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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
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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 J Efficient 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 As an ENERGY STAR " Partr _ er Peerless Healer Company has delermined • Honeywell Gas Valve and Venturi System that thi8 producl meel _ Ihe ENERGY STAR gwdelin es for energy efficiency • State oJ : the - Arf Control Board with LED Light Indicator • Spark Ignition Quiet Operation • As Quiet as Most Home Appliances • Honeywell Gas Valve Comprehensive Warranty • Burner Fan • One - Year Parts & Labor Warranty • High Limit Temperature Control • Lin _ ited . 12 - Year Warranty on the Heat Exchanger • 30 PSI Sol - ely RelieJ Valve • See Below _ lbr Warranty Description • Combination Temperature - Pressure Gauge Environmentally Friendly • 3 " PVC Screened Air Intake Terminal and • Low Emissions 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 Pitlllacl _ h slttilllt ! ss steel boiler calT _ es a fitU oHe yeQr warrcItllt . ] o11 tilt " t , ltlir ( " boils'r : Pt ! url _ ' ss lvJU pttrchase all _ lddiitollQ ! II ' ( IKI ' ( UII { t , , sl tllat ( ' over . s Iclbor . lbr r _ ' l ) lat'irlg tcatTanled parts . lioln the ! 31 " " day thro _ lgh th _ ' . llrst y ( ' _ u qlh'r iHsiclllalion , prolqctt'd lh ( ' it , ¢ ut ( mt ! l r % qi . strilliotl ccuH is l't'llutled . 111additiotL Pt ' ( , d ¢ ' ss Q [ lt ! ra o lilniled , pm rated . 12 yt ' ( u w ( ullmlg oil tilt ? ] l ( ' _ lt cxch ( mgt'r ol llu ' PifuItl { ' l ( ' I ) Oil ( ' E [ PIPt ' [ llld It , ll - year ( ' xtetld ( ' ( t Ii _ € . lrr ( ltlti { ' F . oil ] ) Qrt . ¢ _ a / id l [ ll ) ol ill ( l ! ] [ lINo t ) { ' ! ' } lH ' ( ' _ KI . v ; t ' [ I . Wllis SllllllIl ( lQ ] i . s ilol ( I spt ? c { ] ic u , ancmtg . Pk ! tzse corlslllt Pt'edess [ It * ¢ ller ( onlpany Jbr conq _ lea , It , al'l'glllig il { ! ( ) rnttlliolL Peerless Heater Company * 231 North Walnut Street • Boyertown , PA 19512 1021 * 610 - 307 - 2153 • www . peerless - heater . com FA9 PI RI _ I 0i 75M ) Ps , ' _ r / , d m LI _
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E . EXTENDED VENT LENGTHS WITH USING THIS MANUAL 1 4 " PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 A . INSTALLATION SEQUENCE . . . . . . . . . . . . . 1 E CONDENSATE . . . . . . . . . . . . . . . . . . . . . . 14 B . SPECIAL ATTENTION BOXES . . . . . . . . . . . 1 G . BOILER REMOVAL FROM COMMON VENTING SYSTEM . . . . . . . . . . . . . . . . . . . 14 1 . PREINSTALLATION A . ACCESSIBILITY CLEARANCES . . . . . . . . . . 2 6 . ELECTRICAL B . CLEARANCE FROM COMBUSTIBLE A . WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . 2 B . ZONED SYSTEM WIRING . . . . . . . . . . . . . 15 C . LIQUEFIED PETROLEUM ( LP ) GAS . . . . . . . 2 C . SEQUENCE OF OPERATION . . . . . . . . . . . 17 D . INSTALLATION SURVEY . . . . . . . . . . . . . . . 2 E . PLANNING THE LAYOUT . . . . . . . . . . . . . . . 2 A . COMPLETING THE INSTALLATION . . . . . . 18 B . LIGHTING / OPERATING INSTRUCTIONS . . 19 C . CONTROL DESCRIPTIONS . . . . . . . . . . . . . 20 D . CHECK - OUT PROCEDURE . . . . . . . . . . . . . 20 A . BOILER SUPPLY , RETURN AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . 4 B . CIRCULATOR SIZING . . . . . . . . . . . . . . . . . . 5 A . SHUT - DOWN . . . . . . . . . . . . . . . . . . . . . . 21 C . SAFETY RELIEF VALVE . . . . . . . . . . . . . . . . 5 B . BOILER FAULT CODES . . . . . . . . . . . . . . . . 22 D . PIPING FOR ZONED SYSTEMS . . . . . . . . . . 6 C . BOILER FAULT CONDITIONS . . . . . . . . . . . 22 E . EXPANSION TANK . . . . . . . . . . . . . . . . . . . . 7 E INDIRECT - FIRED WATER HEATER . . . . . . . . 7 G . FREEZE PROTECTION . . . . . . . . . . . . . . . . . 7 A . GENERAL ( WITH BOILER IN USE ) . . . . . . . 24 B . WEEKLY ( WITH BOILER IN USE ) . . . . . . . . 24 4 , GAS PIPING " . . . . . . . . C . ANNUALLY ( BEFORE START OF HEATING SEASON ) . . . . . . . . . . . . . . . . . . 24 A . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B . EXHAUST VENT / AIR INLET VENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 C . EXHAUST VENT INSTALLATION . . . . . . . . 10 D . AIR INLET VENT INSTALLATION . . . . . . . . 11
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Follow the installation instructions provided in this Indicates a condition or hazard which will cause manual in the order shown . The order of these instructions has been set in order to provide the installer severe personal injury , death or major property damage . with a logical sequence of steps that will minimize potential interferences and maximize safet F during boiler installation . Throughout this manual you will see special attention Indicates a condition or hazard which may cause severe personal injury , death or major property boxes intended to supplement the instructions and make damage . special notice of potential hazards . These categories mean , in the judgment of Peerless Heater Company : 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 .
