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PB Heat MI User's Manual

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1. CORRECT 11 VENTING C VENT PIPING AND CHIMNEY 4 Before connection of joints inspect the vent pipe interior for foreign objects such as tools equipment 1 Install vent piping in accordance with Venting of rags etc and remove if present Equipment part of the National Fuel Gas Code ANSI T 2223 1 NFPA 54 sections 7 2 7 3 or 7 4 of 5 Insert vent pipe into but not beyond the inside wall CAN CSA B149 1 Natural Gas and Propane of the chimney flue Installation Code or applicable provisions of the 6 Do not connect vent connectors serving appliances local buildi des EE vented by natural draft into any portion of mechanical draft systems operating under positive pressure 2 Inspect the existing chimney and lining for structural soundness corrosion and perforations Repair as necessary 2 7 Support horizontal portions of the venting system to prevent sagging by use of metal strapping or equivalent means Locate supports at no more than 4 foot 1 2 meter intervals 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 SLOPE UP A E VENT TO CHIMNE Y PER FOOT 21mm PER METER VENT DAMPE DRAF N SUPPORT HOOD AS REQUIRED RELIEF OPENING D
2. MI MIH CE ER Boilers Installation Operation amp Maintenance Manual TABLE OF CONTENTS USING THIS MANUAL 1 A COMPLETING THE INSTALLATION 21 A INSTALLATION SEQUENCE 1 B CONTROL DESCRIPTIONS 25 B SPECIAL ATTENTION BOXES 1 C ADJUSTMENT OF GAS PRESSURE REGULATOR za fete edt 25 1 PREINSTALLATION 2 D ADJUSTMENT OF PILOT GAS FLOW 25 A ACCESSIBILITY CLEARANCES 2 E CHECKING BURNER 26 B CLEARANCE FROM COMBUSTIBLE CHECK OUT PROCEDURE 26 CONSTRUCTION 2 C AIR FOR COMBUSTION AND 8 TROUBLESHOOTING 28 VENTILATION 2 A SHUT DOWN CAUSED BY PILOT OUTAGE BLOCKED VENT SHUT OFF SWITCH OR D INSTALLATION SURVEY 5 Ge DUE S EET SIE OE E PLANNING THE LAYOUT 5 SWITCH See ee 28 eT le B TROUBLESHOOTING GUIDES 28 9 MAINTENANCE 31 SSE MBI EF PIPING ANDIGONTREDES 1 A GENERAL vats 32 A BOILER SUPPLY AND RETURN 7 B DAILY WITH BOILER IN USE B SAFETY RELIEF VALVE 8 C WEEKLY WITH BOILER IN USE 3 C PIPING FOR ZONED SYSTEMS 9 D MONTHLY WITH BOILER IN USE SS D EXPANSION TANK 10 E ANNUALLY BEFORE START OF HEATING E INDIRECT FIRED WATER HEATER 10 SEASON 33 FREEZE PROTECTI
3. representative or download it from PeerlessBoilers com i The interlock shall prevent the main burner from igniting if the damper fails to open during burner startup ii The interlock shall shut down the burner if E PLANNING THE LAYOUT the damper closes during burner operation Prepare sketches and notes of the layout to minimize the possibility of interferences with new or existing 9 Combustion Air Ducts uw equipment piping venting and wiring a Ducts shall be constructed of galvanized steel or an equivalent corrosion resistant material b Ducts shall terminate in an unobstructed space allowing free movement of combustion air to the 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 BOILER SET UP 1 Provide a sound level foundation Locate boiler as near to the chimney or outside wall as possible and centralized with respect to the heating system 2 Locate boiler in front of installation position before removing crate 3 If using combustible floor pan position pan on foundation or flooring Separate the wood shipping pallet from the boiler base by removing two 2 hold down bolts at each end of the boiler base Move boiler into final position If usin
4. Boiler LP Gas Input Cubic Feet Hour Cubic Meters Hour Table 5 3 MIH Boiler Natural Gas Input Cubic Feet Hour Cubic Meters Hour Table 5 4 Pipe Capacity Capacity of pipe of different diameters and lengths in cubic feet per hour cubic meter per hour with a pressure drop of 0 3 inches of water 75 Pa and specific aravity of 0 60 No allowance for an ordinary number of fittings is required Pipe Length in Feet Meters 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 Gravity other than 0 60 Specific Gravity Correction Factor Specific Gravity Correction Factor Specific Gravity Correction Factor 15 6 ELECTRICAL Install all electrical wiring in accordance with the National Electrical Code and local requirements NOTICE This unit when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the current edition of the National
5. Electrical Code ANSI NFPA 70 and or the Canadian Electrical Code Part 1 CSA C22 1 Electrical Code CONTROLS 1 See Figure 6 1 for location of wiring and controls 1 For proper location of controls and accessories refer Use Figures 6 2 and 6 3 to connect the boiler to a to Figure 6 1 and Section 11 power supply and to connect components to the boiler 2 See the attached control sheets for specific details regarding the installation of the various controls 2 Connect the boiler by a separate permanently live electrical supply line with a fused switch 3 This boiler is supplied with safety devices in addition to the limit For a description of these devices and 3 Connect the vent damper harness to the damper how they work to ensure the safe operation of the motor as shown in Figure 6 1 boiler see Section 7B 4 Adjust the thermostat heat anticipator to 0 2 Amp 4 If the circulator is mounted in the supply piping B ZONED SYSTEM WIRING See Figure 6 5 for typical wiring with zone valves See Figure 6 6 for typical wiring with zone circulators When wiring a zoned heating system follow all applicable codes ordinances and regulations NOTICE 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 SAFETY RELIEF VALVE TEMPERATURE PRESSURE GAUGEA TO THERMOST
6. Off if used Consult the manufacturer s instructions for the low water cut off operational check procedure Check the system to make sure there are no leaks or overfilling problems which might cause excessive make up water to be added Make up water causes liming in the boiler and brings in oxygen Oxygen can cause severe damage to the boiler though oxygen corrosion pitting 5 10 START UP PROCEDURES 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 Do not allow the system controls to subject the boiler to excessively low water temperatures which would cause condensation of flue gases and corrosion of the boiler Operate the boiler at a temperature above 130 F 54 C Adjust the boiler limit as required to maintain boiler temperature above this level Check the general condition of the system including piping support joints etc Check cleanliness of the radiators baseboard units and or convectors Clean them to the extent possible If radiators do not heat evenly vent any remaining air from them Review operation and User s Information Manual with end user Complete the Warranty Card and submit it to PB Heat LLC Hang the Installation Operation and Maintenance Manual and Information Manua
7. ake THERMOSTAT THERMOSTAT THERMOSTAT 24V 24V 24V J Box J Box I m e e E JUMPER FACTORY AQUASTAT INSTALLED RELAY HONEYWELL O L8148E ZONE 1 ZONE 2 VALVE VALVE NOTES O ALL WIRING MUST COMPLY WITH APPLICABLE CODES ORDINANCES AND REGULATIONS WIRE REMAINDER OF AQUASTAT RELAY IN ACCORDANCE WITH SYSTEM WIRING DIAGRAM SUPPLIED LEGEND BOILER CIRCULATOR LINE VOLTAGE LOW VOLTAGE TRANSFORMER l F 40VA Figure 6 5 Zone Wiring with Zone Valves 120V 60HZ L1 HOT TO MAIN DISCONNECT L2 SWITCH ON zi ZONE 2 ZONE 3 ZONE 1 THERMOSTAT THERMOSTAT PE THERMOSTAT 24V 24V I I DOO E o I JUMPER ay ud 1 cse WMPER OF OH INSTALLED O E orl Bi Xe ates Eee nets O el HONEYWELL G INSTALLED GH INSTALLED 18148 5 e eae E Fog D 2 ZONE 2 ZONE 3 1 SWITCHING SWITCHING Kei RELAY RELAY peek ah ZONE 2 ZONE 3 x CIRCULATOR CIRCULATOR EE fee ee AD t EE 4 I BOILER I CIRCULATOR beeen eee sees eee ZONE 1 NOTES LEGEND LINE VOLTAGE LOW VOLTAGE ALL WIRING MUST COM
8. any part has been under water Improper or dangerous operation may result Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water N CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing N CAUTION 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 TROUBLESHOOTING Table 8 1 PROBLEM POSSIBLE CAUSES Boiler Troubleshooting Guide CORRECTIVE ACTIONS Burners not functioning 1 No power 1 Check line voltage wiring and fuses 2 Limit Aquastat not working 2 Check wiring and contacts relay temperature setting Clean and adjust as necessary 3 Flame rollout switch open 3 Replace switch Locate cause and correct 4 Blocked vent switch open 4 Reset blocked vent switch Locate cause and correct 5 Gas off at boiler gas valve 5 Start boiler using Lighting Operating Instructions 6 Gas off external to boiler 6 Check any gas valves in the line 7 Plugged orifice spuds 7 Check clean and re install 8 Defective gas valve 8 Use Figure 8 1 to t
