PEERLESS 0103001 Series MI-e Gas Boilers User Manual
- June 9, 2024
- Peerless
Table of Contents
0103001 Series MI-e Gas Boilers
Series MI-e®
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 &
VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
D. INSTALLATION SURVEY . . . . . . . . . . . . . . . . . . . . . . .6
E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . . . . . . . .6
F. BOILER WATER TREATMENT . . . . . . . . . . . . . . . . . . .6
2. BOILER SET-UP
7
3. WATER PIPING & CONTROLS
8
A. BOILER SUPPLY & RETURN . . . . . . . . . . . . . . . . . . . .8
B. SAFETY RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . .9
C. LOW WATER CUT-OFF. . . . . . . . . . . . . . . . . . . . . . . .9
D. PIPING FOR ZONED SYSTEMS . . . . . . . . . . . . . . . . .10
E. EXPANSION TANK . . . . . . . . . . . . . . . . . . . . . . . . . .11
F. INDIRECT-FIRED WATER HEATER . . . . . . . . . . . . . .11
G. FREEZE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . .11
4. VENTING
12
A. INTEGRAL DRAFT HOOD . . . . . . . . . . . . . . . . . . . . .12
B. VENT DAMPER INSTALLATION GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
C. VENT PIPING & CHIMNEY . . . . . . . . . . . . . . . . . . . .13
D. BOILER REMOVAL FROM COMMON VENTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .14
5. GAS PIPING
15
6. ELECTRICAL
17
A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
B. ZONED SYSTEM WIRING . . . . . . . . . . . . . . . . . . . . .17
C. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
D. SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . .20
7. START-UP PROCEDURES
21
A. COMPLETING THE INSTALLATION . . . . . . . . . . . . .21
B. CONTROL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . .26
C. ADJUSTMENT OF GAS PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
D. CHECKING BURNER INPUT . . . . . . . . . . . . . . . . . . .26
E. AIR SHUTTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
F. CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . .27
8. TROUBLESHOOTING
30
A. SHUT-DOWN CAUSED BY PILOT OUTAGE, BLOCKED VENT SHUT-OFF SWITCH OR FLAME ROLL-OUT SAFETY SHUT-OFF SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
B. TROUBLESHOOTING GUIDES . . . . . . . . . . . . . . . . .30
9. MAINTENANCE
32
A. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
B. DAILY (WITH BOILER IN USE) . . . . . . . . . . . . . . . . .33
C. WEEKLY (WITH BOILER IN USE) . . . . . . . . . . . . . . .33
D. MONTHLY (WITH BOILER IN USE) . . . . . . . . . . . . .33
E. ANNUALLY (BEFORE START OF HEATING SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
10. BOILER DIMENSIONS & RATINGS 35
11. REPAIR PARTS
36
A. BOILER PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
B. MANIFOLD, GAS VALVE & PILOT . . . . . . . . . . . . . .38
C. CONTROLS/CIRCULATOR/ VENT DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
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. 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.:
DANGER
Indicates a hazardous situation, which, if not avoided, will result in death
or serious injury and major property damage.
WARNING
Indicates a hazardous situation, which, if not avoided, could result in death
or serious injury and major property damage.
CAUTION
Indicates a hazardous situation, which, if not avoided, could result in minor
or moderate injury, and minor property damage.
NOTICE
Indicates special attention is needed, not related to personal injury or
property damage.
1
PREINSTALLATION
1. PREINSTALLATION
WARNING
This manual is intended for use by Qualified Heating Professionals only.
Installation, service, or adjustment of this heating appliance by anyone other
than a Qualified Heating Professional can cause significant property damage,
personal injury, or death.
Read carefully, study these instructions before beginning work. 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
Z223.1/NFPA 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.
IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy and Conservation
Act, this boiler is equipped with a feature that saves energy by reducing the
boiler water temperature as the heating load decreases. This feature is
equipped with an override which is provided primarily to permit the use of an
external energy management system that serves the same function. THIS OVERRIDE
MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:
· An external energy management system is installed that reduces the boiler
water temperature as the heating load decreases.
· This boiler is not used for any space heating · This boiler is part of a
modular or multiple boiler system having a total input of 300,000
BTU/hr or greater. · This boiler is equipped with a tankless coil.
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 (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. 6 (152 mm) between rear of jacket and combustible construction.
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 Table 11.1 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.
2
PREINSTALLATION
C. AIR FOR COMBUSTION & 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
installed 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 m3/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-eTM Boiler shall be determined as follows:
Required Volumeother =
( ) 21 ft3
ACH
I other 1000Btu/hr
where: Iother = Input of appliances other than fan
assisted in Btu/hr ACH = air change per hour (percent of the
volume of the space exchanged per hour, expressed as a decimal)
For fan assisted appliances, calculate the required volume of air using the following equation:
Required Volumefan =
( ) 15 ft3
ACH
I fan 1000Btu/hr
Ifan = Input of the fan assisted appliances in Btu/hr
Note: These calculations are not to be used for infiltration rates greater than 0.60 ACH.
3. Indoor Air Opening Size and Location: Openings connecting indoor spaces
shall be sized and located as follows: a. Combining spaces on the same floor:
Provide two permanent openings communicating with additional spaces that have
a minimum free area of 1 in2 per 1000 Btu/hr (22 cm2 per 1000 W) of the total
input rating of all gas fired equipment but not less than 100 in2 (645 cm2).
One opening is to begin within 12 inches (305 mm) from the top of the space
and the other is to begin within 12 inches (305 mm) from the floor. The
minimum dimension of either of these openings shall be 3 inches (76 mm). See
Figure 1.1 for an illustration of this arrangement.
Figure 1.1: Air Openings All Air from Indoors on the Same Floor
b. Combining spaces on different floors: Provide one or more permanent
openings communicating with additional spaces that have a total minimum free
area of 2 in2 per 1000 Btu/hr (44 cm2 per 1000 W) of total input rating of all
equipment. See Figure 1.2 for an illustration of this arrangement.
Figure 1.2: Air Openings All Air from Indoors on Different Floors
3
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. The openings are to
communicate directly or by ducts with the outdoors or with spaces that freely
communicate with the outdoors. The size of the openings shall be determined as
follows:
i. Where communicating directly or through vertical ducts with the outdoors
each opening shall have a minimum free area of 1 in2 per 4000 Btu/hr (22 cm2
per 4000 W) of total input rating for all equipment in the space. See Figure
1.3 for openings directly communicating with the outdoors or Figure 1.4 for
openings connected by ducts to the outdoors.
ii. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in2 per 2000 Btu/hr (22 cm2 per 2000 W) of total rated input for all appliances in the space. See Figure 1.5.