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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 [ _ _ : _ [ Igl ! [ oll J = 1 ; I 1 : 1DI " J : ili ; ( o ] I : l I hV _ ll . _ lliC - r _ _ The following are the recommended minimum The following LP requirements from the Uniform accessibility clearances between boiler and adjacent wall Mechanical Code , section 304.6 , may be in effect in or other appliances . your geographic area : 1 . 16 " from right side or left side of boiler . " Liquefied petroleum gas burning appliances shall 2 . 15 " from top of boiler . not be installed in a pit , basement or similar location 3 . 4 " from front of boiler . where heavier - than - air gas might collect . Appliances so fueled shall not be installed in an above - grade 4 . Provide clearance for annual inspection of vent pipe under - floor space or basement unless such location and condensate connections . 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 For new and existing installations , a Water Installation with the following clearances : Survey is available from Peerless Heater Company . The I . 0 " from left side , right side , rear , top , bottom , front survey will provide information on how a hot water and combustible construction . boiler works with your specific system and will provide 2 . O " from vent pipe and combustible construction . an overview of hot water system operation in general . 3 . This boiler is design certified for use on combustible You can also use this survey to locate system problems floors . which will have to be corrected . To obtain copies of the Water Installation Survey , contact your Peerless representative . : 11 I'J IL _ _ I L _ Ib _ [ € ' l i / - " I = I I / ; V . ' o ] ll Do not install this boiler on carpeting . Boiler installation on carpeting is a fire hazard . 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 . 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 . Boiler is certified as an indoor appliance . Do not install boiler outdoors or locate where it will be exposed to freezing temperatures . 2
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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 . 3
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6 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 Size the supply and return to suit the system . Refer entering the boiler to Figure I . Refer also to the I - B = R Installation Guide No . 2000 and the Peerless Water Survey for 7 . When the boiler is connected to heating coils additional guidance during water piping installation . located in air handling units where they may be exposed to refrigerated air circulation , install flow 2 . The boiler incorporates a pressure switch in the control valves or other automatic means to prevent Outlet Manifold . This switch will not let the boiler gravity circulation of the boiler water during the operate without a minimum of 10 PSI on system . cooling cycle . 3 . Refer to Figure ] for suggested controls and 8 . If the boiler is installed above radiation level , provide components location in the near boiler piping . a low water cutoff device at the time of boiler installation . 4 . In older hydronic systems where sediment may exist , install a basket strainer to prevent particles from returning to boiler . 5 . 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 . ) All piping must be properly supported . See Figure 1 . SYSTEM SYSTEM F _ I _ _ VltCH _ I _ BACK rL _ , 4 pREVeNTER . _ . _ I _ ) LOW pRESSURE FIED ( 15 _ NQIqI _ L } CD _ N _ _ I _ EXPANSION T & _ _ IU _ R HO t _ I ) Alll VEtlT ( Mi rco bubbler Air ¢ OL _ Etimtnltol " Recmer _ led ) _ F _ j ( ( t _ _ _ ) _ RGE & BALANCE VALVE _ UP = PLY _ _ E : o _ JST E _ rl / KET • _ DRAIN VALVE _ TEMPERATURE I pRESSURE GAEE _ l _ ONt tITE _ $ U I _ PLIEOBYC _ ITRACTOR CONNECT TO _ OILER SUPPLY I _ IT CONNECT TO BOILER RETURN COLD NOTE : I _ I U _ R CONNECTIONS _ . L pe . _ = _ U = T E _ m _ lU . V _ ttW'a _ T [ It ARE I I / i " N _ T LEfT _ I _ VI { W Figure 1 : Supply and Return Near Boiler Piping 4
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: ! [ 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 - F 19 - RIC 18 - 17 - T 16 - IO 15 - N 14 - 13 - 12 - F 11 - E 10 - E T 9 8 7 6 H E 5 A 4 D 3 2 1 n , , n n n IIIIIIII 1 23 45 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 FLOW IN GALLONS PER MINUTE TACO P / N GRUNDFOS P / N PI - 80 007 ( 1 ) 15 - 42 F SPD - 2 P1 - 140 0010 ( 1 ) 26 - 64 F P1 - 199 0011 ( 1 ) 26 - 96 F 1 ) THE RECOMMENDED CIRCULATORS ARE BASED ON 1 GPM PER 10,000 BTU / HR W / 20 ° At Figure 2 : Circulator Sizing
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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 FROM SYSTEM TO SYSTEM ZONE ZONE ZONE ZONE ZONE ZONE 1 2 5 5 2 1 l ZONE BALANCING ( 3 - D _ z ETZ _ VALVES VALVES - , I I CONNECT TO CONNECT TO BOILER BOILER SUPPLY RETURN Figure 3 : Zone Piping with Zone Valves TO SYSTEM FROM SYSTEM ZONE ZONE ZONE ZONE ZONE ZONE 1 2 5 5 2 1 FLOW ZONE CONTROL / RCULATORS VALVES _ " CONNECT CONNECT TO TO BOILER BOILER SUPPLY RETURN Figure 4 : Zone Piping with Circulators 6
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: _ " mI = : t : : l : : P : , l : I _ ; , I : { oleeI : T _ J / [ O ] _ For new or existing systems that must be freeze - i . Consult the tank manufacturer's instructions for protected : 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 Use only inhibited propylene glycol solutions of up to and check valves for reducing supply water pressure 50 % by volume with water . Ethylene glycol is toxic and maintaining minimum system pressure . Check and can attack gaskets and seals used in hydronic the design features of the tank and provide valves as systems . necessary . Boiler system requires 12 PSI minimum . Refer back to Figure 1 for typical expansion tank piping . 1 . Glycol in hydronic applications is specially formulated for this purpose . It includes inhibitors which prevent the glycol from attacking metallic I _ I1 _ , I _ D ] I ; t : [ kl I _ = I ; t : 1D ] iTA _ I ' - / _ : I1 : ! 1 : I = Lr - ' _ = n1l : system components . Make certain that the system If the boiler is to be used in conjunction with an indirect - fluid is checked for the correct glycol concentration fired water heater , refer to Figure 4 for typical piping . and inhibitor level . Follow the instructions provided by the water heater 2 . manufacturer . Pipe the water heater as a separate zone . The antifreeze solution should be tested at least once a year and as recommended by the antifreeze manufacturer . 3 . 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 . 4 . For more information , consult the Peerless Water Installation Survey and the antifreeze manufacturer . FROM SUPPLY TO I I BOILER SYSTEM SUPPLY 7 [ 3 - RETURN FROM SYSTEM BALANCING INDIRECT - FIRED VALVE WATER HEATER f HOT DOMESTIC WATER SUPPLY TOILER BO SUPPLY I RETURN TO TANK BALANCING VALVE COLD DOMESTIC WATER SUPPLY Figure 5 : Typical Piping with Indirect - Fired Water Heater
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Size and install the gas supply piping properly in order to provide a supply of gas sufficient to meet I the maximum demand without exceeding a pressure drop greater than . 5 " W . C . between the meter and _ JACKET the boiler . SERVICE VALVE - - - J _ " - _ 2 . Determine the volume of gas to be provided to the boiler in cubic feet per hour . To obtain this value , O . J . UNION _ 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 SEDIMENT TRAP the gas supplier . As an alternative , use Table 1 or 2 on the next page to obtain the volume of gas to be FLOOR LINE _ provided to the boiler . 3 . Use the value obtained above as the basis for piping sizing . Size the gas piping in accordance with Table 3 Figure 6 : Gas Connection to Boiler 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 . 9 . Disconnect the boiler and its individual shut - off valve from the gas supply piping system during any 4 . Locate the drop pipe adjacent to , but not in front of pressure testing of that system at test pressure in the boiler . excess of i / 2 psig ( 3.5 kPa ) . Remove the mounting screws of the flanged gas connection on the gas 5 . Install a sediment trap . See Figure 6 . Locate a tee in valve , and disconnect flange from valve . the drop pipe at same elevation as the gas inlet connection to the boiler . Extend the drop pipe to a pipe cap . 6 . Install a ground joint union ahead of the gas control Do not subject the gas valve to more than 112 psi assembly to permit servicing of the control . Install a pressure . Doing so may damage the valve . service valve as shown in Figure 6 . 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 ) . Use a pipe joint sealing compound that is resistant to the action of liquefied petroleum gas . A non - resistant 10 . Check for proper supply pressures to boiler at compound may lose sealing ability in the presence of sediment trap location . Remove pipe cap and this gas , resulting in a gas leak and fire or explosion provide fittings as required . Minimum permissible potential . supply pressure ( Inches Water Column ) : Natural Gas 3.7 " LP Gas 3.7 " 7 . Check piping for leaks prior to placing the boiler in operation . Maximum permissible supply pressure to the boiler Use an approved gas detector , a non - corrosive leak ( Inches Water Column ) : detection fluid or other leak detection method . If Natural Gas 13.5 " leaks are found , turn off all gas flow and repair as LP Gas 13.5 " necessar _ 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 When checking for leaks , do not use matches , normal main burner ignition . 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 .
