PEERLESS PUREFIRE PF-850, PUREFIRE PF-1000, PureFirePF-1500 Installation, Operation & Maintenance Manual

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Page 1

PUREFIRE

Boilers

PF-850 PF-1000

Gas

Installation, Operation & Maintenance Manual

Page 2

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

Page 3

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

Page 4

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.

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

Page 5

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:

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.

PREINSTALLATION

Figure 1.1: Minimum Accessibility Clearances – PF-850, PF-1000

15 ft

fan

ACH 1000

Btu

Required Volume

fan

⎛ ⎜ ⎝

⎛

⎜

⎝

Page 6

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 1.2 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

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

per

4000 Btu/hr (22 cm

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.

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

Page 7

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 1.6.

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

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:

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.

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

req

= A

full

x 1 –

avail

req

⎛ ⎜ ⎝

⎛

⎜

⎝

Page 8

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

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

Page 9

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

Page 10

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

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

Page 11

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

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

Page 12

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

Page 13

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

Page 14

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)

Page 15

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"

Page 16

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.

Page 17

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

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

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

Page 18

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

Page 19

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

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

Page 20

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

(°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

(°F) PF-850 PF-1000

Taco

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

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

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

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

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

Page 21

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

Page 22

WATER PIPING & CONTROLS

Figure 4.4: Recommended Piping – One Boiler with Multiple CH Zones & One DHW Tank

Page 23

WATER PIPING & CONTROLS

Figure 4.5: Alternate Piping – One Boiler with Multiple CH Zones & One DHW Tank

Page 24

WATER PIPING & CONTROLS

Figure 4.6: Recommended Piping – Multiple Boilers with Multiple CH Zones & One DHW Tank

Page 25

WATER PIPING & CONTROLS

Figure 4.7: Alternate Piping – Multiple Boilers with Multiple CH Zones (Zone Valves) & One DHW Tank

Page 26

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

Page 27

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

(

)

(

Btu

)

(

Btu

)

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)

(3.0)

1,050

(30)

1,600

(45)

3,050

(86)

4,800

(136)

8,500 (241)

17,500

(496)

44,000 (1246)

(6.1)

730

(21)

1,100

(31)

2,100

(59)

3,300

(93)

5,900 (167)

12,000

(340)

31,000

(878)

(9.1)

590

(17)

890 (25)

1,650

(47)

2,700

(76)

4,700 (133)

9,700 (275)

25,000

(708)

(12.2)

500

(14)

760 (22)

1,450

(41)

2,300

(65)

4,100 (116)

8,300 (235)

22,000

(623)

(15.2)

440

(12)

670 (19)

1,270

(36)

2,000

(57)

3,600 (102)

7,400 (210)

20,000

(566)

(18.3)

400

(11)

610 (17)

1,150

(33)

1,850

(52)

3,250

(92)

6,800 (193)

18,000

(510)

(21.3)

370

(10)

560 (16)

1,050

(30)

1,700

(48)

3,000

(85)

6,200 (176)

17,000

(481)

(24.4)

350

(10)

530 (15)

930 (26)

1,500

(42)

2,600

(74)

5,400 (153)

15,000

(425)

(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)

(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)

(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)

(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)

(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)

(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)

(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)

(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)

(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)

(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

Page 28

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

WARNING

Page 29

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

) and carbon monoxide (CO) emissions in the exhaust vent pipe.

3. 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.

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

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

)

8.8% to

10.0%

8.5% to

9.5%

9.8% to

11.0%

9.5% to

10.5%

Excess

Oxygen

)

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

Page 30

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

Page 31

2. Tubing Size: The connection at the rear of the heat exchanger is designed for connection to 3/4" ID PVC or similar tubing. Do not reduce the size of the condensate drain tubing.

3. Tubing Pitch: Be sure that the pipe or tubing is pitched away from the boiler with a slope of no less than 1/4" per foot.

4. Multiple Boilers: Condensate drain tubes from multiple boilers should be run separately to prevent a nuisance lockout of multiple boilers due to a single clogged drain tube.

5. Condensate Pumps: If the boiler 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 TRAP & DRAIN SYSTEM

Brand Name Model Number

ITT Bell & Gossett LS

Little Giant VCMA-15UL

Beckett CB151LSUL

Hartell KT-15-1UL

Table 6.1: Recommended Condensate Pumps

Page 32

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.

The boiler must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code, ANSI/NFPA 70, and/or the Canadian Electrical Code Part I, CSA C22.1, Electrical Code.

B. CUSTOMER CONNECTIONS

1. Electrical knockouts are provided on the rear panel of the PF-850 and PF-1000 boiler to connect supply wiring, circulator wiring, external controls, and/or external sensors. Figure 7.1 shows these knockouts.

a. There are (5) 7/8" diameter knockouts for line

voltage connections such as supply wiring, circulator wiring and low water cutoff (LWCO) wiring.

b. There are (4) 7/8" diameter knockouts for low

voltage connections such as outdoor sensors, domestic hot water (DHW) tank sensors and system sensors.

2. Electrical terminals are located behind the control cabinet cover plate where the Burner LCD Displays are mounted (See Figure 7.1).

a. The cover plate can be removed by removing the

single sheet metal screw on the lower center of the panel. The top of the panels is supported by tabs into the top of the cabinet enclosure.

b. The terminal strips can be removed by gently

pulling them away from the wired blocks. This allows the installer to attach wires to the connector before plugging the terminal strip into the mounted block.

3. Figure 7.2 shows the customer connections for the PF-850 and PF-1000 boilers. Table 7.1 lists the terminal numbers with nominal voltage and detailed descriptions of the connections.

ELECTRICAL CONNECTIONS & INTERNAL WIRING

7. ELECTRICAL CONNECTIONS & INTERNAL WIRING

Figure 7.1: Electrical Terminal Access

Table 7.1: Terminal Description

Termi na l

Input/

Output

Voltage Description

Output 24 VAC

CH Thermostat, Boiler Output from Zone Control Panel, or Zone Valve End Switches.

Output 5 VDC

Outdoor Sensor (12 kW NTC Thermister) – To be located outside the building (north side in the shade).

Output 5 VDC

DHW Sensor (12 kW NTC Thermister) or DHW Tank Thermostat.

Input/

Output

VDC

Master Communication Link – Wire to terminals 9 & 10 on each Dependent Boiler.

Input/

Output

VDC

Dependent Communication Link – Wire to terminals 7 & 8 on Master Boiler and 9 & 10 on more Dependent Burners.

Output

VAC

Remove jumper to wire to external limit controls such as Low Water Cutoff, Damper or Power Vent Interlocks.

Output

VDC

System Sensor (12 kW NTC Thermister) – To be located on the system supply header.

15 (-)

Input

0-10 VDC

External analog input for boiler target setpoint temperature from Building Management System (BMS).

16 (+)

Output

120

VAC

DHW Circulating Pump – Use this output to power the domestic hot water (DHW) circulator (Limited Priority).

Output

120

VAC

CH Circulating Pump – Use this output to power the central heating (CH) circulator.

Output

120

VAC

GEN Circulating Pump – Use this output to power the GEN (Boiler) circulator.

Input

120

VAC

120 VAC, 60 Hertz, 1 Phase supply from a fused disconnect switch to power the boiler controls and blowers.

Output

120

VAC

Line voltage output for probe-type low water cutoff (LWCO) power.

Input

120

VAC

120 VAC, 60 Hertz, 1 Phase supply from a fused disconnect switch to power the boiler circulators.

N/A Ground Earth ground.

Dry Contacts

Alarm contacts (Operation may be changed from the Installer Menu to allow common venting of multiple boilers).

Page 33

C. ZONE CIRCULATOR WIRING

1. Wiring for a typical circulator zone panel is shown in figure 7.3.

2. Note that the jumper between the hot leg of the supply (H) and the zone circulator power input (ZC) must be removed. Then a wire from terminal 19 of the main panel will power all of the zone circulators.

3. If the total current rating of all of the zone pumps exceeds 10 amps, an isolation relay must be used.

D. INTERNAL WIRING

Figure 7.4 shows the complete boiler wiring schematic for PF-850 and PF-1000 boilers. The following is a list of internal wiring components and a short description of each:

1. User Interface Pixel Display: A single user interface display is located on the front of the boiler behind the smoked lens on the jacket front panel. This interface provides information on the boiler system and allows the user to set the boiler address for cascade systems.

2. Installer Interface Displays: The installer interface display allow the installer or service contractor to display status information for many different values. These displays also allow the installer/contractor to change settings to optimize system efficiency and operation. A detailed description of the status and settings available is provided in Section 8 of this manual.

3. Interface Module: This component provides the following functions:

a. Alarm Contacts

: These dry contacts can be used to connect to an alarm bell, auto-dialer or other device to alert personnel in the event of a blocking or lockout error.

b. Analog Input

: This allows a 0-10 VDC input for

external control of the system setpoint.

c. Modbus Communication

: This provides two way communication using Modbus interface for external control of the setpoint and feedback of system temperatures, error codes and other values.

ELECTRICAL CONNECTIONS & INTERNAL WIRING

Figure 7.3: Typical Zone Circulator Relay Wiring

Figure 7.2: Customer Connection – PF-850 & PF-1000

Page 34

ELECTRICAL CONNECTIONS & INTERNAL WIRING

Figure 7.4: Internal Wiring Schematic for PF-850 & PF-1000

Page 35

ELECTRICAL CONNECTIONS & INTERNAL WIRING

4. Relay Module: This fused module provides isolation for the pump contacts on the main control board. The maximum rating for each pump attached is 10 amps. Since only two pumps will operate at any one time, this limits the incoming power required for this module to 20 amps. This separate power supply is to be connected to terminals 27 and 28 on the right terminal strip.

5. Integrated Primary Controls: There are two primary ignition controls on the P

UREFIRE

PF-850 and PF-1000 boiler. They are integrated controls that supervise all of the ignition timing as well as the burner modulation. The “managing burner” control is located in the blower vestibule area and is mounted adjacent to the top, “managing burner”. The “dependent burner” control is located adjacent to the lower “dependent burner.

6. Supply Temperature Sensors: The supply temperature sensors provide input to their respective control which use them to determine the input rate of each burner. These sensors are 12kW NTC thermistors.

7. Return Temperature Sensor: The return temperature sensors provide information on the boiler return water temperature to prevent unsafe operation of the boiler. These sensors are 12kW NTC thermistors.

8. Header Temperature Sensor: The header temperature sensor provides the outlet supply temperature of the boiler to the managing control to control the overall boiler system operation. These sensors are 12kW NTC thermistors.

9. Flue Temperature Sensor: The 12kW flue temperature sensor provides the exhaust vent temperature to the managing control to prevent unsafe operation of the boiler.

10. Supply Limit Switches: The supply limit switches are UL353 certified temperature switches that prevent the boiler from exceeding 210°F (99°C) which is the maximum operating temperature allowed by ASME Boiler and Pressure Vessel Code, Section IV. These switches along with the manual reset circuitry of the primary controls meet the high limit requirements of ASME CSDAFB (CSD-1).

11. Thermal Fuses: The thermal fuses located at the rear of each combustion chamber prevent unsafe operation of the boilers in the event of ceramic deterioration in the combustion chamber target wall.

12. Condensate Drain Float Switch: This switch is connected to the managing primary control and prevents the boiler from operating if the condensate in the condensate collector vessel exceeds its maximum level.

13. Blocked Vent Pressure Switch: This switch is connected to the managing primary control and prevents the boiler from operating if the pressure in the combustion chamber exceeds 4.5 in. w.c. (11 mbar). This will prevent the boiler from operating with the condensate displaced from the trap due to pressure.

14. Flapper Proof-of-closure Switches: These switches transmit the position of the flapper to their respective primary control. If the switch indicates that the flapper is not closed on the inactive burner while the other burner is operating, it will start the blower for the inactive burner. This will assure a positive combustion chamber pressure and prevent combustion gases from back-feeding through the inactive burner in the event of a flapper failure.

Page 36

BOILER CONTROL: OPERATION

8. BOILER CONTROL: OPERATION

A. IGNITION SEQUENCE

Figure 8.1 shows the ignition sequence for the PUREFIRE

boiler control. Table 8.1 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.

Figure 8.1: Ignition Cycle – Graphical Representation

Table 8.1: Ignition Sequence

Period Demand Status Burner LCD Display

Standby

No demand is present

If the power is on to the PUREFIRE®boiler and there is no heat demand, the burner LCD 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 burner LCD 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

Page 37

BOILER CONTROL: OPERATION

Table 8.1: Ignition Sequence (cont’d)

Period Demand Status Burner LCD 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 the number of ignition failures exceeds the allowable number in one call for heat, the control will post purge and lock out. If the “One Hour Retry” parameter is set to, “ON”, the control will retry ignition one hour after an ignition failure. The control records 4 flame signal values during the last two seconds of this period that can be accessed from the “Installer Menu” under “Status”.

Burner On

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

Once a flame signal is established, the burner will run until a demand is satisfied, the setpoint is exceeded, or a blocking/lockout 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.

Page 38

B. STATUS DISPLAY

The PUREFIRE®boiler display screens are designed to provide the user and installer with useful information about the boiler function. The PF-850 and PF-1000 boilers have three different display screens available.

1. Master Pixel Display: This display is located behind

the smoked lens at the top of the boiler front panel. Removing the lens allows access to the display.

