f. Place the appliance being inspected in operation. Follow the lighting instructions and adjust the thermostat so that the appliance operates continuously. g. 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. h. 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 condition of use. i. 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. j. The common venting system should be resized to approach the minimum size determined by using the appropriate tables located in the National Fuel Gas Code, ANSI Z223.1/NFPA 54, "Sizing of Category I Venting." 24

27 ELECTRICAL 6. ELECTRICAL Install all electrical wiring in accordance with the National Electrical Code, ANSI/NFPA 70, and local requirements. NOTICE 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. A. WIRING 1. Refer to Figure 6.1 for connecting the power supply to the boiler. 2. Connect boiler to a 110 volt, single phase, 60 hertz electrical supply line with a fused disconnect switch. The boiler is fused for a load of 6.3 amperes. 3. The boiler electrical connection is located on the left side of the boiler in the junction box which houses the service switch. Figure 6.1: Wiring Connections to Boiler Junction Box 25

28 ELECTRICAL 4. Make sure to maintain correct polarity on the incoming power supply wires. If polarity is reversed, the boiler control will not sense the main burner flame. 5. Connect the ground wire from the incoming power supply to the green ground screw in the junction box. Also, the boiler ground should be connected to this screw. 6. Figure 6.1 shows connections to boiler circulator. a) The maximum current load for the circulator circuit is 4.0 amperes. b) For loads greater than 4.0 amps, isolate the circulator using a switching relay. c) An example of this wiring using a Honeywell R845A relay is shown in Figure The thermostat connections are shown in Figure 6.1 or 6.2. The setting for the thermostat anticipator is 0.56 amps. 8. The boiler circulator board is shown in Figure Factory wiring of all controls and safety devices are shown in Figure 6.4. B. SEQUENCE OF OPERATION 1. System Power-Up: a) When power is first applied to the boiler, the control will initially run through a self-diagnostic routine. The interface unit shows the system supply temperature. b) Next, it will power the combustion air fan for a 10 second purge cycle. c) Finally the combustion air shuts down and if there is no call for heat the control board enters a standby mode. 2. Heating Cycle: a) When the thermostat calls for heat (closing the contact between the two gray [TSTAT] wires) and the boiler control senses a supply temperature lower than the set point by more than the differential, the boiler initiates a heating cycle. b) The control then powers the combustion air fan at the speed prescribed for the particular boiler model and performs a 6 second pre-purge of the combustion chamber. c) 0.5 second before the pre-purge is complete power is applied to the spark igniter. Figure