PEERLESS Series MI Instruction manual

MI/MIH
Boilers
Installation,
Operation
Maintenance
Manual
Pr=-EI_LESS _
CAST IRON BOILERS

MI Model Available for Natural or LP Gas
•Standit_g Pilot (3 9 sectior_) with 8(7_ AFUE
•[-Ioneywell SmartValve ®Intermittent Ignition (3-9 section)
with 82% AFUE
MIH Mid-E._f_ency Model Available in 3-6 Sections
for Natural Gas
• Honeywell SmartValve ®Intermittent Ignition with 83% AFUE
•Qualifies for Utility Company Energy Rebates in Some Areas
Natural Draft (Chimney) Venting
Low Profile Design
•Internal Horizontal to Vertical Draft Diverter
•Ideal for Ir_stallations with Low Ceilings
Steel Push Nipples
• Provici( _a Permar_ent _Vct_'r 7"(c)hl Seed Between Sections
•Unaffected by PetroIcum alzd Oilier Contaminants
Deluxe Insulated Enameled Steel Jacket
•Reduces Boiler Heat Loss
•Completely Encloses Gas Valve and Burners
Safety Controls
•Vent Safety ShutoffSwitch
•Flame Rollout Safety ShutoffSwitch •Standing Pilot or Honeywell SmartValve _
Intermittent Ignition
•Honeywell Operating Controls
• Taco Circulator
• Elec. Operated Automatic Vent Damper
•Grundfos Circulator
• 50 PSI Safety Relief Valve
•Non-Combustible Floor Pan
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Peerless Heater Company * 231 North Walnut Street * Boyertown. PA 19512 1021 * 610 367 2153 * www,peerless-heater.eom
FAB MI l_l {3/02 5M)
Pnnled _n U S A

USING THIS MANUAL 1
A. INSTALLATION SEQUENCE ............. 1
B. SPECIAL ATTENTION BOXES ........... 1
1. PREINSTALLATION 2
A. ACCESSIBILITY CLEARANCES .......... 2
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION ..................... 2
C. AIR FOR COMBUSTION AND
VENTILATION ....................... 2
D. LIQUEFIED PETROLEUM (LP) GAS ....... 4
E. INSTALLATION SURVEY ............... 4
E PLANNING THE LAYOUT ............... 4
7. START-UP PROCEDURES 20
A. COMPLETING THE INSTALLATION ...... 20
B. CONTROL DESCRIPTIONS ............. 24
C. ADJUSTMENT OF GAS PRESSURE
REGULATOR ....................... 24
D. ADJUSTMENT OF PILOT GAS FLOW .... 24
E. CHECKING BURNER INPUT ............ 24
E CHECK-OUT PROCEDURE ............. 25
8. TROUBLESHOOTING 26
A. SHUT-DOWN CAUSED BY PILOT OUTAGE,
BLOCKED VENT SHUT-OFF SWITCH OR
FLAME ROLL-OUT SAFETY SHUT-OFF
SWITCH ........................... 26
B. TROUBLESHOOTING GUIDES .......... 26
A. BOILER SUPPLY AND RETURN .......... 6
B. SAFETY RELIEF VALVE ................ 7
C. PIPING FOR ZONED SYSTEMS .......... 8
D. EXPANSION TANK .................... 9
E. INDIRECT-FIRED WATER HEATER ........ 9
E FREEZE PROTECTION ................. 9
A. INTEGRAL DRAFT HOOD ............. !0
B. VENT DAMPER INSTALLATION -
GENERAL .......................... 10
C. VENT PIPING AND CHIMNEY .......... 11
D. BOILER REMOVAL FROM COMMON
VENTING SYSTEM ................... 12
A. GENERAL .......................... 29
B. DAILY (WITH BOILER IN USE) .......... 29
C. WEEKLY (WITH BOILER IN USE) ........ 29
D. MONTHLY (WITH BOILER IN USE) ....... 29
E. ANNUALLY (BEFORE START OF HEATING
SEASON) .......................... 30
10. BOILER DIMENSIONS _ _TINGS 31
A. BASE/COMBUSTIBLE FLOOR PAN ....... 32
B. MANIFOLD/GAS TRAIN ............... 34
C. BLOCK/DRAFT HOOD ................ 36
D. JACKET ........................... 38
E. CONTROLS/CIRCULATOR/VENT
DAMPER .......................... 40
A. WIRING ........................... 15
B. ZONED SYSTEM WIRING ............. 15
C. CONTROLS ........................ 15
D. SEQUENCE OF OPERATION ........... 16

