PB Heat Gas Boiler User Manual

Peerless Pinnacle

Stainless Steel Gas Boilers

WARNING

If the information in this manual is not

followed exactly, a fire or explosion may

result causing property damage, personal

injury or loss of life.

– Do not store or use gasoline or other

flammable vapors and liquids in the vicinity

of this or any other appliance.

– WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch;

do not use any phone in your building.

• Immediately call your gas supplier from

a neighbor’s phone. Follow the gas

supplier’s instructions.

• If you cannot reach your gas supplier,

call the fire department.

– Installation and service must be performed

by a qualified installer, service agency or

the gas supplier.

As an ENERGY STAR^®Partner, PB Heat, LLC has

determined that this product meets the ENERGY STAR^®

guidelines for energy efficiency.

Installation,

Operation &

Maintenance

Manual

USING THIS MANUAL

A. INSTALLATION SEQUENCE

DANGER

Indicates a condition or hazard which will cause

severe personal injury, death or major property

damage.

Follow the installation instructions provided in this

manual in the order shown. The order of these

instructions has been set in order to provide the installer

with a logical sequence of steps that will minimize

potential interferences and maximize safety during

boiler installation.

WARNING

B. SPECIAL ATTENTION BOXES

Indicates a condition or hazard which may cause

severe personal injury, death or major property

damage.

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:

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.

PREINSTALLATION

1. PREINSTALLATION

A. GENERAL

C. ACCESSIBILITY CLEARANCES

1. Pinnacle boilers are supplied completely assembled

as packaged boilers. The package should be

inspected for damage upon receipt and any damage

to the unit should be reported to the shipping

company and wholesaler. This boiler should be

stored in a clean, dry area.

1. The Pinnacle boiler is certified for closet installations

with zero clearance to combustible construction. In

addition, it is design certified for use on combustible

floors.

2. Refer to Figure 1.1 and Figure 1.2 for the

recommended clearance to allow for reasonable

access to the boiler. Local codes or special

conditions may require greater clearances.

2. Carefully read these instructions and be sure to

understand the function of all connections prior to

beginning installation. Contact your PB Heat, LLC

Representative for help in answering questions.

D. COMBUSTION AND VENTILATION AIR

3. This boiler must be installed by a qualified

contractor. The boiler warranty may be voided if the

boiler is not installed correctly.

1. The Pinnacle boiler is designed only for operation

with combustion air piped from outside (sealed

combustion). PVC pipe must be supplied between

the air inlet connection at the rear of the boiler

through an outside wall.

4. A hot water boiler installed above radiation or as

required by the Authority having jurisdiction, must be

provided with a low water fuel cut-off device either as

part of the boiler or at the time of installation.

2. No additional combustion or ventilation air is

required for this appliance.

5. This boiler can be installed at high altitudes above

5,000 feet elevation with no burner adjustments. For

boilers equipped for firing liquefied petroleum (LP)

gas at elevations above 7,000 feet contact the factory.

DANGER

Do not install this boiler on carpeting.

B. CODES & REGULATIONS

1. Installation and repairs are to be performed in strict

accordance with the requirements of state and local

regulating agencies and codes dealing with boiler

and gas appliance installation.

3. Refer to Section 5 of this manual, Venting, for

specific instructions for piping combustion air.

E. PLANNING THE LAYOUT

2. In the absence of local requirements the following

should be followed.

1. Prepare sketches and notes showing the layout of the

boiler installation to minimize the possibility of

interferences with new or existing equipment, piping,

venting and wiring.

a. ASME Boiler and Pressure Vessel Code, Section

IV - "Heating Boilers"

b. ASME Boiler and Pressure Vessel Code, Section

VI - Recommended Rules for the Care and

Operation of Heating Boilers"

2. The following sections of this manual should be

reviewed for consideration of limitations with

respect to:

a. Water Piping: Section 3

b. Fuel Piping: Section 4

c. Venting: Section 5

d. Air Intake Piping: Section 5

e. Condensate Removal: Section 5

f. Electrical Wiring: Section 6

WARNING

Liquefied Petroleum (LP) Gas or Propane is heavier

than air and, in the event of a leak, may collect in low

areas such as basements or floor drains. The gas

may then ignite resulting in a fire or explosion.

c. ANSI Z223.1/NFPA 54 - "National Fuel Gas Code"

d. ANSI/NFPA 70 - "National Electrical Code"

e. ANSI/NFPA 211 - "Chimneys, Fireplaces, Vents

and Solid Fuel Burning Appliances"

3. Where required by the authority having jurisdiction,

the installation must conform to the Standard for

Controls and Safety Devices for Automatically Fired

Boilers, ANSI/ASME CSD-1.

PREINSTALLATION

WARNING

This boiler is certified as an indoor appliance. Do not

install this boiler outdoors or locate where it will be

exposed to freezing temperatures.

Do not install this boiler where gasoline or other

flammable liquids or vapors are stored or are in use.

Figure 1.1: Accessibility Clearances – Floor Standing Units

Figure 1.2: Accessibility Clearances – Wall Hung Units

BOILER SET-UP

2. BOILER SET-UP

3. Use a minimum of 1/4" threaded fasteners for

supporting the boiler. Do not mount the boiler to

wall board only.

A. GENERAL

1. Pinnacle boilers are to be installed in an area with a

floor drain or in a suitable drain pan. Do not install

any boiler where leaks or relief valve discharge will

cause property damage.

WARNING

Make sure the boiler is adequately supported. Do not

install this boiler on drywall unless adequately

supported by wall studs.

2. This boiler is not intended to support external piping.

All venting and other piping should be supported

independently of the boiler.

4. Be sure to adequately support the boiler while

installing external piping. Be sure to pipe condensate

to a suitable drain or condensate pump.

3. Install this boiler level to prevent condensate from

backing up inside the boiler.

CAUTION

C. FLOOR MOUNTED BOILERS

This boiler is must be installed level to prevent

condensate from backing up inside the boiler.

1. PI-80, PI-140, and PI-199 boilers are designed for

floor mounting. The PI-80 can be wall mounted

using the optional boiler stand available through

your PB Heat, LLC distributor (Part Number 91439).

B. WALL HUNG BOILERS

2. The boiler stand may used for floor mounting of the

PI-140 and PI-199 boilers.

1. The PI-T50 and PI-T80 Boilers are provided with

slots for wall mounting and feet for floor mounting.

Refer to Figure 10.1 in this manual for dimensions &

locations.

2. If wall mounted, the boiler must be attached to a

wall that provides adequate support for the boiler.

WATER PIPING AND CONTROLS

3. WATER PIPING AND CONTROLS

4. Expansion Tank: An expansion tank (such as a Bell &

Gossett Series HFT) is required to provide room for

expansion of the heating medium (water or glycol

solution). Consult the expansion tank manufacturer's

instructions for specific information regarding

A. GENERAL

1. The water supply and return piping of this appliance

are to be sized according to system requirements. Do

not use piping smaller than the boiler connections.

installation. The expansion tank is to be sized for the

required system volume and capacity. In addition, be

sure that the expansion tank is sized based on the

proper heating medium. Glycol solutions may expand

more than water for a similar temperature rise.

2. In hydronic systems where sediment may exist,

install a strainer device in the boiler return piping to

prevent large particles and pipe scale from entering

the boiler heat exchanger coil. Use a large mesh

screen in the strainer.

CAUTION

3. Install this boiler so that the gas ignition system

components are protected from water (dripping,

spraying, etc.) during appliance operation and

service (circulator replacement, condensate trap

cleaning, control replacement, etc.).

Use only inhibited propylene glycol solutions which

are specifically formulated for hydronic systems.

Unlike automotive antifreeze, solutions for hydronic

applications contain corrosion inhibitors that will

protect system components from premature failure

due to corrosion.

B. OPERATING PARAMETERS

1. The Pinnacle boiler is designed to operate in a closed

loop hydronic system at approximately 15 psi. A

pressure limit in the boiler header will prevent the

unit from operating if the pressure drops below 10

psi. This is to keep the appliance from operating in

the event of a system leak or other condition in which

water is not flowing through the heat exchanger.

WARNING

Use only inhibited propylene glycol solutions which

are specifically formulated for hydronic systems.

Ethylene glycol is toxic and may cause an

environmental hazard if a leak or spill occurs.

2. Table 3.1 shows minimum water flow rates for

Pinnacle boilers. If a glycol solution is to be used,

contact the factory for minimum flow rates.

