PEERLESS PUREFIRE PF-850, PUREFIRE PF-1000, PureFirePF-1500 Installation, Operation & Maintenance Manual
PUREFIRE
®
Boilers
PF-850 PF-1000
Gas
Installation,
Operation &
Maintenance
Manual
®
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 . . . . . . . . . .3
E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . . . . .6
2. BOILER SET-UP 7
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
B. STACKING MULTIPLE BOILERS . . . . . . . . . . . . .7
3. VENTING & AIR INLET PIPING 8
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
B. APPROVED MATERIALS . . . . . . . . . . . . . . . . . . .8
C. EXHAUST VENT/AIR INTAKE
PIPE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . .8
D. EXHAUST VENT/AIR INTAKE PIPE SIZING . . . .12
E. EXHAUST VENT/AIR INTAKE PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .12
F. TEST PORT FOR EXHAUST SAMPLING . . . . . .13
G. COMMON VENTING MULTIPLE BOILERS . . . .13
H. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . .14
4. WATER PIPING & CONTROLS 15
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
B. OPERATING PARAMETERS . . . . . . . . . . . . . . . .15
C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . .15
D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . . . . .19
E. FREEZE PROTECTION . . . . . . . . . . . . . . . . . . . .19
F. SPECIAL APPLICATIONS . . . . . . . . . . . . . . . . . .24
5. FUEL PIPING 25
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . . . . .25
C. GAS SUPPLY PIPING – INSTALLATION . . . . . .25
D. GAS SUPPLY PIPING – OPERATION . . . . . . . . .26
E. MAIN GAS VALVES – OPERATION . . . . . . . . . .27
6. CONDENSATE TRAP & DRAIN SYSTEM 28
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
B. CONDENSATE SYSTEM . . . . . . . . . . . . . . . . . .28
C. CONDENSATE DRAIN PIPING . . . . . . . . . . . . . .28
7. ELECTRICAL CONNECTIONS &
INTERNAL WIRING 30
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
B. CUSTOMER CONNECTIONS . . . . . . . . . . . . . . .30
C. ZONE CIRCULATOR WIRING . . . . . . . . . . . . . . .31
D. INTERNAL WIRING . . . . . . . . . . . . . . . . . . . . . .31
8. BOILER CONTROL: OPERATION 34
A. IGNITION SEQUENCE . . . . . . . . . . . . . . . . . . . .34
B. STATUS DISPLAY . . . . . . . . . . . . . . . . . . . . . . . .36
C. USER MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
D. INSTALLER MENU . . . . . . . . . . . . . . . . . . . . . . .41
E. DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
F. MULTIPLE BOILERS . . . . . . . . . . . . . . . . . . . . . .53
9. START-UP PROCEDURE 57
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
B. CHECK WATER PIPING . . . . . . . . . . . . . . . . . . .57
C. CHECK ELECTRIC POWER . . . . . . . . . . . . . . . .57
D. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . . . . .57
E. CHECK OPERATION . . . . . . . . . . . . . . . . . . . . . .57
F. COMBUSTION TEST . . . . . . . . . . . . . . . . . . . . .57
G. TEST OPERATING LIMIT . . . . . . . . . . . . . . . . . .58
H. TEST HIGH LIMIT . . . . . . . . . . . . . . . . . . . . . . . .59
I. MULTIPLE BOILER SYSTEMS . . . . . . . . . . . . . .59
J. LIGHTING & OPERATING INSTRUCTIONS . . . .59
10. TROUBLESHOOTING 61
A. ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
B. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . . . . .61
C. LOCKING ERRORS . . . . . . . . . . . . . . . . . . . . . . .61
D. WARNING ERRORS . . . . . . . . . . . . . . . . . . . . . .61
E. SPECIAL IGNITION/FLAME FAILURE . . . . . . . .62
F. INTERLOCKS OPEN . . . . . . . . . . . . . . . . . . . . . .62
11. MAINTENANCE 69
A. GENERAL (WITH BOILER IN USE) . . . . . . . . . .70
B. WEEKLY (WITH BOILER IN USE) . . . . . . . . . . . .70
C. ANNUALLY (BEFORE THE START OF
HEATING SEASON) . . . . . . . . . . . . . . . . . . . . . .70
D. CONDENSATE SYSTEM CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .70
E. COMBUSION CHAMBER COIL CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .71
12. BOILER DIMENSIONS & RATINGS 73
13. REPAIR PARTS 76
APPENDIX A. PIXEL DISPLAY SCREEN 86
A. STAND ALONE PIXEL DISPLAY . . . . . . . . . . . .86
B. MULTIPLE BOILER (CASCADE) PIXEL
DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
APPENDIX B. BURNER LCD STATUS
SCREENS 88
APPENDIX C. USER MENU 90
APPENDIX D. INSTALLER MENU
STRUCTURE 92
APPENDIX E. COMBUSTION TEST
RECORD 94
SERVICE LOG 95
TABLE OF CONTENTS
TABLE OF CONTENTS
A. INSTALLATION SEQUENCE
Follow the installation instructions provided in this manual
in the order shown. The order of these instructions has
been set in order to provide the installer with a logical
sequence of steps that will minimize potential
interferences and maximize safety during boiler
installation.
B. SPECIAL ATTENTION BOXES
Throughout this manual special attention boxes are
provided to supplement the instructions and make special
notice of potential hazards. The definition of each of
these categories, in the judgement of PB Heat, LLC
are as follows:
USING THIS MANUAL
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
NOTICE
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
CAUTION
DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING
1
USING THIS MANUAL
A. GENERAL
1. PUREFIRE®boilers are supplied completely assembled
as packaged boilers. The package should be inspected
for damage upon receipt and any damage to the unit
should be reported to the shipping company and
wholesaler. This boiler should be stored in a clean, dry
area.
2. Carefully read these instructions and be sure to
understand the function of all connections prior to
beginning installation. Contact your PB Heat, LLC
Representative for help in answering questions.
3. This boiler must be installed by a qualified contractor.
The boiler warranty may be voided if the boiler is not
installed correctly.
4. A hot water boiler installed above radiation or as
required by the Authority having jurisdiction, must be
provided with a low water fuel cut-off device either as
part of the boiler or at the time of installation.
B. CODES & REGULATIONS
1. Installation and repairs are to be performed in strict
accordance with the requirements of state and local
regulating agencies and codes dealing with boiler and
gas appliance installation.
2. In the absence of local requirements the following
should be followed:
a. ASME Boiler and Pressure Vessel Code, Section
IV - “Heating Boilers”
b. ASME Boiler and Pressure Vessel Code, Section
VI - “Recommended Rules for the Care and
Operation of Heating Boilers”
c. ANSI Z223.1/NFPA 54 - “National Fuel Gas Code”
d. ANSI/NFPA 70 - “National Electrical Code”
e. ANSI/NFPA 211 - “Chimneys, Fireplaces, Vents
and Solid Fuel Burning Appliances”
3. Where required by the authority having jurisdiction,
the installation must conform to the Standard for
Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1.