9. any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department Use only your hand to slide the gas control switch Never use tools If the switch will not slide by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water game ee INSTRUCTIONS 8 STOP Read the safety information above on this label Set the thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand GAS CONTROL OUTLET 5 Ifthe gas valve is not visible remove control access panel If the gas control switch is not in the OFF position slide the switch to OFF Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow in the safety information above this label If you don t smell gas go to the next step Slide the gas control switch to ON Replace cont
10. at least once a year and as recommended by the glycol manufacturer 3 Glycol solutions expand more than water For example a 50 by volume solution expands 4 8 in volume for a temperature increase from 32 F 0 C to 180 F 82 C while water expands 3 with the same temperature rise Allowance must be made for this expansion in system design 4 For more information consult the PB Heat Water Installation Survey and the glycol manufacturer SYSTEM CHECK CIRCULATOR VALVE PRESSURE REGULATOR SUPPLY TO SYSTEM EXPANSION WATER ZONE VALVES TANK et RETURN FROM SYSTEM E SHUTOFF SHUTOFF INDIRECT FIRED WATER VALVE HEATER BALANCING HOT DOMESTIC VALVE WATER SUPPLY Seet COLD BALANCING DOMESTIC VALVE WATER SUPPLY Figure 3 7 Typical Piping with Indirect Fired Water Heater 10 4 VENTING A INTEGRAL DRAFT HOOD B VENT DAMPER INSTALLATION GENERAL 1 The MI MIH boiler is equipped with a built in draft hood This device is designed to 1 Do not use one vent damper to control two or more a provide for the ready escape of flue gases from the boiler in the event of no draft b prevent a backdraft from entering the boiler c control stack draft during operation These tasks are accomplished without the extra height requirements of a separate draft hood heating appliances See Figure 4 1 Follow these and the installation
11. to be provided to the boiler in cubic feet per hour To obtain this value divide the Btu per hour rating on the boiler rating plate by the heating value of the gas in Btu per cubic feet Obtain the heating value of the gas from the gas supplier As an alternative use Table 5 1 5 2 or 5 3 on the next page to obtain the volume of gas to be provided to the boiler 3 Use the value obtained above as the basis for piping sizing Size the gas piping in accordance with Table 5 4 Consult the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code for proper sizing options 4 Locate the drop pipe adjacent to but not in front of the boiler 5 Install a sediment trap See Figure 5 1 Locate a tee in the drop pipe at same elevation as the gas inlet connection to the boiler Extend the drop pipe to a pipe cap 6 Install a ground joint union ahead of the gas control assembly to permit servicing of the control Some local codes require an additional service valve when using the combination gas controls If your code requires such a valve a suggested location is shown in Figure 5 1 A WARNING Use a pipe joint sealing compound that is resistant to the action of liquefied 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 7 Check piping for leaks Use an approved gas detector a no
12. 610 mm between top of jacket and combustible construction 3 6 152 mm between draft hood and combustible construction 4 6 152 mm between vent pipe and combustible construction 5 10 254 mm between rear of jacket and combustible construction A WARNING Do not install this boiler on combustible flooring unless it is installed on a special combustible floor pan provided by PB Heat LLC 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 WARNING Do not install this boiler on carpeting Boiler installation on carpeting is a fire hazard Install this boiler on non combustible flooring or use a combustible floor pan to install this boiler on other non carpeted flooring AIR FOR COMBUSTION AND VENTILATION 1 Adequate combustion air and ventilation air must be provided for this appliance in accordance with the section of the National Fuel Gas Code entitled Air for Combustion and Ventilation or applicable provisions of the local building code Subsections 2 through 8 as follows are based on the National Fuel Gas Code requirements 2 Required Combustion Air Volume The total required volume of indoor air is to be the sum of the required volumes for all appliances located within the space Rooms communicating directly with the space in which the appliances are insta
13. 899 50899 50899 50899 elevation specily LP Gas 0 2000 ft 0 610 m Orifice Spud 57 50900 50900 50900 elevation specify qty 9 Honeywell VR8200A2116 Gas Valve Natural Gas 50581 50581 50581 Honeywell VR8200C6040 Gas LP Gas 50221 50221 50221 Honeywell VR8300A4003 Gas Valve Natural Gas 50587 50587 50587 50587 Honeywell VR8300C4035 Gas LP Gas 91333 91333 91333 91333 10 Honeywell Q314A3505 Pilot Natural Gas 51688 51688 51688 51688 51688 51688 51688 Honeywell Q314A3703 Pilot LP Gas 50555 50555 50555 50555 50555 50555 50555 11 Johnson K16BA 24D Thermocouple 51318 51318 51318 51318 51318 51318 51318 For elevations over 2 000 feet above sea level contact PB Heat LLC 36 REPAIR PARTS Figure 11 3a Gas Valve and Pilot Standing Pilot Continuous Ignition Ignition Figure 11 3b Gas Valve and Pilot Intermittent Table 11 3a Manifold Gas Train MI Intermittent Ignition Item ee Part Selection 5 Steel Burner Specify quantity 51537 51537 51537 51537 51537 51537 51537 6 Steel Burner w Pilot Clip 1 per boiler 51539 51539 51539 51539 51539 51539 51539 7 Gas Manifold 50978 50979 50980 50981 50954 50955 50956 Natural Gas 0 2000 ft 0 610 m 8 Orifice Spud 48 da 50894 50894 50894 50894 elevation specily q
14. AT TO LINE VOLTAGE POWER SUPPLY TO CIRCULATOR Figure 6 1 Wiring Controls and Safety Devices 16 provide longer wiring harness as required AUTOMATIC VENT DAMPER 7 GAS VALVE BLOCKED VENT SWITCH BURNER OBSERVATION COVER FLAME ROLLOUT SWITCH ELECTRICAL CONNECTION DIAGRAM LADDER DIAGRAM VENT 24V THERMOSTAT BY OTHERS 115 60 1 12 DAMPER POWER LB148E COMBINATION SUPPLY i pe d LIMIT CONTROL 3241 CIRCULATOR BK w FACTORY Bk 4 3 cl Ft 19 0 INSTALLED E MO JUMPER ye FUSED DISCONNECT FUSED RI V 7 SWITCH DISCONNECT SERVICE R SWITCH SWITCH s 4 PRIMARY SEN o Jo TRANSFORMER L2 115 60 1 fet peo eos 9 power SECONDARY SUPPLY 0 982 ud o SERVICE 12 SWITCH _ EE RELAY THESE ITEMS TO Ww COIL T THERMOSTAT BY INSTALLER ree gt SE o R o B O T THERMOCOUPLE pah i EE FLAME ROLLOUT eure r BVS FRS SWITCH FRS Ken KE ccu pex E Y I BLOCKED VENT VALVE 1 TH I TCH fave y Y pc GAS E LJ L SMTH GNO a vae UEM R RED R2 LIMIT SENT BK BLACK H H o p 0 o gt 2 gt DAMPER w WHITE CONNECTION DIAGRAM LEGEND D GRANGE e x A OCOUPLE UNE VOLTAGE SIZ
15. CH BVS 3 t p SWrm e BK BLACK mos D WHITE B R B VENT 0 HH 0 2 gt 5 DAMPER CONNECTION DIAGRAM LEGEND BL BLUE Ee LUNE VOLTAGE SIZE 14 AWG TYPE TW TFFN OR TEW AWM WIRE BiH BLACK GNITOR FLAME LINE VOLTAGE SIZE 16 18 AWG TYPE TW TFFN OR TEW AWM WIRE STRIPE LADDER DIAGRAM LEGEND ELEMENT SENSOR group LOW VOLTAGE SIZE 18 AWG TYPE CL2X CABLE PILOT HONEYWELL PILOT WIRE 2 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE o REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN MI SV NI016 RO Figure 6 3 Wiring and Connection Diagram Intermittent Ignition 2 Intermittent Ignition see Figure 6 3 above the blocked vent switch is closed and the flame rollout switch is closed When the call for heat ends a The vent damper is continuously powered On a call for heat limit relay R is energized which energizes g e Limit relay R de energizes which opens e the circulator when used through contact contacts R1 and R2 R1 and e the vent damper operator through contact R2 provided that the high limit aquastat switch is closed e The circulator shuts down e The gas valve de energizes The vent damper closes The damper operatorionens iha want damper d If temperature exceeds limit setting main burners SR P shut off and circulator continues to operate b Once the damper is proven ope
16. E 14 AWG TYPE TW TEEN OR TEW AWM WIRE BL BLUE LADDER DIAGRAM LEGEND THERMOCOUP LINE VOLTAGE SIZE 16 18 AWG TYPE TW TFFN OR TEW AWM WIRE E 490 INTERNAL MAING LOW VOLTAGE SIZE 18 AWG TYPE CL2X WIRE ZNATE 200 EXTERNAL WIRING LOW VOLTAGE SIZE 16 18 AWG WIRE TYPE TEW AWM TFFN WIRE STRIPE GE Le NOTES 24V EXTERNAL WIRING 1 ALL WIRING MUST COMPLY WITH APPLIANCE CODES ORDINANCES AND REGULATIONS 18148 TERMINAL 2 IF OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN 5106 M7017 RO Figure 6 2 Wiring and Connection Diagram Standing Pilot Continuous Ignition 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 D SEQUENCE OF OPERATION 1 Standing Pilot See Figure 6 2 above a The vent damper is continuously powered On a call for heat limit relay R is energized which energizes e the circulator when used through contact R1 and c When the call for heat ends e the vent damper operator through contact R2 e Limit relay R de energizes which opens provided that the high limit switch is contacts 1 and R2 1 5 SES The circulator shuts down Th t t the d e vent damper
