PEERLESS Stainless Steel Gas Boilers Instruction manual

Pinnacle®
Gas Boilers
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 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.
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
As an ENERGY STAR®Partner, PB Heat, LLC has
determined that this product meets the ENERGY STAR®
guidelines for energy efficiency.

USING THIS MANUAL 1
A. INSTALLATION SEQUENCE . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B. CODES & REGULATIONS . . . . . . . . . . . . . . .2
C. LIQUIFIED PETROLEUM (LP) GAS . . . . . . . .2
D. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2
E. COMBUSTION AND VENTILATION AIR . . . .2
F. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .2
2. BOILER SET-UP 4
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
B. WALL HUNG BOILERS . . . . . . . . . . . . . . . . . .4
C. FLOOR MOUNTED BOILERS . . . . . . . . . . . . .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 . . . . . . . . . . . . . . .14
4. GAS PIPING 16
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .16
B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . .16
C. GAS SUPPLY PIPING INSTALLATION . . . . .16
D. GAS SUPPLY PIPING – OPERATION . . . . . .17
E. MAIN GAS VALVE – OPERATION . . . . . . . .18
5. VENTING, INLET AIR & CONDENSATE 19
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .19
B. APPROVED MATERIALS FOR EXHAUST
VENT AND INLET AIR PIPE . . . . . . . . . . . . .19
C. EXHAUST VENT / AIR INLET PIPE
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . .19
D. EXHAUST VENT AND INLET AIR PIPE
SIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
E. EXHAUST VENT AND AIR INLET PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .21
F. EXHAUST TAPPING FOR VENT
SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
G. CONDENSATE DRAIN INSTALLATION . . . .25
H. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . .25
6. ELECTRICAL 26
A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
B. SEQUENCE OF OPERATION . . . . . . . . . . . .26
C. SAFETY INTERLOCKS . . . . . . . . . . . . . . . . .28
D. CONTROL FUNCTIONS . . . . . . . . . . . . . . . .28
7. START-UP PROCEDURES 30
A. COMPLETING THE INSTALLATION . . . . . . .30
B. LIGHTING/OPERATING INSTRUCTIONS . . .31
C. CHECK-OUT PROCEDURE . . . . . . . . . . . . . .32
8. TROUBLESHOOTING 33
A. SHUT-DOWN . . . . . . . . . . . . . . . . . . . . . . . .33
B. BOILER FAULT CODES . . . . . . . . . . . . . . . .33
9. MAINTENANCE 35
A. GENERAL (WITH BOILER IN USE) . . . . . . .35
B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .35
C. ANNUALLY (BEFORE START OF
HEATING SEASON) . . . . . . . . . . . . . . . . . . .35
10. BOILER DIMENSIONS & RATINGS 36
A. BOILER DIMENSIONS . . . . . . . . . . . . . . . . .36
11. REPAIR PARTS 39
APPENDIX A. WHAT’S NEW WITH THE
P125 CONTROL BOARD 41
A. ADVANTAGES OF THE P125
CONTROL BOARD . . . . . . . . . . . . . . . . . . . .41
B. P125 CONTROL BOARD QUICK
REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . .41
C. P125 CONTROL BOARD VS. WHA
CONTROL BOARD COMPARISON . . . . . . .42
TABLE OF CONTENTS
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. For
boilers equipped for firing liquefied petroleum (LP)
gas at elevations above 7,000 feet contact the factory.
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.
C. LIQUIFIED PETROLEUM (LP) GAS
The following LP requirements from the Uniform
Mechanical Code, section 304.6, may be in effect in
your geographical 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."
D. 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 and Figure 1.2 for the
recommended clearance to allow for reasonable
access to the boiler. Local codes or special
conditions may require greater clearances.
E. 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 inlet connection at the rear of the boiler
through an outside wall.
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.
F. 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
PREINSTALLATION
1. PREINSTALLATION
Do not install this boiler on carpeting.
DANGER
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

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 where it will be
exposed to freezing temperatures.
WARNING
Figure 1.1: Accessibility Clearances – Floor Standing Units
Figure 1.2: Accessibility Clearances – Wall Hung Units