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Table 1 : Natural Gas Model InputFt / ( Cubic 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 . I Pipe 3 / ' 4 " * 1 # 1 ¼ " 1 ½ " Length Pipe I Pipe Pipe Pipe Feet 10 278 520 I 1,050 1,600 20 190 i 350 730 1,100 30 152 285 590 890 40 130 245 500 760 50 115 215 440 i 670 60 105 195 400 J 610 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 0.70 Multiplier . . . . . . . . 1.10 1.04 1.00 0.962 0.926 9
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2 Determine air inlet vent location r , _ 1 [ € - I = b , _ I = h _ ± _ . a Provide I foot clearance between bottom of vent Install vent system in accordance with these and ground level and normal snow lines . instructions and with Part 7 , V _ ' nting of Equipment , National Fuel Gas Code , ANSI Z223 . 1 / NFPA 54 , 3 Refer to venting diagrams ( Figures 7 through 12 ) for CAN / CGA B149 , or applicable provisions of the local typical sidewall and vertical vent / air inlet piping . building codes • a . Maintain distances between air inlet , vent . and exhaust vent as indicated in Figures 7 , 8 , and 11 . 2 . Boiler is a direct vent appliance . The boiler vent is Do not space the air inlet vent and exhaust vent listed as Category IV . greater than 6 feet apart • b . When sidewall venting multiple 3 " concentric vent rA | vivhl ; t ii , , kits , the vent kits must remain in a horizontal plane and placed no closer than 8 " center to This vent system will operate with a positive center • Also refer to instructions provided with pressure in the vent pipe , Do not connect vent vent kit . connectors serving appliances vented by natural draft into any portion of mechanical draft systems c . When sidewall venting multiple VI000 vent kits operating under positive pressure . refer to instructions provided with vent kit . I . For minimum and maximum vent pipe lengths refer to Table 4 , 2 . Use only 3 " PVC , CPVC , or ABS solid schedule 40 or 80 material for exhaust vent , 4 " PVC , CPVC , or Flue gases will condense as they exit the vent ABS solid schedule 40 or 80 pipe is also approved termination . This condensate can freeze on exterior under special conditions ; see Section E , Extended building surfaces which may cause discoloration of Vent Lengths with 4 " Pipe , in this section for details , these surfaces . FOAM CORE PIPING IS NOT APPROVED • 3 . Vent connection is located on rear of boiler and is i . Determine exhaust vent location , marked " exhaust outlet " . a . Vent is approved for 0 " clearance to combustible 4 . constr _ ction . Alljoints must be properly cleaned , primed , and cemented , Use only approved cement and primer for b . Provide 3 feet clearance above any forced air PVC , CPVC and ABS materials . Cement must inlet within 10 feet . conform to ASTM D - 2564 ( PVC ) or D2235 ( ABS ) . C . Provide 1 foot clearance below , I foot beside , or 5 . Remove all burrs and debris from joints and fittings . 1 foot above any door , window , or gravity air inlet into any building • 6 . Horizontal lengths must slope back to boiler connection not less than 1 / 4 " per foot to allow d , Provide I foot clearance between bottom of vent codensate to flow back to boiler • terminal and ground level and normal snow lines • 7 . A screened 3 " straight coupling is provided with e . Provide 4 feet horizontal clearance from , and in boiler for use as a vent termination • Optional vent no case above or below , unless a 4 foot terminations approved for use with the Pinnacle horizontal distance is maintained , from electric boiler are 3 " concentric KGAVT0601CVT Vent Kit meters , gas meters , regulators and relief and V1000 Vent Kit . Both are available from a equipment . Peerless Distributor . Do not locate vent terminal over public walkways 8 . Vent piping must be supported at 4 ft . intervals to where condensate could create a nuisance or prevent sagging . The boiler is not intended as a hazard . support means for vent . g . When adjacent to a public walkway , locate vent terminal at least 7 feet above grade . h . Do not locate directly under roof overhangs to prevent icicles from forming . i . Provide 3 foot clearance from inside corner of adjacent walls • I0
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ivl _ _ lih _ [ € ] i ] . f - ' ll ; t h _ llllitill _ ll Ih _ t - ' tP - 1 ! l ! - ' _ l / [ l ] _ Table 4 : Minimum / Maximum Vent Length I . For minimum and maximum pipe length rpfer to Total Combined * * Equivalent Length of 3 _ Table 4 . Exhaust Vent Plus 3 _ Air Inlet Vent Boiler 2 Use same material as noted in Section C for exhaust Model * Minimum Length * Maximum Length vent All 16 feet 85 feet 3 Air inlet pipe connections is located in the rear of boiler and is marked " air inlet " Connection is a slip * Lengths are the combined added lengths of the exhaust fit . No sealant is required . vent and air inlet vent . 4 . All joints and fittings are to be assembled as per instructions for vent pipe in Section C . * * Include equivalent length of fittings as follows : 3 " 90 degree elbow = 5 equivalent feet 5 A screened inlet air tee is provided with boiler , to be 3 " 45 degree elbow - 3 equivalent feet used as an outside termination . 3 " concenlric vent kit = 3 equivalent feet 3 " air inlet tee = 0 feet 6 . Provide same suport means as noted for exhaust 3 " VI000 vent kit = 0 feet vent in Section C . Refer to Venting Diagram Figures 7 through 12 for Sidewall and Vertical Venting arangements . 11
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DIAGRAMS FOR SIDEWALL VENTING T _ E { VERTICAL _ COUPLING TEE ( VErtiCAL ) EXTERIOR WALL FRONTeLEVAT _ N qMULTIPLeVENTS ) EXTERIOR WALL 1 " MIN . BOILER _ INTAKE BOILER 1 " MIN , EXHAUST _ 12 " _ . . . . STRAIGHT ST _ mHT OT & P CcuPUNG - - . - - 3 " EXHAUST _ INTAKE _ j = = = _ _ " TS _ EWW R _ " T _ OZ ViEW SlDEE _ EVAXl0N * * IMPORTANT NOTE : All vent pipes must be glued , properly * * IMPORTANT NOTE : All vent pipes must be glued , properly supported , and the exhaust must be pitched minimum of a supported , and the exhaust must be pitched minimum of a 1 / 4 " per foot back to the boiler ( to allow drainage of 1 / 4 " per foot back to the boiler ( to allow drainage of condensate ) . condensate ) . Figure 7 : 3 " Sidewall Vent with Tee ( Intake ) b Figure 8 : 3 _ Sidewall Vent with Tee ( Intake ) 8 " Coupling ( Exhaust ) Coupling ( Exhaust ) EXTERIOR WALL EXTERIOR WALL BOILER BOILER - - IMFOR _ ANT _ NTAKE LEG MUST WE FACI _ Up * * VI000 INT3A " KE VENT KIT OT & P OT & P coupu _ ST _ , aHr EXHA T ¢ _ pu , o US " _ r - - _ INTAKE eX _ XOUUSTTLEEXTHAUST RIGHT SIDE V _ EW RIGHT SIDE ViEW * * IMPORTANT NOTE : All vent pipes must be glued , properly * * IMPORTANT NOTE : All vent pipes must be glued , properly supported , and the exhaust must be pitched minimum of a supported , and the exhaust must be pitched minimum of a i / 4 " per foot back to the boiler ( to allow drainage of 1 / 4 " per foot back to the boiler ( to allow drainage of condensate ) . condensate ) . Figure 9 : 3 _ Sidewall Vent with VlOOO Kit Figure 10 : 3 _ Sidewall Vent with 3 _ Concentric Vent Kit ( KGAVT06OICVT ) 12