**Please read if installing in Massachusetts**
Massachusetts requires manufacturers of Side Wall
Vented boilers to provide the following information
from the Massachusetts code:
·
A hard wired carbon monoxide detector with an
alarm and battery back-up must be installed on
the floor level where the gas equipment is to be
installed AND on each additional level of the
dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment.
·
In the event that the side wall horizontally vented
gas fueled equipment is installed in a crawl space
or an attic, the hard wired carbon monoxide
detector with alarm and battery back-up may be
installed on the next adjacent floor level.
·
Detector(s) must be installed by qualified licensed
professionals.
·
APPROVED CARBON MONOXIDE
DETECTORS: Each carbon monoxide detector
shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.
·
SIGNAGE: A metal or plastic identification plate
shall be permanently mounted to the exterior of
the building at a minimum height of eight (8) feet
above grade directly in line with the exhaust vent
terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall
read, in print size no less than one-half (1/2) inch
in size, “GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS”.
·
EXEMPTIONS to the requirements listed above:
°
The above requirements do not apply if the
exhaust vent termination is seven (7) feet or
more above finished grade in the area of the
venting, including but not limited to decks and
porches.
°
The above requirements do not apply to a
boiler installed in a room or structure separate
from the dwelling, building or structure used in
whole or in part for residential purposes.
·
This boiler installation manual shall remain with
the boiler at the completion of the installation.
See the latest edition of Massachusetts Code 248 CMR
for complete verbiage and also for additional (non-vent
related) requirements (248 CMR is available online).
If your installation is NOT in Massachusetts, please
see your authority of jurisdiction for requirements that
may be in effect in your area. In the absence of such
requirements, follow the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.
2
PREINSTALLATION
1. PREINSTALLATION
Liquefied Petroleum (LP) Gas or Propane is heavier
than air and, in the event of a leak, may collect in low
areas such as basements or floor drains. The gas
may then ignite resulting in a fire or explosion.
WARNING
C. ACCESSIBILITY CLEARANCES
1. The PUREFIRE®boiler is certified for closet installations
with zero clearance to combustible construction. In
addition, it is design certified for use on combustible
floors. Do not install on carpeting.
2. Figure 1.1 shows the minimum recommended
clearances to allow reasonable access to the boiler for
inspection and maintenance. However, local codes or
special conditions may require greater clearances.
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). Combustion
air can be supplied from within the building only if
adequate combustion 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 codes.
2. If the combustion air is piped directly to the boiler
from outside the building, no additional combustion
or ventilation air is required. Otherwise, follow the
National Fuel Gas Code recommendations
summarized in subsections 3 through 10.
3. Required Combustion Air Volume: The total required
volume of indoor air is to be the sum of the required
volumes for all appliances located within the space.
Rooms communicating directly with the space in
which the appliances are installed and through
combustion air openings sized as indicated in
Subsection 3 are considered part of the required
volume. The required volume of indoor air is to be
determined by one of two methods.
a. Standard Method
: The minimum required volume
of indoor air (room volume) shall be 50 cubic feet
per 1000 BTU/Hr (4.8 m3/kW). This method is to
be used if the air infiltration rate is unknown or if
the rate of air infiltration is known to be greater
than 0.6 air changes per hour. As an option, this
method may be used if the air infiltration rate is
known to be between 0.6 and 0.4 air changes per
hour. If the air infiltration rate is known to be
below 0.4 then the Known Air Infiltration Rate
Method must be used. If the building in which this
appliance is to be installed is unusually tight, PB
Heat recommends that the air infiltration rate be
determined.
b. Known Air Infiltration Rate Method
:
where:
I
fan
= Input of the fan assisted appliances
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.
3
PREINSTALLATION
Figure 1.1: Minimum Accessibility Clearances – PF-850, PF-1000
15 ft
3
I
fan
ACH 1000
Btu
/
hr
Required Volume
fan
=
⎛
⎜
⎝
⎛
⎜
⎝
4. Indoor Air Opening Size and Location: Openings
connecting indoor spaces shall be sized and located as
follows:
a. Combining Spaces on the Same Floor
: Provide
two permanent openings communicating with
additional spaces that have a minimum free area
of 1 in
2
per 1000 Btu/hr (22 cm2per 1000 W) of
the total input rating of all gas fired equipment but
not less than 100 in
2
(645 cm2). One opening is
to begin within 12 inches (305 mm) from the top
of the space and the other is to begin within 12
inches (305 mm) from the floor. The minimum
dimension of either of these openings shall be 3
inches (76 mm). See Figure 1.2 for an illustration
of this arrangement.
b. Combining Spaces on Different Floors
: Provide
one or more permanent openings communicating
with additional spaces that have a total minimum
free area of 2 in
2
per 1000 Btu/hr (44 cm2per
1000 W) of total input rating of all equipment. See
Figure 1.3 for an illustration of this arrangement.
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 in
2
per
4000 Btu/hr (22 cm
2
per 4000 W) of total input
rating for all equipment in the space. See Figure
1.4 for openings directly communicating with
the outdoors or Figure 1.5 for openings
connected by ducts to the outdoors.
4
Figure 1.4: Air Openings – All Air Directly from
Outdoors
Figure 1.5: Air Openings – All Air from Outdoors
through Vertical Ducts
PREINSTALLATION
Figure 1.2: Air Openings – All Air from Indoors
on the Same Floor
Figure 1.3: Air Openings – All Air from Indoors
on Different Floors
ii. Where communicating with the outdoors
through horizontal ducts, each opening shall
have a minimum free area of 1 in
2
per 2000
Btu/hr (22 cm2per 2000 W) of total rated
input for all appliances in the space. See
Figure 1.6.
b. One Permanent Opening Method
: Provide one
permanent opening beginning within 12 inches
(305 mm) of the top of the space. The opening
shall communicate directly with the outdoors,
communicate through a vertical or horizontal duct,
or communicate with a space that freely
communicates with the outdoors. The opening
shall have a minimum free area of 1 in
2
per 3000
Btu/hr of total rated input for all appliances in the
space and not less than the sum of the crosssectional areas of all vent connectors in the space.
The gas-fired equipment shall have clearances of
at least 1 inch (25 mm) from the sides and back
and 6 inches (150 mm) from the front of the
appliance. See Figure 1.7 for this arrangement.
6. Combination Indoor and Outdoor Combustion Air: If
the required volume of indoor air exceeds the
available indoor air volume, outdoor air openings or
ducts may be used to supplement the available indoor
air provided:
a. The size and location of the indoor openings
comply with Subsection 3.
b. The outdoor openings are to be located in
accordance with Subsection 4.
c. The size of the outdoor openings are to be sized
as follows:
where:
A
req
= minimum area of outdoor openings.
A
full
= full size of outdoor openings calculated
in accordance with Subsection 4.