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

A. GENERAL
1. The water supply and return piping of this appliance
are to be sized according to system requirements. Do
not use piping smaller than the boiler connections.
2. In hydronic systems where sediment may exist,
install a strainer device in the boiler return piping to
prevent large particles and pipe scale from entering
the boiler heat exchanger coil. Use a large mesh
screen in the strainer.
3. Install this boiler so that the gas ignition system
components are protected from water (dripping,
spraying, etc.) during appliance operation and
service (circulator replacement, condensate trap
cleaning, control replacement, etc.).
B. OPERATING PARAMETERS
1. The Pinnacle boiler is designed to operate in a closed
loop hydronic system at approximately 15 psi. A
pressure limit in the boiler header will prevent the
unit from operating if the pressure drops below 10
psi. This is to keep the appliance from operating in
the event of a system leak or other condition in which
water is not flowing through the heat exchanger.
2. Table 3.1 shows minimum water flow rates for
Pinnacle boilers. If a glycol solution is to be used,
contact the factory for minimum flow rates.
C. SYSTEM COMPONENTS
1. Figure 3.1 shows the symbol key for piping diagrams
in this section. The following are brief description 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-T50 0.50 (1.89) 2 (7.6)
PI-T80 0.63 (2.40) 4 (15.2)
PI-80 0.63 (2.40) 4 (15.2)
PI-140 0.93 (3.50) 6 (22.7)
PI-199 1.13 (4.26) 8 (30.3)
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
5

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. The Table 3.2 shows the
Boiler Output as reported to the Hydronics
Institute division of GAMA. These values are
based on a pickup factor of 1.15.
WATER PIPING AND CONTROLS
Table 3.2 – Boiler Inputs and Outputs
Boiler
Model
Boiler Input
(Btu/hr [kW])
Net I=B=R Output
(Btu/hr [kW])
PI-T50 50,000 (14.7) 40,000 (11.7)
PI-T80 80,000 (23.4) 64,000 (18.8)
PI-80 80,000 (23.4) 64,000 (18.8)
PI-140 140,000 (41.0) 112,000 (32.8)
PI-199 199,000 (58.3) 159,000 (46.6)
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

7
c. The required flow rate can be calculated based
on the design temperature difference from the
return to the supply of the boiler. For a PI-T80
with a design temperature difference of 20°F the
calculation is as follows:
d. Table 3.3 shows the pressure drop (in feet of
water) for a flow rate which gives a 20°F
temperature difference for each boiler model.
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.
10. 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
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
Output 64,000
= = 6.4 GPM
∆T x 500 20 x 500
Required Flow =
Table 3.3 – Flow Rate and Pressure Drop
Boiler
Model
Flow Rate
(GPM [LPM])
Pressure Drop
(Feet [meters])
PI-T50 4.0 (15.1) 4.5 (1.22)
PI-T80 6.4 (24.2) 5.0 (1.52)
PI-80 6.4 (24.2) 5.0 (1.52)
PI-140 11.2 (42.4) 8.0 (2.44)
PI-199 15.9 (60.2) 13.0 (4.02)
Table 3.4 – Recommended Circulators
Boiler
Model
TACO
Circulator Grundfos Circulator
PI-T50 006 UPS 15-58FC SPD-1
PI-T80 007 UPS 15-58FC SPD-2
PI-80 007 UPS 15-58FC SPD-2
PI-140 0010 UPS 15-58FC SPD-3
PI-199 0011 UP 26-64F

8
D. SYSTEM PIPING
1. Figure 3.3 shows a single boiler with two zones. In
this application, the Peerless Partner indirect water
heater and the single heating zone require similar
water temperature.
2. Figure 3.4 shows an additional zone in which
baseboard radiation is the heat load. This zone also
requires water temperatures similar to the indirect
water heater.
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.
WATER PIPING AND CONTROLS
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Flow Rate (GPM)
Pressure Drop (Feet of Head)
PI-T50
PI-T80/80
PI-140
PI-199
Figure 3.2: Pinnacle Curculator Sizing Graph

9
Figure 3.3: One Boiler, Primary/Secondary with Two Zones (Zone Circulator)
WATER PIPING AND CONTROLS

10
Figure 3.4: One Boiler, Primary/Secondary with Three Zones (Zone Circulator)
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
Antifreeze solutions expand more than water. For example, a
50% by volume solution expands 4.8% for a 148°F
temperature rise while water expands about 3% for the same
temperature increase. Allowance for this expansion must be
considered in sizing expansion tanks and related components.
4. The flow rate in systems utilizing glycol solution
should be increased compared with a water system
to compensate for increased heating capacity.
5. Due to increased flow rate and fluid viscosity the
circulator head requirement will increase. Contact the
pump manufacturer to correctly size the circulator for
a particular application based on the glycol
concentration and heating requirements.
6. A strainer, sediment trap, or some other means for
cleaning the piping system must be provided. It
should be located in the return line upstream of the
boiler and must be cleaned frequently during the
initial operation of the system. Glycol solution is
likely to remove mill scale from new pipe in new
installations.
7. Glycol solution is expensive and leaks should be
avoided therefore weld or solder joints should be
used where possible and threaded joints should be
avoided. Make up water should not be added to the
system automatically when a glycol solution is used.
Adding make-up water may significantly dilute the
system.
8. Check local regulations to see if systems containing
glycol solutions must include a back-flow preventer
or require that the glycol system be isolated from the
water supply.
9. Do not use galvanized pipe in glycol systems.
10. Use water that is low in mineral content and make
sure there are no petroleum products in the solution.
11. Mix solution at room temperature.
12. Do not use a chromate treatment.
13. Do not use glycol solution in a system that may
reach temperatures above 250°F.
14. Refer to Technical Topics, #2a published by the
Hydronics Institute Division of GAMA for further
glycol system considerations.
F. SPECIAL APPLICATIONS
1. If the boiler is used in conjunction with a chilled
medium system, pipe the chiller in a separate
secondary loop.
a. Assure that the boiler circulator is disabled during
chiller operation so chilled water does not enter
the boiler.
b. Install a flow control valve (spring check valve) to
prevent gravity flow through the boiler.
c. See figure 3.8 for recommended system piping.
2. For boilers connected to heating coils in a forced air
system where they may be exposed to chilled air
circulation, install flow control valves or other
automatic means to prevent gravity circulation of the
boiler water during cooling cycles. See figure 3.9 for
illustration.
WATER PIPING AND CONTROLS