Figure 1.3: Air Openings All Air Directly from Outdoors
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 in2 per 3000 Btu/hr
of total rated input for all appliances in the space and not less than the sum
of the crosssectional 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.
Figure 1.4: Air Openings All Air from Outdoors through Vertical Ducts
Figure 1.6: Air Openings All Air from Outdoors through One Opening
4
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. The size of the outdoor openings are to be sized as follows:
( ) Areq = Afull x
1 Vavail Vreq
where: Areq = minimum area of outdoor openings. Afull = full size of outdoor
openings calculated
in accordance with Subsection 4. Vavail = available indoor air volume Vreq =
required indoor air volume
6. Engineered Installations: Engineered combustion air installations shall
provide an adequate supply of combustion, ventilation, and dilution air and
shall be approved by the authority having jurisdiction.
7. 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 ft3/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.
c. Each of the appliances served shall be interlocked to the mechanical air
supply to prevent main burner operation when the mechanical air supply system
is not in operation.
d. In buildings where the combustion air is provided by the mechanical
ventilation system, the system shall provide the specified combustion air rate
in addition to the required ventilation air.
8. Louvers & Grills:
a. The required size of openings for combustion, ventilation, and dilution air
shall be based on the net free area of each opening.
i. Where the free area through a louver or grille is known, it shall be used
in calculating the opening size required to provide the free area specified.
PREINSTALLATION
ii. Where the free area through a louver or grille is not known, it shall be
assumed that wooden louvers will have 25% free area and metal louvers and
grilles will have 75% free area.
iii. Nonmotorized dampers shall be fixed in the open position.
b. Motorized dampers shall be interlocked with the equipment so that they are
proven in the full open position prior to ignition and during operation of the
main burner.
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 the damper closes during
burner operation.
9. Combustion Air Ducts
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.
e. Ducts shall not be screened where terminating in an attic space.
f. Horizontal upper combustion air ducts shall not slope downward toward the
source of the combustion air.
g. The remaining space surrounding a chimney liner, gas vent, special gas
vent, or plastic piping installed within a masonry, metal, or factory built
chimney shall not be used to supply combustion air.
h. Combustion air intake openings located on the exterior of buildings shall
have the lowest side of the combustion air intake opening at least 12 inches
(305 mm) above grade.
WARNING
Liquefied Petroleum (LP) is heavier than air and may collect or “pool” in a
low area in the event of a leak from defective equipment. This gas may then
ignite, resulting in a fire or explosion.
5
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.com.
E. PLANNING THE LAYOUT
Prepare sketches and notes of the layout to minimize the possibility of
interferences with new or existing equipment, piping, venting and wiring.
F. BOILER WATER TREATMENT
If the boiler water quality is outside the criteria shown below, consult a
qualified water treatment specialist to bring the water quality within the
criteria shown.
Water Quality Criteria:
1. Boiler water pH should be in 7.5 to 11 range.
2. Boiler water chloride concentration should be less than 30 ppm.
3. The water hardness should be less than 9 grains per gallon to prevent
scale build-up.
6
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.
2. Locate boiler in front of installation position before removing crate.
3. If using combustible floor pan, position pan on foundation or flooring.
BOILER SET-UP
4. Separate the wood shipping pallet from the boiler base by removing two (2)
hold-down bolts at each end of the boiler base.
5. Move boiler into final position. If using combustible floor pan, install
boiler on pan as outlined in the instructions included with the pan.
7
WATER PIPING & CONTROLS
3. WATER PIPING & CONTROLS
A. BOILER SUPPLY & 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. Pipe the drain valve nipples and tee to the 1-1/4 NPT return tapping as
shown in Figure 3.1.
3. Supply Piping: Pipe the supply to the 1-1/2 NPT supply tapping at the top
and rear of the boiler.
WARNING
Low water temperatures can deteriorate the vent system, which can result in
flue gas spillage and carbon monoxide emissions.
4. When system return water temperature will be below 130°F (54°C), pipe the
boiler with a bypass arrangement to blend the system return and hot supply to
obtain at least 130°F (54°C) entering the boiler. For more information on
bypass piping, consult the PB Heat Water Survey.
Figure 3.1: Supply and Return Piping 8
WATER PIPING & CONTROLS
5. 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.).
6. 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. A drawing illustrating this hook-up is provided in Figure 3.2.
7. 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.
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 VALVE SUPPLY LINE
BOILER
WATER CHILLER
RETURN LINE
THREE WAY VALVE
Figure 3.2: Parallel Hook-Up with Water Chiller
SUPPLY
SAFETY RELIEF VALVE
3/4″ X 6″ NIPPLE
C. LOW WATER CUT-OFF
Low water cut-off feature is incorporated in the Hydrolevel Control with
standard Electo-Well. The low water cutoff feature is recommended on all
installations, and is required if boiler is installed above radiation level or
where required by local code. See Hydrolevel manual for details.
TO DRAIN
Figure 3.3: Safety Relief Valve Hook-Up Installation with Air Elimination in
System Piping
SUPPLY
SAFETY RELIEF VALVE
TO AIR ELIMINATION
DEVICE
3/4″ TEE
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
9
WATER PIPING & CONTROLS D. 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 3.6: Zone Piping with Circulators 10
WATER PIPING & CONTROLS
E. EXPANSION TANK
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.
Check the design features of the tank and provide valves as necessary. Refer
back to Figure 3.1 for typical expansion tank piping.
F. INDIRECT-FIRED WATER HEATER
If the boiler is to be used in conjunction with an indirectfired water heater,
refer to Figure 3.7 for typical piping. Follow the instructions provided by
the water heater manufacturer. Pipe the water heater as a separate zone.
G. FREEZE PROTECTION
For new or existing systems that must be freeze-protected:
WARNING
Use only inhibited propylene glycol solutions of up to 50% by volume with
water. Ethylene glycol is toxic and can attack gaskets and seals used in
hydronic systems.
1. Glycol in hydronic applications is specially formulated for this purpose.
It includes inhibitors which prevent the glycol from attacking metallic system
components. Make certain that the system fluid is checked for the correct
glycol concentration and inhibitor level.
2. The glycol solution should be tested at least once a year and as
recommended by the glycol 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.
Figure 3.7: Typical Piping with Indirect-Fired Water Heater 11
VENTING
4. VENTING
A. INTEGRAL DRAFT HOOD
1. The Series MI-e® 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.
c. control stack draft during operation.