5. Y-Type Strainer: In older systems where a significant

amount of sediment may be present, it may be

necessary to install a Y-type strainer. The strainer

should be checked often and cleaned during the first

few months of operation to assure that sediment

does not reach the heat exchanger and clog the

passages. Use a large mesh screen in the strainer.

Table 3.1 – Minimum Flow Rate and Water Volume

Boiler

Model

Total Water

Minimum Flow

Volume-Gallon (Liter) Rate-GPM (LPM)

PI-T50

PI-T80

PI-80

0.50 (1.89)

0.63 (2.40)

0.93 (3.50)

1.13 (4.26)

2 (7.6)

4 (15.2)

6 (22.7)

8 (30.3)

6. Flow Control Valve: Flow control valves such as the

TACO Flo-Chek or Bell & Gossett Flo-Control™ are

used to prevent gravity circulation by incorporating a

check valve with a weighted disc.

PI-140

PI-199

7. Pressure Reducing Valve: A pressure reducing valve,

such as the Bell & Gossett B-38 or a TACO #329, is

used in a hydronic system to automatically feed

water to the system whenever pressure in the system

drops below the pressure setting of the valve. These

valves should not be used on glycol systems unless

close supervision of the glycol solution is practiced.

C. SYSTEM COMPONENTS

1. Figure 3.1 shows the symbol key for piping diagrams

in this section. The following are brief descriptions of

system components.

2. Pressure/Temperature Gauge: A combination

pressure/temperature gauge is provided with each

Pinnacle boiler to be mounted in the piping from the

boiler supply to the system. Most local codes require

this gauge.

8. Back Flow Preventer: A back flow preventer (check

valve) is required by some jurisdictions to prevent

the hydronic system water from backing up into the

city water supply. This is especially important on

systems in which glycol solution is used as the

heating medium.

3. Air Elimination: Any closed loop hydronic system in

which the Pinnacle boiler is installed must have an

air elimination device. As the system water is heated,

dissolved oxygen and carbon dioxide will separate

from the liquid. An air elimination device (such as a

TACO 430 Series Air Scoop with automatic air vent)

is required to remove the dissolved gasses from the

system preventing corrosion in the piping system and

eliminating system noise.

WATER PIPING AND CONTROLS

Figure 3.1: Piping Symbol Key

9. Pressure Relief Valve: The boiler pressure relief valve

is factory installed into the right side boiler manifold

(inside the jacket). Pipe the discharge of the relief

valve to within 12" of the floor and close to a floor

drain. Provide piping that is the same size or larger

than the relief valve outlet.

b. The circulator should be sized based on the net

output of the boiler. The Table 3.2 shows the

Boiler Output as reported to the Hydronics

Institute division of GAMA. These values are

based on a pickup factor of 1.15.

Table 3.2 – Boiler Inputs and Outputs

CAUTION

Boiler

Model

Boiler Input

(Btu/hr [kW])

Net I=B=R Output

(Btu/hr [kW])

Pipe the discharge of the relief valve as close as

possible to the floor and away from high traffic areas.

Pipe the discharge to a floor drain. Failure to do so

may result in personal injury and/or property damage.

PI-T50

PI-T80

PI-80

50,000 (14.7)

80,000 (23.4)

140,000 (41.0)

199,000 (58.3)

40,000 (11.7)

64,000 (18.8)

112,000 (32.8)

159,000 (46.6)

PI-140

PI-199

10. Circulator: The boiler circulator is to be sized to

overcome the pressure drop of the system while

providing the flow required by the boiler.

a. If the boiler is piped in a secondary loop of a

primary/secondary heating system, the circulator

will need only to overcome the resistance of the

boiler and any fittings in that loop.

WATER PIPING AND CONTROLS

c. The required flow rate can be calculated based

on the design temperature difference from the

return to the supply of the boiler. For a PI-T80

with a design temperature difference of 20°F the

calculation is as follows:

g. Special consideration must be given if anti-freeze is

to be used as a heating medium. Propylene glycol

has a higher viscosity than water therefore the

system pressure drop will be higher.

Output

64,000

10. Indirect Water Heater: An indirect water heater

should be piped in a dedicated zone. It consists of a

water tank that is heated by boiler water passing

through an internal coil. Examples of indirect water

heating are shown in the System Piping subsection

of this Section.

Required Flow =

= 6.4 GPM

∆T x 500

20 x 500

d. Table 3.3 shows the pressure drop (in feet of

water) for a flow rate which gives a 20°F

temperature difference for each boiler model.

Table 3.3 – Flow Rate and Pressure Drop

Boiler

Model

Flow Rate

(GPM [LPM])

Pressure Drop

(Feet [meters])

PI-T50

PI-T80

PI-80

4.0 (15.1)

6.4 (24.2)

11.2 (42.4)

15.9 (60.2)

4.5 (1.22)

5.0 (1.52)

8.0 (2.44)

13.0 (4.02)

PI-140

PI-199

e. The boiler pressure drop for various flow rates

can be determined by using Figure 3.2, the

Pinnacle Circulator Sizing Graph.

f. Table 3.4 gives the recommended circulators for

a boiler on a secondary loop with water as the

heating medium.

Table 3.4 – Recommended Circulators

Boiler

Model

TACO

Circulator

Grundfos Circulator

PI-T50

PI-T80

PI-80

006

007

UPS 15-58FC SPD-1

UPS 15-58FC SPD-2

UPS 15-58FC SPD-3

UP 26-64F

007

PI-140

PI-199

0010

0011

NOTICE

The circulator sizing given is for primary/secondary

installations only. The system circulators must be

sized based on the flow and pressure drop

requirements of the system.

WATER PIPING AND CONTROLS

Figure 3.2: Pinnacle Circulator Sizing Graph

PI-T50

PI-T80/80

PI-140

PI-199

Flow Rate (GPM)

D. SYSTEM PIPING

E. FREEZE PROTECTION

1. Figure 3.3 shows a single boiler with two zones. In

this application, the Peerless Partner indirect water

heater and the single heating zone require similar

water temperature.

1. Glycol for hydronic applications is specially

formulated for this purpose. It includes inhibitors

which prevent the glycol from attacking metallic

system components. Make certain that the system

fluid is checked for the correct glycol concentration

and inhibitor level.

2. Figure 3.4 shows an additional zone in which

baseboard radiation is the heat load. This zone also

requires water temperatures similar to the indirect

water heater.

2. Use only inhibited propylene glycol solutions of up

to 50% by volume. Ethylene glycol is toxic and can

chemically attack gaskets and seals used in hydronic

systems.

3. Figure 3.5 shows diverter tees used in combination

with conventional hydronic radiators on an

additional zone. A second boiler is also added to the

system. Notice that the boilers are piped in parallel

on the secondary loop. It is important that the

common headers are sized to match the system

piping. Smaller headers may result in flow

fluctuations through the boilers.

3. The antifreeze solution should be tested at least once

per year and as recommended by the antifreeze

manufacturer.

4. Figure 3.6 shows a system in which several different

types of loads and multiple boilers are shown. This

system illustrates how different temperature zones

can be supplied from the same source by mixing

down the temperature using a three way mixing

valve. Radiant flooring typically requires much lower

temperatures than baseboard radiation and indirect

water heating. Notice that a third boiler is included in

this system.

5. Figure 3.7 shows zone valves used in place of zone

circulators. Notice that this system utilizes reverse

return piping which makes it easier to balance the

system. If the heating zones are very different in

length, the balancing valves on the return side of

each loop are required.

WATER PIPING AND CONTROLS

Antifreeze solutions expand more than water. For example, a

50% by volume solution expands 4.8% for a 148°F

temperature rise while water expands about 3% for the same

temperature increase. Allowance for this expansion must be

considered in sizing expansion tanks and related components.

9. Do not use galvanized pipe in glycol systems.

10. Use water that is low in mineral content and make

sure there are no petroleum products in the solution.

11. Mix solution at room temperature.

12. Do not use a chromate treatment.

4. The flow rate in systems utilizing glycol solution

should be increased compared with a water system

to compensate for increased heating capacity.

13. Do not use glycol solution in a system that may

reach temperatures above 250°F.

5. Due to increased flow rate and fluid viscosity the

circulator head requirement will increase. Contact the

pump manufacturer to correctly size the circulator for

a particular application based on the glycol

14. Refer to Technical Topics, #2a published by the

Hydronics Institute Division of GAMA for further

glycol system considerations.

concentration and heating requirements.

