PEERLESS PUREFIRE PFW-399, PUREFIRE PFW-200 Installation, Operation & Maintenance Manual
PUREFIRE®PFW™SERIES
Hot Water Supply Boilers
PFW-200 PFW-399
Gas
Installation,
Operation &
Maintenance
Manual
As an ENERGY STAR®Partner, PB Heat, LLC has determined that
this product meets the ENERGY STAR guidelines for energy efficiency.
®
USING THIS MANUAL 1
A. INSTALLATION SEQUENCE . . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B. CODES & REGULATIONS . . . . . . . . . . . . . . . .2
C. ACCESSIBILITY CLEARANCES . . . . . . . . . . . .3
D. COMBUSTION & VENTILATION AIR . . . . . . . .3
E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .6
2. BOILER SET-UP 7
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
B. FLOOR STANDING INSTALLATION . . . . . . . . .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 . .13
E. EXHAUST VENT/AIR INTAKE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .13
F. EXHAUST TAPPING FOR VENT SAMPLE . .14
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . . .14
4. WATER PIPING AND CONTROLS 15
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
B. OPERATING PARAMETERS . . . . . . . . . . . . . .15
C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .15
D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .17
5. FUEL PIPING 24
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . . .24
C. GAS SUPPLY PIPING – INSTALLATION . . . .24
D. GAS SUPPLY PIPING – OPERATION . . . . . . .25
E. MAIN GAS VALVE – OPERATION . . . . . . . . .25
6. CONDENSATE DRAIN PIPING 27
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
B. CONDENSATE SYSTEM . . . . . . . . . . . . . . . .27
C. CONDENSATE DRAIN PIPE MATERIAL . . . .28
D. CONDENSATE DRAIN PIPE SIZING . . . . . . .28
E. CONDENSATE DRAIN PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .28
7. ELECTRICAL CONNECTIONS 29
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
B. CUSTOMER CONNECTIONS . . . . . . . . . . . . .29
C. INTERNAL WIRING . . . . . . . . . . . . . . . . . . . .29
8. BOILER CONTROL: INTERNAL
WIRING & OPERATION 32
A. IGNITION SEQUENCE . . . . . . . . . . . . . . . . . .32
B. USER MENU . . . . . . . . . . . . . . . . . . . . . . . . . .34
C. INSTALLER MENU . . . . . . . . . . . . . . . . . . . . .35
9. START-UP PROCEDURE 43
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
B. CHECK WATER PIPING . . . . . . . . . . . . . . . . .43
C. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . . .43
D. CHECK OPERATION . . . . . . . . . . . . . . . . . . . .43
E. LIGHTING & OPERATING PROCEDURES . . .45
10. TROUBLESHOOTING 46
A. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . . .46
B. LOCKING ERRORS . . . . . . . . . . . . . . . . . . . . .46
C. WARNING ERRORS . . . . . . . . . . . . . . . . . . . .50
11. MAINTENANCE 51
A. GENERAL (WITH BOILER IN USE) . . . . . . . .52
B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .52
C. ANNUALLY (BEFORE START OF HEATING
SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
D. CONDENSATE CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .52
E. COMBUSTION CHAMBER COIL CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .53
12. BOILER DIMENSIONS & RATINGS 54
13. REPAIR PARTS 56
APPENDIX A. STATUS SCREENS 61
APPENDIX B. USER MENU 64
APPENDIX C. INSTALLER MENU 66
APPENDIX D. COMBUSTION TEST
RECORD 72
TABLE OF CONTENTS
TABLE OF CONTENTS
A. INSTALLATION SEQUENCE
Follow the installation instructions provided in this manual
in the order shown. The order of these instructions has
been set in order to provide the installer with a logical
sequence of steps that will minimize potential
interferences and maximize safety during boiler
installation.
B. SPECIAL ATTENTION BOXES
Throughout this manual special attention boxes are
provided to supplement the instructions and make special
notice of potential hazards. The definition of each of
these categories, in the judgement of PB Heat, LLC.
are as follows:
USING THIS MANUAL
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
NOTICE
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
CAUTION
DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING
1
USING THIS MANUAL
A. GENERAL
1. PureFire boilers are supplied completely assembled as
packaged boilers. The package should be inspected
for damage upon receipt and any damage to the unit
should be reported to the shipping company and
wholesaler. This boiler should be stored in a clean, dry
area.
2. Carefully read these instructions and be sure to
understand the function of all connections prior to
beginning installation. Contact your PB Heat
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.
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.