V
avail
= available indoor air volume
V
req
= required indoor air volume
7. Engineered Installations: Engineered combustion air
installations shall provide an adequate supply of
combustion, ventilation, and dilution air and shall be
approved by the authority having jurisdiction.
8. Mechanical Combustion Air Supply:
a. In installations where all combustion air is
provided by a mechanical air supply system, the
combustion air shall be supplied from the
outdoors at the minimum rate of 0.35 ft
3
/min per
1000 Btu/hr (0.034 m
3
/min per 1000 W) of the
total rated input of all appliances in the space.
b. In installations where exhaust fans are installed,
additional air shall be provided to replace the
exhaust air.
c. Each of the appliances served shall be interlocked
to the mechanical air supply to prevent main
burner operation when the mechanical air supply
system is not in operation.
d. In buildings where the combustion air is provided
by the mechanical ventilation system, the system
shall provide the specified combustion air rate in
addition to the required ventilation air.
9. Louvers & Grills:
a. The required size of openings for combustion,
ventilation, and dilution air shall be based on the
net free area of each opening.
i. Where the free area through a louver or grille
is known, it shall be used in calculating the
opening size required to provide the free area
specified.
ii. Where the free area through a louver or grille
is not known, it shall be assumed that wooden
louvers will have 25% free area and metal
louvers and grilles will have 75% free area.
iii. Non-motorized dampers shall be fixed in the
open position.
b. Motorized dampers shall be interlocked with the
equipment so that they are proven in the full open
position prior to ignition and during operation of
the main burner.
5
Figure 1.6: Air Openings – All Air from Outdoors
through Horizontal Ducts
Figure 1.7: Air Openings – All Air from Outdoors
through One Opening
PREINSTALLATION
A
req
= A
full
x 1 –
V
avail
V
req
⎛
⎜
⎝
⎛
⎜
⎝
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. Combustion air intake openings located on the
exterior of buildings shall have the lowest side of
the combustion air intake opening at least 12
inches (305 mm) above grade.
11. Refer to Section 3 of this manual, Venting & Air Inlet
Piping, for specific instructions for piping the exhaust
and combustion air.
E. PLANNING THE LAYOUT
1. Prepare sketches and notes showing the layout of the
boiler installation to minimize the possibility of
interferences with new or existing equipment, piping,
venting and wiring.
2. The following sections of this manual should be
reviewed for consideration of limitations with
respect to:
a. Venting and Air Inlet Piping: Section 3
b. Water Piping: Section 4
c. Fuel Piping: Section 5
d. Condensate Removal: Section 6
e. Electrical Connections: Section 7
f. Boiler Control: Section 8
g. Boiler Dimensions and Ratings: Section 12
6
PREINSTALLATION
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
7
BOILER SET-UP
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. Many jacket panels on the P
UREFIRE
®
boiler are
removable to allow inspection and maintenance. Do
not attached fixed brackets for piping or wiring on
removable jacket parts. Piping and/or wiring should
not obstruct access to removable panels.
4. Install the boiler level to prevent condensate from
backing up inside the boiler.
5. Use leveling feet to assure that the boiler is completely
level. This will prevent condensate from collecting in
the boiler and causing degradation of the heat
exchanger.
B. STACKING MULTIPLE BOILERS
Identical PF-850 and PF-1000 boilers can be stacked to
save floor space on the installation. Figure 2.1 shows how
the upper boiler is to be attached to the lower boiler.
1. Remove all side jacket panels from the both boilers
and the top jacket panels from the lower boiler.
2. Remove the leveling legs from the boiler to be
installed on top.
3. Lift the upper boiler into place by passing 5 to 10 foot
(2-3 meter) lengths of 1" to 1-1/4" Schedule 40 or 80
steel pipe through the holes provided in the boiler
frame.
4. Insert spacers, washers and bolts (provided) through
the holes provided in the frame of the lower boiler
and thread them into the threaded inserts on the base
of the upper boiler. Figure 2.1 shows this assembly.
Tighten the bolts securely.
5. Replace all the side jacket panels and discard the top
jacket panels from the lower boiler.
2. BOILER SET-UP
Figure 2.1: Stacking and Securing Boilers
This boiler must be installed level to prevent
condensate from backing up inside the boiler.
CAUTION
Do not lift these boilers by hand. Failure to comply
may result in serious injury, death or major property
damage.
WARNING
Figure 2.2: Lifting the Upper Boiler
DO NOT LIFT
BY HAND
FORKLIFT OR
CRANE LIFT ONLY
8
VENTING & AIR INLET PIPING
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 approved for positive pressure
exhaust venting using either indoor air or air piped
from outside. It is ETL Listed as a Category IV
(Positive Pressure, Condensing Exhaust Vent)
Appliance.
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 exhaust
venting in confined spaces such as closet or alcove
installations or vent pipe that passes through attics.
3. Table 3.2 lists appropriate materials for air inlet piping.
Air inlet piping is to be sealed suitably to prevent
introduction of dirt, chemicals or other contaminants
to the inlet air stream.
* 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.
3. VENTING & AIR INLET PIPING
The venting system for this product is to be installed in
strict accordance with these venting instructions.
Failure to install the vent system properly may result in
severe personal injury, death or major property damage.
WARNING
This vent system operates under positive pressure.
Vent connectors serving appliances vented by
natural draft shall not be connected into any portion
of this venting system. Failure to comply may result
in serious injury, death or major property damage.
WARNING
Only the materials listed below are approved for use
with the
P
UREFIRE
®
boiler. Use only these components
in accordance with these instructions. Failure to use
the correct material may result in serious injury,
death, or major property damage.
WARNING
Table 3.1: Approved Materials for Exhaust Vent Pipe
Use of cellular core pipe for any exhaust vent
component is prohibited. Use of cellular core pipe
may result in severe personal injury, death, or major
property damage.
WARNING
If the maximum equivalent vent length is exceeded,
the maximum burner input rate may be reduced.
NOTICE
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
FasNSeal
®
UL-1738 & ULC-S636
MUGRO
®
ULC-S636
Pipe Cement
(PVC & CPVC Only)
PVC/CPVC Cement ANSI/ASTM D2564
Table 3.2: Approved Materials for Air Inlet Piping
Description Material
Air Inlet Pipe
& Fittings
PVC (Cellular Core or Solid)
CPVC
ABS
Smoke Pipe (Galvanized or Steel)
Dryer Vent Pipe
Flexible Duct
Stainless Steel
Polypropylene
VENTING & AIR INLET PIPING
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. 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.
d. 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.
e. The exhaust outlet of the vent pipe should not be
angled any more than 5º from horizontal.
f. 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 4 feet (1.22 m)
clearance distance from any door, operable
window, or gravity air intake into any building.
• Provide a minimum of 6 feet (1.83 m)
clearance to adjacent facing walls.
• 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.
Figure 3.1: Vent Pipe Spacing for Multiple
P
UREFIRE
®
Boilers
Figure 3.2: Exit Terminal Location for Mechanical Draft and Direct-Vent Venting Systems
Condensing flue gases can freeze on exterior
building surfaces which may cause discoloration and
degradation of the surfaces.
