PEERLESS Pinnacle PI-399 User manual

Pinnacle®
Gas Boilers PI-399 Rev 2
Peerless®
Stainless Steel
Installation,
Operation &
Maintenance
Manual
– 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.
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.
WARNING

TABLE OF CONTENTS
USING THIS MANUAL 1
A. INSTALLATION SEQUENCE . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B. CODES & REGULATIONS . . . . . . . . . . . . . . .2
C. ACCESSIBILITY CLEARANCES . . . . . . . . . . .3
D. COMBUSTION AND VENTILATION AIR . . . .3
E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .3
2. BOILER SET-UP 4
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3. WATER PIPING AND CONTROLS 5
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
B. OPERATING PARAMETERS . . . . . . . . . . . . . .5
C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .5
D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . . .8
E. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .8
F. SPECIAL APPLICATIONS . . . . . . . . . . . . . . . .8
4. GAS PIPING 15
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .15
B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . .15
C. GAS SUPPLY PIPING INSTALLATION . . . . .15
D. GAS SUPPLY PIPING – OPERATION . . . . . .16
E. MAIN GAS VALVE – OPERATION . . . . . . . .17
5. VENTING, INTAKE AIR & CONDENSATE 18
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .18
B. APPROVED MATERIALS FOR EXHAUST
VENT AND INTAKE AIR PIPE . . . . . . . . . . .18
C. EXHAUST VENT / AIR INTAKE PIPE
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . .18
D. EXHAUST VENT AND INTAKE AIR PIPE
SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
E. EXHAUST VENT AND AIR INTAKE PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .20
F. EXHAUST TAPPING FOR VENT
SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
G. CONDENSATE DRAIN INSTALLATION . . . .23
H. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . .23
6. ELECTRICAL 24
A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
B. SEQUENCE OF OPERATION . . . . . . . . . . . .25
C. SAFETY INTERLOCKS . . . . . . . . . . . . . . . . .27
D. CONTROL FUNCTIONS . . . . . . . . . . . . . . . .28
E. HEATING CURVE . . . . . . . . . . . . . . . . . . . . .30
7. START-UP PROCEDURES 32
A. COMPLETING THE INSTALLATION . . . . . . .32
B. LIGHTING/OPERATING PROCEDURES . . . .33
C. CHECK-OUT PROCEDURE . . . . . . . . . . . . . .34
8. TROUBLESHOOTING 36
A. BOILER ERROR CODES . . . . . . . . . . . . . . . .36
B. BOILER FAULT CODES . . . . . . . . . . . . . . . .36
9. MAINTENANCE 38
A. GENERAL (WITH BOILER IN USE) . . . . . . .39
B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .39
C. ANNUALLY (BEFORE START OF
HEATING SEASON) . . . . . . . . . . . . . . . . . . .39
D. CONDENSATE CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .39
E. COMBUSTION CHAMBER COIL CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .40
10. BOILER DIMENSIONS & RATINGS 41
A. BOILER DIMENSIONS . . . . . . . . . . . . . . . . .41
11. REPAIR PARTS 44
APPENDIX A. STARTUP COMBUSTION
RECORD 46
TABLE OF CONTENTS

1
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:
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
NOTICE
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
CAUTION
DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
USING THIS MANUAL
USING THIS MANUAL
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING

2
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 elevation with no burner adjustments. This
applies to boilers 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"
c. ANSI Z223.1/NFPA 54 - "National Fuel Gas Code"
d. ANSI/NFPA 70 - "National Electrical Code"
e. ANSI/NFPA 211 - "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 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.
·The 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.
PREINSTALLATION
1. PREINSTALLATION
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.
WARNING

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.
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
3
PREINSTALLATION
Do not install this boiler where gasoline or other
flammable liquids or vapors are stored or are in use.
WARNING
This boiler is certified as an indoor appliance. Do not
install this boiler outdoors or locate it where it will be
exposed to freezing temperatures.
WARNING
Figure 1.1
Do not install this boiler on carpeting.
DANGER

4
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.
4. An optional boiler stand is available for Pinnacle
boilers. Two part number 91439 boiler stands are
required for the PI-399.
2. BOILER SET-UP
BOILER SET-UP
This boiler must be installed level to prevent
condensate from backing up inside the boiler.
CAUTION

5
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 the
Pinnacle PI-399 Boiler. If a glycol solution is to be
used, contact the factory for minimum flow rates.
C. SYSTEM COMPONENTS
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.
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.
3. WATER PIPING AND CONTROLS
WATER PIPING AND CONTROLS
Table 3.1 – Minimum Flow Rate and Water Volume
Boiler
Model
Total Water
Volume-Gallon (Liter)
Minimum Flow
Rate-GPM (LPM)
PI-399 1.30 (4.92) 20 (75.7)
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.
CAUTION
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.
WARNING

6
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.
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.
b. The circulator should be sized based on the net
output of the boiler. Table 3.2 shows the Boiler
Output as reported to the Hydronics Institute
division of GAMA.
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-399
with a design temperature difference of 20°F the
calculation is as follows:
WATER PIPING AND CONTROLS
Table 3.2 – Boiler Inputs and Outputs
Boiler
Model
Boiler Input
(Btu/hr [kW])
Gross Output
(Btu/hr [kW])
PI-399 399,000 (116.9) 379,000 (111.1)
Figure 3.1: Piping Symbol Key
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.
CAUTION
Output 379,000
= = 37.9 GPM
ΔT x 500 20 x 500
Required Flow =

