Series MI/MIH
Gas Boilers
Installation,
Operation &
Maintenance
Manual
USING THIS 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.
1
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
Z223.1/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.
A. ACCESSIBILITY CLEARANCES
C. AIR FOR COMBUSTION AND
VENTILATION
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.
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.
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION
The design of this boiler is certified for alcove installation
with the following clearances:
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.
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. 10″ (254 mm) between rear of jacket and
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.
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 Section 11A of this manual.
b. Known Air Infiltration Rate Method: Where
the air infiltration rate of a structure is known,
the minimum required volume of indoor air for
appliances other than fan assisted and for the
Series MI Boiler shall be determined as follows:
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.
⎝
21 ft3
ACH
I other
1000Btu
⎛
⎜
⎝
⎜
⎛
Required Volumeother
=
/
hr
2
PREINSTALLATION
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:
⎝
15 ft3
ACH
I fan
1000Btu
⎛
⎜
⎝
⎜
⎛
Required Volumefan
=
/
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.
Figure 1.2: Air Openings – All Air from Indoors
on Different Floors
3. Indoor Air Opening Size and Location: Openings
connecting indoor spaces shall be sized and located
as follows:
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. 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
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:
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.
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.
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 1.3: Air Openings – All Air Directly from
Outdoors
3
PREINSTALLATION
Figure 1.4: Air Openings – All Air from Outdoors
through Vertical Ducts
Figure 1.6: Air Openings – All Air from Outdoors
through One Opening
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.
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:
⎝
⎛
⎜
⎝
Vavail
Vreq
⎜
⎛
Areq = Afull
x
1 –
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
Figure 1.5: Air Openings – All Air from Outdoors
through Horizontal Ducts
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.
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 cross-sectional areas of all vent
connectors in the space. The gas-fired equipment
shall have clearances of at least 1 inch (25 mm)
from the sides and back and 6 inches (150 mm)
from the front of the appliance. See Figure 1.6
for this arrangement.
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.
4
PREINSTALLATION
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.
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.
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.
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.
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.
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.
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.
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.
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.
D. INSTALLATION SURVEY
iii. Nonmotorized dampers shall be fixed in the
open position.
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.
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.
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
i. The interlock shall prevent the main burner
from igniting if the damper fails to open
during burner startup.
representative or download it from PeerlessBoilers.com.
E. PLANNING THE LAYOUT
ii. The interlock shall shut down the burner if
the damper closes during burner operation.
Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring.
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.
5
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. If using combustible
floor pan, install boiler on pan as outlined in the
instructions included with the pan.
3. If using combustible floor pan, position pan on
foundation or flooring.
6
WATER PIPING AND CONTROLS
3. WATER PIPING AND CONTROLS
3. Supply Piping:
A. BOILER SUPPLY AND RETURN
Pipe the supply to the 1-1/2 NPT supply tapping at
the top and rear of the boiler.
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.
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.
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.
Figure 3.1: Supply and Return Piping
7
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. A drawing illustrating this hook-
up is provided in Figure 3.2.
8. When the boiler is connected to heating coils
located in air handling units where they may be
exposed to refrigerated air circulation, install flow
control valves or other automatic means to prevent
gravity circulation of the boiler water during the
cooling cycle.
9. If this boiler is installed above radiation level,
provide a low water cutoff device, either as a part of
the boiler or at the time of boiler installation.
Figure 3.2: Parallel Hook-Up with Water Chiller
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.
Figure 3.3: Safety Relief Valve Hook-Up
Installation with Air Elimination in
System Piping
Figure 3.4: Safety Relief Valve Hook-Up with
Air Elimination
8
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 3.6: Zone Piping with Circulators
9
WATER PIPING AND CONTROLS
D. EXPANSION TANK
F. FREEZE PROTECTION
For new or existing systems that must be freeze-
protected:
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.
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.
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.
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.
E. INDIRECT-FIRED WATER HEATER
If the boiler is to be used in conjunction with an indirect-
fired 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.
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
10
VENTING
4. VENTING
A. INTEGRAL DRAFT HOOD
B. VENT DAMPER INSTALLATION –
GENERAL
1. The MI/MIH boiler is equipped with a built-in draft
hood. This device is designed to:
1. Do not use one vent damper to control two or more
heating appliances. See Figure 4.1.
a. provide for the ready escape of flue gases from
the boiler in the event of no draft.
2. Follow these and the installation instructions that are
included with the vent damper. Observe the cautions
and warnings that accompany all instructions.
b. prevent a backdraft from entering the boiler.
c. control stack draft during operation.
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.
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.
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.
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.
Figure 4.1: Venting Multiple Appliances
11
VENTING
4. Before connection of joints, inspect the vent pipe
interior for foreign objects such as tools, equipment,
rags, etc. and remove if present.
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.
5. Insert vent pipe into but not beyond the inside wall
of the chimney flue.
6. Do not connect vent connectors serving appliances
vented by natural draft into any portion of
mechanical draft systems operating under positive
pressure.
2. Inspect the existing chimney and lining for structural
soundness, corrosion and perforations. Repair as
necessary.
