PEERLESS PF-50, PF-80, PF-110, PF-140, PF-210 Installation, Operation & Maintenance Manual

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PUREFIRE

REV

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

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

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.

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

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:

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

per 1000 Btu/hr (22 cm2per 1000 W) of the total input rating of all gas fired equipment but not less than 100 in

(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

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.

15 ft

fan

ACH 1000

Btu

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

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

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

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.

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:

req

= minimum area of outdoor openings.

full

= full size of outdoor openings calculated

in accordance with Subsection 4.

avail

= available indoor air volume

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

/min per

1000 Btu/hr (0.034 m

/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

PREINSTALLATION

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

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

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

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.

VENTING & AIR INLET PIPING

Figure 3.1: Vent Pipe Spacing for Multiple

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

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.

VENTING & AIR INLET PIPING

Figure 3.7: Standard Vertical Vent Installation

Figure 3.8: Concentric PVC Vertical Vent Installation

Figure 3.9

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.

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

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

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

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

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

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.

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

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

(°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

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

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

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

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

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

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

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

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

WATER PIPING AND CONTROLS

Figure 4.5: Recommended Piping – One Boiler, Primary/Secondary with Two Zones (Zone Circulator)

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

WATER PIPING AND CONTROLS

Figure 4.7: Two Boilers, Primary/Secondary with Four Zones (Zone Circulator)

Figure 4.8: Three Boilers, Primary/Secondary with Five Zones (Zone Circulator)

WATER PIPING AND CONTROLS

Figure 4.9: Three Boilers, Primary/Secondary with Four Zones (Zone Valves)

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

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

, LP input

rates are based on 2,500 Btu/ft

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

(3.0)

132

(3.7)

278

(7.9)

520

(14.7)

1,050 (29.7)

1,600 (45.3)

(6.1)

(2.6)

190

(5.4)

350

(9.9)

730

(20.7)

1,100 (31.1)

(9.1)

(2.1)

152

(4.3)

285

(8.1)

590

(16.7)

890

(25.2)

(12.2)

(1.8)

130

(3.7)

245

(6.9)

500

(14.2)

760

(21.5)

(15.2)

(1.6)

115

(3.3)

215

(6.1)

440

(12.5)

670

(19.0)

(18.3)

(1.4)

105

(3.0)

195

(5.5)

400

(11.3)

610

(17.3)

(21.3)

(1.3)

(2.7)

180

(5.1)

370

(10.5)

560

(15.9)

(24.4)

(1.2)

(2.5)

170

(4.8)

350

(9.9)

530

(15.0)

(27.4)

(1.1)

(2.4)

160

(4.5)

320

(9.1)

490

(13.9)

100

(30.5)

(1.1)

(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

(

)

(

Btu

)

(

Btu

)

3. Install a ground joint union between the sediment trap and the boiler to allow service to the appliance.

4. Install a service valve as shown in Figure 5.1 to allow the gas supply to be interrupted for service.

5. Maintain a minimum distance of 10 feet between the gas pressure regulator and the boiler.

6. Check all gas piping for leaks prior to placing the boiler in operation. Use an approved gas detector, non-corrosive lead detection fluid, or other leak detection method. If leaks are found, turn off gas flow and repair as necessary.

7. Figure 5.1 shows the gas shutoff valve for the

UREFIRE

boiler. This valve is to be used in addition to the gas service valve shown upstream of the sediment trap.

D. GAS SUPPLY PIPING - OPERATION

1. The gas line must be properly purged of air to allow the boiler to operate properly. Failure to do so may result in burner ignition problems.

2. Table 5.3 shows the maximum and minimum fuel gas supply pressure to the boiler.

a. Gas pressure below 3.5 inches of water may result

in burner ignition problems.

b. Gas pressure above 13.5 inches of water may

result in damage to the automatic gas valve.

3. To check the gas supply pressure to on the gas valve: a. Turn off the power at the service switch.

b. Close the gas shutoff valve.

c. Using a flat screwdriver, turn the screw inside the

inlet tap fitting (see Figure 5.2) one turn 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.

g. Turn off the boiler and close the gas shutoff valve.

h. Remove the manometer tube from the pressure

tap fitting.

i. Turn the internal screw clockwise to close the

valve.

j. Turn on the gas shutoff valve and boiler service

switch.

k. Fire the boiler and check for fuel gas odor around

the gas valve. If an odor is evident check to make sure that the pressure tap fitting is closed.

4. All gas piping must be leak tested prior to placing the

boiler in operation.

a. If the leak test pressure requirement is higher than

13.5 inches of water column, the boiler must be isolated from the gas supply piping system.

b. If the gas valve is exposed to pressure exceeding

13.5 inches of water column, the gas valve must be replaced.

5. Install the boiler such that the gas ignition system

components are protected from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate collector and neutralizer cleanout, control replacement etc.)

FUEL PIPING

When checking for leaks, do not use matches, candles, open flames or other methods that provide an ignition source. This may ignite a gas leak resulting in a fire or explosion.

WARNING

Do not subject the gas valve to more that 1/2 psi (13.5" W.C.) of pressure. Doing so may damage the gas valve.

CAUTION

Fuel Type

Pressure Inches W.C. (Pa)

Minimum Maximum

Natural Gas 3.5 13.5

LP Gas 3.5 13.5

Table 5.3: Maximum and Minimum Fuel Pressure

Figure 5.1: Gas Supply Pipe and Shut-off

E. MAIN GAS VALVE - OPERATION

1. Figure 5.2 is an illustration of the gas valve/venturi assembly for the P

UREFIRE

boiler.

a. Adjustments should not be made to the gas valve

without instrumentation to measure carbon dioxide (CO

) and carbon monoxide (CO)

emissions in the vent pipe.

b. Turning the throttle screw clockwise will decrease

the gas flow (decreasing CO

) and turning it counterclockwise will increase the gas flow rate (increasing CO

). Markings adjacent to the throttle

screw show + and – indicating this operation.

c. The recommended CO

settings are given in Table

5.4. In no case should the boiler be allowed to operate with CO emissions above 150 ppm.

2. Refer to Section 3, Venting and Air Intake for information on obtaining vent samples from this boiler.

FUEL PIPING

Figure 5.2: Gas Valve/Venturi

Gas Type

Firing

Rate

Ven t CO

Natural

Low 8-1/2% to 9-1/2% < 50 ppm

High 8-1/2% to 9-1/2% < 100 ppm

Low 9-1/2% to 10-1/2% < 50 ppm

High 9-1/2% to 10-1/2% < 100 ppm

Table 5.4: Recommended CO2Settings

A. GENERAL

1. The disposal of all condensate into public sewage systems is to be in accordance with local codes and regulations. In the absence of such codes, follow these instructions.

2. Proper piping and removal of condensation from combustion is critical to the operation of a condensing appliance. Follow these instructions carefully to assure that your P

UREFIRE

boiler operates correctly.

3. Depending on several factors, the condensate from gas fired condensing appliances may have a pH value as low as 2.5 (similar to cola soft drinks). Some local codes require the use of neutralization equipment to treat acidic condensate.

B. CONDENSATE SYSTEM

The PUREFIRE®condensate system is designed to prevent condensate from backing up into the heat exchanger, trap the condensate to prevent combustion gases from escaping and neutralize acidic condensate. Refer to Figure

6.1 for an illustration of the system components.

1. Condensate Drain Hoses: The PF-50, PF-80, PF-110, and PF-140 boilers have two drain hoses attached to the heat exchanger. The first hose drains condensate from the combustion chamber of the boiler. The second hose drains condensate from the vent system. This prevents dirt and debris from the venting system from entering the heat exchanger and fouling the heating surface.

PF-210 and PF-399 boilers have only one drain attached directly to the combustion chamber. To prevent debris from entering the heat exchanger, a separate drain can be added to the vent system as shown in Figure 6.2. However, be sure to adequately trap any vent system drains.

2. Condensate Collector Container: The condensate collector container is a transparent container in the base of the boiler near the back. This container collects the condensate and acts as a part of a trap to prevent combustion gases from escaping. The container is fitted with a level switch that will prevent the boiler from operating if the condensate line is clogged.

3. Condensate Float Switch: This switch will prevent the boiler from operating if the condensate outlet is clogged before the level of condensate reaches the heat exchanger.

CONDENSATE DRAIN PIPING

6. CONDENSATE DRAIN PIPING

Figure 6.1: Condensate Trap System

Figure 6.2: Separate Vent Condensate Drain

Installation

4. Condensate Neutralizer Container: The condensate neutralizer container is an additional transparent container near the front of the boiler. Fill this container with the condensate neutralizer provided. The neutralizer will be consumed during normal operation and should be checked occasionally to determine if additional neutralizer is necessary. Neutralizer is available in 1 lb bags (#54159) from your PB Heat Distributor.

5. Bulkhead fitting: The bulkhead fitting allows the condensate tubing to pass through the jacket without providing a path for leakage from the jacket. A PVC TEE is to be attached to the outlet of this fitting to prevent siphoning of the trap.

6. Neutralizer: Condensate neutralizer is provided in a package with the boiler to fill the condensate neutralizer container (Item 4).

7. Neutralizer Cap: This cap provides access for adding and inspecting the condensate neutralizer.

8. Condensate Drain Tube: This pre-formed tube connects the condensate system to the bulkhead fitting for attachment to an external drain.

C. CONDENSATE DRAIN PIPE MATERIAL

The condensate drain is to be piped using PVC, polypropylene, or other material resistant to acidic condensate. Do not use steel, brass or galvanized pipe for this purpose. The acidic condensate will attack most metals and corrode.

D. CONDENSATE DRAIN PIPE SIZING

The bulkhead fitting for condensate connection is for 3/4" schedule 40 PVC Pipe. Be sure to use 3/4" or larger tubing from the boiler to the drain.

E. CONDENSATE DRAIN PIPE INSTALLATION

1. Connect a 3/4" schedule 40 PVC Tee to the outlet of the bulkhead fitting as shown in Figure 6.3. Pipe from the bottom of the tee to a suitable drain.

2. Be sure that the piping slopes away from the boiler with a pitch of 1/4" per foot of pipe.

3. If the boiler condensate drain is above the level of a gravity drain, a condensate pump should be used. Table 6.1 lists several available brands. Contact your PB Heat, LLC Distributor for availability.

CONDENSATE DRAIN PIPING

Brand Name Model Number

Little Giant VCMA-15UL

Beckett CB151LSUL

Hartell KT-15-1UL

Table 6.1: Recommended Condensate Pumps

Figure 6.3: Condensate Drain Piping

A. GENERAL

This appliance is to be wired in accordance with local codes and regulations as defined by the Authority having jurisdiction. In the absence of such local codes, the

UREFIRE

boiler is to be wired in accordance with the latest

edition of the National Electrical Code, ANSI/NFPA 70.

B. CUSTOMER CONNECTIONS

1. Electrical knockouts are provided on the top panel of the boiler to connect supply wiring, circulator wiring and wiring to various instruments.

2. Electrical terminals are located behind the User Interface and can be accessed by loosening the two nuts shown in Figure 7.1.

a. Remove one of the nuts and leave the other fully

loosened in order to leave the display interface panel connected to the appliance.

b. The terminals can be removed by gently pulling

them away from their wired blocks. This allows the installer to easily attach wires to the connector before plugging it into the block.

3. Figure 7.2 shows customer connections for the PF-50, PF-80, PF-110 and PF-140 boilers.

a. Terminals 1-10 on the left side are for low voltage

customer connections to the CH thermostat, outdoor sensor, DHW sensor or thermostat, system sensor and low water cutoff contacts. The outdoor sensor is included. The DHW sensor (54157) and the system sensor (54156) are optional components and the low water cutoff, if used, is to be supplied by others.

b. Terminals 11-20 on the right side are for line

voltage customer connections to DHW, CH, and General Circulators; voltage supply, and low water cutoff (LWCO) power output.

4. Figure 7.3 shows customer connections for the PF-210 and PF-399 boilers.

a. Terminals 1-10 on the left side are for low voltage

b. Terminals 11 & 12 on the left side are for

connecting multiple boilers together using a cascade link which is described in Section 8.

c. Terminals 13 & 14 on the left side are dry contacts

that will close when there is a DHW call for heat. These provide a signal to a zone controller to prevent the CH circulators from operating during a DHW call-for-heat.

d. Terminals 15 & 16 are not yet active.

e. Terminals 17 through 26 on the right side are for

line voltage customer connections to DHW, CH, and General Circulators; voltage supply, and low water cutoff (LWCO) power output.

ELECTRICAL CONNECTIONS

7. ELECTRICAL CONNECTIONS

Figure 7.1: Electrical Terminal Access

Figure 7.2: Customer Connections – PF-50, PF-80, PF-100 & PF-140

f. Terminals 27 through 30 are a ground bus for any

line voltage ground connections.

g. Terminals 31 & 32 are not yet active.

5. Note that the service switch does not disconnect power to the convenience outlet.

C. ZONE CIRCULATOR WIRING

Wiring for a typical circulator zone relay is shown in Figure 7.4.

D. INTERNAL WIRING

Figure 7.5 shows the complete boiler wiring schematic for PF-50, PF-80, PF-110 and PF-140 boilers. Figure 7.6 shows the schematic for the PF-210 and PF-399 boilers. The following is a list of internal wiring components.

1. User Interface: The user interface is attached to the front of the electrical junction box and is accessible by removing the tinted lens on the front of the boiler. This interface allows users and installers to communicate with the control.

2. Supply Sensor/Limit Switch: This component, located on the left header is a thermistor that provides temperature information to the control. Also incorporated into this component is a high temperature limit switch that will prevent the boiler from operating if the supply water temperature is above 195°F (91°C). Be sure to use only a P

UREFIRE

supply thermister for this boiler.