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
2
PREINSTALLATION
C. ACCESSIBILITY CLEARANCES
1. The PureFire boiler is certified for closet installations
with zero clearance to combustible construction. In
addition, it is design certified for use on combustible
floors.
2. Figure 1.1 shows the minimum recommended
clearances to allow reasonable access to the boiler for
Models PFW-200 and PFW-399. However, local
codes or special conditions may require greater
clearances.
E. D. COMBUSTION AND
VENTILATION AIR
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 may be supplied from within the building only if
adequate combustion air and ventilation air is
provided in accordance with the National Fuel Gas
Code or applicable provisions of the local building
code. Subsections 3 through 10 as follows are based
on the National Fuel Gas Code requirements.
2. If the combustion air is piped directly to the boiler
from outside the building, no additional combustion
or ventilation air is required. Otherwise, follow the
National Fuel Gas Code recommendations
summarized in subsections 3 through 10.
3. Required Combustion Air Volume: The total required
volume of indoor air is to be the sum of the required
volumes for all appliances located within the space.
Rooms communicating directly with the space in
which the appliances are installed and through
combustion air openings sized as indicated in
Subsection 3 are considered part of the required
volume. The required volume of indoor air is to be
determined by one of two methods.
a. Standard Method
: The minimum required volume
of indoor air (room volume) shall be 50 cubic feet
per 1000 BTU/Hr (4.8 m3/kW). This method is to
be used if the air infiltration rate is unknown or if
the rate of air infiltration is known to be greater
than 0.6 air changes per hour. As an option, this
method may be used if the air infiltration rate is
known to be between 0.6 and 0.4 air changes per
hour. If the air infiltration rate is known to be
below 0.4 then the Known Air Infiltration Rate
Method must be used. If the building in which this
appliance is to be installed is unusually tight, PB
Heat recommends that the air infiltration rate be
determined.
b. Known Air Infiltration Rate Method
:
where:
I
fan
= Input of the fan assisted appliances
assisted in Btu/hr
ACH = air change per hour (percent of the
volume of the space exchanged per
hour, expressed as a decimal)
Note: These calculations are not to be used for
infiltration rates greater than 0.60 ACH.
Figure 1.1: Minimum Accessibility Clearances – PFW-200 & PFW-399
3
PREINSTALLATION
15 ft
3
I
fan
ACH 1000
Btu
/
hr
Required Volume
fan
=
⎛
⎜
⎝
⎛
⎜
⎝
4. Indoor Air Opening Size and Location: Openings
connecting indoor spaces shall be sized and located as
follows:
a. Combining Spaces on the Same Floor
: Provide
two permanent openings communicating with
additional spaces that have a minimum free area
of 1 in
2
per 1000 Btu/hr (22 cm2per 1000 W) of
the total input rating of all gas fired equipment but
not less than 100 in
2
(645 cm2). One opening is to
begin within 12 inches (305 mm) from the top of
the space and the other is to begin within 12
inches (305 mm) from the floor. The minimum
dimension of either of these openings shall be 3
inches (76 mm), see Figure 1.2 for an illustration
of this arrangement.
b. Combining Spaces on Different Floors
: Provide
one or more permanent openings communicating
with additional spaces that have a total minimum
free area of 2 in
2
per 1000 Btu/hr (44 cm2per
1000 W) of total input rating of all equipment, see
Figure 1.3 for an illustration of this arrangement.
5. Outdoor Combustion Air: Outdoor combustion air is
to be provided through one or two permanent
openings. The minimum dimension of these air
openings is 3 inches (76 mm).
a. Two Permanent Opening Method
: Provide two
permanent openings. One opening is to begin
within 12 inches (305 mm) of the top of the space
and the other is to begin within 12 inches (305
mm) of the floor. The openings are to
communicate directly or by ducts with the
outdoors or with spaces that freely communicate
with the outdoors. The size of the openings shall
be determined as follows:
i. Where communicating directly or through
vertical ducts with the outdoors each opening
shall have a minimum free area of 1 in2 per
4000 Btu/hr (22 cm
2
per 4000 W) of total
input rating for all equipment in the space, see
Figure 1.4 for openings directly
communicating with the outdoors or Figure
1.5 for openings connected by ducts to the
outdoors.