7. Support horizontal portions of the venting system to
prevent sagging by use of metal strapping or
equivalent means. Locate supports at no more than
4 foot (1.2 meter) intervals.
3. Install vent pipe to slope upward at least 1/4” per
lineal foot (21 mm per meter) between the draft
hood outlet and the chimney.
Figure 4.2: Venting with Vent Damper in Vertical Position
Figure 4.3: Venting with Vent Damper in Horizontal Position
12
VENTING
d. Place in operation the appliance being inspected.
D. BOILER REMOVAL FROM COMMON
VENTING SYSTEM
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.
At the time of removal of an existing boiler, follow these
steps with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation:
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame
of a match or candle, or smoke from a cigarette,
cigar, or pipe.
f. After it has been determined that each 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.
a. Seal any unused openings in the common venting
system.
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.
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.
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.
13
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. 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.
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).
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.
CAUTION
Do not subject the gas valve to more than 1/2 psi (3.5
kPa) pressure. Doing so may damage the valve.
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.
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:
WARNING
MI-09 Standing Pilot
Natural Gas
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.
5.2″ WC (1.3 kPa)
All other MI/MIH
Natural Gas
5.0″ WC (1.2 kPa)
All MI LP Gas
11.0″ WC (2.7 kPa)
Maximum permissible supply pressure to the boiler:
7. Check piping for leaks.
All MI/MIH Natural Gas
All MI LP Gas
13.5″ WC (3.5 kPa)
13.5″ WC (3.5 kPa)
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.
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.
14
GAS PIPING
Table 5.1: MI Boiler – Natural Gas
Input
Model
Cubic Feet / Hour Cubic Meters / Hour
MI-03
MI-04
MI-05
MI-06
MI-07
MI-08
MI-09
70
105
140
175
195
227.5
260
2.0
3.0
4.0
5.0
5.5
6.4
7.4
Table 5.2: MI Boiler – LP Gas
Input
Model
Cubic Feet / Hour Cubic Meters / Hour
MI-03
MI-04
MI-05
MI-06
MI-07
MI-08
MI-09
28
42
0.8
1.2
1.6
2.0
2.2
2.6
2.9
56
70
78
91
104
Table 5.3: MIH Boiler – Natural Gas
Input
Model
Cubic Feet / Hour Cubic Meters / Hour
MIH-03
MIH-04
MIH-05
MIH-06
65
97.5
130
1.8
2.8
3.7
4.6
162.5
Table 5.4: Pipe Capacity
Capacity of pipe of different diameters and lengths in cubic feet
per hour [cubic meter per hour] with a pressure drop of 0.3
inches of water (75 Pa) and specific gravity of 0.60. No
allowance for an ordinary number of fittings is required.
Pipe
Length in
Feet
3/4"
Pipe
1"
Pipe
1-1/4"
Pipe
1-1/2"
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]
40 [12.2] 130 [3.7] 245 [6.9] 500 [14.2]
50 [15.2] 115 [3.3] 215 [6.1] 440 [12.5]
60 [18.3] 105 [3.0] 195 [5.5] 400 [11.3]
890 [25.2]
760 [21.5]
670 [19.0]
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
15
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 6.1 for location of wiring and controls.
1. For proper location of controls and accessories refer
to Figure 6.1 and Section 11.
Use Figures 6.2 and 6.3 to connect the boiler to a
power supply and to connect components to the
boiler.
2. See the attached control sheets for specific details
regarding the installation of the various controls.
2. Connect the boiler by a separate, permanently live
electrical supply line with a fused switch.
3. This boiler is supplied with safety devices in addition
to the limit. For a description of these devices and
how they work to ensure the safe operation of the
boiler, see Section 7B.
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.
4. If the circulator is mounted in the supply piping,
provide longer wiring harness as required.
B. ZONED SYSTEM WIRING
See Figure 6.5 for typical wiring with zone valves. See
Figure 6.6 for typical wiring with zone circulators. When
wiring a zoned heating system, follow all applicable
codes, ordinances and regulations.
NOTICE
Do not power zone valves directly from the boiler
limit. Doing so will greatly reduce the life of the
transformer. Use a separate transformer sized to
handle the total of all zone valve electrical loads.
Figure 6.1: Wiring, Controls and Safety Devices
16
ELECTRICAL
Figure 6.2: Wiring and Connection Diagram – Standing Pilot (Continuous Ignition)
Pilot flame is monitored through the pilot
D. SEQUENCE OF OPERATION
thermocouple. If pilot flame is lost during a call
for heat, main and pilot gas flow will be shut off.
The valve must then be manually reset by
following the Lighting Instructions mounted on
the jacket panel and included in Section 7 of this
manual.
1. Standing Pilot (See Figure 6.2 above)
a. The vent damper is continuously powered. On a
call for heat, limit relay R is energized, which
energizes:
●
the circulator (when used) through contact
R1, and
c. When the call for heat ends:
●
the vent damper operator through contact R2,
provided that the high-limit switch is
closed.
●
Limit relay R de-energizes, which opens
contacts R1 and R2.
●
The circulator shuts down.
The gas valve de-energizes.
The vent damper closes.
The vent damper operator opens the damper.