These tasks are accomplished without the extra height requirements of a
separate draft hood.
2. The draft hood relief opening is the large rectangular passage at the
front of the boiler. Make certain that there are no obstructions to airflow in
front of this opening.
3. A vent safety shut-off switch is located within the draft relief opening
to shut off the boiler in case of a blocked vent condition. See Section 7B for
details regarding this device. See Figure 6.1 in Section 6 (Electrical) for
spill switch location.
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.
B. VENT DAMPER INSTALLATION GENERAL
1. Do not use one vent damper to control two or more heating appliances. See
Figure 4.1.
2. Follow these and the installation instructions that are included with the
vent damper. Observe the cautions and warnings that accompany all
instructions.
3. 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.
4. Orient the damper operator to facilitate connection of the harness with
the vent damper and boiler. Note flue gas flow arrow on vent damper and orient
as required. For installation with damper mounted in vertical position, see
Figure 4.2. For installation with damper mounted in horizontal position, mount
the unit as shown in Figure 4.3 to avoid excessive heat on the operator or
condensation drips into the operator.
INCORRECT Figure 4.1: Venting Multiple Appliances 12
CORRECT
VENTING
C. VENT PIPING & CHIMNEY
WARNING
Failure to follow all instructions can result in flue gas spillage and carbon
monoxide emissions.
1. Inspect the existing chimney or vent system. Make sure it is in good
condition. Inspect chimney liner and repair or replace if necessary.
2. The vent system and installation must be in accordance with Venting of
Equipment chapter of the current edition 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.
3. Chimney/Vent Operation: The vent system must be sized and installed to
provide the draft needed to remove all combustion products. If the vent system
does not provide enough draft, combustion products will spill into the
building from the draft hood relief opening. If spillage of combustion
products occurs, check the vent system, the combustion and ventilation
openings and make sure the boiler room is never under negative pressure.
4. Chimney flue gas condensation is affected by a number of factors such as
chimney design, flue connector length, common venting, and flue gas
temperature. If your application experiences flue gas condensation,
installation of a listed corrosion resistant metal liner is required.
5. Inspect the existing chimney and lining for structural soundness,
corrosion and perforations.
6. Do not alter boiler draft hood or place any obstruction or non-listed
damper in the vent system.
7. 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.
Installer le tuyau d’évent avec une pente ascendante minimum de 21 mm au mètre
(1/4 po au pied) à la sortie du coupe-tirage et la cheminée.
8. Before connection of joints, inspect the vent pipe interior for foreign
objects such as tools, equipment, rags, etc. and remove if present.
9. Insert vent pipe into but not beyond the inside wall of the chimney flue.
10. Do not connect vent connectors serving appliances vented by natural draft
into any portion of mechanical draft systems operating under positive
pressure.
11. 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.
Fournir un support à toute portion horizontale du système d’évacuation à
l’aide de courroies de métal ou une méthode équivalente afin de l’empêcher de
s’affaisser. Placer les supports à des intervalles ne dépassant pas cent vingt
deux (122) centimètres (4 po), ou en suivant les recommandations d’
installation du fabricant.
12. Secure all joints including flue collar, draft hood, vent damper, using
sheet metal screws or per listed vent manufacturer’s instructions.
SLOPE UP A MINIMUM
OF 1/4″ PER FOOT
(21mm PER METER)
VENT TO CHIMNEY
VENT DAMPER
Figure 4.2: Venting with Vent Damper in Vertical Position
DRAFT HOOD RELIEF OPENING
SUPPORT AS REQUIRED
DRAFT HOOD OUTLET
SLOPE UP A MINIMUM
OF 1/4″ PER FOOT
(21mm PER METER)
VENT DAMPER
A
VENT TO CHIMNEY
11 O’CLOCK POSITION
A SUPPORT AS REQUIRED
HEAT ZONE
1 O’CLOCK POSITION
DAMPER OPERATOR
CONDENSATION ZONE
7 O’CLOCK POSITION
5 O’CLOCK POSITION
DO NOT MOUNT DAMPER OPERATOR IN SHADED REGION
SECTION A-A
Figure 4.3: Venting with Vent Damper in Horizontal Position 13
VENTING
D. BOILER REMOVAL FROM COMMON
VENTING SYSTEM
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
venting system are not in operation:
Au moment de retirer une chaudière existante, il est important de suivre les
étapes suivantes pour chaque appareil raccordé au système d’évacuation commun
qui sont en service, alors que les autres appareils demeurant raccordés au
système d’évacuation commun ne sont pas en service:
a. Seal any unused openings in the common venting system.
Sceller toute ouverture du système d’évacuation commun non utilisée.
b. Visually inspect the venting system for proper size and horizontal pitch
and determine there is no blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe condition.
Effectuer un contrôle visuel du système d’évacuation pour vérifier la taille
et la pente horizontale et s’assurer qu’il n’existe aucun blocage ou
obstruction, fuite, corrosion ni tout autre problème pouvant menacer la
sécurité.
c. Insofar as is practical, close all building doors and 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.
Dans la mesure du possible, fermer toutes les portes et fenêtres de l’immeuble
ainsi que toutes les portes entre l’espace dans lequel les appareils qui
demeurent raccordés au système d’évacuation commun se trouvent et le reste de
l’immeuble. Mettre en marche les sécheuses et tout autre appareil non raccordé
au système d’évacuation commun. Mettre en marche tous les ventilateurs
aspirant, tels que les hottes de cuisinière et les ventilateurs de salle de
bain, en les faisant fonctionner à vitesse maximum. Ne pas faire fonctionner
les ventilateurs aspirant d’été. Fermer les registres de foyers.
d. Place in operation the appliance being inspected. Follow the lighting
instructions. Adjust thermostat so appliance will operate continuously.
Mettre en service l’appareil à inspecter. Suivre les instructions concernant
l’allumage. Régler le thermostat afin que l’appareil fonctionne sans arrêt.
e. Test for spillage at the draft hood relief opening after 5 minutes of main
burner operation. Use the flame of a match or candle, or smoke from a
cigarette, cigar, or pipe.
Vérifier toute fuite à l’orifice de décharge du coupetirage après que le
brûleur ait fonctionné pendant 5 minutes. Utiliser la flamme d’une allumette
ou d’une chandelle ou encore la fumée d’une cigarette, d’un cigare ou d’une
pipe.
f. 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 conditions of use.