2. Managing Burner LCD Display: This display is located on the right side of the boiler behind the heat exchanger side panel. The managing burner display is located toward the front of the boiler and controls the upper burner assembly.

3. Dependent Burner LCD Display: This display is located on the right side of the boiler behind the heat exchanger side panel. The dependent display is toward the rear of the boiler and controls the lower burner assembly.

BOILER CONTROL: OPERATION

Table 8.2: Initialization Screens

Figure 8.2: Pixel Display Illustration

Initialization

Screens

Pixel Displays LCD Displays

The software version indicated by [ x x x x ] indicates the version of the program for the display interface.

Initialization screens are displayed for the first few seconds after power is applied to the front Pixel display and both burner LCD displays.

Page 39

BOILER CONTROL: OPERATION

Table 8.3: Display Screens Under Various Conditions

Pixel Displays LCD Displays

Standby

Managing (Boiler—Pressing the up or down key displays the boiler system information)

Dependent

Central Heating

(CH) Demand

Managing (Boiler)

Dependent

Domestic Hot

Water (DHW)

Demand

Managing

Dependent

Supply at

Setpoint

Special Demand

Functions

Page 40

BOILER CONTROL: OPERATION

Pixel Displays LCD Displays

Service

Notification

Pixel Displays Dependent LCD Displays

Error Handling

Managing LCD Display

Table 8.3: Display Screens Under Various Conditions (cont’d)

Pixel Displays LCD Displays

Ignition

Failure Error

Handling

Flame

Failure Error

Handling

Ignition Retry

Page 41

BOILER CONTROL: OPERATION

C. USER MENU

To access the user menu for each burner, simply press the “Menu” key on the corresponding managing or dependent LCD display located on the right side of the boiler behind the heat exchanger access panel. The managing display is on the left and corresponds to the upper burner. The dependent display is on the right and corresponds to the lower burner. Use the “L” and “

M”

keys on the display to move the cursor to the desired selection. Pressing “Select” will access the submenu for the selection. The submenus are described in detail below.

1. LCD Status Menu Status Menu

: The user status menu gives the user or installer access to basic information about the boiler system. The first screen shows the Current Supply Setpoint. If the boiler is in CH Mode 0, 2 or 6, this is the temperature that the boiler targets. As the boiler approaches this target, the burners will modulate their input.

The next screens show temperature values read by the temperature sensors in the control system. The supply and return temperatures are measured at the header on the outlet side of the heat exchanger. There is a supply and return sensor for each burner. In addition to the supply and return sensors, there is a header (system) sensor on the boiler supply (outlet) pipe.

Typical Values for Water Sensors: (Supply/Return/System/DHW): 70°F (21°C) to 200°F (93°C).

A value of 14°F (-10°C) indicates an open sensor and a value of 244°F(118°C) indicates a short for these sensors.

Typical Values for the Vent Sensor are: 70°F (21°C) to 200°F (93°C).

A value of 50°F (-10°C) indicates an open sensor and a value of 244°F(118°C) indicates a short. Since boilers installed in low temperature environments such as a garage may experience vent temperatures below 50°F, the control works as follows:

a. If the Vent Temperature Sensor reads less than

50°F, the boiler will continue to operate normally, unless,

b. If the return temperature exceeds 80°F (27°C) or

the supply temperature exceeds 120°F (49°C) the burners will operate at their minimum modulation until the call for heat ends or the vent temperature exceeds 50°F.

The outdoor sensor temperature should correspond to the current outdoor temperature. If the sensor is mounted in direct sunlight or near an appliance exhaust vent, erratic operation can result due to large changes in the apparent outdoor temperature.

A value of -40°F (-40°C) indicates an open sensor and a value of 244°F(118°C) indicates a short for this sensor.

The final screen of the status menu provides information on the status of each of the circulators. Since these circulators on the PF-850 and PF-1000 boilers are connected to the managing burner, only the statuses of these circulators are of interest.

2. LCD Settings Menu The user settings menu provides access to basic settings on the P

UREFIRE

control. After choosing the “Settings Menu” the Central Heating Setpoint menu appears. To access the other menus, press the

M key.

Some of the menus shown below will not appear depending on the CH or DHW mode chosen.

a. Central Heating Setpoint

: Depending on the CH Mode chosen (in the Installer Menu), the user may be able to adjust the boiler water temperature that is targeted by the control on a central heat demand. If the CH Mode is 1 or 2 (Outdoor Reset), this screen will show “OD RESET” along with the target temperature calculated by the control algorithm. The user is not allowed to override the calculated temperature. If CH Mode 0 or 6 is chosen, the target temperature can be changed by pressing the “Select” key and using the “L” and “

M” keys to increase or decrease the

value. The following shows the range and default values for the Central Heating Setpoint.

Figure 8.3: User Menu

Figure 8.4: Status – Supply Setpoint

Figure 8.5: Status – Temperature

Figure 8.6: Status – Circulators

Figure 8.7: Settings – CH Setpoint

Page 42

BOILER CONTROL: OPERATION

b. DHW Boiler Setpoint: This value determines the

target temperature for the boiler supply to an indirect domestic hot water (DHW) storage tank. This should not be confused with the DHW Tank temperature. If the DHW Mode is set to Mode 0 (No DHW) this screen will not be visible.

c. DHW Tank Setpoint

: This screen allows the user to select the target temperature for the indirect DHW storage tank. This screen is only visible if the DHW Mode is set to Mode 1 (DHW Tank with Sensor) and an optional 12 kW DHW Tank sensor is purchased (PB Stock Code 54157).

d. Time & Date

: This screen allows the user to set the current date & time for the burner. Setting the current date and time allows the installer to set up alert messages for routine inspection and maintenance.

•

Press the “Select” key. The third line will alternately flash the day of the week and “---”.

•

Use the “” and “” keys to change the day. Press the “Select” key to select the correct day.

•

The date value will flash. Use the “” and “” keys to change the date. Press the “Select” Key.

•

The month value will flash. Use the “” and “” keys to change the month. Press the “Select” Key.

•

The year value will flash. Use the “” and “” keys to change the year. Press the “Select” Key.

•

The hour value will flash. Use the “” and “” keys to change the hour. Press the “Select” Key. (Note that the hour is displayed in the 24 hour format so that 3:00 pm = 15:00.)

•

The minute value will flash. Use the “” and “” keys to change the minutes. Press the “Select” Key.

The date and time will be stored in non-volatile memory so the date will not require resetting if the power is disconnected.

e. Temperature Units

: This screen allows the user to change the temperature unit display. The default units are Fahrenheit °F. To change the unit display, press the “Select” key. The current unit system will flash. Use the “” and “” keys to change the value to Celsius °C. Press the “Select” key again to choose the units.

3. LCD Message Menu The messages menu allows the user to view the last blocking error or last lockout error. The display will also show the interval between the last blocking or lockout error and the error before the last. To determine the interval between the current time and the error displayed, create an error by disconnecting the supply sensor wire.

WARNING

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.

Figure 8.8: Settings – DHW Boiler Setpoint

Figure 8.9: Settings – DHW Tank Setpoint

Figure 8.10: Settings – Date & Time

Figure 8.11: Settings – Temperature Units

Table 8.4: CH Setpoint Range & Defaults

Central

Heating

Setpoint

Minimum Maximum Default

50°F 195°F 160°F

10°C 91°C 71°C

Table 8.5: DHW Boiler Setpoint Range & Defaults

DHW Boiler

Setpoint

Minimum Maximum Default

122°F 195°F 180°F

50°C 91°C 82°C

Table 8.6: DHW Tank Setpoint Range & Default

DHW Tank

Setpoint

Minimum Maximum Default

50°F 158°F 120°F

10°C 70°C 49°C

Be sure to only use the 12 kW tank sensor indicated. Other sensors will not provide accurate tank temperatures and may cause severe personal injury due to scalding.

DHW Boiler Setpoint Setting is only available in DHW Mode 1 & 2.

NOTICE

DHW Tank Setpoint Setting is only available in DHW Mode 1.

NOTICE

Page 43

BOILER CONTROL: OPERATION

a. Last Lockout Error: The last lock menu allows the

user to view the reason for the last lockout. See Table 10.2 for a list of locking errors and the associated codes. Note that a value of #255 indicates that there are no lockout errors in the control history. Also, note that the errors displayed may have occurred during the factory fire test or field commissioning of the equipment.

b. Last Blocking Error

: The last block screen allows the user to view the reason for the last blocking error. See Table 10.1 for a list of blocking errors and the associated “E” codes. Note that a value of #255 indicates that there are no blocking errors in the control history. Also, note that the errors displayed may have occurred during the factory fire test or during field commissioning of the equipment.

D. INSTALLER MENU

1. Menu Overview The installer menu allows installing or service contractors to view and/or make adjustments to the permanent boiler settings based on the installation configuration, desired operation and local codes. The menu structure is shown in Figure 8.13.

To access the installer menu, press and hold the “Menu” and “Select” key on the LCD display corresponding to the burner on which the parameter change is to be made.

a. Managing Burner (Burner M)

: The top burner on each PF-850 or PF-1000 boiler is designated as “Burner M” or “managing burner”. This burner control is connected to the GEN (Boiler) circulator, the CH and/or DHW circulator* and all external sensors*. In the following section, all parameters which affect only the managing burner will be designated with “(M)”.

*Stand-Alone configuration or Master Boiler

in multiple boiler configuration.

b. Dependent Burner (Burner D)

: The bottom burner on each boiler is designated as the “Burner D” or “dependent” burner. This burner control is started and stopped by the managing burner only. Its operation is not affected by external inputs.

2. Status The status menu is designed to monitor key parameters and aids the installer or service contractor in determining if there are problems with boiler operation.

a. Current Supply Setpoint

: The setpoint value will change for DHW demands or CH demands depending on the setpoint chosen for these modes of operation. When outdoor reset modes are selected, this value is the calculated target for the system.

b. Fan Speeds

: Screens #2 & #3 display fan speed information. The current fan speed will vary during operation between the low power and high power values. The Low Power, Ignition, and Hi Power values are preset at the factory for a specific model size. Table 12.3, in Section 12 of this manual, shows the fan speed presets for each model size. Note that these values may vary slightly due to air setting changes.

c. Flame Measurements

: Screens #4, #5 & #6 display flame signal information. The first value, Flame Signal, is the current flame rectification signal in micro amps (µA). The minimum value for this signal that will allow the burner to continue running is 2.8 µA the maximum value for this is 10 µA.

Figure 8.12: Messages – Last Errors

Figure 8.13: Installer Menu

Figure 8.14: Status – Supply Setpoint

Figure 8.15: Status – Fan Speeds

Figure 8.16: Status – Flame Signal

Page 44

BOILER CONTROL: OPERATION

The next value, Flame Failures, is the number of times the burner has dropped out due to flame failure. Several flame failures may have occurred during the factory firetests and installation. If there are a large number of flame failures showing on this screen, contact your Peerless

Representative.

On Screens #5 and #6, the Flame Measurement values 1-4 are logged in the last two seconds of the most recent ignition sequence in 1/2 second intervals. This helps service contractors to diagnose ignition issues.

d. Ignition Attempts

: Screen #7 provides information about ignition attempts. Obviously, the total ignition attempts are the sum of the successful and failed attempts. Several ignition failures may occur during factory firetest and equipment commissioning. However, if there are a large number of failed ignition attempt showing on this screen, contact your Peerless

Representative. If there is an unusually large number of total ignition attempts, there may be a problem with the boiler short cycling.

e. Burner Run Time

: Screen #8 provides information about the total run time of each burner. The total burner run time is the sum of the central heating (CH) and domestic hot water (DHW) hours. The total boiler run time is the sum of both burner run times.

f. Blocking Errors:

Screen #9 provides error history about the last 16 blocking errors. Blocking errors are errors that prevent the burner from operating until the condition causing the error is corrected. Sensor errors, low water, and blocked vent are examples of this type of error. To review previous errors, press the select key. The number in the upper right changes from the status screen “9” to a blinking “0” indicating that this is the most recent error. Use the arrow keys to scroll through previous errors from 0 to 15. If the screen shows “#255” in the error number location, this indicates that there is no error stored in this location. All errors on screens higher than one showing “#255” should also indicate no error. Table 10.1 (in Section 10) provides a list of blocking errors.

g. Lockout Errors:

Screen #10 provides error history about the last 15 locking errors. Locking errors are errors that require a manual reset on the control board (pushing the “Reset” key on the display) to reset the burner once the condition causing the error has been corrected. Ignition Failure, Flame Failure and High Limit Temperature are examples of this type of error. To review previous errors, press the “Select” key. The number in the upper right changes from the status screen number “10” to a blinking “0” indicating that the screen is showing the most recent lockout error. If the burner is not in lockout, this position should show “#255” in the error number location. Use the arrow keys to scroll through previous errors from 1 to 15. As with blocking errors, “#255” always indicates that no error is stored in this location. Table 10.2 provides a list of lock out errors.