17. ELECTRICAL CONNECTION THROUGH THE PILOT NO MAIN VALVE OPENS AND MAIN BURNER LIGHTS TUBING IF BOTH OF THE ABOVE ARE GOOD REPLACE IGNITER FLAME ROD ASSEMBLY SYSTEM IS OKAY lt o NO MAIN BURNER LIGHTS REPLACE GAS VALVE CYCLE THERMOSTAT OFF AND BACK ON Figure 8 1 Intermittent Ignition System Troubleshooting Sequence 30 9 MAINTENANCE AA WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers RCF Airborne RCF when inhaled have been classified by the International Agency for Research on Cancer IARC as a possible carcinogen to humans After the RCF materials have been exposed to temperatures above 1800 F 980 C they can change into crystalline silica which has been classified by the IARC as carcinogenic to humans If particles become airborne during service or repair inhalation of these particles may be hazardous to your health Avoid Breathing Fiber Particulates and Dust Suppliers of RCF recommend the following precautions be taken when handling these materials Precautionary Measures Provide 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
18. IR OPENINGS For fan assisted appliances calculate the required Minimum Total gt in er u volume of air using the following equation 44 1000 W Required 15 3 Tes ACH 10008 lg Input of the fan assisted appliances in BOILER Btu hr Note These calculations are not to be used for infiltration rates greater than 0 60 ACH E MI EU T ME 2 3 Indoor Air Opening Size and Location Openings Figure 1 2 Openings All Air from Indoors connecting indoor spaces shall be sized and located on Different Floors as follows a Combining spaces on the same floor Provide two permanent openings communicating with additional spaces that have a minimum free inas is 3 inches 76 area of 1 in2 per 1000 Btu hr 22 cm2 per 1000 W openings is 3 inches 76 mm f of the total input rating of all gas fired equipment a Two Permanent Opening Method Provide but not less than 100 in2 645 cm2 One two permanent openings One opening is to opening is to begin within 12 inches 305 mm begin within 12 inches 305 mm of the top of from the top of the space and the other is to the space and the other is to begin within 12 begin within 12 inches 305 mm from the floor inches 305 mm of the floor The openings are The minimum dimension of either of these to communicate directly or by ducts with the openings shall be 3 inches 76 mm See Figure outdoors or with spaces that freely c
19. LVE SUPPLY LINE BOILER WATER THREE WAY CHILLER VALVE Figure 3 2 Parallel Hook Up with Water Chiller SAFETY RELIEF VALVE SUPPLY 3 4 X 6 NIPPLE TO DRAIN Figure 3 3 Safety Relief Valve Hook Up Installation with Air Elimination in System Piping TO AIR ELIMINATION DEVICE SUPPLY 3 4 TEE SAFETY RELIEF VALVE 3 4 X 6 NIPPLE 3 4 x 2 NIPPLE TO DRAIN 3 4 STREET ELBOW Figure 3 4 Safety Relief Valve Hook Up with Air Elimination WATER PIPING AND CONTROLS C PIPING FOR ZONED SYSTEMS 1 See Figures 3 5 and 3 6 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 3 2 1 ZONE SYSTEM VALVES CIRCULATOR CONNECT CHECK TO TO BYPASS VALVE SUPPLY CITY WATER P4 SHUTOFF VALVE PRESSURE REGULATOR Figure 3 5 Zone Piping with Zone Valves FROM SYSTEM ZONE ZONE ZONE 3 BALANCING VALVES CONNECT TO RETURN FROM BYPASS EXPANSION TANK FROM SYSTEM TO SYSTEM ZONE ZONE ZONE ZONE ZONE ZONE 2 3 3 2 1 ZONE FLOW CIRCULATORS H H CONTROL KX FX VALVES 4 A L BR ER CHECK VALVE CONNECT CONNECT TO x TO RETURN CITY WATER SUPPLY TAPPING SHUTOFF VAL
20. ON 10 10 BOILER DIMENSIONS amp RATINGS 34 4 VENTING 11 A INTEGRAL DRAFT HOOD 11 TEE E EE B Eege EN ME n A BASE COMBUSTIBLE FLOOR PAN 35 GENEE 5 B MANIFOLD GAS TRAIN 36 D BOILER RENOVA FEON CORIMON C BLOCK DRAFT HOOD 38 VENTING SYSTEM 13 via ea bead eom Pa wu a esas rs 39 E CONTROLS CIRCULATOR VENT 5 GAS PIPING 14 DAMPER eo EEN en 40 6 ELECTRICAL 16 WIRING anan Ges 16 B ZONED SYSTEM WIRING 16 C CONTROLS 16 D SEQUENCE OF OPERATION 17 7 START UP PROCEDURES 21 USING THIS MANUAL A INSTALLATION SEQUENCE A DANGER Follow the installation instructions provided in this manual in the order shown The order of these Indicates a condition or hazard which will cause instructions has been set in order to provide the installer severe personal injury death or major property with a logical sequence of steps that will minimize damage 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 AA WARNING Indicates a condition or hazard which may cause severe personal injury death or major pro
21. OR Figure 7 1 Gas Valve Manifold and Burner Assembly Standing Pilot Continuous Ignition STEEL RNER e ORIFICE PILOT TUBING i IL IT TI TT rt terre SECTION A lt TEST TAPPING Figure 7 2 Gas Valve Manifold and Burner Assembly Intermittent Ignition GAS PRESSURE REGULATOR INLET ADJUSTMENT SCREW PRESSURE UNDER CAP SCREW TAP OUTLET PRESSURE TAP INLET P OUTLET THERMOCOUPLE PILOT ADJUSTMENT SCREW CONNECTION UNDER CAP SCREW STANDING PILOT ONLY NOTE LOCATIONS ARE SIMILAR FOR STANDING PILOT AND INTERMITTENT IGNITION VALVES Figure 7 3 Valve Tapping and Adjustment Screw Locations 22 START UP PROCEDURES rop YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance e Do not touch any electric switch do not use
22. PLY WITH APPLICABLE CODES ORDINANCES AND REGULATIONS WIRE REMAINDER OF LIMIT IN ACCORDANCE WITH SYSTEM WIRING DIAGRAM SUPPLIED Figure 6 6 Zone Wiring with Circulators 20 START UP PROCEDURES 7 START UP PROCEDURES A COMPLETING THE INSTALLATION 1 Confirm that all water gas and electricity are turned off Inspect the boiler combustion chamber for foreign objects and remove if present Check physical condition of burners and pilot Make certain that there are no unusual bends or perforations in the burners or pilot Replace components if necessary Verify that water piping venting gas piping and electrical wiring and components are installed properly Refer back to previous sections of these instructions as well as equipment manufacturer s instructions as necessary Fill the boiler and system with water making certain to vent all air from all points in the system To check water level in the system open and close each vent in the system Water should exit from each vent when it is opened The pressure reducing valve on the fill line will typically allow the system to be filled and pressurized to 12 psi 83 kPa Consult the valve and expansion tank manufacturer for more specific information Check joints and fittings throughout the system for leaks If leaks are found drain the system and repair as required 10 11 12 13 Connect a manometer to the gas valve on the valve outlet gas
23. RAFT HOOD lt OUTLET ll Figure 4 2 Venting with Vent Damper Vertical Position SLOPE UP A MINIMUM VENT TO OF 1 4 VENT CHIMNEY PER FOOT DAMPER 21mm PER METER 11 O CLOCK 1 O CLOCK POSITION NG POSITION DAMPE KN HEAT L OPERATOR L AN SUPPORT AS ZONE m REQUIRED CONDENSATION 2 ZONE 22 7 O CLOCK s O CLOCK POSITION POSITION NOT MOUNT DAMPER OPERATOR IN SHADED REGION SECTION I Figure 4 3 Venting with Vent Damper in Horizontal Position 12 VENTING D BOILER REMOVAL FROM COMMON d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 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 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 venting system are not in operation a Seal any unused openings in the common venting system 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 b Visually inspect the venting system for proper size doors windows exhaust fans fireplace dampers and and ho
24. Read SI Metric Units Input kW 3600 x FxH Tx 3 6 Where 3600 Seconds per hour 3 6 Megajoule MJ per kilowatt hour kwhr F Cubic Meters of Gas Registered on Meter H Heating Value of Gas in MJ Cubic Meter T Time in Seconds the Meter is Read As an alternative use Table 7 1 a and 7 1 b Use the heating value provided by gas supplier Use a stopwatch to record the time it takes for 2 cubic feet 0 0566 cubic meter of gas to pass through the meter Read across and down to determine rate Table 7 1a Meter Conversion Natural Gas U S Customary Units Burner inputs in Btu hr for various meter timings and heat values Table based on 2 cubic feet of gas through meter Time that Heat Value of Gas meter is Btu cubic foot read sec 1025 26 288000 295200 302400 240000 246000 252000 205714 210857 216000 180000 184500 189000 160000 164000 168000 144000 147600 151200 130909 134182 137455 120000 123000 126000 110769 113538 116308 102857 105429 108000 96000 98400 100800 90000 92250 94500 84706 86824 88941 80000 82000 84000 75789 77684 79579 72000 73800 75600 68571 70286 72000 65455 67091 68727 62609 64174 65739 60000 61500 63000 57600 59040 60480 Table 7 1b Meter Conversion Natural Gas SI Metric Units Burner inputs in kW for for various meter timings and heat values Table based on 0 0566 cubic meter of gas through meter Time that Heat Value of Gas meter is MJ cubic meter rea
