Series MI/MIH II™ Gas Boilers Installation, Operation & Maintenance Manual
TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 1 A. INSTALLATION SEQUENCE . . . . . . . . . . . . .1 B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1 1. PREINSTALLATION 2 A. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2 B. CLEARANCE FROM COMBUSTIBLE CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . .2 C. AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . .3 D. INSTALLATION SURVEY . . . . . . . . . . . . . . . .6 E. PLANNING THE LAYOUT . . . . . . . . . . .
USING THIS MANUAL USING THIS MANUAL A. INSTALLATION SEQUENCE Follow the installation instructions provided in this manual in the order shown. The order of these instructions has been set in order to provide the installer with a logical sequence of steps that will minimize potential interferences and maximize safety during boiler installation. B.
PREINSTALLATION 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 Z223.
PREINSTALLATION C. 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.
PREINSTALLATION 4. Outdoor Combustion Air: Outdoor combustion air is to be provided through one or two permanent openings. The minimum dimension of these air openings is 3 inches (76 mm). a. Two Permanent Opening Method: Provide two permanent openings. One opening is to begin within 12 inches (305 mm) of the top of the space and the other is to begin within 12 inches (305 mm) of the floor.
PREINSTALLATION 5. 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.
PREINSTALLATION D. INSTALLATION SURVEY For new and existing installations, a Water Installation Survey is available from PB Heat, LLC. The survey will provide information on how a hot water boiler works with your specific system and will provide an overview of hot water system operation in general. You can also use this survey to locate system problems which will have to be corrected. To obtain copies of the Water Installation Survey, contact your PB Heat representative or download it from PeerlessBoilers.
BOILER SET-UP 2. 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. 4. Separate the wood shipping pallet from the boiler base by removing two (2) hold-down bolts at each end of the boiler base. 2. Locate boiler in front of installation position before removing crate. 5. Move boiler into final position.
WATER PIPING AND CONTROLS 3. WATER PIPING AND CONTROLS A. BOILER SUPPLY AND RETURN 1. Size the supply and return to suit the system. A typical piping arrangement is shown in Figure 3.1. Refer also to the I=B=R Guide - Residential Hydronic Heating Installation/Design and the PB Heat Water Survey for additional guidance during water piping installation. 2. Return Piping: 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.
WATER PIPING AND CONTROLS 6. Install this boiler so that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacements, etc.). 7. If this boiler and distribution system is used in conjunction with a refrigeration system, pipe the chilled medium in parallel with the boiler and install the proper valve to prevent the chilled medium from entering the boiler.
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. Figure 3.5: Zone Piping with Zone Valves Figure 3.
WATER PIPING AND CONTROLS D. EXPANSION TANK F. For new or existing systems that must be freezeprotected: 1. Consult the tank manufacturer’s instructions for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity. See Table 10.2 in Section 10 for boiler water content. 2. Expansion tanks are available with built-in fill valves and check valves for reducing supply water pressure and maintaining minimum system pressure.
VENTING 4. VENTING A. INTEGRAL DRAFT HOOD 1. The MI/MIH II™ boiler is equipped with a built-in draft hood. This device is designed to: a. provide for the ready escape of flue gases from the boiler in the event of no draft. b. prevent a backdraft from entering the boiler. B. VENT DAMPER INSTALLATION – GENERAL 1. Do not use one vent damper to control two or more heating appliances. See Figure 4.1. 2. Follow these and the installation instructions that are included with the vent damper.
VENTING C. VENT PIPING AND CHIMNEY 1. Install vent piping in accordance with Venting of Equipment part of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, sections 7.2, 7.3 or 7.4 of CAN/CSA B149.1, Natural Gas and Propane Installation Code, or applicable provisions of the local building codes. 2. Inspect the existing chimney and lining for structural soundness, corrosion and perforations. Repair as necessary. 3.
VENTING D.
GAS PIPING 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 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.
GAS PIPING Table 5.1: MI™ Boiler – Natural Gas Model Input Cubic Feet / Hour Cubic Meters / Hour MI-03 70 2.0 MI-04 105 3.0 MI-05 140 4.0 MI-06 175 5.0 MI-07 195 5.5 MI-08 227.5 6.4 MI-09 260 7.4 Table 5.2: MI™ Boiler – LP Gas Model Input Cubic Feet / Hour Cubic Meters / Hour MI-03 28 0.8 MI-04 42 1.2 MI-05 56 1.6 MI-06 70 2.0 MI-07 78 2.2 MI-08 91 2.6 MI-09 104 2.9 Table 5.
