PEERLESS PF-50, PF-80, PF-110, PF-140, PF-210 Installation, Operation & Maintenance Manual
...
PUREFIRE
®
REV
2
Boilers
PF-50 PF-80 PF-110 PF-140 PF-210 PF-399
Gas
Installation,
Operation &
Maintenance
Manual
As an ENERGY STAR®Partner, PB Heat, LLC has determined that
this product meets the ENERGY STAR guidelines for energy efficiency.
®
USING THIS MANUAL 1
A. INSTALLATION SEQUENCE . . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B. CODES & REGULATIONS . . . . . . . . . . . . . . . .2
C. ACCESSIBILITY CLEARANCES . . . . . . . . . . . .3
D. COMBUSTION & VENTILATION AIR . . . . . . . .4
E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .6
2. BOILER SET-UP 8
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
B. WALL MOUNTING . . . . . . . . . . . . . . . . . . . . . .8
C. FLOOR STANDING INSTALLATION . . . . . . . . .8
3. VENTING & AIR INLET PIPING 9
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
B. APPROVED MATERIALS . . . . . . . . . . . . . . . . .9
C. EXHAUST VENT/AIR INTAKE
PIPE LOCATION . . . . . . . . . . . . . . . . . . . . . . . .9
D. EXHAUST VENT/AIR INTAKE PIPE SIZING . .13
E. EXHAUST VENT/AIR INTAKE PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .13
F. EXHAUST TAPPING FOR VENT SAMPLE . .14
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . . .14
4. WATER PIPING AND CONTROLS 15
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
B. OPERATING PARAMETERS . . . . . . . . . . . . . .15
C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .15
D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .19
E. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .19
F. SPECIAL APPLICATIONS . . . . . . . . . . . . . . . .25
5. FUEL PIPING 26
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . . .26
C. GAS SUPPLY PIPING – INSTALLATION . . . .26
D. GAS SUPPLY PIPING – OPERATION . . . . . . .27
E. MAIN GAS VALVE – OPERATION . . . . . . . . .28
6. CONDENSATE DRAIN PIPING 29
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
B. CONDENSATE SYSTEM . . . . . . . . . . . . . . . .29
C. CONDENSATE DRAIN PIPE MATERIAL . . . .30
D. CONDENSATE DRAIN PIPE SIZING . . . . . . .30
E. CONDENSATE DRAIN PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .30
7. ELECTRICAL CONNECTIONS 31
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .31
B. CUSTOMER CONNECTIONS . . . . . . . . . . . . .31
C. ZONE CIRCULATOR WIRING . . . . . . . . . . . . .32
D. INTERNAL WIRING . . . . . . . . . . . . . . . . . . . .32
8. BOILER CONTROL: INTERNAL
WIRING & OPERATION 36
A. CONTROL OVERVIEW . . . . . . . . . . . . . . . . . .36
B. IGNITION SEQUENCE . . . . . . . . . . . . . . . . . .38
C. BOILER CONTROL . . . . . . . . . . . . . . . . . . . . .40
D. CENTRAL HEATING . . . . . . . . . . . . . . . . . . . .42
E. DOMESTIC HOT WATER (DHW) . . . . . . . . . .45
F. SERVICE NOTIFICATION . . . . . . . . . . . . . . . .46
G. SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . .47
H. STATUS & FAULT HISTORY . . . . . . . . . . . . . .47
I. SENSOR RESISTANCE . . . . . . . . . . . . . . . . .48
J. MULTIPLE BOILERS . . . . . . . . . . . . . . . . . . . .48
K. DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . .53
9. START-UP PROCEDURE 54
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
B. CHECK WATER PIPING . . . . . . . . . . . . . . . . .54
C. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . . .54
D. CHECK OPERATION . . . . . . . . . . . . . . . . . . . .54
E. LIGHTING & OPERATING PROCEDURES . . .56
10. TROUBLESHOOTING 57
A. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . . .57
B. LOCKING ERRORS . . . . . . . . . . . . . . . . . . . . .57
C. ERROR MESSAGES IN A CASCADE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
D. WARNING ERRORS . . . . . . . . . . . . . . . . . . . .61
11. MAINTENANCE 63
A. GENERAL (WITH BOILER IN USE) . . . . . . . .64
B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .64
C. ANNUALLY (BEFORE START OF HEATING
SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
D. CONDENSATE CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .64
E. COMBUSTION CHAMBER COIL CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .65
12. BOILER DIMENSIONS & RATINGS 66
13. REPAIR PARTS 70
APPENDIX A. STATUS SCREENS 78
APPENDIX B. USER MENU 82
APPENDIX C. INSTALLER MENU 83
APPENDIX D. COMBUSTION TEST
RECORD 88
TABLE OF CONTENTS
TABLE OF CONTENTS
A. INSTALLATION SEQUENCE
Follow the installation instructions provided in this manual
in the order shown. The order of these instructions has
been set in order to provide the installer with a logical
sequence of steps that will minimize potential
interferences and maximize safety during boiler
installation.
B. SPECIAL ATTENTION BOXES
Throughout this manual special attention boxes are
provided to supplement the instructions and make special
notice of potential hazards. The definition of each of
these categories, in the judgement of PB Heat, LLC
are as follows:
USING THIS MANUAL
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
NOTICE
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
CAUTION
DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING
1
USING THIS MANUAL
A. GENERAL
1. PUREFIRE®boilers are supplied completely assembled
as packaged boilers. The package should be inspected
for damage upon receipt and any damage to the unit
should be reported to the shipping company and
wholesaler. This boiler should be stored in a clean, dry
area.
2. Carefully read these instructions and be sure to
understand the function of all connections prior to
beginning installation. Contact your PB Heat, LLC
Representative for help in answering questions.
3. This boiler must be installed by a qualified contractor.
The boiler warranty may be voided if the boiler is not
installed correctly.
4. A hot water boiler installed above radiation or as
required by the Authority having jurisdiction, must be
provided with a low water fuel cut-off device either as
part of the boiler or at the time of installation.
B. CODES & REGULATIONS
1. Installation and repairs are to be performed in strict
accordance with the requirements of state and local
regulating agencies and codes dealing with boiler and
gas appliance installation.
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 Electrical Code”
e. ANSI/NFPA 211 - “Chimneys, Fireplaces, Vents
and Solid Fuel Burning Appliances”
3. Where required by the authority having jurisdiction,
the installation must conform to the Standard for
Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1.
**Please read if installing in Massachusetts**
Massachusetts requires manufacturers of Side Wall
Vented boilers to provide the following information
from the Massachusetts code:
·
A hard wired carbon monoxide detector with an
alarm and battery back-up must be installed on
the floor level where the gas equipment is to be
installed AND on each additional level of the
dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment.
·
In the event that the side wall horizontally vented
gas fueled equipment is installed in a crawl space
or an attic, the hard wired carbon monoxide
detector with alarm and battery back-up may be
installed on the next adjacent floor level.
·
Detector(s) must be installed by qualified licensed
professionals.
·
APPROVED CARBON MONOXIDE
DETECTORS: Each carbon monoxide detector
shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.