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
Figure 1.4: Air Openings – All Air Directly from
Outdoors
Figure 1.5: Air Openings – All Air from Outdoors
through Vertical Ducts
4
PREINSTALLATION
ii. Where communicating with the outdoors through
horizontal ducts, each opening shall have a
minimum free area of 1 in
2
per 2000 Btu/hr (22
cm2per 2000 W) of total rated input for all
appliances in the space, see Figure 1.6.
b. One Permanent Opening Method
: Provide one
permanent opening beginning within 12 inches
(305 mm) of the top of the space. The opening
shall communicate directly with the outdoors,
communicate through a vertical or horizontal duct,
or communicate with a space that freely
communicates with the outdoors. The opening
shall have a minimum free area of 1 in
2
per 3000
Btu/hr of total rated input for all appliances in the
space and not less than the sum of the crosssectional areas of all vent connectors in the space.
The gas-fired equipment shall have clearances of
at least 1 inch (25 mm) from the sides and back
and 6 inches (150 mm) from the front of the
appliance, see Figure 1.7 for this arrangement.
6. Combination Indoor and Outdoor Combustion Air: If
the required volume of indoor air exceeds the
available indoor air volume, outdoor air openings or
ducts may be used to supplement the available indoor
air provided:
a. The size and location of the indoor openings
comply with Subsection 3.
b. The outdoor openings are to be located in
accordance with Subsection 4.
c. The size of the outdoor openings are to be sized
as follows:
where:
A
req
= minimum area of outdoor openings.
A
full
= full size of outdoor openings calculated
in accordance with Subsection 4.
V
avail
= available indoor air volume
V
req
= required indoor air volume
7. Engineered Installations: Engineered combustion air
installations shall provide an adequate supply of
combustion, ventilation, and dilution air and shall be
approved by the authority having jurisdiction.
8. Mechanical Combustion Air Supply:
a. In installations where all combustion air is
provided by a mechanical air supply system, the
combustion air shall be supplied from the
outdoors at the minimum rate of 0.35 ft
3
/min per
1000 Btu/hr (0.034 m
3
/min per 1000 W) of the
total rated input of all appliances in the space.
b. In installations where exhaust fans are installed,
additional air shall be provided to replace the
exhaust air.
c. Each of the appliances served shall be interlocked
to the mechanical air supply to prevent main
burner operation when the mechanical air supply
system is not in operation.
d. In buildings where the combustion air is provided
by the mechanical ventilation system, the system
shall provide the specified combustion air rate in
addition to the required ventilation air.
9. Louvers & Grills:
a. The required size of openings for combustion,
ventilation, and dilution air shall be based on the
net free area of each opening.
i. Where the free area through a louver or grille
is known, it shall be used in calculating the
opening size required to provide the free area
specified.
ii. Where the free area through a louver or grille
is not known, it shall be assumed that wooden
louvers will have 25% free area and metal
louvers and grilles will have 75% free area.
iii. Non-motorized dampers shall be fixed in the
open position.
b. Motorized dampers shall be interlocked with the
equipment so that they are proven in the full open
position prior to ignition and during operation of
the main burner.
Figure 1.6: Air Openings – All Air from Outdoors
through Horizontal Ducts
Figure 1.7: Air Openings – All Air from Outdoors
through One Opening
5
PREINSTALLATION
i. The interlock shall prevent the main burner
from igniting if the damper fails to open during
burner startup.
ii. The interlock shall shut down the burner if the
damper closes during burner operation.
10. Combustion Air Ducts:
a. Ducts shall be constructed of galvanized steel or
an equivalent corrosion-resistant material.
b. Ducts shall terminate in an unobstructed space,
allowing free movement of combustion air to the
appliances.
c. Ducts shall serve a single space.
d. Ducts shall not serve both upper and lower
combustion air openings where both such
openings are used. The separation between ducts
serving upper and lower combustion air openings
shall be maintained to the source of combustion
air.
e. Ducts shall not be screened where terminating in
an attic space.
f. Horizontal upper combustion air ducts shall not
slope downward toward the source of the
combustion air.
g. The remaining space surrounding a chimney liner,
gas vent, special gas vent, or plastic piping
installed within a masonry, metal, or factory built
chimney shall not be used to supply combustion
air unless it is directly piped to the air inlet as
shown in Figure 3.9.
h. Combustion air intake openings located on the
exterior of buildings shall have the lowest side of
the combustion air intake opening at least 12
inches (305 mm) above grade.
11. Refer to Section 3 of this manual, Venting & Air Inlet
Piping, for specific instructions for piping the exhaust
and combustion air.
E. PLANNING THE LAYOUT
1. Prepare sketches and notes showing the layout of the
boiler installation to minimize the possibility of
interferences with new or existing equipment, piping,
venting and wiring.