Follow thetnsta[lattoninstructionspro',,'_dedill this
manual m the order shown The order ot these
mstructLons has been set m order to provide the installer
with a logical sequence ol steps that wdl mulmllze
potenhal interferences and maximize safety, during
boiler mstallatLon
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
Throughout thLs manual you will see speoal attenuon
boxes intended to supplement the mstmct=ons and make
speoal nohce of potenhal hazards These categories
mean m the judgment of Peerless Heater Company
indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
Indmates 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.

1.!B INS
Read carefully, study these msh-uchons before beginning work
This bo,le_ must be installed by a quahfled con_ac_or
The bonler warranty can be voided _t the boder Is not installed, maintained and serviced correctly
The equipment must be installed maccordance 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.
Where requtred 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, ASME CSD-I.
r_*wr:_o,[o.]:[.."[.."]I:] I ! / ik'd_a,]l :f;1:_r_*l_[q _
Install boiler not less than 24" between the left slde. top,
and tront ot the boiler and adjacent wall or other
apphance, when access is reqmred for servicing
The design of ths boiler _scertffled for alcove mstallatlon
wlth the following clearances
I 6" between s,des and combustible construction
2 24" between top of jacket and combushble
construction
3 6" between draft hood and combustible
COl_ls_uctlon
4 6" between vent pipe and combustLble construction
5 10" between rear of ]acket and combushble
consiluctlon
Do not install this boiler on combusttble flooring
unless it is installed on a special combustible floor
pan provided by Peerless Heater Company. Boiler
installation on combustible flooring without the
special pan is a fire hazard.
To order combustible floor pan, use the 5-digit stock
codes listed in Section 11A of this manual.
Do not install this boiler on carpeting. Boiler
installation on carpeting asafire hazard. Install this
boder on non.combustible flooring or use a
combustible floor pan to install thts boder on other
non-carpeted flooring.
2
Prowde adequate facflltnes for combustlon and
vent]lahon a_r unaccordance w_th Sechon 5 3. ALrfor
Combustion and Ventilation Nanonal Fuel Gas
Code ANSI -7223 1/NFPA 54, or apphcable
prows_ons of the local budding code Subsechons 2
through 6 below are based on National Fuel Gas
Code ANSI Z223 1!NFPA 54 requnrements
DehnltlOnS
Unconfined Space: a space whose volume usnot
less than fifty (50) cubnc feet per 1000 Btu/hr of the
total input rahng of all apphances installed Jnthat
space Rooms commumeatmg dnrectly w_th the space
m which the apphances are installed, through
opemngs not furmshed w_th doors, are considered
part of the unconfined space
Unusually Tight Construction: Constmchon
where
Walls and cenlmgs exposed to the outsMe
atmosphere have a continuous water vapor
retarder wlth a rating of iperm or less wLth
openings gasketed or sealed, and
b Weatherstnppmg has been added on openable
windows and doors, and
CaulkLng or sealants are supphed to areas such
as joints around window and door frames.
between sole plates and floors, between wall-
ceflmg joints, between wall panels, at
penetratlons for plumbing, electrical and gas
hnes, and at other openings
2

