PeerlessBoilers MI-03, Installation & Maintenance Manual

Page 1: ...MI MIH Boilers Series Gas Installation Operation Maintenance Manual ...

Page 2: ...RICAL 16 A WIRING 16 B ZONED SYSTEM WIRING 16 C CONTROLS 16 D SEQUENCE OF OPERATION 17 7 START UP PROCEDURES 21 A COMPLETING THE INSTALLATION 21 B CONTROL DESCRIPTIONS 25 C ADJUSTMENT OF GAS PRESSURE REGULATOR 25 D ADJUSTMENT OF PILOT GAS FLOW 25 E CHECKING BURNER INPUT 26 F CHECK OUT PROCEDURE 26 8 TROUBLESHOOTING 28 A SHUT DOWN CAUSED BY PILOT OUTAGE BLOCKED VENT SHUT OFF SWITCH OR FLAME ROLL OU...

Page 3: ...o 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...

Page 4: ...he air infiltration rate is known to be between 0 6 and 0 4 air changes per hour If the air infiltration rate is known to be below 0 4 then the Known Air Infiltration Rate Method must be used If the building in which this appliance is to be installed is unusually tight PB Heat recommends that the air infiltration rate be determined b Known Air Infiltration Rate Method Where the air infiltration ra...

Page 5: ...ing with additional spaces that have a total minimum free area of 2 in2 per 1000 Btu hr 44 cm2 per 1000 W of total input rating of all equipment See Figure 1 2 for an illustration of this arrangement 4 Outdoor Combustion Air Outdoor combustion air is to be provided through one or two permanent openings The minimum dimension of these air openings is 3 inches 76 mm a Two Permanent Opening Method Pro...

Page 6: ...available indoor air provided a The size and location of the indoor openings comply with Subsection 3 b The outdoor openings are to be located in accordance with Subsection 4 c The size of the outdoor openings are to be sized as follows where Areq minimum area of outdoor openings Afull full size of outdoor openings calculated in accordance with Subsection 4 Vavail available indoor air volume Vreq ...

Page 7: ...e appliances c Ducts shall serve a single space d Ducts shall not serve both upper and lower combustion air openings where both such openings are used The separation between ducts serving upper and lower combustion air openings shall be maintained to the source of combustion air e Ducts shall not be screened where terminating in an attic space f Horizontal upper combustion air ducts shall not slop...

Page 8: ... installation position before removing crate 3 If using combustible floor pan position pan on foundation or flooring 4 Separate the wood shipping pallet from the boiler base by removing two 2 hold down bolts at each end of the boiler base 5 Move boiler into final position If using combustible floor pan install boiler on pan as outlined in the instructions included with the pan 2 BOILER SET UP ...

Page 9: ...m of the left section Pipe the return to the tee Pipe the drain valve nipples and tee to the 1 1 4 NPT return tapping as shown in Figure 3 1 3 Supply Piping Pipe the supply to the 1 1 2 NPT supply tapping at the top and rear of the boiler 4 When system return water temperature will be below 130 F 54 C pipe the boiler with a bypass arrangement to blend the system return and hot supply to obtain at ...

Page 10: ...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 B SAFETY RELIEF VALVE 1 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 3 3 ...

Page 11: ... 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 WATER PIPING AND CONTROLS Figure 3 5 Zone Piping with Zone Valves Figure 3 6 Zone Piping with Circulators ...

Page 12: ...ms that must be freeze protected 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 glycol solution should be tested at least once a year and as recommended by the glycol manufa...

Page 13: ...ood outlet vent connector on top of the boiler or in vent piping close to the boiler See the Vent Damper Installation Instructions below B VENT DAMPER INSTALLATION GENERAL 1 Do not use one vent damper to control two or more heating appliances See Figure 4 1 2 Follow these and the installation instructions that are included with the vent damper Observe the cautions and warnings that accompany all i...

Page 14: ...epair as necessary 3 Install vent pipe to slope upward at least 1 4 per lineal foot 21 mm per meter between the draft hood outlet and the chimney 4 Before connection of joints inspect the vent pipe interior for foreign objects such as tools equipment rags etc and remove if present 5 Insert vent pipe into but not beyond the inside wall of the chimney flue 6 Do not connect vent connectors serving ap...

Page 15: ...te a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e 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 f After it has been determined that each a...

Page 16: ...sted location is shown in Figure 5 1 7 Check piping for leaks Use an approved gas detector a non corrosive leak detection fluid or other leak detection method If leaks are found turn off all gas flow and repair as necessary 8 Disconnect the boiler and its individual shut off valve from the gas supply piping system during any pressure testing of that system at test pressure in excess of 1 2 psig 3 ...