2. The following sections of this manual should be
reviewed for consideration of limitations with
respect to:
a. Venting and Air Inlet Piping: Section 3
b. Water Piping: Section 4
c. Fuel Piping: Section 5
d. Condensate Removal: Section 6
e. Electrical Connections: Section 7
f. Boiler Control: Section 8
g. Boiler Dimensions and Ratings: Section 12
6
PREINSTALLATION
Do not install this boiler where gasoline or other
flammable liquids or vapors are stored or are in use.
WARNING
This boiler is certified as an indoor appliance. Do not
install this boiler outdoors or locate where it will be
exposed to freezing temperatures.
WARNING
Do not install this boiler in the attic.
WARNING
7
BOILER SET-UP
A. GENERAL
1. PureFire boilers are intended for installation in an area
with a floor drain or in a suitable drain pan. Do not
install any boiler where leaks or relief valve discharge
will cause property damage.
2. The PureFire boiler is not intended to support external
piping. All venting and other piping should be
supported independently of the boiler.
3. Install the boiler level to prevent condensate from
backing up inside the boiler.
B. FLOOR STANDING INSTALLATION
1. For floor standing installations, use the leveling feet to
assure that the boiler is completely level. This will
prevent condensate from backing up in the boiler.
2. Be sure to leave adequate space for condensate
piping or a pump if required.
2. BOILER SET-UP
This boiler must be installed level to prevent
condensate from backing up inside the boiler.
CAUTION
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 PureFire boiler is a direct vent appliance and is
ETL Listed as a Category IV appliance with Intertek
Testing Laboratories, Inc.
3. Sources of combustion air contaminated with chlorine,
ammonia or alkali agents must be avoided. Do not
install this boiler near a swimming pool, hot tubs or
laundry. Do not store chemicals near the boiler.
B. APPROVED MATERIALS
1. Table 3.1 lists approved materials for vent pipe (and
adhesives where applicable). Use only these materials
for exhaust vent piping.
2. PVC pipe and fittings are not to be used for venting in
confined spaces such as closet installations. Use only
CPVC or approved polypropylene (InnoFlue or
PolyPro) vent pipe under these conditions.
3. Cellular core piping is approved for inlet air piping only.
* PVC pipe/fittings are not to be used for venting within confined spaces.
Notice: Installations in Canada require compliance with
ULC S636 – Standard for Type BH Gas Venting Systems.
C. EXHAUST VENT/AIR INTAKE PIPE
LOCATION
1. Install vent piping before installing water, fuel, or
condensate piping. Working from largest to smallest
diameter reduces the complexity of piping
interferences.
2. Vent and air intake piping is to be installed so that
there is sufficient access for routine inspection as
required in Section 11 of this manual.
3. The vent piping for this boiler is approved for zero
clearance to combustible construction. However, a fire
stop must be used where the vent pipe penetrates
walls or ceilings.
4. The 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 PureFire boiler is about 200 equivalent
feet (60 m). Be sure that the boiler is located such that
the maximum vent length is not exceeded.
6. Air Intake Pipe Location – Sidewall Venting:
a. Provide 1 foot (30 cm) clearance from the bottom
of the air intake pipe to the level of maximum
snow accumulation. Snow removal may be
necessary to maintain clearances.
b. Do not locate air intake pipe in a parking area
where machinery may damage the pipe.
c. Maintain a minimum of 8” horizontal distance
between exhaust vent and the air intake.
Increasing this distance minimizes the potential for
contamination of the inlet air with exhaust.
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 materials listed in Table 3.1 are approved for use
with PureFire boilers. 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
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
8
VENTING & AIR INLET PIPING
Table 3.1: Approved Materials for Exhaust Vent Pipe
Description Material
Conforming to
Standard
Exhaust Vent Pipe &
Fittings
PVC (Sch 40 or 80)*
ANSI/ASTM D1785
CPVC (Sch 40 or 80) ANSI/ASTM D1785
PVC-DWV*
ANSI/ASTM D2665
FasNSeal
®
UL1738 & ULC S636
PolyPro
®
ULC-S636
InnoFlue
®
UL1738 & ULC S636
Pipe Cement
(PVC & CPVC Only)
PVC/CPVC Cement ANSI/ASTM D2564
9
VENTING & AIR INLET PIPING
d. If the vent pipe and air inlet pipe terminations
penetrate the wall at the same level the minimum
distance between them is 8" center-to-center.
e. Multiple Boiler Installations:
• The minimum horizontal distance between the
inlet of one boiler to the exhaust of an adjacent
boiler is 8” center-to-center. In addition, the
minimum vertical distance between the exhaust
air and air inlet is 6”. See Figure 3.1.
• DO NOT CONNECT air inlet pipes together.