●
●
b. Once the damper is proven open, the gas valve
energizes, provided that all of the following
conditions are met:
d. If temperature exceeds limit setting, main burners
shut off and circulator continues to operate.
●
the pilot thermocouple is proving flame
●
the blocked vent switch is closed, and
●
the flame rollout switch is closed.
17
ELECTRICAL
Figure 6.3: Wiring and Connection Diagram – Intermittent Ignition
●
the blocked vent switch is closed, and
the flame rollout switch is closed.
c. When the call for heat ends:
2. Intermittent Ignition (see Figure 6.3 above)
●
a. The vent damper is continuously powered. On a
call for heat, limit relay R is energized, which
energizes:
●
Limit relay R de-energizes, which opens
contacts R1 and R2.
●
the circulator (when used) through contact
R1, and
●
The circulator shuts down.
●
the vent damper operator through contact R2,
●
The gas valve de-energizes.
provided that the high-limit aquastat switch is
closed.
●
The vent damper closes.
d. If temperature exceeds limit setting, main burners
shut off and circulator continues to operate.
The damper operator opens the vent damper.
b. Once the damper is proven open, the ignition
circuit within the gas valve energizes, provided
that all of the following conditions are met:
18
ELECTRICAL
Figure 6.4: Intermittent Ignition System Operating Sequence
19
ELECTRICAL
Figure 6.5: Zone Wiring with Zone Valves
Figure 6.6: Zone Wiring with Circulators
20
START-UP PROCEDURES
7. START-UP PROCEDURES
8. Connect a manometer to the gas valve on the valve
outlet (gas manifold). Use the 1/8 NPT tapping
provided.
A. COMPLETING THE INSTALLATION
1. Confirm that all water, gas and electricity are
turned off.
9. Confirm that the gas supply pressure to the boiler is
above the minimum and below the maximum values
for the gas being used. See the end of Section 5 for
these values. If a supply pressure check is 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.
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.
10. Turn on electricity and gas to boiler.
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.
11. Light the boiler by following the Lighting/Operating
Instructions label mounted to the jacket panel. The
initial ignition may require several tries as the piping
is purged of air.
12. Use the sequence descriptions in Figures 6.2, 6.3
and 6.4 in Section 6 (Electrical) to follow light-off
and shutdown sequences and to assist in diagnosing
problems. If the boiler does not function properly,
consult Section 8, Troubleshooting.
5. Fill the boiler and system with water, making certain
to vent all air from all points in the system. To check
water level in the system, open and close each vent
in the system. Water should exit from each vent
when it is opened.
13. The gas manifold and control assembly are made of
gas-tight, completely factory assembled and installed
components of the base assembly. See Figure 7.1
and 7.2.
6. 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.
7. Check joints and fittings throughout the system for
leaks. If leaks are found, drain the system and repair
as required.
21
START-UP PROCEDURES
Figure 7.1: Gas Valve, Manifold and Burner Assembly – Standing Pilot (Continuous Ignition)
Figure 7.2: Gas Valve, Manifold and Burner Assembly – Intermittent Ignition
Figure 7.3: Valve Tapping and Adjustment Screw Locations
22
START-UP PROCEDURES
Figure 7.4: Operating Instructions
23
START-UP PROCEDURES
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING: If you do not follow these instructions exactly, a fire or explosion may
result causing property damage, personal injury, or loss of life.
A. This appliance has a pilot which must be lighted by
hand. When lighting the pilot, follow these
instructions exactly.
If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or
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 LIGHTING smell all around the appliance area
for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the
floor.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance
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 instruction.
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.
LIGHTING INSTRUCTIONS
1. STOP! Read the safety information above on this
label.
8. Find pilot - follow metal tube
from gas valve. The pilot is
between two burner tubes
2. Set the thermostat to lowest setting.
Pilot Burner
9. Turn the gas control knob counterclockwise
"PILOT".
to
3. Turn off all electric power to the appliance.
4. If the gas valve is not visible, remove control access
panel.
10. Push in red reset button all the way and hold in.
Immediately light the pilot with a match. Continue to
hold the reset button in for about one (1) minute after
the pilot is lit. Release button and it will pop back up.
Pilot should remain lit. If it goes out, repeat steps 5
through 10.
5. If the gas control knob is not in the "OFF" position,
turn the knob clockwise
to "OFF".
Gas Control Knob
(shown in "OFF"
position)
Red Reset Button
If button does not pop up when released, stop and
immediately call your service technician or gas
supplier.
If the pilot will not stay lit after several tries, turn the
gas control knob to "OFF" and call your service
technician or gas supplier.
11. Replace pilot access panel, if applicable.
6. Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas,
STOP! Follow "B" in the safety information above on
this label. If you don't smell gas, go to the next step.
12. Turn gas control knob counterclockwise
13. Replace control access panel, if applicable.
14. Turn on all electric power to the appliance.
15. Set thermostat to desired setting.
to "ON".
7. Remove the pilot access panel, if supplied, located
below and behind the gas valve directly above burner
tubes.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
4. Turn the gas control knob clockwise
to "OFF".
2. Turn off all electric power to the appliance if service is
to be performed.