25. SHUT OFF SWITCH FLAME ROLL OUT SWITCH A thermally activated switch located between the first burner from the left and the manifold bracket The flame roll out safety shut off switch will sense excessive temperature caused by continued flame roll out and shut down main burner gas This is a non recycling switch that must be replaced once it has been activated and the cause of the roll out eliminated VENT SAFETY SHUT OFF SWITCH SPILL SWITCH A thermally activated manually resetable switch located in the draft hood relief opening If venting system becomes partially or totally blocked the vent safety shut off switch will sense excessive temperature caused by flue products exiting the draft hood relief opening and shut down main burner gas LIMIT AQUASTAT A thermally activated manually adjustable switch located on the left side of the boiler towards the top and rear The temperature sensing element is placed in the supply and will shut down main burner gas if the supply water exceeds the preset temperature limit This is a recycling switch that will automatically reset when the supply water falls below the preset temperature LOW WATER CUT OFF FOR GRAVITY SYSTEMS OR HOT WATER BOILERS INSTALLED ABOVE RADIATION LEVEL A level sensing device float or probe located in supply piping near the boiler If water level in the system drops below the control s position it will shut down main burner gas The control will a
26. T SIDE FRONT RIGHT SIDE Figure 10 1 Boiler Views Table 10 1 Series MI MIH Boiler Dimensions SERIES MI MIH BOILER DIMENSIONS Boiler Jacket Left of Jacket to Rear of Jacket to Vent Connector Model Depth c l of Vent D c l of Vent E Size F Number B inch inch inch inch MI MIH 03 6 201346 MI MIH 04 7926 201346 MI MIH 05 958 211346 MI MIH 06 11546 211346 MI 07 13 211346 MI 08 141 6 23916 MI 09 16 24546 Table 10 2 Series MI MIH Boiler Ratings SERIES MI MIH BOILER RATINGS Seasonal Seasonal DOE Heating Net I B R Ratings Efficiency Efficiency Boiler Capacity Water1 2 Std Pilot Intermittent Water Content Model w Damper Ignition Number MBH KW MBH KW AFUE AFUE MIH MI MI MI MI MI Gallon MI MIH 03 MI MIH 04 MI MIH 05 MI MIH 06 MI 07 MI 08 MI 09 1 Net I B R water ratings based on an allowance of 1 15 2 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc 3 Heating Capacity and Annual Fuel Utilization Efficiency AFUE ratings are based on U S Government test MIH Models Available as Natural Gas with Intermittent Ignition Only 34 11 REPAIR PARTS REPAIR PARTS SERIES MI MIH GAS BOILER Repair parts are available from your instal
27. THERMOSTAT TO CALL FOR HEAT 24 VOLT COMMON 24 VOLT HOT CHECK FOR DAMAGED OR MISSING TERMINALS IN CONNECTOR INSET B CHECK FOR PROPER VOLTAGE NO CHECK AT CONTROL HARNESS SEE INSET ole A VOLTAGE SHOULD BE 5 LINE VOLTAGE POWER HSI Lo lolo L BETWEEN THERMOSTAT AND LOW VOLTAGE TRANSFORMER TERMINAL 24V COMMON AND 24V BETWEEN SE 24V COMMON AND 24V HOT SENE e VENT DAMPER IS OPEN AND END L SWITCH MAKES e PLUG HARNESS INTO GAS VALVE CONTROL WAIT FOR INTERNAL CHECK DELAY NO UNPLUG PILOT BURNER CABLE IGNITER WARMS UP AND MEASURE VOLTAGE AT GAS VALVE REPLACE GAS VALVE GLOWS RED HSI ELEMENT OUTPUT SEE INSET B 24V NOMINAL RECONNECT PILOT BURNER CABLE REPLACE IGNITER FLAME ROD ASSEMBLY RECONNECT PILOT BURNER CABLE NO NO TURN ON GAS SUPPLY CHECK THAT PILOT GAS IS FLOWING REPLACE GAS VALVE PILOT BURNER LIGHTS WAIT TO ASSURE PILOT GAS TUBING IS PURGED NOTE IGNITER WILL CYCLE OFF AND BACK ON ONCE DURING THE 90 SECOND IGNITION TRIAL YES YES NO MEASURE VOLTAGE BETWEEN 24V CHECK TRANSFORMER AND HOT AND 24V COMMON LEADS TO GAS LINE VOLT SUPPLY VALVE MUST MEASURE AT LEAST 19 5 VAC WITH IGNITER POWERED YES SEE INSET A TO IDENTIFY PROPER LEAD THIS CHECK MUST BE DONE WITH THE GAS VALVE CONNECTED AND IGNITER POWERED YES REPLACEIGNITER FLAME ROD ASSEMBLY CHECK THAT PILOT FLAME MAKES GOOD CONTACT WITH PILOT BURNER FLAME ROD CHECK FOR GOOD
28. VE TL PRESSURE REGULATOR Figure 3 6 Zone Piping with Circulators EXPANSION TANK WATER PIPING AND CONTROLS For new or existing systems that must be freeze 1 Consult the tank manufacturer s instructions for protected specific information relating to tank installation Size the expansion tank for the required system volume and capacity See Table 10 2 in Section 10 for boiler WARNING water content Use only inhibited propylene glycol solutions of up to 2 Expansion tanks are available with built in fill valves 50 by volume with water Ethylene glycol is toxic and check valves for reducing supply water pressure and can attack gaskets and seals used in hydronic and maintaining minimum system pressure Check systems the design features of the tank and provide valves as necessary Refer back to Figure 3 1 for typical expansion tank piping 1 Glycol in hydronic applications is specially formulated for this purpose It includes inhibitors which prevent the glycol from attacking metallic E INDIRECT FIRED WATER HEATER system components Make certain that the system If the boiler is to be used in conjunction with an indirect fluid is checked for the correct glycol concentration fired water heater refer to Figure 3 7 for typical piping and inhibitor level Follow the instructions provided by the water heater 2 manufacturer Pipe the water heater as a separate zone The glycol solution should be tested
29. amper SES MI MIH MI MIH Honeywell L8148E1182 Limit w 34 Well 51689 51689 51689 51689 51689 51689 Temperature Pressure Gauge 51774 51774 51774 51774 51774 51774 Safety Relief Valve 30 psi Conbraco 10 408 05 50501 50501 50501 50501 50501 50501 Safety Relief Valve 50 psi Watts 350 99950 99950 99950 99950 99950 99950 Flame Roll Out Safety Shut Off Switch 51587 51587 51587 51587 51587 51587 Blocked Vent Shut Off Spill Switch MI Only 90592 90592 90592 90592 90592 90592 Blocked Vent Shut Off Spill Switch MIH Only 90593 90593 90593 90593 90593 90593 Vent Damper 90612 90612 90613 90613 90614 90615 Available from distributor 40 Series MI MIH Gas Boilers Installation Operation amp Maintenance Manual TO THE INSTALLER This manual 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 amp HI Division ASME of gama p D PeerlessBoilers com PB HEAT LLC PO BOX 447 NEW BERLINVILLE PA 19545 0447 2005 MI8038 R9 10 05 10M Printed in U S A
30. by the manufacturer Test limit as described in Section 7E Check Out Procedure Test function of gas safety shut off features as described by gas valve and ignition control manufacturer Cycle the boiler at least once and check operation of the vent damper MAINTENANCE E ANNUALLY BEFORE START OF HEATING SEASON A DANGER When servicing or replacing components be absolutely certain that the following conditions are met e Water gas and electricity are off The boiler is at room temperature e There is no pressure in the boiler 1 Check flueways and burners for cleanliness and clean if necessary Use the following procedure if cleaning is required a Refer to the Lighting Operating Instructions in Figures 7 4 and 7 5 to properly turn off the gas to the boiler b Turn off all electrical power to the boiler c Remove burners and brush orifice spuds lightly using a soft bristle brush d Remove the vent pipe vent damper top jacket panels and flue collector draft diverter Remove baffles on MIH models e Brush flueways with wire brush f To the extent possible inspect inside of vent pipe and vent damper for obstructions in flow or vent damper movement Remove or replace as necessary g Re install baffles on MIH models When replacing the flue collector draft hood be certain that the blanket seal between the flue collector and top section makes a tight seal to prevent leakage of the pro
31. d sec 38 19 F CHECK OUT PROCEDURE 1 After starting the boiler be certain all controls are working properly Check to be sure that the limit will shut off the boiler in the event of excessive water temperature This can be done by lowering the limit setting until the main burners shut down When proper limit function is confirmed return the dial to its previous setting 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 flow iii Reset the boiler by following Lighting Instructions iv Observe boiler operation through one complete cycle b Intermittent Ignition System i Turn gas supply off ii Set thermostat or controller above room temperature to call for heat Watch for igniter glow at pilot burner iii Igniter will continue to glow for 30 seconds de energize for 30 seconds then re energize and glow for another 30 seconds It will then de energize for 5 minutes before restarting the sequence iv Turn gas supply on v Reset the boiler and control by following Operating Instructions vi Observe boiler operation through one complete cycle Low Water Cut