ELECTRICAL 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 Electrical Code, ANSI/NFPA 70 and/or the Canadian Electrical Code, Part 1 CSA C22.1, Electrical Code. A. WIRING C. CONTROLS 1. See Figure 6.
Figure 6.
Figure 6.
ELECTRICAL D. SEQUENCE OF OPERATION Figure 6.
START-UP PROCEDURES 7. START-UP PROCEDURES A. COMPLETING THE INSTALLATION 1. Confirm that all water, gas and electricity are turned off. 2. Inspect the boiler combustion chamber for foreign objects and remove if present. 3. 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. 4. Verify that water piping, venting, gas piping and electrical wiring and components are installed properly.
START-UP PROCEDURES Figure 7.
START-UP PROCEDURES Figure 7.
START-UP PROCEDURES B. CONTROL DESCRIPTIONS See Figure 6.1 in Section 6 (Electrical) for locations of these devices. 1. FLAME ROLL-OUT SAFETY 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.
START-UP PROCEDURES 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). Heat Value of Gas (MJ/cubic meter) Time that meter is read (sec) 37.26 38.19 39.12 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 84.36 70.30 60.25 52.72 46.86 42.18 38.34 35.15 32.44 30.13 28.12 26.36 24.81 23.43 22.20 21.09 20.08 19.17 18.34 17.57 16.87 86.46 72.05 61.76 54.
TROUBLESHOOTING 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 rollout safety shut-off switch effecting a shut-down of the main burners: a. Refer to the Operating Instructions in Figure 7.3 to properly turn off the gas to the boiler. b. Turn off all electric power to the boiler. c.
TROUBLESHOOTING Table 8.1: Boiler Troubleshooting Guide PROBLEM Burners not functioning. POSSIBLE CAUSES 1. No power. 2. Limit not working. 3. Flame rollout switch open. 4. Blocked vent switch open. 5. Gas off at boiler gas valve. 6. Gas off external to boiler. 7. Plugged orifice spuds. 8. Defective gas valve. 9. Improper wiring. 10. Vent damper malfunctioning. Burners will not shut down. Flashback or burning at orifice spuds. 1. Defective gas valve. CORRECTIVE ACTIONS 1.
TROUBLESHOOTING START BEFORE TROUBLESHOOTING, FAMILIARIZE YOURSELF WITH THE STARTUP AND CHECKOUT PROCEDURES. NOTE: “CALL FOR HEAT” 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL. TURN GAS SUPPLY OFF, TURN THERMOSTAT (CONTROLLER) TO “CALL FOR HEAT.” POWER TO MODULE? (24 V NOMINAL) NO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING ALSO.
MAINTENANCE 9. MAINTENANCE 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.
MAINTENANCE A. GENERAL D. MONTHLY (WITH BOILER IN USE) 1. Disconnect this boiler from the gas supply piping during any pressure testing of the gas system. 1. Check boiler room floor drains for proper functioning. 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. 2.
MAINTENANCE 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 II™ 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 II™ models.
BOILER DIMENSIONS & RATINGS 10. BOILER DIMENSIONS & RATINGS Figure 10.1: Boiler Views Table 10.
REPAIR PARTS 11. REPAIR PARTS REPAIR PARTS SERIES MI/MIH II™ GAS BOILER Repair parts are available from your local PB Heat, LLC distributor or from Parts To Your Door at 1 (610) 916-5380 (www.partstoyourdoor.com). Note: Remember to include the boiler model number and serial number when ordering parts. Figure 11.1: Base/Combustible Floor Pan Table 11.
REPAIR PARTS Figure 11.2: Manifold Figure 11.
REPAIR PARTS Table 11.
REPAIR PARTS Figure 11.4: Block/Draft Hood Figure 11.
REPAIR PARTS Table 11.
REPAIR PARTS Figure 11.
REPAIR PARTS Table 11.
NOTES 40
Series MI/MIH II™ Gas Boilers Installation, Operation & Maintenance Manual TO T H E I N S TA L L E R : This manual is the property of the owner and must be affixed near the boiler for future reference. TO T H E O W N E R : This boiler should be inspected annually by a Qualified Service Agency. PB HEAT, LLC 131 S. CHURCH STREET • BALLY, PA 19503 ©2014 PB Heat, LLC. All rights reserved. MI8038 R15 (12/14-3M) Printed in U.S.A.