5. Replace control access panel, if applicable.
3. If the gas valve is not visible, remove the control access
panel.
H24V VR8200/VR8300 9177R
Figure 7.5: Lighting Instructions
24
START-UP PROCEDURES
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. GAS FLOW
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. This is a non-recycling
switch that must be replaced once it has been
activated and the cause of the roll-out eliminated.
D. ADJUSTMENT OF PILOT GAS FLOW
To maximize thermocouple life, particularly on natural
gas installations with gas supply pressures above 9″ W.C.
(2.2 kPa), reduce the pilot gas flow.
WARNING
Turn off all electric power to the appliance.
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.
Turn Gas Control Knob to “Pilot” position as shown
in Figure 7.3.
1. Locate and remove the pilot adjustment cap screw
using Figure 7.3.
2. Remove pilot observation port cover on base front
panel.
3. LIMIT (AQUASTAT) – A thermally activated,
manually adjustable switch located on the left side of
the boiler, towards the top and rear. The temperature
sensing element is placed in the supply and will shut
down main burner gas if the supply water exceeds
the preset temperature limit. This is a recycling
switch that will automatically reset when the supply
water falls below the preset temperature.
3. Turn the pilot adjustment screw clockwise until the
pilot flame extinguishes. Then increase the pilot flow
just to the point that the gas valve holds in when
relighting the pilot per steps 9 and 10 of Lighting
Instructions in Figure 7.5 (turn screw no more than
an 1/8 turn).
4. Turn on electric power to the appliance.
4. LOW WATER CUT-OFF (FOR GRAVITY SYSTEMS
OR HOT WATER BOILERS INSTALLED ABOVE
RADIATION LEVEL) – A level-sensing device (float
or probe) located in supply piping near the boiler. If
water level in the system drops below the control’s
position, it will shut down main burner gas. The
control will automatically reset once the water level
rises above its position.
NOTICE
The first few turns of the adjustment screw may not
cause any change in the pilot flow. Subsequent
partial turns of the adjustment screw may have a
great impact on pilot flow.
5. Turn Gas Control Knob to “On” position per the
Lighting Instructions in Figure 7.5.
C. ADJUSTMENT OF GAS PRESSURE
REGULATOR
6. Verify pilot remains lit after shutdown from a boiler
“ON” cycle of at least ten minutes. If pilot
1. Using the manometer setup installed in part 7A, set
manifold pressure as follows for various gases.
extinguishes, follow Lighting Instructions in Figure
7.5 and again slightly increase pilot flow.
a. Natural Gas . . .3.5″ Water Column (0.9 kPa)
b. LP Gas . . . . .10.0″ Water Column (2.5 kPa)
7. Make a final slight increase in the size of the pilot to
ensure sufficient pilot signal under all operating
conditions, just to the point that you observe a slight
increase in the size of the flame (no more than an
1/8 turn).
8. Replace adjustment cap screw and observation port
cover.
2. To adjust gas pressure, turn adjusting screw of gas
pressure regulator counterclockwise to decrease
pressure, clockwise to increase pressure. Refer to
Figure 7.3 for location of gas pressure regulator.
Replace the cap screw when adjustment is complete.
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.
25
START-UP PROCEDURES
Table 7.1b: Meter Conversion – Natural Gas
(SI Metric Units)
E. 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.
Burner inputs in kW for for various meter timings and
heat values. (Table based on 0.0566 cubic meter of gas
through meter).
2. Check input by use of the following formulas
(PB Heat, LLC suggests reading meter for 2 Cu. Ft.):
Heat Value of Gas
(MJ/cubic meter)
Time that
meter is
read (sec)
37.26
38.19
39.12
U.S. Customary Units
Input (BTU/Hr.)= 3600 x F x H
T
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
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
54.04
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
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
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
100
105
110
115
120
125
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.
F. CHECK-OUT PROCEDURE
Table 7.1a: Meter Conversion – Natural Gas
(U.S. Customary Units)
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.
Burner inputs in Btu/hr for various meter timings and heat
values. (Table based on 2 cubic feet of gas through meter).
Heat Value of Gas
Time that
(Btu/cubic foot)
meter is
read (sec)
1000
1025
1050
2. To check operation of the ignition system safety
shut-off features:
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
288000
240000
205714
180000
160000
144000
130909
120000
110769
102857
96000
90000
84706
80000
75789
72000
68571
65455
62609
60000
57600
295200
246000
210857
184500
164000
147600
134182
123000
113538
105429
98400
92250
86824
82000
77684
73800
70286
67091
64174
61500
59040
302400
252000
216000
189000
168000
151200
137455
126000
116308
108000
100800
94500
88941
84000
79579
75600
72000
68727
65739
63000
a. Standing Pilot:
i) Turn the gas control knob counterclockwise to
“PILOT”. The main burner should go out
and the pilot should remain lit.
ii) Extinguish the pilot flame. Pilot gas flow
should stop within 2-1/2 minutes. Complete
shutdown is proven since the safety shut-off
valve has stopped main and pilot gas flow.
iii) Reset the boiler by following Lighting
Instructions.
iv) Observe boiler operation through one
complete cycle.