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DIAGRAMS FOR VERTICAL VENTING STRAIGHT COUPLING , , 24 " MIN . _ J MAINTAIN12 " , ( 18 " FORCANADA ) , _ MINIMUMCLEARANCEABOVE NORMALSNOWLINES . MAINTAIN 12 _ , ( 18 " FOR CANADA ) , _ I t I " " , DO NOT EXTEND MORE THAN 24 " ABOVE ROOF LINE . BO / LER BOILER m 3 , , 3 , , INTAKE fNTAKE STRA _ HT O T & P STRAIGHT OT & P COUpLiNG COUPUNG r J 3 " 3 " EXHAUST ex _ ust OUTU _ T _ T _ TL _ r EXHAUST RIGHT S _ DE _ IEW R _ HT SlOEVIEW * ' _ [ MPORTANT NOTE : All vent pipes must be glued , properly * * IMPORTANT NOTE : All vent pipes must be glued , properly supported , and the exhaust must be pitched minimum of a supported , and the exhaust must be pitched minimum of a 1 / 4 " per foot back to the boiler ( to allow drainage of 1 / 4 " per foot back to the boiler ( to allow drainage of condensate ) . condensate ) . Figure 1 1 : 3 " Roof Vent with Tee ( Intake ) 6 ' Figure 12 : 3 " " Roof Vent with 3 " Concentric Coupling ( Exhaust ) Vent Kit ( KGAVTO6OICVT ) 13
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: 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 At the time of removal of an existing boiler , follow these from boiler a minimum of 15 equivalent feet before steps with each appliance remaining connected to the transitioning to 4 " vent common venting system placed in operation , while the other appliances remaining connected to the common 2 . The maximum length shown in Table 4 can be venting system are not in operation : increased by using 4 " PVC , CPVC , or ABS solid a . Seal any unused openings in the common venting schedule 40 or 80 pipe . system • 3 . Use a 4 " x 3 " reducing coupling to transition to b . Visually inspect the venting system for proper size 4 " vent • and horizontal pitch and determine there is no blockage or restriction , leakage , corrosion and other 4 . The maximum combined * equivalent length of 4 " deficiencies which could cause an unsafe condition . air inlet vent plus 4 " exhaust vent must not exceed C . Insofar as is practical , close all building doors and 125 feet • windows and all doors belween the space in which * Equivalent Length of 4 " Piping : the appliances remaining connected to the common 4 " 90 degree elbow - 3 feet venting system are located and other spaces of the 4 " 45 degree elbow - I foot building • Turn on any clothes dryers and any 4 " air inlet tee = 0 feet appliance not connected to common venting system . Turn on any exhaust fans , such as range hoods and 5 . Use the same pipe sizes for air inlet vent and bathroom exhausts , so they will operate at maximum exhaust vent . speed . Do not operate a summer exhaust fan + Close fireplace dampers . 6 . To use the VI000 Vent Kit or 3 " Concentric Vent Kit transition 4 " pipe to 3 " pipe at exit point of building . d + Place in operation the appliance being inspected • Follow the lighting instructions . Adjust thermostat so appliance will operate continuously • I ; 4 [ _ o ) L _ I u _ ] : IL'l _ + , . " f ' . I * I _ l e . Test for spillage at the draft hood relief opening after I . This boiler is a high efficiency unit that produces 5 minutes of main burner operation • Use the flame condensate . of a match or candle , or smoke from a cigarette , cigar , or pipe . 2 . The rear of the boiler has a plastic hose for f . After it has been determined that each appliance connection of a 5 / 8 " size plastic tubing . remaining connected to the common venting system properly vents when tested as outlined above , return Slope condensate tubing down and away from boiler doors , windows , exhaust fans , fireplace dampers and into a drain pan or condensate neutralizing filter . any other gas - burning appliance to their previous Condensate has a low PH level ; check with local conditions of use . codes or ordinances before connecting to drain . g . Any improper operation of the common venting 4 + Do not expose condensate line to freezing system should be corrected so that the installation temprature . conforms with the National Fuel Gas Code , ANSI Z223 . 1 / NFPA 54 and / or CAN / CGA B149 . When 5 . Use only plastic tubing as a condensate drain line . resizing any portion of the common venting system , the common venting system should be resized to 6 . To allow for proper drainage on large horizontal approach minimum size as determined using the runs , a second line vent may be required and tubing appropriate tables located in the Chapter " Sizing of size may need to increase to i " . Category I Venting Systems " of the National Fuel Gas Code , ANSI Z223 . J / NFPA 54 . 7 . A condensate removal pump is required if boiler is below drain • 14
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InstaallllelectricwailringinaccordanwcieththeNational 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 _ [ = 1 , Refer to Figures 13 and 14 for power supply The Building System Ground must be inspected by a connection to boiler . Use # 14 AWG size wire . qualified Electrician . 2 . Connect boiler to a separate , permanently live electrical supply line with a fused switch . 120 volts , 8 . For connection to system circulator and room 60 HZ , 15 amp service . thermostat refer to Figures 13 and 14 . Thermostat anticipator setting is 0.56 amp . 3 . The boiler electrical connection is located on the left side of unit . 9 . The boiler control board and factory wiring are shown in Figure 17 . 4 . The boiler is supplied with a burner service switch . When refering to Figures 13 and 14 , wire the burner : m _ [ e ] L ' _ l : : le ] t * . . " b'd . , . ' ] lll : : l _ ' | JvIA _ il ; th , _ [ { service switch in the ( HOT ) line to boiler . See Figure 15 for typical wiring with zone valves . See 5 . Wires in the electrical J Box have been labeled at the Figure 16 for typical wiring with zone circulators . When factory . Do not remove labels . wiring a zoned heating system , follow all applicable codes , ordinances and regulations . 6 . 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 . Do not power zone valves directly from the boiler transformer . Doing so will greatly reduce the life of 7 . Connect building service ground ( green wire ) , and the transformer . Use a separate transformer sized to boiler ground ( green wire ) to green ground screw handle the total of all zone valve electrical loads . located in boiler J Box . GP . J : EN ( GROUNO ) WHITE DRY PUMP RELAy BLACK RED RED RED ( NOT USED ) NORMALLY OPEN NORMALLY OPEN THERHO _ I'ATN _ ERHOSTAT CONNECTIO CONNECTION G GRAY WH _ E _ _ O G _ ( NEUTRA • L ) BLACK ( HOT ) GREEN GREEN - - ( GROUNO ) • _ GROUND SCREW SCREW ELECTRICAL ELECTR [ CAL SWITCH JUNCTION BOX SW _ CH JUNCtiON BOX 120V 60 HZ 120V 60 HZ t j GROUND Figure 13 : Connection Wiring with Circulator Relay Figure 14 : Connection Wiring without Circulator Relay 15