3Appliances Located in Unconfined Spaces:
For installations in unconfined spaces with other
than unusually tight construction, the supply of air
for combustion and ventilation can usually be
considered adequate.
4. Unusually Tight Construction:
For equipment located in buildings of unusually tight
construction as defined on the previous page,
provide air for combustion and ventilation using the
methods described in 5a or 5b below.
5. Appliances Located in Confined Spaces:
a. All air from inside the building: Provide two
permanent openings communicating directly with
an additional room or rooms of sufficient volume
so that the combined volume of all spaces meets
the criteria for an unconfined space. Use the total
input of all gas utilization equipment installed in
the combined space in making this
determination.
Size each opening with a minimum free area of
one square inch per 1000 Btu/hr. of the total
rating of all gas utilization equipment in the
confined space, but not less than I00 square
inches. Begin with one opening 12 inches from
the top, and begin the other opening within 12
inches of the bottom of the enclosure. See Figure
1. Provide air openings with minimum
dimensions not less than three (3) inches.
b. All air from outside the building. Connect the
confined space with the outdoors in accordance
with methods i) or ii) below. Provide air openings
with minimum dimensions not less than three (3)
inches. Where ducts are used, make certain that
they are the same cross-sectional area as the free
area of the openings to which they connect.
Provide two permanent openings, one
commencing within 12 inches of the top and
one commencing within 12 inches of the
bottom of the enclosure. Connect the
openings directly or by duets, with the
outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
Where directly communicating with the
outdoors (see Figure 2) or where
communicating to the outdoors through
vertical ducts (see Figure 3), size each
opening with a minimum free area of one (I)
square inch per 4000 Btu/hr. of total rating of
all equipment in the enclosure.
i ?
I
12" max
TWO AIR OPENINGS:
Minimum
Free Area Each -
1 in2per 1000 Btuh
at Least 100 in2
BUILDING
Must communicatefreely
withoutdoors
Must not beunder
negativepressure
12" max
Figure 1: Air Openings -All Air from Indoors
TWO AIR OPENINGS:
Minimum
Free Area Each -
1 in_per 4000 Btuh
Figure 2: Air Openings - All Air Directly from
Outdoors
Figure 3: Air Openings - All Air from Outdoors
through Vertical Ducts

6. :_ IIL_l_uf±lUHff±_ugl[e]L_l[_'q_|J;kVJ_k
7.
Where communicating with the outdoors
through horizontal ducts, size each opening
with a minimum free area of one (1) square
inch per 2000 Btu/hr of total input rating of
all equipment in the enclosure. See Figure 4.
ii) Where the equipment has clearances of at
least one (1) inch from the sides and back
and six (6) inches from the front of the
appliance, the code allows one permanent
opening, commencing within 12 inches of
the top of the enclosure. Connect the
opening directly with the outdoors or through
a vertical or horizontal duct to the outdoors
or spaces (crawl or attic) that freely
communicate with the outdoors. Size the
opening with a minimum free area of one
square inch per 3000 Btu!hr. of the total
input rating of all equipment in the enclosure,
and not less than the sum of the areas of all
vent connectors in the confined space.
In calculating free area of an opening, take into
account the blocking affect of louvers, grilles and
screens. Do not use screens smaller than i/4" mesh.
If the free area is known, use this value in calculating
the size of the opening required. If it is not known,
assume that wood louvers provide 20-25% free area,
and metal louvers and grilles provide 60-75% free
area.
Remove sources of hydrocarbons (bleaches,
cleaners, chemicals, sprays, paint removers, fabric
softeners, etc.) from the boiler area. The vapors
generated by these substances can contaminate the
combustion air and contribute to shortened
boiler/vent system life. I_ff±!_l_ll_[dl|ll:lt_VLelll
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. See the instructions
below.
ii-i ..
12"maxl [ i 1--
, _t [jT TWO AIR OPENINGS: |
)1' Minimum l
Free Area Each =
in_per 2000 Btuh !
_ min
?
12"max
Figure 4: Air Openings - All Air from Outdoors
through Horizontal Ducts
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.
IIJ ! [o|lJ :l ;i I:ll]'.J :Eld:{o] ! ::[IILVA|_[€-r_,_..
The following LP requirements from the Uniform
Mechanical Code, section 304.6, may be in effect in
your geographic area:
"Liquefied peh'oleum 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."

l_.]llF'4T_'i:i_IrJ_
2
3
Provide a sound, level foundahon Locate boiler as
near to the chmney or outside v_ali as possLble and
cennahzed v_Jth respect to the heahng system
Locate boiler [n front of installation pos[hon before
_movll_g crate
If using combushble floor pan, poslhon pan on
foundat,on or flooring
4 Separate the wood shppmg pallet from the boiler
base by removing two (2) hold-down bolts at each
end of the boder base
5 Move boder into hnal poslhon If using combustLble
floor pan, install boder on pan as outhned ,n the
instructions included wlth the pan