CAUTION
9
VENTING & AIR INLET PIPING
b. Figure 3.3, 3.4 and 3.5 show approved sidewall
venting configurations using standard PVC or
CPVC fittings. A similar configuration using
FasNSeal stainless steel exhaust pipe can be used
with either PVC or other approved material for the
combustion air intake piping.
8. Figures 3.6 through 3.8 show recommended vertical
venting configurations.
a. Figure 3.6 illustrates a vertical venting
configuration using PVC inlet and exhaust. A
similar configuration can be constructed using a
FasNSeal stainless steel vent termination. PVC or
other approved materials may be used for air inlet
piping.
i. The opening of the air inlet piping is to be a
minimum of 12" (300 mm) above the
expected snow accumulation on the roof
surface or 24" (600 mm) above the roof
surface, whichever is greater.
ii. Locate the opening of the exhaust vent pipe a
minimum of 12" above the air inlet opening to
prevent flue gas from recirculating to the air
inlet.
b. Figure 3.7 shows vertical exhaust venting through
an unused chimney. In this case, combustion air is
supplied from inside the building. Section 1.D
provides guidelines for determining adequate
inside air.
c. Figure 3.8 illustrates another vertical venting
configuration through an unused chimney. In this
arrangement the combustion air is supplied
through the chimney as well.
Figure 3.3: Sidewall Exhaust Vent and Air Inlet Pipe
Figure 3.5: Offset Sidewall Exhaust Vent and Air
Inlet Pipe
Figure 3.4: Sidewall Exhaust Vent with Indoor Air
10
VENTING & AIR INLET PIPING
Figure 3.6: Vertical Exhaust and Air Inlet Pipe
Figure 3.7: Vertical Exhaust Routed Through an
Unused Chimney with Indoor Air
Figure 3.9: Drain Tee and Air Inlet Connections
Figure 3.8: Vertical Exhaust Routed Through an
Unused Chimney with Outdoor Air
11
D. EXHAUST VENT/AIR INTAKE PIPE SIZING
1. PUREFIRE®boiler models PF-850 and PF-1000 are to
be installed using 6" piping for both exhaust and air
inlet. A list of approved materials for the exhaust are
in Table 3.1 and a list of approved materials for air
inlet are in Table 3.2
2. The total combined length of exhaust vent and air
intake piping is 200 equivalent feet (60 m).
a. The P
UREFIRE
®
PF-850 and PF-1000 may be
provided with room air as long as there is
adequate combustion and ventilation air provided.
See Section 1.D: Combustion and Ventilation Air
of this manual for the minimum requirements. In
this case, a maximum of 200 equivalent feet of
exhaust vent pipe can be used.
b. The equivalent length of elbows, tees and other
fittings are listed in Table 3.3.
c. The total equivalent length can be calculated as
shown in Table 3.4.
E. EXHAUST VENT/AIR INTAKE
INSTALLATION
1. Figure 3.10 shows the exhaust connection on the rear
of the boiler on the vertical centerline. The exhaust
connection is a 6" FasNSeal stainless steel connection.
2. A 6" FasNSeal stainless steel boot tee with a drain
fitting is included with each PF-850 & PF-1000 boiler.
This should be connected directly to the rear of the
boiler as shown below.
3. The Air Intake connection is a 6" galvanized collar to
the right and below the exhaust connection. This can
be connected to any of the approved air intake piping
materials.
4. The Air Intake connection should be secured with (3)
screws and sealed.
5. Remove all burrs and debris from the joints and fittings.
6. Care should be taken to prevent dirt or debris from
entering the air intake connection. A screen is
provided inside the Air Intake fitting to prevent large
objects from entering the combustion system.
7. 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.
Les sections horizontales de l’évacuation doivent être
installées avec une pente d’au moins 1/4 po au pied
(21 mm par mètre) en direction de la chaudière afin
que le condensat puisse s’évacuer du tuyau
d’évacuation. Si le tuyau d’évacuation est acheminé
autour d’un obstacle qui crée un point bas dans la
tuyauterie, il est nécessaire alors d’installer un drain
équipé d'une vidange adéquate.
8. 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.
Tous les tuyaux doivent être parfaitement soutenus.
Utiliser des attaches de tuyau tous les 4 pieds (1,22
mètres) pour éviter le fléchissement des tuyaux.
9. Exhaust and air inlet piping is to be supported
separately and should not apply force to the boiler.
Les tuyaux d’évacuation et d’arrivée d’air doivent
avoir des dispositifs de support distincts et ne pas
exercer de pression sur la chaudière.
10. Penetration openings around the vent pipe and air
intake piping are to be fully sealed to prevent exhaust
gases from entering building structures.
11. 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 PVC or CPVC coupling can be used as an
outside vent termination. In this configuration,
place one of the 6" diameter screens provided
between the coupling and exhaust connection
before gluing it. This is intended to prevent birds
or rodents from entering.
d. A PVC or CPVC tee can be used as an outside air
intake termination. When using this configuration,
place one of the 6" diameter screens provided
between the tee and the air inlet connection
before gluing it. This is intended to prevent birds
or rodents from entering.
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 100' 50' 150'
90° Elbows, SR 2 x 5'= 10' 1 x 5' = 5' 15'
45° Elbows, SR 2 x 3' = 6' 6'
Air Intake Tee 0' 0'
Outlet Coupling 0' 0'
Total 171'
Table 3.4: Sample Equivalent Length Calculation
Table 3.3: Equivalent Length of Fittings
Fitting Description Equivalent Length
Elbow, 90° Short Radiusz 5 feet (1.5 m)
Elbow, 90° Long Radius 4 feet (1.2 m)
Elbow, 45° Short Radius 3 feet (0.9 m)
Coupling 0 feet (0 m)
Air Intake Tee 0 feet (0 m)
12
F. TEST PORT FOR EXHAUST SAMPLING
1. Figure 3.10 shows an illustration of the plugged
sample port on the outlet of the drain tee for the PF850 and PF-1000 boiler.
2. To obtain an exhaust sample during operation,
remove the test port plug and insert the probe from a
suitable combustion analyzer.
3. Be sure to replace the plug before leaving the boiler
unattended.
G. COMMON VENTING MULTIPLE BOILERS
1. Multiple PUREFIRE®PF-850 and PF-1000 boilers may
be connected to a common vent system if they are set
up to operate in the cascade mode described in
Section 8.
a. The boilers must communicate in a
Master/Dependent relationship provided in the
system software.
b. The backflow prevention valves supplied on the
gas/air premix inlet prevent products of
combustion from backing up through the burners
into occupied space.
c. A safety control algorithm will operate the blower
to prevent backflow in case of a backflow
prevention valve failure.
2. Figure 3.11 shows two P
UREFIRE
®
PF-850 boilers
connected with a common vent system.
a. The drain tee from the common vent section
should be trapped and neutralized separately from
the boilers.
b. The condensate drain from each boiler should be
run separately to the drain system to prevent a
clogged condensate line from shutting down
multiple boilers.
c. Table 3.5 shows recommended sizing for common
vent piping.
