PEERLESS Pinnacle PI-199 Instruction manual

Pinnacle T"
Gas Boilers
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
-Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
- WHATTO DO IFYOU SMELL GAS
•Do not try to light any appliance.
• Do not touch any electrical switch;
do not use any phone in your building.
• Immediately call your gas supplier from
a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier,
call the fire department.
- Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
Installation,
Operation
Maintenance
Manual
p=E_Lr=-ss"
PINNACLE"
mOH EFFICIENCY STAINLSSS _TE_L BOMLER

3 Sizes 27 to 199 MBH Input 92% AFUE
Three Sizes Available
•PI80 27to80MBHInputModulation
•PI 140 -46 to 140 MBH Input Modulation
•PI 199 -66 to 199 MBH Input Modulation
Fully Modulating Burner for Maximum Efficiency
• 92% AFUE Energy Star JEfficient
Natural or LP Gas
Direct Vent
• Sealed Combustion
• No Chimney Required -Horizontal or Vertical Venting
• Uses Standard Schedule 40 PVC Plastic Pipe for Venting
•ConceTitric PVC or V1000 Aluminum Vent Kits Available
Compact, Light-Weight Design
• Installation Flexibility
•Z_'ro Cl_!aran_? to Combustibles
• Lightweight Des_n (75 to 111 lbs.) & Small Footprint
Stainless Steel Construction
•High Grad<" Stainless StPeI Burner and Heat Exchanger
Safe Operation
• Honeywell Gas Valve and Venturi System
• State oJ:the-Arf Control Board with LED Light Indicator
•Spark Ignition
Quiet Operation
• As Quiet as Most Home Appliances
Comprehensive Warranty
• One-Year Parts & Labor Warranty
•Lin_ited. 12-Year Warranty on the Heat Exchanger
• See Below_lbr Warranty Description
Environmentally Friendly
•Low Emissions
As an ENERGY STAR" Partr_er Peerless Healer Company has delermined
that thi8 producl meel_ Ihe ENERGY STAR gwdelin es for energy efficiency
•Honeywell Gas Valve
• Burner Fan
•High Limit Temperature Control
• 30 PSI Sol-ely RelieJ Valve
• Combination Temperature-Pressure Gauge
• 3" PVC Screened Air Intake Terminal and
Exhatlsl Terminal
• 3" V1000 Aluminunl Outside Venl Termination Kit
•3" Concemcic PVC Venl Terminalion Kil
• Ad.]uslable Steel Boilt, r Slartd
Pt_erless l h,cltt'i Company is pleased to o[]-er one ql ttle most comprehensive w_rrrulty piogranls in t!2e industry. T/t(, P{,t,d(,ss
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
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Peerless Heater Company *231 North Walnut Street •Boyertown, PA 19512 1021 *610-307-2153 • www.peerless-heater.com
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1.
USING THIS MANUAL 1
A. INSTALLATION SEQUENCE ............. 1
B. SPECIAL ATTENTION BOXES ........... 1
PREINSTALLATION
A. ACCESSIBILITY CLEARANCES .......... 2
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION ..................... 2
C. LIQUEFIED PETROLEUM (LP) GAS ....... 2
D. INSTALLATION SURVEY ............... 2
E. PLANNING THE LAYOUT ............... 2
A. BOILER SUPPLY, RETURN AND
CONTROLS ......................... 4
B. CIRCULATOR SIZING .................. 5
C. SAFETY RELIEF VALVE ................ 5
D. PIPING FOR ZONED SYSTEMS .......... 6
E. EXPANSION TANK .................... 7
E INDIRECT-FIRED WATER HEATER ........ 7
G. FREEZE PROTECTION ................. 7
4, GAS PIPING " ........
A. GENERAL .......................... 10
B. EXHAUST VENT/AIR INLET VENT
LOCATION ......................... 10
C. EXHAUST VENT INSTALLATION ........ 10
D. AIR INLET VENT INSTALLATION ........ 11
E. EXTENDED VENT LENGTHS WITH
4" PIPE ............................ 14
E CONDENSATE ...................... 14
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM ................... 14
6. ELECTRICAL
A. WIRING ........................... 15
B. ZONED SYSTEM WIRING ............. 15
C. SEQUENCE OF OPERATION ........... 17
A. COMPLETING THE INSTALLATION ...... 18
B. LIGHTING/OPERATING INSTRUCTIONS . .19
C. CONTROL DESCRIPTIONS ............. 20
D. CHECK-OUT PROCEDURE ............. 20
A. SHUT-DOWN ...................... 21
B. BOILER FAULT CODES ................ 22
C. BOILER FAULT CONDITIONS ........... 22
A. GENERAL (WITH BOILER IN USE) ....... 24
B. WEEKLY (WITH BOILER IN USE) ........ 24
C. ANNUALLY (BEFORE START OF
HEATING SEASON) .................. 24

Follow the installation instructions provided in this
manual in the order shown. The order of these
instructions has been set in order to provide the installer
with a logical sequence of steps that will minimize
potential interferences and maximize safet F during
boiler installation.
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
Throughout this manual you will see special attention
boxes intended to supplement the instructions and make
special notice of potential hazards. These categories
mean, in the judgment of Peerless Heater Company:
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.