3. WATER PIPING AND CONTROLS
"-I [:{=]ll_;l[.-llJ'J_Jl_'m_,]l_ll] I;l:i[IJ;|k'
1. Size the supply and return to suit the system. A
t_pical piping arrangement is shown in Figure 5.
Refer also to the I-B-R Installation Guide No. 200
and the Peerless Water Survey for additional
guidance during water piping installation.
2. Return Piping:
a. For boilers equipped with a factory mounted
circulator, pipe the return to the inlet connection
of the circulator.
b. For boilers equipped with a separate, unmounted
circulator, pipe the outlet connection of the
circulator to a tee, provided with a drain valve, at
the 1-1/4 NPT return tapping near the bottom of
the left section. Pipe the return to the inlet
connection of the circulator.
3
4.
5.
Supply Piping:
Pipe the supply to the I i/2 NPT supply tapping at
the top and rear of the boiler.
When system return water temperature will be below
130°E pipe the boiler with a bypass arrangement to
blend the system return and hot supply to obtain at
least 130°F entering the boiler. For more information
on bypass piping, consult the Peerless Water Survey.
If desired, install the circulator in the alternate
location shown in Figure 5. Consult the Peerless
Water Survey for more information on circulator
location.
COLD
WATER
FILL
VAL VE
DRAIN
VAI VE J
TO
DRAIN l
i
,7
Figure 5: Supply and Return Piping

6. 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 )
7. If this boiler and distribution system is used in
conjunction with a refrigeration system, pipe the
chilled medium in parallel with the boiler and install
the proper valve to prevent the chilled medium from
entering the boiler. A drawing illustrating this hook-
up is provided in Figure 6
8. 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.
9. If this boiler is installed above radiation level,
provide a low water cutoff device, either as a part of
the boiler or at the time of boiler installation.
C HECj VAILVEI
SUPPLY
LINE
LINE
WATER THREE WAY
_HILLER VALVE
Figure 6: Parallel Hook-up with Water Chiller
I:m l-'f!1=:lL'dI;t=l!l=l:l krl±lLvd
i I Locate safety relief valve and fittings in bag
assembly.
2. If air elimination is not required at the safety relief
valve tapping, install valve and piping as shown in
Figure 7.
3. For air elimination at the safety relief valve tapping,
install valve and piping as shown in Figure 8.
SAFETY
RELIEF
VALVE
x6"
NIPPLE
Pipe the discharge of safety relief valve to prevent
injury in the event of pressure relief, Pipe the
discharge to adrain. Provide piping that is the same
size as the safety relief valve outlet.
Figure 7: Safety Relief Valve Hook-Up Installation
with Air Elimination in System Piping
TO AIR
ELIMINATION
DE_CE
SUPPLY TEE
SAFETY X6 _
RELIEF NIPPLE
VALVE
NIPPLE
TO DRAIN
5/4" STREET
ELBO_
Figure 8: Safety Relief Valve Hook-Up with
Air Elimination
7

loll I'JI_IL'_[_ l;:[e];l v_[o]L'ql:lm]F.._'_"-]Ii :hVj_
1. See Figures 9 and 10 for basic zoned system layouts.
2 Run each zone pipe down then up to zone to
prevent air accumulation in piping
3. If required, provide means to isolate and drain each
zone separately,
TO SYSTEM
ZONE ZONE ZONE
5 2 /
ZONE
VALVES
II
TO
SUPPLY
FROM SYSTEbl
BAL _,NCINO
VAi VES m',
CONNECT TO
RETURN
(CIRCULATOR INLET)
ZONE ZONE ZONE
I 2 3
I
I
±
Figure 9: Zone Piping with Zone Valves
TO SYSTEM
ZONE ZONE ZONE
5 2 1
FROM SYSTEM
ZONE ZONE
1 2 3
FLOW
CONTROL _]
VALVES
I- q
CONNECT
TO
SUPPLY
ZONE
CIRCULATORS
CONNECT TO
RETURN
TAPPING
Figure 10: Zone Piping with Circulators
8