7
d. Table 3.3 shows the pressure drop (in feet of
water) for a flow rate which gives a 20°F
temperature difference for the PI-399 boiler.
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.
The recommended circulators are based on water using
primary secondary piping with the boilers on a secondary loop.
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.
WATER PIPING AND CONTROLS
Table 3.3 – Flow Rate and Pressure Drop
Boiler
Model
Flow Rate
(GPM [LPM])
Pressure Drop
(Feet [meters])
PI-399 37.9 (143.5) 17.9 (5.46)
Table 3.4 – Recommended Circulators
Boiler
Model
TACO
Circulator
Bell & Gosset
Circulator
Grundfos
Circulator
PI-399 1400-50 PL-130 UP43-70
Figure 3.2: Pinnacle Circulator Sizing Graph
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
The P825 Control gives the DHW Circulator priority
over the Boiler Circulator. The DHW Circulator should
also be sized per 10a. through g.
NOTICE

8
D. SYSTEM PIPING
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.
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.
4. 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.
5. The flow rate in systems utilizing glycol solution
should be increased compared with a water system
to compensate for increased heating capacity.
6. 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.
7. 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.
8. 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.
9. 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.
10. Do not use galvanized pipe in glycol systems.
11. Use water that is low in mineral content and make
sure there are no petroleum products in the solution.
12. Mix solution at room temperature.
13. Do not use a chromate treatment.
14. Do not use glycol solution in a system that may
reach temperatures above 250°F.
15. 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.
WATER PIPING AND CONTROLS

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

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

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

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

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

14
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

15
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 54.
2. 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:
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.
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 4.3 for gas with a specific
gravity other than 0.60 to obtain the corrected
capacity. 4. The gas piping to the boiler must be a minimum of
1-1/4" pipe. The boiler is supplied with a 1-1/4" NPT
x 1" 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. Do not install any piping directly over or in front of
the boiler. Locate the drop pipe adjacent to the
boiler.
4. GAS PIPING
Boiler Input Rate
Gas Heating Value
Input Rate (ft³/hr)=(Btu/hr)
(Btu/ft³)
Boiler
Model
PI-399
Gas Input Rate* (ft³/hr)
Natural Gas
399
LP Gas
160
*Natural gas input rates are based on 1000 Btu/ft³, LP input
rates are based on 2500 Btu/ft³.
Table 4.2: Maximum Capacity of Pipe (CFH) for a
Pressure Drop of 0.3" of Water
Table 4.3: Maximum Capacity Correction Factors
for Specific Gravity other than 0.60
Specific
Gravity 0.50 0.55 0.60 0.65 0.70 0.75
Correction
Factor 1.10 1.04 1.00 0.96 0.93 0.90
Specific
Gravity 0.80 0.85 0.90 1.00 1.10 1.20
Correction
Factor 0.87 0.84 0.82 0.78 0.74 0.71
Specific
Gravity 1.30 1.40 1.50 1.60 1.70 1.80
Correction
Factor 0.68 0.66 0.63 0.61 0.59 0.58
Table 4.1: Gas Input Rates
Pipe
Length
(Feet)
1-1/4"
NPT
Pipe
1-1/2"
NPT
Pipe
2" NPT
Pipe
2-1/2"
NPT
Pipe
10 1,050 1,600 3,050 4,800
20 730 1,100 2,100 3,300
30 590 890 1,650 2,700
40 500 760 1,450 2,300
50 440 670 1,270 2,000
60 400 610 1,150 1,850
70 350 560 1,050 1,700
90 320 490 930 1,500
100 305 460 870 1,400
150 250 380 710 1,130
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.

16
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.
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.
7. Figure 11.1 shows the gas shutoff valve (item 8) 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.
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.
c. Using a flat screwdriver, turn the screw inside the
intake pressure tap fitting (see Figure 4.2) 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.
GAS PIPING
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.
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.
WARNING
Figure 4.1: Gas Supply Piping – Sediment Trap
Figure 4.2: Gas Valve/Venturi PI-399
Do not adjust the throttle screw without monitoring
the carbon dioxide (CO²) and carbon monoxide (CO)
in the vent pipe. Vent CO emissions above 400 ppm
are in excess of most safety standards.
WARNING
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.
CAUTION

17
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.
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 intake 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
1. Figure 4.2 shows an illustration of the gas valve/venturi
assembly for the Pinnacle PI-399.
a. The throttle screw on the valve should not be
adjusted without a means to measure carbon
monoxide (CO) and carbon dioxide (CO²)
emissions.
b. Turning the throttle screw clockwise will decrease
the gas flow (decreasing CO²) and turning it
counterclockwise will increase the gas flow
(increasing CO²).
c. The recommended CO²settings 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.
GAS PIPING
Gas
Type
Fuel Pressure (inches of water)
Minimum Maximum
Natural 3.5 13.5
LP 3.5 13.5
Table 4.4: Maximum and Minimum Fuel Pressure
Gas Type
Firing
Rate Vent CO²Vent CO
Natural Low 8-1/2% to 9-1/2% < 50 ppm
High 8-1/2% to 9-1/2% < 100 ppm
LP Low 9-1/2% to 10-1/2% < 50 ppm
High 9-1/2% to 10-1/2% < 100 ppm
Table 4.5: Recommended Vent CO²Settings
Do not adjust the throttle screw without monitoring
the carbon dioxide (CO²) and carbon monoxide (CO)
in the vent pipe. Vent CO emissions above 400 ppm
are in excess of most safety standards.
WARNING

18
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.
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-1785.
b. Non Foam Core CPVC (Chlorinated Polyvinyl
Chloride) Pipe conforming to ASTM D-1785.
Non Foam Core ABS (Acrylonitrile-Butadiene-
Styrene) Pipe conforming to ASTM D3965.
.
2. 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.
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 intake on multiple
Pinnacles is 8" (0.2 m) center-to-center. See
Figure 5.2.
VENTING, INTAKE AIR AND CONDENSATE
5. VENTING, INTAKE AIR AND CONDENSATE
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.
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.
WARNING