3. Burner Settings The burner settings menu allows the installation or service contractor to change settings which effect the burner operation. The following are descriptions of the available settings.

a. Burner Mode

: The burner modes are set by default from the factory. The upper burner, which corresponds to the display closest to the front of the boiler, is always the “managing burner”. The lower burner, with its display toward the rear, is always the “dependent burner”. These values are not intended to be changed in the field.

b. Boiler Address

: The PUREFIRE®PF-850 & PF-1000 can be operated with as many as 15 identical boilers as a cascade boiler system by adding 2 wire communication links between the boilers. The following chart shows the role of the boiler depending on the boiler address. Multiple boiler operation is covered in-depth at the end of this section of the manual. This screen is available only on the managing burner.

Figure 8.17: Status – Ignition

Figure 8.18: Status – Burner Run Time

Figure 8.19: Status – Blocking Errors

Figure 8.20: Status – Locking Errors

Figure 8.21: Burner Settings – Burner Mode &

Boiler Address

Table 8.7: Boiler Address

Boiler Address

Value

Description

0 Stand-Alone Boiler

1 Master Boiler in a Cascade System

2-16 Dependent Boilers in a Cascade System

Managing Burner Only

Page 45

BOILER CONTROL: OPERATION

c. Installation Location & Vent Material: Due to

differing national codes in the United States and Canada, there are different material requirements for exhaust vent pipe. Therefore, the maximum vent limit temperature is different depending on the material used.

Screens #3 and #4 allow the installer to select the installation location and vent material. Based on the information given, Table 8.8 shows the exhaust temperature that the control will allow before reducing the burner input rate. If the temperature of the exhaust gas approaches these values, the control will reduce the input rate on both burners until the temperature begins to drop. If the flue temperature continues to rise, the control will shut down both burners.

Note: Although stainless steel can withstand a temperature higher than 230°F (110°C) the temperature limit is set to this temperature since the vent temperature should not exceed this temperature unless there is a problem with the heat exchanger.

d. Freeze Protection

: Freeze protection is intended to

prevent freezing the central heating system.

•

First, the control activates pumps to distribute heat uniformly through the system.

– If the boiler supply (header) temperature

drops below the value selected for “Freeze Protection starts at:”, the General (boiler) circulator is activated.

– If either of the boiler return sensors reports a

value below this temperature, the CH circulator is started.

•

Next, if Burner M return temperature drops more than 9°F (5°C) below the “Freeze Protection starts at:” value, the control activates Burner M (managing burner) at it minimum rate.

– If a central heat demand is detected while the

burner is operating for Freeze Protection, the burner will run normally to satisfy the demand.

– Finally, once the return temperature

increases to 9°F (5°C) above the chosen value, the burner is switched off and the pumps are deactivated.

e. Blower Postpurge Time

: The blower postpurge time can be increased to address problems under extreme conditions (long exhaust vent runs, high winds, etc.) where the products of combustion are not fully expelled from the venting system. This feature should be used sparingly as it may lead to decreased efficiency and higher fuel bills in certain situations.

f. Additional Safety Functions

: This feature allows the installer to choose between using a low water cut-off or a flow switch to assure proper water circulation and operation of the boiler. Either of these devices should be wired to the terminals 11 & 12 (Safety Interlocks) of the P

UREFIRE

PF-850 or PF-1000 boilers. Note that these terminals are connected internally to the high & low gas pressure switches so that a “Safety Interlock Open” error may occur due to high or low gas pressure in addition to anything connected to these terminals.

Figure 8.25: Burner Settings – Additional Safety

Functions

Figure 8.24: Burner Settings – Blower Post Purge

Table 8.10: Freeze Protection Range & Default

Table 8.11: Blower Post Purge Range & Default

Table 8.8: Vent Temperature Limits

Vent Material

Location

U.S.A. Canada

PVC

190°F (80°C)

149°F

(65°C)

CPVC

230°F

(110°C)

190°F

(80°C)

Polypropylene

(PPs)

230°F

(110°C)

230°F

(110°C)

Stainless Steel

230°F

(110°C)

230°F

(110°C)

Freeze Protection

Starts at

Default Minimum Maximum

50°F (10°C) 45°F (7°C) 56°F (13°C)

Blower Post Purge Time

Default Minimum Maximum

30 sec 30 sec 120 sec

Table 8.9: Location & Vent Material Default

Figure 8.23: Burner Settings – Freeze Protection

Parameter Default

Location U.S.A.

Vent Material PVC

Figure 8.22: Burner Settings – Location & Vent

Material

Managing Burner Only

Page 46

BOILER CONTROL: OPERATION

•

LowWaterCO: This is the default selection on the control. However, no low water cut-off (LWCO) device is supplied with the boiler. A probe-type LWCO, such as the Hydrolevel Model 1150 or McDonnell & Miller RB-120 should be used with

UREFIRE

boilers. Figure 8.27 shows the

recommended wiring of these devices.

•

FlowSwitch: A flow switch, such as the McDonnell & Miller FS250, is designed to trigger a blocking error immediately on a loss of flow in the system. To protect from a false flow reading on this type of device, the control assures that the flow switch is open (indicating no flow) before activating the General and the CH or DHW circulator. After these pumps are activated, it will not proceed into a trial for ignition until the switch closes.

g. Ignition Attempts

: The control is configured from the factory to not allow the burner to recycle after a failed ignition attempt. At installation, the control can be configured to allow up to 3 ignition attempts before locking out and requiring a manual reset. In addition, the control may be configured to retry for ignition, one hour after lockout without a manual reset. Check applicable codes before changing these parameters.

h. Flame Failures

: The control is configured from the factory to not allow the burner to recycle after a flame failure. At installation, the control can be configured to allow up to 2 retries after a flame failure before locking out and requiring a manual control reset. In addition, the control may be configured to retry for ignition one hour after a lockout without a manual reset. Check applicable codes before changing these parameters.

i. Air Adjustment

: Screens #12 and #13 allow the fan speed to be increased if required. The following is an explanation of the conditions under which these adjustments should be made.

j. Minimum Fan Speed

: The minimum fan speed adjustment is intended to respond to potential issues with the loss of flame due to pressure fluctuations in the venting system. These concerns may be due to wind gusts on sidewall vented boilers or other sources of exhaust vent pressure spikes. The minimum fan speed may be adjusted in 30 RPM increments up to the minimum fan speed + 540 RPM. This feature should only be used to address nuisance flame failure or flapper valve failure lockout errors.

Figure 8.27: Low Water Cut-off (LWCO) Wiring

Figure 8.28: Burner Settings – Flame Failures

Allowed

Figure 8.26: Burner Settings – Ignition Attempts

Allowed

Table 8.12: Ignition Attempts Ranges & Defaults

Table 8.13: Flame Failures Allowed Ranges &

Defaults

Parameter Default Minimum Maximum

Ignition Attempts

Allowed

1 1 3

Ignition Attempts

1 Hr Retry

OFF OFF ON

Parameter Default Minimum Maximum

Flame Failure

Retries Allowed

0 0 2

Flame Failure

1 Hr Retry

OFF OFF ON

Figure 8.29: Burner Settings – Air Adjustment

Page 47

k. Maximum Fan Speed: The maximum fan speed

adjustment is intended to compensate for long exhaust vent runs if the boiler fails to keep up with the required load. Since the input rate may drop off slightly under increased resistance due to long exhaust vent installations, the boiler input may be incrementally increased to compensate. This adjustment should only be made if both of the following conditions are met:

•

The boiler is not keeping up with the required load.

•

The input rate has been determined to be below the rated input by timing the gas supply meter.

If these conditions are not met, contact your Peerless

Representative for assistance.

l. Alarm Mode

: The alarm mode allows the installing contractor to set the menu to the mode appropriate for the installation. The default setting is “Stand Alone” in which the alarm contacts (Terminals #31 & #32) simply close if an alarm condition exists. Figure 8.31 shows the proper wiring arrangement for the “Common Vent” alarm mode. In this configuration, the alarm will sound if a boiler loses power.

4. Central Heating (CH) Settings CH settings manage the boiler temperature and circulators for the central heating load. Although the menu items that follow are factory set, by default, to values that can operate in any installation, they can be adjusted to maximize the efficiency of this product. The boiler can be configured to operate with a fixed setpoint or using outdoor reset to vary the boiler target temperature according to the load implied by the outdoor temperature.

a. Setpoint Operation

: When using a setpoint strategy, the boiler targets a fixed setpoint which is set in the User Menu on the P

UREFIRE

control. As the boiler supply (outlet) temperature approaches this target, the burner begins to modulate the fuel input, reducing the output rate of the boiler. If the boiler reaches a temperature of 9°F (5°C) above the setpoint before the heat demand ends, the burner will shut down. If the heat demand continues and the boiler temperature drops 9°F (5°C) below the setpoint, the burner will restart.

b. Outdoor Reset Operation

: Outdoor reset strategies

are ideal for condensing boilers for two reasons:

•

Heat distribution units, such as radiators, radiant floors and copper baseboard are sized to deliver the heat required on the coldest day at a set temperature. For the remainder of the heating season, the maximum output is not required, so the distribution can be set to a cooler temperature.

•

Condensing boilers, like the PUREFIRE®, are designed to withstand acidic condensate and therefore can be operated at as low a temperature that is reasonable. At lower temperatures [below 120°F (49°C) return temperature], these boilers condense more and are more efficient.

c. CH Modes

: The CH modes allow the operator to change the way the boiler operates to satisfy central heating demands.

BOILER CONTROL: OPERATION

Table 8.14: Air Adjustment Ranges & Defaults

Parameter Default Minimum Maximum

Air Adjustment Min Fan Speed

0 rpm 0 rpm 540 rpm

Air Adjustment

Max Fan Speed

0 rpm 0 rpm 540 rpm

Figure 8.31

Figure 8.30: Burner Settings – Alarm Mode

Managing Burner Only

Page 48

•

Mode 0, Indoor Thermostat: This is the default mode in which the boiler responds to a demand from an indoor thermostat or zone control panel at terminals #1 and #2 in the

UREFIRE

control panel. The control targets a fixed setpoint and as the boiler water temperature approaches the target, the control begins to reduce the fuel input. This mode doesn’t require an outdoor sensor.

•

Mode 1, Indoor Thermostat with Outdoor Reset: When operating in this mode, the

control uses the outdoor temperature and installer selected data to calculate a target boiler water temperature. A detailed description of outdoor reset is presented later in this section.

•

Mode 2, Permanent Demand and Outdoor Reset: In this mode, the boiler operates to

maintain a supply (header) temperature calculated by the outdoor reset algorithm. The boiler operates independently of any room thermostats. This is useful in buildings with many zones which operate on independent thermostats to prevent the boost function (described later in this text) from increasing the target temperature due to a long sustained call for central heat resulting from overlapping individual calls.

•

Mode 3, Permanent Demand: This mode is similar to Full Outdoor Reset except that the control targets a fixed setpoint instead of a calculated setpoint based on the outdoor temperature. Again, the boiler control operates independently of input from room thermostats. If a switch between terminals #1 and #2 is closed, the target temperature will be set back by 18°F (10°C).

•

Mode 4, 0 -10V Input to Modulate Setpoint: This allows the boiler supply target to be set by an external analog 0-10 volt signal. The input for this signal is at terminals #15 & #16. A call for heat will be generated by a signal of

1.5 VDC or higher. The setpoint for an input voltage between 1.5 and 2.0 VDC will result in a boiler setpoint of 68°F (20°C). An input voltage of 10 VDC will result in a setpoint of 195°F (91°F).

•

Setback: If a switch is closed across terminals #1 & #2, a setback of 18°F (10°C) is applied to the calculated target temperature. This feature is useful in a building (such as an office building) that is unoccupied during certain times. A switch or timer can be used to set back the boiler target temperature during unoccupied periods.

d. Pump Purge Time: The installer can define the

length of time that the circulators operate after the end of call for heat. The CH and General circulator post purge time can be set independently. The following chart shows the range and default values for both of these pumps.

e. Outdoor Reset

: Since heating loads are typically lower when the outdoor temperature rises, outdoor reset lets the installer reduce the boiler target temperature as the outdoor temperature increases. As mentioned above, this increases the efficiency of the boiler. This is especially true with condensing boilers because it helps to recover the heat from the water vapor which, in conventional boilers, carries valuable energy out with the exhaust.

f. System Type Presets

: For convenience, the

UREFIRE

boiler control provides preset values for the outdoor reset parameters based on the system type. Table 8.17 shows the values that are applied when different system preset types are selected. If the system type, “User Defined” is chosen the outdoor reset definition values may be adjusted. If changes are made to the boiler design or mild weather boiler temperatures, the system type is automatically switched to, “User Defined”.

BOILER CONTROL: OPERATION

Table 8.16: Pump Purge Time Ranges & Defaults

Figure 8.33: CH Settings – Pump Purge Time

Table 8.15: CH Modes

Mode Display

Target

Temperature

Action when

Terminals #1 &

#2 Closed

Indoor

Thermostat

Fixed Setpoint

Call for Central

Heating

Indoor

Thermostat

with OD Reset

Outdoor Reset

Calculation

Call for Central

Heating

Permanent

Demand & OD

Reset

Outdoor Reset

Calculation

18°F (10°C)

Target Setback

Permanent

Demand

Fixed Setpoint

18°F (10°C)

Target Setback

0-10 V Input

to Modulate

Setpoint

External Analog

(0-10 VDC) Input

of Setpoint

No Effect

Circulating Pump Minimum Default Maximum

Central Heating (CH) 0 1 minute 60 minutes

General 0 1 minute 60 minutes

Managing Burner Only

Figure 8.32: CH Settings – CH Modes

Managing Burner Only

Page 49

BOILER CONTROL: OPERATION

g. Warm Weather Shutdown: If the boiler is set to

operate in CH Mode 1 or 2, the P

UREFIRE

control is set by default to prevent the boiler from operating to satisfy a central heat demand if the outdoor temperature is above 70°F (21°C). This value can be adjusted using the values shown below.