32. ducts 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 enveloping 3 8 to 1 2 1 cm to 1 2 cm of the flame sensor If required adjust the pilot as stated in the gas valve manufacturer s instructions or paragraph 7 D The main burner flame inner cone should be approximately 1 1 2 4 cm high and should have a very sharp blue color characteristic OUTER CONE 15 DARK BLUE IN COLOR INNER CONE 15 BLUE IN COLOR PILOT FLAME Figure 9 1 Standing Pilot and Main Burner Flame OUTER CONE IS DARK BLUE IN COLOR PILOT INNER CONE IS FLAMES BLUE IN COLOR OHH Figure 9 2 Intermittent Pilot and Main Burner Flame 33 BOILER DIMENSIONS amp RATINGS 10 BOILER DIMENSIONS amp RATINGS I 2 3 8 15 11 16 3 5 16 Es I 398 84 mm 7 Pp 1 1 2 NPT LA ii iL d LIMIT 7s i TEMPERATURE 7 0 1 1 4 NPT J PRESSURE RETURN B i GAUGE GAS 1 INLET FLOOR i LINE 1 12 3 8 Ge SEH 25 314 mm 8 3 8 584 mm 213 mm Lo et LEF
33. er If there is evidence that hard scale has formed on the internal surfaces the boiler should be cleaned by chemical means as prescribed by a qualified water treatment specialist 4 There must not be signs of continuous wetness at the chimney If signs of continuous wetness are Observed a qualified service agency must be consulted to modify the vent configuration to prevent the formation of condensate Daily boiler observation can be performed by the owner If any potential problems are found a qualified installer or service technician agency must be notified 1 Remove any combustible materials gasoline and other flammable liquids and substances that generate flammable vapors from the area where the boiler is contained Make certain that the boiler area has ample air for combustion and ventilation and that there are no obstructions to the free flow of air to and from the boiler 2 Observe general boiler conditions unusual noises vibrations etc 3 Observe operating temperature and pressure on the combination gauge located on the left side of the boiler Boiler 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 sh
34. for an illustration of this arrangement era E E Figure 1 3 Air Openings All Air Directly from Outdoors PREINSTALLATION TET XU x 12 305mm max TWO AIR OPENINGS Minimum Free Area Each 1 in per 4000 Btuh 22 cm per 4000 W BOILER 3 7 305mm 76mm max min TERR ae 4 Figure 1 4 Air Openings All Air from Outdoors through Vertical Ducts ii Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 in per 2000 Btu hr 22 cm2 per 2000 W of total rated input for all appliances in the space See Figure 1 5 12 305mm max Y TWO AIR OPENINGS Z Minimum VES 76mm Free Area Each 7 min 1 in per 2000 Btuh i 22 cm per 2000 W Y 7 3 76mm 7 min 7 I BOILER 12 305mm max Figure 1 5 Air Openings All Air from Outdoors through Horizontal Ducts b One Permanent Opening Method Provide one permanent opening beginning within 12 inches 305 mm of the top of the space The opening shall communicate directly with the outdoors communicate through a vertical or horizontal duct or communicate with a space that freely communicates with the outdoors The opening shall have a minimum free area of 1 in per 3000 Btu hr of total rated input for all appliances in the space and not less than t
35. g combustible floor pan install boiler on pan as outlined in the instructions included with the pan 3 WATER PIPING AND CONTROLS A BOILER SUPPLY AND RETURN 3 Supply Piping Pipe the supply to the 1 1 2 NPT supply tapping at 1 Size the supply and return to suit the system A the top and rear of the boiler typical piping arrangement is shown in Figure 3 1 Refer also to the I B R Guide Residential 4 When system return water temperature will be below Hydronic Heating Installation Design and the PB 130 F 54 C pipe the boiler with a bypass Heat Water Survey for additional guidance during arrangement to blend the system return and hot water piping installation supply to obtain at least 130 F 54 C entering the boiler For more information on bypass piping 2 Return Piping consult the PB Heat Water Survey Pipe the drain valve to a tee provided and the 1 1 4 NPT return tapping near the bottom 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 AIR VENT CIRCULATOR AIR ELIMINATOR SUPPLY nx COLD T WATER Ki 64 gt lt SAFETY 55 RELIEF SHUTOFF Es VALVE VALVE SHU TOFF VALVE TTITITITIITI PRESSURE 4 REGULATOR EXPANSION TANK TO CHECK DRAIN VALVE RETURN gt lt DRAIN VALVE Figure 3 1 Supply and Return Piping WATER PIPING AND CONTROLS 6 Install this boiler so that the gas
36. gth 4 Inadequate chimney or venting system 4 Check chimney and venting recommendations Boiler not heating 1 Underfiring 1 Increase rate to input on rating label properly 2 Limit set too low 2 Reset aquastat to higher setting 3 Air in system 3 Vent air from all points in system 4 Circulator malfunctioning 4 Check circulator replace if necessary 5 Circulation system clogged 5 Shut down and cool boiler drain and flush system 6 Incorrect thermostat heat anticipator setting 6 Adjust heat anticipator Fumes or gas odors 1 Leaks in gas piping or fittings 1 Locate and repair or replace 2 Leaks in gas service line or meter 2 Shut down boiler and notify gas provider 3 Obstructed chimney 3 Check repair and or clean chimney 4 Obstructed flueways or vent 4 Clean flueways or vent and remove obstructions 5 Undersized chimney or vent high draft loss 5 Check National Fuel Gas Code and vent in vent manufacturer s recommendations 6 Draft problem in boiler room 6 Check air supply ventilation and venting system 7 Overfiring 7 Reduce rate to input on rating label 8 Vent damper malfunctioning 8 Refer to vent damper manufacturer s instructions Replace if necessary 29 TROUBLESHOOTING INSET A 24 VOLT END VIEW THERMOSTAT OF CONTROL OR PRESSURE HARNESS START SWITCH CONNECTOR TURN OFF GAS SUPPLY ASSURE GAS VALVE SWITCH IS IN ON POSITION DISCONNECT SYSTEM CONTROL HARNESS SET
37. he sum of the cross sectional areas of all vent connectors in the space The gas fired equipment shall have clearances of at least 1 inch 25 mm from the sides and back and 6 inches 150 mm from the front of the appliance See Figure 1 6 for this arrangement 12 305mm max ALTERNATE p LAC LOCATION 12 305mm x max NOY i ONE AIR OPENING Minimum Free Area Each 1 in per 3000 Btuh ON 22 cm per 3000 W and not less than the sum of the areas of all vent connectors MINIMUM CLEARANCES 1 25mm From sides and back 6 150mm from front BOILER Figure 1 6 Air Openings All Air from Outdoors 5 6 through One Opening Combination Indoor and Outdoor Combustion Air If the required volume of indoor air exceeds the available indoor air volume outdoor air openings or ducts may be used to supplement the 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 X L _ Vova where minimum area of outdoor openings full size of outdoor openings calculated in accordance with Subsection 4 Vwai available indoor air volume Vieq required indoor air volume Engineered Installations Engi
38. i Natural Gas 0 2000 ft 0 610 m Orifice Spud 49 50895 50895 50895 elevation specify qty LP Gas 0 2000 ft 0 610 m Orifice Spud 56 m 50899 50899 50899 elevation specily qi LP Gas 0 2000 ft 0 610 m Orifice Spud 57 NES 50900 50900 50900 elevation specily qi 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 LP Gas 51692 51692 51692 51692 10 Honeywell Q3480B1025 Pilot Natural Gas 51684 51684 51684 51684 51684 51684 51684 Honeywell Q3480B1033 Pilot LP Gas 51685 51685 51685 51685 51685 51685 51685 For elevations over 2 000 feet above sea level contact PB Heat LLC Table 11 3b Steel Burner Specify quantity Manifold Gas Train MIH Intermittent Ignition REN Part Selection Description E Information 51537 51537 51537 Steel Burner w Pilot Clip 1 per boiler 51539 51539 51539 51539 Gas Manifold 50978 50979 50980 Orifice Spud 49 Natural Gas 0 2000 ft 0 610 m elevation specify qty 50895 50895 50895 50895 Honeywell SV9501M2700 Gas Valve Natural Gas 51682 51682 51682 Honeywell SV9601M4167 Gas Val
39. ignition system components are protected from water dripping spraying etc during appliance operation and service circulator replacement condensate trap control replacements etc 7 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 3 2 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 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 3 For air elimination at the safety relief valve tapping install valve and piping as shown in Figure 3 4 CAUTION Pipe the discharge of safety relief valve to prevent injury in the event of pressure relief Pipe the discharge to a drain Provide piping that is the same size as the safety relief valve outlet CHECK VA