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120V - 60HZ TO MAIN DISCONNECT SWITCH ( _ THERMOBTA ( _ V t © © 1T _ ANSFORMER I I I I I J I i 120 / 24V - - 60HZ j I I I I I ( HOT ) [ I r I J I I I iIr I I 40VA _ I I I I I JUNCllON I I I BOX I I I J I 4 I Y ] J Y J I TO THERMOSTAT I CONNECTION - I GRAY raRES I I LOCATED IN BOILER JUNCTION Y ] Y ! ZONE VALVE BOX _ " H - V8043E R I I I II J I R I I I R I II LOW VOLTAGE J R - - LINE VOLTAGE NOT £ _ ALL WlRING MUST COMPLY WITH APPLICABLE CODES , ORDINANCES , AND REGULATIONS Figure 15 : Zone Wiring with Zone Valves 120V - 60HZ TO MAIN THERMOSTAT , 2 € V DISCONNECT SWITCH { _ / - SWITCHING RELAY / H - R845A OR / W / R - 829A - 845 TO THERMOSTAT CONNECTION GRAY BOILER JUNCTION . . . . . BOX _ " / _ ' _ CULATOR LOW VOLTAGE LINE VOLTAGE ZONE # 1 ZONE # 2 ZONE # 3 NOTE : ALL WIRING MUST COMPLY WITH APPLICABLE CODES , ORDINANCES , AND REGULATIONS Figure 16 : Zone Wiring with Circulators 16
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= ilit : : [ _ i + _ [ o , 7 ' iTili THERM [ ] DISC TEMP . SWITC _ 210 DEGREE WATER PRESSURE SWITCH ECO WATER / HIGH LIMIT INLET TEMP PROBE 120 VAC 24 VAC t20 VAC CDNBUSTION BLOWER LINE _ II _ T ( _ 1 _ 0 VAC GAS VALVE SPARK { ] LIT V FLAME ROD PRESSURE SWITCH PROVE AIR _ CIRC . pUMP Figure 17 : Boiler Control Board Factory Wiring 5 . . [ . " ] : loll J : 1L _ [ I . ] = [ o ] : 11o ] ' ] : 1t # , . 31 / [ m ] i When water temperature reaches the temperature dial set point plus i0 ° F ( or if the thermostat call - for - 1 , heat is satisfied ) , the gas valve is closed and the When power is first applied to the control , the control enters a 4 second post - purge ( blower on max control will initially run through a self - diagnostic speed ) . NOTE : IF THE THERMOSTAT IS STILL routine , and then go into its operating mode . The CALLING FOR HEAT , THE CIRCULATOR PUMP green LED light will pulse in a dim to bright WILL CONTINUE TO RUN UNTIL THE sequence indicating a normal operating mode . If THERMOSTAT CALL FOR HEAT IS SATISFIED . there is no call for heat , the control will go into the idle state . 6 . When post - purge is complete , the control enters the 2 . If the thermostat is calling for heat , the control will idle state while continuing to monitor temperature and the state of other system devices . If a call - for - apply power to the circulator pump . If the control heat is received , the control will automatically return determines the appliance water temperature is below to step 2 and repeat the entire operating cycle . the temperature dial set point value less the switching differential , the control will initiate a During the idle state and heat state , if the control heating cycle . detects an improper operating condition for external 3 . devices such as the high - limit switch , the green LED The control then performs selected system diagnostic on the control will flash an error code sequence . checks . If all checks are successfully passed , a 5 second pre - purge cycle is initiated ( blower on max 7 . During the call for heat the boiler control board will speed ) . continually monitor the return and supply water 4 . temps in relation to the temperature dial set point When the pre - purge period is complete , power is applied to the spark ignitor for a 6 second trial for and the differential switch setting . The control board ignition . If a flame is not verified during the trial - for - will use this input to modulate the blower speed . The ignition , the gas valve is immediately closed , and the blower coupled with the gas valve venturi system will control will return to step 2 . If after three trials a modulate the premix air / gas input to the burner . The flame is not verified , the control will go into lockout gas valve and venturi system provide the optimum mode . If a flame is confirmed , the control enters the gas / air ratio through the full burner modulation . heating mode . 17
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8 . Adjust set point temperature and differential settings l , _ ll [ iI * ] lviI : l I : : l / IL ' [ _ ci i l I = IIb . ' ff . - I'l ' _ I ! i ! ' _ l / 1 * ] i as follows : 1 . Confirm that all water , gas and electricity are a . Temperature Adjustment : A potentiometer turned off . located on the control board is used to adjust the set point temperature on the boiler appliance . 2 . Verify that water piping , venting , gas piping and This can be set between 70 and 210 degrees . electrical wiring and components are installed b . properly . Refer back to previous sections of these Temperature Differential Adjustment : A " DIP " switch is located on the control board . instructions as well as equipment manufacturer's instructions as necessary . Depending upon the configuration of the " DIP " switch , the differential selection is 6 , 12 , 20 , or 3 . Fill the boiler and system with water , making certain 30 . See the figure below for further detail . to vent all air from all points in the system . To check NOTE : the differential adjustment is the value below water level in the system , open and close each vent the set point , when the burner will fire . ( Example : in the system . Water should exit from each vent 190 degrees set point , 30 degrees differential , burner when it is opened . will not fire until return water drops below 160 4 . The pressure reducing valve on the fill line will degrees and will modulate the flame until 200 typically allow the system to be filled and pressurized degrees is reached , then post purge and idle state to 12 PSI . Consult the valve and expansion tank will be achieved . If at any point " IT is satisfied , the manufacturer for more specific information . cycle will be interrupted by post purge and idle state . 