F. SPECIAL APPLICATIONS

6. A strainer, sediment trap, or some other means for

cleaning the piping system must be provided. It

should be located in the return line upstream of the

boiler and must be cleaned frequently during the

initial operation of the system. Glycol solution is

likely to remove mill scale from new pipe in new

installations.

1. If the boiler is used in conjunction with a chilled

medium system, pipe the chiller in a separate

secondary loop.

a. Assure that the boiler circulator is disabled during

chiller operation so chilled water does not enter

the boiler.

7. Glycol solution is expensive and leaks should be

avoided. Weld or solder joints should be used where

possible and threaded joints should be avoided.

Make up water should not be added to the system

automatically when a glycol solution is used. Adding

make-up water may significantly dilute the system.

b. Install a flow control valve (spring check valve) to

prevent gravity flow through the boiler.

c. See figure 3.8 for recommended system piping.

2. For boilers connected to heating coils in a forced air

system where they may be exposed to chilled air

circulation, install flow control valves or other

automatic means to prevent gravity circulation of the

boiler water during cooling cycles. See figure 3.9 for

illustration.

8. Check local regulations to see if systems containing

glycol solutions must include a back-flow preventer

or require that the glycol system be isolated from the

water supply.

WATER PIPING AND CONTROLS

Figure 3.8: Boiler in conjunction with a Chilled Water System

Figure 3.9: Boiler Connected to a Heating Coil in a Forced Air System

GAS PIPING

4. GAS PIPING

Table 4.2: Maximum Capacity of Pipe (CFH) for a

Pressure Drop of 0.3" of Water

A . GENERAL

1. All fuel piping to the boiler is to be in accordance

with local codes. In the absence of local regulations

refer to the National Fuel Gas Code, ANSI

Z223.1/NFPA 54.

Pipe

Length

(Feet)

1-1/4"

NPT

1-1/2"

NPT

3/4" NPT

Pipe

1" NPT

Pipe

278

190

152

130

115

105

520

350

285

245

215

195

1,050

730

590

500

440

400

1,600

1,100

890

2. Size and install piping to provide a supply of gas

sufficient to meet the maximum demand of all

appliances supplied by the piping.

760

B. FUEL LINE SIZING

670

1. The rate of gas to be provided to the boiler can be

determined by the following:

610

The values are based on a specific gravity of 0.60 (typical

for natural gas). See Table 4.3 for capacity correction

factors for gases with other specific gravities.

Btu

( )

Boiler Input Rate

Gas Heating Value

Input Rate

( )

Btu

( )

/_ft³

Obtain the gas heating value from the gas supplier.

Table 4.3: Maximum Capacity Correction Factors

for Specific Gravity other than 0.60

2. As an alternative use Table 4.1 which uses typical

heating values for natural gas and liquefied

petroleum (LP) gas.

Specific

0.50 0.55 0.60 0.65 0.70 0.75

Gravity

Correction

Factor

1.10

1.04

1.00

0.96

0.93

0.90

Table 4.1: Gas Input Rates

Specific

Gravity

0.80 0.85 0.90 1.00 1.10 1.20

Gas Input Rate* (ft /hr)

Natural Gas

Boiler

LP Gas

Model

PI-T50

PI-T80

PI-80

Correction

Factor

0.87

0.84

0.82

0.78

0.74

0.71

Specific

Gravity

1.30 1.40 1.50 1.60 1.70 1.80

Correction

Factor

PI-140

PI-199

140

199

0.68

0.66

0.63

0.61

0.59

0.58

*Natural gas input rates are based on 1000 Btu/ft , LP

4. The gas piping to the boiler must be a minimum of

3/4" pipe. The boiler is supplied with a 3/4" NPT x

1/2" NPT bell reducer. Do not remove the reducer.

input rates are based on 2500 Btu/ft .

5. Size and install the gas supply piping for no more

than 0.5 inches of water pressure drop between the

gas regulator and the boiler.

3. Table 4.2 shows the maximum flow capacity of

several pipe sizes based on 0.3" of pressure drop.

a. The values shown are based on a gas specific

gravity of 0.60 (Typical for natural gas).

C. GAS SUPPLY PIPING INSTALLATION

b. Multiply the capacities listed by the factors

indicated in Table 5.3 for gas with a specific

gravity other than 0.60 to obtain the corrected

capacity.

1. Do not install any piping directly over or in front of

the boiler. Locate the drop pipe adjacent to the

boiler.

GAS PIPING

2. Install a sediment trap as shown in Figure 4.1. Be

sure to allow clearance from the floor for removal of

the pipe cap.

5. Maintain a minimum distance of 10 feet between the

gas pressure regulator and the boiler.

6. Check all gas piping for leaks prior to placing the

boiler in operation. Use an approved gas detector,

non-corrosive leak detection fluid, or other leak

detection method. If leaks are found, turn off all gas

flow and repair as necessary.

WARNING

Use a pipe joint sealing compound that is resistant to

liquefied petroleum gas. A non-resistant compound

may lose sealing ability in the presence of this gas,

resulting in a gas leak. Gas leaks may potentially

cause an explosion or fire.

WARNING

When checking for leaks, do not use matches,

candles, open flames or other methods that provide

an ignition source. This may ignite a gas leak

resulting in a fire or explosion.

3. Install a ground joint union between the sediment

trap and the boiler to allow service of the appliance.

4. Install a service valve as shown in Figure 4.1 to allow

the gas supply to be interrupted for service.

7. Figure 4.2 and 4.3 are illustrations of the gas shutoff

valve for the Pinnacle Boiler. This valve is to be used

in addition to the gas service valve shown

in Figure 4.1.

D. GAS SUPPLY PIPING - OPERATION

1. The gas line must be properly purged of air to allow

boiler to operate. Failure to do so may result in

burner ignition problems.

2. Table 4.4 shows the maximum and minimum supply

pressure to the boiler.

a. Gas pressure below the minimum pressure may

result in burner ignition problems.

b. Gas pressure above the maximum may result in

damage to the gas valve.

CAUTION

Do not subject the gas valve to more than 1/2 psi

(13.5" W.C.) of pressure. Doing so may damage the

gas valve.

Figure 4.1: Gas Supply Piping – Sediment Trap

Figure 4.2: PI-80/PI-140/PI-199

Gas Valve Shut Off

Figure 4.3: PI-T50/PI-T80 Gas Valve Shut Off

GAS PIPING

Table 4.4: Maximum and Minimum Fuel Pressure

WARNING

Pressure (inches of water)

Gas

Do not adjust the throttle screw without monitoring

Type

Minimum

3.7

Maximum

13.5

the carbon dioxide (CO ) and carbon monoxide (CO)

Natural

in the vent pipe. Vent CO emissions above 400 ppm

are in excess of most safety standards.

3.7

13.5

3. To check the gas supply pressure on the gas valve:

a. Turn off the power at the service switch.

b. For both gas valve arrangements, turning the

throttle screw clockwise will decrease the gas flow

(decreasing CO ) and turning it counterclockwise

b. Turn off the gas shutoff valve.

will increase the gas flow (increasing CO ).

c. The recommended CO settings are given in

c. Using a flat screwdriver, turn the screw inside the

inlet pressure tap fitting (see figure 4.4 and 4.5)

one turn counterclockwise.

Table 4.5. In no case should the boiler be

allowed to operate with CO emissions in excess

of 150 ppm.

d. Attach the manometer tube to the pressure tap

fitting.

2. Refer to Section 5, Venting for information on

obtaining vent samples from this boiler.

e. Open the gas shutoff valve and start the boiler.

Table 4.5: Recommended Vent CO Settings

f. Read and record the gas pressure while the boiler

is firing.

Firing

Rate

Gas Type

Vent CO

g. Turn off the boiler and gas shutoff valve

Low

High

Low

High

8-1/2% to 9-1/2%

9-1/2% to 10-1/2%

< 50 ppm

< 100 ppm

< 50 ppm

< 100 ppm

Natural

h. Remove the manometer tube from the pressure

tap fitting and turn the screw to close the internal

valve.

i. Turn on the gas shutoff valve and boiler service

switch.

4. All gas piping must be leak tested prior to placing the

boiler in operation.

a. If the leak test pressure requirement is higher

than the maximum inlet pressure noted in Table

4.4, the boiler must be isolated from the gas

supply piping system.

b. If the gas valve is exposed to pressures exceeding

13.5" of water, the gas valve must be replaced.