·
SIGNAGE: A metal or plastic identification plate
shall be permanently mounted to the exterior of
the building at a minimum height of eight (8) feet
above grade directly in line with the exhaust vent
terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall
read, in print size no less than one-half (1/2) inch
in size, “GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS”.
·
EXEMPTIONS to the requirements listed above:
°
The above requirements do not apply if the
exhaust vent termination is seven (7) feet or
more above finished grade in the area of the
venting, including but not limited to decks and
porches.
°
The above requirements do not apply to a
boiler installed in a room or structure separate
from the dwelling, building or structure used in
whole or in part for residential purposes.
·
This boiler installation manual shall remain with
the boiler at the completion of the installation.
See the latest edition of Massachusetts Code 248 CMR
for complete verbage and also for additional (non-vent
related) requirements (248 CMR is available online).
If your installation is NOT in Massachusetts, please
see your authority of jurisdiction for requirements that
may be in effect in your area. In the absence of such
requirements, follow the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.
2
PREINSTALLATION
1. PREINSTALLATION
Liquefied Petroleum (LP) Gas or Propane is heavier
than air and, in the event of a leak, may collect in low
areas such as basements or floor drains. The gas
may then ignite resulting in a fire or explosion.
WARNING
C. ACCESSIBILITY CLEARANCES
1. The PUREFIRE®boiler is certified for closet installations
with zero clearance to combustible construction. In
addition, it is design certified for use on combustible
floors.
2. Figure 1.1 shows the minimum recommended
clearances to allow reasonable access to the boiler for
Models PF-50, PF-80, PF-110 and PF-140. For
Models PF-210 & PF-399, Figure 1.2 shows the
minimum recommended accessibility clearances.
However, Local codes or special conditions may
require greater clearances.
E. D.
COMBUSTION AND VENTILATION AIR
3
PREINSTALLATION
Figure 1.1: Minimum Accessibility Clearances – PF-50, PF-80, PF-110 & PF-140
Figure 1.2: Minimum Accessibility Clearances – PF-210 & PF-399
D. COMBUSTION AND VENTILATION AIR
1. The PUREFIRE®boiler is designed for operation with
combustion air piped directly to the boiler from
outside the building (sealed combustion). If the boiler
is vented vertically, the combustion air can be
supplied from within the building only if adequate
combustion air and ventilation air is provided 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 3 through 10 as follows are based on the
National Fuel Gas Code requirements.
2. If the combustion air is piped directly to the boiler
from outside the building, no additional combustion
or ventilation air is required. Otherwise, follow the
National Fuel Gas Code recommendations
summarized in subsections 3 through 10.
3. Required Combustion Air Volume: The total required
volume of indoor air is to be the sum of the required
volumes for all appliances located within the space.
Rooms communicating directly with the space in
which the appliances are installed and through
combustion air openings sized as indicated in
Subsection 3 are considered part of the required
volume. The required volume of indoor air is to be
determined by one of two methods.
a. Standard Method
: The minimum required volume
of indoor air (room volume) shall be 50 cubic feet
per 1000 BTU/Hr (4.8 m3/kW). This method is to
be used if the air infiltration rate is unknown or if
the rate of air infiltration is known to be greater
than 0.6 air changes per hour. As an option, this
method may be used if the air infiltration rate is
known to be between 0.6 and 0.4 air changes per
hour. If the air infiltration rate is known to be
below 0.4 then the Known Air Infiltration Rate
Method must be used. If the building in which this
appliance is to be installed is unusually tight, PB
Heat recommends that the air infiltration rate be
determined.
b. Known Air Infiltration Rate Method
:
where:
I
fan
= Input of the fan assisted appliances
assisted in Btu/hr
ACH = air change per hour (percent of the
volume of the space exchanged per
hour, expressed as a decimal)
Note: These calculations are not to be used for
infiltration rates greater than 0.60 ACH.
4. Indoor Air Opening Size and Location: Openings
connecting indoor spaces shall be sized and located as
follows:
a. Combining Spaces on the Same Floor
: Provide two
permanent openings communicating with additional
spaces that have a minimum free area of 1 in
2
per
1000 Btu/hr (22 cm2per 1000 W) of the total input
rating of all gas fired equipment but not less than 100
in
2
(645 cm2). One opening is to begin within 12
inches (305 mm) from the top of the space and the
other is to begin within 12 inches (305 mm) from the
floor. The minimum dimension of either of these
openings shall be 3 inches (76 mm). See Figure 1.3
for an illustration of this arrangement.
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 in
2
per 1000 Btu/hr (44 cm2per
1000 W) of total input rating of all equipment. See
Figure 1.4 for an illustration of this arrangement.
4
15 ft
3
I
fan
ACH 1000
Btu
/
hr
Required Volume
fan
=
⎛
⎜
⎝
⎛
⎜
⎝
Figure 1.3: Air Openings – All Air from Indoors
on the Same Floor
Figure 1.4: Air Openings – All Air from Indoors
on Different Floors
PREINSTALLATION
5. Outdoor Combustion Air: Outdoor combustion air is
to be provided through one or two permanent
openings. The minimum dimension of these air
openings is 3 inches (76 mm).
a. Two Permanent Opening Method
: Provide two
permanent openings. One opening is to begin
within 12 inches (305 mm) of the top of the space
and the other is to begin within 12 inches (305
mm) of the floor. The openings are to
communicate directly or by ducts with the
outdoors or with spaces that freely communicate
with the outdoors. The size of the openings shall
be determined as follows:
i. Where communicating directly or through
vertical ducts with the outdoors each opening
shall have a minimum free area of 1 in2 per
4000 Btu/hr (22 cm
2
per 4000 W) of total
input rating for all equipment in the space. See
Figure 1.5 for openings directly
communicating with the outdoors or Figure
1.6 for openings connected by ducts to the
outdoors.
ii. Where communicating with the outdoors through
horizontal ducts, each opening shall have a
minimum free area of 1 in
2
per 2000 Btu/hr (22
cm2per 2000 W) of total rated input for all
appliances in the space. See Figure 1.7.
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 in
2
per 3000
Btu/hr of total rated input for all appliances in the
space and not less than the sum of the crosssectional areas of all vent connectors in the space.
The gas-fired equipment shall have clearances of
at least 1 inch (25 mm) from the sides and back
and 6 inches (150 mm) from the front of the
appliance. See Figure 1.8 for this arrangement.
5
Figure 1.5: Air Openings – All Air Directly from
Outdoors
Figure 1.6: Air Openings – All Air from Outdoors
through Vertical Ducts
Figure 1.7: Air Openings – All Air from Outdoors
through Horizontal Ducts
Figure 1.8: Air Openings – All Air from Outdoors
through One Opening
PREINSTALLATION
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 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:
where:
A
req
= minimum area of outdoor openings.
A
full
= full size of outdoor openings calculated
in accordance with Subsection 4.
V
avail
= available indoor air volume
V
req
= required indoor air volume
7. 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.
8. 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 ft
3
/min per
1000 Btu/hr (0.034 m
3
/min per 1000 W) of the
total rated input of all appliances in the space.
b. In installations where exhaust fans are installed,
additional air shall be provided to replace the
exhaust air.
c. Each of the appliances served shall be interlocked
to the mechanical air supply to prevent main
burner operation when the mechanical air supply
system is not in operation.
d. In buildings where the combustion air is provided
by the mechanical ventilation system, the system
shall provide the specified combustion air rate in
addition to the required ventilation air.