5 . Check joints and fittings throughout the system for leaks . If leaks are found , drain the system and repair 9 . Turn on electricity and gas to boiler . Check to see if as required . LED light is illuminated on control board . 6 . Connect a manometer at the sediment trap location . 10 . Light the boiler by following the Lighting / Operating Refer to Figure 6 . Remove pipe cap and provide Instructions in this section . The initial ignition may fittings as required . require several tries as the piping is purged of air . 7 . Confirm that the gas supply pressure to the boiler is 11 . Use the sequence of operation description and above the minimum and below the maximum values Figure 17 in Section 6 ( Electrical ) to follow light - off for the gas being used . See the end of Section 4 for and shutdown sequences and to assist in diagnosing these values . If a supply pressure check is required problems . If the boiler does not function properly , isolate the boiler and gas valve before performing consult Section 8 , Troubleshooting . the pressure check . If the supply pressure is too high or too low , contact the gas supplier . CK CK CK CK 1 2 I 2 1 2 1 2 Differential Dip Switch Adjustments 18
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: H I [ of : / i h _ [ € _ Lo ] : , 1 : 1 : f , _ ' t / IL _ [ € ' l IL _ I , . i Ii : 1ILO , ] il [ 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 If you cannot reach your gas supplier , call the with an ignition device which automatically lights the fire department . burner . Do not try to light the burner by hand , C , Use only your hand to turn the gas control knob . Never B . BEFORE OPERATING smell all around the appliance use tools . If the handle will not turn by hand , don't try area for gas . Be sure to smell next to the floor to repair it , call a qualified service technician . Force or because some gas is heavier than air and will settle attempted repair may result in a fire or explosion . on the floor . D . Do not use this appliance if any part has been under WHAT TO DO IF YOU SMELL GAS water . Immediately call a qualified service technician to inspect the appliance and to replace any part of the • Do not try to light any appliance . control system and any gas control which has been Do not touch any electric switch ; do not use any under water , phone in your building . • Immediately call your gas supplier from a neighbor's phone . Follow the gas suppliers ' instructions . OPERATING INSTRUCTIONS 1 . STOP ! Read the safety information above . 5 . Remove front cover . 2 . Set the thermostat to lowest setting . 6 . Turn gas shutoff valve clockwise to " off " . Handle will be vertical , do not force . 3 . Turn off all electric power to the appliance . 7 . Wait five ( 5 ) minutes to clear out any gas . If you then 4 . This appliance is equipped with an ignition device smell gas , STOP ! Follow " B " in the safety information which automatically lights the burner . Do not try to light above on this label . If you don't smell gas , go to next the burner by hand . step . Combination 8 . Turn gas shutoff valve counterclockwise to " on " . Handle will be horizontal Gas Control / 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 Gas Shutoff " To Turn Off Gas To Appliance " and call your service Valve technician or gas suppllier . TO TURN OFF GAS TO APPLIANCE 1 . Set the thermostat to lowest setting . 4 . Turn gas shutoff valve clockwise to " off " . Handle will be vertical . Do not force . 2 . Turn off all electric power to the appliance if service is to be performed . 5 . Install front cover . 3 . Remove front cover . 19
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b . Set thermostat or controller above room [ a , , ] il [ _ o ] L _ IIii ; { o ] niIl . ] : ; ( . . " _ o ; . t ] I : , inId [ o ] L _ _ temperature to call for heat . See Figure 19 for Location of these devices . c Ignition sequence should try 3 times before going 1 . SUPPLY WATER TEMPERATURE THERMISTOR into lockout mode . Senses supply water temperature from boiler Shuts down main burner gas upon reaching i0 degrees d Turn gas supply on . over control board set point . As supply temperature e . Reset by turning 120V power supply off then on . falls , boiler ignition will restart . f . Observe boiler operation through one complete 2 . RETURN WATER TEMPERATURE THERMISTOR - cycle . Senses return water temperature from system . As thermistor senses a drop in return water temperature 3 . Low Water Cut - Off ( if used ) - Consult the below the control board set point minus the manufacturer's instructions for the low water cut - off differential set point , boiler ignition sequence begins . operational check procedure . 3 . WATER HIGH LIMIT SWITCH - Senses supply 4 , Check the system to make sure there are no leaks or water temperature and shuts down main burner gas overfilling problems which might cause excessive upon reaching limit set point . Boiler control will go make - up water to be added . Make - up water causes into lockout mode upon activation of high limit . liming in the boiler . 4 . WATER PRESSURE SWITCH - Senses boiler water 5 . Check the expansion tank and automatic fill valve ( if system pressure and shuts down main burner gas used ) to confirm that they are operating correctly . If when pressure falls to 8 PSI . Boiler contiol will go either of these components causes high pressure in into lockout mode upon activation of water pressure the system , the boiler relief valve will weep or open , switch . allowing fresh water to enter the system . 5 . AIR PRESSURE SWITCH - Senses burner manifold 6 . Check the general condition of the system including pressure and prevents ignition sequence activation if piping support , joints , etc . Check cleanliness of the blower is not operating . radiators , baseboard units and ! or convectors . Clean them to the extent possible . If radiators do not heat 6 , THERMODISC TEMPERATURE SWITCH - Senses evenly , vent any remaining air from them . combustion chamber outside surface temperature and shuts down main burner gas upon reaching set 7 . Review operation with end - user . point of 210 ° E Boiler control will go into lockout mode upon reaching set point . This is a manually 8 . Complete the Warranty Card and submit it to resetable switch . Peerless Heater Company . Ira1 [ _ : l : [ _ [ _ ellli I : J ; { elq = llllJ : ! 9 . Hang the Installation , Operation and Maintenance Manual in an accessible position near the boilen 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 . 2O