Air inlet must be piped separately to prevent
drawing exhaust and/or moist condensate back
through the blower of an idle boiler.
• If multiple boilers are installed without piping
the air intake to outdoors, care must be taken
to be sure that the boiler room is well
ventilated and is not negatively pressurized
when the boilers or other air moving
equipment are in operation.
f. The exhaust outlet of the vent pipe should not be
angled any more than 5º from horizontal.
g. Precautions should be taken to prevent
recirculation of flue gases to the air inlet pipe of
the boiler or other adjacent appliances.
7. Sidewall Venting Configuration:
a. See Figure 3.2 for an illustration of clearances for
location of exit terminals of direct-vent venting
systems.
• The boiler vent system shall terminate a least 3
feet (0.9 m) [“B” Figure 3.2] above any forced
air inlet located within 10 feet (3 m) [“A” Figure
3.2]. Note: This does not apply to the
combustion air intake of a direct vent appliance.
• Provide a minimum of 4 feet (1.22 m)
distance from any door, operable window, or
gravity intake into any building.
• Provide a minimum of 1 foot (30 cm) clearance
from the bottom of the exit terminal above the
expected snow accumulation level. Snow
removal may be required to maintain clearance.
• Provide a minimum of 4 feet (1.22 m)
horizontal clearance from electrical meters, gas
meters, gas regulators, and relief equipment. In
no case shall the exit terminal be above or
below the aforementioned equipment unless
the 4 foot horizontal distance is maintained.
• Do not locate the exhaust exit terminal over
public walkways where condensate could drip
and create a hazard or nuisance.
• When adjacent to public walkways, locate the
exit terminal at least 7 feet above grade.
• Do not locate the exhaust termination directly
under roof overhangs to prevent icicles from
forming or recirculation of exhaust gases from
occurring.
• Provide 3 feet clearance from the inside corner
of adjacent walls.
Figure 3.1: Vent Pipe Spacing for Multiple PureFire
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
Figure 3.3: Standard Exhaust & Air Inlet Pipe
Terminations
Figure 3.4: Offset Exhaust & Air Inlet Terminations
10
VENTING & AIR INLET PIPING
Figure 3.5: Optional Concentric Vent Kit
Installation
Figure 3.6: Exhaust & Air Inlet on Opposite Walls
b. Figure 3.3 and 3.4 show approved sidewall venting
configurations using the standard fittings supplied.
c. Figure 3.4 is only approved for locations in which
the outdoor temperature is above -5°F (-21°C) in
accordance with ASHRAE 90A-1980
recommendations.
d. Figure 3.5 shows an approved sidewall vent
configuration using an optional concentric vent
termination kit. 3” (54498) or 4” (54499).
e. Figure 3.6 shows an approved configuration with
the exhaust termination and inlet air piped to
opposite walls
f. Figure 3.7 shows an approved configuration with
combustion air supplied from indoors. Refer to
Section 1.D to be sure that there is adequate air
for combustion and ventilation at the boiler.
8. Vertical Venting Configuration:
a. Figure 3.8 shows the approved venting
configuration for vertical venting using the
standard fittings supplied.
• Locate the air intake pipe inlet 12" above the
expected snow accumulation on the roof
surface or 24" above the roof surface,
whichever is greater.
• Locate the end of the exhaust vent pipe a
minimum of 12" above the inlet to the air
intake pipe.
b. Figure 3.9 shows an approved vertical vent
configuration using the optional concentric vent
termination kit. 3" (54500) or 4" (54501)
c. Figure 3.10 shows an option for routing the
exhaust through an unused chimney while
bringing combustion air from the space
surrounding the vent pipe.
d. Figure 3.11 shows an option for routing the
exhaust through an unused chimney with the
combustion air supplied from inside the building.
Be sure to note the requirements for combustion
air as listed under Section 1.D. "Combustion and
Ventilation Air". These requirements are in
accordance with the National Fuel Gas Code.
e. Figure 3.12 shows an option for routing the
exhaust through an unused chimney in which
combustion air is piped in from a sidewall.
11
VENTING & AIR INLET PIPING
Figure 3.7: Sidewall Exhaust with Indoor Air
Figure 3.8: Standard Vertical Vent Installation
DO NOT USE the indoor air configuration shown in
Figure 3.7 if there are exhaust fans or other air
moving equipment (furnaces, heating boilers, etc.) in
operation in the same location. Damage to
equipment may occur from drawing combustion air
back through and idle appliance.