I_ I:l;f:l:_,l: I;J;{e]i:_l,]i[o]_
1. Consult the tank manufacturer's instructions for
specific information relating to tank installation Size
the expansion tank for the required system volume
and capacity. See Table 8 in Section 10 for boiler
water 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.
Refer back to Figure 5 for typical expansion tank piping.
I::m I I£qm]I:| =[o,]iI_:ll:t ::1e]I_l,__ii =1;t I:I_,__ii ::1
If the boiler is to be used in conjunction with an indirect-
fired water heater, refer to Figure 11 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. 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.
2. The anitfreeze solution should be tested at least once
a year and as recommended by the antifreeze
manufacturer.
3.
4.
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°F, 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.
SUPPLY TO
SYSTEM
RETURN FROM
SYSTEM
ZONE VALVES
INDIRECT FIRED
WATER HEATER
HOT DOMESTIC
WATER
SUPPLY
COLD
DOMESTIC _-
WATER SUPPLY
SUPPLY
TO
TANK
J
BALANCING
VALVE
]BALANCING
VALVE
i I
SYSTEM
CIRCULATOR _
DRAIN
Figure 11: Typical Piping with Indirect-Fired Water Heater
9

Lt/:1_/Jl_[,':t
4; VENTING
|_,!1 h,'_ii::[d; f_,_II o] ;f_,_;Iil -"[o_o] g
1. The MIiMIH boiler is equipped with a built in draft
hood This device is designed to:
a provide for the ready escape of flue gases from
the boiler in the event of no draft.
b. prevent a backdraft [Tom entering the boilen
c. control stack draft during operation.
These tasks are accomplished without the extra
height requirements of a separate draft hood.
2. The draft hood relief opening is the large rectangular
passage at the front of the boiler. Make certain that
there are no obstructions to airflow in front of this
opening.
3. A vent safety shut off switch is located within the
draft relief opening to shut off the boiler in case of a
blocked vent condition. See Section 7B for details
regarding this device. See Figure 16 in Section 6
(Electrical) for spill switch location.
4. The vent damper can be mounted directly onto the
round draft hood outlet (vent connector) on top of
the boiler, or in vent piping close to the boiler. See
the Vent Damper Installation Instructions below.
].
2.
3.
4.
Do not use one vent damper to control two or more
heating appliances. See Figure 12.
Follow these and the installation instructions that are
included with the vent damper. Observe the cautions
and warnings that accompany all instructions.
Make certain that minimum clearances provided in
the vent damper manufacturer's instructions are
maintained and that adequate space is available for
damper accessand service.
Orient the damper operator to facilitate connection
of the harness with the vent damper and boiler. Note
flue gas flow arrow on vent damper and orient as
required. For installation with damper mounted in
vertical position, see Figure 13. For installation with
damper mounted in horizontal position, mount the
unit as shown in Figure 14 to avoid excessive heat
on the operator or condensation drips into the
operator.
BOILER
c:::::::_ c:::::::_
c:::=_ c:::::_
c:::::::_ c:::::::_
OTHER
HEATING
&PPLIANCE
INCORRECT CORRECT
Figure 12: Venting Multiple Appliances
10

_o,,NkVJ:h,_/uI:JI:,,]h,1[€_V_*l_._ID][o,]-"I hVjh._I_"
1. Install vent piping in accordance with Part 7. Venting
of Equipment, National Fuel Gas Code, ANSI
Z223. I/NFPA 54 or applicable provisions of the local
building codes.
2. Inspect the existing chimney and lining for structural
soundness, corrosion and perforations. Repair as
neces_Fy.
3. Install vent pipe to slope upward at least I/4" per
lineal foot between the draft hood outlet and the
chimney.
4.
5.
6.
7.
Before connection of joints, inspect the vent pipe
interior for foreign objects such as tools, equipment,
rags, etc. and remove if present.
Insert vent pipe into but not beyond the inside wall
of the chimney flue.
Do not connect vent connectors serving appliances
vented by natural draft into any portion of
mechanical draft systems operating under positive
pressure.
Support horizontal portions of the venting system to
prevent sagging by use of metal strapping or
equivalent means. Locate supports at no more than
four (4) foot intervals.
SLOPE uP
A MINIMUM
OF 1/4"
PER FOOT
VENT
DAMP
DRAFT _ _ f¢3
HOOD
RELIEF
flVENT TO
CHIMNEY
SUPPORT
AS REQUIRED,
DRAFT HOOD
OUTLET
Figure 13: Venting with Vent Damper in Vertical Position
SLOPE UP VENT
A MINIMUM DAMPER
OF I/4"
PER FOOT_,,_
_VENT TO
CHIMNEY
11 O'CLOCK i O'CLOCK
POSITION POSITION
!
SUPPORT AS
REQUIRED
ri
HEAT
_CONDENSATION
ZONE
7O'CLOCK _5 O'CLOCK
POSITION POSIT'ON
DO NOT MOUNT DAMPER
OPERATOR IN SHADED REGION
SECTION A
Figure 14: Venting with Vent Damper in Horizontal Position
11