3. Return Sensor: This thermistor is also located on the left header toward the rear of the boiler. It provides return temperature information to the control. Be sure to use only a P

UREFIRE

return thermistor for this

boiler.

4. Flue Sensor: This thermistor provides flue temperature information to the control. It is located in the back of the electrical junction box behind the user interface.

5. Condensate Drain Float Switch: This switch is mounted in the condensate collector below the heat exchanger in the rear of the cabinet.

6. Service Switch: The service switch interrupts the power to the P

UREFIRE

boiler to allow service to be

performed.

ELECTRICAL CONNECTIONS

Figure 7.3: Customer Connections – PF-210 & PF-399

Figure 7.4: Typical Zone Circulator Relay Wiring

ELECTRICAL CONNECTIONS

Figure 7.5: Internal Wiring Schematic for PF-50, PF-80, PF-110 & PF-140 boilers.

Figure 7.6: Internal Wiring Schematic for PF-210 & PF-399 boilers.

ELECTRICAL CONNECTIONS

7. Convenience Outlet: The convenience outlet is provided for a condensate pump during operation. It is not switched with the service switch to allow its use for lighting during maintenance.

8. Flame Sensor: The flame sensor uses the principal of flame rectification to sense the burner flame. This is located on the right side of the heat exchanger front plate. After ignition, the control also senses flame through the ignition electrode.

9. Gas Valve: The gas valve is connected through a special cord and connector. The connector is attached to the valve with a screw.

10. Ignition Electrode: This electrode is located on the left side of the heat exchanger front plate. A 10,000 volt charge is initiated by the control to provide a spark for lighting the burner. After the burner lights, and no spark is present, the control uses this electrode as a second source of flame detection.

11. Combustion Air Fan: The combustion air fan has two connections. There is a 120 volt power connection (3wire) and a low voltage control connection (4-wire).

12. Relay: A relay is provided in the PF-210 & PF-399 to allow the installer to provide a signal to the priority zone of a zone controller to prevent CH zones from being activated when a call for DHW is present.

Table 8.3: Pump Modes

Pump Mode

Display Text Brief Description

Detail

Section

Page

0 DHW or CH & DHW pump

The General pump is on when the CH pump runs on CH demand. The DHW pump runs on DHW demand. Either the CH or DHW pump runs; they never run at the same time.

8.C.1 40

1 General pump with 3-way valve

The General pump is always on when burner is on. A line voltage (120 VAC) 3-way valve is operated to supply water to the DHW tank.

8.C.1 41

2 Manifold with pump for DHW

The General pump is always on when the burner is on. The CH pump runs on CH demand. The DHW pump runs on DHW Demand. Either the CH or DHW pump runs; they never run at the same time.

8.C.1 41

A. CONTROL OVERVIEW

The PUREFIRE®boiler control is one of the primary safety devices for the boiler. It controls the ignition sequence, temperature limits, circulators and gas flow to the boiler. It also provides many unique features.

The control provides 7 central heating modes and 3 domestic hot water modes. In addition, the boiler can be adapted to several different piping schemes using the 4 different pump modes.

To provide maximum flexibility, several special features are also included.

1. Central Heating (CH) Modes: The P

UREFIRE

boiler control allows the installer to choose from several different central heating modes. The following table shows the central heating modes. In addition, the table shows the display text associated with each CH mode and a brief description of the operation.

2. Domestic Hot Water (DHW) Modes: The P

UREFIRE

boiler control also allows the installer

to choose from three different DHW modes.

3. Pump Modes: The P

UREFIRE

boiler allows three different pump modes to give the installer flexibility in piping arrangements.

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.1: Central Heating Modes

8. BOILER CONTROL: INTERNAL WIRING & OPERATION

Mode

Display Text Brief Description

Detail

Section

Page

0 Indoor Thermostat

Call-for-Heat signal from thermostat with user selected boiler supply target setpoint temperature.

8.D.1 42

1 Thermostat and Outdoor Reset

Call-for-Heat signal from thermostat with boiler supply target temperature calculated using outdoor temperature.

8.D.1 42

Permanent Demand and Outdoor Reset

Continuous heat demand with boiler supply target temperature calculated using outdoor temperature. Thermostat input used for setback.

8.D.1 42

3 Permanent Demand

Continuous heat demand with user selected boiler supply target temperature. Thermostat input used for setback.

8.D.1 42

0-10 V Input to modulate Setpoint

Requires PFA-1 Interface Adapter. Allows 0-10 volt input from an external source (ie. building management system) to change setpoint temperature.

8.D.1 42

5 0-10 V Input to modulate Rate

Requires PFA-1 interface Adapter. Allows 0-10 volt input from an external source (ie. boiler sequencing control) to change input firing rate.

8.D.1 42

6 Hydro-Air Unit

Call-for-Heat signal from a thermostat with user selected supply target setpoint temperature optimized for hydro-air heating system.

8.D.1 42

Table 8.2: Domestic Hot Water (DHW) Modes

DHW Mode

Display Text Brief Description

Detail

Section

Page

0 No DHW No domestic hot water tank is used. 8.E.1 38

1 DHW store with sensor

The domestic hot water tank is equipped with a temperature sensor. The

PUREFIRE®control modulates the boiler firing rate based on tank temperature.

8.E.1 38

2 DHW store with thermostat

The domestic hot water tank is equipped with a thermostat. The PUREFIRE

control responds to the demand from the thermostat and modulates the boiler firing rate targeting the DHW boiler setpoint.

8.E.1 38

4. Special Features: The P

UREFIRE

control offers several special features to give the installer options in setting up the boiler. These options are shown in the following table.

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.4: Control Features

Feature Brief Description

Detail

Section

Page

Cascade* Multiple boilers operate together in order to satisfy the heating or DHW demand.

8.I 44

One Hour Retry*

One hour after a lockout on ignition or flame failure, the PUREFIRE®control will reinitiate boiler operation.

10.B.4 53

Restore System Defaults*

Allows the installer to reset all parameters to the factory defaults if desired. The installer can also save and restore site defaults.

8.J 49

Adjustable Blower Postpurge*

This feature allows the installer to increase the blower postpurge to counteract the effects of high winds or unusual wind currents.

8.C.4 38

Flame Signal Log*

This troubleshooting tool captures the flame signal at four increments during the two second flame proving period. This can help installers/service personnel to quickly diagnose problems with flame rectifications.

10.B.5 53

Freeze Protection

Activates pumps if temperatures fall below the specified value. If the temperatures continue to fall, the boiler is activated.

8.C.3 38

DHW Tank Warm Hold

Prevents boiler from ramping up to high power if the DHW demand is only to keep the tank warm.

8.E.3 42

Ramp Delay Step Modulation

This feature is used to prevent short cycling in systems using very small zones. The input rate is gradually increased from 20% to 100% over 2 minutes. When used, this only effects central heating operation.

8.D.4 41

Add’l Safety Functions

Allows the installer to choose between a low water cutoff and a flow switch for water level safety shutdown.

8.C.5 38

Vent Temperature Safety Limit

Reduces the firing rate if the vent temperature approaches the maximum limit of the vent material. If the vent temperature continues to climb, the PUREFIRE®control will shut down the boiler.

8.C.2 38

Outdoor Reset

The PUREFIRE®control changes the boiler supply target temperature to compensate for changes in load due to milder outdoor temperatures. This increases the efficiency of the boiler and is more comfortable.

8.D.3 39

System Type Presets*

By choosing the heat distribution type (finned tube baseboard, hydro air, cast iron radiators, cast iron baseboard, low mass radiant or high mass radiant) the installer can automatically select practical boiler design and mild weather temperatures.

8.D.3 40

Temperature Boost

The temperature boost function increases the boiler supply target to recover more quickly from setback conditions.

8.D.3 40

Warm Weather Shutdown

The PUREFIRE®control will shut down the boilers CH functions if the outdoor temperature is above an installer defined maximum. This prevents the boiler from running during warm weather.

8.D.3 40

Anti-Cycling

The anti-cycling function prevents rapid on/off cycling of the boiler. This includes an override function to be sure that all loads are satisfied.

8.D.4 41

Limited DHW Priority

The PUREFIRE®control provides DHW priority for boiler operation. However, the control will automatically switch between CH and DHW loads after an installer determined switch time.

8.E.2 42

DHW Heat Dump

If enabled, the DHW heat dump function serves to dump heat from the boiler system to the DHW tank after a CH demand has ended.

8.E.4 42

Service Notification

If enabled, the PUREFIRE®control will display a service notification after an installer defined number of hours or cycles. It can also display a notification based on a date of the installers choosing.

8.F 42

System Test

The PUREFIRE®boiler will allow the installer to operate the boiler at low power, high power and ignition input for troubleshooting purposes.

8.G 43

Fault History

The PUREFIRE®control allows service personnel to access the last 15 Blocking Errors and the last 15 Lockout Errors in addition to records of the interval between Errors.

8.H.3 43

*New features

B. IGNITION SEQUENCE

Figure 8.1 shows the ignition sequence for the PUREFIRE

boiler control. Table 8.4 describes each step in the sequence in detail. The P

UREFIRE

boiler control provides dual sensing of the flame to maximize the reliability. The control senses the burner flame with both the flame sensor and the ignition electrode.

BOILER CONTROL: INTERNAL WIRING & OPERATION

Figure 8.1: Ignition Cycle – Graphical Representation

Table 8.5: Ignition Sequence

Period Demand Status User Interface Display

Standby

No demand is present

If the power is on to the PUREFIRE®boiler and there is no heat demand, the user interface will display “Standby” and show the boiler supply temperature in the lower right corner. The time, in 24 hour format, is shown in the upper right. When a heat demand (either CH or DHW) is present, the boiler begins the ignition cycle.

Pre Purge

A CH or DWH demand must be present to initiate ignition. Once initiated the boiler will light.

When a demand is present, the PUREFIRE®control starts the combustion air fan. The fan speed then increases to ignition speed and the user interface displays the Source of the call for heat along with “Trial for ignition.” This screen is displayed until the burner is lit and stable or until a fault occurs. Once the ignition sequence begins it will continue through ignition even if the demand has ended.

Igntion Cycle

Safety On/Off

Standby

Pre-Purge

Pre-Ignition

Ignition

Burner On

Demand

Fan

Pump

Gas Valve

Ignitor

Flame Signal

Maximum 24 hours

2 seconds

4 seconds

5 seconds

2 seconds

320 milliseconds

Purge

Post Purge 1

maximum

10 seconds

Post Purge 2

minimum

30 seconds

Circulator Post

Depends on

boiler settings

State

On Off

High

Ignition

Low

Off

On Off

BOILER CONTROL: INTERNAL WIRING & OPERATION

Period Demand Status User Interface Display

Safety

On/Off

A heat demand has no influence in the Safety On/Off period. The Safety On/Off step will continue even if the demand has ended.

This step very quickly opens and closes the gas valve relays and determines if the control is operating correctly. The CH pump is turned off during this test.

Pre-Ignition

A heat demand has no influence in the Pre-Ignition period.

Once the internal check is complete, the control begins a Pre-Ignition sequence. The igniter is energized while the gas valve remains off. If a flame is detected at the end of the pre-ignition period a lockout will occur.

Ignition

A heat demand has no influence in the Ignition period.

The following displays occur on ignition failure only.

The igniter remains energized for the first 4 seconds of the Ignition period. For the final 2 seconds of the Ignition period, the igniter is turned off and the control checks for a flame signal through both the ignition electrode and the flame sensor. If no flame signal is present at the end of the Ignition period, the control initiates a post-purge and then begins the ignition cycle again. If there are three consecutive ignition failures, the control will post purge and lockout. The control records 4 flame signal values during the final 2 seconds of this period that can be accessed from the installer status menu. The control will retry ignition one hour after an ignition failure lockout.

Burner On

A heat demand must be present for the control to stay in this period.

Once the flame signal is established, the burner will run until the demand is satisfied, the setpoint is exceeded, or a blocking error occurs. The maximum run period for the burner is 24 hours. If the boiler runs continuously for 24 hours, the control will override the demand and turn off the burner. After this a restart will occur and the burner will continue to run.

Post Purge 1

After the Post Purge period begins, a heat demand will be ignored until after this period.

The following screen is displayed when the demand has ended.

During post purge 1, the control monitors the flame signal to be sure that the flame has extinguished. If a flame is detected after the maximum 10 second time period, a control lockout will occur.

Post Purge 2

During this period a heat demand has no effect on operation.

The following screen will be displayed if the supply temperature exceeds the target setpoint.

During this period, the combustion air fan runs at high speed to purge combustion gases from the heat exchanger. The default fan post purge period is 30 seconds. It is adjustable up to 120 seconds.

Pump Purge

No heat demand is present.

The operation of the circulators and the boiler depend on the pump mode and the heat demand status.

C. BOILER CONTROL

1. Pump Modes:

The P

UREFIRE

control enables the installer to choose from 3 different pump modes depending on the installation. Table 8.3 provides a brief overview of the 3 available pump modes. The following are detailed explanations of the pump modes.

Pump Mode 0 – CH or CH&DHW Pump

: This mode is intended for a single heating zone with, or without, a DHW tank. Figure 8.2 shows typical piping for a single zone without DHW. Figure 8.3 shows typical piping for a single zone with DHW.

In this case, circulation through the boiler is to be provided by the CH pump when in a central heating mode. When satisfying a DHW demand, the circulation through the boiler is provided by the DHW pump.

Figures 8.2 & 8.3 both show the electrical connections from the boiler to the circulators. Either the CH pump or the DHW pump can be energized but they can never run simultaneously.

BOILER CONTROL: INTERNAL WIRING & OPERATION

The CH and DHW circulator must be sized correctly to provide the minimum flow required through the boiler. If the boiler is not piped primary/secondary do not rely on the pump recommendations in Section 4, Water Piping.