VENTING & AIR INLET PIPING
Figure 3.11: Multiple Boilers with Common Venting
Table 3.5: Common Exhaust Vent Sizing
Figure 3.10
Number
of Boilers
Boiler Model
PF-850 PF-1000
2 8" 9"
3 10" 12"
4 12" 12"
5 14" 14"
6 14" 16"
7 16" 16"
8 16" 18"
9 18" 18"
10 18" 20"
11 20" 20"
12 20" 22"
13 20" 22"
14 22" 24"
15 22" 24"
16 24" 24"
13
14
VENTING & AIR INLET PIPING
H. BOILER REMOVAL FROM COMMON
VENTING SYSTEM
At the time of removal of an existing boiler, follow these
steps with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation:
Retrait de la chaudière d’un système d’évacuation
commun. Au moment de retirer une chaudière existante,
il est important de suivre les étapes suivantes pour chaque
appareil raccordé au système d’évacuation commun qui
sont en service, alors que les autres appareils demeurant
raccordés au système d’évacuation commun ne sont pas
en service :
1. Seal any unused openings in the common venting
system.
Sceller toute ouverture du système d’évacuation
commun non utilisée.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
Effectuer un contrôle visuel du système d’évacuation
pour vérifier la taille et la pente horizontale et
s’assurer qu’il n’existe aucun blocage ou obstruction,
fuite, corrosion ni tout autre problème pouvant
menacer la sécurité.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building.
Dans la mesure du possible, fermer toutes les portes
et fenêtres de l’immeuble ainsi que toutes les portes
entre l’espace dans lequel les appareils qui demeurent
raccordés au système d’évacuation commun se
trouvent et le reste de l’immeuble.
4. Turn on any clothes dryers and any appliance not
connected to common venting system. Turn on any
exhaust fans, such as range hoods and bathroom
exhausts, so they will operate at maximum speed. Do
not operate a summer exhaust fan.
Mettre en marche les sécheuses et tout autre appareil
non raccordé au système d’évacuation commun.
Mettre en marche tous les ventilateurs aspirant, tels
que les hottes de cuisinière et les ventilateurs de salle
de bain, en les faisant fonctionner à vitesse maximum.
5. Close fireplace dampers.
Ne pas faire fonctionner les ventilateurs aspirant d’été.
Fermer les registres de foyers.
6. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.
Mettre en service l’appareil à inspecter. Suivre les
instructions concernant l’allumage. Régler le
thermostat afin que l’appareil fonctionne sans arrêt.
7. Test for spillage at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar, or
pipe.
Vérifier toute fuite à l’orifice de décharge du coupetirage après que le brûleur ait fonctionné pendant 5
minutes. Utiliser la flamme d’une allumette ou d’une
chandelle ou encore la fumée d’une cigarette, d’un
cigare ou d’une pipe.
8. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas-burning appliance to their previous
conditions of use.
Après avoir établi que les résidus de combustion de
chaque appareil qui demeure raccordé au système
commun sont adéquatement évacués lorsque soumis
au test décrit ci-dessus, remettre en place les portes,
fenêtres, portes intérieures, ventilateurs aspirants,
registres de foyer et appareils fonctionnant au gaz.
9. Any improper operation of the common venting system
should be corrected so that the installation conforms
with the National Fuel Gas Code, ANSI Z223.1/NFPA
54 or CAN/CGA B149 Installation Codes.
Tout fonctionnement inadéquat du système
d’évacuation commun doit être corrigé de manière à
respecter les normes du National Fuel Gas Code,
ANSI Z223.1/NFPA 54 et/ou des Codes d’installation
CAN/ACG B149.
10. When resizing any portion of the common venting
system, the common venting system should be resized
to approach minimum size as determined using the
appropriate tables located in the chapter “Sizing of
Category I Venting Systems,” of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 or CAN/CGA B149
Installation codes.
Lorsqu’il est nécessaire de modifier les dimensions de
toute portion du système d’évacuation commun, ces
dernières doivent être modifiées de manière à
respecter les dimensions minimums indiquées dans les
tableaux du chapitre « Sizing of Category I Venting
Systems » du National Fuel Gas Code, ANSI
Z223.1/NFPA 54 ou des Codes d’installation
CAN/ACG B149.
15
A. GENERAL
1. Size water supply and return piping in accordance
with system requirements. Do not use smaller
diameter piping than the boiler connections.
2. If the P
UREFIRE
®
boiler is used to replace an existing
boiler, make sure that the system piping is thoroughly
cleaned and free from debris before installing this boiler.
3. In hydronic systems where sediment may exist, install
a strainer in the boiler return piping to prevent large
particles and pipe scale from entering the boiler heat
exchanger. Use a large mesh screen in the strainer.
4. Install this boiler so that the gas ignition system
components are protected from water (dripping, spraying,
etc.) during operation and service (circulator replacement,
condensate trap cleaning, sensor replacement, etc.).
B. OPERATING PARAMETERS
1. The PUREFIRE®boiler is designed to operate in a
closed loop hydronic heating system under forced
circulation. This requires the system to be completely
filled with water and requires a minimum water flow
rate through the boiler to assure proper flow
distribution.
2. The minimum system operating pressure is 14.5 PSI
(69 kPa).
3. Table 4.1 lists the minimum flow rates for each
P
UREFIRE
®
model covered in this manual. Also shown
is the minimum flow rate for 50% glycol solution. For
other glycol concentrations, contact your PB Heat,
LLC representative for the minimum flow rates.
4. Section 4.E provides detailed information about using
glycol for freeze protection. Table 4.2 provides the
water volume of the heat exchangers for calculating
the system volume.
C. SYSTEM COMPONENTS
Figure 4.1 shows the symbol key for piping diagrams in
this section. The following are brief descriptions of system
components.
1. Pressure/Temperature Gauge: A combination
pressure/temperature gauge is provided with each
P
UREFIRE
®
boiler to be mounted in the piping from the
boiler supply to the system as shown in Figure 4.2.
Most local codes require this gauge.
2. Air Elimination: Closed loop hydronic systems require
air elimination devices. As the system water is heated,
dissolved oxygen and other gases will separate from
the liquid. An air elimination device (such as a TACO
Vortech
®
Air Separator) is required to remove the
dissolved gases preventing corrosion in the piping
system and eliminating noise.
3. Expansion Tank: An expansion tank (such as a Bell &
Gossett Series HFT) is required to provide room for
expansion of the heating medium (water or glycol
solution). Consult the expansion tank manufacturer's
instructions for specific information regarding
installation. The expansion tank is to be sized for the
required system volume and capacity. In addition, be
sure that the expansion tank is sized based on the
proper heating medium. Glycol solutions may expand
more than water for a similar temperature rise.