100
105
110
115
120
125
60480
26
START-UP PROCEDURES
b. Intermittent Ignition System:
i) Turn gas supply off.
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.
ii) Set thermostat or controller above room
temperature to call for heat. Watch for igniter
glow at pilot burner.
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.
iii) Igniter will continue to glow for 30 seconds,
de-energize for 30 seconds, then re-energize
and glow for another 30 seconds. It will then
de-energize for 5 minutes before restarting
the sequence.
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.
iv) Turn gas supply on.
v) Reset the boiler and control by following
Operating Instructions.
8. Review operation and User’s Information Manual
with end-user.
vi) Observe boiler operation through one
complete cycle.
9. Complete the Warranty Card and submit it to
PB Heat, LLC.
3. Low Water Cut-Off (if used) – Consult the
manufacturer’s instructions for the low water cut-off
operational check procedure.
10. Hang the Installation, Operation and Maintenance
Manual and User’s Information Manual in an
accessible position near the boiler.
4. Check the system to make sure there are no leaks or
overfilling problems which might cause excessive
make-up water to be added. Make-up water causes
liming in the boiler and brings in oxygen. Oxygen
can cause severe damage to the boiler though
oxygen corrosion pitting.
27
TROUBLESHOOTING
8. TROUBLESHOOTING
DANGER
A. SHUT-DOWN CAUSED BY PILOT
OUTAGE, BLOCKED VENT SHUT-OFF
SWITCH OR FLAME ROLL-OUT SAFETY
SHUT-OFF SWITCH
When servicing or replacing items that communicate
with the boiler water, be certain that:
●
There is no pressure on the boiler.
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:
●
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.
a. Refer to the Lighting/Operating Instructions in
Figures 7.4 and 7.5 to properly turn off the gas to
the boiler.
●
b. Turn off all electric power to the boiler.
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.
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.
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.
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
TROUBLESHOOTING
Table 8.1: Boiler Troubleshooting Guide
PROBLEM
POSSIBLE CAUSES
CORRECTIVE ACTIONS
Burners not functioning.
1. No power.
1. Check line voltage wiring and fuses.
2. Limit (Aquastat) not working.
2. Check wiring and contacts, relay, temperature
setting. Clean and adjust as necessary.
3. Flame rollout switch open.
4. Blocked vent switch open.
5. Gas off at boiler gas valve.
3. Replace switch. Locate cause and correct.
4. Reset blocked vent switch. Locate cause and correct.
5. Start boiler using Lighting/Operating
Instructions.
6. Gas off external to boiler.
7. Plugged orifice spuds.
8. Defective gas valve.
6. Check any gas valves in the line.
7. Check, clean and re-install.
8. Use Figure 8.1 to troubleshoot intermittent
ignition gas valve. Replace if necessary.
9. Improper wiring.
9. Check and correct in accordance with wiring
diagrams in Section 6.
10. Vent damper malfunctioning.
10. Refer to vent damper manufacturer’s instructions.
Replace if necessary.
Burners will not shut
down.
1. Defective gas valve.
2. Short circuit.
1. Use Figure 8.1 to troubleshoot intermittent
ignition gas valve. Replace if necessary.
2. Check and correct wiring.
Flashback or burning
at orifice spuds.
1. Manifold gas pressure too low.
2. Improperly sized/drilled orifice spuds.
3. Leaking gas valve.
1. Adjust to proper pressure.
2. Install correct spuds.
3. Replace valve.
4. Burrs on orifice.
4. Remove burrs.
5. Low supply gas pressure.
5. Contact gas supplier if natural gas. Adjust
regulator if LP gas.
6. Excessive downdraft or draft problems in
boiler room.
6. Check air supply, ventilation and venting system.
Delayed ignition.
1. Insufficient pilot flame.
2. Pilot burner/orifice clogged.
3. Overfiring.
1. Increase pilot gas flow.
2. Clean pilot burner and orifice.
3. Reduce rate to input on rating label.
4. Realign burners or pilot.
4. Misaligned burners or pilot.
5. Draft problem in boiler room.
5. Check air supply, ventilation and venting
system.
Excessive condensation in
vent.
1. Underfiring.
1. Increase rate to input on rating label.
2. Reset aquastat to higher setting.
2. Limit (Aquastat) set too low.
3. Vent pipe too long.
3. Reposition boiler to reduce length.
4. Check chimney and venting recommendations.
4. Inadequate chimney or venting system.
Boiler not heating
properly.
1. Underfiring.
1. Increase rate to input on rating label.
2. Reset aquastat to higher setting.
3. Vent air from all points in system.
4. Check circulator, replace if necessary.
2. Limit set too low.
3. Air in system.
4. Circulator malfunctioning.
5. Circulation system clogged.
5. Shut down and cool boiler, drain and flush
system.
6. Incorrect thermostat heat anticipator setting.
6. Adjust heat anticipator.
Fumes or gas odors
1. Leaks in gas piping or fittings.
2. Leaks in gas service line or meter.
3. Obstructed chimney.
1. Locate and repair or replace.
2. Shut down boiler and notify gas provider.
3. Check, repair and/or clean chimney.
4. Clean flueways or vent and remove obstructions.
4. Obstructed flueways or vent.
5. Undersized chimney or vent, high draft loss
in vent.