NOTICE

Figure 8.2: Pump Mode = 0, 1, or 2, DHW Mode 0

Figure 8.3: Pump Mode = 0, DHW Mode = 1 or 2

Pump Mode 1 – General Pump with 3-Way Valve: Mode 1 allows the boiler to be installed with a three way valve which diverts water from the boiler supply connection to either central heating or domestic hot water. Figure 8.2 shows typical piping for Pump Mode 1 without a DHW tank and Figure 8.4

* shows

typical piping with a DHW tank.

*as revised.

In this mode, the general pump always runs when the boiler is operating. The three-way valve always direct the water toward the DHW tank when no heat demand is present.

Pump Mode 2 – Manifold with Pump for DHW

: Mode 2 is intended for use with primary/secondary piping or other hydraulic separation. Figure 8.2 shows typical piping for Pump Mode 2 for central heating only and Figure 8.5 shows typical piping for central heating with a DHW tank.

This mode is preferred if multiple heating zones are used. The general pump operates to assure proper flow through the boiler at all times.

Like mode 1, the general pump always runs when the boiler is operating. The Ch pump provides circulation to CH zones and the DHW pump provides circulation to the DHW tank.

The figures also show the electrical connections from the pumps to the boiler terminals.

In this mode, the general pump always runs when the boiler is operating. The three way valve always directs the water toward the DHW tank when a heat demand has ended.

BOILER CONTROL: INTERNAL WIRING & OPERATION

Figure 8.4: Pump Mode = 1, DHW Mode = 1 or 2

Figure 8.5: Pump Mode = 2, DHW Mode = 1 or 2

2. Installation Location & Vent Material: The P

UREFIRE

boiler allows the installer to input the installation location and the vent material used. This information is used to determine the suitable vent temperature limit based on National Codes. Table 8.6 shows the vent temperature limit based on the location and vent material.

The P

UREFIRE

control will reduce the boiler firing rate if the vent temperature approaches the vent temperature limit. If the vent temperature continues to rise, the control will shut down the boiler.

3. Freeze Protection: The P

UREFIRE

boiler control is intended to prevent the central heating system from freezing. The default temperature to activate this function is 50°F (10°C).

If the supply temperature drops to below the freeze protection setpoint, the general pump and/or the CH pump (depending on pump mode) will be activated. If the supply or return temperature drops more than 9°F (5°C) below the setpoint, the control lights the boiler using the ignition sequence described in section 8.B.

The control will operate the burner at minimum power until the both the supply and return boiler temperature are more than 9°F (5°C) above the freeze protection setpoint.

While this function is active the interface panel will display the following:

4. Blower Postpurge Time: The P

UREFIRE

boiler control allows the installer to change the burner postpurge timing. This is useful under extreme conditions where high winds and unusual wind currents prevent proper purging of the combustion chamber.

This parameter is adjustable from 30 seconds to 120 seconds with the 30 second minimum as its default. It is important to note that increased purge times may slightly reduce the boiler efficiency.

5. Additional Safety Functions: The P

UREFIRE

boiler control is equipped with terminals for either a low water cutoff or a flow switch. The low water cutoff option is the factory default and a factory supplied jumper is installed. This jumper is to be removed if a low water cutoff or flow switch is

installed.

Low Water Cutoff

: The installer can connect the power supply wires for a probe-type low water cutoff to terminal #19 (Hot) and #20 (Neutral) in the main terminal box. The contacts should be wired to terminals #9 and #10.

Flow Switch

: If a flow switch is used, simply wire the contacts to terminals #9 and #10 in the main terminal box.

D. CENTRAL HEATING

1. Heating Modes: Table 8.1 provides an overview of the central heating (CH) modes. The following are detailed descriptions of the operation of these modes:

Mode 0 – Indoor Thermostat

: This is the default mode for the control. When this mode is selected, the control starts the boiler in response to a demand from the indoor thermostat. The boiler will target the User selected setpoint each time there is a heat demand. In this case, the outdoor thermostat is not required.

Mode 1 – Thermostat and Outdoor Reset

: In this mode, the control uses the outdoor temperature to calculate a target for the boiler setpoint.

The installer selects design temperatures and mild weather temperatures on the installer menu. The control then calculates a target supply temperature based on the current outdoor temperature.

A detailed explanation of Outdoor Reset is provided in section 8.D.3.

Mode 2 – Permanent Demand and Outdoor Reset

: In this mode, the boiler control operates on a permanent demand independent of room thermostats. The boiler is held at a target supply temperature calculated using the current outdoor temperature. In this mode, a contact closure across terminals #1 and #2 (CH T’Stat) will result in an 18°F temperature setback. This can be used in conjunction with a timer or switch for night or unoccupied setback periods. A detailed explanation of Outdoor Reset is provided in section 8.D.3.

Mode 3 – Permanent Demand

: Mode 3 is similar to Mode 2 except that the boiler target is a constant user defined setpoint. Again, a contact closure across terminals #1 and #2 (CH T’Stat) will result in an 18°F temperature setback.

Mode 4 – 0-10 V Input to Modulate Setpoint

: This feature requires the use of an optional PFA-1 Interface Adapter kit (54271). With this adapter, this mode allows the boiler setpoint to be controlled by an external source using a 0-10 VDC analog signal. An input of 0 volts corresponds to a setpoint of 50°F and an input of 10 volts corresponds to a setpoint of 195°F. The setpoint is proportional for all points in between these. This mode is commonly used in conjunction with a Building Management System (BMS) to control the boiler setpoint temperature based on the building requirements.

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.6: Vent Temperature Limits

Vent Limit Temperature

Ven t

Material

Location

U.S.A. Canada

PVC

190°F

(80°C)

149°F

(65°C)

CPVC

230°F

(110°C)

190°F

(80°C)

PP(s)

230°F

(110°C)

230°F

(110°C)

Mode 5 – 0-10 V Input to Modulate Firing Rate: This feature also requires the use of an optional PFA-1 Interface Adapter kit (54271). With this adapter, this mode allows the boiler input firing rate to be controlled by an external source using a 0-10 VDC analog signal. In this case, voltages below 2.0 volts DC prevent the boiler from operating. An input voltage of 2 volts will cause the boiler to operate at it minimum input (1% modulation) and 10 volts will cause the boiler to operate at maximum (100% modulation). Between these points, the input rate will be proportional. Note that the boiler high limit is set at 210°F and will cause a lockout if this temperature is reached.

Mode 6 – Hydro-Air Unit

: This mode is specifically for boilers supplying hot water to a hot water coil in a forced air heating system using a User defined boiler target setpoint temperature.

This mode is nearly identical to Mode 1 except that the response parameters are adjusted differently. The boiler control targets the setpoint temperature and modulates based on this temperature.

2. Setpoint operation: When operating in CH mode 0, 3 or 6 the user can select a target temperature for the boiler supply. The control modulates the boiler based on three conditions:

1) The difference between the current supply temperature and the target; 2) The speed with which the supply temperature increases; and 3) The speed at which the system reacts to the temperature increase.

When the boiler supply temperature approaches the target setpoint, the burner will modulate down to decrease the input. If the temperature begins to decrease, the control will increase the input rate.

3. Outdoor Reset Operation: To maximize fuel savings, P

UREFIRE

boilers are factory equipped for outdoor reset operation. The following describes the operating principal of this feature.

Operating Principle:

• Heat Loss decreases as Outdoor Temperatures increases.

• Heat distribution system is sized for Design Conditions (Coldest Outdoor Temperature).

• Boilers operate more efficiently at lower water temperatures.

• Condensing boilers have no minimum return water temperature.

The integrated control system on the P

UREFIRE

boiler adjusts the boiler supply setpoint based on outdoor temperature. In the installer menu, under “CH Settings” there are two parameters that define the design point of the boiler. The design point represents the conditions for which the boiler was sized.

Boiler Design Temperature

: The boiler supply temperature required to heat the building under its design load is called Boiler Design Temperature. For example, if the building was designed with copper finned tube baseboard with 180°F water, this is the design temperature that should be entered. The factory default for the Boiler Design Temperature is 180°F (82°C).

Outdoor Design Temperature

: The outdoor design temperature is the outdoor temperature used to calculate the heat loss of the building to determine the maximum heat load.

Commonly used values for this can be found in Table

8.7 for many North American Cities. The factory default for this setting is 0°F (-18 °C).

Mild Weather Boiler Temperature

: This is the temperature required to heat the building under a minimum load. Table 8.8 shows recommended values for this temperature setting.

The default for this is 70°F (21°C). However, depending on the type of heat distribution used, this value should be increased.

For example, if the boiler targets 70°F when a kick space heater or unit heater is used, the heating unit is likely to supply cold air if there is no thermostat to prevent it from running.

Mild Weather Outdoor Temperature

: This is the outdoor temperature at which the boiler should operate at its minimum heat load. The default value for this is 70°F (21°C).

Example:

Figure 8.9 shows how the Design Point and the

Mild Weather Point define a line used to calculate boiler supply temperature based on outdoor temperature.

The design point is shown for an outdoor design temperature of 0°F and a boiler design supply temperature of 160°F. The mild weather point is shown for an outdoor temperature of 70°F and a boiler supply temperature of 95°F.

From this, the P

UREFIRE

control calculates a boiler supply temperature of 130°F when the outdoor temperature is 32°F.

System Type Presets

: The PUREFIRE®Control allows the installer to select preset values for Boiler Design Temperature and Mild Weather Boiler Temperature based on the type of heat distribution used. Table 8.7 shows the system types and the corresponding boiler temperatures.

Type #7 is designated user defined and shows the default boiler temperatures. Once this choice is selected, the installer can change the numbers as desired.

BOILER CONTROL: INTERNAL WIRING & OPERATION

System Type

Temperatures

Boiler

Design

Mild Weather

Boiler

1. Finned Tube Baseboard 180 140

2. Hydro Air Unit 190 140

3. Cast Iron Radiator 160 120

4. Cast Iron Baseboard 150 110

5. Low Mass Radiant 140 70

6. High Mass Radiant 120 70

7. User Defined (Default) 180 70

Table 8.7: System Type Presets

Boiler Minimum: The boiler minimum is a value that is used to limit the minimum temperature that the boiler can target as a supply setpoint.

This is useful if the boiler is used in conjunction with fan coil units, kick space heaters, unit heaters or other instances where a low boiler supply temperature can cause uncomfortable conditions.

Boiler Maximum

: If the boiler is connected in a situation where a temperature that is too high can cause damage to tubing or floors, this will limit the maximum temperature that can be achieved.

Unlike the boiler design temperature, the control will not let the boiler run if the supply is at this temperature.

The default for this temperature is 180°F (82°C).

Boost Function

: The boost function increases the boiler supply target temperature by the value, “Temp”, if the demand is not satisfied in the value, “Time.” Both of these values are selected by the installer.

The default for these values are as follows: Temp = 18°F and Time = 20 minutes.

This function is designed to help the boiler recover from a setback condition. It will also help if too low of a value is chosen for the boiler design and/or mild weather temperature.

This value will continue to increase by the Temp value if the demand continues through consecutive Time periods.

The value is allowed to exceed the design temperature but can never exceed the boiler maximum temperature.

Warm Weather Shutdown

: In any CH mode utilizing outdoor reset, the warm weather shutdown feature prevents the boiler from operating if the outdoor temperature exceeds the selected temperature. The default value for this function is 70°F (21°C).

4. Other Features: Pump Post Purge

: The PUREFIRE®control allows the installer to set post purge times for the CH and/or General Pumps. The circulator will continue to run for the time selected after the call for heat has ended.

These values are settable from 0 to 900 seconds and the factory default is 60 seconds.

Ramp Delay Step Modulation

: This feature is useful for systems with very small zones which can cause a boiler to short cycle. The Ramp Delay Step Modulation function only applies to Central Heating and is not applied to DHW demands.

After the ignition sequence, the control modulates down to 20% of input. Then the input rate is gradually increased until the supply temperature approaches its target. At this time, the control modulates normally.

Anti-Cycling

: The PUREFIRE®boiler control allows the installer to set a minimum off time to prevent short cycling of the boiler. This only affects short cycling due to reaching the temperature limit setpoint. If the CH or DHW demand cycles, the control will cycle to match the demand.

“The minimum off time can be set from 0 to 15 minutes in 1 minute increments. It has a default of 3 minutes.

BOILER CONTROL: INTERNAL WIRING & OPERATION

Figure 8.6: Outdoor Reset Operation

The value for “TDiff” is the difference in temperature between the supply temperature and the target temperature that will override the minimum off time. This temperature difference indicates the presence of a substantial heat load.”

The default value for TDiff is 30°F and can be set to values between 20°F and 40°F. TDiff can also be disabled by choosing “Off”. To do this push the down arrow until “Off” is displayed.

Warm Weather Shut Down

: The PUREFIRE®control will prevent the boiler from operating if the outdoor temperature is above the temperature chosen by the installer. This helps to prevent wasting fuel if windows are open and the indoor temperature drops below the thermostat value. This function can be activated in either setpoint or outdoor reset CH modes as long as the outdoor sensor is attached. This only affects CH demands. The boiler will continue to operate for DHW loads regardless of outdoor temperatures.

Maximum CH Input Limit

: The PUREFIRE®control allows the installer to limit the maximum input of the boiler under a CH load if desired. This can be used when the boiler is sized primarily for a DHW load and is oversized for the CH load. This can be set between 50% and 100% and the default is 100%.

E. DOMESTIC HOT WATER (DHW)

1. DHW Modes: Table 8.2 provides an overview of the domestic hot water modes. The following are detailed descriptions of the operation of these modes:

Mode 0 – No DHW

: This is the default mode for the control. When this mode is selected, the control will not respond to either a thermistor signal or a contact closure at the DHW terminals (#5 & #6). There is also no output to DHW Pump Terminals.