4. Y-Type Strainer or Filter Ball
®
Valve: PB Heat
recommends the use of a strainer device in the system to
prevent dirt or sediment from clogging the heat
exchanger. A 20 mesh stainless steel screen is adequate to
protect the heat exchanger. The strainer should be
cleaned often in the first several months of operation. The
Filter Ball
®
Valve from Jomar International incorporates a
strainer into a ball valve which allows the technician to
isolate the water circuit while cleaning the strainer.
5. Flow Control Valve: Flow control valves such as the
TACO Flo-Chek or Bell & Gossett Flo-Control™ are
used to prevent gravity circulation by incorporating a
check valve with a weighted disc.
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-850 39.5 (149.5) 49.4 (187.0)
PF-1000 46.5 (176.0) 58.2 (220.3)
Table 4.1: Minimum Boiler Flow Rates
PUREFIRE
®
Model
Total Water Capacity
Gallons Liters
PF-850 6.2 23.4
PF-1000 7.2 27.1
Table 4.2: Heat Exchanger Water Capacity
WATER PIPING & CONTROLS
16
6. Pressure Reducing Valve: A pressure reducing valve,
such as the Bell & Gossett B-38 or a TACO #329, is
used in a hydronic system to automatically feed water
to the system whenever pressure in the system drops
below the pressure setting of the valve. These valves
should not be used on glycol systems unless close
supervision of the glycol solution is practiced.
7. Back Flow Preventer: A back flow preventer (check
valve) is required by some jurisdictions to prevent water
in the hydronic system from backing up into the city
water supply. This is especially important on systems in
which glycol solution is used as the heating medium.
8. Pressure Relief Valve: The boiler pressure relief valve is
shipped in the miscellaneous parts box for field
installation. It is extremely important to install this device.
The valve is to be installed on the boiler supply pipe
as shown in Figure 4.2. 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 & 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
17
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-850 with a design temperature
difference of 20°F the calculation is as follows:
Output 816,000
Required Flow =
________=_________
= 81.6 GPM
D
T x 500 20 x 500
d. The boiler pressure drop for various flow rates
can be determined using Figure 4.3, the P
UREFIRE
®
PF-850/PF-1000 Sizing Graph.
e. Table 4.4 provides the flow rate and pressure drop
information that corresponds to various boiler
temperature rise values (DT). The pressure drop
shown is for the boiler only. If there is significant
system pressure drop in the piping, this should be
considered when specifying circulators.
WATER PIPING & CONTROLS
Table 4.3: Boiler Input and Output
Figure 4.3: PUREFIRE®Circulator Sizing Graph (General Pump – Primary/Secondary)
Figure 4.2: Relief Valve and Pressure/Temperature
Gauge Installation
PUREFIRE
®
Model
Boiler Input Boiler Output
Btu/hr kW Btu/hr kW
PF-850 850,000 249 817,700 240
PF-1000 1,000,000 293 966,000 283
18
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.
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.
Table 4.4: Flow Rate & Pressure Drop for Various System Temperature Rise Values
DT
(°F)
Flow Rate & Pressure Drop
PF-850 PF-1000
GPM FT cu. m/hr mbar GPM FT cu. m/hr mbar
10 163.5 91.90 37.14 2747 193.2 98.87 43.88 2955
15 109.0 42.65 24.76 1275 128.8 45.37 29.25 1356
20 81.8 24.94 18.57 745 96.6 26.30 21.94 786
25 65.4 16.52 14.86 494 77.28 17.32 17.55 518
30 54.5 11.83 12.38 353 64.4 12.35 14.63 369
35 46.7 8.93 10.61 267 55.2 9.29 12.54 278
40 39.5 6.57 8.97 196 48.3 7.29 10.97 218
Table 4.5: Circulator Selection Chart (General Pump – Primary/Secondary Piping)
Circulator
Manufacturer
DT
(°F) PF-850 PF-1000
Taco
20
1635/1935, 138, 133 1635/1935
Grundfos UPS50-160/2F speed 2 UPS50-160/2F, speed 3
Bell & Gossett PD-38 PD-38
Wilo - Top S (1 Ph) 2.0 x 50 (max) 2.0 x 50 (max)
Wilo - Stratos 2.0 3 x 35 3.0 3 x 30
Taco
25
1635/1935, 132 1635/1935, 132
Grundfos UPS40-80/4F speed 3 UPS50-80/4F, speed 3
Bell & Gossett PL-130 PL-130
Wilo - Top S (1 Ph) 1.5 x 30 (max) 1.5 x 30 (min)
Wilo - Stratos 1.5 3 x 40 1.5 3 x 40
Taco
30
1611/1911, 131, 122, 121 1635/1935, 131
Grundfos UPS50-60F, speed 3 UPS40-80/4F, speed 3
Bell & Gossett 2.5" / LD3 2.5" / LD3
Wilo - Top S (1 Ph) 1.5 x 30 (min) 1.5 x 30 (min)
Wilo - Stratos 1.5 3 x 40 1.5 3 x 40
Taco
35
122, 121 122
Grundfos UPS50-60F, speed 2 UPS50-60F, speed 3
Bell & Gossett PL-75 2.5" / LD3
Wilo - Top S (1 Ph) 1.5 x 20 (max) 1.5 x 20 (max)
Wilo - Stratos 1.25 3 x 30 1.25 3 x 30
Taco
40
120 2400-60/2400-65
Grundfos UPS43-44FC, speed 3 UPS50-60F, speed 2
Bell & Gossett PL-45/NRF-45 PL-45
Wilo - Top S (1 Ph) 1.5 x 20 (min) 1.5 x 20 (min)
Wilo - Stratos 1.25 3 x 30 1.25 3 x 30
WATER PIPING & CONTROLS
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
D. SYSTEM PIPING
1. Figure 4.4 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. An alternate piping schematic for piping an indirect
water heater, such as the Peerless
®
Partner®, is
depicted in Figure 4.5. Note that, in this configuration,
the circulating pump for the indirect tank must be
sized to provide the minimum flow rate of the boiler.
In this configuration, both the GEN and CH
circulation pumps should be wired to the CH Pump
output on the terminal strip. This is required to
prevent the General (Boiler) pump from running when
a DHW demand is being satisfied. The total load of
CH and GEN pumps must not exceed 10 amps. If the
load is higher, then an isolation relay must be used.
3. The configuration illustrated in Figure 4.6 is for
multiple boilers. This figure shows an indirect DHW
tank in parallel with the heating zones. Notice that the
return to the boilers from the closely spaced tees in
the primary secondary arrangement is reverse return
to provide similar lengths of piping through each
boiler. This configuration shows the boilers in groups
of two to take advantage of the P
UREFIRE
®
PF-850 or
PF-1000 stacking capability.
4. Figure 4.7 shows a multiple boiler configuration which
uses zone valves instead of zone circulators. Systems
which combine both zone valves and zone circulators
can help to minimize electrical loads if there are small
zones in the system. Contact your PB Heat, LLC
representative for assistance with larger systems.