Page 17: ...8 2 2 MI 08 91 2 6 MI 09 104 2 9 Pipe Length in Feet Meters 3 4 Pipe 1 Pipe 1 1 4 Pipe 1 1 2 Pipe 10 3 0 278 7 9 520 14 7 1050 29 7 1600 45 3 20 6 1 190 5 4 350 9 9 730 20 7 1100 31 1 30 9 1 152 4 3 285 8 1 590 16 7 890 25 2 40 12 2 130 3 7 245 6 9 500 14 2 760 21 5 50 15 2 115 3 3 215 6 1 440 12 5 670 19 0 60 18 3 105 3 0 195 5 5 400 11 3 610 17 3 Maximum Capacity Correction Factors for Specific ...

Page 18: ...the various controls 3 This boiler is supplied with safety devices in addition to the limit For a description of these devices and how they work to ensure the safe operation of the boiler see Section 7B 4 If the circulator is mounted in the supply piping provide longer wiring harness as required ELECTRICAL 6 ELECTRICAL This unit when installed must be electrically grounded in accordance with the r...

Page 19: ...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 ...

Page 20: ...t 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 vent damper closes d If temperatur...

Page 21: ...19 Figure 6 4 Intermittent Ignition System Operating Sequence ELECTRICAL ...

Page 22: ...ELECTRICAL Figure 6 5 Zone Wiring with Zone Valves Figure 6 6 Zone Wiring with Circulators 20 ...

Page 23: ...ings throughout the system for leaks If leaks are found drain the system and repair as required 8 Connect a manometer to the gas valve on the valve outlet gas manifold Use the 1 8 NPT tapping provided 9 Confirm that the gas supply pressure to the boiler is above the minimum and below the maximum values for the gas being used See the end of Section 5 for these values If a supply pressure check is r...

Page 24: ... Valve Manifold and Burner Assembly Standing Pilot Continuous Ignition Figure 7 2 Gas Valve Manifold and Burner Assembly Intermittent Ignition Figure 7 3 Valve Tapping and Adjustment Screw Locations START UP PROCEDURES ...

Page 25: ...23 START UP PROCEDURES Figure 7 4 Operating Instructions ...

Page 26: ...AS TO APPLIANCE 8 Find pilot follow metal tube from gas valve The pilot is between two burner tubes Pilot Burner 9 Turn the gas control knob counterclockwise to PILOT 10 Push in red reset button all the way and hold in Immediately light the pilot with a match Continue to hold the reset button in for about one 1 minute after the pilot is lit Release button and it will pop back up Pilot should remai...

Page 27: ...kwise to decrease pressure clockwise to increase pressure Refer to Figure 7 3 for location of gas pressure regulator Replace the cap screw when adjustment is complete 3 In no case should the final manifold pressure vary more than 0 3 inches water column 0 07 kPa from the above specified pressures Any necessary major changes in the flow should be made by changing the size of the burner orifice spud...

Page 28: ... dial to its previous setting 2 To check operation of the ignition system safety shut off features a Standing Pilot i Turn the gas control knob counterclockwise to PILOT The main burner should go out and the pilot should remain lit ii Extinguish the pilot flame Pilot gas flow should stop within 2 1 2 minutes Complete shutdown is proven since the safety shut off valve has stopped main and pilot gas...

Page 29: ...on pitting 5 Check the expansion tank and automatic fill valve if used to confirm that they are operating correctly If either of these components causes high pressure in the system the boiler relief valve will weep or open allowing fresh water to enter the system 6 Do not allow the system controls to subject the boiler to excessively low water temperatures which would cause condensation of flue ga...

Page 30: ...ndividuals must follow all applicable codes and regulations in repair of any boiler problems TROUBLESHOOTING 8 TROUBLESHOOTING Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump This may aggravate the problem and increase the likelihood of boiler damage Instead shut off the gas supply at a location external to the appliance C...

Page 31: ...ntilation and venting system 1 Insufficient pilot flame 2 Pilot burner orifice clogged 3 Overfiring 4 Misaligned burners or pilot 5 Draft problem in boiler room Delayed ignition 1 Increase pilot gas flow 2 Clean pilot burner and orifice 3 Reduce rate to input on rating label 4 Realign burners or pilot 5 Check air supply ventilation and venting system 1 Underfiring 2 Limit Aquastat set too low 3 Ve...

Page 32: ...30 Figure 8 1 Intermittent Ignition System Troubleshooting Sequence TROUBLESHOOTING ...

Page 33: ...rovide adequate ventilation Wear a NIOSH MSHA approved respirator Wear long sleeved loose fitting clothing and gloves to prevent skin contact Wear eye goggles Minimize airborne dust prior to handling and removal by water misting the material and avoiding unnecessary disturbance of materials Wash work clothes separately from others Rinse washer thoroughly after use Discard RCF materials by sealing ...