If the installer prefers to use custom values for the outdoor reset parameters, the following provides guidance.

h. Design Point

: The design point is defined by the

outdoor design temperature and the boiler design temperature.

i. Boiler Design Temperature

: The boiler design temperature is the temperature at which the boiler is designed to operate in order to meet the load. Copper finned tube radiators are typically rated at 180°F (82°C). The Table 8.19 shows typical boiler design temperatures for different types of head distribution units.

j. Outdoor Design Temperature

: The heat loss for the structure is determined by considering the coldest sustained outdoor temperature that is expected at the site location. For a detailed list of outdoor design temperatures by state, refer to the H-22 heat loss calculation guide published by AHRI.

Figure 8.35: Outdoor Reset Operation

Table 8.17: System Type Presets

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 8.18: Warm Weather Shutdown Range &

Default

Parameter Minimum Default Maximum

Warm Weather Shutdown 35°F (-18°C) 70°F (21°C) 100°F (38°C)

Figure 8.36: CH Settings – Reset Curve Design

Table 8.19: Reset Curve Design Ranges & Defaults

Parameter Minimum Default Maximum

Boiler Design Temp. 61°F (16°C) 180°F (82°C) 195°F (91°C)

Outdoor Design Temp. -40°F (-40°C) 0°F (-18°C) 70°F (21°C)

Managing Burner Only

Figure 8.34: CH Settings – Warm Weather Shutdown

Managing Burner Only

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BOILER CONTROL: OPERATION

k. Mild Weather Point: The mild weather point is

defined by the mild weather outdoor temperature and the mild weather boiler temperature.

l. Mild Weather Boiler Temperature

: This is the minimum temperature that the boiler will target to satisfy a CH demand. In radiant floor design, this temperature can be set very low. However, avoid setting the temperature too low in systems with limited radiator surface and in lower floors with open stairways that can allow heat to migrate up to higher floors.

m. Mild Weather Outdoor Temperature

: This temperature is the highest outdoor temperature at which the boiler is expected to run. The default value for this is 70 which equals the default warm weather shutdown value.

The example in Figure 8.35 shows an outdoor temperature of 0°F (-18°C) which corresponds to the value for Springfield, Massachusetts. The boiler temperature is shown at 160°F (71°C) to meet the load as determined by the system designers. The mild weather point is at an outdoor temperature of 70°F (21°C) and a boiler temperature of about 85°F (29°C). When the outdoor temperature is 32°F (0°C), the boiler will target 130°F (54°C).

n. Boiler Limits

: The boiler limits are available to limit the minimum and maximum temperature that the boiler can target. Note that these limits will override the values set in the outdoor reset design and mild weather outdoor reset parameters.

o. Boiler Min

: The boiler will not target a temperature lower than what is chosen in this menu screen. The default for this is, “Off” since low temperatures will not affect the boiler. However, it may be useful in installations that require a minimum temperature to operate (like a fan coil unit that will not allow a fan to operate below a certain temperature).

p. Boiler Max

: The boiler will not target a temperature higher than that chosen in this menu. This can be useful to prevent damage due to high temperatures in temperature sensitive situations such as radiant floors.

q. Boost

: The boost function is designed to compensate for a system that is not meeting the required load. If there is a constant call for central heat for the length of time specified, the target temperature will be increased by the temperature value selected. The boiler will never target a temperature higher than that specified by the boiler max. parameter.

There are several reasons why the boost function may or may not be implemented.

•

In buildings which have many zones, there may seldom be a period when none of the zones is calling for heat. In this case, the boiler will very often be operating at the temperature selected by the “boiler max.” parameter, and much of the advantage of a condensing boiler may be lost. Therefore, it may be better to use CH Mode 2, “Permanent Demand and Outdoor Reset” in these situations. In this mode, the boost function is not applied therefore the boiler will continue to run at the temperature calculated by the outdoor reset algorithm.

•

Programmable thermostats can give a building owner the ability to set back the thermostat significantly during unoccupied periods. After an aggressive setback, it may take the boiler a significant amount of time to recover. However, this may lead to the boiler frequently operating at higher temperatures, where it is less efficient. Before using setback thermostats, the building owner should be made aware that aggressive setback s of 10°F (6°C) or more may not have the desired effect.

•

If the outdoor reset parameters are set for design conditions at a certain outdoor design temperature, and the outdoor temperature drops below that temperature for a significant amount of time causing cold indoor temperatures, the boost function can allow the boiler to target temperatures up to the boiler maximum to satisfy the load.

Table 8.21: Reset Curve Min/Max Ranges & Defaults

Figure 8.39: CH Settings – Temperature Boost

Table 8.22: Temperature Boost Ranges & Defaults

Parameter Minimum Default Maximum

Boost Temperature 0°F (0°C) 18°F (10°C) 36°F (20°C)

Boost Time 1 minute 20 minutes 60 minutes

Figure 8.37: CH Settings – Reset Curve Mild

Weather

Figure 8.38: CH Settings – Reset Curve Min/Max

Table 8.20 Reset Curve Mild Weather Ranges &

Defaults

Parameter Minimum Default Maximum

Mild Weather Boiler Temp.

36°F (2°C) 70°F (21°C) 160°F (71°C)

Mild Weather

Outdoor Temp.

36°F (2°C) 70°F (21°C) 85°F (29°C)

Parameter Minimum Default Maximum

Boiler Minimum “Off” or 40°F (4°C) OFF 180°F (82°C)

Boiler Maximum 81°F (27°C) 195°F (91°C) 195°F (91°C)

Managing Burner Only

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BOILER CONTROL: OPERATION

r. Anti-Cycling Time: This function allows the

installer to set the minimum amount of time that the boiler can be off on setpoint before recycling. If the supply temperature drops by a value higher than Tdiff, the boiler will ignore the minimum off time and resume operation. If excessive cycling occurs due to cycling of the thermostat or zone relay, then the operation of these items should be examined.

s. System Response Time

: To modify the reaction time of the system for a CH demand, the I-value parameter can be changed. The following chart shows the range of values with descriptions of the corresponding response speed.

Increase this value to reduce cycling in systems with smaller zones. Decrease this value for a more aggressive reaction to CH loads. This parameter effects only the CH response time, a similar parameter is available in the DHW Settings menu.

t. Maximum Allowable CH Rate

: If the boiler is sized primarily for a DHW load that is significantly higher than the CH load, this value can be decreased to limit the input rate of the boiler for central heating. The following chart shows the effective input values for various modulation percentages. As an example, if the DHW load is 1000 MBH and the CH load is 680 MBH, set the “Max Allowable CH Rate” to 60%.

5. Domestic Hot Water (DHW) Settings DHW settings manage the boiler temperature and circulators for the domestic water heating load. The boiler can be configured to operate without a domestic hot water load, with an indirect-fired hot water tank which incorporates a conventional thermostat, or with an indirect-fired hot water tank equipped with a water tank temperature sensor (PB#54157). The configuration using the optional tank temperature sensor allows the control to maximize the efficiency of the system by limiting the input rate to recover from standby losses.

a. Domestic Hot Water Modes

: This menu is used to

change the control response to calls for DHW.

•

Mode 0, No DHW: Mode 0 indicates that there is no DHW load. The DHW pump outputs will be deactivated and the control will not respond to any signals at terminals #5 & #6.

•

Mode 1, DHW Tank with Sensor: Mode 1 is used with a temperature sensor input from the DHW tank. The optional sensor (PB #54157) transmits the tank temperature to the control which allows the control to determine the most efficient boiler operation to address the heat demand.

Figure 8.43: DHW Settings – DHW Modes

Table 8.26: DHW Modes

Mode Display

Input to Terminals

#5 & #6

0 No DHW None Required

DHW Tank

with Sensor

NTC Thermistor

Temperature Input

DHW Tank

with Thermostat

Dry Contacts from

DHW Thermostat

Table 8.24: System Response Range & Default

I-Value Response Time Description

15-20 Very Fast 25-40 Fas t

45-80 (Default=60) Medium

85-110 Slow

115-120 Very Slow

Figure 8.42: CH Settings – Maximum CH Rate

Table 8.25: Maximum CH Rate Range & Default

% Modulation PF-850 PF-1000

50% 255 MBH per Burner 300 MBH per Burner 60% 289 MBH per Burner 340 MBH per Burner 70% 323 MBH per Burner 380 MBH per Burner 80% 357 MBH per Burner 420 MBH per Burner 90% 391 MBH per Burner 460 MBH per Burner

100%

(Default)

424 MBH per Burner 500 MBH per Burner

Table 8.23: Anti-Cycling Ranges & Defaults

Figure 8.41: CH Settings – System Response

Figure 8.40: CH Settings – Anti-Cycling

Parameter Minimum Default Maximum

Anti-Cycling Time 0 minutes 3 minutes 15 minutes Anti-Cycling Tdiff 20°F (11°C) 30°F (17°C) 40°F (22°C)

Managing Burner Only

Page 52

BOILER CONTROL: OPERATION

When this mode is chosen, the DHW Boiler Temperature and the DHW Tank Temperature setpoint values are available on the User Menu. The control will modulate the burner input based on feedback from the boiler supply temperature sensor. Therefore, if the tank temperature meets its setpoint before the boiler supply is close to its setpoint, the boiler may shut down while still in high fire. If this occurs often, lowering the DHW boiler supply setpoint will help to initiate modulation sooner.

Mode 1 can also decrease operating costs by assuring that the boiler operates at its minimum firing rate to address loads due only to standby losses.

•

Mode 2, DHW Tank with Thermostat: This is the default DHW mode and it operates with a contact closure from a typical indirect tank thermostat. In this mode, the control targets the DHW boiler setpoint in the User Menu.

b. DHW Switch Time

: When the PUREFIRE®boiler control is supervising the CH and DHW circulating pumps, it operates with a limited DHW priority strategy.

•

If there is a CH demand from the thermostat when the DHW tank calls for heat, the control will immediately switch from CH to satisfy the DHW demand.

–

The control will continue to attempt to satisfy the DHW load until the selected switch time is reached.

–

Once the switch time is reached, the boiler will switch back to the CH demand.

– If either the CH or DHW demand is satisfied,

the boiler will then focus on satisfying the remaining load.

•

If there is a CH demand during a call for DHW, the boiler will continue satisfying the tank load until the switch time is reached.

– After that it will alternate loads at the end of

each switch time until one of the loads is satisfied.

– Then again, it will focus on the remaining

call for heat.

c. DHW Heat Dump

: Scientists at Brookhaven National Laboratories have performed experiments which suggest that diverting heat from the boiler into an indirect storage tank at the end of each cycle improves the overall efficiency of the heating system. The heat dump function is designed to take advantage of this principal.

•

At the end of a heating cycle, when the CH demand is satisfied, the control switches off the CH circulating pump and turns on the DHW pump for the Max Time period.

•

If the temperature difference between the supply and return of the boiler drops lower than the Min Diff value, the pumps shut down.

d. System Response Time

: The system response time works identically for DHW demands as it does for CH demands. These values are designed to allow independent modification of the response time for CH and DHW loads. For small DHW loads, the IValue can be increased. For large DHW loads, this value can be decreased. If the burner doesn’t modulate when it satisfies a DHW load, this value should be increased.

e. Maximum Allowable DHW Rate

: If the boiler is sized primarily for a CH load that is significantly higher than the DHW load, this value can be decreased to limit the input rate of the boiler for domestic hot water.

6. Service Notification The P

UREFIRE

boiler control gives installers several options to notify building owners when boiler service should be performed. The first screen that appears, after choosing Service Notification, is Reset Notifications. Pressing select resets the hours and cycles to “0”.

The default for this optional feature is, “OFF”. However, if it is enabled, the installer can choose the number of hours, the number of cycles or the date when, “SERVICE” appears on the LCD menu screens.

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

Table 8.28: DHW Heat Dump Ranges & Defaults

Table 8.27: DHW Priority Swtich Time Range &

Default

Figure 8.44: CH Settings – DHW Priority Swtich Time

Figure 8.45: DHW Settings – Heat Dump

Figure 8.46: DHW Settings – Response Time

Figure 8.47: DHW Settings – Maximum DHW Rate

Parameter Minimum Default Maximum

DHW Heat Dump OFF OFF ON

Maximum Time 0 minutes 1 minute 60 minutes

Minimum Difference 0°F (0°C) 5°F (3°C) 10°F (6°C)

Parameter Minimum Default Maximum

CH/DHW Switch Time 5 minutes 30 minutes 60 minutes

Page 53

If desired, the installer can select a specific date for the Service Notification. Simply press the “Select” key when viewing the “Notification on:” date screen. Use the “” and “” keys to set the value. Pressing “Select” activates the next date parameter.

7. System Test System Test settings allow the installer or service person to operate each burner manually at it maximum, minimum and ignition rates. The following outlines the system test operation.

a. Managing Burner Only

•

Eliminate all heat demands to the boiler by disconnecting the CH thermostat from terminals #1 & #2 and disconnecting the DHW sensor or thermostat from terminals #5 & #6.