5. Check National Fuel Gas Code and vent
manufacturer’s recommendations.
6. Draft problem in boiler room.
7. Overfiring.
6. Check air supply, ventilation and venting system.
7. Reduce rate to input on rating label.
8. Vent damper malfunctioning.
8. Refer to vent damper manufacturer’s instructions.
Replace if necessary.
29
TROUBLESHOOTING
Figure 8.1: Intermittent Ignition System Troubleshooting Sequence
30
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.
31
MAINTENANCE
A. GENERAL
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
1. Disconnect this boiler from the gas supply piping
during any pressure testing of the gas system.
Lighting/Operating Instructions in Section 7.
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.
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.
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
D. MONTHLY (WITH BOILER IN USE)
1. Check boiler room floor drains for proper
functioning.
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. 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.
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.
4. There must not be signs of continuous wetness at the
chimney. If signs of continuous wetness are
observed, a qualified service agency must be
consulted to modify the vent configuration to prevent
the formation of condensate.
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.
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.
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.
2. Observe general boiler conditions (unusual noises,
vibrations, etc.)
3. Test low-water cut-off (if used) as described by the
manufacturer.
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. Test limit as described in Section 7F, “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.
32
MAINTENANCE
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.
1. Check flueways and burners for cleanliness and clean
if necessary. Use the following procedure if cleaning
is required:
Figure 9.1: Standing Pilot and Main Burner Flame
a. Refer to the Lighting/Operating Instructions in
Figures 7.4 and 7.5 to properly turn off the gas to
the boiler.
b. Turn off all electrical power to the boiler.
c. Remove burners and brush orifice spuds lightly
using a soft bristle brush.
d. Remove the vent pipe, vent damper, top jacket
panels and flue collector/draft diverter. Remove
baffles on MIH models.
e. Brush flueways with wire brush.
f. To the extent possible, inspect inside of vent pipe
and vent damper for obstructions in flow or vent
damper movement. Remove or replace as
necessary.
g. Re-install baffles on MIH models. When replacing
the flue collector/draft hood, be certain that the
blanket seal between the flue collector and top
section makes a tight seal to prevent leakage of
the products of combustion.
Figure 9.2: Intermittent Pilot and Main
Burner Flame
h. Re-install the top of the jacket, vent damper and
vent pipe.
i. Re-install burners.
2. Inspect entire venting system for corrosion, support
and joint integrity. Repair as necessary.
3. Check the pilot and main burner flame. See Figures
9.1 and 9.2. The pilot should provide a steady flame
enveloping 3/8″ to 1/2″ (1 cm to 1.2 cm) of the
flame sensor. If required, adjust the pilot as stated in
the gas valve manufacturer’s instructions or
paragraph 7.D. The main burner flame inner cone
should be approximately 1-1/2″ (4 cm) high and
should have a very sharp, blue color characteristic.
33
BOILER DIMENSIONS & RATINGS
10. BOILER DIMENSIONS & RATINGS
Figure 10.1:Boiler Views
Table 10.1: Series MI/MIH Boiler Dimensions
SERIES MI/MIH BOILER DIMENSIONS
Jacket
Left of Jacket to Rear of Jacket to Vent Connector
Boiler
Model
Number
Width
“A”
Depth
“B”
To Floor
“C”
c/l of Vent “D”
c/l of Vent “E”
Size “F”
