Embassy Peak-40 Installation And Operating Instructions Manual Download

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“Combi” Gas-Fired

Boiler/Water Heater

Model Peak-40

Installation and

Operating Instructions

PKIOM-1

01/2019

315 Oser Avenue • Hauppauge, NY 11788

Tel: (631) 694-1800 • Fax: (631) 694-1832

www.embassyind.com

Summary of Contents for Peak-40

Page 1: ... Combi Gas Fired Boiler Water Heater Model Peak 40 Installation and Operating Instructions PKIOM 1 01 2019 315 Oser Avenue Hauppauge NY 11788 Tel 631 694 1800 Fax 631 694 1832 www embassyind com ...

Page 2: ...ONS 29 A GENERAL 29 B CUSTOMER CONNECTIONS 29 C INTERNAL WIRING 29 8 BOILER CONTROL INTERNAL WIRING OPERATION 32 A CONTROL OVERVIEW 32 B AVAILABLE CENTRAL HEAT MODES 32 C AVAILABLE DOMESTIC HOT WATER MODES 33 D DISPLAY UTILIZATION 33 E USER MENU 35 F STATUS MENU 1000 LEVEL 35 G INSTALLER MENU 2000 LEVEL 37 H MENU LEVELS 3000 4000 5000 39 I OUTDOOR RESET OPERATION 40 J IGNITION SEQUENCE 41 K ADDITI...

Page 3: ...age Indicates special attention is needed but not directly related to potential personal injury or property damage Indicates special attention is needed but not directly related to potential personal injury or property damage 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...

Page 4: ...int A temperature limiting device listed to ASSE 1070 or ASSE 1017 is required 2 In the absence of local requirements the following should be followed a ASME Boiler and Pressure Vessel Code Section IV Heating Boilers b ASME Boiler and Pressure Vessel Code Section VI Recommended Rules for the Care and Operation of Heating Boilers c ANSI Z223 1 NFPA 54 National Fuel Gas Code d ANSI NFPA 70 National ...

Page 5: ...bustible floors Do not install on carpeting 2 Figure 1 1 shows the minimum recommended clearances to allow reasonable access to the boiler for Model Peak 40 However Local codes or special conditions may require greater clearances D COMBUSTION AND VENTILATION AIR 1 The Peak boiler is designed for operation with combustion air piped directly to the boiler from outside the building sealed combustion ...

Page 6: ...om the floor The minimum dimension of either of these openings shall be 3 inches 76 mm See Figure 1 2 for an illustration of this arrangement PREINSTALLATION 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 Figur...

Page 7: ...ll 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 7 for this arrangement 6 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 th...

Page 8: ...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 10 Combustion Air Ducts a Ducts shall be constructed of galvanized steel or an equi...

Page 9: ...et level on the wall using 5 16 lag bolts Be sure the lag bolts are fully supported by wall studs or adequate wall structure CAUTION This boiler must be installed level to prevent condensate from backing up inside the boiler 3 The mounting bracket has 4 holes on 16 centers as shown in Figure 2 1 This is intended to give installers the ability to mount the bracket on two wall studs spaced at this i...

Page 10: ...stem properly may result in severe personal injury death or major property damage This vent system operates under positive pressure Vent connectors serving appliances vented by natural draft shall not be connected into any portion of this venting system Failure to comply may result in serious injury death or major property damage Only the materials listed below are approved for use with the Peak b...

Page 11: ...ustible construction However a fire stop must be used where the vent pipe penetrates walls or ceilings 4 The Peak boiler like all high efficiency gas fired appliances is likely to produce a vapor plume due to condensation Surfaces near the vent termination will likely become coated with condensation 5 Air Intake Pipe Location Sidewall Venting a Provide 1 foot 30 cm clearance from the bottom of the...

Page 12: ... above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained Do not locate the exhaust exit terminal over public walkways where condensate could drip and create a hazard or nuisance When adjacent to public walkways locate the exit terminal at least 7 feet above grade Do not locate the exhaust termination directly under roof overhangs to prevent icicles from form...

Page 13: ...13 VENTING AIR INLET PIPING Figure 3 6 Exhaust and Air Inlet on Opposite Walls Figure 3 7 Sidewall Exhaust with Indoor Air Figure 3 8 Optional Concentric Vent Kit Installation ...

Page 14: ...oof surface c Locate the end of the exhaust vent pipe a minimum of 12 above the inlet to the air intake pipe d Figure 3 10 shows an approved vertical vent configuration using the optional concentric vent termination kit e Figure 3 11 shows an option for routing the exhaust and air inlet piping through an unused chimney f Figure 3 12 shows this option using inlet air from a sidewall position Figure...