9. Louvers & Grills:
a. The required size of openings for combustion,
ventilation, and dilution air shall be based on the
net free area of each opening.
i. Where the free area through a louver or grille
is known, it shall be used in calculating the
opening size required to provide the free area
specified.
ii. Where the free area through a louver or grille
is not known, it shall be assumed that wooden
louvers will have 25% free area and metal
louvers and grilles will have 75% free area.
iii. Non-motorized dampers shall be fixed in the
open position.
b. Motorized dampers shall be interlocked with the
equipment so that they are proven in the full open
position prior to ignition and during operation of
the main burner.
i. The interlock shall prevent the main burner
from igniting if the damper fails to open during
burner startup.
ii. The interlock shall shut down the burner if the
damper closes during burner operation.
10. Combustion Air Ducts:
a. Ducts shall be constructed of galvanized steel or
an equivalent corrosion- resistant material.
b. Ducts shall terminate in an unobstructed space,
allowing free movement of combustion air to the
appliances.
c. Ducts shall serve a single space.
d. Ducts shall not serve both upper and lower
combustion air openings where both such
openings are used. The separation between ducts
serving upper and lower combustion air openings
shall be maintained to the source of combustion
air.
e. Ducts shall not be screened where terminating in
an attic space.
f. Horizontal upper combustion air ducts shall not
slope downward toward the source of the
combustion air.
g. The remaining space surrounding a chimney liner,
gas vent, special gas vent, or plastic piping
installed within a masonry, metal, or factory built
chimney shall not be used to supply combustion
air unless it is directly piped to the air inlet as
shown in Figure 3.9.
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.
11. Refer to Section 3 of this manual, Venting & Air Inlet
Piping, for specific instructions for piping the exhaust
and combustion air.
E. PLANNING THE LAYOUT
1. Prepare sketches and notes showing the layout of the
boiler installation to minimize the possibility of
interferences with new or existing equipment, piping,
venting and wiring.
2. The following sections of this manual should be
reviewed for consideration of limitations with
respect to:
a. Venting and Air Inlet Piping: Section 3
b. Water Piping: Section 4
c. Fuel Piping: Section 5
d. Condensate Removal: Section 6
e. Electrical Connections: Section 7
f. Boiler Control: Section 8
g. Boiler Dimensions and Ratings: Section 12
6
PREINSTALLATION
7
Do not install this boiler where gasoline or other
flammable liquids or vapors are stored or are in use.
WARNING
This boiler is certified as an indoor appliance. Do not
install this boiler outdoors or locate where it will be
exposed to freezing temperatures.
WARNING
Do not install this boiler in the attic.
WARNING
PREINSTALLATION
8
A. GENERAL
1. PUREFIRE®boilers are intended for installation in an
area with a floor drain or in a suitable drain pan. Do
not install any boiler where leaks or relief valve
discharge will cause property damage.
2. The P
UREFIRE
®
boiler is not intended to support
external piping. All venting and other piping should
be supported independently of the boiler.
3. Install the boiler level to prevent condensate from
backing up inside the boiler.
4. P
UREFIRE
®
boilers can be wall mounted or floor
standing. The following instructions provide guidance
for both configurations.
B. WALL MOUNTING
1. Models PF-50, PF-80, PF-110 and PF-140:
a. An optional wall mounting bracket kit (54171) is
available for wall mounting these sizes.
b. Mount the bracket level on the wall using 5/16" lag
bolts. Be sure the lag bolts are fully supported by
wall studs or adequate wall structure.
c. 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 interval. If existing wall
studs are spaced differently or if the desired
location is not in line with the wall studs,
additional support is required.
d. If the boiler is wall mounted using the optional
wall bracket, be sure that the wall provides
adequate support for the boiler.
e. Be sure to adequately support the boiler while
installing external piping or other connections.
f. Be sure that condensate piping is routed to a
suitable drain or condensate pump.
2. All Models can be wall mounted by using the optional
stand (91400).
a. Use the leveling feet provided with the boiler to
assure proper level.
b. Be sure to leave adequate provisions for
condensate piping and/or a pump (if required).
C. FLOOR STANDING INSTALLATION
1. For floor standing installations, use the leveling feet to
assure that the boiler is completely level. This will
prevent condensate from backing up in the boiler.
2. Be sure to leave adequate space for condensate
piping or a pump if required.
BOILER SET-UP
2. BOILER SET-UP
The wall mounting bracket is designed to support the
boiler. External piping for water, venting, air intake
and fuel supply is to be supported separately
WARNING
Figure 2.1: Optional Wall Mounting Bracket for PF-50, PF-80, PF-110 and PF-140 Boilers
This boiler must be installed level to prevent
condensate from backing up inside the boiler.
CAUTION
Make sure the boiler wall bracket is adequately
supported. Do not install this bracket on dry wall
unless adequately supported by wall studs.
WARNING
9
A. GENERAL
1. Install the PUREFIRE®boiler venting system in accordance
with these instructions and with the National Fuel Gas
Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, and/or
applicable provisions of local building codes.
2. The P
UREFIRE
®
boiler is a direct vent appliance and is
ETL Listed as a Category IV appliance with Intertek
Testing Laboratories, Inc.
B. APPROVED MATERIALS
1. Table 3.1 lists approved materials for vent pipe (and
adhesives where applicable). Use only these materials
for exhaust vent piping.
2. PVC pipe and fittings are not to be used for venting in
confined spaces such as closet installations. Use only
CPVC or Mugro™ vent pipe under these conditions.
3. Cellular core piping is approved for inlet air piping only.
* PVC pipe/fittings are not to be used for venting within
confined spaces.
Notice: Installations in Canada require compliance with
ULC S636 Standard for Type BH Gas Venting Systems.
C. EXHAUST VENT/AIR INTAKE PIPE
LOCATION
1. Install vent piping before installing water, fuel, or
condensate piping. Working from largest to smallest
diameter reduces the complexity of piping
interferences.
2. Vent and air intake piping is to be installed so that
there is sufficient access for routine inspection as
required in Section 11, of this manual.
3. The vent piping for this boiler is approved for zero
clearance to combustible construction. However, a fire
stop must be used where the vent pipe penetrates
walls or ceilings.
4. The Peerless
®
PUREFIRE®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. The maximum combined vent and air inlet vent
length for the Peerless
®
PUREFIRE®boiler is about 200
equivalent feet (60 m).Be sure that the boiler is
located such that the maximum vent length is not
exceeded.
6. Air Intake Pipe Location – Sidewall Venting:
a. Provide 1 foot (30 cm) clearance from the bottom
of the air intake pipe to the level of maximum
snow accumulation. Snow removal may be
necessary to maintain clearances.
b. Do not locate air intake pipe in a parking area
where machinery may damage the pipe.
c. The maximum distance between the air intake
and exhaust is 6 feet (1.8 m).
VENTING & AIR INLET PIPING
3. VENTING & AIR INLET PIPING
The venting system for this product is to be installed in
strict accordance with these venting instructions.