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L'W _ . _ : ] lilt _ t eIolY , _ J _ In the event of a shut down caused by thermodisc When servicing or replacing items that communicate temperature switch , water pressure switch or high limit with the boiler water , be certain that : switch effecting a shut - down of the main burner and • There is no pressure on the boiler . ignition control lockout : • The boiler is not hot . a . Refer to section " C . Boiler Fault Conditions , " item 1 . , • The power is off . " Limit String Open , " in this section and follow the When servicing all other boiler controls , be certain procedure to restart the boiler . that : b . If control goes into ignition lockout mode again refer • The gas is off . to the Lighting / Operating Instructions , Section 7 , to properly turn off the gas to the boiler . • The electricity is off . c . Turn off electric power to the boiler . d . Call a qualified heating service organization or local gas company and have the cause of the shut - down investigated and corrected . Do not use this appliance if any part has been under water . Improper or dangerous operation may result . e . Refer to Lighting / Operating Instructions , Section 7 , Immediately call a qualified service technician to to re - start boiler . 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 . 21
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d . Check that the flame rod is connected , and also : 11 I : [ o ] lll ' : l : llgL " _ llRI [ e , [ o ] e ] : l . ; that the flame rod is clean . When a fault condition occurs , the control board goes to a LOCKOUT mode . When in the LOCKOUT mode , the e . If items " a " through " d " are correct replace the Low - Voltage Cable assembly . 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 ) . 4 . Open Return Water Temperature Thermistor - 5 PULSES To reset the Control from the LOCKOUT state , remove and re - apply 120VAC line power to the Control board . The control will sense an open temperature thermistor If an open thermistor is sensed , the # of LED Pulses conttol will go into the lockout state . D _ scfintion of Fault a . Verify that the return thermistor wiring is properly Limit String Open . . . . . . . . . . . . . . . . . . . . 2 connected to the control . Flame Stuck ON . . . . . . . . . . . . . . . . . . . . . . 3 Ignition Fault ( No Flame ) . . . . . . . . . . . . . . . . 4 b . If the temperature thermistor is in anywait Return Water Temperature Thermistor Fault . . 5 environment of less then 0 ° F then for Supply Water Temperature Thermistor Fault . . 6 ambient temperature to rise , or apply heat to Air Pressure Switch Fault , Stuck Closed . . . . . 7 the unit . Air Pressure Switch Fault , Stuck Open . . . . . . 8 Redundant Gas Valve Relay Stuck ON . . . . . . 9 c . If the temperature thermistor is in an Gas Valve Relay Stuck ON . . . . . . . . . . . . . . 9 environment of more then 230 ° F then wait for Redundant Gas Valve Relay Stuck OFF . . . . 10 the temperature to drop below 200 ° F Gas Valve Relay Stuck OFF . . . . . . . . . . . . . 10 Gas Valve wire disconnected . . . . . . . . . . . . 11 5 . Open Supply Water Temperature Thermistor - ROM Checksum Failure . . . . . . . . . . . . . . . . 12 6 PULSES RAM Test Failure . . . . . . . . . . . . . . . . . . . . . 13 The control will sense an open temperature 60 Hz Failure . . . . . . . . . . . . . . . . . . . . . . . 14 thermistor . If an open thermistor is sensed , the control will go into the lockout state . * , e , ] llI : { e ] lll : : l - ' t _ ' _ IlIII | O , [ O ] L ' _ ID ] II [ O ] L'q _ a . Verify that the return thermistor wiring is properly connected to the control board . 1 . LIMIT STRING OPEN - 2 PULSES ( Thermodisc Temp Switch , Water Pressure Switch , b . If the temperature thermistor is in an High Limit Switch ) environment of less then 0 ° F then wait for If the limit string opens , the control will immediately ambient temperature to rise , or apply heat to remove power to the gas valve , complete a post the unit . purge cycle , and enter lockout mode . To restart the control , make sure that there is a least 10 PSI in the c . If the temperature thermistor is in an water system . Allow boiler water temperature to cool environment of more then 230 ° F then wait for below control setpoint less the differential , press reset the temperature to drop below 200 ° F buflon of thermodisc temperature switch , then 6 . Air Pressure Switch Fault Stuck Closed - 7 PULSES remove and re - apply 120 VAC line power . 2 . Flame Stuck ON - 3 PULSES If the control senses the blower pressure switch is closed when it is expected to be open , the control The current state of the flame may be determined by will wait approximately 90 seconds for the fault looking through the view port on the combustion condition to clear . If after approximately 90 seconds chamber . If the flame is stuck ON / OFF then the the control still senses the blower pressure switch is flame rod insulator or the connector CN6 may not closed , the control will go into the lockout state . be clean , or unplugged . a . Verify that the blower motor is operational and 3 . Ignition Failure ( No Flame ) - 4 PULSES that the 120 VAC power cable is connected to If an ignition failure occurs during the trial - for - the blower . ignition , the control will return to the pre - purge state and attempt another ignition trial . If after three trials b . Check that the wires are connected to the blower an ignition failure is still occurring , the control will go air pressure switch and that the air pressure into the lockout mode . switch is functional . This may require turning the a . Check that the gas valve is operating correctly screw in the center of the air pressure switch I turn clockwise to correct ( initial set - up only ) . and the electrical plug is fully connected into the valve . c . After any air pressure switch adjustment , you must cycle the appliance several times to insure b . Verify that the gas supply is turned on . proper operation . c . Check for proper connection to the 120VAC line source . 22