inch
mm
318
403
489
575
660
746
832
inch
mm
676
676
676
676
676
752
752
inch
mm
797
797
797
797
797
797
797
inch
mm
159
195
244
287
330
373
416
inch
20¹³⁄₁₆
20¹³⁄₁₆
21¹³⁄₁₆
21¹³⁄₁₆
21¹³⁄₁₆
23⁵⁄₁₆
24⁵⁄₁₆
mm
529
529
554
554
554
592
618
inch
mm
127
127
152
152
178
203
203
MI/MIH-03
MI/MIH-04
MI/MIH-05
MI/MIH-06
MI-07
12¹⁄₂
15⁷⁄₈
19¹⁄₄
22⁵⁄₈
26
26⁵⁄₈
26⁵⁄₈
26⁵⁄₈
26⁵⁄₈
26⁵⁄₈
29⁵⁄₈
29⁵⁄₈
31³⁄₈
31³⁄₈
31³⁄₈
31³⁄₈
31³⁄₈
31³⁄₈
31³⁄₈
6¹⁄₄
7¹¹⁄₁₆
9⁵⁄₈
11⁵⁄₁₆
13
5
5
6
6
7
8
8
MI-08
MI-09
29³⁄₈
32³⁄₄
14¹¹⁄₁₆
16³⁄₈
Table 10.2: Series MI/MIH Boiler Ratings
SERIES MI/MIH BOILER RATINGS
Seasonal
Efficiency
Std Pilot Intermittent
Seasonal
Efficiency
DOE Heating
Capacity³
Net I=B=R Ratings
Input
,
Boiler
Model
Water¹ ²
Water Content
w/Damper³
Ignition³
Number
MBH
kW
MBH
kW
MBH
kW
AFUE
AFUE
MI MIH MI MIH MI MIH MI MIH MI MIH MI MIH MI MIH MI MIH Gallon Liter
MI/MIH-03
70
65
21
19
29
38
48
58
86
54
81
17
25
34
42
47
55
62
16
24
32
40
50
75
100 94
47
70
15
22
29
14
21
28
34
80.2 N/A 82.2 83.2
80.2 N/A 82.1 83.1
80.2 N/A 82.0 83.0
80.3 N/A 82.0 83.0
4.72
6.00
7.28
8.56
9.84
17.87
22.71
27.55
32.40
37.24
42.09
46.93
MI/MIH-04 105 97.5 31
MI/MIH-05 140 130 41
MI/MIH-06 175 162.5 51
MI-07
MI-08
MI-09
115 108
143 135
124 117 36
195 N/A
227.5 N/A
260 N/A
57
67
76
N/A 160 N/A
N/A 186 N/A
N/A 211 N/A
N/A 139 N/A 41 N/A 80.5 N/A 82.0 N/A
N/A 162 N/A 47 N/A 80.3 N/A 82.0 N/A
N/A 183 N/A 54 N/A 80.1 N/A 82.0 N/A
11.12
12.40
1 Net I=B=R water ratings based on an allowance of 1.15.
2 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation,
extensive piping systems, etc.
3 Heating Capacity and Annual Fuel Utilization Efficiency (AFUE) ratings are based on U.S. Government test.
MIH Models Available as Natural Gas with Intermittent Ignition Only.
34
REPAIR PARTS
11. REPAIR PARTS
REPAIR PARTS
SERIES MI/MIH GAS BOILER
Repair parts are available from your installer or by contacting PB Heat, LLC, New
Berlinville, PA 19545-0447. Use the figures and tables on pages 34-40 to assist in
ordering parts.
Note: Remember to include boiler model number and serial number when ordering parts.
Figure 11.1: Base/Combustible Floor Pan
Table 11.1: Base/Combustible Floor Pan
Item
No.
Part Selection
Information
MI/MIH MI/MIH MI/MIH MI/MIH
Description
MI-07
MI-08
MI-09
-03
-04
-05
-06
1
2
3
4
Base Assembly
7800
51771
50867
90700
7801
51771
50867
90701
7802
51771
50867
90702
7803
51771
50867
90703
7804
51771
50867
90704
7805
51771
50867
90705
7806
51771
50867
90706
Observation Cover Door
Base Blanket Seal
Specify length
Combustible Floor Pan Assembly
*For elevations over 2,000 feet above sea level contact PB Heat, LLC.
35
REPAIR PARTS
Figure 11.2:Manifold
Table 11.2: Manifold/Gas Train (MI – Standing Pilot)
Item
No.
Part Selection
Information
Description
Steel Burner
MI-03 MI-04 MI-05 MI-06 MI-07 MI-08 MI-09
5
6
7
Specify quantity
51537 51537 51537 51537 51537 51537 51537
51263 51263 51263 51263 51263 51263 51263
50978 50979 50980 50981 50954 50955 50956
Steel Burner w/ Pilot Clip
Gas Manifold
1 per boiler
Natural Gas, 0-2000 ft. (0-610 m)
8
Orifice Spud, #48
Orifice Spud, #49
Orifice Spud, #56
Orifice Spud, #57
50894 50894 50894 50894
elevation (specify qty)*
Natural Gas, 0-2000 ft. (0-610 m)
50895 50895 50895
elevation (specify qty)*
LP Gas, 0-2000 ft. (0-610 m)
50899 50899 50899 50899
elevation (specify qty)
LP Gas, 0-2000 ft. (0-610 m)
50900 50900 50900
elevation (specify qty)
9
Honeywell VR8200A2116 Gas Valve
Honeywell VR8200C6040 Gas Valve
Honeywell VR8300A4003 Gas Valve
Honeywell VR8300C4035 Gas Valve
Natural Gas
LP Gas
50581 50581 50581
50221 50221 50221
Natural Gas
LP Gas
50587 50587 50587 50587
91333 91333 91333 91333
10 Honeywell Q314A3505 Pilot
Honeywell Q314A3703 Pilot
Natural Gas
LP Gas
51688 51688 51688 51688 51688 51688 51688
50555 50555 50555 50555 50555 50555 50555
51318 51318 51318 51318 51318 51318 51318
11 Johnson K16BA-24D Thermocouple
*For elevations over 2,000 feet above sea level contact PB Heat, LLC.
36
REPAIR PARTS
Figure 11.3a: Gas Valve and Pilot – Standing Pilot
(Continuous Ignition)
Figure 11.3b: Gas Valve and Pilot – Intermittent
Ignition
Table 11.3a:
Manifold/Gas Train (MI – Intermittent Ignition)
Item
No.