Après avoir établi que les résidus de combustion de chaque appareil qui
demeure raccordé au système commun sont adéquatement évacués lorsque soumis au
test décrit ci-dessus, remettre en place les portes, fenêtres, portes
intérieures, ventilateurs aspirants, registres de foyer et appareils
fonctionnant au gaz.
g. Any improper operation of the common venting system should be corrected so
that the installation 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.
Tout fonctionnement inadéquat du système d’évacuation commun doit être corrigé
de manière à respecter les normes du National Fuel Gas Code, ANSI Z223.1/NFPA
54 et/ou des Codes d’installation CAN/ ACG B149. Lorsqu’il est nécessaire de
modifier les dimensions de toute portion du système d’évacuation commun, ces
dernières doivent être modifiées de manière à respecter les dimensions
minimums indiquées dans les tableaux du chapitre «Sizing of Category I Venting
Systems» du National Fuel Gas Code, ANSI Z223.1/NFPA 54 ou des Codes
d’installation CAN/ACG B149
14
5. GAS PIPING
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. 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.
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 non-corrosive leak detection fluid or other
leak detection method. If leaks are found, turn off all gas flow and repair as
necessary.
To Gas Supply Service Valve Ground Joint Union
To Boiler Gas Control Train
Sediment Trap
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).
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:
Natural Gas
5.0 WC (1.2 kPa)
LP Gas
11.0 WC (2.7 kPa)
Check when boiler and other gas applicances are running.
Maximum permissible supply pressure to the boiler:
Natural Gas
13.5 WC (3.5 kPa)
LP Gas
13.5 WC (3.5 kPa)
WARNING
When checking for leaks, do 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.
15
GAS PIPING
Table 5.1: Series MI-e® Boiler Natural Gas
Model
MI-e-03 MI-e-04 MI-e-05 MI-e-06 MI-e-07 MI-e-08 MI-e-09
Input
Cubic Feet / Hour Cubic Meters / Hour
70
2.0
105
3.0
140
4.0
175
5.0
210
5.9
245
6.9
280
7.9
Table 5.2: Series MI-e® Boiler LP Gas
Model
MI-e-03 MI-e-04 MI-e-05 MI-e-06 MI-e-07 MI-e-08 MI-e-09
Input
Cubic Feet / Hour Cubic Meters / Hour
28
0.8
42
1.2
56
1.6
70
2.0
84
2.4
98
2.8
112
3.2
Table 5.3: 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 gravity of 0.60. No allowance for an ordinary number of fittings is required.
Pipe
Length 3/4″
1″
1-1/4″
1-1/2″
in Feet Pipe
Pipe
Pipe
Pipe
[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
0.50 0.55 0.60 0.65 0.70 0.75 1.10 1.04 1.00 0.96 0.93 0.90
0.80 0.85 0.90 1.00 1.10 1.20 0.87 0.84 0.82 0.78 0.74 0.71 1.30 1.40 1.50
1.60 1.70 1.80 0.68 0.66 0.63 0.61 0.59 0.58
16
6. ELECTRICAL
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
1. See Figure 6.1 for location of wiring and controls. Use Figures 6.2 and
6.5 to connect the boiler to a power supply and to connect components to the
boiler.
2. Connect the boiler by a separate, permanently live electrical supply line
with a fused switch.
3. Connect the vent damper harness to the damper motor as shown in Figure
6.1.
4. Adjust the thermostat heat anticipator to 0.2 Amp.
B. ZONED SYSTEM WIRING
Refer to Limit Control Instructions for details on Zone Wiring. 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.
C. CONTROLS
1. For proper location of controls and accessories refer to Figure 6.1 and
Section 11.
2. See the attached control sheets for specific details regarding the
installation of the various controls.
3. This boiler is supplied with safety devices in addition to the limit. For
a description of these devices and how they work to ensure the safe operation
of the boiler, see Section 7B.
4. If the circulator is mounted in the supply piping, provide longer wiring
harness as required.
5. A zone relay is required when a PV Partner limit control is connected to
the Hydrostat. See Figure 6.3
LIMIT CONTROL
SENSOR
SAFETY RELIEF VALVE TEMPERATURE-PRESSURE GAUGE AUTOMATIC VENT DAMPER
LIMIT CONTROL
GAS VALVE
FLAME ROLLOUT SWITCH
BLOCKED VENT SWITCH
Figure 6.1: Wiring, Controls and Safety Devices
BURNER OBSERVATION OPENING TRANSFORMER
17
ELECTRICAL
BOILER JUNCTION BOX
HYDROSTAT DHW/ZONE 2 TERMINALS
SUPPLY 120V 60HZ
GR BK
WH
WH
CH CIRCULATOR
BL
BK
DHW/ZONE 2
CIRCULATOR
PR
(WHERE USED)
CONNECT DHW/ZONE 2 THERMOSTAT TO SCREW TERMINALS ON BACK OF HYDROSTAT CONTROL (WHERE USED)
CH THERMOSTAT
DHW/ZONE 2
THERMOSTAT *
(WHERE USED)
BR BR
KNOCKOUT IN JACKET
- RELAY REQUIRED WHEN
WIRING TO PV PARTNER CONTROL
Figure 6.2: Field Connections
Figure 6.3: PV Partner Thermostat Wiring
TO DHW CIRC LEADWIRES ON BOILER *
TO PARTNER PV ETC101 THERMOSTAT
T
T
SWITCHING RELAY, TYPICAL HONEYWELL R845A, WHITE-RODGERS 829A-845 (BY OTHERS)
PARTNER PV L2 CIRCULATOR
L1
46
21
35
TO DHW THERMOSTAT TERMINALS ON HYDROSTAT 4200 CONTROL
- PARTNER PV CIRC MAY INSTEAD BE CONTROLLED USING RELAY TERMINALS 3 & 4.
Figure 6.4: Hydrostat 4200 Limit Control Display Panel – See Hydrolevel manual for details. 18
ELECTRICAL 19
Figure 6.5: Wiring Diagram Intermittent Ignition 4200 Control
ELECTRICAL D. SEQUENCE OF OPERATION
Figure 6.6: Intermittent Ignition System Operating Sequence 20
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. Refer back to previous sections of these
instructions as well as equipment manufacturer’s instructions as necessary.
5. Set the air pressure on the expansion tank to the system water pressure
before filling system. 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.
6. Fill the boiler and system with water making certain to vent air from all
high points in the system. Water should bleed from each air vent when it is
opened.
7. See Section 1 – Preinstallation for boiler water treatment requirements.
8. Check joints and fittings throughout the system for leaks. If leaks are
found, drain the system and repair as required.