5. Install the boiler such that the gas ignition system

components are protected from water (dripping,

spraying, rain, etc) during operation and service

(circulator replacement, condensate trap cleanout,

and control replacement, etc).

Figure 4.4: Gas Valve/Venturi PI-T50/PI-T80

E. MAIN GAS VALVE - OPERATION

1. Figure 4.4 shows an illustration of the gas valve/venturi

assembly for the Pinnacle PI-T50 and PI-T80 and

Figure 4.5 shows an illustration of the gas valve/venturi

assembly for the PI-80, PI-140, and PI-199.

a. The throttle screw on either of these valves

should not be adjusted without a means to

measure carbon monoxide (CO) and carbon

dioxide (CO ) emissions.

Figure 4.5: Gas Valve/Venturi PI-80, PI-140, PI-199

VENTING, INLET AIR AND CONDENSATE

5. VENTING, INLET AIR AND CONDENSATE

A. GENERAL

C. EXHAUST VENT / AIR INTAKE PIPE

LOCATION

1. Install the boiler venting system in accordance with

these instructions and with the National Fuel Gas

Code, ANSI Z223.1/NFPA 54, CAN/CGA B149,

and/or applicable provisions of local building codes.

1. Determine exhaust vent location:

a. The vent piping for this boiler is approved for

zero clearance to combustible construction.

2. This boiler is a direct vent appliance and is listed as a

Category IV appliance with Underwriters

Laboratories, Inc.

b. See Figure 5.1 for an illustration of clearances for

location of exit terminals of direct-vent venting

systems.

c. This boiler vent system shall terminate at least 3

feet (0.9 m) above any forced air intake located

within 10 ft (3 m). Note: this does not apply to

the combustion air intake of a direct-vent

appliance.

WARNING

This vent system will operate with a positive

pressure in the pipe. Do not connect vent connectors

serving appliances vented by natural draft into any

portion of mechanical draft systems operating under

positive pressure.

d. Provide a minimum of 1 foot distance from any

door, operable window, or gravity intake into any

building.

e. Provide a minimum of 1 foot clearance from the

bottom of the exit terminal above the expected

snow accumulation level. Snow removal may be

necessary to maintain clearance.

WARNING

Follow these venting instructions carefully. Failure to

do so may result in severe personal injury, death, or

substantial property damage.

f. Provide 4 feet horizontal clearance from electrical

meters, gas meters, gas regulators, and relief

equipment. In no case shall the exit terminal be

above or below the aforementioned equipment

unless the 4 foot horizontal distance is

maintained.

B. APPROVED MATERIALS FOR EXHAUST

VENT AND INTAKE AIR PIPE

1. Use only Non Foam Core venting material. The

following materials are approved for use as vent pipe

for this boiler:

g. Do not locate the exit terminal over public

walkways where condensate could drip and/or

freeze and create a nuisance or hazard.

a. Non Foam Core PVC (Polyvinyl Chloride) Pipe

conforming to ASTM D-1784 Class 12454-B

(formerly designated Type 1, Grade 1).

h. When adjacent to a public walkway, locate exit

terminal at least 7 feet above grade.

b. Non Foam Core CPVC (Chlorinated Polyvinyl

Chloride) Pipe conforming to ASTM D-1784

Class 23447-B (formerly designated Type IV,

Grade 1).

i. Do not locate the exit termination directly under

roof overhangs to prevent icicles from forming.

j. Provide 3 feet clearance from the inside corner

of adjacent walls.

c. Non Foam Core ABS (Acrylonitrile-Butadiene-

Styrene) Pipe conforming to ASTM D3965

Class 3-2-2-2-2.

2. Determine air intake pipe location.

a. Provide 1 foot clearance from the bottom of the

air inlet pipe and the level of maximum snow

accumulation. Snow removal may be necessary

to maintain clearances.

WARNING

Do not use Foam Core Pipe in any portion of the

exhaust piping from this boiler. Use of Foam Core

Pipe may result in severe personal injury, death, or

substantial property damage.

b. Do not locate air intake pipe in a parking area

where machinery may damage the pipe.

c. Maximum distance between air intake and

exhaust vent is 6 feet (1.8 m). Minimum distance

between exhaust vent and air intake on single

Pinnacle is 8" (0.2 m) center-to-center. Minimum

distance between vents and intakes on multiple

Pinnacles is 8" (0.2 m) center-to-center. See

Figure 5.2.

2. Cellular foam core piping may be used on air inlet

piping only. Never use cellular foam core material for

exhaust piping.

VENTING, INLET AIR AND CONDENSATE

Figure 5.1: Location of exit terminals of mechanical draft and direct-vent venting systems.

(Reference: National Fuel Gas Code ANSI Z223.1/NFPA 54 2002).

Table 5.1: Fitting Equivalent Length Table

Fitting Description

Elbow, 90°, Short Radius

Elbow, 45°, Short Radius

Coupling

Equivalent Length

Air Intake Tee

Concentric Vent Kit

V1000 & V500 Vent Kit

Exhaust Vent Pipe Equivalent Length = (2x5)+10=20 feet

Figure 5.2: Multiple Pinnacle Vent Spacing

Further, if the intake air pipe has two 90° elbows,

one 45° elbow and 10 feet of PVC pipe, the

following calculation applies:

D. EXHAUST VENT AND INTAKE AIR PIPE

SIZING

Air Intake Pipe Equivalent Length = (2x5)+3+10=23 feet

1. For the PI-T50 and PI-T80 Boilers the exhaust vent

and air intake pipes should be 2" Schedule 40 or 80.

Finally, if a concentric vent kit is used we find:

Total Combined Equivalent Length = 20+23+3=46 feet

2. For the PI-80, PI-140, PI-199 the exhaust vent and

air intake pipes should be 3" Schedule 40 or 80.

Therefore, the total combined equivalent length

is 46 feet which is well below the maximum of

85 feet.

3. The total combined equivalent length of exhaust

vent and intake air pipe should not exceed 85 feet.

c. The intake air pipe and the exhaust vent are

intended to penetrate the same wall or roof of

the building.

a. The equivalent length of elbows, tees, and other

fittings are listed in Table 5.1.

b. For example: If the exhaust vent has two 90°

elbows and 10 feet of PVC pipe we will

calculate:

d. Effort should be made to keep a minimum

difference in equivalent length between the air

intake pipe and the exhaust vent.

VENTING, INLET AIR AND CONDENSATE

4. The minimum combined equivalent length is 16

equivalent feet.

4. Remove all burrs and debris from joints and fittings.

5. All joints must be properly cleaned, primed, and

cemented. Use only cement and primer approved for

use with the pipe material. Cement must conform to

ASTM D2564 for PVC or CPVC pipe and ASTM

D2235 for ABS pipe.

5. The maximum combined equivalent length can be

extended by increasing the diameter of the vent

pipe. However, the transitions should begin a

minimum of 15 equivalent feet from the boiler.

a. Transitions should always be made in vertical

sections of pipe to prevent the condensate from

pooling in the vent pipe.

WARNING

All joints of positive pressure vent systems must be

sealed completely to prevent leakage of flue products

into the living space.

b. Use a 3" x 2" reducing coupling to transition from

the PI-T50 and PI-T80 boiler connections to a 3"

vent.

6. Horizontal lengths of exhaust vent must slope back

towards the boiler not less than ¼" per foot to allow

condensate to drain from the vent pipe. If the vent

pipe must be piped around an obstacle that causes a

low point in the pipe, a drain pipe must be

c. Use a 4" x 3" reducing coupling to transition from

the PI-80, PI-140, and PI-199 boiler connections

to 4" vent.

d. The maximum equivalent length for the

increased diameter vent pipes is 125 feet.

connected to allow condensate to drain.

7. All piping must be fully supported. Use pipe hangers

at a minimum of 4 foot intervals to prevent sagging

of the pipe where condensate may form.

e. If the transition occurs at a distance greater than

15 equivalent feet from the boiler, the maximum

equivalent length will be reduced. See Table 5.2.

Standard Vent Pipe is 2” and Oversized Vent

Pipe is 3” for PI-T50 and PI-T80. Standard Vent

Pipe is 3” and Oversized Vent Pipe is 4” for PI-

80 through PI-199.

8. Do not use the boiler to support any piping.

9. A screened straight coupling is provided with the

boiler for use as an outside exhaust termination.

10. A screened inlet air tee is provided with the boiler to

be used as an outside intake termination.

Table 5.2: Maximum Equivalent Vent Length for

Oversized Vent Pipe

11. The following are optional intake air/exhaust vent

terminations available from your PB Heat, LLC

distributor for use with Pinnacle boilers.