40. ill not stay lit after several tries turn the gas control knob to OFF and call your service technician or gas supplier Wait five 5 minutes to clear out any gas Then smell 11 Replace pilot a ess panel if applicable for gas including near the floor If you smell gas 12 STOP Follow B in the safety information above on this label If you don t smell gas go to the next step 13 Replace control access panel if applicable Turn gas control knob counterclockwise to ON Remove the pilot access panel if supplied located 14 below and behind the gas valve directly above burner tubes 15 Set thermostat to desired setting Turn on all electric power to the appliance TO TURN OFF GAS TO APPLIANCE S Setthe thermostat to lowest setting 4 Turn the gas control knob clockwise N to OFF Turn off all electric power to the appliance if service is 5 Replace control access panel if applicable to be performed Ifthe gas valve is not visible remove the control access panel H24V VR8200 VR8300 9177R Figure 7 5 Lighting Instructions 24 START UP PROCEDURES B CONTROL DESCRIPTIONS 4 When adjustment is complete turn off boiler gas flow and electricity to boiler Remove manometer See Figure 6 1 in Section 6 Electrical for locations of connection from valve and plug tapping with plug these devices provided Turn utilities back on and resume checkout 1 FLAME ROLL OUT SAFETY
41. ilution air shall be based on the h Combustion air intake openings located on the net free area of each opening exterior of buildings shall have the lowest side of the combustion air intake opening at least 12 i Where the free area through a louver or grille inches 305 mm above grade is known it shall be used in calculating the opening size required to provide the free area VN WARNING specified Liquefied Petroleum LP is heavier than air and may ii Where the free area through a louver or grille collect or pool in a low area in the event of a leak is not known it shall be assumed that wooden from defective equipment This gas may then ignite louvers will have 25 free area and metal resulting in a fire or explosion louvers and grilles will have 75 free area iii Nonmotorized dampers shall be fixed in the D INSTALLATION SURVEY open position For new and existing installations a Water Installation Survey is available from PB Heat LLC The survey will b Motorized dampers shall be interlocked with the provide information on how a hot water boiler works equipment so that they are proven in the full with your specific system and will provide an overview open position prior to ignition and during of hot water system operation in general operation of the main burner 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 PB Heat
42. 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 access and service 2 The draft hood relief opening is the large rectangular passage at the front of the boiler Make certain that Orient the damper operator to facilitate connection there are no obstructions to airflow in front of this of the harness with the vent damper and boiler Note opening flue gas flow arrow on vent damper and orient as T T required For installation with damper mounted in 3 Avent safety shut off switch is located within the vertical position see Figure 4 2 For installation with draft relief opening to shut off the boiler in case of a damper mounted in horizontal position mount the blocked vent condition See Section 7B for details unit as shown in Figure 4 3 to avoid excessive Beat regarding this device See Figure 6 1 in Section 6 on the operator or condensation drips into the Electrical for spill switch location operator 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 DAMPER HEATING INCORRECT Figure 4 1 Venting Multiple Appliances OTHER HEATING APPLIANCE
43. l in an accessible position near the boiler 27 8 TROUBLESHOOTING A SHUT DOWN CAUSED BY PILOT OUTAGE BLOCKED VENT SHUT OFF SWITCH OR FLAME ROLL OUT SAFETY SHUT OFF SWITCH In the event of a shut down caused by a pilot outage action of the blocked vent shut off switch or flame roll out safety shut off switch effecting a shut down of the main burners a Refer to the Lighting Operating Instructions in Figures 7 4 and 7 5 to properly turn off the gas to the boiler b Turn off all electric power to the boiler Call a qualified heating service organization or local gas company and have the cause of the shut down investigated and corrected d Refer to Lighting Operating Instructions to re start boiler B TROUBLESHOOTING GUIDES Use Table 8 1 to assist in determining causes and providing corrective actions to boiler problems Refer also to Figure 8 1 to troubleshoot the Intermittent Ignition System Control These guides must be used only by qualified service technicians These individuals must follow all applicable codes and regulations in repair of any boiler problems 28 A DANGER When servicing or replacing items that communicate with the boiler water be certain that There is no pressure on the boiler The boiler is not hot e The power is off When servicing the gas valve or pilot be certain that The gas is off The electricity is off A WARNING Do not use this appliance if
44. ler or by contacting PB Heat LLC New Berlinville PA 19545 0447 Use the figures and tables on pages 34 40 to assist in ordering parts Note Remember to include boiler model number and serial number when ordering parts Figure 11 1 Base Combustible Floor Pan Table 11 1 Base Combustible Floor Pan e Part Selection MI MIH MI MIH MI MIH 7800 7801 7802 7803 7804 7805 Observation Cover Door 51771 51771 51771 51771 51771 51771 Base Blanket Seal Specify length 50867 50867 50867 50867 50867 50867 Combustible Floor Pan Assembly 90700 90701 90702 90703 90704 90705 90706 Base Assembly For elevations over 2 000 feet above sea level contact PB Heat LLC 35 REPAIR PARTS Figure 11 2 Manifold Table 11 2 Manifold Gas Train MI Standing Pilot Item SIS Part Selection 5 Steel Burner Specify quantity 51537 51537 51537 51537 51537 51537 51537 6 Burner w Pilot Clip 1 per boiler 51263 51263 51263 51263 51263 51263 51263 7 Gas Manifold 50978 50979 50980 50981 50954 50955 50956 Natural Gas 0 2000 ft 0 610 m 8 Orifice Spud 48 E 50894 50894 50894 50894 elevation specily Natural Gas 0 2000 ft 0 610 m Orifice Spud 49 50895 50895 50895 elevation specify qty LP Gas 0 2000 ft 0 610 m Orifice Spud 56 SE 50
45. lled and through combustion air openings sized as indicated in Subsection 3 are considered part of the required volume The required volume of indoor air is to be determined by one of two methods a Standard Method The minimum required volume of indoor air room volume shall be 50 cubic feet per 1000 BTU Hr 4 8 m kW This method is to be used if the air infiltration rate is unknown or if the rate of air infiltration is known to be greater than 0 6 air changes per hour As an option this method may be used if the 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 rate of a structure is known the minimum required volume of indoor air for appliances other than fan assisted and for the Series MI Boiler shall be determined as follows 21 ft I other ACH 1000Btu Required Volume PREINSTALLATION BUILDING SPACES ON DIFFERENT STORY ae h NN Must not be under negative pressure Input of appliances other than fan dd Mur in Btu hr SSS zz ACH air change per hour percent of the volume of the space exchanged per hour expressed as a decimal ONE OR MORE A
46. manifold Use the 1 8 NPT tapping provided 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 required isolate the boiler and gas valve before performing the pressure check If the supply pressure is too high or too low contact the gas supplier Turn on electricity and gas to boiler Light the boiler by following the Lighting Operating Instructions label mounted to the jacket panel The initial ignition may require several tries as the piping is purged of air Use the sequence descriptions in Figures 6 2 6 3 and 6 4 in Section 6 Electrical to follow light off and shutdown sequences and to assist in diagnosing problems If the boiler does not function properly consult Section 8 Troubleshooting The gas manifold and control assembly are made of gas tight completely factory assembled and installed components of the base assembly See Figure 7 1 and 7 2 21 START UP PROCEDURES GAS THERMOCOUPLE VALVE PILOT e ORIFICE PILOT LEAD m VUN LU THERMOCOUPLE a LEAD eos N MANIFOLD GAS CONT SN KNOB TEST SECTION GAS PRESSURE REGULAT
47. n the ignition circuit within the gas valve energizes provided that all of the following conditions are met 18 ELECTRICAL START APPLY 24 VAC TO APPLIANCE THERMOSTAT CALLS FOR HEAT FIVE MINUTE RETRY DELAY FLAME SIGNAL WAIT FOR FLAME SIGNAL DETECTED TO DISAPPEAR PILOT VALVE IGNITER REMAIN OFF INTERNAL CHECK OKAY TRIAL FOR PILOT VALVE OPENS THREE SECOND FLAME IGNITION IGNITER POWERED FAILURE RECYCLE DELAY PILOTLIGHTS AND FLAME SE IS SENSED DURING e IGNITER OFF TRIAL FOR IGNITION MAIN BURNER IGNITER OFF OPERATION MAIN VALVE OPENS FLAME SIGNAL LOST e MAIN AND PILOT VALVES CLOSE NO THERMOSTAT CALL FOR FLAME LOST MORE THAN HEAT ENDS FIVE TIMES IN ONE CALL FOR HEAT MAIN AND PILOT VALVES CLOSE END A IGNITER WILL TURN OFF ABOUT 30 SECONDS INTO THE TRIAL FOR IGNITION IF THE PILOT FLAME HAS NOT LIT IT WILL TURN BACK ON FOR THE FINAL 30 SECONDS OF THE 90 SECOND TRIAL FOR IGNITION THE PILOT VALVE WILL BE ENERGIZED DURING THE ENTIRE TRIAL FOR IGNITION THIS IS NORMAL OPERATION FOR THIS GAS IGNITION SYSTEM Figure 6 4 Intermittent Ignition System Operating Sequence 19 ELECTRIC 115V 60HZ 11 HOT TO L2 DISCONNECT SWITCH GND ZONE 1 ZONE 2 ZONE 3