At the time of removal of an existing boiler, follow these
steps with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation:
a. Seal any unused openings in the common venting
system.
b, Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.
C_ Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on any clothes dryers and any
appliance not connected to common venting system.
Turn on any exhaust fans, such as range hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
fireplace dampers.
d
e.
g.
Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.
Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame
of a match or candle, or smoke from a cigarette,
cigar, or pipe,
After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas-burning appliance to their previous
conditions of use.
Any improper operation of the common venting
system should be corrected so that the installation
conforms with the current edition of the National
Fuel Gas Code, ANSI 7-223.1/NFPA 54. When
resizing any portion of the common venting system,
the common venting system should be resized to
approach minimum size as determined using the
appropriate tables located in the chapter "Sizing of
Category IVenting Systems," in the current edition of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
12

2
3
4
5
SLZeand w,-_tal[the gas supply plpmg properly in
ordeT to provide a supply of gas sufflc,ent to meet
the maximum demand wlthout undue loss of
pressure between the meter and the boder
Determine the volume of gas to be provlded to the
boller in cublc feet per hour To obtain this value,
thv]de the Btu per hour rating (on the boiler rating
plate) by the heating value ot the gas ]n Btu per
cubic feet Obtain the heating value of the gas from
the gas suppher As an alternatwe use Table 1 2 or
3 on the next page to obtain the volume of gas to be
p_ovLded to the boder
Use the value obtained above as the bas_s for p_pmg
SLZmg SLze the gas piping m accordance w_th Table
4 Consult the Natzonal Fuel Gas Code ANSI
Z223 I,'NFPA 54 for other slzlng optmns
Locate the drop pipe adjacent to, but not m front of
the boder
Install a sedlment trap See Figure 15 Locate a tee
m the drop plpe at same elevatlon as the gas inlet
connechon to the bo_Ler Extend the drop p_pe to a
pLpe cap
Install a ground joint umon ahead of the gas control
assembly to permit serwcmg of the control Some
Localcodes reqmre an additional serwce valve when
using the combmat,on gas controls If your code
reqmres such a valve a suggested IocatLon Lsshown
in FLgure 15
Use a pipe joint sealing compound that is resistant to
the action of tiquefied petroleum gas. A non-resistant
compound may lose sealing ability in the presence of
this gas, resulting in a gas leak and fire or explosion
potential.
Check pLpmg for leaks
Use an approved gas detector, a non-corroslve leak
detectlon flu,d or other leak detecUon method If
leaks are found turn off all gas flow and repalr as
necessal_j
j _ SERVICE
-----JAC K ET
_GJ. UNION
_ I _fSEDIMENT TRAP
_/FLOOR LINE
Figure 15: Gas Connection to Boiler
8 Disconnect the boiler and its ]ndlwdual shut-off valve
from the gas supply piping system dunng any
pressure testLng of that system at test pressure m
excess of i '2 psLg (3 5 kPa)
Do not subject the gas valve to more than 1/2 psi
pressure. Doing so may damage the valve.
Isolate the boiler from the gas supply p_pmg system
by closing _ts _ndw_dual serwce valve dunng any
pressure testing of the gas supply plpmg system at
test pressure equal to or less than i 2 pslg (3 5 kPa)
9 Mlmmum permlsslble supply pressule for purposes of
,nput adjustment (Inches Water Column)
MI-09 Standing Pdot Natural Gas 5 2"
All other MI/MIH Natural Gas 5 0"
All MI LPGas II 0"
Maximum permlsslble supply pressure to the boder
(Inches Water Column)
All MI/MIH Natural Gas 13 5"
All MI LP Gas 13 5"
When checking for leaks, do not use matches,
candles, open flames or other methods that provide a
source of =gnition.This can ignite a gas leak,
resulting in fire or explosion.
13