Mode 1 – DHW Store with Sensor

: In this mode, the

UREFIRE

control accepts a temperature input from an optional domestic tank sensor (54157). This sensor provides the DHW water temperature value to the control. The control targets the user selected DHW setpoint and modulates the boiler firing rate accordingly.

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.8: Outdoor Design Temperature (ODT) – U.S. Cities

City State ODT City State ODT City State ODT

Mobile AL 29°F -2°C Springfield IL 2°F -17°C Albuquerque NM 16°F -9°C

Anchorage AK -18°F -28°C Indianapolis IN 2°F -17°C New York City NY 15°F -9°C

Juneau AK 1°F -17°C Des Moines IA -5°F -21°C Rochester NY 5°F -15°C

Flagstaff AZ 4°F -16°C Wichita KS 7°F -14°C Greensboro NC 18°F -8°C

Tucson AZ 32°F 0°C Bowling Green KY 10°F -12°C Farg o ND -18°F -28°C

Little Rock AR 20°F -7°C New Orleans LA 33°F 1°C Columbus OH 5°F -15°C

Fayetteville AR 12°F -11°C Bangor ME -6°F -21°C Tu l sa OK 13°F -11°C

Sacramento CA 32°F 0°C Portland ME -1°F -18°C Portland OR 24°F -4°C

San Diego CA 44°F 7°C Baltimore MD 13°F -11°C Philadelphia PA 14°F -10°C

San Francisco CA 38°F 3°C Boston MA 9°F -13°C Pittsburgh PA 5°F -15°C

Boulder CO 8°F -13°C Springfield MA 0°F -18°C Charleston SC 28°F -2°C

Denver CO 1°F -17°C Detroit MI 6°F -14°C Sioux Falls SD -11°F -24°C

Hartford CT 7°F -14°C Marquette MI -8°F -22°C Dallas TX 22°F -6°C

Waterbury CT 2°F -17°C Minneapolis MN -12°F -24°C Salt Lake City UT 8°F -13°C

Wilmington DE 14°F -10°C Jackson MS 25°F -4°C Burlington VT -7°F -22°C

Orlando FL 38°F 3°C St. Louis MO 6°F -14°C Richmond VA 17°F -8°C

Tallahassee FL 30°F -1°C Billings MT -10°F -23°C Seattle WA 27°F -3°C

Atlanta GA 22°F -6°C Omaha NE -4°F -20°C Spokane WA 2°F -17°C

Boise ID 10°F -12°C Carson City NV 9°F -13°C Morgantown WV 8°F -13°C

Idaho Falls ID -6°F -21°C Manchester NH -3°F -19°C Green Bay WI -9°F -23°C

Chicago IL -4°F -20°C Atlantic City NJ 13°F -11°C Cheyene WY -1°F -18°C

DANGER

Water temperatures over 125°F can instantly cause severe burns or death from scalding. Children, elderly and disabled individuals are at the highest risk of scalding. See instruction manual for the indirect tank before setting the water heater temperature. Instruct users to feel the water temperature before bathing or showering. Anti-scald valves are recommended.

Be sure to use only the tank sensor indicated. Other sensors will not provide accurate tank temperatures and may cause severe personal injury due to scalding.

WARNING

Mode 2 – DHW Store with Thermostat: In this mode, the P

UREFIRE

control is connected to the DHW tank temperature limit. When the limit closes, the control modulates the boiler firing rate to target a boiler supply setpoint. This setpoint is a user selected value with a factory default of 180 °F. The allowable range for this value is 134°F to 195°F.

2. DHW Priority: The P

UREFIRE

boiler control provides limited domestic hot water priority with an installer selectable maximum time limit.

The CH/DHW Switch Time indicates the maximum amount of time that the boiler should operate to satisfy a CH demand or a DHW demand.

If there is a domestic hot water demand during a call for central heating, the control will immediately shut down the CH pump, start the DHW pump and target the DHW setpoint.

The control will continue to target the DHW setpoint until the time limit is reached or the demand is satisfied. Then, if there is still a CH demand, it will shut down the DHW pump, start the CH pump and target the required CH temperature.

If there is a central heating demand during a DHW call, the boiler will continue targeting the DHW setpoint with the DHW pump operating and the CH pump idle until the time limit is reached.

For example, if the CH/DHW Switch Time is set for 30 minutes, and a CH demand is activated after 6 minutes of a DHW call the following will occur. The boiler will continue to target the DHW setpoint and the DHW pump will continue to run for the remaining 24 minutes. After which time, the control will shut down the DHW pump, start the CH pump and target the required CH temperature.

3. Store Warm Hold: When using a DHW tank sensor, the P

UREFIRE

boiler control can detect if the DHW heat demand is required only to overcome standby heat loss in the tank and is not a result of a hot water draw. In this instance, the burner will fire at low power (1% on the display) and continue until the tank setpoint is satisfied.

4. Heat Dump Function: Brookhaven National Laboratories have performed studies that show diverting excess boiler heat to the DHW tank after a CH demand will greatly improve the system efficiency of the boiler installation. The Heat Dump Function is designed to take advantage of this.

Essentially the boiler will operate normally on a call for heat. Once the call for heat ends, the pumps will operate to dump heat to the indirect tank. Which pumps operate depends on the pump mode and DHW mode selected.

• Pump Mode 0 – DHW Mode 1 & 2

: The DHW pump will operate to divert excess boiler heat to the indirect tank. The CH pump shuts down until this is accomplished.

• Pump Mode 1 – DHW Mode 1 & 2

: The General pump will operate and the 3-way valve will direct excess boiler heat to the indirect tank.

• Pump Mode 2 – DHW Mode 1 & 2

: The General pump will operate with the DHW pump to direct excess boiler heat to the DHW Tank. The CH pump is deactivated.

The pumps/3-way valves operate to dump heat to the DHW tank until the return temperature is less than the installer selected “Min Diff” temperature or until the “Max Time” limit is reached. This function can be disabled by choosing “Off” on the menu under “DHW Heat Dump.”

5. Maximum DHW Input Limit: The P

UREFIRE

control allows the installer to limit the maximum input of the boiler under a DHW load if desired. This can be used when the boiler is sized primarily for a CH load and is oversized for the DHW load. This can be set between 50% and 100% and the default is 100%.

F. SERVICE NOTIFICATION

The PUREFIRE®boiler control allows the installer to enable Service Notification through the installer menu. After enabling this feature, the installer selects the number of hours, the number of cycles, or the date when the “SERVICE” text appears on the display screen. This will prompt the user to call for service on the appliance.

The following chart shows the range and default values for the Service Notification feature.

If desired, the installer can set a specific date for the Service Notification.

To access the Notification menu operate the boiler under System Test, enter the installer menu by holding down the “Menu” and “Select” keys simultaneously for 10 seconds. Then press the “

M” key until the “” indicates “Service

Notif.” Press the “Select” key to choose the menu.

The first option is to reset the Notification Timer / Counter. Pressing the “Select” key will reset the timers and counters and “Done” will be shown in place of “Reset” on the lower right of the screen.

BOILER CONTROL: INTERNAL WIRING & OPERATION

Table 8.9: Service Notification Value Ranges

Notification

Min. Max. Default

On Off Off

Hours 0 8,000 4,000

Cycles 0 50,000 10,000

The “Store Warm Hold” function will not be functional if the DHW tank mode is set to 2. This requires a DHW tank sensor.

NOTICE

Pressing the “M” key displays the “SERVICE Notification on” screen. The default setting for “Notification on:” is “Off” indicating that no notification will occur. The installer can choose from the number of hours (HRS), the number of cycles (CYCLES) or the Date at which the “SERVICE” indication will appear on the display screen.

The menus that follow allow the installer to choose the actual values for the Service Notification.

G. SYSTEM TEST

The System Test feature allows the installer or service person to make the control operate at Low Power, Ignition Power, or Maximum Power. This is a setup and troubleshooting tool that allows the installer or service person to obtain combustion readings or observe operation.

To operate the boiler under System Test, enter the installer menu by holding down the “Menu” and “Select” keys simultaneously for 10 seconds. Then press the “

M”

key until the “” indicates System Test. Press the “Select” key to choose the menu. The default setting for System Test is “Off”. Choose the desired setting and press “Select” again to initiate the test.

Once the System Test is initiated, the service person may exit the menu screen by pressing the “Menu” key until the status screen is displayed. “System Test” will be displayed at the top of the display screen until the operator exits the system test mode.

H. STATUS & FAULT HISTORY

1. General: The P

UREFIRE

boiler control allows the installer to view the status of several key parameters. In addition, it provides details in English about the last 15 Blocking Errors and the last 15 Lockout Faults.

The Status and Fault History can be viewed from the Installer Menu. The Installer Menu Structure is shown in Appendix C of this manual.

This menu can be accessed by pressing and holding the “Menu” and “Select” keys simultaneously for 10 seconds. The “” indicator will be indicating “Status”. Press the “Select” Key to access this feature.

2. Status: Current Supply Setpoint

: The first screen indicates the current supply setpoint. In CH Mode 0, 3, and 6 this will be the setpoint selected from the User Menu. If the boiler is operating an outdoor reset mode (CH Mode 1 or 2) this value will be the target setpoint temperature calculated based on the outdoor temperature. In CH Mode 4, this value will correspond to the 0-10 V signal input.

Fan Speeds

: By pressing the “M” key the operator can view the current fan speed and the low power fan speed. The current fan speed will be directly comparable to the current input rate. The low power fan speed is a factory preset software parameter that indicates the minimum input to the boiler.

Pressing the “

M” key again displays the ignition and high

power fan speed. Both of these are factory preset software parameters that cannot be changed by the installer. The ignition speed is the speed at which the blower runs during the ignition period. The high power fan speed corresponds to the maximum input to the boiler.

Flame Signal/Failures

: Pressing the “M” key again will display the Flame Signal/Failures Screen. The flame signal is an indication of combustion stability of the burner. If this value is below 1.7 µA (microampere) the control will close the gas valve and the burner will recycle through the ignition cycle. The flame signal should be above 5.0 µA in normal operation.

If the control loses its flame signal 3 times during one call for heat, it will lock out the control indicating, “Flame Failure”. The number of flame failures in the history of the control is displayed below the flame signal on the menu screen.

The P

UREFIRE

boiler control uses dual flame sensing to minimize nuisance lockouts. See Section 10, Troubleshooting, to address flame failure issues.

Ignition Attempts

: Once again, press the “M” key to advance to the Ignition attempts status screen. This screen displays the number of successful and failed ignition attempts that have been made by the control. If excessive ignition attempts are shown on this screen, reference Section 10, Troubleshooting.

Boiler Run Time

: Pressing the “M” key again advances the menu to show Boiler Run Time. This indicates the number of hours that the boiler has operated under CH or DHW demand. The values are rounded to the nearest hour.

3. Fault History: The following sections provide instructions on how to access the fault history that is stored on the control. The

UREFIRE

control stores the last 15 blocking errors and the last 15 lockout errors and allows the installer or service person to review the fault history of the control.

Section 10, Troubleshooting, provides detailed descriptions and troubleshooting approaches to the errors reported by the control.

Last Block

: By continuing to press the “M” key, the status menu displays the following screen. The last block indicates the last blocking error (error that does not cause a lockout). The first number indicates the time interval in minutes since the previous error. The #EXX represents the Error Code which can be referenced in Section 10, Troubleshooting. The last two lines provide an English description of the error.

BOILER CONTROL: INTERNAL WIRING & OPERATION

Be sure to set the System Test parameter back to “Off” before leaving the installation. Otherwise, problems with cycling or insufficient heat may occur.

NOTICE

Last Lock: The next screen accessed by pressing the “M” key provides information about the last lockout error. Again the first number represents the interval since the last lockout error. #AXX represents the Fault Code which can be referenced in Section 10, Troubleshooting. Again the last two lines provide an English description of the fault.

I. SENSOR RESISTANCE

See Figure 8.7 for typical resistance of the boiler sensors.

J. MULTIPLE BOILERS

1. To cascade PF-50 and PF-80 models, check that the display sub base has the cascade link as illustrated in Figure 8.10 Cascade Link connection & Switch Setting.

2. P

UREFIRE

boiler controls can operate together to control up to 16 boilers for one central heat or domestic hot water demand. Only the addition of a system sensor (54156) is required to provide this operation.

3. Overview: a. Master Boiler

: In a multiple boiler system, a boiler designated as the “Master” boiler controls the function of the boiler system.

• Attached to a system sensor which monitors the system water temperature.

• Can also be connected to an outdoor sensor (54112), included with each boiler, as well as an optional DHW sensor (54157) or a standard DHW thermostat.

• Determines which boiler operates first (lead) and when to bring on additional boilers.

• Determines the input rate to operate individual boilers.

• Shuts down all boilers in the system if the LWCO contacts are opened.

b. Dependent Boilers

: The “dependent” boilers operate at the input rate and/or temperature that the Master boiler specifies.

• Maintain all of their own safety parameters such as safety limit, vent temperature limit, and freeze protection.

• Control their own general circulator that is energized whenever there is a call for either Central Heat or Domestic Hot Water.

• Shuts down the individual boiler if the dependent boiler LWCO contacts are opened.

4. System Piping & Wiring: a. Multiple boilers with multiple zones with zone valves.

• Figure 8.8 shows a typical system which uses a CH circulator, a DHW circulator and zone valves to distribute the heating load to the building.

• A three zone valve control panel (not included) controls circulation to individual zones.

• A call from any of the heating zones initiates a contact closure from the zone relay across the CH thermostat connections (terminals #1 &2) on the master boiler. This initiates ignition of the “lead” boiler and its general pump. In addition, the CH circulator is energized.

• A call for domestic hot water can either be initiated internally by the control when it sees a drop in indirect tank temperature or by a tank thermostat. In either case, the lead boiler is ignited and its general pump operates. The DHW circulator is also energized.

b. Multiple boilers with multiple zones with zone

circulators.