Page 15: ...using the vent adapters provided with the boiler The adapters are compatible with 3 PVC or CPVC 3 or 80mm polypropylene and 3 AL 29 4C grade stainless steel 3 Combined systems using separate polypropylene exhaust air inlet pipes which transitions to concentric can also be installed Contact you Centrotherm Duravent or NovaFlex representative for more information 4 All 2 SCH40 PVC applications requi...

Page 16: ...The following are optional combination air intake exhaust terminations that are available separately from your distributor for use with Peak boilers Table 3 4 Concentric Vent Termination Kits f Refer to Figures 3 4 through 3 8 for sidewall venting options using PVC or CPVC pipe g Refer to Figures 3 9 through 3 13 for vertical venting options using PVC or CPVC pipe F EXHAUST TAPPING FOR VENT SAMPLE...

Page 17: ...tch 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 8 After it has been determined that each appliance remaining connected to the common venting system properly vents wh...

Page 18: ...s are recommended during installation a Provide Air Elimination Means An automatic air vent should be installed at the highest point in the system and at any points air could potentially be trapped When replacing an existing boiler ensure any automatic air vents installed in the system are functioning correctly and installed in a proper location A hydronic separator is another option to provide a ...

Page 19: ...auge A combination pressure temperature gauge is provided with each Peak boiler to be mounted in the piping from the boiler supply to the system as shown in Figures 4 2 4 3 Most local codes require this gauge 2 Air Elimination Closed loop hydronic systems require air elimination devices As the system water is heated dissolved oxygen and other gases will separate from the liquid An air elimination ...

Page 20: ... type LWCO locate the LWCO in the boiler supply above the top jacket panel Refer to Section 7 Electrical Connection in this manual for wiring details 10 Circulator The Central Heat circulator is to be sized to overcome the pressure drop of the system while providing the flow required by the boiler The Peak boilers have a built in circulator that guarantees the minimum flow rate is maintained throu...

Page 21: ...ped in a primary secondary fashion i Use closely spaced tees less than 4 pipe diameters apart ii Use a low loss header system or a hydronic separator such as a Caleffi 548 series b Central Heat Circulator A properly sized circulator should be installed to provide heat out to the system off of the Primary secondary header NOTICE For existing systems that use iron pipe for heating piping the install...

Page 22: ...22 WATER PIPING AND CONTROLS Figure 4 6 Recommended Central Heat Piping ...

Page 23: ...23 WATER PIPING AND CONTROLS Figure 4 7 Recommended Central Heat Piping with Hydronic Separator ...

Page 24: ...24 WATER PIPING AND CONTROLS Figure 4 8 Recommended Domestic Hot Water Piping ...

Page 25: ... the boiler g A drain valve should be located immediately before the domestic inlet and after the domestic outlet of the boiler This allows for easy flushing and descaling of the plate heat exchanger A set of shutoff valves should be placed before the domestic inlet drain valve and after the domestic outlet drain valves as well in order to isolate the rest of the domestic supply to the structure a...

Page 26: ...lated from the water supply 10 Do not use galvanized pipe in glycol systems 11 Use water that is low in mineral content and make sure that there are no petroleum products in the solution a Less than 50 ppm of calcium b Less than 50 ppm of magnesium c Less than 100 ppm 5 grains gallon of total hardness d Less than 25 ppm of chloride e Less than 25 ppm of sulfate 12 Check with the local water suppli...

Page 27: ...ater pressure drop between the gas regulator and the boiler C GAS SUPPLY PIPING INSTALLATION Figure 5 1 Suggested Near Boiler Gas Piping Boiler Input Rate Gas Heating Value Input Rate ft hr Btu hr Btu ft Table 5 1 Pipe Capacity Maximum Capacity of pipe in cubic feet per hour cubic meters per hour with a pressure drop of 0 3 of water 75 Pa CAUTION Use a backing wrench on the gas valve inside of the...

Page 28: ... counter clockwise d Attach the tube from the manometer to the pressure tap fitting e Open the gas valve and start the boiler f Read and record the gas pressure while the boiler is firing at max input as well as with any other appliances to the same gas line at their maximum inputs g Turn off the boiler and close the gas shutoff valve h Remove the manometer tube from the pressure tap fitting i Tur...

Page 29: ...ettings are given in Table 5 4 In no case should the boiler be allowed to operate with CO emissions above 200 ppm 2 Refer to Section 3 Venting and Air Intake for information on obtaining vent samples from this boiler Table 5 3 Recommended CO2 Settings Natural Gas Propane LP Low Fire High Fire Low Fire High Fire Carbon Monoxide CO 75 ppm 200 ppm 75 ppm 200 ppm Carbon Dioxide CO2 8 8 to 11 6 8 5 to ...