[tl :I-2[_igl_tl
Table 1: MI Boiler- Natural Gas
Model Input
(Cubic F_Hr)
MI 03 70
MI-04 105
MI-05 140
MI Ofi 175
MI 07 195
M] 0_ 227 5
MI 09 260
Based on i000 Btu/Cubic Ft
Table 2: MI Boiler - LP Gas
Model Input
(Cubic FI/Hr)
Ml-03 28
MI 04 42
MI-05 56
MI-06 70
MI-07 78
M[ 08 91
MI-09 104
Based on 2500 Bt_ICubicFt
Table 3: MIH Boiler - Natural Gas
Model Input
(Cubic FffHr)
MIH-03 65
MIH-04 97.5
MIH 05 130
MIH 06 162.5
Based on 1000Btu/CubicFt,
Table 4: 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 fi_ings is required.
Pipe V4" l" 11/4" 11/2u
Length
Feet Pipe Pipe Pipe Pipe
I0 278 520 1,050 1,600
20 190 350 730 1,100
30 152 285 590 890
40 130 245 500 760
50 115 215 440 670
60 105 195 400 610
Multipliers to be used with the above table when the
specific gravity of the gas is other than 060:
Specific Gravity . 0 5 055 0.60 065 070
Multiplier ........ 110 1,04 1.00 0.962 0.926
14

6.*ELECTRICAL
Install all elechlcal wrong m accoldance wLth the National Elecmcal Code and local requirements
This umt when installed must be electrically grounded in accordance with the requirements of the authority
having JUrlSdtctton or, in the absence of such requirements, with the current edlbon of the National Electrical
Code, ANSI/NFPA 70.
r_,! iv=,il;llL_[€ _.41[*(o] L_iiII-'{e]I_
2
3
See Figure 16 for locatEon of wrong and conh'ols
Use Figures 17 and 18 to connect the boder to a
power supply and to connect components to the
boiler
Connect the bo=le_ by a separate, permanently live
electrLcal supply hne with a fused switch
Connect _he vent damper harness to the polarLzed
connector Lnthe boder vest=bule as shown m
Figure 16
4 Adjust the thermostat heat antlcipator to 0 2 Amp
1
2
3
4
For proper locatlon of controls and accessories refer
to Flgure 16 and Section I i
See the attached control sheets for specific details
regarding the instal]atlon of the various conlzols
Thin boiler is supphed wlth safety dev=ces m addttlon
to the hmlt For a descnpt_on of these dewces and
how they work to ensure the safe operatlon of the
boiler, see Secuon 7B
If the clrculator [smounted m the supply plpmg,
provLde longer wrong harness as requLred
See Figure 20 for typLcal wiring w=th zone valves See
Figure 21 for t_pLcal wrong with zone cLrculators When
wLrlng a zoned heating system, follow all apphcable
codes ordinances and regulations
Do not power zone valves directly from the boiler
limit. Doing so will greatly reduce the life of the
transformer Use a separate transformer sized to
handle the total of all zone valve electrical loads
i9 LIHL OL IACE
T,:, THEPrlOST_T_
Lit IIT -_._
C, Jr I-L_IPE_ POL'I:t2ED
F _,r Jr JEC T,)_' iIPI3BDL
E JlLC_ P_ /IBLILE,
_- _ TO ','EN7 DAMPEP
_ "---... _ GLC,CXED _Er_T SWITCH
DB_E_.',' nbr4 CO_L_
LeL_t IE _JCILLOU T
Figure 16: Wiring, Controls and Safety Devices
15