Read carefully, study these instructions before beginnin 9 work
This boiler must be installed by a qualified contractor.
The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly.
Boiler can be installed at high altitude with no burner adjustments. LP equipped boilers must not be installed at
elevations above 7,000 feet.
The equipment must be installed in accordance with those installation requirements of the authority having
jurisdiction or, in the absence of such requirements, to the current edition of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CGA B149 Installation Codes.
Where required by the authority having jurisdiction, the installation must conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
I_,! If_,T0(H:(.,'_"]I:] I! / li'd [H I d_'l; f'_1L_[_ :_
The following are the recommended minimum
accessibility clearances between boiler and adjacent wall
or other appliances.
1. 16" from right side or left side of boiler.
2. 15" from top of boiler.
3. 4" from front of boiler.
4. Provide clearance for annual inspection of vent pipe
and condensate connections.
[Igl ! [oll J=1;I 1:1DI "J:ili ;(o] I :l I hV_ll._lliC-r__
The following LP requirements from the Uniform
Mechanical Code, section 304.6, may be in effect in
your geographic area:
"Liquefied petroleum gas burning appliances shall
not be installed in a pit, basement or similar location
where heavier-than-air gas might collect. Appliances
so fueled shall not be installed in an above-grade
under-floor space or basement unless such location
is provided with an approved means for removal of
unburned gas."
Jill Ih_l.'lllf:lll/:_l/[O]L_l F.'lll;iVJ:li'
The design of this boiler is certified for closet installation
with the following clearances:
I. 0" from left side, right side, rear, top, bottom, front
and combustible construction.
2. O" from vent pipe and combustible construction.
3. This boiler is design certified for use on combustible
floors.
:11 I'J IL_ _IL_Ib_[€'l i /-"I= I I/;V.'o]ll
Do not install this boiler on carpeting. Boiler
installation on carpeting is a fire hazard.
Liquefied Petroleum (LP) is heavier than air and may
collect or "pool" in a low area in the event of a leak
from defective equipment. This gas may then ignite,
resulting in a fire or explosion.
For new and existing installations, a Water Installation
Survey is available from Peerless Heater Company. The
survey will provide information on how a hot water
boiler works with your specific system and will provide
an overview of hot water system operation in general.
You can also use this survey to locate system problems
which will have to be corrected. To obtain copies of the
Water Installation Survey, contact your Peerless
representative.
Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring. Review
limitations on vent pipe, vent terminal, and air inlet pipe
locations in Section 5, Venting.
Boiler is certified as an indoor appliance. Do not
install boiler outdoors or locate where it will be
exposed to freezing temperatures.
2

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

2.
3.
4.
5.
Size the supply and return to suit the system. Refer
to Figure I. Refer also to the I-B=R Installation
Guide No. 2000 and the Peerless Water Survey for
additional guidance during water piping installation.
The boiler incorporates a pressure switch in the
Outlet Manifold. This switch will not let the boiler
operate without a minimum of 10 PSI on system.
Refer to Figure ] for suggested controls and
components location in the near boiler piping.
In older hydronic systems where sediment may exist,
install a basket strainer to prevent particles from
returning to boiler.
Install this boiler so that the gas ignition system
components are protected from water {dripping,
spraying, etc.) during appliance operation and
service {circulator replacement, condensate trap,
control replacements, etc.)
6
7.
8.
If this boiler and distribution system is used in
conjunction with a refrigeration system, i_Jipe the
chilled medium in parallel with the boiler and install
the proper valve to prevent the chilled medium from
entering the boiler
When the boiler is connected to heating coils
located in air handling units where they may be
exposed to refrigerated air circulation, install flow
control valves or other automatic means to prevent
gravity circulation of the boiler water during the
cooling cycle.
If the boiler is installed above radiation level, provide
a low water cutoff device at the time of boiler
installation.
All piping must be properly supported. See Figure 1.
SYSTEM
_ (_F_jt_(_) _RGE & BALANCE VALVE _UP=PLY__
_ I_ BACK rL_,4 pREVeNTER ._.
_ I_) LOW pRESSURE FIED (15 _ NQIqI_L}
_ I_ EXPANSION T&_
t _I)Alll VEtlT (Mi rco bubbler Air
Etimtnltol" Recmer_led)
• _ DRAIN VALVE
_ TEMPERATURE I pRESSURE GAEE
tITE_$U I_PLIEOBYC_ITRACTOR CONNECT TO _OILER SUPPLY I_IT
SYSTEM F_ I_
_VltCH
CD_N _
E:o_JST E
_ rl/KET
CONNECT TO BOILER RETURN COLD
_.L pe._= _U=T E _m_lU.V _ttW'a_T[It
_IU_R HO
¢OL_
_l_ONt
NOTE: I_I U_R CONNECTIONS
ARE I I/i" N_T
LEfT _I_ VI{W
Figure 1: Supply and Return Near Boiler Piping
4