Failure to install the vent system properly may result in
severe personal injury, death or major property damage.
WARNING
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.
WARNING
Only the materials listed below are approved for use
with the
P
UREFIRE
®
boiler. Use only these components
in accordance with these instructions. Failure to use
the correct material may result in serious injury,
death, or major property damage.
WARNING
Table 3.1: Approved Materials for Exhaust Vent Pipe
Use of cellular core pipe for any exhaust vent
component is prohibited. Use of cellular core pipe
may result in severe personal injury, death, or major
property damage.
WARNING
If the maximum equivalent vent length is exceeded,
the maximum burner input rate may be reduced.
NOTICE
Locating air intake and exhaust pipes on different
sides of a building can cause erratic operation due to
wind gusts. When using the sidewall venting
configuration always locate both terminations on the
same outside wall.
NOTICE
Description Material
Conforming to
Standard
Vent Piping & Fittings
PVC (Sch 40 or 80)*
ANSI/ASTM D1785
CPVC (Sch 40 or 80) ANSI/ASTM D1785
PVC-DWV*
ANSI/ASTM D2665
MUGRO™ PP(s) ULC S636
Pipe Cement
(PVC & CPVC Only)
PVC/CPVC Cement ANSI/ASTM D2564
d. If the vent pipe and air inlet pipe terminations
penetrate the wall at the same level the minimum
distance between them is 8" center-to-center.
e. For multiple boiler installations, the minimum
horizontal distance between the inlet of one boiler
to the exhaust of an adjacent boiler is 8" center-tocenter. In addition, the minimum vertical distance
between the exhaust and air inlet is 6". See Figure
3.1 for an illustration.
f. The exhaust outlet of the vent pipe should not be
angled any more than 5º from horizontal.
g. Precautions should be taken to prevent
recirculation of flue gases to the air inlet pipe of
the boiler or other adjacent appliances.
7. Sidewall Venting Configuration:
a. See Figure 3.2 for an illustration of clearances for
location of exit terminals of direct-vent venting
systems.
• This boiler vent system shall terminate at least
3 feet (0.9 m) above any forced air inlet
located within 10 ft (3 m). Note: This does not
apply to the combustion air intake of a directvent appliance.
• Provide a minimum of 1 foot (30 cm) distance
from any door, operable window, or gravity
intake into any building.
• Provide a minimum of 1 foot (30 cm) clearance
from the bottom of the exit terminal above the
expected snow accumulation level. Snow
removal may be required to maintain clearance.
• Provide a minimum of 4 feet (1.22 m)
horizontal clearance from electrical meters, gas
meters, gas regulators, and relief equipment. In
no case shall the exit terminal be above or
below the aforementioned equipment unless
the 4 foot horizontal distance is maintained.
• 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
forming or recirculation of exhaust gases from
occurring.
• Provide 3 feet clearance from the inside corner
of adjacent walls.
b. Figure 3.3 and 3.4 show approved sidewall venting
configurations using the standard fittings supplied.
c. Figure 3.4 is only approved for locations in which
the outdoor temperature is above -5°F (-21°C) in
accordance with ASHRAE 90A-1980
recommendations.
d. Figures 3.5 and 3.6 show approved sidewall vent
configurations using optional vent termination kits.
10
VENTING & AIR INLET PIPING
Figure 3.1: Vent Pipe Spacing for Multiple
P
UREFIRE
®
Boilers
Figure 3.2: Exit Terminal Location for Mechanical Draft and Direct-Vent Venting Systems
Condensing flue gases can freeze on exterior
building surfaces which may cause discoloration and
degradation of the surfaces.
CAUTION
11
VENTING & AIR INLET PIPING
Figure 3.3: Standard Exhaust and Air Inlet Pipe
Penetrations
Figure 3.4: Offset Exhaust and Air Inlet
Terminations
Figure 3.5: Optional Stainless Steel Vent Kit
Installation
Figure 3.6: Optional Concentric PVC Vent Kit
Installation
8. Vertical Venting Configuration:
a. Figure 3.7 shows the approved venting
configuration for vertical venting using the
standard fittings supplied.
b. Locate the air intake pipe inlet 12" above the
expected snow accumulation on the roof surface
or 24" above the roof surface, whichever is greater.
c. Locate the end of the exhaust vent pipe a minimum
of 12" above the inlet to the air intake pipe.
d. Figure 3.8 shows an approved vertical vent
configuration using the optional concentric vent
termination kit.
e. Figure 3.9 shows an option for routing the exhaust
and air inlet piping through an unused chimney.
f. Figure 3.10 shows an option for routing the
exhaust through an unused chimney with the
combustion air supplied from inside the building.
Be sure to note the requirements for combustion
air as listed under Section 1.D. "Combustion and
Ventilation Air". These requirements are in
accordance with the National Fuel Gas Code.
12
VENTING & AIR INLET PIPING
Figure 3.7: Standard Vertical Vent Installation
Figure 3.8: Concentric PVC Vertical Vent Installation
Figure 3.9
13
D. EXHAUST VENT/AIR INTAKE PIPE SIZING
1. PUREFIRE®boiler models PF-50, PF-80, PF-110, PF-
140 and PF-210 are to be installed using 3" Schedule
40 or 80 PVC or CPVC piping using the provided
vent adapter. P
UREFIRE
®
model PF-399 boilers are to
be installed using 4" Schedule 40 or 80 PVC or CPVC
piping using the vent adapter provided.
2. Concentric polypropylene venting systems can be
installed using optional MUGRO™ vent adapters.
Table 3.2 shows the appropriate Stock Codes.
Contact your PB Heat, LLC Representative for more
information on this option.
3. The total combined length of exhaust vent and air
intake piping is 200 equivalent feet (60 m).
a. The equivalent length of elbows, tees and other
fittings are listed in Table 3.3.
b. The equivalent length can be calculated as follows.
This is well below the 200 feet maximum
equivalent length. If the total is above 200
equivalent feet, alternate boiler locations or
exhaust penetration location should be considered.
E. EXHAUST VENT/AIR INTAKE
INSTALLATION
1. Figures 12.1 & 12.2 show the exhaust connection on
top of the boiler, near the rear in the center.
a. The exhaust connection for PF-50, PF-80, PF- 110
and PF-140 boilers is a 3" CPVC Female Pipe
Adapter.
b. The exhaust connections for the PF-210 (3") and
PF-399 (4") are male CPVC pipe.
c. These connections are to be joined with suitable
PVC/CPVC adhesives in accordance with
manufacturers’ instructions.
2. The Air Intake connection is to the right of the exhaust.
3. Both connections are clearly marked.
4. Remove all burrs and debris from the joints and fittings.
5. Horizontal lengths of exhaust vent must be installed with
a slope of not less than 1/4" per foot (21mm per meter)
toward the boiler to allow condensate to drain from the
vent pipe. If the vent pipe must be piped around an
obstacle that causes a low point in the piping, a drain
with an appropriate trap must be installed.
VENTING & AIR INLET PIPING
This appliance uses a positive pressure venting
system. All joints must be sealed completely to
prevent leakage of flue products into living spaces.
Failure to do this may result in severe personal injury,
death or major property damage.