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10 . Gas Valve NOT Connected - 11 PULSES 7 . Air Pressure Switch Fault Stuck Open 8 PULSES If the controller detects that the gas valve is not If the control senses the blower pressure switch is not closed during the pre - purge cycle , the control will connected it will go into the lockout state . attempt two additional pre - purge trials . If after three Check the connection to the gas valve . pre - purge trials the control is still sensing the blower 11 . ROM Checksum Failure 12 PULSES pressure switch is not closing , the control will enter the If the controller detects that the ROM check has failed lockout state . then it will go into a lockout state . a . Check that the blower motor is off and verify that a . Turn the 120V power OFF then ON . the blower air pressure switch is functional . This may require turning the screw in the center of the b . If the problem persists , replace the control board air pressure switch in 1 / 4 turn counter clockwise to correct ( initial set - up only ) . 12 . RAM Test Failure 13 PULSES b . After any air pressure switch adjustment , you must If the controller detects that the RAM test failed it will cycle the appliance several times to insure proper go into a lockout state . operation . a . Turn the 120V power OFF then ON . 8 . Redundant Gas Valve / Gas Valve Relay Stuck ON 9 b . If the problem persists , replace the control board , PULSES 13.60 Hz Failure 14 PULSES If the controller senses the redundant gas valve or the gas valve relay is stuck ON it will go into the lockout If the generator , inverter , or other power source does state . not provide 60Hz , then the power source must be replaced . a . Check for short - circuit ( s ) from the 24VAC and no continuity between CN4 pins 3 and 4 . a . If the power source used supplies 60Hz , turn the 120V power OFF then ON . b . If the problem persists , replace the control board . 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 . 23
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I _ T ' _ l _ l _ o _ l d . IF : llc - 1 = h , ' _ 1 : ; 1 . r _ * 1 ! ilVl _ l I / : nn : { o ] III = 1 ; | I L _ III _ - - ] _ Release the try lever and allow the valve to close . If the valve leaks , operate the lever two or three General boiler observation can be performed by the times to clear the valve seat of foreign matter . It owner . If any potential problems are found , a qualified may take some time to determine if the valve has installer or service technician / agency must be notified . shut completely . I . Remove any combustible materials , gasoline and e . If the valve continues to leak , it must be replaced other flammable liquids and substances that generate before the boiler is returned to operation . flammable vapors from the area where the boiler is contained . f . Check that operating pressure and temperature have returned to normal . 2 . Observe general boiler conditions ( unusual noises , vibrations , etc . ) g . Check again to confirm that valve has closed completely and is not leaking , 3 . Observe operating temperature and pressure on the combination gauge located in the supply piping on 3 . Test low - water cut - off ( if used ) as described by the the left side of the boiler . Boiler pressure should manufacturer . never be higher than 5 psi below the rating shown on the safety relief valve ( 25 psig maximum for a 30 4 . Test limit as described in Section 7 , Part D , " Check - psig rating ) . Boiler temperature should never be Out Procedure " . higher than 240 ° P 4 . 5 Test function of ignition system safety shut - off Check for water leaks in boiler and system piping . features as described in Section 7 , Part D , " Check - 5 . Out Procedure " . 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 . When servicing or replacing components , be : ! 1 ItAtl : l : l [ 11 _ ' m LIiIlll ; l ; { o ] ll : llh ; _ llllj . " ] : 1 absolutely certain that the following conditions are met : 1 . Flush float - type low - water cut - off { if used ) to remove • Water , gas and electricity are off . sediment from the float bowl as stated in the • The boiler is at room temperature . manufacturer's instructions . • 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 . 7 . Inspect burner for deterioration . Replace if necessary . The following annual inspection must be performed 8 . With boiler in operation cheek that condensate is by a qualified service technician . dripping from drain hose . Cheek for any restriction in condensate drain line . 1 . Check boiler room floor drains for proper functioning . 9 . Inspect exhaust vent and air inlet vents for proper support and joint integrity . Repair as necessary . Refer 2 , Check function of the safety relief valve by to Section 5 , VENTING . performing the following test : a . Check valve piping to determine that it is 10 . Inspect exhaust vent and air inlet vent terminations for obstructions . 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 Leaks in the vent system will cause products of seconds or until clean water is discharged , combustion to enter structure ( vent system operates under positive pressure ) , 24
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I _ o ] ] ll _ l = ] l _ , _ l : : : l _ [ - , , . ' ] [ = ] _ _ ! [ [ _ = ' _ _ ] PI - 80 - - 1712 aPP _ OX - - - - _ _ 3e _ ! 0 _ S _ UPPL _ o • e _ ox _ - - _ 0 x 4 _ APe _ OX - - eXMAUST DUTL _ r BOILER gDILER RCE _ tU _ SU _ PPt _ L 2132 APP ' 0 × _ II ' ° ' _ p _ l w _ v - - 1 _ TS - - L _ FT SIDe vIEv 35 _ PeeOx - - _ q _ XH _ USt OUtLet _ LIEr v _ v _ I . . . . . . ] - i _ c _ vi [ v PI - 140 / PI - 199 32 _ 75 _ P _ X G _ S St _ PL _ ' _ S SU _ OL - - _ SVltC _ eoo - - 2t3 f _ kl [ rLV _ VA eLBI AP _ OX _ XH _ US _ _ UTLET , 3 ! 8 i , _ Pp _ x LErr S _ D [ V _ V [ Nk £ T _ _ x _ a _ JST _ UTLET _ EL _ Er V _ V £ / con _ nsat [ _ H0 _ 375 I Figure 18 : Boiler Dimensions 25
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Boiler Supply / Return Gas Air Inlet Vent ! Model Connection Connection Exhaust Size All 1 1 / 4 " NPT 3 t , 3 / 4 " NPT 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 MBH g 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 26
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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 ) 27
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i ; l : l ' . / flhl _ I Table 6 : Repair Parts I Blower 91423 91424 91425 2 Transformer 91413 91413 91413 3 Control Board 91404 91405 91406 4 Gas Valve 91426 91426 91426 5 J / Box ! 91422 6 Supply / Return Water Temperature Thermistor 91422 _ 91422 7 Water Pressure Switch 91427 91427 i 91427 8 Air Pressure Switch 91428 91428 91428 I i 91430 91430 9 { Relief Valve 91430 l 91410 ' 9i410 ] 10 High Limit Water Temperature Switch 91410 I 1 ! Thermodisc Temperature Switch 91429 91429 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 28
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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 © 2003 Peerless Heater Company PI8008 R4 ( 1 / 03 - 2M ) Printed in U . S . A .
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