9. Connect a manometer to the gas valve on the valve outlet (gas manifold).
Use the 1/8 NPT tapping provided.
10. 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.
11. Turn on electricity and gas to boiler.
12. Light the boiler by following the Lighting/Operating Instructions label
mounted to the jacket panel. Operating Instructions are also shown in Figures
7.5 thru 7.7. The initial ignition may require several tries as the piping is
purged of air.
13. Use the sequence description in Figure 6.6 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.
14. 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.
Figure 7.1: Gas Valve, Manifold and Burner Assembly
OUTLET
INLET
Figure 7.2: Valve Tapping and Adjustment Screw Locations, Residio Gas Valve
PILOT ADJUSTMENT SCREW (UNDER CAP SCREW)
PILOT GAS OUTLET
OUTLET
INLET PRESSURE
TAP
INLET
GAS PRESSURE REGULATOR
ADJUSTMENT SCREW (UNDER CAP SCREW)
OUTLET PRESSURE TAP
Figure 7.3: Valve Tapping and Adjustment Screw Locations, White Rodger Gas Valve
PILOT ADJUSTMENT SCREW (UNDER CAP SCREW)
OUTLET PRESSURE
TAP
PILOT GAS OUTLET INLET PRESSURE TAP
INLET
OUTLET
GAS PRESSURE REGULATOR ADJUSTMENT SCREW (UNDER CAP SCREW)
Figure 7.4: Valve Tapping and Adjustment Screw Locations, Robertshaw Gas Valve
21
START-UP PROCEDURES
Figure 7.5: Operating Instructions, Residio Gas Valve 22
START-UP PROCEDURES
Figure 7.6: Operating Instructions, Residio Gas Valve
1 23
START-UP 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 is equipped with an ignition device which automatically
lights the pilot. Do not try to light the pilot by hand.
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.
WHAT TO DO IF YOU DO 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
supplier’s instructions.
If you cannot reach your gas supplier, call the fire department.
C. 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.
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.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on this label.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which automatically
lights the pilot. Do not try to light the pilot by hand.
5. If the gas valve is not visible, remove control access panel.
6. If the gas control knob is not in the “OFF” position, turn the knob
clockwise to “OFF”.
7. 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 the next step.
8. Turn the gas control knob counterclockwise to “ON”.
9. Replace control access panel, if applicable.
10. Turn on all electrical power to the 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.
2. Turn off all electric power to the appliance if service is to be
performed.
3. If the gas valve is not visible, remove the control access panel.
4. Turn the gas control knob clockwise to “OFF”. 5. Replace control access
panel, if applicable.
7000 9363 REV 1
Figure 7.7: Operating Instructions, Robertshaw Gas Valve 24
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 shutoff 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.
2. 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.
3. MULTI-FUNCTION BOILER CONTROL (LIMIT/ IGNITION CONROL) – The Hydrolevel
4200 control provides the following functions:
a. Boiler water temperature limit control – burner gas will shut down if the
supply water temp exceeds the control target setpoint. The target setpoint is
determined by the dial temperature setting and the economy dial setting, and
when reached is indicated by the “target” lamp on the control. The control
will automatically reset when the boiler supply water temp drops below the
control target setpoint.
b. Low water cut-off The low water cut-off function is active using default
control settings. Burner gas will shut down if the water level in the boiler
drops below the control’s sensing well. The “low water” lamp on the control
will illuminate. The low water cut-off switch will automatically reset when
the water level is above the control’s sensing well.
c. Ignition sequencing and flame safety burner gas will shut down if pilot
flame is not detected during the trial for ignition period. Control will
restart ignition sequence after a wait period. The ignition status is
indicated on the “Ignition” lamps on the control. See Figure 6.6 in Section 6
(Electrical) for ignition sequence and flame safety operation. See Hydrolevel
instructions for further information.
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)
2. To adjust gas pressure, turn adjusting screw of gas pressure regulator
counterclockwise to decrease pressure, clockwise to increase pressure. Refer
to Figures 7.2 thru 7.4 for location of gas pressure regulator. Replace the
cap screw when adjustment is complete.
3. In no case should the final manifold pressure vary more than ±0.3 inches
water column (0.07 kPa) from the above specified pressures. Any necessary
major changes in the flow should be made by changing the size of the burner
orifice spuds.
4. When adjustment is complete, turn off boiler, gas flow and electricity to
boiler. Remove manometer connection from valve and plug tapping with plug
provided. Turn utilities back on and resume checkout.
D. CHECKING BURNER INPUT
1. Refer to rating label mounted on the jacket top panel 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.
2. 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 Read
SI Metric Units Input (kW)= 3600 x F x H T x 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
3. 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.
25
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 meter is read (sec)
25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125
1000
288000 240000 205714 180000 160000 144000 130909 120000 110769 102857 96000
90000 84706 80000 75789 72000 68571 65455 62609 60000 57600
Heat Value of Gas (Btu/cubic foot)
1025
295200 246000 210857 184500 164000 147600 134182 123000 113538 105429 98400
92250 86824 82000 77684 73800 70286 67091 64174 61500 59040
1050
302400 252000 216000 189000 168000 151200 137455 126000 116308 108000 100800
94500 88941 84000 79579 75600 72000 68727 65739 63000 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 meter is
read (sec)
25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125
37.26
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
Heat Value of Gas (MJ/cubic meter)
38.19
86.46 72.05 61.76 54.04 48.03 43.23 39.30 36.03 33.25 30.88 28.82 27.02 25.43
24.02 22.75 21.62 20.59 19.65 18.80 18.01 17.29
39.12
88.57 73.81 63.26 55.35 49.20 44.28 40.26 36.90 34.06 31.63 29.52 27.68 26.05
24.60 23.31 22.14 21.09 20.13 19.25 18.45 17.71
START-UP PROCEDURES
E. AIR SHUTTERS Air shutters are factory installed on burners of LP gas
modelsof MI-e-06 thru MI-e-09. Shutters may be adjusted where needed to reduce
noise and/or flame lifting and fine tune ignition. Verify shutters are open a
minimum of 1/2″. Do not close shutters to the point where flames turn yellow.
Yellow flames indicate incomplete combustion and the formation of carbon
monoxide. Yellow flames are not the same as flame yellow tipping, which often
occurs due to dust in the air and does not indicate poor combustion. Use care
when working around boiler to avoid creating air movements which will cause
fluctuations in the flames, making it difficult to determine correct shutter
settings.