WARNING
Exhaust Air Inlet Total
Straight Length of Pipe 50' 50' 100'
90° Elbows, SR 2 x 5'= 10' 1 x 5' = 5' 15'
45° Elbows, SR 2 x 3' = 6' 6'
Conc. Vent Termination 1 x 3' = 3' 3'
Total 124'
Table 3.4: Sample Equivalent Length Calculation
Figure 3.10
Boiler Model Stock Code Boiler Model Stock Code
PF-50 54155 PF-140 54155
PF-80 54155 PF-210 54236
PF-110 54155 PF-399 54237
Table 3.2: Stock Codes
Fitting Description Equivalent Length
Elbow, 90° Short Radius 5 feet
Elbow, 90° Long Radius 4 feet
Elbow, 45° Short Radius 3 feet
Coupling 0 feet
Air Intake Tee 0 feet
Stainless Steel Vent Kit 1 foot
Concentric Vent Kit 3 feet
Table 3.3: Equivalent Length of Fittings
6. All piping must be fully supported. Use pipe hangers
at a minimum of 4 foot (1.22 meter) intervals to
prevent sagging of the pipe.
7. Exhaust and air inlet piping is to be supported
separately and should not apply force to the boiler.
8. Penetration openings around the vent pipe and air
intake piping are to be fully sealed to prevent exhaust
gases from entering building structures.
9. PVC & CPVC Piping:
a. Use only solid PVC or CPVC Schedule 40 or 80
pipe for exhaust venting. Cellular core PVC or
CPVC is not approved for exhaust vent.
b. All joints in vent pipe, fittings, attachment to the
boiler stub, and all vent termination joints must be
properly cleaned, primed and cemented. Use only
cement and primer approved for use with PVC or
CPVC pipe that conforms to ANSI/ASTM D2564.
c. A straight coupling is provided with the boiler to
be used as an outside vent termination. One of
the two screens is to be installed to prevent birds
or rodents from entering.
d. An air intake tee is provided with the boiler to be
used as an outside air intake termination. A screen
is to be installed to prevent birds or rodents from
entering.
e. The following are optional combination air
intake/exhaust terminations that are available
separately from your PB Heat, LLC distributor for
use with P
UREFIRE
®
boilers.
f. Refer to Figures 3.3 to 3.6 for sidewall venting
options using PVC or CPVC pipe.
g. Refer to Figures 3.7 & 3.8 for vertical venting
options using PVC or CPVC pipe.
F. EXHAUST TAPPING FOR VENT SAMPLE
To properly install the boiler, carbon dioxide (CO2) and
carbon monoxide (CO) readings are to be determined
from a sample of combustion gases from the vent pipe.
To do this, a hole must be drilled in the vent pipe.
a. Drill a 21/64" diameter hole in the exhaust vent
pipe at a point between 6" and 12" from the
boiler connection.
b. Tap the hole with a 1/8" NPT pipe tap.
c. Use a 1/8" NPT, PVC or Teflon Pipe Plug to seal
the hole.
See Section 9.D.7 for instructions on taking combustion
readings.
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM
If removing an existing boiler from a common vent
system the following steps must be carried out for each
appliance that remains connected. These steps are to be
completed for each appliance while the other appliances
that remain connected are not in operation.
a. Seal any unused openings in the common venting
system.
b. Visually inspect the venting system for proper size
and horizontal pitch. Verify that there is no
blockage or restriction, leakage, corrosion, and
other deficiencies which could cause an unsafe
condition.
c. Where practical, close all building doors and
windows. This includes interior doors between the
space in which the appliances remaining
connected to the common venting system are
located and other interior spaces in the building.
d. Turn on clothes dryers and any other appliance
not connected to the common venting system.
Exhaust fans such as range hoods or bathroom
exhaust fans are to be operated at their maximum
speed (Do not operate a summer exhaust fan).
e. Close fireplace dampers.
f. Place the appliance that is being inspected in
operation. Follow the lighting instructions and
adjust the thermostat so that the appliance will
operate continuously.
g. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame from a match or candle, or smoke from a
cigarette, cigar, or pipe.
h. After each appliance remaining connected to the
common vent system has been determined to vent
properly as outlined above, doors, windows,
exhaust fans, fireplace dampers and any other gas
burning appliance are to be returned to their
previous condition of use.
i. Any improper operation of the common venting
system should be corrected at once so that the
installation conforms with the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA
B149 Natural Gas and Propane Installation Code.
j. When resizing any portion of the common venting
system, it the system should be resized to
approach the minimum size as determined using
the appropriate tables in Part 11 of the National
Fuel Gas Code, ANSI Z223.1/NFPA 54 and or
CAN/CSA B149.1, Natural Gas and Propane
Installation Code.
14
VENTING & AIR INLET PIPING
Description Stock Code
3" PVC Concentric Vent Termination Kit 91403
3" Stainless Steel Vent Termination Kit 54161
Table 3.5: Vent Termination Kits
15
A. GENERAL
1. Size water supply and return piping in accordance
with system requirements. Do not use smaller
diameter piping than the boiler connections.
2. If the P
UREFIRE
®
boiler is used to replace an existing
boiler, make sure that the system piping is thoroughly
cleaned and free from debris before installing this boiler.
3. In hydronic systems where sediment may exist, install
a strainer in the boiler return piping to prevent large
particles and pipe scale from entering the boiler heat
exchanger. Use a large mesh screen in the strainer.
4. Install this boiler so that the gas ignition system
components are protected from water (dripping, spraying,
etc.) during operation and service (circulator replacement,
condensate trap cleaning, sensor replacement, etc.).
B. OPERATING PARAMETERS
1. The PUREFIRE®boiler is designed to operate in a
closed loop hydronic system under forced circulation.
This requires the system to be completely filled with
water and requires a minimum water flow through the
boiler to operate effectively.
2. The minimum system pressure is 14.5 PSI (69 kPa).
3. Table 4.1 lists the minimum flow rates for each
P
UREFIRE
®
model. If a glycol solution is to be used,
contact your PB Heat, LLC representative for
minimum flow rates.
Section 4.E provides detailed information about using
glycol for freeze protection.
Table 4.2 provides the water volume of the heat
exchanger including the supply and return pipes that
are attached at the factory.
C. SYSTEM COMPONENTS
Figure 4.1 shows the symbol key for piping diagrams in
this section. The following are brief descriptions of system
components.
1. Pressure/Temperature Gauge: A combination
pressure/temperature gauge is provided with each
P
UREFIRE
®
boiler to be mounted in the piping from the
boiler supply to the system as shown in Figure 4.2.
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 device (such as a TACO
Vortech
®
Air Separator) is required to remove the
dissolved gases preventing corrosion in the piping
system and eliminating noise.
3. Expansion Tank: An expansion tank (such as a Bell &
Gossett Series HFT) is required to provide room for
expansion of the heating medium (water or glycol
solution). Consult the expansion tank manufacturer's
instructions for specific information regarding
installation. The expansion tank is to be sized for the
required system volume and capacity. In addition, be
sure that the expansion tank is sized based on the
proper heating medium. Glycol solutions may expand
more than water for a similar temperature rise.
4. Y-Type Strainer or Filter Ball
®
Valve: PB Heat
recommends the use of a strainer device in the system to
prevent dirt or sediment from clogging the heat
exchanger. A 20 mesh stainless steel screen is adequate to
protect the heat exchanger. The strainer should be
cleaned often in the first several months of operation. The
Filter Ball
®
Valve from Jomar International incorporates a
strainer into a ball valve which allows the technician to
isolate the water circuit while cleaning the strainer.
5. Flow Control Valve: Flow control valves such as the
TACO Flo-Chek or Bell & Gossett Flo-Control™ are
used to prevent gravity circulation by incorporating a
check valve with a weighted disc.
WATER PIPING AND CONTROLS
4. WATER PIPING & CONTROLS
Use only inhibited propylene glycol solutions which
are specifically formulated for hydronic systems.
Unlike automotive antifreeze, solutions for hydronic
applications contain corrosion inhibitors that will
protect system components from premature failure
due to corrosion.
CAUTION
Use only inhibited propylene glycol solutions which
are specifically formulated for hydronic systems.
Ethylene glycol is toxic and may cause any
environmental hazard if a leak or spill occurs.
WARNING
PUREFIRE
®
Model
Minimum Flow Rate
Water
GPM (LPM)
50% Glycol Solution
GPM (LPM)
PF-50 2.2 (8.3) 2.8 (10.6)
PF-80 3.3 (12.5) 4.1 (15.5)
PF-110 4.4 (16.7) 5.5 (20.8)
PF-140 5.5 (20.8) 6.8 (25.7)
PF-210 5.5 (20.8) 6.8 (25.7)
PF-399 13.2 (50.0) 16.5 (62.5)
Table 4.1: Minimum Flow Rate
PUREFIRE
®
Model
Total Water Capacity
Gallons (Liters)
PF-50 0.62 (2.35)
PF-80 0.72 (2.73)
PF-110 0.89 (3.37)
PF-140 1.25 (4.73)
PF-210 1.19 (4.50)
PF-399 2.60 (9.84)
Table 4.2: Heat Exchanger Water Capacity
16
6. Pressure Reducing Valve: A pressure reducing valve,
such as the Bell & Gossett B-38 or a TACO #329, is
used in a hydronic system to automatically feed water
to the system whenever pressure in the system drops
below the pressure setting of the valve. These valves
should not be used on glycol systems unless close
supervision of the glycol solution is practiced.
7. Back Flow Preventer: A back flow preventer (check
valve) is required by some jurisdictions to prevent water
in the hydronic system from backing up into the city
water supply. This is especially important on systems in
which glycol solution is used as the heating medium.
8. Pressure Relief Valve: The boiler pressure relief valve
is shipped separately for field installation. It is
extremely important that this is installed on the boiler
return pipe (at the rear of the boiler).
The valve is to be installed as shown in Figures 4.2 or
4.3. Pipe the discharge of the relief valve to within 12"
of the floor and close to a floor drain.
Provide piping that is the same size or larger than the
relief valve outlet.
9. Circulator: The boiler circulator is to be sized to
overcome the pressure drop of the system while
providing the flow required by the boiler.
a. If the boiler is piped in a secondary loop of a
primary/secondary heating system, the circulator
will need only to overcome the resistance of the
boiler and any fittings in that loop.
WATER PIPING AND CONTROLS
Figure 4.1: Piping Symbol Key
Do not operate this appliance without installing the
pressure relief valve supplied with the boiler or one
with sufficient relieving capacity in accordance with
the ASME Rating Plate on the boiler heat exchanger.
WARNING
Pipe the discharge of the relief valve as close as
possible to the floor and away from high traffic areas.
Pipe the discharge to a floor drain. Failure to do so
may result in personal injury and/or property
damage.
CAUTION
b. The circulator should be sized based on gross
output of the boiler. Table 4.3 shows the Boiler
Output as reported to the Hydronics Institute
Section of AHRI. c. The required flow is calculated based on the design
temperature difference from the return to the supply
of the boiler. For a PF-110 with a design temperature
difference of 20°F the calculation is as follows.
Output 101,000
Required Flow =
________=_________
= 10.1 GPM
D
T x 500 20 x 500
d. The boiler pressure drop for various flow rates can
be determined using Figure 4.4, the P
UREFIRE
®
Boiler Circulator Sizing Graph.
17
WATER PIPING AND CONTROLS
PUREFIRE
®
Model
Boiler Input
Btu/hr (kW)
Gross Output
Btu/hr (kW)
PF-50 50,000 (14.7) 46,000 (13.5)
PF-80 80,000 (23.4) 73,000 (21.4)
PF-110 110,000 (34.2) 101,000 (29.6)
PF-140 140,000 (41.0) 130,000 (38.1)
PF-210 210,000 (61.5) 192,000 (56.3)
PF-399 399,000 (116.9) 373,000 (109.3)
Table 4.3: Boiler Inputs and Outputs
Figure 4.4: PUREFIRE®Circulator Sizing Graph (General Pump – Primary/Secondary)
Figure 4.2: Relief Valve Installation – PF-50, PF-80,
PF-110 & PF-140
Figure 4.3: Relief Valve Installation – PF-210 & PF-399
18
e. Table 4.4 provides the flow rate and pressure drop
information that corresponds to various system
temperature rise values (DT). The pressure drop
shown is for the boiler only. If there is significant
system pressure drop in the system, this should be
included when specifying circulators.
f. Table 4.5 provides a list of recommended
circulators for boilers on a secondary loop of a
primary/secondary system which uses water as a
heating medium.
Table 4.4: Flow Rate and Pressure Drop for Various System Temperature Rise Values
DT
(°F)
Flow Rate & Pressure Drop
PF-50 PF-80 PF-110 PF-140 PF-210 PF-399
GPM FT GPM FT GPM FT GPM FT GPM FT GPM FT
40 2.3 2.17 3.7 3.92 5.1 3.74 6.5 2.70 9.6 6.23 18.7 4.97
35 2.6 2.72 4.2 4.95 5.8 4.75 7.4 3.51 11.0 7.69 21.3 6.38
30 3.1 3.54 4.9 6.49 6.7 6.27 8.7 4.75 12.8 9.81 24.9 8.50
25 3.7 4.83 5.8 8.95 8.1 8.70 10.4 6.80 15.4 13.09 29.8 11.93
20 4.6 7.06 7.3 13.25 10.1 12.99 13.0 10.55 19.2 18.63 37.3 18.08
15 6.1 11.52 9.7 21.97 13.5 21.78 17.3 18.58 25.6 29.35 49.7 30.90
10 9.2 22.97 14.6 44.81 20.2 45.11 26.0 41.26 38.4 55.71 74.6 65.74
Table 4.5: Circulator Selection Chart (General Pump – Primary Secondary)
* A model 007 circulator can be substituted for those marked with an asterisk based on availability.
Circulator
Manufacturer
Temperature
Difference
PF-50 PF-80 PF-110 PF-140 PF-210 PF-399
Taco
10
0011 1400-50 1400-50 1400-50
1619/7.5"
1.5 HP
1911/4.5"
3 HP
Grundfos
UPS26-99FC
Hi Speed
N/A N/A
UPS40-160F
Hi Speed
N/A N/A
Bell & Gossett NRF-45 90-36 90-36 90-2 90-3 90-5
Wilo
Top S 1.25 x 25
Max
N/A
Top S 1.5.x 60
Min 230/1 only
Top S 1.5 x 50
Max
Top S 1.5.x 60
Min 230/1 only
IL 1.5 70/130-4
Taco
15
008 0011 0013 0013 1400-50 1615/6.3" 1 HP
Grundfos
UPS15-58FC
Hi Speed
UPS26-99FC
Hi Speed
UPS32-80F
Hi Speed
UPS32-80F
Med Speed
UPS32-160F
Med Speed
UPS40-160F
Hi Speed
Bell & Gossett NRF-22 NRF-45 NRF-36 NRF-36 PL-55 90-2
Wilo
Star S 21 FX
Hi Speed
Star 30 F
Top S 1.25 x 25
Max
Top S 1.25 x 25
Max
Top S 1.5 x 40
Min
Top s 1.5 x 40
Max
Taco
20
005* 009 0014 0014 1400-20 1400-50
Grundfos
UPS15-58FC
Med Speed
UPS15-58FC
Hi Speed
UPS26-99FC
Med Speed
UPS26-99FC
Med Speed
UPS32-80F
Med Speed
UPS32-160F
Med Speed
Bell & Gossett NRF-22 NRF-22 NRF-36 NRF-25 NRF-36 PL-55
Wilo
Star S 21 FX
Med Speed
Star S 21 FX
Hi Speed
Star S 21 FX
Hi Speed
Star 30 F
Top S 1.25 x 25
Max
Top S 1.25 x 35
Max
Taco
25
006F* 007 008 007 0014 1400-20
Grundfos
UPS15-58FC
Lo Speed
UPS15-58FC
Med Speed
UPS15-58FC
Hi Speed
UPS15-58FC
Hi Speed
UPS26-99FC
Med Speed
UPS32-80F
Med Speed
Bell & Gossett NRF-9F/LW NRF-22 NRF-22 NRF-22 NRF-45 PL-50
Wilo
Star S 21 FX
Low Speed
Star S 21 FX
Med Speed
Star S 21 FX
Hi Speed
Star S 21 FX
Hi Speed
Star 30 F
Top S 1.25 x 35
Max
Taco
30
006F* 005* 005* 005* 0014 0013
Grundfos UP15-10F
UPS15-58FC
Med Speed
UPS15-58FC
Med Speed
UPS15-58FC
Med Speed
UPS26-99FC
Med Speed
UPS26-99FC
Hi Speed
Bell & Gossett NRF-9F/LW NRF-22 NRF-22 NRF-22 NRF-25 NRF-36
Wilo
Star S 21 FX
Min Speed
Star S 21 FX
Med Speed
Star S 21 FX
Med Speed
Star S 21 FX
Hi Speed
Star 30 F Star 17 FX
Taco
35
006F* 006F* 006F* 006F* 0010 0014
Grundfos UP15-10F
UPS15-58FC
Lo Speed
UPS15-58FC
Med Speed
UPS15-58FC
Med Speed
UPS15-58FC
Hi Speed
UPS26-99FC
Hi Speed
Bell & Gossett N/A NRF-9F/LW NRF-9F/LW NRF-9F/LW NRF-22 NRF-45
Wilo
Star S 21 FX
Min Speed
Star S 21 FX
Min Speed
Star S 21 FX
Med Speed
Star S 21 FX
Med Speed
Star S 21 FX
Hi Speed
Star 30 F
Taco
40
006F* 006F* 006F* 006F* 007 0010
Grundfos UP15-10F
UPS15-58FC
Lo Speed
UPS15-58FC
Lo Speed
UPS15-58FC
Lo Speed
UPS15-58FC
Hi Speed
UPS26-99FC
Med Speed
Bell & Gossett N/A NRF-9F/LW NRF-9F/LW NRF-9F/LW NRF-22 NRF-33
Wilo
Star S 21 FX
Min Speed
Star S 21 FX
Min Speed
Star S 21 FX
Min Speed
Star S 21 FX
Min Speed
Star S 21 FX
Hi Speed
Star 30 F
WATER PIPING AND CONTROLS
19
WATER PIPING AND CONTROLS
g. Special consideration must be given if a glycol
based anti-freeze solution is used as a heating
medium. Propylene glycol has a higher viscosity
than water, therefore the system pressure drop will
be higher.
10. Indirect Water Heater: An indirect water heater should
be piped to a dedicated zone. The P
UREFIRE
®
boiler
provides electrical terminals for connecting a domestic
hot water (DHW) circulator. Examples of piping for
the indirect water heater are shown under subsection
“D”, System Piping of this section.
D. SYSTEM PIPING
1. Figure 4.5 shows a single boiler with multiple heating
zones. In this case, the DHW zone is piped in parallel
to the heating zones on the primary loop.
2. For a single boiler with one heating zone and one
DHW zone which utilizes an indirect water heater like
the Peerless
®
Partner®, pipe the boiler as shown in
Figure 4.6. In systems like this, the DHW circulator
must be sized to provide the minimum flow rate
through the boiler.
3. In Figure 4.7 an additional boiler is added and more
heating zones are shown. Notice that the two boilers
are piped in parallel on the secondary loop. This
maximizes the efficiency of the boilers since the lowest
temperature system water is returning to both boilers.
4. Figure 4.8 shows a multiple boiler system with several
different types of heat distribution units. This system
illustrates how different temperature zones can be
supplied from the same source by blending supply
and return water to the zone.
5. In Figure 4.9 zone valves are used instead of zone
circulators. Notice that the system is piped using
reverse return piping to help balance the flow through
the zones. If the zone lengths vary balancing valves
are required on each loop.
E. FREEZE PROTECTION
1. Glycol for hydronic applications is specially formulated
for heating systems. It includes inhibitors which prevent
the glycol from attacking metallic system components.
Make sure that the system fluid is checked for correct
glycol concentration and inhibitor level.
2. Use only inhibited polypropylene glycol solutions of
up to 50% by volume. Ethylene glycol is toxic and
can chemically attack gaskets and seals used in
hydronic system.
3. The anti-freeze solution should be tested at least once
per year and as recommended by the manufacturer of
the product.
4. Anti-freeze solutions expand more than water. For
example, a 50% by volume solution expands 4.8%
with a 148°F temperature rise while water expands
about 3% for the same temperature increase.
Allowance for this expansion must be considered in
sizing expansion tanks and related components.
5. The flow rate in systems utilizing glycol solutions
should be higher than in a water system to
compensate for decreased heating capacity of the fluid.
6. Due to increased flow rate and fluid viscosity, the
circulator head requirement will increase. Contact the
pump manufacturer to correctly size the circulator for
a particular application based on the glycol
concentration and heating requirements.
7. A strainer, sediment trap, or some other means for
cleaning the piping system must be provided. It
should be located in the return line upstream of the
boiler and must be cleaned frequently during the
initial operation of the system. Glycol is likely to
remove mill scale from new pipe in new installations.