48. n corrosive leak detection fluid or other leak detection method If leaks are found turn off all gas flow and repair as necessary WARNING When checking for leaks not use matches candles open flames or other methods that provide a source of ignition This can ignite a gas leak resulting in fire or explosion 14 SERVICE VALVE JACKET G J UNION SEDIMENT TRAP p LINE Figure 5 1 Gas Connection to Boiler 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 5 kPa N CAUTION Do not subject the gas valve to more than 1 2 psi 3 5 kPa pressure Doing so may damage the valve Isolate the boiler from the gas supply piping system by closing its individual service valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 1 2 psig 3 5 kPa 9 Minimum permissible supply pressure for purposes of input adjustment MI 09 Standing Pilot Natural Gas 5 2 WC 1 3 kPa All other MI MIH Natural Gas 5 0 WC 1 2 kPa All MI LP Gas 11 0 WC 2 7 kPa Maximum permissible supply pressure to the boiler All MI MIH Natural Gas 13 5 WC 3 5 kPa All MI LP Gas 13 5 WC 3 5 kPa Table 5 1 MI Boiler Natural Gas Input Cubic Feet Hour Cubic Meters Hour Table 5 2
49. neered combustion air installations shall provide an adequate supply of combustion ventilation and dilution air and shall be approved by the authority having jurisdiction Mechanical Combustion Air Supply a In installations where all combustion air is provided by a mechanical air supply system the combustion air shall be supplied from the outdoors at the minimum rate of 0 35 ft min per 1000 Btu hr 0 034 m3 min per 1000 W of the total rated input of all appliances in the space b In installations where exhaust fans are installed additional air shall be provided to replace the exhaust air PREINSTALLATION c Each of the appliances served shall be e Ducts shall not be screened where terminating in interlocked to the mechanical air supply to an attic space prevent main burner operation when the mechanical air supply system is not in operation f Horizontal upper combustion air ducts shall not slope downward toward the source of the d In buildings where the combustion air is provided combustion air by the mechanical ventilation system the system shall provide the specified combustion air rate in g The remaining space surrounding a chimney addition to the required ventilation air liner gas vent special gas vent or plastic piping installed within a masonry metal or factory built 8 Louvers amp Grills chimney shall not be used to supply combustion air a The required size of openings for combustion ventilation and d
50. of Lighting Instructions in Figure 7 5 turn screw no more than an 1 8 turn 4 Turn on electric power to the appliance NOTICE The first few turns of the adjustment screw may not cause any change in the pilot flow Subsequent partial turns of the adjustment screw may have a great impact on pilot flow 5 Turn Gas Control Knob to On position per the Lighting Instructions in Figure 7 5 6 Verify pilot remains lit after shutdown from a boiler ON cycle of at least ten minutes If pilot extinguishes follow Lighting Instructions in Figure 7 5 and again slightly increase pilot flow 7 Make a final slight increase in the size of the pilot to ensure sufficient pilot signal under all operating conditions just to the point that you observe a slight increase in the size of the flame no more than an 1 8 turn 8 Replace adjustment cap screw and observation port cover 25 START UP PROCEDURES CHECKING BURNER INPUT 1 Refer to rating label mounted on the jacket top panel 3 to obtain the rated BTU per hour input In no case shall the input to the boiler exceed the value shown on the rating label Check input by use of the following formulas PB Heat LLC suggests reading meter for 2 Cu Ft U S Customary Units Input BTU Hr 3600 x F x H T Where 3600 Seconds per hour F Cubic Feet of Gas Registered on Meter H Heat Value of Gas in BTU Cubic Feet T Time in Seconds the Meter is
51. ommunicate 1 1 for an illustration of this arrangement with the outdoors The size of the openings shall be determined as follows 4 Qutdoor Combustion Air Outdoor combustion air is to be provided through one or two permanent openings The minimum dimension of these air 2 i Where communicating directly or through A vertical ducts with the outdoors each opening 12 305mm shall have a minimum free area of 1 in per AISCH max 4000 Btu hr 22 cm2 per 4000 W of total Minimum emm input rating for all equipment in the space EEN 7 min See Figure 1 3 for openings directly 22 cm per 1000 W i communicating with the outdoors or Figure GE eost 10g BUILDING 1 4 for openings connected by ducts to the 645 cm SPACES ON 4 SAME STORY outdoors Must not be under negative pressure 2 3 76 BOILER Z mn i 12 305mm max 12 305mm mox i 7 TWO AIR OPENINGS Ed 3 76mm Ge Minimum E 4 A Bag E id min 7 Free Area Each in per 4000 Btuh Figure 1 1 Openings from Indoors e b Combining spaces on different floors gt Provide one or more permanent openings 3 76mm 2 communicating with additional spaces that have min 7 BOILER a total minimum free area of 2 in per 1000 Btu hr 44 per 1000 W of total input rating 12 305mm of all equipment See Figure 1 2
52. operator opens the damper Wee b Once the damper is proven open the gas valve The vent damper closes energizes provided that all of the following conditions are met d If temperature exceeds limit setting main burners shut off and circulator continues to operate e the pilot thermocouple is proving flame e the blocked vent switch is closed and the flame rollout switch is closed 17 ELECTRICAL CONNECTION DIAGRAM LADDER DIAGRAM u 115 60 1 12 POWER 24 THERMOSTAT BY OTHERS 49 L8148E COMBINATION SURREY SE LIMIT CONTROL CIRCULATOR FACTORY BK ere W FUSED DISCONNEC FUSED SWITCH DISCONNECT SERVICE SWITCH SWITCH BANJAR TEE EES IMARY t d 07 ep e u TRANSFORMER io 115 60 1 POWER SECONDARY SUPPLY SERVICE L2 SWITCH i EE d RELAY THESE ITEMS TO BE SUPPLIED 7 w 1 BY INSTALLER ao teman pat bem P NG LOW VOLTAGE SIZE 16 18 AWG WIRE TYPE TEW AWM TFFN WIRE KADA ER ene 120V EXTERNAL WIRING 24V INTERNAL WIRING NOTES 24V EXTERNAL WIRING 1 ALL WIRING MUST COMPLY WITH APPLIANCE CODES ORDINANCES AND REGULATIONS PILOT WIRING L8148 TERMINAL I 820 1 A mE FLAME ROLLOUT GE p d BVS FRS 55 SWITCH ERS m ce WIRE CODE San 9 ToT BLOCKED VENT a VALVE YELLOW RED r lt SWIT
53. osion WHAT TO DO IF YOU SMELL GAS D Do not use this appliance if any part has been under e Do try to light any appliance water Immediately call a qualified service technician Do not touch any electric switch to inspect the appliance and to replace any part of the do not use any phone in your building control system and any gas control which has been Immediately call your gas supplier from a neighbor s under water phone Follow the gas supplier s instruction LIGHTING INSTRUCTIONS STOP Read the safety information above on this 8 Find pilot follow metal tube label from gas valve The pilot is between two burner tubes Set the thermostat to lowest setting Pilot Burner Turn off all electric power to the appliance 9 Turn the gas control knob counterclockwise Y to PILOT If the gas valve is not visible remove control access panel 10 Push in red reset button all the way and hold in zc Immediately light the pilot with a match Continue to If the gas control knob is not in the OFF position hold the reset button in for about one 1 minute after turn the knob clockwise to OFF the pilot is lit Release button and it will pop back up Gas Control Knob Pilot should remain lit If it goes out repeat steps 5 shown in OFF Red Reset Button through 10 position If button does not pop up when released stop and immediately call your service technician or gas supplier If the pilot w