LOOSEN SCREW TO SLIDE SHUTTER
SHUTTER OPENING,
1/2″ MIN.
Figure 7.8: Air Shutters, LP Gas MI-e-06 thru MI-e-09 Models
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.
2. To check operation of the ignition system safety shut-off features: ·
Refer to Figure 7.5 thru 7.7 Operating Instructions and Figure 6.6
Intermittent Ignition System Operating Sequence.
3. Low Water Cut-Off (if used) Consult the manufacturer’s instructions for
the low water cut-off operational check procedure.
4. Check the system to make sure there are no leaks or overfilling problems
which might cause excessive makeup 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. 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.
26
START-UP PROCEDURES
6. 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.
7. 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.
8. Review operation and User’s Information Manual with end-user.
9. Complete the Warranty Card and submit it to PB Heat, LLC.
10. Hang the Installation, Operation and Maintenance Manual and User’s
Information Manual in an accessible position near the boiler.
27
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 roll-out safety shut-off switch effecting a
shut-down of the main burners:
a. Refer to the Operating Instructions in Figures 7.5 thru 7.7 to properly
turn off the gas to the boiler.
b. Turn off all electric power to the boiler.
c. 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.
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. · The power is
off. When servicing the gas valve or pilot, be certain that: · The gas is off.
· The electricity is off.
WARNING
Do not use this appliance if 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.
CAUTION
Label all wires prior to disconnection when servicing controls. Wiring errors
can cause improper and dangerous operation. Verify proper operation after
servicing.
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.
28
Table 8.1: Boiler Troubleshooting Guide
TROUBLESHOOTING
PROBLEM
Burners not functioning.
POSSIBLE CAUSE
1. No power to limit control display. 2. No call for heat (no decimal after
3-digit display). 3. Water temperature above limit control economizing
setpoint (ECON TARGET). 4. Open safety control, as indicated on HydroStat
display:
a) Flame rollout switch (LIMITS), or b) Blocked vent switch (LIMITS). c) Vent
damper (V-PWR, V-SW).
d) Low water (LOW WATER). e) No pilot (FLAME). 5. Gas off at boiler gas valve.
6. Gas off external to boiler. 7. Plugged orifice.spuds. 8. Improper wiring.
Burners will not shut down.
Flashback or burning at orifice spuds.
1. Defective gas valve.
2. Short circuit. 1. Manifold gas pressure too low. 2. Improperly
sized/drilled orifice spuds. 3. Leaking gas valve. 4. Burrs on orifice. 5. Low
supply gas pressure.
Delayed ignition.
Excessive condensation in vent.
Boiler not heating properly.
Fumes or gas odors.
6. Excessive downdraft or draft problems in boiler room.
1. Pilot burner/orifice clogged. 2. Overfiring. 3. Misaligned burners or
pilot. 4. Draft problem in boiler room.
1. Underfiring. 2. Limit control set to low. 3. Economizer setting too high.
4. Vent pipe too long. 5. Inadequate chimney or venting system.
1. Underfiring. 2. Limit control set to low. 3. Economizer setting too high.
4. Air in system. 5. Circulator malfunctioning. 6. Circulator system clogged.
7. Incorrect thermostat heat anticipator setting.
1. Leaks in gas piping or fittings. 2. Leaks in gas service line or meter. 3.
Obstructed chimney. 4. Obstructed flueways or vent. 5. Undersized chimney or
vent, high draft loss in vent. 6. Draft problem in boiler room. 7. Overfiring.
8. Vent damper malfunctioning.
CORRECTIVE ACTION
1. Check line voltage wiring and fuses. Check transformer. 2. Check
thermostat. See HydroStat instructions. 3. See HydroStat instructions.
4. See also HydroStat instructions. a) Replace switch. Locate cause and
correct. b) Reset switch. Locate cause and correct. c) Refer to vent damper
manufacturer’s instructions. Replace if necessary. d) Add water or clean
sensor. See HydroStat instructions. e) See HydroStat and Honeywell
instructions.
5. Start boiler using Operating Instructions. 6. Check any gas valves in the
line. 7. Check, clean and re-install. 8. Check and correct in accordance with
wiring diagrams
in Section 6.
1. See HydroStat and Honeywell instructions. Replace if necessary.
2. Check and correct wiring.
1. Adjust to proper pressure. 2. Install correct spuds. 3. Replace valve. 4.
Remove burrs. 5. Contact gas supplier if natural gas.
Adjust regulator if LP gas. 6. Check air supply, ventilation and venting
system.
1. Clean pilot burner and orifice. 2. Reduce rate to input on rating label.
3. Realign burners or pilot. 4. Check air supply, ventilation and venting
system.
1. Increase rate to input on rating label. 2. Reset limit to highest setting.
See HydroStat instructions. 3. Reset Economizer setting. See HydroStat
instructions. 4. Reposition boiler to reduse length. 5. Check chimney and
venting recommendations.
1. Increase rate to input on rating label. 2. Reset limit to highest setting.
See HydroStat instructions. 3. Reset Economizer setting. See HydroStat
instructions. 4. Vent air from all points in system. 5. Check circulator,
replace if necessary. 6. Shut down annd cool boiler,drain and flush system. 7.
Adjust heat anticipator.
1. Locate and repair or replace. 2. Shut down boiler and notify gas
provider.’ 3. Check, repair and/or clean chinmey. 4. Clean flueways or vent
and remove obstructions. 5. Check National Fuel Gas Code and vent
manufacturer’s
recommendation. 6. Check air supply, ventilation and venting system. 7. Reduce
rate to input on rating label. 8. Refer to vent damper manufacturer’s
instructions.
Replace if necessary.
29
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. 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 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.
30
MAINTENANCE
A. GENERAL
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 matter. See
Section 1 – Preinstallation for boiler water treatment requirements. 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.
B. DAILY (WITH BOILER IN USE)
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 should never be higher than 250°F (121°C).
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 in Section 7.
D. MONTHLY (WITH BOILER IN USE)
1. Check boiler room floor drains for proper functioning.
2. 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. 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.
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 that operating pressure and temperature have returned to normal.
g. Check again to confirm that valve has closed completely and is not leaking.
3. Test low-water cut-off (if used) as described by the manufacturer.
4. Test limit as described in Section 7E, “Check-Out Procedure.”
5. Test function of gas safety shut-off features as described by gas valve
and ignition control manufacturer.
6. Cycle the boiler at least once and check operation of the vent damper.
E. ANNUALLY (BEFORE START OF HEATING SEASON)
DANGER
When servicing or replacing components, be absolutely certain that the
following conditions are met:
Water, gas and electricity are off. The boiler is at room temperature. There
is no pressure in the boiler.