CAUTION
12
VENTING & AIR INLET PIPING
Figure 3.9: Concentric Vertical Vent Installation
Figure 3.10: Venting Through A Chimney Using
Outdoor Air
Figure 3.12: Venting Through A Chimney Using
Sidewall Outside Air
Figure 3.11: Venting Through A Chimney Using
Indoor Air
13
D. EXHAUST VENT/AIR INTAKE PIPE SIZING
1. PureFire boiler model PFW-200 is to be installed using
3” Schedule 40 or 80 PVC or CPVC piping using the
provided vent adapter. PureFire boiler model PFW-399
is to be installed using 4” Schedule 40 or 80 PVC or
CPVC using the vent adapter provided..
2. Polypropylene vent systems may be installed using
optional InnoFlue
®
or PolyPro®vent adapters. Table
3.2 shows the appropriate PB Heat stock codes.
Contact your PB Heat Representative for more
information on this option.
3. Combined systems using separate polypropylene
exhaust & air inlet pipes which transition to concentric
can also be installed. Contact your Centrotherm or
DuraVent representative for more information.
4. The total combined length of exhaust vent and air
intake piping is 200 equivalent feet (60 m).
a. The equivalent length of elbows, tees and other
fittings are listed in Table 3.3.
b. The equivalent length can be calculated as follows.
This is well below the 200 feet maximum
equivalent length. If the total is above 200
equivalent feet, alternate boiler locations or
exhaust penetration location should be considered.
E. EXHAUST VENT/AIR INTAKE
INSTALLATION
1. Figure 12.1 shows the exhaust connection on top of
the boiler, near the rear in the center.
a. The exhaust connection for the PFW-200 is 3”
male CPVC pipe. The exhaust connection for the
PFW-399 is 4” male CPVC pipe..
b. These connections are to be joined with suitable
PVC/CPVC adhesives in accordance with
manufacturers’ instructions.
2. The Air Intake connection is to the right of the exhaust.
3. Both connections are clearly marked.
4. Remove all burrs and debris from the joints and fittings.
5. Horizontal lengths of exhaust vent must be installed with
a slope of not less than 1/4" per foot (21 mm 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.
6. All piping must be fully supported. Use pipe hangers
at a minimum of 4 foot (1.22 meter) intervals to
prevent sagging of the pipe.
7. Exhaust and air inlet piping is to be supported
separately and should not apply force to the boiler.
8. Penetration openings around the vent pipe and air
intake piping are to be fully sealed to prevent exhaust
gases from entering building structures.
9. PVC & CPVC Piping:
a. Use only solid PVC or CPVC Schedule 40 or 80
pipe for exhaust venting. Cellular core PVC or
CPVC is not approved for exhaust vent.
b. All joints in vent pipe, fittings, attachment to the
boiler stub, and all vent termination joints must be
properly cleaned, primed and cemented. Use only
cement and primer approved for use with PVC or
CPVC pipe that conforms to ANSI/ASTM D2564.
c. A straight coupling is provided with the boiler to
be used as an outside vent termination. One of
the two screens is to be installed to prevent birds
or rodents from entering.
d. An air intake tee is provided with the boiler to be
used as an outside air intake termination. A screen
is to be installed to prevent birds or rodents from
entering.
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
Fitting Description Equivalent Length
Elbow, 90° Short Radius 5 feet
Elbow, 90° Long Radius 4 feet
Elbow, 45° Short Radius 3 feet
Coupling 0 feet
Air Intake Tee 0 feet
Stainless Steel Vent Kit 1 foot
Concentric Vent Kit 3 feet
Table 3.3: Equivalent Length of Fittings
Exhaust Air Inlet Total
Straight Length of Pipe 50' 50' 100'
90° Elbows, SR 2 x 5'= 10' 1 x 5' = 5' 15'
45° Elbows, SR 2 x 3' = 6' 6'
Conc. Vent Termination 1 x 3' = 3' 3'
Total 124'
Table 3.4: Sample Equivalent Length Calculation
Table 3.2: Polypropylene Vent Adapters
Boiler
Model
Centrotherm
InnoFlue
®
DuraVent
Pol yPro
®
PFW-200 54632 54630
PFW-399 54633 54631
14
VENTING & AIR INLET PIPING
e. Table 3.5 shows optional concentric air
intake/exhaust terminations that are available
separately from your PB Heat distributor for use
with PureFire boilers
f. Refer to Figures 3.3 to 3.6 for sidewall venting
options using PVC or CPVC pipe.
g. Refer to Figures 3.7 & 3.8 for vertical venting
options using PVC or CPVC pipe.