• Figure 8.9 shows a typical system which uses a circulator zone control panel to control the central heating zones.

• The DHW circulator can be operated by the priority zone or can be connected directly to the boiler (as shown). In either case, the priority zone cannot be used for heating.

• Again, a call for heat from any of the heating zones causes the master boiler to initiate operation of the lead boiler and its general circulator. The CH circulators are controlled by the zone control relay panel.

• A DHW call results in operation of the lead boiler and its general pump. The DHW pump is also energized. On the PF-210 & PF-399 a builtin relay provides a signal to the zone controller that the priority zone is operating. This prevents any of the CH zone circulators from operating.

• Wiring for a typical circulator zone relay is shown in Figure 7.4.

BOILER CONTROL: INTERNAL WIRING & OPERATION

The central heating (CH) circulator and the domestic hot water (DHW) circulator must be sized in accordance with good Engineering practices based on the required flow and pressure drop of the system. Failure to do so may result in system performance problems.

NOTICE

Figure 8.7: Sensor Resistance

BOILER CONTROL: INTERNAL WIRING & OPERATION

Figure 8.8: Multiple Boiler (Cascade) Piping / Electrical Connections for Systems with Zone Valves

BOILER CONTROL: INTERNAL WIRING & OPERATION

Figure 8.9: Multiple Boiler (Cascade) Piping / Electrical Connections for Systems with Zone Circulators

BOILER CONTROL: INTERNAL WIRING & OPERATION

5. Setting up Multiple Boiler Operation: a. Setting the Boiler Address

• Press the “Menu” and “Select” keys simultaneously for 5 seconds to enter the Installer Menu.

• Use the “

M” key to scroll down to “Cascade

Settings” on the menu.

• Pressing “Select” will cause the Boiler Address value to blink. Use the “

M” or “L” key to

change the value.

• The master boiler will be designated as Boiler Address: 1.

• All dependent boilers must have sequential boiler address settings as shown on the following table.

• Once a boiler is designated as a dependent boiler, the display will show the individual boiler supply temperature and its status.

• The master boiler will display the system temperature and the overall status of the cascade system.

• By pressing the “

M” or “L” key the operator

can view the master boiler status.

b. Connecting the Cascade Links – PF-50 through

PF-140.

• Remove the User Interface Display from the boiler by pressing the tab on bottom edge and rotating it outward and upward as shown in Figure 8.10.

• There will be two sets of terminals on the subbase still attached to the boiler. The first set will have wires attaching the display to the Main Control board.

• Attach 2 wires to the second set of terminals on each boiler to be connected.

• For the Master Boiler only, slide the

switch lever toward the center of the panel to the “ON” position.

• For all dependent boilers, the switch should remain in the “OFF” position toward the side of the printed circuit board.

• Re-assemble the User Interface Display and connect wires to each boiler in the system.

• All of these wires are to be connected to the Master Boiler as shown in Figure 8.11.

c. Connecting the Cascade Links – PF-210 & PF-399.

• Remove the User Interface Display from the Master boiler only.

• Slide the Master Switch Lever toward the center of the printed circuit board. The Master Switch Lever is not marked with “ON” or “OFF” but the switch is in the “ON” position when it is moved to the left as viewed from the back of the display. This position is shown in Figure 8.10.

• Re-attach the User Interface Display.

• Connect wires from terminals #11 & #12 between all boilers in the system.

6. Cascade Operation: a. When a call for Central Heat (CH) or Domestic

Hot Water (DHW) is present, the Master boiler chooses which boiler will lead based on the Cascade Rotation Interval

b. Before starting the Lead boiler, the Master control

will first check to be sure that the System temperature is lower than the System Setpoint + Stop Boiler Differential

c. After a Trial For Ignition (TFI), the lead boiler will

modulate its input rate to meet the heat demand.

d. Any time that a boiler is started the Cascade Start

Delay Time will be initiated and no boiler will be allowed to start before this time elapses. This is to allow time for the system to stabilize before bringing on an additional boiler.

e. After the delay time has elapsed, one of the

following conditions must be met before starting the next boiler:

• The System Temperature must be lower than the Set Point minus the Cascade Start Boiler Differential temperature, or

• The input rate of all boilers operating must be higher than the Next Boiler Start Rate

Boiler

Operation

Cascade

Address

System

Sensor

Outdoor

Sensor

DHW

Sensor

Stand-alone Boiler

Not

Active

Active Active

Boiler #1 Master

1 Active Active Active

Boiler #2 Dependent

Not

Active

Not

Active

Not

Active

Boiler #3 Dependent

Not

Active

Not

Active

Not

Active

➞

Boiler #16 Dependent

Not

Active

Not

Active

Not

Active

Table 8.10: Cascade Addresses and Sensor Functions

Figure 8.10: Cascade Link Connection & Switch Setting

To cascade PF-50 and PF-80

models, display must include

On/Off switch and sub-base must

include dual terminal blocks.

BOILER CONTROL: INTERNAL WIRING & OPERATION

f. After operation of the second boiler is initiated,

the Cascade Start Delay Time

must elapse before bringing on additional boilers. Again, in order to initiate operation of additional boilers one of the same conditions must be met.

g. When the boiler system approaches its Setpoint,

the boilers will reduce input rates at approximately equal values. When the input rates of all of the operating boilers fall below the Next Boiler Stop Rate, the master control will shut down the last boiler that started after the Cascade Stop Delay Time has elapsed.

h. The Calculated Setpoint Max Offset Up

and

Calculated Setpoint Max Offset Down

are applied to individual boilers in multiple boiler cascade operation.

• These temperature offset values are used to change the response of individual boilers to the system setpoint.

• Increasing these values will cause the system to react more quickly, but may result in frequent cycling.

• Decreasing these values will cause the system to react more slowly to achieve the setpoint.

• By increasing the Calculated Setpoint Max Offset Up value, the Master boiler will offset individual boiler setpoints temperature by a larger amount in order to achieve the system setpoint.

• By increasing the Calculated Setpoint Max Offset Down value, the boilers will decrease the boiler setpoints by a larger amount to achieve the system setpoint.

i. The Rotation Interval

is the frequency at which the Master Boiler will change the Lead boiler in the sequence.

• For example, if the Rotation Interval

is set to 4 days and there are 4 boilers operating together, the following chart shows the operating sequence over the next 25 days.

7. Multiple Boilers – Boost & Warm Weather

Shutdown (WWSD):

a. To use the Boost function with multiple boilers, the

parameters on the master boiler are used. Boost parameters set on dependent boilers have no effect on the system operation.

Table 8.11: Rotation Interval Sequence

Days of Operation Start/Stop Sequence

1-5 1-2-3-4

6-10 2-3-4-1

11-15 3-4-1-2

16-20 4-1-2-3

21-25 1-2-3-4

Figure 8.11: Interconnection of Cascade Link Wires

To cascade PF-50 and PF-80 models, check that the display sub-base has the cascade link as illustrated in Figure 8.10.

b. Similarly, the WWSD Temperature set on the

master boiler will prevent any boilers from operating for a CH demand when the outdoor temperature is above this value.

8. Multiple Boilers – Ramp Delay: a. The ramp delay feature can be set on each

individual boiler.

b. However, it is important to note that since the

dependent boilers treat DHW demands as a CH call, the ramp delay will take effect even when the DHW tank calls.

9. Multiple Boilers – Anti-Cycling: a. The Anti-Cycling feature is active on all boilers

unless it is disabled.

b. This will prevent dependent boilers from operating

within the prescribed time limit. However, it will only prevent the boiler from cycling on its own limit. Repetitive calls from the master boiler will result in cycling.

10. Multiple Boilers – DHW Operation: a. Since the DHW tank sensor or thermostat is

connected only to the Master boiler, this is the only boiler that will receive the DHW demand.

b. The master control will start boilers as necessary

to meet the demand.

c. Boilers with a boiler address of 2 or higher will

automatically be switched to DHW Mode 0 (No DHW).

K. DEFAULTS

1. Factory Defaults – Restore: By pressing the “Select” key while in the “Factory Defaults” screen. All factory settings will be restored on the control.

2. Site Defaults – Save: To save the current settings as “Site Defaults,” press the “Select” key while in the following menu.

3. Site Defaults – Reset: To restore the “Site Defaults,” press the “Select” key while in the following menu.

BOILER CONTROL: INTERNAL WIRING & OPERATION

A. GENERAL

1. Confirm that all water, gas and electricity are turned off.

2. Verify that the water piping, venting & air intake piping, gas piping, electrical wiring and electrical components are installed in accordance with the manufacturer’s instructions. Be sure that the boiler is installed in accordance with this manual and good engineering practice.

3. Turn on electricity and gas to the boiler

B. CHECK WATER PIPING

1. Fill the boiler and system with water, making certain to purge all air from the system. Open each vent in the system until all air is released and water begins to be discharged. Then close the vent.

2. The pressure reducing valve on the fill line will typically allow the system to be pressurized to 12 PSI. Consult manufacturers instructions for operation of the valve and expansion tank.

3. Check joints and fittings throughout the system and repair as required.

C. CHECK GAS PIPING

1. Turn on gas to the boiler using the shut-off valve upstream of the sediment trap. Be sure that the gas shut-off valve supplied 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 low, contact the fuel gas supplier.

5. Double check the fuel gas supply pressure after the boiler is running to be sure that the pressure doesn’t drop off significantly under operation.

D. CHECK OPERATION

1. Either disconnect or set CH thermostat and DHW tank thermostat to assure that no call for heat.

2. Turn on electricity and all manual gas valves to the boiler. Check to see if the LCD display is lit. The control will display, “Standby”.

3. Refer to Section 8, Boiler Control, to set up the control for the desired operation.

4. Use the ignition sequence, Figure 8.1 to follow the light off and shutdown sequences and to assist in troubleshooting operation problems. If the boiler does not function properly, consult Section 10, Troubleshooting.

5. After starting the boiler, be certain that all controls are working properly and that the combustion is properly set up. Paragraphs 6 and 7 below provide instructions on how to do this.

6. Check that the boiler will shut down when the supply water temperature reaches the control setpoint.

a. Note the boiler setpoint by accessing the User

Menu, Status Display. Press the “Menu” key on the keypad. Choose Status by pressing the “Select Key”. Use the “

M” and “L” key to scroll through

the CH and DHW setpoints. Refer to Appendix B for the User Menu.

b. Use the System Test Mode in the Installer Menu to

choose High Input Power.

c. Monitor the boiler temperature on the temperature

gauge (supplied for field mounting) and on the Status display.

d. The boiler should shut down at the boiler setpoint

plus 10°F (5.6°C). If it does not shut down turn off the boiler and contact your PB Heat representative.

7. Check combustion readings in the boiler vent pipe.

a. Drill and tap a 1/8" NPT threaded hole in the

boiler vent pipe within 12" (305 mm) of the boiler vent connection. (21/64" Drill and 1/8" NPT Pipe Tap recommended) This is to be used as the combustion test port for the combustion analyzer. See Figure 9.1.

b. Using a combustion analyzer with the capability to

read carbon dioxide (CO

) and carbon monoxide (CO), place the probe into the combustion test port. See Figure 9.2.

c. Manually set the boiler to Maximum power by

entering the System Test Mode. See Appendix C, Installer Menu.

9. START-UP PROCEDURE

Figure 9.1: Drill and Tap Combustion Test Port

START-UP PROCEDURE

• Verify that the fan speed indicated is within 30 rpm of the maximum power fan speed in Table 12.2.

• Verify that the CO and CO

emissions are

within the parameters specified in Table 5.4.

d. Manually set the boiler to Low Power by entering

the System Test Mode. See Appendix C, Installer Menu.

• Verify that the fan speed indicated is within 100 rpm of the Low Power fan speed listed in Table 12.2.

• Verify that the CO and CO

emissions are

within the parameters specified in Table 5.4.

e. If the values in either of these instances falls outside

the parameters listed in Table 5.4, turn off the boiler and contact your PB Heat representative. For best results, the value should be set for the middle of the range (9% for Natural Gas and 10% for LP Gas).

f. Be sure to set the System Test mode to Off so that

the boiler will modulate correctly in accordance with the load.

g. After removing the analysis probe from the vent

pipe, insert a PVC or Stainless Steel pipe plug into the test port. See Figure 9.3.

h. Record the combustion readings on the “Start-up

Combustion Record” in Appendix D. It is very important to record all of the information requested on the sheet for follow up and troubleshooting.

START-UP PROCEDURE

Figure 9.2: Insert Analyzer Test Probe into Test Port

Figure 9.3: Insert Pipe Plug into Test Port

E. LIGHTING & OPERATING PROCEDURES

START-UP PROCEDURE

Figure 9.1: Lighting & Operating Instructions

FOR YOUR SAFETY

READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life.

A. This appliance does not have a pilot. It is

equipped with an ignition device which automatically lights the burner. Do not light the burner by hand.

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU DO SMELL GAS

Do not try to light any appliance.

•

Do not touch any electric switch;

•

do not use any phone in your building.

Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

try to

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

Gas Control Knob (show in the “OFF” position)

If you cannot reach your gas supplier,

call the fire department.

C. Use only your hand to turn the gas control

valve. Never use tools. If the handle will not 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.

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.

5. Turn gas shutoff valve clockwise Handle will be perpendicular to pipe, do not force.

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.

7. Turn gas shutoff valve counterclockwise to "ON". Handle will be in line with the pipe.

8. Turn on all electric power to appliance.

9. Set thermostat to desired setting.

10. If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.

to "OFF".

TO TURN OFF GA S TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

(PF)

3. Turn the gas shutoff valve clockwise Handle will be perpendicular to pipe, do not force.

"OFF".