15
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

16
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 5.3 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
3/4" pipe. The boiler is supplied with a 3/4" NPT x
1/2" NPT bell reducer. Do not remove the reducer.
5. Size and install the gas supply piping for no more
than 0.5 inches of water pressure drop between the
gas regulator and the boiler.
C. GAS SUPPLY PIPING INSTALLATION
1. 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
Gas Input Rate* (ft³/hr)
Natural Gas LP Gas
PI-T50 50 20
PI-T80 80 32
PI-80 80 32
PI-140 140 56
PI-199 199 79
*Natural gas input rates are based on 1000 Btu/ft³, LP
input rates are based on 2500 Btu/ft³.
Pipe
Length
(Feet)
3/4" NPT
Pipe
1" NPT
Pipe
1-1/4"
NPT
Pipe
1-1/2"
NPT
Pipe
10 278 520 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
The values are based on a specific gravity of 0.60 (typical
for natural gas). See table 4.3 for capacity correction
factors for gases with other specific gravities.
Table 4.1: Gas Input Rates
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

17
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 4.2 and 4.3 are illustrations of the gas shutoff
valve for the Pinnacle Boiler. This valve is to be used
in addition to the gas service valve shown
in Figure 4.1.
D. GAS SUPPLY PIPING - OPERATION
1. The gas line must be properly purged of air to allow
boiler to operate. Failure to do so may result in
burner ignition problems.
2. Table 4.4 shows the maximum and minimum supply
pressure to the boiler.
a. Gas pressure below the minimum pressure may
result in burner ignition problems.
b. Gas pressure above the maximum may result in
damage to the gas valve.
GAS PIPING
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
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: PI-80/PI-140/PI-199
Gas Valve Shut Off
Figure 4.3: PI-T50/PI-T80 Gas Valve Shut Off

18
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
inlet pressure tap fitting (see figure 4.4 and 4.5)
one turn counterclockwise.
d. Attach the manometer tube to the pressure tap
fitting.
e. Open the gas shutoff valve and start the boiler.
f. Read and record the gas pressure while the boiler
is firing.
g. Turn off the boiler and gas shutoff valve
h. Remove the manometer tube from the pressure
tap fitting and turn the screw to close the internal
valve.
i. Turn on the gas shutoff valve and boiler service
switch.
4. All gas piping must be leak tested prior to placing the
boiler in operation.
a. If the leak test pressure requirement is higher
than the maximum inlet pressure noted in Table
4.4, the boiler must be isolated from the gas
supply piping system.
b. If the gas valve is exposed to pressures exceeding
13.5" of water, the gas valve must be replaced.
5. Install the boiler such that the gas ignition system
components are protected from water (dripping,
spraying, rain, etc) during operation and service
(circulator replacement, condensate trap cleanout,
and control replacement, etc).
E. MAIN GAS VALVE - OPERATION
1. Figure 4.4 shows an illustration of the gas valve/venturi
assembly for the Pinnacle PI-T50 and PI-T80 and
Figure 4.5 shows an illustration of the gas valve/venturi
assembly for the PI-80, PI-140, and PI-199.
a. The throttle screw on either of these valves
should not be adjusted without a means to
measure carbon monoxide (CO) and carbon
dioxide (CO²) emissions.
b. For both gas valve arrangements, 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
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
Gas
Type
Pressure (inches of water)
Minimum Maximum
Natural 3.7 13.5
LP 3.7 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
Figure 4.4: Gas Valve/Venturi PI-T50/PI-T80
Figure 4.5: Gas Valve/Venturi PI-80, PI-140, PI-199