Page 30: ... 1 The condensate trap is installed in the condensate drain hole in the front left side of the unit 2 Insert the barbed and thread portion on the top of the trap through the hole and secure using the 3 4 G plastic locknut 3 Press the condensate drain hose onto the barbed fitting on the trap and secure using the provided hose clamp 4 The condensate traps outlet is a compression fitting compatible w...

Page 31: ...erface The user interface 975LB Display is attached to the front of the electrical panel and is accessible through the front panel This interface allows users and installer to access information on the boiler operation and change settings on the control See Section 8 for more information 2 Return Sensors This component located on the right side of the Combination Hydronic Block CHB above the pump ...

Page 32: ... 4 gallons per minute is detected the boiler will fire in DHW mode to provide domestic hot water Figure 7 2 CHB Electrical Component Locations 15 Stepper Motor The stepper motor is located in the CHB behind the flow sensor The motor controls the position of the diverting valve in the CHB that determines where the boiler loop supply water can flow The stepper motor defaults to the DHW position for ...

Page 33: ...33 ELECTRICAL CONNECTIONS Figure 7 4 Wiring Schematic and Connection ...

Page 34: ...mprove fuel usage and boiler efficiency Setpoint Boost function for long CH demand periods Boiler targets calculated CH setpoint and operates off of Supply temperature hysteresis when demand is present When the Boost Function was active and CH demand is not present the CH setpoint decreases back to the calculated setpoint No restrictions 2 Outdoor reset with Permanent Demand Demand initiated by co...

Page 35: ...ia the Installer menu DHW modes 2 3 4 6 7 and 8 are not functional with the Peak boiler Button Default Screen Menu Selection User Installer Level Lockout L1 Adjust CH setpoint up CH Mode 0 and 3 only Back None L2 Adjust CH setpoint down CH Mode 0 and 3 only Back None R1 Adjust DHW setpoint up Change Selection Up None R2 Adjust DHW setpoint down Change Selection Down None M Enter Menu Selection Ent...

Page 36: ...led 2 CH Temperature DHW Temperature Special Status Code number Parameter value Blinking parameter value Parameter actively being adjusted 3 Units of value being displayed by Icon 2 Not used 4 Pressure unit when Icon 1 is displaying CH loop water pressure OUTSIDE when Icon 1 is displaying Outdoor Temperature Not used 5 Shown when Central Heat is enabled Flashing when CH demand is being handled Not...

Page 37: ... DHW Setpoint DHW enable disable Temperature 0200 10 minute System Test Once 10 minute timer is over boiler will return to normal state Additional Access with Installer access PIN Input installer PIN using CODE menu then return to User Menu for advanced system test functions OFF System Test Disabled FAN Test blower fixed speed Lo Test burner at low power Ign Test burner at igniton power Hi Test bu...

Page 38: ...r of flame failures 1054 Number of successful ignitions 1055 Number of failed ignitions 1056 Total hours of operation for CH Hours x 10 1057 Total hours of operation for DHW Hours x 10 1058 Total system run time Days 1059 Interval between lockout 1 MIN 2 HRS 3 DAY 4 WK 1060 Interval between blocking error 1 MIN 2 HRS 3 DAY 4 WK 1061 Instantaneous turbine speed value used to measure parameter 1062 ...

Page 39: ...ti Cycling Period F 16 2014 Maximum CH Power Limits maximum CH input available to the control to satisfy a demand Default values should not be changed Peak 40 61 2015 Minimum CH Power Limits the minimum power available to the boiler to satisfy a demand 1 2019 Boiler Supply Design Temperature Sets the reset curve design temperature that will be targeted when the outdoor temperature is at the chosen...

Page 40: ...tion in Peak Applications Minutes 60 2044 DHW Post Purge Circulator Seconds 10 2048 DHW Setpoint F 122 2064 Preheat Mode 0 OFF 1 Anti Frost plate heat exchanger is kept above 41 F 2 Eco Mode plate heat exchanger is kept above 86 F for faster response at expense of fuel utilization 3 Comfort Mode plate heat exchanger is kept at DHW for fastest response at greatest expense to fuel utilization 1 2091...

Page 41: ...NG INSTALLED WARNING FAILURE TO PROPERLY SET THE APPLIANCE MODE CAN LEAD TO BOILER FAILURE CAUSING PROPERTY DAMAGE SEVERE PERSONNEL INJURY OR DEATH Peak 40 NG Peak 40 LP 2139 De Air Functionality On power cycle the unit will go through a period of 3 minutes of pump cycling to drive air out of the system Enable Disable Enable 2140 NON FUNCTIONAL 2141 NON FUNCTIONAL 2201 CH Enable Setting Enables or...