TEL of

Transition

Point

(ft from

boiler)

Maximum

TEL of all

Vent Pipe (ft)

Standard 2” Oversized 3”

or 3” Vent

Pipe (ft)

or 4” Vent

Pipe (ft)

Table 5.3: Vent Termination Kits

77-1/2

60-1/2

125

117-1/2

110-1/2

103

Stock

Description

Code

2" PVC Concentric Vent Termination Kit

91469

3" PVC Concentric Vent Termination Kit

2" Stainless Steel Vent Termination Kit

3" Stainless Steel Vent Termination Kit

4" Stainless Steel Vent Termination Kit

91403

91465

91402

91401

8-1/2

88-1/2

None

TEL = Total Equivalent Length

E. EXHAUST VENT AND AIR INTAKE PIPE

INSTALLATION

12. Refer to Figure 5.3 to 5.10 for sidewall venting and

Figures 5.11 to 5.14 for vertical venting.

1. On the PI-T50 and PI-T80 the 2" exhaust vent

connection is located on the top, right side of the

boiler and the air intake is on the top, left side. See

Figure 10.1. The air intake connection is intended

for a slip fit. No sealant or adhesive is required.

2. On the PI-80, PI-140, and PI-199 Boilers the 3”

exhaust vent connection is located on the rear of the

boiler and the air intake is higher and toward the left

side when the boiler is viewed from the front. See

Figure 10.2. The air intake connection is intended for

a slip fit. No sealant or adhesive is required.

3. Use only solid PVC, CPVC, or ABS schedule 40 or

80 pipe. FOAM CORE PIPING IS NOT APPROVED.

VENTING, INLET AIR AND CONDENSATE

Figure 5.3: PI-80, PI-140, and PI-199 Sidewall

Venting with 3" Pipe (Exhaust

Termination at Higher Elevation than

Air Intake).

Figure 5.5: PI-80, PI-140, PI-199 Sidewall Venting

with 3" Pipe (Air Intake and Exhaust on

the same Elevation).

Figure 5.4: PI-T50 & PI-T80 Sidewall Venting with

2" Pipe (Exhaust Termination at Higher

Elevation than Air Intake).

Figure 5.6: PI-T50 & PI-T80 Sidewall Venting with

2" Pipe (Air Intake and Exhaust on the

same Elevation).

WARNING

All exhaust vent pipes must be glued, properly

supported, and pitched at a minimum of ¼" per foot

back to the boiler. Failure to do so may result in severe

personal injury, death, or substantial property damage.

VENTING, INLET AIR AND CONDENSATE

Figure 5.7: PI-80, PI-140, PI-199 Sidewall Venting

with 3" Pipe (3" Vent Kit).

Figure 5.9: PI-80, PI-140, PI-199 Sidewall Venting

with 3" Pipe (Concentric Vent Kit).

Figure 5.8: PI-T50 & PI-T80 Sidewall Venting with

2" Pipe (2" Vent Kit).

Figure 5.10: PI-T50 & PI-T80 Sidewall Venting with

2" Pipe (Concentric Vent Kit).

WARNING

All exhaust vent pipes must be glued, properly

supported, and pitched at a minimum of ¼" per foot

back to the boiler. Failure to do so may result in

severe personal injury, death, or substantial property

damage.

VENTING, INLET AIR AND CONDENSATE

Figure 5.11:

PI-80, PI-140, PI-199 Vertical

Venting with 3" Pipe.

Figure 5.13:

PI-80, PI-140, PI-199 Vertical

Venting with 3" Pipe (Concentric

Vent Kit).

Figure 5.12:

PI-T50 & PI-T80 Vertical Venting

with 2" Pipe.

Figure 5.14:

PI-T50 & PI-T80 Vertical Venting

with 2" Pipe (Concentric Vent Kit).

VENTING, INLET AIR AND CONDENSATE

F. EXHAUST TAPPING FOR VENT SAMPLE

H. BOILER REMOVAL FROM COMMON

VENTING SYSTEM

To obtain a combustion sample a hole must be drilled in

the exhaust vent pipe just above the first elbow at the

outlet of the boiler.

1. At the time of removal of an existing boiler from a

common venting system, follow these steps with

each appliance that remains connected. These steps

are to be completed while all components which

remain connected to the common venting system are

not in operation.

a. Drill a 21/64" diameter hole in the vent pipe just

above the first elbow.

b. Tap the hole with a 1/8" NPT Pipe Tap.

a. Seal any unused openings in the common

venting system.

c. Take combustion samples through the tapped

hole.

b. Visually inspect the venting system for proper size

and horizontal pitch. Verify there is no blockage

or restriction, leakage, corrosion, and other

deficiencies which could cause an unsafe

condition.

d. Thread a standard 1/8" NPT Pipe Plug into the

hole.

G. CONDENSATE DRAIN INSTALLATION

1. This boiler is a high efficiency unit that produces

condensate. The condensate must be drained from

the unit.

c. Where practical, close all building doors and

windows, including interior doors between the

space in which the appliances that remain

connected to the common venting system are

located and other areas of the building.

2. The white hose under the unit is a condensate trap

which prevents products of combustion from exiting

the boiler through the condensate drain.

d. Turn on any clothes dryers and any appliance

not connected to the common venting system.

Turn on any exhaust fans, such as range hoods

and bathroom exhaust fans, at their maximum

speed. (Do not operate a summer exhaust fan).

3. The black plastic 3/4" NPT fitting at the left rear

corner of the boiler is intended for connection to

plastic piping. Do not block vent hole at the top of

the fitting.

e. Close fireplace dampers.

4. Slope the condensate drain piping down away from

the unit into a floor drain or condensate pump.

Check with local codes or ordinances to

determine if the condensate must first be

neutralized before running it to a drain.

f. Place the appliance being inspected in operation.

Follow the lighting instructions and adjust the

thermostat so that the appliance operates

continuously.

g. 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.

CAUTION

Make sure the condensate drain piping is below the

level of the boiler to prevent condensate from filling

up the combustion chamber and damaging the boiler.

h. After it has been determined that each appliance

remaining connected to the common venting

system properly vents when tested as outlined

above, return doors, windows, exhaust fans,

fireplace dampers and any other gas-burning

appliance to their previous condition of use.

5. Do not route the condensate piping through

unheated spaces that may reach freezing

temperatures.

i. Any improper operation of the common venting

system should be corrected so that the

installation conforms with the National Fuel Gas

Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA

B149.

6. Use only plastic piping for the condensate drain line.

Metal pipes will corrode and cause blockage of the

condensate drain.

7. To allow for proper drainage on large horizontal

runs, a second line vent may be required and the

required tubing size may increase to 1" I.D.

j. The common venting system should be resized to

approach the minimum size determined by using

the appropriate tables located in the National

Fuel Gas Code, ANSI Z223.1/NFPA 54, "Sizing

of Category I Venting."

8. A condensate removal pump is required if the boiler

is below the drain.

ELECTRICAL

6. ELECTRICAL

Install all electrical wiring in accordance with the National

Electrical Code, ANSI/NFPA 70, and local requirements.

c) An example of this wiring using a Honeywell R845A

relay is shown in Figure 6.2

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 Electrical Code, ANSI/NFPA 70.

A. WIRING

1. Refer to Figures 6.1 for connecting the power supply

to the boiler.

Figure 6.2: Wiring Circulator with R845A

Switching Relay

8. The thermostat connections are shown in Figure 6.1

or 6.2. The setting for the thermostat anticipator is

0.56 amps.

9. The boiler control board and factory wiring are

shown in figure 6.3.

B. SEQUENCE OF OPERATION

1. System Power-Up:

Figure 6.1: Wiring Connections to Boiler

Junction Box

a) When power is first applied to the boiler, the

control will initially run through a self-diagnostic

routine. The interface unit shows the system

supply temperature.

2. Connect boiler to a 110 volt, single phase, 60 hertz

electrical supply line with a fused disconnect switch.

The boiler is fused for a load of 6.3 amperes.

b) Next, it will power the combustion air fan for a 10

second purge cycle.

3. The boiler electrical connection is located on the left

side of the boiler in the junction box which houses

the service switch.

c) Finally the combustion air shuts down and if there

is no call for heat the control board enters a

standby mode.

4. Wire the burner service switch in the hot line to the

boiler as shown in Figure 6.1.