F. EXHAUST TAPPING FOR VENT SAMPLE
To properly install the PureFire boiler, carbon dioxide
(CO
2
) and carbon monoxide (CO) readings must be
determined from a sample of combustion products.
1. To do this in PVC or CPVC vent pipe, a hole must be
drilled in the exhaust vent pipe:
a. Drill a 21/64” diameter hole in the exhaust vent
pipe positioned so that the combustion analyzer
probe can be inserted between 6” and 12” from
the boiler connection.
b. Tap the hole with a 1/8” NPT pipe tap.
c. Us a 1/8” NPT PVC or Teflon Pipe Plug to seal
the hole.
2. InnoFlue
®
and PolyPro®vent systems offer test port
fittings for obtaining a sample of combustion products.
See your Centrotherm or DuraVent Representative for
recommendations.
3. See Section 9.D.8 for instructions on taking
combustion readings.
G. 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.
Boiler
Model
Description
Stock
Code
PFW-200
Sidewall Vent Termination Kit –
Polypro 3PPS-HK
54498
Vertical Vent Termination Kit –
Polypro 3PPS-VK
54500
PFW-399
Sidewall Vent Termination Kit –
Polypro 3PPS-HK
54499
Vertical Vent Termination Kit –
Polypro 3PPS-VK
54501
Table 3.5: Concentric Vent Termination Kits
15
A. GENERAL
1. Size water supply and return piping in accordance
with system requirements. Do not use smaller
diameter piping than the boiler connections.
2. If the PureFire boiler is used to replace an existing
boiler, make sure that the system piping is thoroughly
cleaned and free from debris before installation.
3. In 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 (pump replacement,
condensate trap cleaning, sensor replacement, etc.).
5. The PureFire boiler is supplied with a default tank
temperature setpoint of 120°F (49°C). However, the
setpoint can be set as high as 158°F (70°C) which can
potentially cause scald injury. If the tank temperature
is set to above 120°F (49°C), PB Heat recommends
the use of a mixing valve to provide lower
temperature water to faucets and shower heads.
B. OPERATING PARAMETERS
1. The PureFire boiler is designed to operate in an open
loop domestic water heating system under forced
circulation with a water storage tank. The system must
be completely filled with water at all times and water
must be circulating through the boiler while the unit is
firing for it to operate effectively.
2. The minimum system pressure is 14.5 PSI (69 kPa).
3. Table 4.1 lists the minimum flow rates for each
PureFire model.
4. Table 4.2 provides the water volume of the heat
exchanger including the supply and return pipes that
are attached at the factory.
5. The required temperature rise and the standard
circulating pump are sized based on the heating of
potable water with a hardness of 5 to 25 grains per
gallon and a total dissolved solids not exceeding 350
ppm. Consult the manufacturer when heating potable
water exceeding these specifications.
Heating of high hardness and/or high total dissolved
solids water may require a larger circulating pump,
and a revised temperature rise specification based on
the water chemistry of the water to be heated.
Water with a hardness of less than 5 grains per gallon
will usually have a pH which can be aggressive and
corrosive causing non-warrantable damage to the
pump, and associated piping. Corrosion due to water
chemistry generally shows up first in the hot water
system because heated water increases the rate of
corrosive chemical reactions.
C. SYSTEM COMPONENTS
1. Pressure/Temperature Gauge: A combination
pressure/temperature gauge is provided with each
boiler to be mounted in the piping from the boiler
supply to the system as shown in Figure 4.1. Most
local codes require this gauge.
2. Potable Water Expansion Tank: An expansion tank 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.
3. 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.
4. WATER PIPING & CONTROLS
Table 4.1: Minimum Flow Rate
Water temperatures over 125°F
(52°C) can cause severe burns
instantly, or death from scalds.
Children, disabled, and elderly
are at the highest risk of being
scalded.
See instruction manual before
setting temperature at water heater.
Feel water before bathing or showering.
Temperature limiting valves are available, see
manual.
DANGER
!
Table 4.2: Heat Exchanger Water Capacity
WATER PIPING AND CONTROLS
Water temperature rise and maximum flow data is
based on heating potable water with a hardness of 5
to 25 grains per gallon and total dissolved solids not
exceeding 350 ppm.
NOTICE
PureFire
Model
Total Water Capacity
Gallons (Liters)
PFW-200 1.19 (4.50)
PFW-399 2.60 (9.84)
PureFire
Model
Minimum Water Flow Rate
GPM (LPM)
PFW-200 5.5 (20.8)
PFW-399 13.2 (50.0)
16
WATER PIPING AND CONTROLS
4. Back Flow Preventer: A back flow preventer (check
valve) is required by some jurisdictions to prevent water
in the system from backing up into the city water supply.