•

Use the “” and “” keys to position the arrow at the desired power setting.

•

Press select to activate System Test. The burner will ignite and then operate at the selected input rate until “Off” is selected from the System Test menu or for 1 hour. The burner may cycle off on limit if the input rate exceeds the heating load.

b. Dependent Burner Only

•

Eliminate all heat demands to the boiler by disconnecting the CH thermostat from terminals #1 & #2 and disconnecting the DHW sensor or thermostat from terminals #5 & #6.

•

Use the “” and “” keys to position the arrow at the desired power setting.

•

c. Both Burners

•

Eliminate all heat demands to the boiler by disconnecting the CH thermostat from terminals #1 & #2 and disconnecting the DHW sensor or thermostat from terminals #5 & #6.

•

Start the managing burner, setting it to Ignition Power in the Service menu.

•

Start the dependent burner, setting it to Ignition Power in the Service menu.

•

Change the individual burner Power to the required input rate. Avoid setting a burner to minimum power and one to high power. (This may cause a flame failure or flapper valve error.)

d. Pump For CH/DHW

•

This function can be used to check the function of the CH and DHW circulating pump outputs.

•

While in “Standby” on both burners, choose the desired pump output from the Installer Menu, System Test screen on the managing burner display.

•

The pump terminals should be activated. If the pumps don’t appear to be operating, check the voltage on the pump output terminals.

e. Multiple Boiler Systems

•

These selections may also be used in a multiple boiler, cascade system when testing a dependent burner.

•

In multiple boiler systems, these pumps are to be connected to the master boiler in the cascade. Therefore, when a dependent boiler is being tested, there will not likely be sufficient heating load to run the boiler for very long.

•

In this case, choose “Pump For CH” or “Pump for DHW” from the System Test menu on the managing burner display of the master boiler in the system before running the dependent boilers.

Figure 8.49: System Test Menu

BOILER CONTROL: OPERATION

Figure 8.48: Service Notification

Table 8.29: Service Notification Ranges & Defaults

Notification On

Minimum Default Maximum

OFF OFF ON

Hours 0 4,000 8,000

Cycles 0 50,000 20,000

Page 54

Table 8.30: Sequence Menu, Ranges & Defaults

BOILER CONTROL: OPERATION

Menu Screen

Ranges & Defaults

Minimum Default Maximum

1 Minute 2 Minutes 15 Minutes

1°F

(0.6°C)

9°F

(5°C)

23°F

(13°C)

1°F

(0.6°C)

18°F

(10°C)

45°F

(25°C)

0°F

(0°C)

18°F

(10°C)

36°F

(20°C)

0°F

(0°C)

9°F

(5°C)

36°F

(20°C)

40% 50% 95%

5% 9% 40%

0 Days

(No Rotation)

5 Days 30 Days

Page 55

8. Sequence (Managing Burner Display Only) Adjustments in the sequence menu affect the sequence of burner operation. The first six parameters will stop and start burners as follows:

a. On a call for heat (either CH or DHW) the 1st

burner will start. The 1st burner can be either the managing or dependent burner based on the

Rotation Interval

chosen.

b. After the 1st burner is activated, the 2nd burner will

come on if all three of the following conditions are met:

i. Supply Temperature < Target Temperature –

Start Burner Differential

ii. 1st Burner Input Rate > Next Burner Start

Rate

iii. Start Delay Time has elapsed (Time from

when both prior parameters are met)

c. The 2nd burner will be deactivated if the following

conditions are met:

i. Supply Temperature > Target Temperature +

Stop Burner Differential

ii. Both Burner Input Rates < Next Burner

Stop Rate

iii. Stop Delay Time has elapsed (Time from

when both prior parameters are met)

d. Calculated Setpoint Max Offset Up/Down

: The target supply temperature of both burners are adjusted if the system supply temperature is above or below the targeted value. For example, if the system supply target temperature is 150°F, each burner will target this temperature. However, if they approach their individual target temperature before the system supply approaches its target, a temperature offset is applied. This offset is calculated based on the Calculated Setpoint Max offset up. Similarly, if the system target is above its target a calculated negative offset based on the Calculated Setpoint Max offset down is applied. The maximum increased setpoint temperature is 195°F (91°C).

E. 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.F: MULTIPLE BOILERS

F. MULTIPLE BOILERS

1. Multiple Boiler Wiring: Two methods for connecting the master boiler to the dependent boilers are allowed.

a. Figure 8.53 shows a daisy chain configuration.

This method is convenient but can lead to more than one boiler shutting down in the case of an open circuit.

b. Figure 8.54 shows the master boiler connected to

each dependent boiler. This method creates independent connections to each dependent boiler.

c. Each boiler controls its own “General” pump that

operates any time that boiler is operating. It is extremely important to have water flow through the boiler during burner operation.

d. All external inputs (Outdoor Temperature Sensor,

DHW Tank Temperature Sensor and System Sensor must be connected to the master boiler.

e. The domestic hot water (DHW) circulating pump

should be connected to the master boiler.

f. The central heating (CH) circulating pump(s)

should be connected to the master boiler if they are intended to be controlled by the boiler system.

2. Multiple Boiler Address & Menu Options: In order to operate multiple boilers in cascade, a unique address must be assigned to each of the dependent boilers.

a. To access the cascade menu:

i. Remove the grey plastic front panel of the

boiler to get full access to the Pixel display module.

ii. Open the lower cover on the display to expose

the extended menu keys.

iii. Press and hold the “ ” key for 5 seconds and

release: The boiler address selection will be displayed. This is the only menu option unless the boiler is configured as the master boiler with a boiler address of “1”.

iv. Use the “

M” and “L” key to scroll through

the option list. The bullet “●” will appear to the left of the option.

v. Pressing the “OK” key selects the parameter to

change. The bullet “●” on the screen will appear between the option name and its value.

vi. Use the “

M” and “L” key to change the value

and press “OK” to update.

vii. Pressing the “MENU” key on the pixel display

will return to the standard display screen.

BOILER CONTROL: OPERATION

Figure 8.50: Restore Factory Defaults Screen

Figure 8.51: Save Site Defaults Screen

Figure 8.52: Restore Site Defaults Screen

Page 56

Figure 8.53: Mutiple Boiler Wiring – Daisy Chain Configuration

Figure 8.54: Multiple Boiler Wiring – Independent Connection to each Dependent Boiler

BOILER CONTROL: OPERATION

Page 57

BOILER CONTROL: OPERATION

Table 8.31: Multiple Boiler Menu Options (Pixel Display on the front of the boiler)

Boiler

Address

Min 0

This value determines the status of the boiler in a cascade system. The default, “0”, indicates it is a stand-alone boiler. “1” is to be assigned to the master boiler in the system and “2” up to “16” are assigned to dependent boilers. In a cascade system, be sure that no boiler address is duplicated.

Max 16

Default 0

Start Delay

Time

Min 1 min

The master control waits for this delay period before bringing on the next boiler. The system temperature must be less than the target temperature by the “Start Boiler Differential” temperature for this period of time before operation of another boiler is initiated.

Max 15 min

Default 2 min

Stop Delay

Time

Min 1 min

The master control waits for this delay period before shedding a boiler from the system. The system temperature must be more than the target temperature by the “Stop Boiler Differential” temperature for this period of time before operation of a dependent boiler is terminated.

Max 15 min

Default 2 min

Start Boiler

Diff.

Min 1°F (0.5°C)

The master control compares the system temperature to the target value to determine whether to add a dependent boiler.

for longer than the Start Delay Time, then the next dependent boiler will be initiated.

Max 23°F (13°C)

Default 9°F (5°C)

Stop Boiler

Diff.

Min 1°F (0.5°C)

The master control compares the system temperature to the target value to determine whether to shed a dependent boiler.

for longer than the Stop Delay Time, then operation of a dependent boiler will be terminated.

Max 45°F (25°C)

Default 9°F (5°C)

Stop All

Boiler Diff.

Min 1°F (0.5°C)

The master control compares the system temperature to the target value to determine whether to stop all boilers in the cascade system.

for longer than the Stop Delay Time, then operation of all boilers will be terminated.

Max 45°F (25°C)

Default 18°F (10°C)

Max Offset

Min 0°F (0°C)

The master control uses a PID function to scale a target temperature offset for boilers in order to approach the system target temperature. Increased values are scaled between the “Max Offset Up” and the system target.

Max 36°F (20°C)

Default 9°F (5°C)

Max Offset

Down

Min 0°F (0°C)

The master control uses a PID function to scale a target temperature offset for boilers in order to approach the system target temperature. Decreased values are scaled between the “Max Offset Down” and the system target.

Max 36°F (20°C)

Default 36°F (20°C)

Rotation

Interval

Min 0 (off)

The master boiler determines which boiler starts first based on the “Rotation Interval”. After that it initiates the next boiler in the address sequence in accordance with the cascade parameters. Boilers are shed in an order reverse of the initiation.

Max 30 days

Default 5 days

P Value

Min 0

The P- Value is the temperature range where the PID function operates in degrees Celsius and is symmetrical across the target temperature. The default value of “20” corresponds to 36°F above and below the target temperature. For example, if the target temperature is 140°F, the temperature range will be from 104°F to 176°F.

Max 255

Default 20

I Value

Min 0

The “I-term” determines the speed at which the control allows the temperature offset for the dependent boilers to change. A lower value makes changes to the target more aggressively than a larger value. This value can be increased for systems which have excess capacity and decreased if the system does not respond quickly enough.

Max 120

Default 40

D Value

Min 0

The “D-Term” should be set to “0” to most effectively utilize the P-Band of the function. Do not change this value without specific direction from the factory.

Max 255

Default 0

Slew Rate

Min 1

The slew rate limits the rate of change for target temperatures on dependent boilers. A larger value allows faster corrections to the dependent boiler offset temperatures.

Max 255

Default 1

Target

Temp.

–

System

Temp.

Start Boiler

Differential

System

Temp.

–

Target

Temp.

Stop Boiler

Differential

System

Temp.

–

Target

Temp.

Stop All

Boiler

Diff.

Page 58

b. The default address for each boiler is “0”

c. Selecting a boiler address of “1” assigns the boiler

as the master. Be sure that this is the boiler that is connected to the system pumps and external sensors.

d. Once a boiler is configured as the master boiler, a

menu containing all cascade options listed in Table

8.31 will be displayed. The remaining options are intended to operate well with most boiler systems using the default parameters. However, the descriptions below allow the experienced installer or service person to modify the operation of the cascade system if improvements are warranted

e) Figures 8.55 and 8.56 show how the P-Value, Max

Offset Up and Max Offset Down values affect the dependent boiler setpoints.

i) The graphs illustrate the default values for the

control with a target temperature of 140°F.

ii) The control scales the actual supply

temperature to a 1-255 scale in the range defined by the target temperature and the PValue. From Figure 8.55 we can see that if the supply temperature is above 176°F the output from the P-Value will be 1.

iii) Conversely, if the supply temperature is below

104°F the output from the P-Value will be 255. At any point within the range, the P-Value will be scaled. As an example, if the supply temperature is at the 140°F setpoint the scaled value will be 128.

f) Figure 8.56 illustrates the range defined by the Max

Offset Down and Max Offset Up parameters.

i) If the output from the P-Value is 1, the

dependent setpoint will be set to the minimum value (104°F in this case).

ii) If the output from the P-Value is 255, the

dependent setpoint will be set to the maximum value (149°F).

iii) From the previous example, the output value

from a supply temperature of 140°F yields a value of 128. Transferring this value to the dependent setpoint scale indicates that the dependent boiler setpoints will be approximately 127°F.

g) The I-Value determines how quickly the setpoint

changes. Larger values result in a slower response time and smaller values decrease the response time.

h) The Slew Rate limits the rate of change in

dependent boiler setpoint. In this case, a larger value allows a faster change in setpoint while a lower value limits the rate of change.

3) Cascade Display: When the master boiler has no heat demand, there is no heat demand to the system. Therefore, each boiler in the cascade will read “CASCADE BOILER #” followed by its boiler address.

a) The master boiler will display, “CASCADE

BOILER #1”.

b) Pressing the down arrow will display the cascade

system information including the master supply sensor temperature and the status of all boilers with which it is communicating. See Figure 8.57 for the cascade status screen illustration.

Figure 8.55: P-Value Output

Figure 8.56: Dependent Setpoint

BOILER CONTROL: OPERATION

Figure 8:57: Cascade Status Screen

Page 59

9. START-UP PROCEDURE

START-UP PROCEDURE

A. GENERAL

1. Confirm all water, gas and electricity supplies to the boiler are off.

2. Verify that the water piping, venting & air intake piping, gas piping and electrical wiring are installed in accordance with this manual and good engineering practice.

B. CHECK WATER PIPING

1. Be sure that the expansion tank is sized, installed and charged in accordance with the manufacturer’s instructions and system requirements.

2. Fill the boiler and system with water, making certain to purge all air from the system.

3. Check joints and fittings throughout the system for leaks and repair as required. Do not allow water to drip on the boiler to prevent damage from corrosion.