54. ould never be higher than 250 F 121 C 4 5 Check for water leaks in boiler and system piping Smell around the appliance area for gas If you smell gas follow the procedure listed in the Lighting Operating Instructions in Section 7 C WEEKLY WITH BOILER IN USE 1 Flush float type low water cut off if used to remove sediment from the float bowl as stated in the manufacturer s instructions D MONTHLY WITH BOILER IN USE js Check boiler room floor drains for proper functioning Check function of the safety relief valve monthly unless specified otherwise by manufacturer by performing the following test a Check valve piping to determine that it is properly installed and supported b Check boiler operating temperature and pressure c Liftthe try lever on the safety relief valve to the full open position and hold it for at least five seconds or until clean water is discharged d Release the try lever and allow the valve to close If the valve leaks operate the lever two or three times to clear the valve seat of foreign matter It may take some time to determine if the valve has shut completely e If the valve continues to leak it must be replaced before the boiler is returned to operation f Check hat operating pressure and temperature have returned to normal g Check again to confirm that valve has closed completely and is not leaking Test low water cut off if used as described
55. perty damage CAUTION Indicates a condition or hazard which will or can cause minor personal injury or property damage NOTICE Indicates special attention is needed but not directly related to potential personal injury or property damage 1 PREINSTALLATION Read carefully study these instructions before beginning work This boiler must be installed by a qualified contractor The boiler warranty can be voided if the boiler is not installed maintained and serviced correctly NOTICE The equipment must be installed in accordance with those installation requirements of the authority having jurisdiction or in the absence of such requirements to the current edition of the National Fuel Gas Code ANSI 2223 1 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code Where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 A ACCESSIBILITY CLEARANCES Install boiler not less than 24 610 mm between the left side top and front of the boiler and adjacent wall or other appliance when access is required for servicing B CLEARANCE FROM COMBUSTIBLE CONSTRUCTION The design of this boiler is certified for alcove installation with the following clearances 1 6 152 mm between sides and combustible construction 2 24
56. rizontal pitch and determine there is no any other gas burning appliance to their previous blockage or restriction leakage corrosion and other conditions of use deficiencies which could cause an unsafe condition g Any improper operation of the common venting c Insofar as is practical close all building doors and system should be corrected so that the installation 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 conforms with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code 5 GAS PIPING 1 Size and install the gas supply piping properly in order to provide a supply of gas sufficient to meet the maximum demand without undue loss of pressure between the meter and the boiler 2 Determine the volume of gas
57. rol access panel if applicable Turn on all electric power to the appliance Set the thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed If the gas valve is not visible remove the control access panel Figure 7 4 Operating Instructions 4 Slide the gas control switch to OFF 5 Replace control access panel if applicable SV9501 SV9601 9318 23 START UP PROCEDURES HE FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance has a pilot which must be lighted by e If you cannot reach your gas supplier call the fire hand When lighting the pilot follow these department instructions exactly C Use only your hand to push in or turn the gas control B BEFORE LIGHTING smell all around the appliance area knob Never use tools If the knob will not push in or for gas Be sure to smell next to the floor because turn by hand don t try to repair it call a qualified some gas is heavier than air and will settle on the service technician Force or attempted repair may floor result in a fire or expl
58. roubleshoot intermittent ignition gas valve Replace if necessary 9 Improper wiring 9 Check and correct in accordance with wiring diagrams in Section 6 10 Vent damper malfunctioning 10 Refer to vent damper manufacturer s instructions Replace if necessary Burners will not shut 1 Defective gas valve 1 Use Figure 8 1 to troubleshoot intermittent down ignition gas valve Replace if necessary 2 Short circuit 2 Check and correct wiring Flashback or burning 1 Manifold gas pressure too low 1 Adjust to proper pressure at orifice spuds 2 Improperly sized drilled orifice spuds 2 Install correct spuds 3 Leaking gas valve 3 Replace valve 4 Burrs on orifice 4 Remove burrs 5 Low supply gas pressure 5 Contact gas supplier if natural gas Adjust regulator if LP gas 6 Excessive downdraft or draft problems in 6 Check air supply ventilation and venting system boiler room Delayed ignition 1 Insufficient pilot flame 1 Increase pilot gas flow 2 Pilot burner orifice clogged 2 Clean pilot burner and orifice 3 Overfiring 3 Reduce rate to input on rating label 4 Misaligned burners or pilot 4 Realign burners or pilot 5 Draft problem in boiler room 5 Check air supply ventilation and venting system Excessive condensation in 1 Underfiring 1 Increase rate to input on rating label vent 2 Limit Aquastat set too low 2 Reset aquastat to higher setting 3 Vent pipe too long 3 Reposition boiler to reduce len
59. separately from others Rinse washer thoroughly after use Discard RCF materials by sealing in an airtight plastic bag First Aid Procedures Inhalation If breathing difficulty or irritation occurs move to a location with fresh clean air Seek immediate medical attention if symptoms persist Skin Contact Wash affected area gently with a mild soap and warm water Seek immediate medical attention if irritation persists Eye Contact Flush eyes with water for 15 minutes while holding eyelids apart Do not rub eyes Seek immediate medical attention if irritation persists Ingestion Drink 1 to 2 glasses of water Do not induce vomiting Seek immediate medical attention 31 MAINTENANCE B DAILY WITH BOILER IN USE 32 1 Disconnect this boiler from the gas supply piping during any pressure testing of the gas system 2 Check pipes adjacent to cold walls or in unheated spaces Insulate and tape them if necessary to be sure they can t freeze up Keeping the water moving at all times will reduce the likelihood of freezing See Section 3 for glycol instructions 3 If there is considerable foreign matter in the boiler water the boiler should be shut down and allowed to cool then drained and thoroughly flushed out Use the drain valve at the bottom of the return connection to drain the boiler Pipe the drain cock to a suitable drain or containment device if a glycol solution is used Flush the system to remove remaining matt
60. utomatically reset once the water level rises above its position C ADJUSTMENT OF GAS PRESSURE REGULATOR 1 Using the manometer setup installed in part 7A set manifold pressure as follows for various gases a Natural Gas 3 5 Water Column 0 9 kPa b LP Gas 10 0 Water Column 2 5 kPa To adjust gas pressure turn adjusting screw of gas pressure regulator counterclockwise 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 Inno 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 spuds D ADJUSTMENT OF PILOT GAS FLOW To maximize thermocouple life particularly on natural gas installations with gas supply pressures above 9 W C 2 2 kPa reduce the pilot gas flow A WARNING Turn off all electric power to the appliance Turn Gas Control Knob to Pilot position as shown in Figure 7 3 1 Locate and remove the pilot adjustment cap screw using Figure 7 3 2 Remove pilot observation port cover on base front panel 3 Turn the pilot adjustment screw clockwise until the pilot flame extinguishes Then increase the pilot flow just to the point that the gas valve holds in when relighting the pilot per steps 9 and 10
61. ve Natural Gas 51683 Honeywell Q3480B1025 Pilot Natural Gas For elevations over 2 000 feet above sea level contact PB Heat LLC 51684 51684 51684 51684 37 REPAIR PARTS p Figure 11 4 Block Draft Hood Table 11 4a Block Draft Hood dide Part Selection MI MIH MI MIH MI MIH MI MIH Block Assembly 90419 90420 90421 90422 90423 90424 13 Flue Collector Draft Hood 90510 90511 90512 90513 90514 90515 90516 Specify length 50866 50866 50866 50866 50866 50866 Flue Collector Blanket Seal Table 11 4b Flue Baffles for MIH Only D scriution Part Selection MIH MIH MIH p Information 03 04 05 15 Flue Baffle 4 1 per flue specify qty 51583 51583 51583 Flue Baffle 8 1 per flue specify qty 38 REPAIR PARTS Figure 11 5 Jacket Table 11 5 Jacket TUS Part Selection MI MIH MI MIH MI MIH MI MIH 16 Jacket Assembly Complete jacket with 90445 90446 90447 90448 90449 90450 90451 insulation and screws Complete Jacket Consists of 16 Left Side Panel 16 Right Side Panel 16 Rear Panel 16 Top Upper Front Panel 16 Inner Front Baffle Panel 16 Removable Front Panel 39 REPAIR PARTS Figure 11 6 Controls Circulator Vent Damper Table 11 6 Controls Circulator Vent D

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