Page 42: ...re 2025 allow for control over what outdoor temperature the boiler will begin ignoring CH demands 6 The Boost Function Increment 2026 allows for control over how aggressively the Boost function will increase the calculated setpoint after the boost delay is met 7 The Boost Function Delay allows for control over the timeframe the CH demand must be present without the call being satisfied before the ...

Page 43: ...int Calculated CH setpoint will always be at or above this value F 190 2024 Maximum CH Setpoint Design Supply Maximum limit Sets upper limit of Calculated CH setpoint Calculated CH setpoint will always be at or below this value F 68 2025 Warm Weather Shutdown Temperature Outdoor temperature that will block all CH demands until temperature falls below this value F 72 2026 Boost Function Increment C...

Page 44: ...F The boiler will always shutdown at this temperature and will never exceed it The Peak is not designed to run beyond this temperature Steps should be taken to improve the system to lower the required setpoint if the Stayburn Temperature is ever reached The boiler will not re ignite until the Startburn temperature is reached below the setpoint The Startburn Temperature is 185 F 85 C BOILER CONTROL...

Page 45: ... with the boiler is in the closed position 2 Connect a manometer to the gas supply upstream of the supplied manual gas valve 3 Confirm that the gas supply pressure to the boiler is between the minimum and maximum values as indicated in Section 5 4 If a supply pressure check is required isolate the boiler and gas valve before performing the pressure test If the supply pressure is too high or too lo...

Page 46: ... 4 c Manually set the boiler to Low Power by entering the System Test Mode Verify that the fan speed indicated is within 100 rpm of the Low Power fan speed listed in Table 12 3 Status Menu parameter 1040 Verify that the CO and CO2 emissions are within the parameters specified in Table 5 4 d If the values in either of these instances falls outside the parameters listed in Table 5 4 turn off the boi...

Page 47: ...47 START UP PROCEDURE E LIGHTING OPERATING PROCEDURES ...

Page 48: ...nsor is not connected D TYPICAL OPERATION CYCLE CENTRAL HEAT 1 Boiler is in standby No demand Central Heat Radiator symbol is constant 2 Demand is applied Central Heat Radiator symbol begins flashing 3 Switching valve stepper motor extends to Central heat position boiler pump and CH pump start 4 Blower begins Pre purge for 7 seconds at ignition speed 5 Spark engages 2 seconds 6 Gas valve opens 7 S...

Page 49: ... ear Also check for 120V across the blue and brown control output wire to the spark module If not spark is present but voltage is Replace module If no voltage is present check parameter 2126 Should be set to 9 If setting is correct replace control Remove flame sensor and check for white build up Clean sensor re install and attempt ignition If ignition still fails perform other actions listed here ...

Page 50: ...ol 20 FLAME_OUT_TOO_LATE Flame still present 10 seconds after closing the gas valve Check flame sensor for a short to ground Replace sensor sensor gasket or harness if short is found Check solenoid on gas valve for operation Gas valve might not be closing properly Replace gas valve 21 FLAME_BEFORE_IGNIT Flame is detected before ignition Check flame sensor for a short to ground Replace sensor senso...

Page 51: ... sensor error Replace sensor if error does not correct itself 116 LOW_WATER_PRESSURE_SENSOR Low water pressure in system Check system pressure Check filling valve setting and expansion tank pressure Check system for leaks 118 WD_COMM_ERROR Watchdog communication error If error persists replace control 119 RETURN_OPEN Return Sensor open Check sensor wiring for solid connection and continuity Replac...

Page 52: ... FLUE_SHORTED Flue Sensor Shorted Check for resistance through the sensor by touching meter lead across both pins on the sensor Resistance should be between 15 kΩ and 500 Ω If no resistance is present replace sensor 132 OUTDOOR_SHORTED Outdoor Sensor Shorted Check for resistance through the sensor by touching meter lead across both pins on the sensor Resistance should be between 15 kΩ and 500 Ω If...

Page 53: ...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...

Page 54: ...he 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 9 Part D Check Operation 5 Test function of ignition system safety shut off features as described in Section 9 Pa...

Page 55: ... condensate piping to the drain connection NOTE When firing the boiler the first few times you may experience some fluttering of the gas burner that may result in a flame lockout This is normal and will require you to recycle the unit until this clears up This is caused by water still present in the combustion chamber 6 Inspect exhaust vent and air intake vents for proper support and joint integri...