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.
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 7.5 thru 7.7 to
properly turn off the gas to the boiler.
b. Turn off all electrical power to the boiler.
31
MAINTENANCE
c. Remove burners and brush gas outlet ports lightly using a soft bristle
brush. If there is extensive corrosion in outlet ports, replace burners.
d. Remove the vent pipe, vent damper, top jacket panel, flue collector/draft
diverter, and flue baffles.
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 flue baffles. 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 products of combustion.
h. Re-install the top of the jacket, vent damper and vent pipe.
i. Re-install burners.
WARNING
A deteriorated or incorrect vent system can result in flue gas spillage and
carbon monoxide emissions.
2. Inspect entire vent system for signs of deterioration, corrosion,
continuous wetness, inadequate support, and joint integrity.
Inadequate vent configuration and low boiler water temperatures contribute to
the formation of condensate, which will deteriorate the vent system. If
operating at low system water temperatures, such as radiant systems or high
mass radiation, a bypass must be installed.
3. Check the pilot and main burner flame. See Figure 9.1. 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. The main burner flame inner cone should be
approximately 1-1/2 (4 cm) high and should have a very sharp, blue color
characteristic. On LP gas models equipped with air shutters, see Section 7 and
Figure 7.9 for checking and adjusting air shutters.
4. For systems using anti-freeze, the glycol solution should be tested at
least once a year and as recommended by the glycol manufacturer.
OUTER CONE IS DARK BLUE IN COLOR
INNER CONE IS BLUE IN COLOR
PILOT FLAMES
Figure 9.1: Intermittent Pilot and Main Burner Flame 32
BOILER DIMENSIONS & RATINGS
10. BOILER DIMENSIONS & RATINGS
Figure 10.1: Boiler Views
Table 10.1: Series MI-e® Boiler Dimensions
Boiler Model Number MI-e-03
MI-e-04 MI-e-05 MI-e-06
MI-e-07
MI-e-08
MI-e-09
Length (Depth) “A”
inch mm 26-5/8 676 26-5/8 676 26-5/8 676 26-5/8 676 26-5/8 676 29-5/8 752
29-5/8 752
Jacket Width “B”
inch mm 12-1/2 318 15-7/8 403 19-1/4 489 22-5/8 575
26 660 29-3/8 746 32-3/4 832
SERIES MI-e® BOILER DIMENSIONS
Height “C”
inch mm 31-3/8 797 31-3/8 797 31-3/8 797 32-1/4 819 32-1/4 819 32-1/4 819
32-1/4 819
Rear of Jacket to c/l of Vent
“D”
inch mm 20-13/16 529
20-13/16 529 21-13/16 554 21-13/16 554 21-13/16 554 23-5/16 592 24-5/16 618
Left of Jacket to c/l of Vent
“E”
inch mm
6-1/4 159
7-11/16 195
9-5/8 244
11-5/16 287
13
330
14-11/16 373
16-3/8 416
Vent Size Diameter
“F”
inch mm 5 127 5 127 6 152 6 152 7 178
8 203
8 203
Height to Return “G”
inch mm 12-3/8 314 12-3/8 314 12-3/8 314 13-1/4 337 13-1/4 337 13-1/4 337
13-1/4 337
Table 10.2: Series MI-e® Boiler Ratings
SERIES MI-e® BOILER RATINGS
Height to Gas Inlet
“H”
inch mm 8-3/8 213
8-3/8 213
8-3/8 213 9-1/4 235 9-1/4 235 9-1/4 235 9-1/4 235
Boiler Model Number
MI-e-03 MI-e-04 MI-e-05 MI-e-06 MI-e-07 MI-e-08 MI-e-09
Boiler Input
MBH
kW
70
21
105
31
140
41
175
51
210
62
245
72
280
82
Series MI-e®
Heating Capacity²
MBH
kW
60
18
89
26
119
35
148
43
178
52
207
61
236
69
Net Ratings Water¹
MBH
kW
52
15
77
23
103
30
129
38
155
45
180
53
205
60
AFUE², %
84.6 84.6 84.5 84.4 84.4 84.3 84.3
Water Content
Gallon
4.72 6.00 7.28 8.56 9.84 11.12 12.40
Liter
17.87 22.71 27.55 32.40 37.24 42.09 46.93
1 Net water ratings based on an allowance of 1.15. Consult PB Heat, LLC before
selecting a boiler for installations having unusual piping and pickup
requirements, such as intermittent system operation, extensive piping systems,
etc.
2 Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are
based on U.S. Government test. Before purchasing this appliance, read
important information about its estimated annual energy consumption or energy
efficiency rating that is available from your retailer.
33
REPAIR PARTS
11. REPAIR PARTS
REPAIR PARTS SERIES SERIES MI-e® 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.
5 5
6 7 1
8
Figure 11.1: Boiler Parts 34
3 2 4
Table 11.1: Boiler Parts
Description
Block Assembly MI-e-03 Block Assembly MI-e-04 Block Assembly MI-e-05 1
Block Assembly MI-e-06 Block Assembly MI-e-07 Block Assembly MI-e-08
Block Assembly MI-e-09 Base Assembly MI-e-03 Base Assembly MI-e-04 Base
Assembly MI-e-05 2 Base Assembly MI-e-06 Base Assembly MI-e-07 Base
Assembly MI-e-08 Base Assembly MI-e-09 3 Base Blanket Seal (4′ to 7′)
Combustible Floor Pan Assembly MI-e-03 Combustible Floor Pan Assembly
MI-e-04 Combustible Floor Pan Assembly MI-e-05 4 Combustible Floor Pan
Assembly MI-e-06 Combustible Floor Pan Assembly MI-e-07 Combustible Floor
Pan Assembly MI-e-08 Combustible Floor Pan Assembly MI-e-09 Flue
Collector/Draft Hood MI-e-03 Flue Collector/Draft Hood MI-e-04 Flue
Collector/Draft Hood MI-e-05 5 Flue Collector/Draft Hood MI-e-06 Flue
Collector/Draft Hood MI-e-07 Flue Collector/Draft Hood MI-e-08 Flue
Collector/Draft Hood MI-e-09 6 Flue Collector Blanket Seal (4′ to 7′) Flue
Baffles 03 Flue Baffles 04 Flue Baffles 05 7 Flue Baffles 06 Flue
Baffles 07 Flue Baffles 08 Flue Baffles 09 Jacket Assembly (Complete
Jacket) MI-e-03 Jacket Assembly (Complete Jacket) MI-e-04 Jacket Assembly
(Complete Jacket) MI-e-05 8 Jacket Assembly (Complete Jacket) MI-e-06
Jacket Assembly (Complete Jacket) MI-e-07 Jacket Assembly (Complete Jacket)
MI-e-08 Jacket Assembly (Complete Jacket) MI-e-09
Part numbers may be subject to change without notice.