2. Heating Cycle:

a) When the thermostat calls for heat (closing the

contact between the two gray [TT] wires) and the

boiler control senses a supply temperature lower

than the set point by more than the differential,

the boiler initiates a heating cycle.

5. Make sure to maintain correct polarity on the

incoming power supply wires. If polarity is reversed,

the boiler control will not sense the main burner

flame.

6. Connect the ground wire from the incoming power

supply to the green ground screw in the junction

box. Also, the boiler ground should be connected to

this screw.

b) The control then powers the combustion air fan

at the speed prescribed for the particular boiler

model and performs a 6 second pre-purge of the

combustion chamber.

7. Figure 6.1 shows connections to system circulator.

c) 0.5 second before the pre-purge is complete

power is applied to the spark igniter.

a) The maximum current load for the circulator

circuit is 4.0 amperes.

d) Once the pre-purge cycle is complete, the fan

speed decreases to the programmed ignition

speed.

b) For loads greater than 4.0 amps, isolate the

circulator using a switching relay.

ELECTRICAL

e) The main gas valve is then energized to allow

gas to mix with the combustion air.

h) As the supply temperature approaches the set

point, the combustion control will reduce the

input rate. The supply temperature will continue

to climb to about 7°F above the boiler set point

before it cycles off.

f) If the main flame is not detected in 5 seconds,

the gas valve closes and the combustion fan goes

into post-purge. Otherwise, the combustion fan

stays at the ignition speed for the length of the

flame stabilization period. (10 to 25 seconds).

i) The differential is applied from this point. For

example if the boiler set point is at 180°F with a

10°F differential, the supply temperature will

reach 187°F before shutting down. It will not

re-start until the supply temperature drops below

177°F.

g) After the flame stabilization period is complete,

the combustion air fan ramps down to its low fire

setting. Then the boiler will begin to modulate

depending on the supply temperature to

maintain the set point temperature.

Figure 6.3: Boiler Control Board Wiring Schematic

ELECTRICAL

Table 6.1: Program Functions

C. SAFETY INTERLOCKS

Alternating

Display

1. Low Water Pressure Limit Switch: This boiler is

intended to operate at pressures exceeding 10 psig. If

the water pressure drops to below 10 psig, there is a

water pressure limit switch that interrupts boiler

operation and displays the message "PR0" on the

interface unit. The combustion air fan completes a

post-purge in this event. Once the low water pressure

condition is corrected the boiler will reinitiate a

heating cycle if there remains a call for heat.

Description

Character

Allowable Range

50°F to 201°F

(10°C to 94°C)

Supply Set Point

5°F to 30°F

(3°C to 17°C)

Set Point Differential

Not Applicable

Measurement Units

C or F

2. High Water Temperature Limit Switch: The boiler is

equipped with a limit switch that will interrupt the

heating cycle and execute a post-purge if the water

temperature increases to above the limit set point of

225°F.

i. The display will alternately show "C" and

then the current set point temperature.

ii. The set point may be adjusted by using the

S1/- (to decrease) or S2/+ (to increase) keys

on the display module.

3. High Flue Temperature Limit Switch: The high flue

temperature limit switch will interrupt the heating

cycle if it senses flue gas temperatures above 210°F.

c. Pressing the S3 "Program" key again will advance

to the next adjustable value, Set Point

4. Blocked Vent Pressure Limit Switch: This switch

prevents the boiler from operating if the vent

pressure exceeds 2 inches of water column. This will

prevent the boiler from operating if the vent pipe is

blocked.

Differential, and the display will alternate

between: "Ch" and the programmed value:

i. The differential adjustment is the difference

between the temperature that the boiler shuts

down (high) and the temperature at which it

re-starts (low).

D. CONTROL FUNCTIONS

1. This Pinnacle boiler is equipped with a P125 Control

Board. This control board with display module has

the following functions:

ii. The differential may be set to values between

5°F (3°C) and 30°F (17°C) in 1°F increments.

a. Shows the boiler supply (outlet) water

temperature on the LED Display as default.

iii. The boiler will always shut down at a

temperature 7°F (4°C) above the set point.

The differential temperature is then applied to

this value.

b. Allows user to adjust the supply water set point,

the set point differential, and change the display

mode between Fahrenheit and Celsius.

iv. The set point differential may be adjusted by

using the S1/- (to decrease) or S2/+ (to

increase) keys on the display module.

c. Provides Error and Fault Codes on the LED

Display.

d. Shows the actual supply and return

temperatures, fan speed, flame signal (µA), boiler

circulator status, boiler set point, total power on

hours, boiler on hours, and the number of cycles.

d. Pressing the S3 "Program" key again will advance

to the next adjustable value. The display will read

"de" and alternate with numerical value. This

value is not applicable to the Pinnacle boiler.

e. Allows manual control of the firing rate using the

Service Mode.

e. Finally, by pressing the S3 "Program" key again,

the display will advance to the Measurement

Units selection. The display will alternate

between "t" and either "F" or "C" depending on

the units selected. This value may be changed by

using the S1/- or S2/+ keys on the display

module.

2. Default Display: Under normal operating conditions

the default display shows the temperature of the

water supply (boiler outlet) to the system. This may

be displayed in Fahrenheit or Celsius according to

user preferences.

f. Pressing the S3 "Program" key once more will

exit the program mode and again display the

supply temperature.

3. Program Functions: By using the S3 "Program" key,

the settings shown in Table 6.1 may be programmed.

a. To access the menu, press and hold the S3

"Program" key on the display module.

b. The control will enter the Supply Set Point

selection.

ELECTRICAL

4. Error Codes: The LED Display will display error codes

if the boiler is in a temporary fault condition. Table 8.1

shows Error Codes and descriptions. In some cases, if

the temporary fault is not corrected within 60 seconds

the controller will go into a Fault Code.

e. To exit the Service Mode, press the S1/- or S2/+

keys simultaneously.

8. Installer Menu: The Pinnacle boiler can be

programmed to be controlled by an external

analog input controlling set point temperature or

fan speed. In addition, it can be programmed for

a 6 minute step modulation sequence.

5. Fault Codes: A Fault Code indicates the controller is

locked-out. Press the S4 "Reset" button to resume

operation after repairing the problem. Table 8.2

shows Fault Codes for this control.

a. To enter the installer menu, press and hold the

S3 "Program" key and S4 "Reset" key

simultaneously for 3 seconds. The display will

show a blinking "000."

6. Status Menu: The status menu, as shown in Table

6.3, allows the installer to display the current boiler

supply (outlet) temperature, return (inlet

Table 6.4: Installer Menu

temperature), fan speed, flame signal (µA), boiler

circulator status, boiler set point, total power on

hours, boiler on hours, and the number of cycles.

a. To access this menu press and hold the S4

"Reset" key on the display module for 3 seconds.

Parameter

No.

Function

0 = Internal Control

1 = External Input from 0-10 volt adapter

b. The display will alternate between "d1" and the

value of the supply temperature.

0 = External Temperature Input

1 = External Fan Speed Input

0 = Step Modulation Disabled

1 = Step Modulation Enabled

c. To scroll through the other status codes, simply

press S4 "Reset", again.

b. Use the S1/- and S2/+ keys to change the display

to read 125. Press the S3 "Program" key to enter

the installer menu. (The control will shut down

the boiler if it is in operation.) The display will

alternate between 1 and a value of either 0 or 1.

d. To exit this menu, press the S3 "Program" key.

Table 6.3: Status Menu

Status

Description

Code

c. Table 6.4 shows the Parameter numbers and

Functions. Press S3 "Program" to advance

through the parameters and use the S1/- and

S2/+keys to change the function values. Do not

change to external input without external

input device installed!

Supply (Outlet) Temperature (F or C)

Return (Inlet) Temperature (F or C)

Fan Speed (rpm ÷ 10) [ex. 200 = 2000 rpm]

Flame Signal (µA)

d. To exit the Installer Menu, press and hold the S4

“Reset” key for 3 seconds.

Boiler Circulator Status (0 = Off, 1 = On)

Boiler Set Point (F or C)

Power On Time (Hrs ÷ 1000) [ex. 0.1 = 100 hrs]

Boiler On Time (Hrs ÷ 1000)

Boiler Cycles (n ÷ 1000)

7. Service Mode: The Pinnacle boiler can be operated

in Service Mode to allow the installer to manually set

the fan speed/input rate of the boiler.

a. To enter service mode, press and hold the S2/+

key and the S3 "Program" key simultaneously.

b. The display will alternately display "SER" and the

fan speed in RPMs ÷ 10. As default, the fan

speed will start at the ignition fan speed (this

value is listed in Section 10, Dimensions and

Ratings, for each boiler size).

c. The fan speed can be adjusted by using the S1/-

key (to decrease speed) or S2/+ key (to increase

speed) on the display module.

d. The fan speed will stay in this mode for 10

minutes or until the boiler reaches 7 degrees

above the set point temperature.