:! [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.
F
R
I
C
T
I
O
N
F
E
E
T
H
E
A
D
21-
20-
19-
18-
17-
16-
15-
14-
13-
12-
11-
10-
9
8
7
6
5
4
3
2
1
n , ,n n n
1 23 45 678910 11 12 13 14 15 16 17 18 19 20 21 22 23
FLOW IN GALLONS PER MINUTE
PI-80
P1-140
P1-199
IIIIIIII
TACO P/N GRUNDFOS P/N
007(1) 15-42 F SPD-2
0010(1) 26-64 F
0011 (1) 26-96 F
1) THE RECOMMENDED CIRCULATORS ARE BASED ON 1 GPM PER 10,000 BTU/HR W/20 ° At
Figure 2: Circulator Sizing

DJ I;JI;,]l_[clI;[e):_(e]K_l:_D][_A'd_liil:lL'd<
I. See Figures 3 and 4 for basic zoned system layouts.
2. If required, provide means to isolate and drain each
zone separately
ZONE
VALVES
TO SYSTEM
ZONE ZONE ZONE
521
D_z
l
ET_Z (3-
CONNECT TO
BOILER
SUPPLY
FROM SYSTEM
ZONE ZONE ZONE
1 2 5
BALANCING
VALVES
-, I I
CONNECT TO
BOILER
RETURN
Figure 3: Zone Piping with Zone Valves
TO SYSTEM
ZONE ZONE ZONE
5 2 1
FROM SYSTEM
ZONE ZONE ZONE
1 2 5
FLOW
CONTROL/
VALVES _" ZONE
RCULATORS
CONNECT
TO BOILER
SUPPLY
CONNECT TO
BOILER
RETURN
Figure 4: Zone Piping with Circulators
6

:_"mI=:t::l::P:,l:_I;,I:{oleeI:T_J/[O]_
i. Consult the tank manufacturer's instructions for
specific information relating to tank installation. Size
the expansion tank for the required system volume
and capacity.
2. Expansion tanks are available with built-in fill valves
and check valves for reducing supply water pressure
and maintaining minimum system pressure. Check
the design features of the tank and provide valves as
necessary. Boiler system requires 12 PSI minimum.
Refer back to Figure 1 for typical expansion tank piping.
I_ I1_,_ID]I ;t:[kl I_=I;t :1D]iTA_I'-_I/ :1:!1:I=Lr-'_nl=1:
If the boiler is to be used in conjunction with an indirect-
fired water heater, refer to Figure 4 for typical piping.
Follow the instructions provided by the water heater
manufacturer. Pipe the water heater as a separate zone.
For new or existing systems that must be freeze-
protected:
Use only inhibited propylene glycol solutions of up to
50% by volume with water. Ethylene glycol is toxic
and can attack gaskets and seals used in hydronic
systems.
1.
2.
3.
4.
Glycol in hydronic applications is specially
formulated for this purpose. It includes inhibitors
which prevent the glycol from attacking metallic
system components. Make certain that the system
fluid is checked for the correct glycol concentration
and inhibitor level.
The antifreeze solution should be tested at least once
a year and as recommended by the antifreeze
manufacturer.
Antifreeze solutions expand more than water. For
example, a 50% by volume solution expands 4.8%
in volume for a temperature increase from 32 ° F to
180 ° E while water expands 3% with the same
temperature rise. Allowance must be made for this
expansion in system design.
For more information, consult the Peerless Water
Installation Survey and the antifreeze manufacturer.
FROM
BOILER
SUPPLY
TO
BOILER
RETURN
BALANCING
VALVE
II
7
[3-
I
BALANCING
VALVE
SUPPLY
TO TANK
INDIRECT-FIRED
WATER HEATER
f
SUPPLY TO
SYSTEM
RETURN FROM
SYSTEM
HOT DOMESTIC
WATER SUPPLY
COLD DOMESTIC
WATER SUPPLY
Figure 5: Typical Piping with Indirect-Fired Water Heater