9474 REV 0

TROUBLESHOOTING

A. BLOCKING ERRORS

1. When a Blocking Error occurs the controller will display a message and an “E” error code on the display module.

2. These error messages and several suggested corrective actions are included in Table 10.1.

3. Certain Blocking Errors will, if uncorrected, become Locking Errors as described is Paragraph B.

B. LOCKING ERRORS

1. When a Locking Error occurs the controller will display a message and an “A” error code on the display module.

2. These error messages and several suggested corrective actions are included in Table 10.2.

3. Press the reset key to clear the Locking Error and resume operation. Be sure to observe the operation of the unit to prevent a recurrence of the fault.

4. The P

UREFIRE

control will retry for ignition after one hour of being in a lockout condition. This will prevent lockout errors from resulting in “No Heat” calls if there is an intermittent problem.

5. The P

UREFIRE

control logs the flame signal four times during the last 2 seconds of the ignition period. This is to aid in troubleshooting ignition errors. A flame signal below 2 micro-amps at the end of this period will result in a lockout. If the flame signal is low, remove the flame sensor and igniter for inspection. Also, be sure that the lead to the flame sensor is not grounded.

C. ERROR MESSAGES IN A CASCADE

SYSTEM

See paragraph D and the Cascade section of Appendix A for further information on how errors are displayed when using a Cascade System.

10. TROUBLESHOOTING

If overheating occurs or the gas supply fails to shut off, do not turn off electrical power to the circulating pump. This may aggravate the problem and increase the likelihood of boiler damage. Instead, shut off the gas supply to the boiler at the gas service valve.

CAUTION

DANGER

When servicing or replacing components that are in direct contact with the boiler water, be certain that:

• There is no pressure in the boiler. (Pull the release on the relief valve. Do not depend on the pressure gauge reading).

• The boiler water is not hot.

• The electrical power is off.

When servicing or replacing any components of this boiler be certain that:

• The gas is off.

• All electrical power is disconnected.

WARNING

Do not use this appliance if any part has been under water. Improper or dangerous operation may result. Contact a qualified service technician immediately to inspect the boiler and to repair or replace any part of the boiler which has been under water.

WARNING

Label all wires prior to disconnection when servicing controls. Wiring errors may cause improper and dangerous operation. Verify proper operation after servicing.

CAUTION

The convenience outlet is powered even when the service switch is off.

CAUTION

Figure 10.1

TROUBLESHOOTING

Table 10.1: Control Board Blocking Error Codes (automatic reset):

“E”

CODE

Error Display

Internal

No.

Error Description Corrective Action

E01

SUPPLY SENSOR NOT CONNECTED

51 Supply sensor not connected. Check harness and sensor.

E02

RETURN SENSOR NOT CONNECTED

52 Return sensor not connected. Check harness and sensor.

E04

DHW SENSOR NOT CONNECTED

55 DHW sensor not connected.

If DHW Mode is not intended to be set to Mode 1, DHW Store with Sensor, then change it to the appropriate Mode.

Check harness and sensor.

E05 STACK SENSOR OPEN 57 Flue gas sensor open. Check vent temperature, harness, sensor.

E11 SUPPLY SENSOR SHORT 59 Supply sensor shorted. Check harness and sensor.

E12 RETURN SENSOR SHORT 60 Return sensor shorted. Check harness and sensor.

E13 STACK SENSOR SHORT 65 Flue gas sensor shorted. Check harness and sensor.

E14 DHW SENSOR SHORT 63 DHW sensor shorted. Check harness and sensor.

E19

COMMUNICATION ERROR E2PROM ERROR

Problems reading from or writing to e2prom.

Contact PB Heat Representative.

E20 FALSE FLAME DETECTED 35 False Flame detected. Verify no flame in observation port. Check Sensor.

E21 HOT/NEUTRAL REVERSED 44

Phase and neutral of mains supply are reversed.

Verify polarity of incoming wiring. Check boiler ground and harness.

E22 POOR GROUND 43

No earth connected or internal hardware error.

Check boiler ground and harness.

E23 NET FREQUENCY ERROR 45

Mains frequency differs more than 2% from 60Hz.

Contact electrical provider and/or an electrician.

E24 POOR GROUND 46 Earth connection is not ok. Check boiler ground and harness.

E25 BLOCKED VENT 38 Blocked Vent Switch is Open

This error applies to PF-210 and PF-399 models. Check for blocked vent pipe or blocked heat exchanger. Check switch and tubing to switch.

E26

BLOCKED CONDENSATE DRAIN

41 Condensate drain blocked.

Check condensate tanks, hoses, condensate switch, and harness.

E30 HIGH STACK TEMPERATURE 39

Flue gas sensor above max flue setpoint + diff.

If flue pipe is hot, check flue temperature and compare to values shown Table 8.6. Check for proper gas input and combustion readings, check for dirty heat exchanger.

If flue pipe is not hot, check flue sensor and harness.

E31 LOW WATER 36 Water level is too low.

Check boiler water level, low water cut-off, harness. If a LWCO is not used, a jumper should be placed

between terminals #9 and #10, LWCO Contact.

E32 HIGH RETURN TEMP 40

Return temperature is above 194°F (90°C).

Check for reversed supply and return piping or pump installed backwards.

E42 INTERNAL HDWRE ERROR 47 Internal hardware error. Replace control.

E45 INTERNAL HDWRE ERROR 31 Internal hardware error. Replace control.

E46 INTERNAL HDWRE ERROR 32 Internal hardware error. Replace control.

E47 INTERNAL HDWRE ERROR 33 Internal hardware error. Replace control.

E48 INTERNAL HDWRE ERROR 34 Internal hardware error. Replace control.

E51

RESET BUTTON ERROR PLEASE WAIT.

Reset button pressed more than 7 times within one minute.

Wait five minutes. If error does not clear, replace control.

TROUBLESHOOTING

Table 10.2: Control Board Locking Error Codes (manual reset):

“A”

CODE

Error Display

Internal

No.

Error Description Corrective Action

A01 IGNITION ERROR 1

Three consecutive unsuccessful ignition attempts.

1. Watch the igniter through the observation window.

2. If no spark is present, check the spark electrode for the proper 3/16" gap.

3. Remove any corrosion from the spark electrode with abrasive.

4. If spark is present but no flame, check the gas supply to the boiler. Check for high or low pressure.

5. If there is a flame, check the flame signal ignition log in the Installer Menu. If values for flame signal are less than 3.1 µA, check wiring connections and clean the harness connector at the control.

6. Determine if gas valve is opening by monitoring gas pressure.

7. Check gas presure.

A02 FLAME FAILURE 24

Three consecutive flame failures during one demand.

1. If boiler sparks, lights briefly and then goes out: a. Disconnect the flame sensor cable and then

retry ignition.*

b. If the flame stays lit, allow the boiler to run for

several minutes and then reattach the cable.*

c. If the problem persists, remove the flame

sensor and inspect the burner through the sensor opening. If metal fibers are protruding from the burner, use a blunt probe to move the fibers away from the sensor.

d. If the problem is still present, replace the flame

sensor.

2. If the unit locks out on flame failure during normal operation: a. Check gas pressure at the inlet to the gas valve

(See figure 5.2) while the boiler is operating.

b. Check the flame signal in the Installer Menu

under Status. This will also show the total number of flame failures. If the flame signal reads less than 2.8 µA, clean the sensor and igniter. Be sure that the wiring harness is fully seated at the control.

c. If the flame signal is consistently low, check the

signal with the sensor disconnected. If the flame signal improves, replace the flame sensor.

A03 OVERHEAT LIMIT OPEN 18

High Temperature Limit Open (Set Temperature: 195°F)

1. Check CH, DHW, General Pump Operation

2. Assure that there is adequate flow through the boiler by checking the status menu and assuring less than 40°F temperature rise across the boiler.

3. Check thermistor reading on the supply thermistor. Replace it if necessary.

A04

INTERNAL ERROR GAS VALVE RELAY

5 Gas Valve Relay Problems. Replace control

A05

INTERNAL ERROR SAFETY RELAY

6 Safety Relay Problems. Replace Control

A09

INTERNAL SOFTWARE ERR RAM ERROR

9 Internal Software Error. Replace Control

A09 INTERNAL SOFTWARE ERR 27 Internal Software Error. Replace Control

A09 INTERNAL SOFTWARE ERR 28 Internal Software Error. Replace Control

A09 INTERNAL SOFTWARE ERR 29 Internal Software Error. Replace Control

A09 INTERNAL SOFTWARE ERR 30 Internal Software Error. Replace Control

A10

COMMUNICATION ERROR E2PROM ERROR

No Communication with E2prom.

Replace Control

* The flame is sensed through both the sensor and the igniter.

TROUBLESHOOTING

“A”

CODE

Error Display

Internal

No.

Error Description Corrective Action

A12

SOFTWARE OUT OF DATE E2PROM OUT OF DATE

Contents of e2prom is not up-to-date.

Replace Control

A13 INTERNAL ERROR 13 Internal Software Error Replace Control

A14 INTERNAL ERROR 14 Internal Software Error Replace Control

A15 INTERNAL ERROR 16 Internal Software Error Replace Control

A16 INTERNAL ERROR 22 Internal Software Error Replace Control

A18 INTERNAL ERROR 19 Internal Software Error Replace Control

A19

FALSE FLAME DETECTED AFTER SHUTDOWN

Flame signal detected 10 sec. after closing the gas valve.

1. Check flame sensor to be sure there is no short to ground.

2. Check igniter to be sure there is not short to ground.

3. This could also indicate that the gas valve doesn’t close completely.

A20

FALSE FLAME DETECTED BEFORE IGNITION

Flame signal detected before gas valve opened.

4. Check flame sensor to be sure there is no short to ground. Check igniter to be sure there is not short to ground.

A23 FLOW_SW_NOT_OPEN 25 CH flow switch not working.

1. Check for electrical continuity between wires connected to terminals 9 & 10 from field supplied flow switch.

2. If there is continuity when the circulator is off, there is a system piping or circulator control problem.

A24 FLOW_SW_NOT_CLOSED 26 CH flow switch not working.

1. Check for electrical continuity between wires connected to terminals 9 & 10 from the field supplied flow switch.

2. If there is no continuity, check to be sure the circulator is working.

3. If the circulator is working correctly, check the flow switch.

A32 FAN NOT RUNNING 23 Internal Software Error.

A33 FAN SPEED ERROR 8

Fan speed detected is more than 300 rpm different from targeted value for more than 60 seconds.

1. Is the fan running at full speed?

• Check 4 wire control connection to blower and control.

• Replace harness.

2. Is the fan running at a modulated speed?

• Check 4 wire control connection to blower and control.

• Replace harness.

3. Is the fan not running?

• Check the 3 wire power connection to the blower and control.

• Replace harness.

• Replace Blower.

A50

RETURN HIGHER THAN SUPPLY

Boiler return water temperature higher than supply for more than 5 ignition attempts.

1. Check system piping. Assure that the water is entering the return connection and exiting the supply connection.

2. Compare the supply thermistor reading to the temperature gauge, if they don’t agree, replace the supply thermistor.

Table 10.2 (cont’d): Control Board Locking Error Codes (manual reset):

D. WARNING ERRORS

The PUREFIRE®boiler control will display a blinking screen under several conditions. Several of these conditions provide the error information directly on the screen. Table 10.3 shows sensor errors and corresponding corrective actions.

1. Outdoor Sensor Error: a. If the boiler control is set to a CH mode in which

an outdoor sensor is required and the sensor is shorted, the screen will blink. Pressing the “Reset” key will display the following error screen.

b. The boiler will not operate until this problem is

corrected.

c. If the Outdoor Sensor is open, the status screen

will read -40°F and the boiler will run at the boiler design temperature as set up in the installer menu.

2. DHW Sensor Error: a. If the boiler control is set to operate on DHW

Mode 1 (DHW Sensor), and there is no sensor connected the boiler will not satisfy a DHW call for heat.

b. The display will blink and the DHW temperature

will read 14°F if there is an open circuit at the sensor terminals. Pressing the “Reset” key will display the following error screen.

c. This will also occur if the wires are not properly

connected.

d. If there is a short at the DHW sensor terminals

and the DHW mode is set to Mode 1, the DHW system will not operate. The display will blink to indicate a warning error. Pressing the “Reset” key will display the following error screen.

3. Flue Sensor Error: a. If the control senses that the flue temperature does

not rise to above 50°F after ignition, and either the supply water temperature rises above 120°F or the return water temperature rises above 80°F, the control will display “Flue Sensor Hold” and run at 1% Input.

b. If “Flue Sensor Hold” continues for an extended

period of time, the display will blink. Pressing the “Reset” key will display the following error screen.

4. Cascade – System Sensor Error: a. In a multiple boiler cascade installation a system

sensor must be connected to the system. If no system sensor is connected or if there is an open circuit the display will blink and the display screen will read as follows:

b. If there is a short circuit in the system sensor

wiring, the display screen will read similarly. Notice that a short circuit results in a high system temperature reading (244°F).

c. Under either of these conditions, the Master boiler

will set the supply setpoints of all of the boilers to match the system setpoint. It will continue to bring on and shut off boilers based on the thermostat demand (terminals #1 and #2) and the Boiler Start/Stop Delay Time.

5. Cascade – Loss of Communication with Master

Boiler:

a. If a dependent boiler is not communicating with the

Master boiler, and it is set as address 2-16, the screen will blink with the following information displayed.

b. The boiler that is not communicating with the Master

boiler will not run until the problem is corrected. Other boilers connected to the Master boiler and the Master boiler itself will operate normally.

TROUBLESHOOTING

Table 10.3: Control Board Warning Error Codes

“W”

CODE

Error Display

Error

Description

Corrective Action

#W01

Blinking Screen – Press “Reset” key to view this message

Outdoor Sensor

Shorted

1) Check wiring connection to Outdoor Sensor.

2) Remove the wires from terminals #3 and #4 on the boiler and check the resistance between them.