Page 34: ...r pressure should never be higher than 5 psi 35 kPa below the rating shown on the safety relief valve 25 psig 172 kPa maximum for a 30 psig 207 kPa rating 45 psig 310 kPa maximum for a 50 psig 345 kPa rating The valve rating can be found on the top of the safety relief valve see Figure 5 for location of the safety relief valve Boiler temperature should never be higher than 250 F 121 C 4 Check for ...

Page 35: ...et seal between the flue collector and top section makes a tight seal to prevent leakage of the products of combustion h Re install the top of the jacket vent damper and vent pipe i Re install burners 2 Inspect entire venting system for corrosion support and joint integrity Repair as necessary 3 Check the pilot and main burner flame See Figures 9 1 and 9 2 The pilot should provide a steady flame e...

Page 36: ... 9 244 21 554 6 152 MI MIH 06 22 575 26 676 31 797 11 287 21 554 6 152 MI 07 26 660 26 676 31 797 13 330 21 554 7 178 MI 08 29 746 29 752 31 797 14 373 23 592 8 203 MI 09 32 832 29 752 31 797 16 416 24 618 8 203 SERIES MI MIH BOILER RATINGS Boiler Model Number Input DOE Heating Capacity Net I B R Ratings Water Seasonal Efficiency Std Pilot w Damper Seasonal Efficiency Intermittent Ignition Water C...

Page 37: ...PARTS Table 11 1 Base Combustible Floor Pan 1 2 3 4 Base Assembly Observation Cover Door Base Blanket Seal Combustible Floor Pan Assembly Item No Description 7800 51771 50867 90700 7806 51771 50867 90706 7805 51771 50867 90705 7804 51771 50867 90704 7803 51771 50867 90703 7802 51771 50867 90702 7801 51771 50867 90701 Specify length Part Selection Information MI MIH 03 MI MIH 04 MI MIH 05 MI MIH 06...

Page 38: ... Natural Gas 0 2000 ft 0 610 m elevation specify qty 50895 50895 50895 Orifice Spud 56 LP Gas 0 2000 ft 0 610 m elevation specify qty 50899 50899 50899 50899 Orifice Spud 57 LP Gas 0 2000 ft 0 610 m elevation specify qty 50900 50900 50900 9 Honeywell VR8200A2116 Gas Valve Natural Gas 50581 50581 50581 Honeywell VR8200C6040 Gas Valve LP Gas 50221 50221 50221 Honeywell VR8300A4003 Gas Valve Natural ...

Page 39: ...899 50899 Orifice Spud 57 LP Gas 0 2000 ft 0 610 m elevation specify qty 50900 50900 50900 9 Honeywell SV9501M2700 Gas Valve Natural Gas 51682 51682 51682 Honeywell SV9501M2064 Gas Valve LP Gas 51691 51691 51691 Honeywell SV9601M4167 Gas Valve Natural Gas 51683 51683 51683 51683 Honeywell SV9601M4225 Gas Valve LP Gas 51692 51692 51692 51692 10 Honeywell Q3480B1025 Pilot Natural Gas 51684 51684 516...

Page 40: ...66 90424 90515 50866 90423 90514 50866 90422 90513 50866 90421 90512 50866 90420 90511 50866 Specify length Part Selection Information MI MIH 03 MI MIH 04 MI MIH 05 MI MIH 06 MI 07 MI 08 MI 09 Table 11 4b Flue Baffles for MIH Only 15 Flue Baffle 4 Flue Baffle 8 Item No Description 51583 51584 51583 51583 1 per flue specify qty 1 per flue specify qty Part Selection Information MIH 03 MIH 04 MIH 05 ...

Page 41: ... MI MIH 04 MI MIH 05 MI MIH 06 MI 07 MI 08 MI 09 16 Jacket Assembly Complete jacket with insulation and screws 90445 90446 90447 90448 90449 90450 90451 16 16 16 16 16 16 Complete Jacket Consists of Left Side Panel Right Side Panel Rear Panel Top Upper Front Panel Inner Front Baffle Panel Removable Front Panel ...

Page 42: ...317 51317 25 Safety Relief Valve 30 psi Conbraco 10 408 05 50501 50501 50501 50501 50501 50501 50501 Safety Relief Valve 50 psi Watts 350 99950 99950 99950 99950 99950 99950 99950 26 Flame Roll Out Safety Shut Off Switch 51587 51587 51587 51587 51587 51587 51587 27 Blocked Vent Shut Off Spill Switch MI Only 90592 90592 90592 90592 90592 90592 90592 27 Blocked Vent Shut Off Spill Switch MIH Only 90...

Page 43: ...nual is the property of the owner and must be affixed near the boiler for future reference TO THE OWNER This boiler should be inspected annually by a Qualified Service Agency MI8038 R10 8 06 10M Printed in U S A 2006 PB HEAT LLC PO BOX 447 NEW BERLINVILLE PA 19545 0447 HI Division of gama ASME ...