5. Pressure Relief Valve: The boiler pressure relief valve
is shipped separately for field installation. It is
extremely important to mount this relief valve in the
vertical position on the boiler supply pipe (toward the
front of the boiler).
The valve is to be installed as shown in Figure 4.1
Pipe the discharge of the relief valve to within 12"
(305 mm) of the floor and close to a floor drain.
Provide piping that is the same size or larger than the
relief valve outlet.
6. Pump: The boiler pump is to be sized to overcome the
pressure drop of the system while providing the flow
required by the boiler.
a. The pump 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.
b. The required flow is calculated based on the design
temperature difference from the return to the supply of
the boiler. For a PFW-200 with a design temperature
difference of 20°F the calculation is as follows:
Output 182,000
Required Flow =
________=_________
= 18.2 GPM
Δ
T x 500 20 x 500
Figure 4.1: Relief Valve Installation - PFW-200 &
PFW-399
PureFire
Model
Max. Boiler Input
Btu/hr (kW)
Gross Output
Btu/hr (kW)
PFW-200 199,000 (58.3) 183,000 (53.6)
PFW-399 399,000 (116.9) 373,000 (109.3)
Table 4.3: Boiler Inputs and Outputs
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
Figure 4.2: PureFire Circulator Sizing Graph
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
70
65
60
55
PFW-200
50
45
40
35
30
Pressure Drop (Ft. of Water)
25
20
PFW-399
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
Flow Rate (GPM)
17
WATER PIPING AND CONTROLS
c. The boiler pressure drop for various flow rates can
be determined using Figure 4.2, the PureFire
Boiler Pump Sizing Graph.
d. Table 4.4 provides the flow rate and pressure drop
information that corresponds to 20°F temperature
rise (ΔT). The pressure drop shown is for the
boiler only. If there is significant system pressure
drop in the circulation system between the boiler
and the tank, this should be included when
specifying pumps.
e. Table 4.5 provides a list of recommended pumps
for PureFire hot water supply boilers.
7. Flow Switch: The flow switch supplied with the boiler
is to be mounted as shown in figure 4.1 using the
fittings supplied with a minimum straight length of 5
pipe diameters before and after the switch.
D. SYSTEM PIPING
1. Figure 4.3 shows piping for a single boiler with a
single storage tank. When using the factory specified
pump, the maximum total pipe length is 30 feet (10
meters) with 6 90° elbows all at the full pipe diameter
of the pump connections.
2. In Figure 4.4, a single boiler is used with multiple
water storage tanks. The pumps are piped in parallel
with reverse return piping.
3. Figure 4.5 shows two boilers piped into a single
storage tank.
4. Figure 4.6 shows piping for two boilers and two water
storage tanks.
5. In Figure 4.7, we show a single boiler with a single
tank using a patented anti-scale principle. In this
configuration, the boiler control switches the 3-way
valve to bypass when the call for heat ends. The
pump is then operated to draw cool water from the
anti-scale buffer tank until the supply and return
temperatures equalize.
6. In Figure 4.8, a plate heat exchanger is used to isolate
the boiler from the domestic hot water supply system.
This strategy can be used if the domestic water does
not meet the water quality guidelines presented earlier
in this section. Note that a hydronic thermal
expansion tank is required in this closed-loop system.
Table 4.5: Pump Selection Chart (20°F ΔT)
Pump
Manufacturer
PFW-200 PFW-399
Bell & Gossett PL-36 PL-55
Grundfos
UPS32-80F
Medium Speed
UPS32-160F
Medium Speed
Taco 1400-20 1400-50
Table 4.4: Flow Rate and Pressure Drop for Various
System Temperature Rise Values
Flow Rate vs Pressure Drop at 20°F
PFW-200 PFW-399
GPM (LPM) Feet (m) GPM (LPM) Feet (m)
18.3 (69.3)
17.3 (5.3)
37.3 (141.2) 18.1 (5.5)
* Pumps must be bronze fitted for potable water application
18
WATER PIPING AND CONTROLS
Figure 4.3: Schematic Piping - One Boiler with a Single Storage Tank
19
WATER PIPING AND CONTROLS
Figure 4.4: Schematic Piping - One Boiler with Multiple Storage Tanks
20
Figure 4.5: Schematic Piping - Two Boilers with a Single Storage Tank
WATER PIPING AND CONTROLS
21
WATER PIPING AND CONTROLS
Figure 4.6: Schematic Piping - Two Boilers with Multiple Storage Tanks
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