C. CHECK ELECTRIC POWER

1. Turn off both burner switches (Managing & Dependent) on the cover of the electrical enclosure located on the right side of the boiler under the heat exchanger jacket panel. “0” indicates that the switch is off while “1” indicates on. Note that these switches do not disconnect power from the circulation pump outputs.

2. Turn on the main power, then turn on the individual burner switches. Verify that both displays on the electrical enclosure panel are lit. Also, be sure that the “Pixel” display on the front of the boiler is on.

3. Check to be sure that the incoming power is within specification. The incoming power should be phaseneutral (Voltage between Neutral & Ground approximately 0 volts) with minimal electrical noise.

4. The voltage reading between the hot (L1) and neutral should approximately equal the voltage between hot (L1) and earth ground (GND). The voltage reading between neutral (L2) and earth ground (GND) should be approximately 0 volts. If the readings are significantly different than this, assure that an appropriate earth ground is connected to the system. The P

UREFIRE

main control is not designed to operate

in a phase-phase power supply configuration.

D. CHECK GAS PIPING

1. Turn off the gas shut-off valve to each burner. These valves are located in the vestibule area at the front of the boiler.

2. Open the gas shut-off valve on the rear of the boiler and allow the gas header to be pressurized. Press the reset buttons on both gas pressure switches to be sure that they are reset and operational. The burner LCD displays on the control cabinet will read “INTERLOCKS OPEN” if the gas pressure switches are not reset or if any of the interlocks connected to terminals #11 & #12 are open.

3. Connect a manometer to the incoming gas line and be sure that the pressure is regulated to between 3.5" and 21.0" of water at the inlet to the boiler. Contact the gas supplier if the pressure to the boiler is too high or too low.

4. Perform gas line pressurization test while the manual shut-off valves to the burners are in the “off” position. This will prevent damage to the gas safety valves during the test due to over-pressurization.

5. Check the incoming gas pressure while the boiler is running to be sure that the pressure doesn’t drop to an unacceptable level during operation.

E. CHECK OPERATION

The installation is not complete until the following systems are tested and the control is set up:

1. Test combustion emissions on each burner individually and with both burners firing.

2. Test the operating control on each burner

3. Test the high limit for each burner

4. Test the interlock circuit (LWCO, etc.)

The following paragraphs (F-I) describe this testing.

F. COMBUSTION TEST

1. Disconnect the CH thermostat and DHW tank thermostat/sensor input or set these inputs to assure no call for heat is present.

2. Turn on the electrical power and all manual gas valves to the burners. Be sure that both LCD Screens on the control cabinet cover are lit and that the main display on the front of the boiler is lit. The LCD screens should show “Standby” and the Pixel display should show “No Demand”.

Minimum Maximum

Supply Voltage 102 volts 132 volts

Supply Frequency 40 hertz 70 hertz

Page 60

3. Managing burner combustion test at high fire (100% Modulation):

a. ON THE MANAGING BURNER, enter the

“Installer Menu” by pressing and holding the “Select” & “Menu” keys simultaneously for 3 seconds.

b. Use the “” key to scroll down until the cursor

(➞) is at “System Test”. Press “Select”.

c. Use the “” key to scroll down to “High Power”.

Pressing select will initiate the burner operation.

d. The burner will ignite and, after a short

stabilization period, run at 100% of modulation. If the supply temperature exceeds the setpoint (or the boiler design temperature if an outdoor reset CH mode is chosen) the burners will shut down.

e. Using a suitable combustion analyzer (Testo 330-2

or equivalent) determine the exhaust emissions of the boiler.

f. Using Table 9.1, determine the appropriate

emissions levels.

g. If the

emissions are incorrect, adjust the throttle screw to correct the combustion. Note that increasing the throttle adjustment (counterclockwise) will decrease the O

and increase the CO2. Decreasing

the throttle will have the opposite effect.

4. Managing burner combustion test at low fire (1% modulation):

a. Enter the “Installer Menu” and choose “System

Test”. Press “Select”.

b. Use the “” key to scroll down to “Low Power”.

Pressing select will initiate the burner operation.

c. The burner will ignite and, after a short

stabilization period, run at 1%.

d. Using a suitable combustion analyzer (Testo 330-2

or equivalent) determine the exhaust emissions of the boiler and compare them with Table 9.1.

e. Do not make throttle adjustments in Low Power

system test. If the low fire values are out of specification, contact your PB Heat representative.

5. Dependent burner combustion test at high fire (100% modulation).

a. ON THE DEPENDENT BURNER enter the

“Installer Menu” and choose “System Test”.

b. Press select and use the “” key to scroll down to

“High Power”.

c. The burner will ignite and, after a short

stabilization period, run at 100%.

d. Using a suitable combustion analyzer determine

the exhaust emissions of the boiler and compare them with Table 9.1.

e. Adjust the throttle screw if necessary to correct the

combustion.

6. Dependent burner combustion test at low fire (1% modulation).

a. ON THE DEPENDENT BURNER, enter the

“Installer Menu” and choose, “System Test”.

b. Press select and use the “” key to scroll down to

“Low Power”.

c. The burner will ignite and, after a short

stabilization period, run at 1%.

d. Using a suitable combustion analyzer (Testo 330-2

or equivalent) determine the exhaust emissions of the boiler and compare them with Table 9.1.

e. Do not make throttle adjustments in Low Power

system test. If the low fire values are out of specification, contact your PB Heat representative.

7. Turn “System Test” to “Off” on both burner displays.

G. TEST OPERATING LIMIT

Check that each burner will shut down when the supply water temperature reaches the control setpoint + 9°F (5°C).

1. On the LCD display for each burner, note the boiler setpoint by accessing the User Menu, Status Display.

a. Press the “Menu” key on the keypad.

b. Choose “Status” by pressing the “Select Key”.

c. Use the “” and “” key to scroll through the CH

and DHW setpoints (Refer to Appendix B for an overview of the User Menu).

2. Enter the “Installer Menu” by pressing and holding the “Select” & “Menu” keys simultaneously for 3 seconds.

a. Use the “” key to scroll down until the cursor

(➞) is at “System Test”.

Be sure that the dependent burner is not running when performing the combustion test on the managing burner. If the other blower is running, the test results will not be valid.

NOTICE

Table 9.1: Recommended Combustion Settings

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 (CO2)

8.8% to

10.0%

8.5% to

9.5%

9.8% to

11.0%

9.5% to

10.5%

Excess

Oxygen (O

)

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%

Be sure that the managing burner is not running when performing the combustion test on the dependent burner. If the other blower is running, the test results will not be valid.

NOTICE

START-UP PROCEDURE

Page 61

b. Press select and use the “” key to scroll down to

“High Power”.

c. The burner will ignite and, after a short

stabilization period, run at 100%.

3. Monitor the boiler temperature on the temperature gauge (factory supplied for field mounting) and on the Status display.

a. The boiler should shut down at the boiler setpoint

plus 9°F (5°C).

b. If it does not shut down turn off the boiler and

contact your PB Heat representative.

H. TEST HIGH LIMIT

Check that each burner will shut down when the high limit circuit is open.

1. On the LCD display for the Dependent burner enter the “Installer Menu” by pressing and holding the “Select” & “Menu” keys simultaneously for 3 seconds.

a. Use the “” key to scroll down until the cursor

(➞) is at “System Test”.

b. Press select and use the “” key to scroll down to

“Low Power”.

c. The burner will ignite and, after a short

stabilization period, run at 1% modulation.

2. Disconnect the wire connection to the high limit (in the lower right side header with red connector).

a. The burner should shut down immediately and

enter a lockout condition.

b. Press the reset button on the control to enable

normal operation.

c. If it does not shut down turn off the boiler and

contact your PB Heat representative.

3. Enter the Installer menu on the managing burner and select, “System Test”.

a. Press select and use the “” key to scroll down to

“Low Power”.

b. The burner will ignite and, after a short

stabilization period, run at 1% modulation.

4. Disconnect the wire connection to the high limit (in the upper right side header with red connector).

a. The burner should shut down immediately and

enter a lockout condition.

b. Press the reset button on the control to enable

normal operation.

c. If it does not shut down turn off the boiler and

contact your PB Heat representative.

5. Turn “System Test” to “Off” on both burner displays.

I. MULTIPLE BOILER SYSTEMS

1. Since all heat distribution circulating pumps (CH/DHW) are connected to the master boiler, it may be necessary to run one of these pumps to get sufficient run time on the boiler for any of the commissioning tests indicated in this section. To do this, choose “System Test” from the “Installer Menu” on the master boiler, managing burner display.

a. Use the “” and “” keys to select “Pump for

CH” or “Pump for DHW” from the “System Test” menu.

b. Note that it is not necessary to operate these

pumps manually when running commissioning tests on the master boiler. In fact, the master boiler will automatically activate the CH pump terminals when operating under system test.

2. If using common venting on multiple boiler systems, be sure that the Alarm Mode (INSTALLER MENU ➞ Burner Settings ➞ Alarm Mode) is set to “Common Venting” to prevent operation of any of the boilers without monitoring the flapper valve closure switches. Turn the power off to one of the boilers (in Standby) in the system to be sure that the alarm sounds.

START-UP PROCEDURE

Page 62

START-UP PROCEDURE

J. LIGHTING & OPERATING INSTRUCTIONS

Figure 9.1: Lighting & Operating Instructions

Page 63

TROUBLESHOOTING

A. ERRORS

1. When an error occurs, the pixel display on the front of the boiler will display a wrench instead of one of the blowers and a message will appear indicating what the error is.

2. These error messages indicate on which burner the error occurred: (M) for managing or (D) for Dependent.

3. There are three kinds of errors that can occur:

a. Blocking Errors

– These are errors which will prevent the boiler from operating until the condition which caused the error is corrected. Then the boiler will restart without intervention.

b. Locking Errors

– These errors will prevent the boiler from operating and require a manual reset to allow the boiler to return to operation. The reset buttons for each burner are on the LCD display screens located behind the right rear jacket panel.

c. Warning Errors

– These errors are typically associated with temperature sensors (Outdoor, DHW or Flue) with circuits that are either open or shorted. These errors will cause the LCD screens on the control cabinet cover to blink. These LCD screens are located behind the right rear jacket panel.

4. The pixel display on the front of the boiler is primarily for status display.

B. BLOCKING ERRORS

1. When a blocking error occurs, the LCD display that corresponds to the burner with the error will show a message in English and an “E” code (E31 Interlocks Open).

2. Table 10.1 provides a list of blocking error codes, descriptions and corrective actions for these errors.

3. Certain blocking errors will, if uncorrected, become locking errors as described in the next paragraph.

C. LOCKING ERRORS

1. When a locking error occurs, the LCD display that corresponds to the burner with the error will show a message in English and an “A” code (A01 Ignition Error).

2. Table 10.2 provides a list of locking error codes, descriptions and corrective actions for these errors.

3. These errors require a manual reset of the display for the burner with the error. These displays are located behind the right rear jacket panel and are designated “Managing” and “Dependent”.

D. WARNING ERRORS

The individual LCD burner displays 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.

10. TROUBLESHOOTING

Figure 10.1: Blocking Error Display

Figure 10.2: Locking Error Display

Figure 10.3: Warning – Outdoor Sensor Shorted

Figure 10.4: User Menu – Temperature Status Screen

Page 64

TROUBLESHOOTING

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. The system (header) sensor is mounted in the

supply (outlet) header on the PF-850 and PF-1000 boiler. If no system (header) sensor is connected or if there is an open circuit, the display will blink and the supply temperature on the front pixel display will read 14°F.

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

wiring, the display screen will blink and the supply temperature on the front pixel display will read 244°F.

c. Under either of these conditions, the managing

burner will set the supply setpoints of both burners 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. No Comm. Error: a. If the dependent burner is not communicating

with the managing burner and it is set as “dependent burner” in the Installer Menu, the screen will blink and the following message will be displayed on the dependent burner LCD screen.

b. The burner will stay off until the condition is

corrected. The managing burner will operate normally. However, if there is a NO COMM CASCADE error, check the Installer Menu, under Burner Options, on the managing burner to be sure that it is set to “managing burner.

E. SPECIAL IGNITION/FLAME FAILURE

1. Depending on local codes the allowable number of

ignition attempts or flame failures may be different. The “Installer Menu” may allow up to three ignition attempts and three recycle attempts on flame failure. In addition, it allows the installer to choose a “One Hour Retry” option that can restart the boiler after one hour of a lockout due to ignition or flame failure. These values are set to the most restrictive from the factory but can be changed at the boiler installation.

2. As a diagnostic tool, the P

UREFIRE

control logs the flame signal four times during the last 2 seconds of each ignition period. Each successive ignition will overwrite the values from the previous ignition. This is to aid in troubleshooting ignition errors. A flame signal below 3.0 µA at the end of this period will result in a failed ignition.

a. If the recorded flame signal values are low, 1.0 to

3.0 µA:

•

assure that the flame at ignition is visible through the observation window

•

check that the position of the flame rod is within 5/16" (9 mm) of the burner. Figure

10.10 shows the correct position of the flame rod and ignition electrode

•

clean the flame rod with abrasive cloth

b. If the recorded flame signal values are below 1.0

µA:

•

check for an appropriate spark gap

•

check the flame rod for cracks in the ceramic or corrosion bridging to metal

F. INTERLOCKS OPEN

1. An error message displaying, “E31 Interlocks Open” may indicate several conditions:

a. Any interlock connected to terminals #11 & #12

on the boiler terminal blocks is open

b. The low or high gas pressure switch is tripped

Figure 10.7: Warning – Flue Sensor Hold

Figure 10.8: Warning – Flue Sensor Open

Figure 10.9: Warning – No Communication Cascade

Figure 10.5: Warning – DHW Sensor Open

Figure 10.6: Warning – DHW Sensor Shorted

Page 65

TROUBLESHOOTING

2. If a temporary jumper between terminals #11 & #12 allows the boiler to proceed to “Trial for Ignition” then one of the external interlocks (LWCO, etc.) may be open. Do not leave a jumper installed if there are interlocks attached to these terminals.