CONNECTION DIAGRAM
24V THERMOSTAT (BY OTHERS)
.... LB148£ C_81NATIO_i DISCONNECT
"r.....
NSTALLF_ _ 60 LI BK
R SUPgLY L2 SER_C£
eK_ THESE]_TO--
0{,.!B.i l 'i
I _ERMO¢OUpI "_
L2T22_ ,
Ii
CONNECTOR rifle RelJ_e,4JTS_l F _=t__
wV#_lTE
C_NEC1]ON DIAGRAM LEG{.ND 0 ORANCE
BL BLUE
-- UNE VOLTAGE _IZE _¢ A_ TYPE TW, TFF'N OR 1EW/A_ _IRE
-- UNE VOLTAGE _ZE 16-18 AWG TYPE I%V TFFN OR I_W/A_%a V_RE
-- LOW '_LTAGE SIZE 18 A_G TYPE TC CABLE
-- -- LOW VOLTAGE SIZE 16-18 AWG WR[ TYPE TEW/AV_, TFFN _R£
NOTESm
I) ALL _RING MUST COMPLY V_IH APPUANC[ CODES, ORDINANCES AND REGULATIONS
2) IF ANY OF 1HE ORIGINAL MRE AS SUpPU_O _4TH THE ApPLiANCE MUST BE
REPLACED, IT MUST B_ REPLACED V4T_ _RE AS SHO_
LADDER OIAGRAM
115/60/i L2
pOV_ER
SUPPLy
C_ C2
FUSE{) RI
DISCONNECT SER_CE
S_TCH S_4TCH pR_MAR Y
TR ANS_Oei4 ER
SZCONDARY
I B2,
I
I PRS BvS
L 1%.
RZ LIMIT I
,
IT_ERNOCOUP_
LAODER DIACRAM I[G_NO I
-- 120v INTERNAL WIRIN_ i
-- 120V EXTERNAL _IRtNG [
24V INI_RNAL _,tRING
-- 24V [XERNAL _IRINg
---- MIU IVOLT _RING
0 L_I4BE _RMtNAL
Figure 17: Wiring and Connection Diagram -Standing Pilot (Continuous Ignition)
I'_ F.']:[olli:l_[o,]:l [o]d[oir,,l=l;__41/[o]_
I. Standing Pilot (See Figure 17 above)
a. The vent damper is continuously powered. On a
call for heat, limit relay R is energized, which
energizes:
• the circulator (when used) through contact
R1, and
• the vent damper operator through contact R2,
provided that the high-limit switch is
closed.
The vent damper operator opens the damper.
b. Once the damper is proven open, the gas valve
energizes, provided that all of the following
conditions are met:
• the pilot thermocouple is proving flame
• the blocked vent switch is closed, and
• the flame rollout switch is closed.
Pilot flame is monitored through the pilot
thermocouple. If pilot flame is lost during a call
for heat, main and pilot gas flow will be shut off.
The valve must then be manually reset by
following the Lighting Instructions mounted on
the jacket panel and included in Section 7 of this
manual.
c. When the call for heat ends:
• Limit relay R de-energizes, which opens
contacts RI and R2.
• The circulator shuts down.
• The gas valve de-energizes.
• The vent damper closes.
d. If temperature exceeds limit setting, main burners
shut off and circulator continues to operate.
16

" i:!!;["_e_2_
CONN£CTI_ DIAGR_ L*_[R [_AGRAM
L 1 11p_o_45_LR_1 L2
¢1 C2
FUSED RI
D'S_EC T_5_ T_I_
T ....
HIGH I
R U_IIT
28R B! I I
LAD{)_R DIAGRAM L[G[NO [ 1_+41T_ __AM_ I
-- ND I
-- 120V INT_RN_L I_IR1NG I _PPILOT
-- t20v [XT_RHAL_RIN_ L _BNC)]
---- _4V iN.HAL _4RIN_
-- -- 24V [XTERNAL _I_IN_
....... _>iLOT _RIN@
oLO14_ T_R_IN_-
Figure 18: Wiring and Connection Diagram - Intermittent Ignition
2. Intermittent Ignition (see Figure 18 above)
a. The vent damper is continuously powered. On a
call for heat, limit relay R is energized, which
energizes:
• the circulator (when used) through contact
RI, and
• the vent damper operator through contact R2,
provided that the high-limit aqu_stat switch is
closed.
The damper operator opens the vent damper.
b. Once the damper is proven open, the ignition
circuit within the gas valve energizes, provided
that all of the following conditions are met:
• the blocked vent switch is closed, and
• the flame rollout switch is closed.
c. When the call for heat ends:
• Limit relay R de-energizes, which opens
contacts R1 and R2.
• The circulator shuts down.
• The gas valve de-energizes.
• The veat damper closes.
d. If temperature exceeds limit setting, main burners
shut off and circulator continues to operate.
17