Page 56: ...ace when removing the screws Pull the PHE up and out of the unit being careful to not get water onto any of the components 5 The PHE has 4 gaskets that seal the connections Remove and check these gaskets for wear or degradation Replace if necessary MAINTENANCE 6 The PHE can be cleaned using a solution of Rydlyme recommended for best results available online www rydlyme com or CLR available at most...

Page 57: ...l CH Input MBH DHW Input MBH Heating Capacity MBH Net Rating MBH AFUE Min Max Min Max Peak 40 15 5 100 15 5 155 95 1 80 9 95 2 Note As an ENERGY STAR Partner Embassy has determined that these firing rates meet the ENERGY STAR guidelines for energy efficiency For installations over 2000 Ft above sea level the boiler will de rate by 3 5 per every additional 1000 Ft in elevation with no adjustment to...

Page 58: ...C Current Amps Voltage VAC Max Current Amps Voltage VAC Max Current Amps Peak 40 120 VAC 60 hz 120 2 120 0 09 120 0 8 120 2 4 EMBASSY PEAK MAIN CONTROL SPECIFICATIONS Power Supply 120 VAC Nominal 102 132 VAC 60 Hertz 40 70 Hz Phase Neutral Fuse 5AT 250V Type GDG Blower Voltage 120 VAC Gas Valve Voltage 120 VAC Nominal 102 132 VAC 60 Hertz 40 70 Hz Phase Neutral Thermostat Contacts 24 VAC Flame Cur...

Page 59: ...59 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 60: ...60 REPAIR PARTS 13 REPAIR PARTS Repair parts are available from your local distributor Figure 13 1 General Repair Parts ...

Page 61: ...anifold 1 54764 13 Combiniation Hydronic Block 1 54747 14 O Ring 20MM for Heat Exchanger 2 5525 15 O Ring CHB Return Square 116 3 5909 16 O Ring CHB Supply 1 5910 17 Heat Exchanger Rail Peak 40 2 54725 18 Heat Exchanher Retention Clamp 2 54723 19 Screw M4 X 6mm 6 54724 20 Screw 10 24 X 1 2 Self Tapping 27 99129 21 Heat Exchanger Mount Peak 40 1 PBC2010 22 Side Panel Peak 40 2 PBC6001 1 23 Plastic ...

Page 62: ...62 REPAIR PARTS Figure 13 2 Peak 40 LP Combustion Components ...

Page 63: ...rew M4 X 10mm For Electrodes 4 6512 6 Burner Door With Burner Peak 40 LP 1 54851 7 M6 Flange Nut 4 6505 8 Burner Door Gasket 1 54790 9 Burner Door Insulation 1 54791 10 Target Wall Insulation 1 54793 11 Peak 40 Isothermic Heat Exchanger 1 98105 12 Blower Outlet Gasket 1 54122 13 Kit NRV118 Venturi w Hardware 1 54823 Kit LP NRV118 Venturi w Hardware 1 54824 14 Set Screw M5 X 25mm 4 54774 15 Nut M5 ...

Page 64: ...64 REPAIR PARTS Figure 13 3 Peak 40 NG Combustion Components ...

Page 65: ...mm Pan Head Phillips 3 54784 17 Gas Valve Adapter Gasket 1 54783 18 Gas Valve Adapter Body 1 54770 19 Gas Valve Adapter Nut 1 54771 20 GB ND 055 D01 Gas Valve 1 54721 21 Screw M4 X 30mm Philips 1 54125 22 Set Screw M5 X 25mm 4 54774 23 Nut M5 Flange 4 54775 Quantity Required Description Stock Code 1 SRV Conbraco 10 407 05 30 535MBH 50664 1 Outdoor Sensor TSA00B4 12 kOhm 54112 1 Hose Clamp Small 54...

Page 66: ...66 REPAIR PARTS Figure 13 4 CHB Parts Detail ...

Page 67: ... 3 Way Stepper Motor 1 54809 12 Flow Sensor Honeywell w Impellor 1 54810 13 Air Vent Caleffi Robacal Bayonet U Cap 1 54812 14 Drain Screw Not Shown Under Pump 1 54813 15 Supply Manifold Clip O Ring Set Not Shown 1 54811 Description Quantity Required Stock Code Gas Valve Harness PBC 40 52 Valve Flame Sensor 1 PBC7001 Stepper Motor Harness 1 PBC7002 Water Sensor Harness Flow sensor Pressure sensor B...

Page 68: ...315 Oser Avenue Hauppauge NY 11788 Tel 631 694 1800 Fax 631 694 1832 www embassyind com ...

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