REPAIR PARTS
Quantity Required
1 1 1 1 1 1 1 1 1 1 1 1 1 1
7 ft. 1 1 1 1 1 1 1 1 1 1 1 1 1 1
7 ft. 2 3 4 5 6 7 8 1 1 1 1 1 1 1
Stock Code
90419 90420 90421 90422 90423 90424 90425 7800 7801 7802 6600 6601 6602 6603
50867
90700 90701 90702 90703 90704 90705 90706 90510 90511 MI5006 91920 91921 91922
91923 50866 51608 51608 51608 51608 51608 51608 51608 Contact Factory Contact
Factory Contact Factory Contact Factory Contact Factory Contact Factory
Contact Factory
35
REPAIR PARTS
12 9
11
Figure 11.2: Manifold
10
14
13
Figure 11.3: Gas Valve and Pilot (Intermittent Ignition)
36
Table 11.2: Manifold, Gas Valve and Pilot
Description
Steel Burner MI-e-03 Steel Burner MI-e-04 Steel Burner MI-e-05 9 Steel
Burner MI-e-06 Steel Burner MI-e-07 Steel Burner MI-e-08 Steel Burner
MI-e-09 9A Air Shutter with Screw, LP 10 Steel Burner w/ Spark Pilot Bracket
Gas Manifold MI-e-03 Gas Manifold MI-e-04 Gas Manifold MI-e-05 11 Gas
Manifold MI-e-06 Gas Manifold MI-e-07 Gas Manifold MI-e-08 Gas Manifold
MI-e-09 Orifice Spud, #48 Natural Gas MI-e-03 Orifice Spud, #48 Natural
Gas MI-e-04 Orifice Spud, #48 Natural Gas MI-e-05 Orifice Spud, #48
Natural Gas MI-e-06 Orifice Spud, #48 Natural Gas MI-e-07 Orifice Spud,
48 Natural Gas MI-e-08 Orifice Spud, #48 Natural Gas MI-e-09 12 Orifice
Spud, #56 LP Gas MI-e-03 Orifice Spud, #56 LP Gas MI-e-04 Orifice Spud,
56 LP Gas MI-e-05 Orifice Spud, #56 LP Gas MI-e-06 Orifice Spud, #56 LP
Gas MI-e-07 Orifice Spud, #56 LP Gas MI-e-08 Orifice Spud, #56 LP Gas MI-e-09 Resideo VR8204A-2001 Gas Valve Spark Natural Gas MI-e-03 thru MI-e-05 Resideo VR8304P-4504 Gas Valve Spark Natural Gas MI-e-06 thru MI-e-09 – 0.9″ WC Step 13 Resideo VR8204A-2103 Gas Valve Spark LP Gas MI-e-03 thru MI-e-05 Resideo VR8304P-4314 Gas Valve Spark LP Gas MI-e-06 thru MI-e-09 – 1.4″ WC Step White Rodgers 36G33-530 Gas Valve Spark – Natural Gas MI-e-03 thru MI-e-05 (Alternate) 13A White Rodgers 36G33-531 Gas Valve Spark – LP Gas MI-e-03 thru MI-e-05 (Alternate) Robertshaw 7000BDER-S7C Gas Valve Spark – Natural Gas MI-e-06 thru MI-e-09 (Alternate) 13B Robertshaw 7000BDER-LP-S7C Gas Valve Spark – LP Gas MI-e-06 thru MI-e-09 (Alternate) Resideo Q3481B-1644 Spark Pilot Natural Gas MI-e-03 thru MI-e-09 14 Resideo Q3481B-1529 Spark Pilot LP MI-e-03 thru MI-e-09
REPAIR PARTS
Quantity Required
3 5 7 9 11 13 15 1 per burner 1 1 1 1 1 1 1 1 4 6 8 10 12 14 16 4 6 8 10 12 14
16 1 1 1 1 1 1 1 1 1 1
Stock Code
51537 51537 51537 51537 51537 51537 51537 7202
51539 50978 50979 50980 50981 50954 50955 50956 50894 50894 50894 50894 50894
50894 50894 50899 50899 50899 50899 50899 50899 50899 50583 50847 50584 50724
50797 50799 50397 50398 50996 50997
37
REPAIR PARTS
22
19 21
17 15 16
24
18
Figure 11.4: Controls/Circulator/Vent Damper
20 23
Table 11.3:Controls/Circulator/Vent Damper
Description
15
Well Hydrolevel HydroStat 48-201
16
Sensor for Hydrolevel HydroStat 4200
17
Grommet Hydrolevel HydroStat 4200 (at Well) All Sizes
18
Temperature-Pressure Gauge
Safety Relief Valve, 30 PSI, Conbraco 10-408-05 19
Safety Relief Valve, 50 PSI, Conbraco 10-418-10
20
Flame Roll-Out Safety Shut-Off Switch
21
Blocked Vent Shut-Off (Spill) Switch (230oF)
Vent Damper MI-e-03, MI-e-04
Vent Damper MI-e-05, MI-e-06 22
Vent Damper MI-e-07
Vent Damper MI-e-08, MI-e-09
23
Transformer, 40VA
24
Limit Control – Hydrolevel HydroStat 4200
O
Wire Harness, Vent Damper, 4 pin to 6 pin
O
Wire Harness, Low Voltage, 9 pin
O
Wire Harness, Line Voltage, 5 pin
O
Wiring Harness Jumper (TR to D-) Robertshaw Gas Valve
38
Quantity Required
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Stock Code 50723 50361 50362 51324 50501 51028 51587 50041 90612 90613 90614
90615 50359 50360 X7132
X7137
X7138
X7141
NOTES 39
Series MI-e®
Gas Boilers
Installation, Operation & 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.
PB HEAT, LLC
131 S. CHURCH STREET · BALLY, PA 19503
©2022 PB Heat, LLC. All rights reserved.
MI8093 R4 (05/22-2M) Printed in U.S.A.
References
- PB Heat: Peerless® Boilers - America's BEST Built Boiler
- Parts To Your Door - Premier reseller of replacement parts for the HVAC industry