3. Pressing the reset buttons on both high and low gas pressure switches may reset the error. However, if this doesn't reset the error, check the incoming gas pressure. If it is between 3.5" and 21" of water then the switches should reset. If the error is occurring at or after ignition, check the gas pressure when the boiler lights off. It may be that the gas pressure drops significantly when the gas valve opens. In this case, contact the gas supplier to increase the available gas pressure.

Do not leave a jumper between terminals #11 & #12 if interlocks are attached to these terminals. Failure to comply may lead to severe personal injury, death or major property damage.

CAUTION

Figure 10.10: Correct Flame Rod and Ignition Electrode Position

Page 66

Table 10.1: Blocking Error Codes (automatic reset):

“E”

CODE

Error Display Error Description Corrective Actions

E01

SUPPLY SENSOR NOT CONNECTED

Supply sensor circuit is open.

1. Be sure sensor is plugged in.

2. Check continuity in both harness leads.

3. Temporarily connect the harness to another sensor to determine if the error is cleared. If so, this indicates a defective sensor.

4. Read the sensor temperature values in the “User Menu” under “Status”. 14°F indicates an open circuit.

Note: The component with the red connector is the high limit switch

not a sensor.

E02

RETURN SENSOR NOT CONNECTED

Return sensor circuit is open.

E04

DHW SENSOR NOT CONNECTED

DHW sensor circuit is open.

E05 STACK SENSOR OPEN Stack sensor circuit is open.

Check the sensor as above, the value in the “User Menu” under “Status” is 50°F.

E11 SUPPLY SENSOR SHORT Supply sensor is short circuited.

1. Check wires for signs of damage.

2. Temporarily connect the harness to another sensor.

3. The value for a shorted sensor in the “User Menu” under “Status” is 244°F.

E12 RETURN SENSOR SHORT Return sensor is short circuited.

E13 STACK SENSOR SHORT Stack sensor is short circuited.

E14 DHW SENSOR SHORT DHW sensor is short circuited.

E19

COMMUNICATION ERROR E2PROM ERROR

Software Error with boiler control.

1. Disconnect all external wires except for the 120 VAC control power.

2. If problem ceases, systematically replace wires to determine the location of the problem.

3. If problem persists, replace control.

E20 FALSE FLAME DETECTED Unexpected flame detected.

1. Verify that no flame is present.

2. Check and clean flame sensor.

3. Check boiler ground.

E21 HOT/NEUTRAL REVERSED

Polarity of power supply wires is reversed.

1. Reverse polarity of power supply wires.

2. Check boiler ground.

E22 POOR GROUND

No earth ground connected or internal hardware error.

1. Check boiler ground.

2. Check incoming frequency (If power supply is from a generator, check incoming frequency.)

E23 NET FREQUENCY ERROR

Frequency of incoming power is below 40 hertz or above 70 hertz.

1. If power supply is from a generator, check that the system is Phase/Neutral and check frequency. If frequency is out of range adjust the generator motor speed to correct it.

2. Check boiler ground.

E24 POOR GROUND

No earth ground connected or internal hardware error.

1. Check boiler ground.

2. Check incoming frequency (If power supply is from a generator, check incoming frequency.)

TROUBLESHOOTING

Page 67

“E”

CODE

Error Display Error Description Corrective Actions

E25 BLOCKED VENT

Pressure switch attached to condensate line is open.

1. Check for blocked exhaust outlet.

2. Check combustion chamber pressure. (Measure the difference in height between the condensate vessels.)

E26

BLOCKED CONDENSATE DRAIN

Float switch in condensate collector has tripped.

1. Check for blockage in condensate system.

2. Clean condensate system.

3. Check for broken wires or bad connections.

E30

HIGH STACK TEMPERATURE

Flue gas sensor temperature is above the maximum.

1. Check stack temperature in “User Menu” under “Status”.

2. Feel flue pipe for high temperature. If temp is high, clean and inspect heat exchanger.

3. Check flue sensor and harness.

E31 INTERLOCKS OPEN

Open circuit in interlocks or high or low gas pressure.

1. Is gas pressure within range?

2. Press gas pressure switch reset buttons.

3. Check connected interlocks.

E32 HIGH RETURN TEMP

Return temperature is above 195°F (90°C).

1. Is GEN pump operating correctly?

2. Is pump reversed?

3. Are supply (outlet) and return (inlet) piped correctly?

E42

INTERNAL HDWRE ERROR Internal error in boiler controls.

Systematically disconnect all wires except the incoming control power that were not supplied by the factory. If the error code discontinues determine which wires may be the source of electrical noise or feedback.

E45

E46

E47

E48

E51

RESET BUTTON ERROR PLEASE WAIT

Reset button pressed more than 7 times in one minute.

1. Wait five minutes for the control to recycle.

2. Exercise patience when resetting errors.

Table 10.1 (cont’d): Blocking Error Codes (automatic reset):

TROUBLESHOOTING

Page 68

TROUBLESHOOTING

Table 10.2: Locking Error Codes (manual reset):

“A”

CODE

Error Display Error Description Corrective Actions

A01 IGNITION ERROR

Maximum number of ignition attempts have been reached.

1. Watch the igniter through the observation window.

2. If no spark is present, check the spark electrode for the proper gap.

3. Remove any corrosion form the spark electrode.

4. IF spark is present but no flame, check the gas supply to the boiler. Check high and low gas pressure switches.

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

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

A02 FLAME FAILURE

Flame failures have exceeded the maximum allowed.

1. Check the burner flame signal at high and low fire. If it is less than 5.0 µA, clean the flame sensor. If the problem persists, change the sensor.

2. If the flame signal is above 5.0 µA, check for possible wind gusts while the boiler is on low fire. If there is indication of this issue, increase the minimum fan speed to prevent further occurances.

A03 OVERHEAT LIMIT OPEN

High temperature limit switch is open (set temperature 210°F).

1. Check CH, DHW and GEN pump operation.

2. Assure adequate flow through the boiler by checking supply & return temperatures in the status menu. The difference should be less than 40°F (22°C).

3. Compare temperature readings on the supply sensor against the temperature gauge. If the gauge is significantly higher check the sensor and replace if necessary.

A04

INTERNAL ERROR GAS VALVE RELAY

Gas valve relay is not reacting correctly to software commands.

1. If persistent locking errors, A04 – A18, occur, systematically disconnect all wires not supplied by the factory with the exception of the power supply (CH T’Stat, DHW T’Stat, LWCO, Pumps, etc.). If the error code goes away, determine which circuit may be introducing electrical noise or feedback.

2. If the error persists after all these wires are disconnected, contact your PB Heat representative.

3. If this error occurs after replacing a control, contact your PB Heat representative.

A05

INTERNAL ERROR SAFETY RELAY

Safety relay is not reacting correctly to software commands.

A09

INTERNAL SOFTWARE ERR RAM ERROR

The software is not operating correctly.

A10

COMMUNICATION ERROR E2PROM ERROR

No communication with the nonvolatile memory in the control board.

A12

SOFTWARE OUT OF DATE E2PROM OUT OF DATE

Possible version mismatch between control and other components.

Page 69

TROUBLESHOOTING

“A”

CODE

Error Display Error Description Corrective Actions

A13

INTERNAL ERROR

Internal error with the control software.

2. If the error persists after all these wires are disconnected, contact your PB Heat representative.

3. Check for the presence of flame in the combustion chamber.

4. Check igniter for a short to ground.

5. Check flame sensor for a short to ground.

A14

A15

A16

A18

A19

FALSE FLAME DETECTED AFTER SHUTDOWN

Unexpected flame signal detected more than 10 seconds after closing the gas valve.

A20

FALSE FLAME DETECTED BEFORE IGNITION

Unexpected flame signal detected before opening the gas valve.

1. Check for the presence of flame in the combustion chamber.

2. Check igniter for a short to ground.

3. Check flame sensor for a short to ground.

4. If a flow switch is not connected to terminals #11 & #12, change to LWCO in User Menu under burner settings (managing burner).

5. If a flow switch is connected, check for continuity across terminals #11 & #12 with the pumps off. Possible blocking of flow paddle due to dirt or debris in the system.

6. If a flow switch is not connected to terminals #11 & #12, change to LWCO in User Menu under burner settings (managing burner).

7. If a flow switch is connected, check for continuity across terminals #11 & #12 with the pumps on. Possible blocking of flow paddle due to dirt or debris in the system.

A23 FLOW SW NOT OPEN

Boiler flow switch is not open with pump turned off.

A24 FLOW SW NOT CLOSED

Boiler flow switch is not closed with pump turned on.

A32 FAN NOT RUNNING No hall pulse signal from blower.

Is the fan running?

• Yes – Check 4-wire blower harness & connectors for loose connections.

• Yes – Check current fan speed under “Status” in “Installer Menu”.

• No – Check 3-wire blower harness & connectors for loose connections.

A33 FAN SPEED ERROR

Fan speed detected differs from targeted value by more than 300 rpm for more than 60 seconds.

Is the fan running?

• Yes – Check 4-wire blower harness & connectors for loose connections.

• Yes – Check current fan speed under “Status” in “Installer Menu”.

• No – Check 3-wire blower harness & connectors for loose connections.

A50

RETURN HIGHER THAN SUPPLY

Return sensor reads higher temperature 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 temperature readings on the supply sensor against the temperature gauge. If the gauge is significantly higher check the sensor and replace if necessary.

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

Page 70

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.

TROUBLESHOOTING

Page 71

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 (apr(s l’entietien’), 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.

Page 72

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 THE START OF

HEATING SEASON)

1. Check boiler room floor drains to assure proper drainage.

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

a. Check the relief valve piping to determine that it

is properly installed:

i. No manual valves are to be between the

relief valve and the boiler.

ii. No manual valves on the outlet side of the

relief valve.

iii. No reduction in pipe size on the outlet side of

the relief valve.

iv. The outlet to the valve should be piped to

within 12 inches of the floor away from people and pets to prevent personal injury in the event of valve discharge.

b. Check the boiler operating temperature and

pressure.

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

open position and hold it for at least 5 seconds.

d. Release the try lever and allow the relief 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 closed 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 their normal condition.

g. Check again to confirm that the valve has closed

completely and is not leaking.

3. Test the low water cutoff (LWCO) as described by the manufacturer of the device.

4. Test the limit operation as described in Section 9.

5. Remove the left rear jacket panel and open the air plenum cover by removing (6) sheet metal screws. Inspect the inside of the plenum for any foreign debris that may have entered through the air intake opening. Also, check the screen for blockage.

6. Inspect the burners, by removing (6) hex nuts on each burner mounting plate and opening the combustion chambers. Replace the burners if necessary.

7. With the boiler in operation, check that condensate is dripping from the condensate tubing. Check for any blockage or restriction in the condensate drain lines.

D. CONDENSATE SYSTEM CLEANING

INSTRUCTIONS

1. Removal of Condensate Containers:

a. Close the manual gas shutoff valve at the rear of

the boiler and turn off both burner service switches.

b. Remove the right rear jacket panel.

c. Remove the wing nuts from both the condensate

collector and condensate neutralizer container.

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

CAUTION

When servicing or replacing components, be absolutely sure 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

Opening the relief valve will result in the discharge of hot water and/or steam. Be sure that there is no one near the outlet of the relief valve piping during this test. Failure to do so may result in severe personal injury or death.

WARNING

Page 73

MAINTENANCE

d. Disconnect both condensate hoses from the top

of the condensate collector.

e. Disconnect the float switch wires from the wiring

harness.

f. Lift the front (condensate collector) container

above the level of the other container to empty some condensate from the system.

g. Disconnect the condensate drain connection

from the rear of the boiler and remove the containers from the boiler.

2. Cleaning the Containers: a. Dump the contents of the containers and flush

them with water.

b. Be sure that there is free movement of liquid

between the containers through the bottom port.

c. Check for leaks at all of the hose clamps.

3. Re-installing the Containers: a. Place the tanks in position and attach both wing

nuts.

b. Connect the hoses to the top of the condensate

collector.

c. Attach the drain hose to the outlet of the system.

d. Connect the wires to the blocked condensate

float switch in the lid of the condensate collector.

e. Fill the condensate neutralizer container with 1-2

inches of neutralizing media.

4. Restarting the Boiler: a. Open the manual gas valve at the rear of the

boiler.

b. Turn both burner service switches on.

c. Observe the boiler function to make sure you see

condensate flow.

d. If no flow of condensate is evident, repeat this

procedure.

5. If the problem persists it is possible that there is a problem with material deposits in the heat exchanger. Follow the Combustion Chamber Coil Cleaning Instructions in this section.

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.

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

Page 74

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.