Figure 6.4: Display Module

START-UP PROCEDURES

7. START-UP PROCEDURES

c) The set point may be adjusted by using the S1/-

A. COMPLETING THE INSTALLATION

(to decrease) or S2/+ (to increase) keys on the

display module.

1. Confirm that all water, gas and electricity are

turned off.

d) Pressing the S3 "Program" key again will advance

to the next adjustable value, Set Point Differential

and the display will alternate between.

2. Verify that water piping, venting, gas piping and

electrical wiring and components are installed

properly and where applicable in accordance with

manufacturers' instructions. Be sure that the boiler is

installed in accordance with this manual and good

engineering practice.

e) The differential adjustment is the difference

between the temperature at which the boiler

shuts down (high) and the temperature at which

it re-starts (low).

3. Fill the boiler and system with water, making certain

to vent all air from each high point in the system.

Open each vent in the system until all air is released

and water begins to be discharged, and then close

the vent.

f) The differential may be set to values between 5°F

(3°C) and 30°F (17°C) in 1°F increments.

g) The boiler will always shut down at a

temperature 7°F (4°C) above the set point. The

differential temperature is then applied to this

value.

4. The pressure reducing valve on the fill line will

typically allow the system to be filled and pressurized

to 12 PSI. Consult the manufacturer's instructions for

operation of the valve and expansion tank.

h) The set point differential may be adjusted by

using the S1/- (to decrease) or S2/+ (to increase)

keys on the display module.

5. Check joints and fittings throughout the system and

repair as required.

i) Pressing the S3 "Program" key again will advance

to the next adjustable value. The display will read

"de" and alternate with numerical value. This

value is not applicable to the Pinnacle boiler.

6. Connect a manometer at or near the service valve to

the boiler.

7. Confirm that the gas supply pressure to the boiler is

between the minimum and maximum values for the

gas being used. These values can be found in Table

4.4 of Section 4.

j) Finally, by pressing the S3 "Program" key again,

the display will advance to the Measurement

Units selection. The display will alternate

between "t" and either "F" or "C" depending on

the units selected. This value may be changed by

using the S1/- or S2/+ keys on the display

module.

8. If a full supply pressure test is required, isolate the

boiler and gas valve before performing the pressure

test. If the supply pressure is too high or too low,

contact the fuel gas supplier.

11. Light the boiler by following the Lighting/Operating

instructions in this section. The initial ignition may

fail several times before the gas piping is completely

purged of air.

9. Turn on electricity and gas to the boiler. Check to see

if the LED display is lit. The combustion air fan will

begin a 5 second purge cycle and then the control

will go into Standby Mode.

12. Use the sequence of operation description and

Figure 6.3, Control Board Wiring Schematic to

follow light off and shutdown sequences and to assist

in diagnosing problems. If the boiler does not

function properly, consult Section 8,

10. Adjust set point temperatures and differential

temperatures by pressing and holding the S3,

"Program" key for 3 seconds.

a) The control will enter the Supply Set Point

selection.

Troubleshooting.

b) The display will alternately show "C" and then

the current set point temperature.

START-UP PROCEDURES

B. LIGHTING AND OPERATING

PROCEDURES

FOR 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.

•

A. This appliance does not have a pilot. It is equipped

with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

If you cannot reach your gas supplier, call the

fire department.

C. Use only your hand to turn the gas control knob. Never

use tools. If the handle will not turn by hand, don’t try

to repair it, call a qualified service technician. Force or

attempted repair may result in a fire or explosion.

B. 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.

D. 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.

WHAT TO DO IF YOU SMELL GAS

•

Do not try to light any appliance.

Do not touch any electric switch; do not use any

phone in your building.

•

Immediately call your gas supplier from a neighbor’s

phone. Follow the gas suppliers’ instructions.

OPERATING INSTRUCTIONS

11. STOP! Read the safety information above.

15. Remove front cover.

12. Set the thermostat to lowest setting.

16. Turn gas shutoff valve clockwise to “off”. Handle will be

vertical, do not force.

13. Turn off all electric power to the appliance.

17. Wait five (5) minutes to clear out any gas. If you then

smell gas, STOP! Follow “B” in the safety information

above on this label. If you don’t smell gas, go to next

step.

14. This appliance is equipped with an ignition device

which automatically lights the burner. Do not try to light

the burner by hand.

18. Turn gas shutoff valve counterclockwise to “on”.

Handle will be horizontal

19. Install Front Cover.

10. Turn on all electric power to appliance.

11. Set thermostat to desired setting.

12. 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

1. Set the thermostat to lowest setting.

4. Turn gas shutoff valve clockwise to “off”. Handle will be

vertical. Do not force.

2. Turn off all electric power to the appliance if service is

to be performed.

5. Install front cover.

3. Remove front cover.

START-UP PROCEDURES

C. CHECK-OUT PROCEDURE

4. Low Water Cut-Off (if used) - Consult the

manufacturer's instructions for the low water cut-off

operational check procedure.

1. After starting the boiler, be certain that all controls

are working properly. Check to be sure that the

boiler will shut down when the water temperature

reaches the control board set point.

5. Check the system to assure that there are no leaks or

overfilling problems which may cause excessive

make up water to be added. Make up water may

cause liming in the boiler and corrosion in ferrous

system parts.

2. To check operation of the ignition system safety shut-

off features:

a) Turn off gas supply.

6. 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.

b) Set thermostat or controller above room

temperature to call for heat.

c) The boiler should perform 3 attempts at ignition

before going into lock-out.

7. Check the condensate drain hose (and pump if

installed) and make sure all condensate is being

removed from heat exchanger.

d) Turn gas supply on.

e) Reset by pushing S4 "Reset" key.

8. Review operation with end-user.

f) Observe boiler operation through one complete

cycle.

9. Complete the Warranty Card and submit it to PB

Heat.

3. Turn off the automatic fill to the boiler and drain

some water to drop the system pressure below 10

psig. Verify that the display module reads "PRO"

after 5 seconds and does not allow the boiler to

operate. Close the boiler drain and turn on the

automatic fill valve.

10. Hang the Installation, Operation, and Maintenance

Manual in an accessible position near the boiler.

TROUBLESHOOTING

8. TROUBLESHOOTING

A. BOILER ERROR

DANGER

1. When an error condition occurs the controller will

display an error code on the display module.

When servicing or replacing components that are in

direct contact with the boiler water, be certain that:

●

There is no pressure in the boiler. (Pull the

release on the relief valve. Do not depend on

the pressure gauge reading).

2. These error codes and several suggested corrective

actions are included in Table 8.1.

3. In the case of E00, E13, and E14 this error, if

uncorrected, will go into a fault condition as

described is Paragraph B.

●

The boiler water is not hot

●

The electrical power is off

B. BOILER FAULT

WARNING

1. When a fault condition occurs the controller will

illuminate the red "fault" indication light and display

a fault code in the format "F##" on the display

module.

Do not use this appliance if any part has been under

water. Improper or dangerous operation may result.

Contact a qualified service technician immediately to

inspect the boiler and to repair or replace any part of

the boiler which has been under water.

2. Note the fault code and refer to Table 8.2 for an

explanation of the fault code along with several

suggestions for corrective actions.

CAUTION

3. Press the reset key to clear the fault and resume

operation. Be sure to observe the operation of the

unit to prevent a recurrence of the fault.

This appliance has wire function labels on all internal

wiring. Observe the position of each wire before

removing it. Wiring errors may cause improper and

dangerous operation. Verify proper operation after

servicing.

WARNING

When servicing or replacing any components of this

boiler be certain that:

CAUTION

●

The gas is off.

●

All electrical power is disconnected

If overheating occurs or the gas supply fails to shut

off, do not turn off electrical power to the circulating

pump. This may aggravate the problem and increase

the likelihood of boiler damage. Instead, shut off the

gas supply to the boiler at the gas service valve.

Table 8.1: P125 Control Board Error Codes

Code

Description

Duration

Corrective Action

1. Check circulation pump operation.

2. Assure that there is adequate flow through the boiler by

accessing the status menu and assuring that there is less

than a 50°F rise from the return thermistor to the supply

thermistor.