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. Table
4.2 provides the water capacity of the heat exchanger
to help in system volume calculations.
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.
WATER PIPING & CONTROLS
19
20
WATER PIPING & CONTROLS
Figure 4.4: Recommended Piping – One Boiler with Multiple CH Zones & One DHW Tank
21
WATER PIPING & CONTROLS
Figure 4.5: Alternate Piping – One Boiler with Multiple CH Zones & One DHW Tank
22
WATER PIPING & CONTROLS
Figure 4.6: Recommended Piping – Multiple Boilers with Multiple CH Zones & One DHW Tank
23
WATER PIPING & CONTROLS
Figure 4.7: Alternate Piping – Multiple Boilers with Multiple CH Zones (Zone Valves) & One DHW Tank
24
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 4.8 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 4.9 for
an illustration.
WATER PIPING & CONTROLS
Figure 4.8: Boiler in conjunction with a Chilled Water System
Figure 4.9: Boiler Connected to a Heating Coil in a Forced Air System
25
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 fuel gas to the boiler can be
determined by the following:
2. As an alternative, use Table 5.1 to determine the
required gas flow rate. This table 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" w.c. pressure drop.
The values shown are based on a natural gas specific
gravity of 0.60.
4. Table 5.3 shows the maximum capacity of pipe sizes
for LP gas with a specific gravity of 1.50.
5. Size the fuel gas supply piping for no more than 0.5
in. w.c. pressure drop between the gas pressure
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 clearance for
removal of the front cover or side panels for
inspection and maintenance.
Boiler Input Rate
Gas Heating Value
Input Rate
(
ft
³
/
hr
)
=
(
Btu
/
hr
)
(
Btu
/
ft
³
)
FUEL PIPING
5. FUEL PIPING
PUREFIRE
®
Model
Required Input Rate
Natural Gas
(@1000 Btu/cu.ft)
LP Gas
(@ 2,500 Btu/cu.ft)
ft3/hr m3/hr ft3/hr m3/hr
PF-850 850 24.1 340 9.6
PF-1000 1000 28.3 400 11.3
Table 5.1: Required Fuel Input
Pipe
Length
1-1/4"
Pipe
1-1/2"
Pipe
2" Pipe
2-1/2"
Pipe
3" Pipe 4" Pipe 6" Pipe
ft (m)
10
(3.0)
1,050
(30)
1,600
(45)
3,050
(86)
4,800
(136)
8,500
(241)
17,500
(496)
44,000
(1246)
20
(6.1)
730
(21)
1,100
(31)
2,100
(59)
3,300
(93)
5,900
(167)
12,000
(340)
31,000
(878)
30
(9.1)
590
(17)
890
(25)
1,650
(47)
2,700
(76)
4,700
(133)
9,700
(275)
25,000
(708)
40
(12.2)
500
(14)
760
(22)
1,450
(41)
2,300
(65)
4,100
(116)
8,300
(235)
22,000
(623)
50
(15.2)
440
(12)
670
(19)
1,270
(36)
2,000
(57)
3,600
(102)
7,400
(210)
20,000
(566)
60
(18.3)
400
(11)
610
(17)
1,150
(33)
1,850
(52)
3,250
(92)
6,800
(193)
18,000
(510)
70
(21.3)
370
(10)
560
(16)
1,050
(30)
1,700
(48)
3,000
(85)
6,200
(176)
17,000
(481)
80
(24.4)
350
(10)
530
(15)
930
(26)
1,500
(42)
2,600
(74)
5,400
(153)
15,000
(425)
90
(27.4)
320
(9)
490
(14)
870
(25)
1,400
(40)
2,500
(71)
5,100
(144)
14,000
(396)
100
(30.5)
305
(9)
460
(13)
710
(20)
1,130
(32)
2,000
(57)
4,100
(116)
11,500
(326)
Table 5.2: Pipe Capacity – Natural Gas
Maximum Capacity of pipe in cubic feet per hour (cubic meters
per hour) with a pressure drop of 0.3" of water (75 Pa).
Pipe
Length
1-1/4"
Pipe
1-1/2"
Pipe
2" Pipe
2-1/2"
Pipe
3" Pipe 4" Pipe 6" Pipe
ft (m)
10
(3.0)
662
(18.7)
1,008
(28.5)
1,922
(54.4)
3,024
(85.6)
5,355
(151.6)
11,025
(312.2)
27,720
(784.9)
20
(6.1)
460
(13.0)
693
(19.6)
1,323
(37.5)
2,079
(58.9)
3,717
(105.3)
7,560
(214.1)
19,530
(553.0)
30
(9.1)
372
(10.5)
561
(15.9)
1,040
(29.4)
1,701
(48.2)
2,961
(83.8)
6,111
(173.0)
15,750
(446.0)
40
(12.2)
315
(8.9)
479
(13.6)
914
(25.9)
1,449
(41.0)
2,583
(73.1)
5,229
(148.1)
13,860
(392.5)
50
(15.2)
277
(7.8)
422
(12.0)
800
(22.7)
1,260
(35.7)
2,268
(64.2)
4,662
(132.0)
12,600
(356.8)
60
(18.3)
252
(7.1)
384
(10.9)
725
(20.5)
1,166
(33.0)
2,048
(58.0)
4,284
(121.3)
11,340
(321.1)
70
(21.3)
233
(6.6)
353
(10.0)
662
(18.7)
1,071
(30.3)
1,890
(53.5)
3,906
(110.6)
10,710
(303.3)
80
(24.4)
221
(6.2)
334
(9.5)
586
(16.6)
945
(26.8)
1,638
(46.4)
3,402
(96.3)
9,450
(267.6)
90
(27.4)
202
(5.7)
309
(8.7)
548
(15.5)
882
(25.0)
1,575
(44.6)
3,213
(91.0)
8,820
(249.8)
100
(30.5)
192
(5.4)
290
(8.2)
447
(12.7)
712
(20.2)
1,260
(35.7)
2,583
(73.1)
7,245
(205.2)
Table 5.3: Pipe Capacity – LP Gas
(1.50 Specific Gravity)
Maximum Capacity of pipe in cubic feet per hour (cubic meters
per hour) with a pressure drop of 0.3" of water (75 Pa).
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
26
2. A sediment trap is included from the factory into the
supply piping at the boiler. Figure 5.1 shows the
sediment trap at the rear of the boiler near the base.
3. High and low gas pressure switches are provided on
the gas supply header inside the boiler cabinet. Figure
5.1 shows the pressure switch location.
4. Install the service valve, supplied by the factory, as
shown in Figure 5.1 on the inlet to the boiler gas
piping.
5. Install a ground joint union upstream of the service
valve to allow service to the appliance.
6. Maintain a minimum distance of 5 feet between the
supply gas pressure regulator and the appliance.
7. Check all gas piping for leaks prior to placing the
boiler in service. Use an approved gas detector, noncorrosive leak detection fluid, or other leak detection
method to determine if there are leaks in the system.