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

WARNING

MAINTENANCE

Page 75

BOILER DIMENSIONS & RATINGS

12. BOILER DIMENSIONS & RATINGS

Table 12.1: Boiler Dimensions

SERIES PEERLESS®PUREFIRE®DIMENSIONS

Boiler Model

“A” “B” “C”

PF-850 36-1/4" (920 mm) 46" (1170 mm) 26-1/2" (675 mm)

PF-1000 39-1/8" (994 mm) 46" (1170 mm) 26-1/2" (675 mm)

Figure 12.1: Dimensional Drawing – PF-850 & PF-1000

Table 12.2: Boiler Ratings

SERIES PEERLESS®PUREFIRE®BOILER RATINGS

Boiler Model

Input

Heating

Capacity

Net

Thermal

Efficiency

Combustion

Efficiency

Minimum Maximum

MBH kW MBH kW MBH kW MBH kW % %

PF-850 85 24.9 850 249.1 818 239.7 711 208.4 96.2%

92.5%

PF-1000 100 29.3 1,000 293.1 966 283.1 840 246.2 96.6%

95.6%

Table 12.3: Combustion Air Fan Speeds

SERIES PEERLESS®PUREFIRE®COMBUSTION AIR FAN SPEEDS

Boiler Model

Maximum Input Fan Speed*

MBH kW Low Power Ignition High Power

PF-850 850 249.1 1860 4530 5790

PF-1000 1,000 293.1 1920 4800 6180

*Fan Speed values may vary depending on menu changes made to compensate for increased exhaust vent length and wind conditions.

Page 76

Table 12.4: PUREFIRE®Main Control Specifications

SERIES PEERLESS®PUREFIRE®MAIN CONTROL SPECIFICATIONS

Power Supply

Voltage 120 VAC Nominal (102-132 VAC)

Frequency 60 Hz Nominal (40 Hz to 70 Hz)

Fuses

Primary Control 3.15 Amp, 250 VAC

Pump Relay (3) 10 Amp, 250 VAC

Blower Voltage 120 VAC

Gas Valve Voltage 120 VAC

Thermostat Contacts Voltage 24 VAC

DHW Contacts Voltage 24 VAC

Flame Current Limits Current

Minimum (running): 2.8 µA

Minimum (ignition): 3.1 µA

Maximum: 10.0 µA

Temperature Sensors NTC Thermistors 12kW at 77°F (25°C)

Supply 14°F (-10°C) to 244°F (118°C)

Return 14°F (-10°C) to 244°F (118°C)

Flue 50°F (10°C) to 280°F (138°C)

Header 14°F (-10°C) to 244°F (118°C)

Outdoor -40°F (-40°C) to 185°F (85°C)

Optional Sensors

DHW 14°F (-10°C) to 244°F (118°C)

System 14°F (-10°C) to 244°F (118°C)

Standards

North America ANSI Z21.20 / CSA C22.2

Europe CE EN298

BOILER DIMENSIONS & RATINGS

Page 77

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Page 78

REPA IR PARTS

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: Heat Exchanger

Page 79

REPA IR PARTS

Table 13.1: Heat Exchanger

Description

Quantity

Required

Stock

Code

Heat Exchanger – PF-850 1 5651

Heat Exchanger – PF-1000 1 5652

2 Burner Mounting Plate 2 54430

3 Flame Sensor Electrode w/Gaskets 2 54432

4 Ignition Electrode w/Gaskets 2 54431

5 Burner Element 2 54433

6 Flapper Assembly 2 54434

Supply/Return Sensor – 1/8" NPT 12 KW

4 54438

8 High Limit Switch – 1/4" NPT 2 54419

Header Supply Sensor – 1/4" NPT 12 KW

1 54418

10 Hex. Flange Nut M6 Fine Thread 12 –

11 Screw M5-0.80 x 16 mm Zinc Plated 10 –

12 Burner Gasket 2 54467

13 Screw M4 x 8 mm Zinc Plated 4 –

14 Flue Temperature Sensor 1 54111

15 Thermal Fuse 2 54466

Page 80

REPA IR PARTS

Figure 13.2: Blower/Gas Train Assembly

Page 81

REPA IR PARTS

Table 13.2: Blower/Gas Train Assembly

Description

Quantity

Required

Stock

Code

1 Blower 2 54428

2 3/4" NPT Flanged Elbow 2 5543

3 Gas Valve GB-057 2 54429

4 1" NPT x 18" Flexible Gas Hose 2 54439

5 1" NPT Gas Shutoff Valve 2 51703

6 Low Gas Pressure Switch 1 50700

7 High Gas Pressure Switch 1 50701

8 3" Flexible Air Inlet Hose 7.5 Ft 54444

9 4" Hose Clamp 4 54443

10 Socket Head Cap Screw M5-0.80 x 12 mm 6 5415

11 Hex Head Cap Screw M5-0.80 x 12 mm 2 5688

12 1/8" ID Reference Tube 5 ft 1052

13 1/8" Hose Tee 1 6159

Page 82

REPA IR PARTS

Figure 13.3: Jacket Assembly

Page 83

REPA IR PARTS

Table 13.3: Jacket Assembly

Description

Quantity

Required

Stock

Code

1 Heat Exchanger Support Panel – Front 1 PF2016

2 Heat Exchanger Support Panel – Rear 1 PF2017

Heat Exchanger Support Rails – PF-850 4 PF2018

Heat Exchanger Support Rails – PF-1000 4 PF-2018-1

4 Blower Cabinet Frame Assembly 1 PF2027

5 Blower Cabinet Support Rails 2 PF2026

Electrical Terminal Enclosure – PF-850 1 PF2029

Electrical Terminal Enclosure – PF-1000 1 PF2029-1

Terminal Enclosure Cover – PF-850 1 PF2030

Terminal Enclosure Cover – PF-1000 1 PF2030-1

8 Thermal Fuse Cover 2 PF2031

9 Blower Cabinet Floor Pan 1 PF2033

Condensate System Tray – PF-850 1 PF5027

Condensate System Tray – PF-1000 1 PF5027-1

11 Air Inlet Plenum Assembly 1 PF5044

12 Blower Cabinet Top Panel 1 PF6067

Side Heat Exchanger Access Panel – PF-850 2 PF6064

Side Heat Exchanger Access Panel – PF-1000 2 PF6064-1

Top Heat Exchanger Access Panel – PF-850 1 PF6066

Top Heat Exchanger Access Panel – PF-1000 1 PF6066-1

15 Blower Cabinet Right Side Panel 1 PF-6067

16 Blower Cabinet Left side Panel 1 PF-6067-1

17 Air Inlet Screen 1 54447

18 Ball Studs 30 5433

19 Front Cover Panel 1 54292

20 Control Lens 1 54127

21 Leveling Legs 6 5659

22 Tubing Connector 1 50770

23 1/4" Rubber Grommet 1 6158

Page 84

Figure 13.4: Control System

REPA IR PARTS

Page 85

REPA IR PARTS

Table 13.4: Control System

Description

Quantity

Required

Stock

Code

1 Integrated Primary Controls 2 54440

2 User Interface Pixel Display 1 54441

3 Installer Interface LED Display 2 54445

4 Interface Module 1 54442

5 Pump Relay Module 1 54437

6 Terminal Block – 10 Pole 2 5450

7 Terminal Block – 6 Pole 2 5547

8 Ignition Cable 2 54115

9 Harness J5M Managing Control Sensors (not shown) 1 54448

10 Harness J5D Dependent Control Sensor (not shown) 1 54449

11 Harness J15M Managing Flapper/Limits (not shown) 1 54450

12 Harness J15D Dependent Flapper/Limits (not shown) 1 54451

13 Harness J2M Managing Control/Blower Power (not shown) 1 54452

14 Harness J2D Dependent Control/Blower Power (not shown) 1 54453

15 Harness J13M Managing Gas Valve/Flame Sensor/High Limit (not shown) 1 54454

16 Harness J13D Dependent Gas Valve/Flame Sensor/High Limit (not shown) 1 54455

17 Harness J7M Managing Gen Circulator (not shown) 1 54456

18 Harness J6M Managing CH/DHW Circulator (not shown) 1 54457

19 Harness Line Voltage Terminal Strip/Power Switch/Relay Module (not shown) 1 54458

20 Harness J9 Blower Control (not shown) 2 54459

21 Harness Managing Thermal Fuse w/ Conduit (not shown) 1 54460

22 Harness Dependent Thermal Fuse w/ Conduit (not shown) 1 54461

23 Harness Ground 2 PF7009

24 Rocker Switch 2 6049

Page 86

Figure 13.5: Condensate System

REPA IR PARTS

Page 87

REPA IR PARTS

Table 13.5: Condensate System

Description

Quantity

Required

Stock

Code

1 Condensate Receiver Container 1 54120

2 Condensate Neutralizer Container 1 54121

3 Condensate Blocked Drain Switch 1 54137

4 1" OD x 3/4" ID PVC Condensate Hose 3 in 5417

5 5/8" OD x 1/2" ID PVC Condensate Hose 4 ft 5416

6 5/8" x 5/8" x 1/4" Hose Barb Tee 1 5665

7 Blocked Vent Pressure Switch 1 54208

8 1/4" ID PVC Tubing 2 ft 5563

Condensate Neutralizer Container Cap

1 5430

Table 13.6: Miscellaneous Components (Shipped Loose or Optional)

Description

Quantity

Required

Stock

Code

Relief Valve – PF-850

51300

Relief Valve – PF-1000 51301

2 Temperature/Pressure Gauge 1 51324

3 Stainless Steel Boot Tee w/Test Port 1 5680

4 Stainless Steel Drain Fitting 1 5681

5 Stainless Steel – PVC Adapter 1 5682

6 6" Diameter Exhaust/Air Intake Screen 3 54446

7 Stacking Spacer 6 1457

8 Outdoor Sensor 1 54112

9 DHW Tank Sensor (Optional) 54157

10 Condensate Neutralizing Media (1 lb bag) 2 54159

Page 88

A. STAND ALONE PIXEL DISPLAY

Figure A.1 below is a map of the boiler pixel display screen for a multiple boiler. When operating as a “standalone” boiler, the keys on the pixel display are not active. Section 8 provides information about status messages for this display.

B. MULTIPLE BOILER (CASCADE) PIXEL

DISPLAY

To operate 2 or more boilers in cascade, the boilers must be connected by 2-wire link connections as described is Section 8.

APPENDIX A. PIXEL DISPLAY SCREEN

Figure A.1: Pixel Display Screen – Stand Alone Boilers

Figure A.2: Pixel Display Module

Page 89

Table A.1 shows the cascade menu screen which is accessed by pressing the button labeled ▲ for 5 seconds and releasing it.

Figure A.3 shows the System Display Screen. As shown in Figure A.2, this is accessed by toggling the “ ” keys.

APPENDIX A. PIXEL DISPLAY SCREEN

Figure A.3: Cascade Status Display

Table A.1: Cascade Menu

Cascade Menu

•

Boiler Address:

Start Delay Time: 4 min

Stop Delay Time: 4 min

Start Boiler Diff: 9 °F

Stop Boiler Diff: 9 °F

Stop All Boiler Diff: 18 °F

Max Offset Up: 36 °F

Max Offset Down: 9 °F

Rotation Interval: 5 days

P-Value 20

I-Value 40

D-Value 0

Stew Rate 1

Page 90

APPENDIX B. BURNER LCD STATUS SCREENS

Initialization Screen Status Screens Boiler Screens

Failure Screens Error Handling – Blocking Errors Error Handling – Locking Errors

Warning Screen

Page 91

APPENDIX B. BURNER LCD STATUS SCREENS

CH Burn Cycle DHW Burn Cycle Special Functions

DHW Tank Warm Hold

Page 92

APPENDIX C. USER MENU

Figure C.1: User Menu – Managing Burner

Page 93

APPENDIX C. USER MENU

Figure C.1: User Menu – Dependent Burner

Page 94

APPENDIX D. INSTALLER MENU STRUCTURE

Page 95

APPENDIX D. INSTALLER MENU STRUCTURE

Page 96

APPENDIX E. COMBUSTION TEST RECORD

Installation Information

Contact: Phone Number:

Service Contractor: Fax Number:

Contractor Address: Email Address:

Job Name: Jobsite Address:

Boiler Model: Boiler Serial No.:

Manufacture Date: Conversion Date:

Pressure Readings

Inlet Gas Pressure – Static

(in. w.c.):

Inlet Gas Pressure Drop

at Startup (in. w.c.):

High Fire Inlet Gas

Pressure (in. w.c.):

Low Fire Inlet Gas

Pressure (in. w.c.):

Combustion Readings – Burner #1

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 (RPM): Fan Speed Low Fire (RPM):

Combustion Readings – Burner #2

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 (RPM): Fan Speed Low Fire (RPM):

Combustion Readings – Both Burners

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 (RPM): Fan Speed Low Fire (RPM):

Exhaust Temperatures

Exhaust Temp High Fire (ºF): Exhaust Temp Low Fire (ºF):

Page 97

SERVICE LOG

Date Serviced By Description of Service

Serial Number

Page 98

NOTES

Page 99

Page 100

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.

PF8146 R0 (10/11-1M)

PB HEAT, LLC

131 S. CHURCH STREET • BALLY, PA 19503

PF-850 PF-1000

PUREFIRE

ASME

CONTROLS