Part Selection
Information
Description
MI-03 MI-04 MI-05 MI-06 MI-07 MI-08 MI-09
5
6
7
Steel Burner
Specify quantity
51537 51537 51537 51537 51537 51537 51537
51539 51539 51539 51539 51539 51539 51539
50978 50979 50980 50981 50954 50955 50956
Steel Burner w/ Pilot Clip
Gas Manifold
1 per boiler
Natural Gas, 0-2000 ft. (0-610 m)
8
Orifice Spud, #48
Orifice Spud, #49
Orifice Spud, #56
Orifice Spud, #57
50894 50894 50894 50894
50895 50895 50895
50899 50899 50899
50900 50900 50900
elevation (specify qty)*
Natural Gas, 0-2000 ft. (0-610 m)
elevation (specify qty)*
LP Gas, 0-2000 ft. (0-610 m)
elevation (specify qty)
LP Gas, 0-2000 ft. (0-610 m)
elevation (specify qty)
9
Honeywell SV9501M2700 Gas Valve Natural Gas
Honeywell SV9501M2064 Gas Valve LP Gas
Honeywell SV9601M4167 Gas Valve Natural Gas
Honeywell SV9601M4225 Gas Valve LP Gas
51682 51682 51682
51691 51691 51691
51683 51683 51683 51683
51692 51692 51692 51692
10 Honeywell Q3480B1025 Pilot
Honeywell Q3480B1033 Pilot
Natural Gas
LP Gas
51684 51684 51684 51684 51684 51684 51684
51685 51685 51685 51685 51685 51685 51685
*For elevations over 2,000 feet above sea level contact PB Heat, LLC.
Table 11.3b:
Manifold/Gas Train (MIH – Intermittent Ignition)
Item
No.
Part Selection
Description
Information
MI-03 MI-04 MI-05 MI-06
5
6
7
Steel Burner
Steel Burner w/ Pilot Clip
Specify quantity
51537 51537 51537 51537
51539 51539 51539 51539
50978 50979 50980 50981
1 per boiler
Gas Manifold
Natural Gas, 0-2000 ft. (0-610 m)
8
9
Orifice Spud, #49
50895 50895 50895 50895
elevation (specify qty)*
Honeywell SV9501M2700 Gas Valve Natural Gas
Honeywell SV9601M4167 Gas Valve Natural Gas
51682 51682 51682
51683
10 Honeywell Q3480B1025 Pilot
Natural Gas
51684 51684 51684 51684
*For elevations over 2,000 feet above sea level contact PB Heat, LLC.
37
REPAIR PARTS
Figure 11.4:Block/Draft Hood
Table 11.4a:
Block/Draft Hood
Item
No.
Part Selection
Information
MI/MIH MI/MIH MI/MIH MI/MIH
Description
MI-07
MI-08
MI-09
-03
-04
-05
-06
12
13
14
Block Assembly
Flue Collector/Draft Hood
Flue Collector Blanket Seal
90419
90510
50866
90420
90511
50866
90421
90512
50866
90422
90513
50866
90423
90514
50866
90424
90515
50866
90425
90516
50866
Specify length
Table 11.4b:
Flue Baffles for MIH Only
Item
No.
Part Selection
Information
MIH-
03
MIH-
04
MIH-
05
MIH-
06
Description
15
Flue Baffle - 4″
Flue Baffle - 8″
1 per flue (specify qty)
1 per flue (specify qty)
51583
51583
51583
51584
38
REPAIR PARTS
Figure 11.5:Jacket
Table 11.5: Jacket
Item
No.
Part Selection
Information
MI/MIH MI/MIH MI/MIH MI/MIH
Description
MI-07
MI-08
MI-09
-03
-04
-05
-06
16
Jacket Assembly
Complete jacket* with
90445
90446
90447
90448
90449
90450
90451
insulation and screws
*Complete Jacket Consists of:
Left Side Panel
16
16
16
16
16
16
Right Side Panel
Rear Panel
Top Upper Front Panel
Inner Front Baffle Panel
Removable Front Panel
39
REPAIR PARTS
Figure 11.6:Controls/Circulator/Vent Damper
Table 11.6: Controls/Circulator/Vent Damper
Item
MI/MIH MI/MIH MI/MIH MI/MIH
Description
No.
MI-07
MI-08
MI-09
-03
-04
-05
-06
23
24
25
51689
51774
50501
99950
51587
90592
90593
90612
51689
51774
50501
99950
51587
90592
90593
90612
51689
51774
50501
99950
51587
90592
90593
90613
51689
51774
50501
99950
51587
90592
90593
90613
51689
51774
50501
99950
51587
90592
90593
90614
51689
51774
50501
99950
51587
90592
90593
90615
51689
51774
50501
99950
51587
90592
90593
90615
Honeywell L8148E1182 Limit w/ ³⁄₄″ Well*
Temperature-Pressure Gauge
Safety Relief Valve, 30 psi*, Conbraco 10-408-05
Safety Relief Valve, 50 psi*, Watts #350
Flame Roll-Out Safety Shut-Off Switch
Blocked Vent Shut-Off (Spill) Switch – MI Only
Blocked Vent Shut-Off (Spill) Switch – MIH Only
Vent Damper
26
27
27
28
*Available from distributor
40
Series MI/MIH
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
Qualified Service Agency.
a
ASME
HI Division
of gama
PB HEAT, LLC
PO BOX 447 • NEW BERLINVILLE, PA 19545-0447
©2005
MI8038 R9 (10/05-10M)
Printed in U.S.A.
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