If leaks are found, turn off the gas flow at the service
valve and repair as necessary.
8. Gas shutoff valves, located in the blower vestibule
cabinet area, are provided for each individual burner.
These valves are to be used in addition to the gas
service valve to interrupt gas flow to the individual
burners.
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 5.4 shows the maximum and minimum fuel gas
supply pressure to the boiler.
a. Gas pressures below 3.5 in. w.c. may result in
burner ignition failures and hard ignitions. A low
gas pressure switch has been provided with the
boiler to prevent low pressure conditions.
b. Gas pressures above 26 in. w.c. may result in
damage to the automatic gas valve.
3. To check the gas supply pressure to the gas valve:
a. Turn off the power at the service switch.
b. Close the gas shutoff valve for the automatic valve
being checked.
c. Using a flat screwdriver, turn the screw inside the
inlet pressure tap fitting (see Figure 5.2) one turn
counterclockwise.
d. Attach the tube from the manometer to the inlet
pressure tap fitting.
e. Turn on the burner service switch.
f. Open the manual gas valve and start the boiler.
g. Read and record the gas pressure while the boiler
is firing.
h. Remove the call for heat and allow the burner to
shutdown normally with a full postpurge.
i. Turn off the burner service switch and close the
gas shutoff valve.
j. Remove the manometer tube from the inlet
pressure tap fitting.
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 than 26 in. w.c.
(65 mbar) of gas pressure. Doing so may damage the
gas valve.
CAUTION
Fuel Type
Fuel Inlet Pressure (Main Gas Shutoff)
Minimum Maximum
in. w.c. mbar in. w.c. mbar
Natural Gas 3.5 8.5 26 65
LP Gas 3.5 8.5 26 65
Table 5.4: Maximum and Minimum Fuel Supply
Pressure
Figure 5.1: Gas Supply Pipe and Shutoff
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
27
k. Turn the internal screw clockwise to close the
valve.
l. Turn on the gas shutoff valve and the boiler
service switch.
m. Start 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.
n. Repeat this procedure on the second gas valve.
4. All gas piping must be leak tested prior to placing the
boiler in operation.
a. If the required leak test pressure is higher than 26
in. w.c., the boiler must be isolated from the gas
supply piping by closing the service valve.
b. If the gas valve is exposed to pressure exceeding
26 in. w.c., the gas valve must be replaced.
5. Install the boiler such that the gas ignition system
components are protected from water (dropping,
spraying, rain, etc.) during operation and service
(circulator replacement, condensate collector and
neutralizer clean out, control replacement, etc.).
E. MAIN GAS VALVES - OPERATION
1. Figure 5.2 is an illustration of the main gas valve,
venturi and blower assembly for the P
UREFIRE
®
boiler.
2. Do not make adjustments to the gas valve without
instrumentation to measure carbon dioxide (CO
2
) and
carbon monoxide (CO) emissions in the exhaust vent
pipe.
3. Turning the throttle screw clockwise will decrease the
gas flow (decreasing CO
2
) and turning it
counterclockwise will increase the gas flow rate
(increasing CO
2
). Markings adjacent to the throttle
screw show + and – indicating this operation.
a. Throttle adjustments should be made only at full
input rate with the other burner off.
b. The exhaust emissions should be checked with
both burners in operation to assure correct
operation.
c. See Section 9, Start-Up Procedure for specific
information about commissioning and adjusting
the boiler.
4. The recommended CO
2
settings are given in Table
5.5. In no case should the boiler be allowed to
operate with CO emissions higher than 150 ppm.
5. Refer to Section 3, Venting and Air Inlet Piping for
information on obtaining exhaust vent samples from
this boiler.
FUEL PIPING
Figure 5.2: Gas Valve, Venturi and Blower Assembly
Natural Gas Propane (LP)
Low Fire High Fire Low Fire High Fire
Carbon
Monoxide
(CO)
< 50 ppm < 100 ppm < 50 ppm < 100 ppm
Carbon
Dioxide
(CO
2
)
8.8% to
10.0%
8.5% to
9.5%
9.8% to
11.0%
9.5% to
10.5%
Excess
Oxygen
(O
2
)
3.4% to
5.4%
4.2% to
6.0%
4.2% to
6.0%
4.9% to
6.5%
Excess Air
17.3% to
31.0%
22.4% to
35.8%
22.4% to
35.8%
27.3% to
40.1%
Table 5.5: Recommended CO2Settings
28
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.
L'élimination de tout condensat dans les systèmes
d’évacuation publics des eaux usées doit s’effectuer
conformément aux codes et règlements en vigueur.
Si ces codes font défaut, suivre alors ces 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.
Pour le bon fonctionnement d’un appareil à
condensation, l'installation d'une tuyauterie adéquate
et la bonne évacuation de la condensation de la
combustion sont indispensables au fonctionnement
d’un appareil à condensation. Suivre attentivement
ces instructions pour assurer le fonctionnement
optimal de la chaudière P
UREFIRE
®
.
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
1. The condensate system for the PUREFIRE®PF-850 and
PF-1000 is designed to:
a. Prevent condensate from backing up into the heat
exchanger
b. Trap the condensate to prevent combustion gases
from escaping
c. Neutralize acidic condensate
2. Figure 6.1 shows the components of the condensate
system.
a. Condensate Collector Container: This vessel is a
transparent plastic container designed to catch the
condensate separately from the heat exchanger
and from the exhaust venting system. This vessel
also acts as part of the trap to prevent combustion
gases from escaping. The container is fitted with a
blocked condensate float switch.
b. Blocked Condensate Float Switch: This switch will
cause a blocking error on the boiler control and
prevent the boiler from operating if the level of
condensate in the vessel becomes too high. High
condensate levels can occur as a result of a
blocked condensate drain or similar problem.
c. Condensate Neutralizer Container: This
transparent vessel completes the trap system. It is
also designed to hold the condensate neutralizing
media that is supplied with the boilers. Open the
screw cap and put neutralizing media into the
container. The amount of media consumed
depends on the acidity and amount of condensate
produced. This vessel should be checked
occasionally to determine if additional media is
required. Neutralizing media is available from your
PB Heat Distributor in 1 lb packages (#54159).
d. Blocked Vent Switch: A blocked vent switch is
connected to the condensate system to shut the
burner down in case of a vent blockage. The
switch will trip if the pressure in the combustion
chamber exceeds 4.5" w.c. (11 mbar) and will
prevent the boiler from continuing to operate with
the condensate trap emptied due to high pressure.
e. FasNSeal Condensate Drain Tee: The condensate
drain tee, included in a separate box inside the
crate, drains condensate to the trap and
neutralization system separately from the heat
exchanger. This prevents dirt and debris from the
venting system from entering the heat exchanger.
C. CONDENSATE DRAIN PIPING
1. 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 cause corrosion.
CONDENSATE TRAP & DRAIN SYSTEM
6. CONDENSATE TRAP & DRAIN SYSTEM
Figure 6.1: Condensate Trap System
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