• If this reading is below 3000 W check the reading at the sensor.

• If the reading is the same at the sensor, replace the sensor.

• If the reading is higher at the sensor, replace the wiring.

#W02

Blinking Screen – Press “Reset” key to view this message

DHW Sensor

Open

1) Be sure the optional DHW Sensor (54157) is connected.

2) Remove the wires from terminals #5 and #6 on the boiler and check the resistance between them.

a. If the resistance is above 10 k W, check the

resistance at the sensor.

b. If the reading at the sensor is the same,

replace the sensor.

c. If the reading at the sensor is lower, replace

the wiring.

#W03

Blinking Screen – Press “Reset” key to view this message

DHW Sensor

Shorted

1) Check wiring connection to DHW Sensor.

2) Remove the wires from terminals #5 and #6 on the boiler and check the resistance between them.

a. If this reading is below 1000 W, check the

reading at the sensor

b. If the reading is the same at the sensor,

replace the sensor.

c. If the reading is higher at the sensor, replace

the wiring.

#W04

Flue Sensor

Open

1) Check wiring connection to flue sensor.

2) Compare sensor resistance to Figure 8.7. If resistance value is incorrect, replace sensor.

MAINTENANCE

11. MAINTENANCE

WARNING

Product Safety Information

Refractory Ceramic Fiber Product

This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF fibers, 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, 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.

MAINTENANCE

A. GENERAL (WITH BOILER IN USE)

General 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.

2. Observe general boiler conditions (unusual noises, vibrations, etc.)

3. Observe operating temperature and pressure on the combination gauge located in the supply piping on the left side of the boiler. Boiler pressure should never be higher than 5 psi below the rating shown on the safety relief valve (25 psig maximum for a 30 psig rating). Boiler temperature should never be higher than 240° F.

4. Check for water leaks in boiler and system piping.

5. Smell around the appliance area for gas. If you smell gas, follow the procedure listed in the Lighting Operating Instructions to shut down appliance in Section 9, Start-Up Procedure Part B.

B. WEEKLY (WITH BOILER IN USE)

Flush float-type low-water cut-off (if used) to remove sediment from the float bowl as stated in the manufacturer’s instructions.

C. ANNUALLY (BEFORE START OF

HEATING SEASON)

1. Check boiler room floor drains for proper functioning.

2. Check function of the safety relief valve by performing the following test:

a. Check valve piping to determine that it is

properly installed and supported.

b. Check boiler operating temperature and pressure.

c. Lift the try lever on the safety relief valve to the

full open position and hold it for at least five seconds or until clean water is discharged.

d. Release the try lever and allow the valve to close.

If the valve leaks, operate the lever two or three times to clear the valve seat of foreign matter. It may take some time to determine if the valve has shut completely.

e. If the valve continues to leak, it must be replaced

before the boiler is returned to operation.

f. Check that operating pressure and temperature

have returned to normal.

g. Check again to confirm that valve has closed

completely and is not leaking.

3. Test low-water cut-off (if used) as described by the manufacturer.

4. Test limit as described in Section 9, Part D, “Check Operation”.

5. Test function of ignition system safety shut-off features as described in Section 9, Part D, “Check Operation”.

6. Remove the top/front jacket panel and inspect for any foreign debris that may have entered through air intake vent.

7. Inspect burner for deterioration. Replace if necessary.

8. With boiler in operation check that condensate is dripping from condensate tubing. Check for any restriction in condensate drain line.

D. CONDENSATE CLEANING

INSTRUCTIONS

1. Removal of Condensate Tanks.

a. Close manual gas shutoff valve on top of boiler

and turn off power to the boiler by placing the boiler service switch to the off position.

b. Remove the front jacket panel.

c. Remove the wing nut securing the front tank and

disconnect the tank from the upper right drain hose. (Some condensate may spill out of this port).

d. Remove the cap from the tank and position a

container in front of the boiler and tilt the tank to drain condensate into the container.

e. Tank and lower hose may be by removed by

disconnecting the lower hose from the rear tank.

f. Clean tank and hose with water and inspect the rear

tank for sediment in the lower connection port. The rear tank can be removed for cleaning if required by removing the wing nut and disconnecting the two float switch wire leads. NOTE: Special care must be taken when removing the hoses from the top of the rear tank. They must be held secure and do not pull hoses downward and away from their upper connections to the heat exchanger and vent adapter.

g. After cleaning, replace tanks and reconnect hoses

and wire leads to float switch. Fill the front tank with water and check for any leaks at connections.

h. Replace the front jacket panel, open the manual

gas valve and place the boiler service switch to the on position.

The following annual inspection must be performed by a qualified service technician.

CAUTION

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.

DANGER

The convenience outlet is powered even when the service switch is off.

CAUTION

MAINTENANCE

2. Before re-starting the PUREFIRE®boiler follow the steps below:

a. Reconnect the thermostat wires.

b. Open the manual gas shutoff valve and reset the

thermostats.

c. Observe the boiler function to make sure you see

a condensate flow.

d. If you do not observe a condensate flow, repeat

the above procedure.

3. If the problem is not corrected at this point, it is possible that there is a material deposit problem. Follow the Coil Cleaning Instructions (Subsection 9E) below to dissolve deposits and clean the heat exchanger.

E. COMBUSTION CHAMBER COIL

CLEANING INSTRUCTIONS

Before beginning this procedure, you must have on hand the following items:

– a nylon or brass brush (not steel)

– “Rydlyme” (recommended for best results)

(available online www.rydlyme.com) or “CLR” (available at most hardware stores)

1. Shut the boiler down and access the heat exchanger using the following steps:

a. Close the manual gas shutoff valve and wait for

the unit to be cool to the touch.

b. Disconnect the condensate piping from the outside

connections (not from the P

UREFIRE

side) so the

flow can be observed.

c. Disconnect compression nut on gas valve inlet

and disconnect the gas valve electrical connector.

d. Remove the six 10 mm nuts from the burner

plate assembly. Disconnect wire leads to the spark igniter and flame sensor. Disconnect two Molex plugs from blower motor.

e. Pull the entire burner plate towards you to access

the heat exchanger coils.

2. Using a spray bottle filled with the recommended product “Rydlyme” or “CLR”, spray liberally on the coils, making sure the solution penetrates and funnels down through the condensate hose. If the condensate hose is blocked, let the chemical penetrate for at least 15 minutes or until it drains.

3. Use the nylon or brass brush (do not use steel) and scrub coils to remove any buildup, then vacuum the debris from the coils.

4. Spray coils with clear water, making sure to confine the spray to the area being cleaned (try to avoid wetting the back ceramic wall of the unit). Flush the combustion chamber with fresh water. At this point, the P

UREFIRE

should be ready to power back up.

5. Reinstall the burner plate assembly using the following steps:

a. Inspect the inside of the heat exchanger for dirt

and debris.

b. Install the burner plate assembly and replace the

six 10 mm nuts.

c. Reconnect the wire leads to the spark igniter,

flame sensor and gas valve. (Be sure that the spark igniter is connected to the lead with the large insulated connection boot.) Reconnect two Molex plugs on blower motor.

d. Connect the compression nut on the gas valve

inlet and reattach the gas valve electrical connector.

e. Reset thermostats. (IMPORTANT: BE SURE

THAT THE VENT CONNECTION IS NOT BLOCKED.)

f. Turn the power to the P

UREFIRE

on. Observe the

display module to assure proper operation.

g. Initiate a call for heat** and observe the

condensate flow.

h. Reconnect the 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 integrity. Repair as necessary. Refer to Section 5, VENTING.

7. Inspect exhaust vent and air intake vent terminations for obstructions or corrosion. Corrosion is an indication of exhaust gas recirculation.

It is extremely important to make sure there is no blockage in the exhaust vent. Failure to do so may result in serious personal injury or death.

WARNING

It is extremely important to check for leaks when reconnecting the gas valve. Failure to do so may result in severe personal injury, death or major property damage.

WARNING

Leaks in the vent system will cause products of combustion to enter structure (vent system operates under positive pressure).

WARNING

BOILER DIMENSIONS & RATINGS

12. BOILER DIMENSIONS & RATINGS

Table 12.1: Boiler Dimensions

SERIES PEERLESS®PUREFIRE®DIMENSIONS (INCHES)

Boiler

Model

“A” “B” “C” “D” “E” “F” “G” “H” “J ” “K” “L”

PF-50 13-1/2 – 3-3/4 – – – – – – – –

PF-80 13-1/2 – 4-3/4 – – – – – – – –

PF-110 19 – 7-1/2 – – – – – – – –

PF-140 19 – 10-1/2 – – – – – – – –

PF-210 16-1/2 1-3/4 3-1/2 2-1/4 8-1/2 8-1/2 4-1/2 3 6-1/2 3 1

PF-399 28 2-3/4 7 2 19-3/4 8-1/2 5-1/4 3-1/2 5-3/4 4 1-1/2

Figure 12.1: Dimensional Drawing – PF-50, PF-80, PF-110 & PF-140

Table 12.2: Boiler Ratings

SERIES PEERLESS®PUREFIRE®BOILER RATINGS

Boiler Model

Input

(MBH)

Heating

Capacity

(MBH)

Net I=B=R

Rating (MBH)

AFUE

(%)

Min. Max.

PF-50 16 50 46 40 95.09

PF-80 26 80 73 63 95.22

PF-110 36 110 101 88 95.84

PF-140 46 140 130 113 95.38

PF-210 42 210 192 167 97.30

Gross

Output

(MBH)

Net I=B=R

Rating (MBH)

Thermal

Efficiency

(%)

Combustion

Efficiency

(%)

PF-399 80 399 373 324 93.4 95.5

BOILER DIMENSIONS & RATINGS

Table 12.3: Combustion Air Fan Speeds

SERIES PEERLESS®PUREFIRE®COMBUSTION AIR FAN SPEEDS

Boiler Model

Input

Rate

Fan Speed

Low Power Ignition High Power

PF-50 50 MBH 1410 2800 3360

PF-80 80 MBH 1890 3250 4800

PF-110 110 MBH 1980 3250 5280

PF-140 140 MBH 1770 3250 4800

PF-210 210 MBH 1350 3250 6150

PF-399 399 MBH 1710 3250 7740

Figure 12.2: Dimensional Drawing – PF-210 & PF-399

Table 12.4: PUREFIRE®Main Control Specifications

SERIES PEERLESS®PUREFIRE®MAIN CONTROL SPECIFICATIONS

Power Supply 120 VAC Nominal (102-132 VAC) 60 Hz Fuse (5650) 3.15 Amp, 250 VAC Blower Voltage 120 VAC Gas Valve Voltage 120 VAC Thermostat Contacts 24 VAC DHW Contacts 24 VAC

Flame Current Limits

Minimum (running): 2.8 µA Minimum (ignition): 3.1 µA Maximum: 10 µA

Temperature Sensors

All PUREFIRE®NTC thermistors are 12k W @ 77°F (25°C). They operate on 5 VDC. Supply Sensor: 14°F (-10°C) to 244°F (118°C) Return Sensor : 14°F (-10°C) to 244°F (118°C) Flue Sensor: 50°F (10°C) to 280°F (138°C) Outdoor Sensor: -40°F (-40°C) to 185°F (85°C)

Optional Sensors

DHW Sensor: 14°F (-10°C) to 244°F (118°C) System Sensor : 14°F (-10°C) to 244°F (118°C)

Standards

Europe: CE EN298 North America: ANSI Z21.20 / CSA C22.2

Table 12.5: Electrical Ratings

SERIES PEERLESS®PUREFIRE®ELECTRICAL RATINGS

Boiler Model

Supply

Voltage

(-15%, +10%)

Frequency

(±1.2 hz)

Blower Gas Valve Pumps

Max Total

Service

Current to

Boiler

Voltage

(VAC)

Current

(Amps)

Voltage

(VAC)

Current

(Amps)

Voltage

(VAC)

Max.

Current

(Amps)

PF-50 120 VAC 60 hz 120 0.53 120 0.09 120 4.38 5.00

PF-80 120 VAC 60 hz 120 0.53 120 0.09 120 4.38 5.00

PF-110 120 VAC 60 hz 120 0.78 120 0.09 120 4.13 5.00

PF-140 120 VAC 60 hz 120 0.71 120 0.09 120 4.20 5.00

PF-210 120 VAC 60 hz 120 2.58 120 0.09 120 4.50 7.17

PF-399 120 VAC 60 hz 120 2.58 120 0.21 120 4.50 7.29

BOILER DIMENSIONS & RATINGS

This page intentionally left blank.

REPA IR PART S

Repair parts are available from your local PB Heat, LLC distributor or from Parts To Your Door at 1 (610) 916-5380 (www.partstoyourdoor.com).

Note: Remember to include the boiler model number and serial number when ordering parts.