E00

High Limit Exceeded

50 Sec.

3. Replace switch if faulty.

Combustion Fan Speed Low.

The boiler combustion air fan speed

less than 70% of expected.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

E13

E14

60 Sec.

Combustion Fan Speed High.

The boiler combustion air fan speed

is more than 130% of expected.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

1. Assure that the system pressure is above 10 psig.

2. Check for leaks in the system piping.

3. Check the switch operation by applying a jumper. (If the

switch is not functioning properly replace it.)

PRO Water Pressure Switch Open

Until Corrected

1. Assure that the vent is not blocked.

Until Corrected 2. Check the switch operation by applying a jumper. (If the

switch is not functioning properly replace it.)

FLu

Blocked Vent Pressure Switch Open

TROUBLESHOOTING

Table 8.2: P125 Control Board Fault Codes

Fault

Code

Description

Corrective Action

1. Check circulation pump operation.

2. Assure that there is adequate flow through the boiler by accessing the status menu

and confirming that there is less than a 50°F rise from the return thermistor to the

supply thermistor.

3. If gray thermostat wires are being used, disconnect them and jump them together.

If F00 code can be reset check thermostat circuit for short circuit or stray voltage.

4. Check supply temperature reading on LED display. Replace High Limit Switch if

supply temperature is below 210°F.

F00

High Limit Exceeded.

5. Temporarily jump out Water Pressure Switch. If F00 code can be reset check wiring

harness and connections. If wiring harness is okay replace Water Pressure Switch.

1. Push the red reset button on the switch.

F01

Vent Temperature Limit Exceeded.

2. Check the flue temperature during operation using a combustion analyzer.

3. Replace the switch if faulty.

Interrupted or Shorted

Supply (Outlet) Thermistor.

1. Check the electrical connection to the thermistor on the outlet manifold.

2. Replace thermistor if necessary.

F02

F03

Interrupted or Shorted

Return (Inlet) Thermistor.

1. Check the electrical connection to the thermistor on the inlet manifold.

2. Replace thermistor if necessary.

1. Check circulation pump operation.

Supply (Outlet)

Temperature exceeded 230°F.

2. Assure that there is adequate flow through the boiler by accessing the status menu

and confirming that there is less than a 50°F rise from the return thermistor to the

supply thermistor.

F05

F06

1. Check circulation pump operation.

Return (Inlet) Temperature

exceeded 230°F.

2. Assure that there is adequate flow through the boiler by accessing the status menu

and confirming that there is less than a 50°F rise from the return thermistor to the

supply thermistor.

1. Watch the igniter through the observation window provided.

No flame detected – The boiler will make three 2. If there is no spark, check the spark electrode for the proper ¼" gap.

attempts at ignition before the control goes into 3. Remove any corrosion from the spark electrode.

F09

F10

this lockout condition.

4. If there is a spark but no flame, check the gas supply to the boiler.

5. If there is a flame, check the flame sensor.

1. Check the gas pressure to the gas valve while the unit is in operation.

2. Assure that the flame is stable when lit.

3. Check to see if the green light on the display module is out while the boiler

Loss of Flame Signal – The boiler will relight 4

times before the control goes into this lockout

condition.

is running.

4. If the green light doesn't come on or goes off during operation check the flame

signal on the status menu.

5. If the signal reads less than 1 microampere, clean the flame sensor.

6. If the sensor continues to read low, replace it.

1. Turn the gas off to the unit at the service valve.

2. If the flame signal is still present replace the flame rod.

3. If the flame signal is not present after turning off the gas supply, check

the gas valve electrical connection.

False Flame Signal – The boiler will lock out if

it senses a flame signal when there should be

none present.

F11

4. If there is no power to the gas valve, remove the valve and check for obstruction

in the valve seat or replace the gas valve.

5. Turn the gas on at the service valve after corrective action is taken.

Combustion Fan Speed Low – The boiler will

1. Check the combustion air fan wiring.

lock out if it senses that the fan speed is less than 2. Replace the combustion air fan.

F13

F14

70% of expected for more than 60 seconds.

3. Replace the control board.

Combustion Fan Speed High – The boiler will

lock out if the fan speed is more than 130% of

expected for more than 60 seconds.

1. Check the combustion air fan wiring.

2. Replace the combustion air fan.

3. Replace the control board.

1. Make sure the connector is correctly connected to the gas valve.

2. Check the electrical wiring from the valve to the control board.

3. Replace the gas valve.

Gas Valve Error

F18

4. Replace control board.

Watchdog

Call factory for further assistance.

F30

F31

F32

F33

Parameter Memory

Parameter Memory Write Error

Programming Error

Neutral Fault – Boiler locks out if it senses

a voltage drop or power feedback on the

neutral wire.

1. Check for adequate supply voltage.

2. Check for power feedback on the neutral wire.

MAINTENANCE

9. MAINTENANCE

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.

A. GENERAL (WITH BOILER IN USE)

General 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.

e. If the valve continues to leak, it must be replaced

before the boiler is returned to operation.

f. Check that operating pressure and temperature

have returned to normal.

2. Observe general boiler conditions (unusual noises,

vibrations, etc.)

g. Check again to confirm that valve has closed

completely and is not leaking.

3. Observe operating temperature and pressure on the

combination gauge located in the supply piping on

the left side of the boiler. Boiler pressure should

never be higher than 5 psi below the rating shown

on the safety relief valve (25 psig maximum for a 30

psig rating). Boiler temperature should never be

higher than 240° F.

3. Test low-water cut-off (if used) as described by the

manufacturer.

4. Test limit as described in Section 7, Part C, “Check-

Out Procedure”.

5. Test function of ignition system safety shut-off

features as described in Section 7, Part C, “Check-

Out Procedure”.

4. Check for water leaks in boiler and system piping.

5. Smell around the appliance area for gas. If you smell

gas, follow the procedure listed in the Lighting

Operating Instructions to shut down appliance in

Section 7, Start-Up Procedure Part B.

DANGER

When servicing or replacing components, be

absolutely certain that the following conditions are

met:

B. 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.

Water, gas and electricity are off.

●

The boiler is at room temperature.

●

There is no pressure in the boiler.

C. ANNUALLY (BEFORE START OF

HEATING SEASON)

6. Remove the top/front jacket panel and inspect for

any foreign debris that may have entered through air

inlet vent.

CAUTION

7. Inspect burner for deterioration. Replace if necessary.

The following annual inspection must be performed

by a qualified service technician.

8. With boiler in operation check that condensate is

dripping from drain hose. Check for any restriction in

condensate drain line.

a. CONDENSATE CLEANING INSTRUCTIONS:

1. Check boiler room floor drains for proper

functioning.

1. Turn the thermostat down or off so the

Pinnacle will not cycle and then follow the

steps below.

2. Check function of the safety relief valve by

performing the following test:

a. Check valve piping to determine that it is

properly installed and supported.

a. Close manual gas shutoff valve.

b. Disconnect the condensate piping from the

outside connection (not from the Pinnacle)

so flow can be observed.

b. Check boiler operating temperature and pressure.

c. Lift the 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.

c. Block the air flow in the exhaust by

temporarily plugging the exhaust from the

outside vent.

MAINTENANCE

d. Disconnect the white, red, blue, and black

1. Shut the Pinnacle down by using the

following steps:

connection from the Molex on the

combustion blower. (Refer to Control

Wiring Schematic, Figure 6.3.) This will

cause the fan to run at 100% which will

then blow out any sediment that has

accumulated in the condensate line. (This

process should only take a few minutes.)

a. Close the manual gas shutoff valve, shut

down the unit and wait for the unit to be

cool to the touch.

b. Disconnect the condensate piping from the

outside connections (not from the Pinnacle

side) so the flow can be observed.

e. The unit should now be ready to restart.

2. Before restarting the Pinnacle follow the

steps below:

c. Remove the (4) screws on the 1/2" NPT

connector on the gas valve.

a. Reconnect the Molex connection and

unblock the vent. (IMPORTANT: MAKE

SURE EXHAUST VENT IS NO

LONGER BLOCKED!)

d. Remove the (6) 10mm nuts from the

burner plate assembly to access the coils.

e. Pull the entire burner plate assembly

towards you, while removing or pushing

aside any wiring to allow the removal of

the assembly.

b. Open the manual gas shutoff valve and

reset the thermostats.

c. Observe the boiler function to make sure

you see a condensate flow.

2. Using a spray bottle filled with the