8. Glycol solution is expensive and leaks should be
avoided. Weld or solder joints should be used where
possible and threaded joints should be avoided.
Make-up water should not be added to the system
automatically when glycol solution is used. Adding
make-up water will dilute the system and reduce the
ability of the solution to protect from freezing.
9. Check local regulations to see if systems containing
glycol solutions must include a back-flow preventer or
require that the glycol system be isolated from the
water supply.
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 supplier for chemical
properties of the water.
13. The following test will determine if the water is of the
appropriate hardness. Collect a sample of 50% water
to 50% propylene glycol. Let the solution stand for 812 hours shaking it occasionally. If white sediment
forms, the water is too hard and should not be used
to dilute the glycol.
14. Mix the solution at room temperature.
15. Do not use a chromate treatment.
16. Refer to Technical Topics #2a published by the
Hydronics Institute for further glycol system
considerations.
The circulator sizing given is for primary/secondary
installations only. The system circulators must be
sized based on the flow and pressure drop
requirements of the system.
NOTICE
20
WATER PIPING AND CONTROLS
Figure 4.5: Recommended Piping – One Boiler, Primary/Secondary with Two Zones (Zone Circulator)
21
WATER PIPING AND CONTROLS
Figure 4.6: Alternate Piping – One Boiler, Primary/Secondary with a Peerless
®
Partner
®
(Zone Circulators).
Note: The DHW Circulator must be sized to provide minimum flow through the boiler
22
WATER PIPING AND CONTROLS
Figure 4.7: Two Boilers, Primary/Secondary with Four Zones (Zone Circulator)
23
Figure 4.8: Three Boilers, Primary/Secondary with Five Zones (Zone Circulator)
WATER PIPING AND CONTROLS
24
WATER PIPING AND CONTROLS
Figure 4.9: Three Boilers, Primary/Secondary with Four Zones (Zone Valves)
25
F. SPECIAL APPLICATIONS
1. If the PUREFIRE®boiler is used in conjunction with a
chilled medium system, pipe the chiller in a separate
secondary loop.
a. Assure that the boiler circulator is disabled during
chiller operation so that chilled water does not
enter the boiler.
b. Install a flow control valve (spring check valve) to
prevent gravity flow through the boiler.
c. See Figure 4.10 for recommended system piping
for chiller operation.
2. For boilers connected to heating coils in a forced air
system where they may be exposed to chilled air
circulation, install flow control valves or other
automatic means to prevent gravity circulation of the
boiler water during cooling cycles. See Figure 4.11 for
an illustration.
WATER PIPING AND CONTROLS
Figure 4.10: Boiler in conjunction with a Chilled Water System
Figure 4.11: Boiler Connected to a Heating Coil in a Forced Air System
26
A. GENERAL
1. All fuel piping to the PUREFIRE®boiler is to be in
accordance with local codes. In the absence of local
regulations refer to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54.
2. Size and install fuel piping to provide a supply of gas
sufficient to meet the maximum demand of all
appliances supplied by the piping.
B. FUEL LINE SIZING
1. The required flow rate of gas fuel to the boiler can be
determined by the following.
The gas heating value can be supplied by the gas
supplier.
2. As an alternative, use Table 5.1 to determine the
required gas flow rate which uses typical heating
values for natural gas and liquefied petroleum (LP)
gas.
3. Table 5.2 shows the maximum flow capacity of
several pipe sizes based on 0.3" of pressure drop.
a. The values shown are based on a gas specific
gravity of 0.60 (Typical for natural gas).
b. Multiply the capacities listed by the correction
factors listed for gas with a specific gravity other
than 0.60 to obtain the corrected capacity.
4. Size and install the fuel gas supply piping for no more
than 0.5 inches of water pressure drop between the
gas regulator and the boiler.
C. GAS SUPPLY PIPING - INSTALLATION
1. Do not install any piping directly in front of the boiler
or along either side. Always provide access to the
front cover and side panel openings.
2. Install a sediment trap as shown in Figure 5.1. Be sure
to allow clearance from the floor or other horizontal
surface for removal of the pipe cap.
* Natural gas input rates are based on 1,000 Btu/ft
3
, LP input
rates are based on 2,500 Btu/ft
3
.
FUEL PIPING
5. FUEL PIPING
Use a pipe joint sealing compound that is resistant to
liquefied petroleum gas. A non-resistant compound
may lose sealing ability in the presence of this gas,
resulting in a gas leak. Gas leaks may potentially
cause an explosion or fire.
WARNING
PUREFIRE
®
Model
Required Input Rate*
Natural Gas ft3/hr
(m3/hr)
LP Gas ft3/hr
(m3/hr)
PF-50 50 (1.4) 20 (0.6)
PF-80 80 (2.3) 32 (0.9)
PF-110 110 (3.1) 44 (1.2)
PF-140 140 (4.0) 56 (1.6)
PF-210 210 (5.9) 84 (2.4)
PF-399 399 (11.3) 166 (4.7)
Table 5.1: Required Fuel Input
Pipe
Length
ft (m)
1/2" NPT
Pipe
3/4" NPT
Pipe
1" NPT
Pipe
1-1/4"
NPT
Pipe
1-1/2"
NPT
Pipe
10
(3.0)
132
(3.7)
278
(7.9)
520
(14.7)
1,050
(29.7)
1,600
(45.3)
20
(6.1)
92
(2.6)
190
(5.4)
350
(9.9)
730
(20.7)
1,100
(31.1)
30
(9.1)
73
(2.1)
152
(4.3)
285
(8.1)
590
(16.7)
890
(25.2)
40
(12.2)
63
(1.8)
130
(3.7)
245
(6.9)
500
(14.2)
760
(21.5)
50
(15.2)
56
(1.6)
115
(3.3)
215
(6.1)
440
(12.5)
670
(19.0)
60
(18.3)
50
(1.4)
105
(3.0)
195
(5.5)
400
(11.3)
610
(17.3)
70
(21.3)
46
(1.3)
96
(2.7)
180
(5.1)
370
(10.5)
560
(15.9)
80
(24.4)
43
(1.2)
90
(2.5)
170
(4.8)
350
(9.9)
530
(15.0)
90
(27.4)
40
(1.1)
84
(2.4)
160
(4.5)
320
(9.1)
490
(13.9)
100
(30.5)
38
(1.1)
79
(2.2)
150
(4.2)
305
(8.6)
460
(13.0)
The values are based on a specific gravity of 0.60 (typical for
natural gas). See Table 4.3 for capacity correction factors for
gases with other specific gravities.
Specific
Gravity
0.50 0.55 0.60 0.65 0.70 0.75
Correction
Factor
1.10 1.04 1.00 0.96 0.93 0.90
Specific
Gravity
0.80 0.85 0.90 1.00 1.10 1.20
Correction
Factor
0.87 0.84 0.82 0.78 0.74 0.71
Specific
Gravity
1.30 1.40 1.50 1.60 1.70 1.80
Correction
Factor
0.68 0.66 0.63 0.61 0.59 0.58
Table 5.2: 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).
Boiler Input Rate
Gas Heating Value
Input Rate
(
ft
³
/
hr
)
=
(
Btu
/
hr
)
(
Btu
/
ft
³
)
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