13. REPAIR PARTS

Figure 13.1: General Repair Parts – PF-50, PF-80, PF-110 & PF-140

REPA IR PART S

Table 13.1: General Repair Parts

Description

Quantity

Required

Stock

Code

1 Front Door Panel with Ball Studs 1 54168

2 Control Lens 1 54167

3 Display Module Revision 2 852RC-3R 1 54423

4 Display Bracket Gasket 1 54153

5 Bracket for Display Module 1 PF2007-1

6 Hex Nut, #6-32 with Lockwasher 2 51553

7 Screw, #6-32 x 1/2" LG Phillips Head 2 5449

8 Flexible Gas Line – 1/2" (includes gasket and hardware) 1 54203

9 Gasket for Gas Line 1 54142

10 Nipple, 1" NPT x Close 1 99211

11 Manual Shut-off Valve, 1/2" NPT 1 54130

12 Screw, #10 x 1/2" Long Hex. Hd. 2 99992

13 Coupling, 1" NPT Brass 2 5534

14 Nipple, 1" NPT x 6" Long Brass 2 5533

Jacket Side Panels – PF-50, PF-80 1 54173

Jacket Side Panels – PF-110, PF-140 1 54192

17 Bulk Head Fitting for Condensate Connection 1 54140

18 Gasket for Bulk Head Fitting 1 54134

19 Leg Leveler 4 5429

20 Hook Bolt 2 5451

21 Convenience Outlet 1 54136

22 Hex. Nut, #8-32 with Lockwasher 4 51573

Control Module, 852MN Kit – PF-50 Revision 0 1 54265

Control Module, 852MN Kit – PF-80 Revision 0 1 54266

Control Module, 852MN Kit – PF-110 Revision 0 1 54267

Control Module, 852MN Kit – PF-140 Revision 0 1 54268

Control Module, 852MN Kit – PF-50 Revision 1 & 2 1 54282

Control Module, 852MN Kit – PF-80 Revision 1 & 2 1 54283

Control Module, 852MN Kit – PF-110 Revision 1 & 2 1 54284

Control Module, 852MN Kit – PF-140 Revision ! & 2 1 54285

24 Switch, Round Toggle, 120 VAC 1 6049

25 Vent / Air Inlet Adapter, 3" 1 54135

26 Gasket, Vent Adapter, 3" 1 54133

27 Screw, #10 x 5/8" Long Phil. Pan Head Type A Zinc 6 5507

28 Condensate Receiver Kit 1 54205

29 Condensate Neutralizer Kit 1 54204

– Wiring Harness, Power (Right Terminal Block) 1 PF7002

– Wiring Harness, Control (Left Terminal Block) 1 PF7003

– Wiring Harness, Blower 1 PF7005

– Wiring Harness, Ground Wire 1 PF7009

– Push-on Terminal Block (for Field Wiring Connections) 2 5450

– Ignition Cable 1 54115

– Relief Valve 1 50664

– Flue Sensor, 12kOhm Tasseron TSDZ0B1 1 54111

– Supply Sensor/Switch, 12kOhm Tasseron Kit 1 54299

– Return Sensor, 12kOhm Tasseron TSD00BS 1 54418

– Outdoor Sensor, 12kOhm Tasseron TSA00B4 1 54112

– DHW Sensor, 12kOhm Tasseron TSK10BH 1 54157

– System Sensor, 12kOhm Tasseron TSA00BC 1 54156

REPA IR PART S

Figure 13.2: Heat Exchanger/Burner Assembly Repair Parts – PF-50, PF-80, PF-110 & PF-140

REPA IR PART S

Table 13.2: Heat Exchanger/Burner Assembly Repair Parts – PF-50, PF-80, PF-110 & PF-140

Description

Quantity

Required

Stock

Code

Burner – PF-50 1 54174 Burner – PF-80 1 54175 Burner – PF-110 1 54176

Burner – PF-140 1 54177 44 Combustion Chamber Cover Plate, includes items #45-#47 1 54183 45 Gasket, Glass Rope 1 54188 46 Gasket, Rubber 1 54187 47 Insulation, Combustion Chamber Cover Plate 1 54184 50 Insulation, Target Wall 1 54185

Heat Exchanger – PF-50 1 5410

Heat Exchanger – PF-80 1 5411

Heat Exchanger – PF-110 1 5412

Heat Exchanger – PF-140 1 5413 52 Gasket, Blower to Channel 1 54122

Blower – PF-50, PF-80 1 54189

Blower – PF-110 1 54190

Blower – PF-140 1 54191 55 Blower Adapter Plate 1 5421

Swirl Plate – PF-50, Blue 1 54144

Swirl Plate – PF-80, Black 1 54143

Swirl Plate – PF-110, White 1 54145

Swirl Plate – PF-140, Red 1 54146

Gas Valve – PF-50, w/ Mtg. Flange, Swirl Plate & Screws 1 54178

Gas Valve – PF-80, w/ Mtg. Flange, Swirl Plate & Screws 1 54179

Gas Valve – PF-110, w/ Mtg. Flange, Swirl Plate & Screws 1 54180

Gas Valve – PF-140, w/ Mtg. Flange, Swirl Plate & Screws 1 54181

Vent Termination Kits

– 3"SS Vent Termination Kit 1 54161 – 4"SS Vent Termination Kit 1 91401 – CPVC Vent/Inlet Adapter 1 54135 – Poly-Propylene Vent/Inlet Adapter 1 54155 – 3" Vent Perf Stainless Steel Screen 1 54150 – PVC 3" DWV P400-030 Tee 1 54151 – PVC 3" DWV P100-030 Coupling 1 54152 – PVC 3" Concentric Termination 1 91403

Poly-Propylene Venting

–

80/125mm White Concentric Sidewall Vent kit – Includes Concentric Vent Termination,

Outer Wall Bracket, Inner Wall Bracket with Securing Tab and Screws

– 54396

–

100/150mm White Concentric Sidewall Vent kit – Includes Concentric Vent Termination, Outer Wall Bracket,

Inner Wall Bracket with Securing Tab and Screws

– 54397

– 80/125mm White, Black Concentric Vertical Termination – 54398 – 100/150mm White, Black Concentric Vertical Termination – 54399 – 80/100 White Concentric 90 Degree Elbow with Locking Band – 54085 – 100/150 White Concentric 90 Degree Elbow with Locking Band – 54435

–

Concentric Adapter Kit – 3" PVC to 80/125mm – Kit Includes 2 PVC to PP Adapters,

1 Two-pipe Adapter and (1) 80 x 500mm PP Pipe Length

– 54296

–

Concentric Adapter Kit – 4" PVC to 100/150mm – Kit Includes 2 PVC to PP Adapters,

1 Two-pipe Adapter and (1) 100 x 500mm PP Pipe Length

– 54297

Miscellaneous

– Large Clamp Hose 1 54138 – Small Clamp Hose 1 54139 – Condensate Neutralizer 1 54121 – Electric Panel MNT Receptacle 1 54136 – Burner Mounting Plate Kit PUREFIRE 1 54128 – Switch Condensate Float w/ Cap Switch 1 54137 – Condensate Collector 1 54120 – Wall Mounting Kit 1 5636 – Gas Line Flex Kit w/ 1-1/2" NPT 1 54203

REPA IR PART S

Figure 13.3: General Repair Parts – PF-210 & PF-399

REPA IR PART S

Table 13.3: General Repair Parts – PF-210 & PF-399

Description

Quantity

Required

Stock

Code

1 Panel, Jacket Front Door, with Ball Studs 1 54256 2 Lens for Jacket Front Door 1 54167 3 Display Module, Argus 852RC 1 54281 4 Gasket for Display Bracket 1 54153 5 Bracket for Display Module 1 PF2007-1 6 Hex Nut, #6-32 with Lockwasher 2 51553 7 Screw, #6-32 x 1/2" LG Phillips Head 2 5449

Flexible Gas Line – 1/2" – PF-210 1 54261

Flexible Gas Line – 3/4" – PF-399 1 54262

9 Gasket for Gas Line 1 54142 10 Manual Shut-off Valve, 3/4" NPT 1 54210 11 Screw, #10 x 1/2" LG Hex. Hd. 2 99992 12 Jacket, Lower Front Panel 1 PF6051

Jacket Side Panel – PF-210 1 54244

Jacket Side Panel – PF-399 1 54245 14 Bulk Head Fitting for Condensate Hose 1 54140 15 Gasket for Bulk Head Fitting 1 54134 16 Leg Leveler 4 5429

Coupling, 1" NPT Brass – PF-210 2 5534

Coupling, 1-1/2" NPT Brass – PF-399 2 5551

Nipple, 1" NPT x 14" LG Brass – PF-210 2 5557

Nipple, 1-1/2" NPT x 14" LG Brass – PF-399 2 5550

Elbow, 1" NPT Brass – PF-210 1 5558

Elbow, 1-1/2" NPT Brass – PF-399 1 5553

Tee, 1" NPT Brass – PF-210 1 5537

Tee, 1-1/2" NPT Brass – PF-399 1 5554

Nipple, 1" NPT x 3" Brass – PF-210 2 5559

Nipple, 1-1/2" NPT x 3" Brass – PF-399 2 5552

Reducing Bushing, 1" x 3/4" NPT Brass – PF-210 1 5539

Reducing Bushing, 1-1/2" x 3/4" NPT Brass – PF-399 1 5556 23 Shut-off Valve, 3/4" NPT Brass 1 50764 24 Nipple, 3/4" NPT x 16" LG Brass 1 5560 25 Convenience Outlet 1 54136 26 Hex. Nut, #8-32 with Lockwasher 4 51573

Control Module, 852MN – PF-210 1 54286

Control Module, 852MN – PF-399 1 54287 28 Switch, Round Toggle, 120 VAC 1 6049

Vent / Air Inlet Adapter, 3" – PF-210 1 54200

Vent / Air Inlet Adapter, 4" – PF-399 1 54201

Gasket, Vent Adapter, 3" – PF-210 1 54216

Gasket, Vent Adapter, 4" – PF-399 1 54217 31 Screw, #10 x 3/4" LG Phillips Pan Hd. Type A Zinc 6 5611

Vent Stub, 3" – PF-210 1 54221

Vent Stub, 4" – PF-399 1 54220

Heat Exchanger Outlet Collar, 3" – PF-210 1 5531

Heat Exchanger Outlet Collar, 4" – PF-399 1 5532 34 Condensate Neutralizer Assembly 1 54204 35 Condensate Receiver Assembly 1 54259 36 Blocked Vent Switch includes items 37 & 38 1 54260 37 3/16" ID Tubing x 12" Long 1 5563 38 90° Barbed Elbow Adapter Fitting 1 5564

– Wiring Harness, Power (Right Terminal Block) 1 PF7022 – Wiring Harness, Control (Left Terminal Block) 1 PF7021 – Wiring Harness, Gas Valve & Flame Sensor 1 PF7023 – Wiring Harness, Ground Wire 1 PF7024 – Push-on Terminal Block (Field Wiring) 10-pole 2 5450 – Push-on Terminal Block (Field Wiring) 6-pole 2 5547 – Ignition Cable 1 54115 – Relief Valve 1 50664 – Flue Sensor, 12kOhm Tasseron TSDZ0B0 1 54209 – Flue Sensor Grommet 1 54291 – Supply Sensor/Switch, 12kOhm Tasseron Kit 1 54299 – Return Sensor, 12kOhm Tasseron TSD00BS 1 54418 – Outdoor Sensor, 12kOhm Tasseron TSA00B4 1 54112

Figure 13.4: Heat Exchanger/Burner Assembly Repair Parts – PF-210 & PF-399

REPA IR PART S

Table 13.4: Heat Exchanger/Burner Assembly Repair Parts – PF-210 & PF-399

Description

Quantity

Required

Stock

Code

1 Ignitor, with Gasket 1 54246 2 Sensor, with Gasket 1 54247

Premix Channel – PF-210 1 54249

Premix Channel – PF-399 1 54250

6 Gasket, Channel to Burner 1 54186

Burner – PF-210 1 54263

Burner – PF-399 1 54264

9 Combustion Chamber Cover Plate, includes items #10-#12 1 54248 10 Gasket, Glass Rope 1 54188 11 Gasket, Rubber 1 54187 12 Insulation, Combustion Chamber Cover Plate 1 54255 15 Insulation, Target Wall 1 54185

Heat Exchanger – PF-210 1 5529 Heat Exchanger – PF-399 1 5530

17 Gasket, Blower to Channel 1 54122

Blower – PF-210 1 54258 Blower – PF-399 1 54257

Blower Adapter Plate – PF-210 1 5421 Blower Adapter Plate – PF-399 1 5610

Swirl Plate – PF-210, Grey 1 54251 Swirl Plate – PF-399, Black 1 54252

Gas Valve – PF-210, includes item #22 1 54253 Gas Valve – PF-399, includes item #22 1 54254

APPENDIX A. STATUS SCREENS

APPENDIX B. USER MENU

APPENDIX C. INSTALLER MENU

APPENDIX D. COMBUSTION TEST RECORD

Contact:

Company Name:

Address:

Phone Number:

Fax Number:

Email Address:

Jobsite Data

Job Name:

Jobsite Address:

Boiler Data

Boiler Model: Boiler Serial No.:

Manufacture Date: Startup Date:

Gas Pressure

Static Inlet Gas Pressure

(in. w.c.) [With Boiler Off]:

Inlet Gas Pressure

Drop After Boiler Startup

(in. w.c.):

High Fire Outlet Gas

Pressure (in. w.c.):

Low Fire Outlet Gas

Pressure (in. w.c.):

Combustion Readings

Flame Signal

High Fire (µA):

Flame Signal

Low Fire (µA):

CO²High Fire (%): CO²Low Fire (%):

CO High Fire (ppm): CO Low Fire (ppm):

Fan Speed High Fire: Fan Speed Low Fire:

Excess Air

High Fire (%):

Excess Air

Low Fire (%):

Exhaust Temperature

High Fire (°F):

Exhaust Temperature

Low Fire (°F):

System Information

Water Pressure: Condensate Line Size:

Vent Length

(Total Equivalent Feet):

Vent Diameter:

Peerless®PUREFIRE®Combustion Test Record

APPENDIX D. COMBUSTION TEST RECORD

BoilersGas

Installation, Operation & Maintenance Manual

TO THE INSTALLER:

This manual is the property of the owner and must be affixed near the boiler for future reference.

TO THE OWNER:

This boiler should be inspected annually by a Qualified Service Agency.

PF8080 R8 (6/11-2M)

Printed in U.S.A.

PB HEAT, LLC

131 S. CHURCH STREET • BALLY, PA 19503

CONTROLS

ASME

PF-50 PF-80 PF-110 PF-140 PF-210 PF-399

PUREFIRE

REV

PEERLESS PF-50, PF-80, PF-110, PF-140, PF-210 Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual