PeerlessBoilers PF-50, PF-80, PF-110, PF-140, PF-200 Installation Manual

...

PUREFIRE

REV

Boilers

PF-50 PF-80 PF-110 PF-140 PF-200 PF-210 PF-300 PF-399

Gas

Installation, Operation & Maintenance Manual

As an ENERGY STAR®Partner, PB Heat, LLC has determined that this product meets the ENERGY STAR guidelines for energy efficiency.

USING THIS MANUAL 1

A. INSTALLATION SEQUENCE . . . . . . . . . . . . . .1

B. SPECIAL ATTENTION BOXES . . . . . . . . . . . . .1

1. PREINSTALLATION 2

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

B. CODES & REGULATIONS . . . . . . . . . . . . . . . .2

C. ACCESSIBILITY CLEARANCES . . . . . . . . . . . .3

D. COMBUSTION & VENTILATION AIR . . . . . . . .4

E. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .6

2. BOILER SET-UP 8

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

B. WALL MOUNTING . . . . . . . . . . . . . . . . . . . . . .8

C. FLOOR STANDING INSTALLATION . . . . . . . . .8

3. VENTING & AIR INLET PIPING 9

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

B. APPROVED MATERIALS . . . . . . . . . . . . . . . . .9

C. EXHAUST VENT/AIR INTAKE

PIPE LOCATION . . . . . . . . . . . . . . . . . . . . . . . .9

D. EXHAUST VENT/AIR INTAKE PIPE SIZING . .14 E. EXHAUST VENT/AIR INTAKE PIPE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .14

F. EXHAUST TAPPING FOR VENT SAMPLE . .15 G. BOILER REMOVAL FROM COMMON

VENTING SYSTEM . . . . . . . . . . . . . . . . . . . .15

4. WATER PIPING AND CONTROLS 17

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

B. OPERATING PARAMETERS . . . . . . . . . . . . . .17

C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .17

D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .21

E. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .21

F. SPECIAL APPLICATIONS . . . . . . . . . . . . . . . .27

5. FUEL PIPING 28

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . . .28

C. GAS SUPPLY PIPING – INSTALLATION . . . .28

D. GAS SUPPLY PIPING – OPERATION . . . . . . .29

E. MAIN GAS VALVE – OPERATION . . . . . . . . .30

6. CONDENSATE DRAIN PIPING 31

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

B. CONDENSATE SYSTEM . . . . . . . . . . . . . . . .31

C. CONDENSATE DRAIN PIPE MATERIAL . . . .32

D. CONDENSATE DRAIN PIPE SIZING . . . . . . .32

E. CONDENSATE DRAIN PIPE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .32

7. ELECTRICAL CONNECTIONS 33

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .33

B. CUSTOMER CONNECTIONS . . . . . . . . . . . . .33

C. ZONE CIRCULATOR WIRING . . . . . . . . . . . . .34

D. INTERNAL WIRING . . . . . . . . . . . . . . . . . . . .34

8. BOILER CONTROL: INTERNAL WIRING & OPERATION 38

A. CONTROL OVERVIEW . . . . . . . . . . . . . . . . . .38

B. IGNITION SEQUENCE . . . . . . . . . . . . . . . . . .40

C. BOILER CONTROL . . . . . . . . . . . . . . . . . . . . .42

D. CENTRAL HEATING . . . . . . . . . . . . . . . . . . . .42

E. DOMESTIC HOT WATER (DHW) . . . . . . . . . .46

F. SERVICE NOTIFICATION . . . . . . . . . . . . . . . .47

G. SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . .48

H. STATUS & FAULT HISTORY . . . . . . . . . . . . . .48

I. SENSOR RESISTANCE . . . . . . . . . . . . . . . . .49

J. MULTIPLE BOILERS . . . . . . . . . . . . . . . . . . . .49

9. START-UP PROCEDURE 55

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

B. CHECK WATER PIPING . . . . . . . . . . . . . . . . .55

C. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . . .55

D. CHECK OPERATION . . . . . . . . . . . . . . . . . . . .55

E. LIGHTING & OPERATING PROCEDURES . . .57

10. TROUBLESHOOTING 58

A. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . . .58

B. LOCKING ERRORS . . . . . . . . . . . . . . . . . . . . .58

C. ERROR MESSAGES IN A CASCADE

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

D. WARNING ERRORS . . . . . . . . . . . . . . . . . . . .62

E. DELAYED IGNITION (HARD LIGHT-OFF) . . .64

BOILER FAILS TO RESPOND TO A CH CALL

.64

11. MAINTENANCE 65

A. GENERAL (WITH BOILER IN USE) . . . . . . . .66

B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .66

C. ANNUALLY (BEFORE START OF HEATING

SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

D. CONDENSATE CLEANING

INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .66

E. INSPECTION AND CLEANING OF

COMBUSTION CHAMBER COILS . . . . . . . . .67

12. BOILER DIMENSIONS & RATINGS 68

13. REPAIR PARTS 71

APPENDIX A. STATUS SCREENS 80

APPENDIX B. USER MENU 84

APPENDIX C. INSTALLER MENU 85

APPENDIX D. COMBUSTION TEST RECORD 90

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

Compliance with the Energy Policy and Conservation Act:

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

Indicates a condition or hazard which will or can cause minor personal injury or property damage.

CAUTION

Indicates special attention is needed, but not directly related to potential personal injury or property damage.

NOTICE

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is not used for any space heating

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

IMPORTANT NOTICE

A. GENERAL

1. PUREFIRE®boilers are supplied completely assembled as packaged boilers. The package should be inspected for damage upon receipt and any damage to the unit should be reported to the shipping company and wholesaler. This boiler should be stored in a clean, dry area.

2. Carefully read these instructions and be sure to understand the function of all connections prior to beginning installation. Contact your PB Heat, LLC Representative for help in answering questions.

3. This boiler must be installed by a qualified contractor. The boiler warranty may be voided if the boiler is not installed correctly.

4. A hot water boiler installed above radiation or as required by the Authority having jurisdiction, must be provided with a low water fuel cut-off device either as part of the boiler or at the time of installation.

B. CODES & REGULATIONS

1. Installation and repairs are to be performed in strict accordance with the requirements of state and local regulating agencies and codes dealing with boiler and gas appliance installation.

2. In the absence of local requirements the following should be followed:

a. ASME Boiler and Pressure Vessel Code, Section

IV - “Heating Boilers”

b. ASME Boiler and Pressure Vessel Code, Section

VI - “Recommended Rules for the Care and Operation of Heating Boilers”

c. ANSI Z223.1/NFPA 54 - “National Fuel Gas Code”

d. ANSI/NFPA 70 - “National Electrical Code”

e. ANSI/NFPA 211 - “Chimneys, Fireplaces, Vents

and Solid Fuel Burning Appliances”

3. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

**Please read if installing in Massachusetts**

Massachusetts requires manufacturers of Side Wall Vented boilers to provide the following information from the Massachusetts code:

A hard wired carbon monoxide detector with an alarm and battery back-up must be installed on the floor level where the gas equipment is to be installed AND on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment.

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

Detector(s) must be installed by qualified licensed professionals.

APPROVED CARBON MONOXIDE DETECTORS: Each carbon monoxide detector shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

EXEMPTIONS to the requirements listed above:

The above requirements do not apply if the exhaust vent termination is seven (7) feet or more above finished grade in the area of the venting, including but not limited to decks and porches.

The above requirements do not apply to a boiler installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

This boiler installation manual shall remain with the boiler at the completion of the installation.

See the latest edition of Massachusetts Code 248 CMR for complete verbage and also for additional (non-vent related) requirements (248 CMR is available online).

If your installation is NOT in Massachusetts, please see your authority of jurisdiction for requirements that may be in effect in your area. In the absence of such requirements, follow the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

PREINSTALLATION

1. PREINSTALLATION

Liquefied Petroleum (LP) Gas or Propane is heavier than air and, in the event of a leak, may collect in low areas such as basements or floor drains. The gas may then ignite resulting in a fire or explosion.

WARNING

C. ACCESSIBILITY CLEARANCES

1. The PUREFIRE®boiler is certified for closet installations with zero clearance to combustible construction. In addition, it is design certified for use on combustible floors. Do not install on carpeting.

2. Figure 1.1 shows the minimum recommended clearances to allow reasonable access to the boiler for Models PF-50, PF-80, PF-110 and PF-140. For Models PF-200, PF-210, PF-300 and PF-399, Figure 1.2 shows the minimum recommended accessibility clearances. However, Local codes or special conditions may require greater clearances.

PREINSTALLATION

Figure 1.1: Minimum Accessibility Clearances – PF-50, PF-80, PF-110 & PF-140

Figure 1.2: Minimum Accessibility Clearances – PF-200, PF-210, PF-300 & PF-399

DANGER

DO NOT INSTALL ON CARPETING.

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 sections of the local building code. Subsections 3 through 10 as follows are based on the National Fuel Gas Code requirements.

2. If the combustion air is piped directly to the boiler from outside the building, no additional combustion or ventilation air is required. Otherwise, follow the National Fuel Gas Code recommendations summarized in subsections 3 through 10.

3. Required Combustion Air Volume: The total required volume of indoor air is to be the sum of the required volumes for all appliances located within the space. Rooms communicating directly with the space in which the appliances are installed and through combustion air openings sized as indicated in Subsection 3 are considered part of the required volume. The required volume of indoor air is to be determined by one of two methods.

a. Standard Method

: The minimum required volume of indoor air (room volume) shall be 50 cubic feet per 1000 BTU/Hr (4.8 m3/kW). This method is to be used if the air infiltration rate is unknown or if the rate of air infiltration is known to be greater than 0.6 air changes per hour. As an option, this method may be used if the air infiltration rate is known to be between 0.6 and 0.4 air changes per hour. If the air infiltration rate is known to be below 0.4 then the Known Air Infiltration Rate Method must be used. If the building in which this appliance is to be installed is unusually tight, PB Heat recommends that the air infiltration rate be determined.

b. Known Air Infiltration Rate Method

where:

fan

= Input of the fan assisted appliances

in Btu/hr

ACH = air change per hour (percent of the

volume of the space exchanged per hour, expressed as a decimal)

Note: These calculations are not to be used for

infiltration rates greater than 0.60 ACH.

4. Indoor Air Opening Size and Location: Openings connecting indoor spaces shall be sized and located as follows:

a. Combining Spaces on the Same Floor

: Provide two permanent openings communicating with additional spaces that have a minimum free area of 1 in

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

(645 cm2). One opening is to begin within 12 inches (305 mm) from the top of the space and the other is to begin within 12 inches (305 mm) from the floor. The minimum dimension of either of these openings shall be 3 inches (76 mm). See Figure 1.3 for an illustration of this arrangement.

b. Combining Spaces on Different Floors

: Provide one or more permanent openings communicating with additional spaces that have a total minimum free area of 2 in

per 1000 Btu/hr (44 cm2per 1000 W) of total input rating of all equipment. See Figure 1.4 for an illustration of this arrangement.

15 ft

fan

ACH 1000

Btu

Required Volume

fan

⎛ ⎜ ⎝

⎛

⎜

⎝

Figure 1.3: Air Openings – All Air from Indoors

on the Same Floor

Figure 1.4: Air Openings – All Air from Indoors

on Different Floors

PREINSTALLATION

5. Outdoor Combustion Air: Outdoor combustion air is to be provided through one or two permanent openings. The minimum dimension of these air openings is 3 inches (76 mm).

a. Two Permanent Opening Method

: Provide two permanent openings. One opening is to begin within 12 inches (305 mm) of the top of the space and the other is to begin within 12 inches (305 mm) of the floor. The openings are to communicate directly or by ducts with the outdoors or with spaces that freely communicate with the outdoors. The size of the openings shall be determined as follows:

i. Where communicating directly or through

vertical ducts with the outdoors each opening shall have a minimum free area of 1 in

per

4000 Btu/hr (22 cm

per 4000 W) of total input rating for all equipment in the space. See Figure 1.5 for openings directly communicating with the outdoors or Figure

1.6 for openings connected by ducts to the outdoors.

ii. Where communicating with the outdoors through

horizontal ducts, each opening shall have a minimum free area of 1 in

per 2000 Btu/hr (22 cm2per 2000 W) of total rated input for all appliances in the space. See Figure 1.7.

b. One Permanent Opening Method

: Provide one permanent opening beginning within 12 inches (305 mm) of the top of the space. The opening shall communicate directly with the outdoors, communicate through a vertical or horizontal duct, or communicate with a space that freely communicates with the outdoors. The opening shall have a minimum free area of 1 in

per 3000 Btu/hr of total rated input for all appliances in the space and not less than the sum of the crosssectional areas of all vent connectors in the space. The gas-fired equipment shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance. See Figure 1.8 for this arrangement.

Figure 1.5: Air Openings – All Air Directly from

Outdoors

Figure 1.6: Air Openings – All Air from Outdoors

through Vertical Ducts

Figure 1.7: Air Openings – All Air from Outdoors

through Horizontal Ducts

Figure 1.8: Air Openings – All Air from Outdoors

through One Opening

PREINSTALLATION

6. Combination Indoor and Outdoor Combustion Air: If the required volume of indoor air exceeds the available indoor air volume, outdoor air openings or ducts may be used to supplement the available indoor air provided:

a. The size and location of the indoor openings

comply with Subsection 3.

b. The outdoor openings are to be located in

accordance with Subsection 4.

c. The size of the outdoor openings are to be sized

as follows:

where:

req

= minimum area of outdoor openings.

full

= full size of outdoor openings calculated

in accordance with Subsection 4.

avail

= available indoor air volume

req

= required indoor air volume

7. Engineered Installations: Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and dilution air and shall be approved by the authority having jurisdiction.

8. Mechanical Combustion Air Supply:

a. In installations where all combustion air is

provided by a mechanical air supply system, the combustion air shall be supplied from the outdoors at the minimum rate of 0.35 ft

/min per

1000 Btu/hr (0.034 m

/min per 1000 W) of the

total rated input of all appliances in the space.

b. In installations where exhaust fans are installed,

additional air shall be provided to replace the exhaust air.

c. Each of the appliances served shall be interlocked

to the mechanical air supply to prevent main burner operation when the mechanical air supply system is not in operation.

d. In buildings where the combustion air is provided

by the mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the required ventilation air.

9. Louvers & Grills:

a. The required size of openings for combustion,

ventilation, and dilution air shall be based on the net free area of each opening.

i. Where the free area through a louver or grille

is known, it shall be used in calculating the opening size required to provide the free area specified.

ii. Where the free area through a louver or grille

is not known, it shall be assumed that wooden louvers will have 25% free area and metal louvers and grilles will have 75% free area.

iii. Non-motorized dampers shall be fixed in the

open position.

b. Motorized dampers shall be interlocked with the

equipment so that they are proven in the full open position prior to ignition and during operation of the main burner.

i. The interlock shall prevent the main burner

from igniting if the damper fails to open during burner startup.

ii. The interlock shall shut down the burner if the

damper closes during burner operation.

10. Combustion Air Ducts: a. Ducts shall be constructed of galvanized steel or

an equivalent corrosion- resistant material.

b. Ducts shall terminate in an unobstructed space,

allowing free movement of combustion air to the appliances.

c. Ducts shall serve a single space.

d. Ducts shall not serve both upper and lower

combustion air openings where both such openings are used. The separation between ducts serving upper and lower combustion air openings shall be maintained to the source of combustion air.

e. Ducts shall not be screened where terminating in

an attic space.

f. Horizontal upper combustion air ducts shall not

slope downward toward the source of the combustion air.

g. 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 LAYOUTS

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

req

= A

full

x 1 –

avail

req

⎛ ⎜ ⎝

⎛

⎜

⎝

Do not install this boiler where gasoline or other flammable liquids or vapors are stored or are in use.

WARNING

This boiler is certified as an indoor appliance. Do not install this boiler outdoors or locate where it will be exposed to freezing temperatures.

WARNING

Do not install this boiler in the attic.

WARNING

PREINSTALLATION

A. GENERAL

1. PUREFIRE®boilers are intended for installation in an area with a floor drain or in a suitable drain pan. Do not install any boiler where leaks or relief valve discharge will cause property damage.

2. The P

UREFIRE

boiler is not intended to support external piping. All venting and other piping should be supported independently of the boiler.

3. Install the boiler level to prevent condensate from backing up inside the boiler.

4. P

UREFIRE

boilers can be wall mounted or floor standing. The following instructions provide guidance for both configurations.

B. WALL MOUNTING

1. Models PF-50, PF-80, PF-110 and PF-140: a. A wall mounting bracket kit (54171) is included

for wall mounting these boiler sizes.

b. Mount the bracket level on the wall using 5/16" lag

bolts. Be sure the lag bolts are fully supported by wall studs or adequate wall structure.

c. The mounting bracket has (4) holes on 16" centers

as shown in Figure 2.1. This is intended to give installers the ability to mount the bracket on two wall studs spaced at this interval. If existing wall studs are spaced differently or if the desired location is not in line with the wall studs, additional support is required.

d. Install the two additional lag bolts supplied with

the boiler into the wall structure approximately 23” below those used to attach the wall mounting bracket to the wall as shown in Figure 2.1. The depth that these are threaded into the wall can be adjusted to assure level mounting of the boiler.

e. If the boiler is wall mounted using the optional

wall bracket, be sure that the wall provides adequate support for the boiler.

f. Be sure to adequately support the boiler while

installing external piping or other connections.

g. Be sure that condensate piping is routed to a

suitable drain or condensate pump.

2. All Models can be wall mounted by using the optional stand (91400).

a. Use the leveling feet provided with the boiler to

assure proper level.

b. Be sure to leave adequate provisions for

condensate piping and/or a pump (if required).

C. FLOOR STANDING INSTALLATION

1. For floor standing installations, use the leveling feet to assure that the boiler is completely level. This will prevent condensate from backing up in the boiler.

2. Be sure to leave adequate space for condensate piping or a pump if required.

BOILER SET-UP

2. BOILER SET-UP

The wall mounting bracket is designed to support the boiler. External piping for water, venting, air intake and fuel supply is to be supported separately

WARNING

Figure 2.1: Optional Wall Mounting Bracket for PF-50,

PF-80, PF-110 and PF-140 Boilers

This boiler must be installed level to prevent condensate from backing up inside the boiler.

CAUTION

Make sure the boiler wall bracket is adequately supported. Do not install this bracket on dry wall unless adequately supported by wall studs.

WARNING

A. GENERAL

1. Install the PUREFIRE®boiler venting system in accordance with these instructions and with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, and/or applicable provisions of local building codes.

2. The P

UREFIRE

boiler is a direct vent appliance and is ETL Listed as a Category IV appliance with Intertek Testing Laboratories, Inc.

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 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 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.

VENTING & AIR INLET PIPING

3. VENTING & AIR INLET PIPING

The venting system for this product is to be installed in strict accordance with these venting instructions. Failure to install the vent system properly may result in severe personal injury, death or major property damage.

WARNING

This vent system operates under positive pressure. Vent connectors serving appliances vented by natural draft shall not be connected into any portion of this venting system. Failure to comply may result in serious injury, death or major property damage.

WARNING

Only the materials listed below are approved for use with the

UREFIRE

boiler. Use only these components in accordance with these instructions. Failure to use the correct material may result in serious injury, death, or major property damage.

WARNING

Table 3.1: Approved Materials for Exhaust Vent Pipe

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel

(polyphenolsulphone) for exhaust vent is prohibited. Use of these materials as exhaust vent 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 F441

PVC-DWV*

ANSI/ASTM D2665

FasNSeal

UL1738 & ULC-S636

PolyPro

ULC-S636

InnoFlue

ULC-S636

Z-DENS

ULC S636

Pipe Cement

(PVC & CPVC Only)

PVC/CPVC Cement ANSI/ASTM D2564

6. Air Intake Pipe Location – Sidewall Venting: a. Provide a minimum 1 foot (30 cm) clearance from

the bottom of the air intake pipe above the expected snow accumulation level. 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.

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 1 foot (30 cm) distance from any door, operable window, or gravity intake into any building.

• Provide a minimum of 1 foot (30 cm) clearance from the bottom of the exit terminal above the expected snow accumulation level. Snow removal may be required to maintain clearance.

• Provide a minimum of 4 feet (1.22 m) horizontal clearance from electrical meters, gas meters, gas regulators, and relief equipment. In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained.

• Do not locate the exhaust exit terminal over public walkways where condensate could drip and create a hazard or nuisance.

• When adjacent to public walkways, locate the exit terminal at least 7 feet above grade.

• Do not locate the exhaust termination directly under roof overhangs to prevent icicles from forming or recirculation of exhaust gases from occurring.

• Provide 3 feet clearance from the inside corner of adjacent walls.

VENTING & AIR INLET PIPING

Figure 3.1: Vent Pipe Spacing for Multiple

UREFIRE

Boilers

Figure 3.2: Exit Terminal Location for Mechanical Draft and Direct-Vent Venting Systems

Condensing flue gases can freeze on exterior building surfaces which may cause discoloration and degradation of the surfaces.

CAUTION

Figure 3.5: Exhaust and Air Inlet on Opposite Walls

b. Figures 3.3 through 3.6 show approved sidewall

venting configurations using the standard fittings supplied.

c. Figure 3.4 is only approved for locations in which

the outdoor temperature is above -5°F (-21°C) in accordance with ASHRAE 90A-1980 recommendations.

d. Figures 3.7 shows an approved sidewall vent

configuration using an optional concentric vent termination kit. 3" (54498) or 4" (54499).

VENTING & AIR INLET PIPING

Figure 3.3: Standard Exhaust & Air Inlet Pipe

Terminations

Figure 3.4: Offset Exhaust and Air Inlet

Terminations

8. Vertical Venting Configuration: a. Figure 3.8 shows the approved venting

configuration for vertical venting using the standard fittings supplied.

b. Locate the air intake pipe inlet a minimum of 12"

above the expected snow accumulation on the roof surface.

c. Locate the end of the exhaust vent pipe a minimum

of 12" above the inlet to the air intake pipe.

d. Figure 3.9 shows an approved vertical vent

configuration using the optional concentric vent termination kit.

e. Figure 3.10 shows an option for routing the

exhaust and air inlet piping through an unused chimney.

f. Figure 3.11 shows this option using inlet air from

a sidewall position.

g. Figure 3.12 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.

Figure 3.7: Optional Concentric Vent Kit

Installation

Figure 3.8: Standard Vertical Vent Installation

VENTING & AIR INLET PIPING

Figure 3.6: Sidewall Exhaust with Indoor Air

VENTING & AIR INLET PIPING

Figure 3.9: Concentric Vertical Vent Installation

Figure 3.10: Venting Through a Chimney Using

Outside Air

Figure 3.11: Venting Through a Chimney Using

Sidewall Outside Air

Figure 3.12: Venting with a Chimney Using Inside Air

D. EXHAUST VENT/AIR INTAKE PIPE SIZING

1. Table 3.2 shows Exhaust Vent/Air Intake Sizes for

UREFIRE

boilers.

2. Polypropylene vent systems can be installed using optional InnoFlue

or PolyPro®vent adapters. Table

3.3 shows the appropriate PB Heat stock codes.

Contact your PB Heat, LLC Representative for more information on this option.

3. Combined systems using separate polypropylene exhaust & air inlet pipes which transitions 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 3.4.

b. The equivalent length can be calculated as follows.

This is well below the 200 feet maximum equivalent length. If the total is above 200 equivalent feet, alternate boiler locations or exhaust penetration location should be considered.

E. EXHAUST VENT/AIR INTAKE INSTALLATION

1. Figures 12.1 & 12.2 show the exhaust connection on top of the boiler, near the rear in the center.

a. The exhaust connection for PF-50, PF-80, PF- 110 &

PF-140 boilers is a 3" CPVC Female Pipe Adapter.

b. The exhaust connections for the PF-200/210 (3”),

PF-300 (4”) and PF-399 (4”) are male CPVC pipe.

c. These connections are to be joined with suitable

PVC/CPVC adhesives in accordance with manufacturers’ instructions.

2. The Air Intake connection is to the right of the exhaust.

3. Both connections are clearly marked.

4. Remove all burrs and debris from the joints and fittings.

5. Horizontal lengths of exhaust vent must be installed with a slope of not less than 1/4" per foot (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.

VENTING & AIR INLET PIPING

This appliance uses a positive pressure venting system. All joints must be sealed completely to prevent leakage of flue products into living spaces. Failure to do this may result in severe personal injury, death or major property damage.

WARNING

Exhaust Air Inlet Total

Straight Length of Pipe 50' 50' 100'

90° Elbows, SR 2 x 5'= 10' 1 x 5' = 5' 15' 45° Elbows, SR 2 x 3' = 6' 6'

Conc. Vent Termination 1 x 3' = 3' 3'

Total 124'

Table 3.5: Sample Equivalent Length Calculation

Boiler Model

Centrotherm

InnoFlue

DuraVent

Pol yPro

Boiler Model

Centrotherm

InnoFlue

DuraVent

Pol yPro

PF-50 54632 54630* PF-200 54632 54630*

PF-80 54632 54630* PF-210 54632 54630* PF-110 54632 54630* PF-300 54633 54631* PF-140 54632 54630* PF-399 54633 54631*

Table 3.3: Polypropylene Vent Adapter Stock Codes

Boiler Model Exhaust Vent/Air Intake Size

PF-50 3" (80 mm)

PF-80 3" (80 mm) PF-110 3" (80 mm) PF-140 3" (80 mm) PF-200 3" (80 mm) PF-210 3" (80 mm) PF-300 4" (100 mm) PF-399 4" (100 mm)

Table 3.2: Exhaust Vent/Air Intake Sizing

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 3.4: Equivalent Length of Fittings

Exhaust Vent/Air Intake length in excess of 200 equivalent feet may result in reduced input due to excessive pressure drop.

NOTICE

Covering non-metallic exhaust venting material is prohibited and may result in severe personal injury, death, or major property damage.

WARNING

*Use Duravent adapter connector, Part# PPS-PAC, with PB Heat Parts

54630 and 54631.

c. A straight coupling is provided with the boiler to

be used as an outside vent termination. One of

the two screens is to be installed to prevent birds

or rodents from entering.

d. An air intake tee is provided with the boiler to be

used as an outside air intake termination. A screen

is to be installed to prevent birds or rodents from

entering.

e. The following are optional combination air

intake/exhaust terminations that are available

separately from your PB Heat, LLC distributor for

use with P

UREFIRE

boilers. A 3” CPVC/PVC coupling is required for the PF-200/210 and a 4” CPVC/PVC coupling is required for the PF-300/399 models when using a concentric vent termination.

f. Refer to Figures 3.3 through 3.7 for sidewall

venting options using PVC or CPVC pipe.

g. Refer to Figures 3.8 through 3.12 for vertical

venting options using PVC or CPVC pipe.

F. EXHAUST TAPPING FOR VENT SAMPLE

To properly install the PUREFIRE®boiler, carbon dioxide (CO

) and carbon monoxide (CO) levels in the exhaust vent must be determined from a sample of combustion products. To do this in PVC or CPVC pipe, a hole must be drilled in the exhaust vent pipe:

a. Drill a 21/64" diameter hole in the pipe in a position

that 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. Use a 1/8" NPT PVC or Teflon Pipe Plug to seal the

hole.

InnoFlue

and PolyPro®vent systems offer test port fittings for obtaining a sample of combustion products. See your Centrotherm or DuraVent Representative for recommendations.

See Section 9.D.7 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.

VENTING & AIR INLET PIPING

Boiler Model

Description

Stock

Code

PF-50,

PF-80, PF-110, PF-140, PF-200, PF-210

Sidewall Vent Termination Kit – PolyPro 3PPS-HK 54498

Vertical Vent Termination Kit – PolyPro 3PPS-VK 54500

PF-300 PF-399

Sidewall Vent Termination Kit – PolyPro 4PPS-HK 54499

Vertical Vent Termination Kit – PolyPro 4PPS-VK 54501

Table 3.6: Concentric Vent Termination Kits

VENTING & AIR INLET PIPING

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.

A. GENERAL

1. Size water supply and return piping in accordance with system requirements rather than the boiler connections.

2. If the P

UREFIRE

boiler is used to replace an existing boiler, make sure the system piping is thoroughly cleaned and free from debris before installing this boiler. Sentinel Performance Solutions (http://www.sentinel-solutions.net/us/) offers a full line of cleaners (X300), sludge remover (X400), antifreeze (X500) and corrosion inhibitors (X100/X500) for hydronic applications.

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.).

5. The P

UREFIRE

heating boiler is intended for use in a closed-loop hydronic system. Leaks in the piping system may require constant make-up water which may include oxygen, calcium and other substances which may cause corrosion, calcium scale buildup, or other attack on the hydronic system piping. The system water should have a pH value of between 8.2 and 9.5. The water hardness is to be maintained between 50 ppm CaCO

(3 gr/gal) and 150 ppm

CaCO

(9 gr/gal). Also, a minimum water pressure of

5 psi is required for proper performance.

B. OPERATING PARAMETERS

1. The PUREFIRE®boiler is designed to operate in a closed loop hydronic system under forced circulation. This requires the system to be completely filled with water and requires a minimum water flow through the boiler to operate effectively.

2. The minimum system pressure is 14.5 psig (100 kPa).

3. Table 4.1 lists the minimum flow rates for each P

UREFIRE

model. If a glycol solution is to be used, contact your PB Heat, LLC representative for minimum flow rates.

Section 4.E provides detailed information about using glycol for freeze protection.

Table 4.2 provides the water volume of the heat exchanger including the supply and return pipes that are attached at the factory.

C. SYSTEM COMPONENTS

Figure 4.1 shows the symbol key for piping diagrams in this section. The following are brief descriptions of system components.

1. Pressure/Temperature Gauge: A combination pressure/temperature gauge is provided with each

UREFIRE

boiler to be mounted in the piping from the

boiler supply to the system as shown in Figure 4.2 &

4.3. 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.

WATER PIPING AND CONTROLS

4. WATER PIPING & CONTROLS

Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems. Unlike automotive antifreeze, solutions for hydronic applications contain corrosion inhibitors that will protect system components from premature failure due to corrosion.

CAUTION

Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems. Ethylene glycol is toxic and may cause an environmental hazard if a leak or spill occurs.

WARNING

PUREFIRE

Model

Minimum Flow Rate

Water

GPM (LPM)

50% Glycol Solution

GPM (LPM)

PF-50 2.2 (8.3) 2.8 (10.6)

PF-80 3.3 (12.5) 4.1 (15.5) PF-110 4.4 (16.7) 5.5 (20.8) PF-140 5.5 (20.8) 6.8 (25.7) PF-200 5.5 (20.8) 6.8 (25.7) PF-210 5.5 (20.8) 6.8 (25.7) PF-300 13.2 (50.0) 16.5 (62.5) PF-399 13.2 (50.0) 16.5 (62.5)

Table 4.1: Minimum Flow Rate

PUREFIRE

Model

Total Water Capacity

Gallons (Liters)

PF-50 0.62 (2.35)

PF-80 0.72 (2.73) PF-110 0.89 (3.37) PF-140 1.25 (4.73) PF-200 1.19 (4.50) PF-210 1.19 (4.50) PF-300 2.60 (9.84) PF-399 2.60 (9.84)

Table 4.2: Heat Exchanger Water Capacity

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.

6. Pressure Reducing Valve: A pressure reducing valve, such as the Bell & Gossett B-38 or a TACO #329, is used in a hydronic system to automatically feed water to the system whenever pressure in the system drops below the pressure setting of the valve. These valves should not be used on glycol systems unless close supervision of the glycol solution is practiced.

7. Back Flow Preventer: A back flow preventer (check valve) is required by some jurisdictions to prevent water in the hydronic system from backing up into the city water supply. This is especially important on systems in which glycol solution is used as the heating medium.

8. Pressure Relief Valve: The boiler pressure relief valve is shipped separately for field installation. The valve is to be installed as shown in Figures 4.2 or

4.3. Pipe the discharge of the relief valve to within 12" of the floor and close to a floor drain.

Provide piping that is the same size or larger than the relief valve outlet.

9. Low Water Cut Off: When installing a probe type LWCO, locate the LWCO in the boiler supply above the top jacket panel. Refer to Section 7. Electrical Connection in this manual for wiring details.

WATER PIPING AND CONTROLS

Figure 4.1: Piping Symbol Key

Do not operate this appliance without installing the pressure relief valve supplied with the boiler or one with sufficient relieving capacity in accordance with the ASME Rating Plate on the boiler heat exchanger.

WARNING

Pipe the discharge of the relief valve as close as possible to the floor and away from high traffic areas. Pipe the discharge to a floor drain. Failure to do so may result in personal injury and/or property damage.

CAUTION

10. 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.

b. The circulator should be sized based on gross

output of the boiler. Table 4.3 shows the Boiler Output as reported to the Hydronics Institute Section of AHRI.

c. The required flow is calculated based on the design

temperature difference from the return to the supply of the boiler. For a PF-110 with a design temperature difference of 20°F the calculation is as follows.

Output 101,000

Required Flow =

________=_________

= 10.1 GPM

T x 500 20 x 500

WATER PIPING AND CONTROLS

PUREFIRE

Model

Boiler Input

Btu/hr (kW)

Gross Output

Btu/hr (kW)

PF-50 50,000 (14.7) 46,000 (13.5)

PF-80 80,000 (23.4) 74,000 (21.7) PF-110 110,000 (34.2) 102,000 (29.9) PF-140 140,000 (41.0) 131,000 (38.4)

PF-200 199,000 (58.3) 183,000 (53.6) PF-210 210,000 (61.5) 193,000 (56.6) PF-300 300,000 (87.9) 289,000 (84.9) PF-399 399,000 (116.9) 373,000 (109.3)

Table 4.3: Boiler Inputs and Outputs

Figure 4.4: PUREFIRE®Circulator Sizing Graph (General Pump – Primary/Secondary)

Figure 4.2: Relief Valve Installation – PF-50, PF-80,

PF-110 & PF-140

Figure 4.3: Relief Valve Installation – PF-200, PF-210, PF-300, PF-399 & PF-460

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PF-80

PF-110

PF-50

PF-200

PF-140

PF-210

PF-300

PF-399

)ORZ5DWH*30

PF-460

d. The boiler pressure drop for various flow rates can

be determined using Figure 4.4, the P

UREFIRE

Boiler Circulator Sizing Graph.

e. Table 4.4 provides the flow rate and pressure drop

information that corresponds to various system temperature rise values (ΔT). The pressure drop shown is for the boiler only. If there is significant pressure drop in the system, this should be included when specifying circulators.

Table 4.4: Flow Rate and Pressure Drop for Various System Temperature Rise Values

ΔT

(°F)

Flow Rate & Pressure Drop

PF-50 PF-80 PF-110 PF-140 PF-200 PF-210 PF-300 PF-399

GPM FT GPM FT GPM FT GPM FT GPM FT GPM FT GPM FT GPM FT

40 2.3 2.17 3.7 3.92 5.1 3.74 6.5 2.70 9.2 5.77 9.6 6.23 14.5 3.11 18.7 4.97 35 2.6 2.72 4.2 4.95 5.8 4.75 7.4 3.51 10.5 7.13 11.0 7.69 16.6 3.99 21.3 6.38 30 3.1 3.54 4.9 6.49 6.7 6.27 8.7 4.75 12.2 9.10 12.8 9.81 19.3 5.32 24.9 8.50 25 3.7 4.83 5.8 8.95 8.1 8.70 10.4 6.80 14.6 12.14 15.4 13.09 23.2 7.47 29.8 11.93 20 4.6 7.06 7.3 13.25 10.1 12.99 13.0 10.55 18.3 17.27 19.2 18.63 29.0 11.32 37.3 18.08 15 6.1 11.52 9.7 21.97 13.5 21.78 17.3 18.58 24.4 27.21 25.6 29.35 38.7 19.34 49.7 30.90 10 9.2 22.97 14.6 44.81 20.2 45.11 26.0 41.26 36.6 51.64 38.4 55.71 58.0 41.14 74.6 65.74

Table 4.5: Circulator Selection Chart (General Pump – Primary Secondary)

Circulator

Manufacturer

Temp.

Difference PF-50 PF-80 PF-110 PF-140 PF-200 PF-210 PF-300 PF-399

Taco

20°F

005* 009 0014 0014 1400-20 1400-20 2400-60 1400-50

Grundfos

UPS15-58FC

Med Speed

UPS15-58FC

Hi Speed

UPS26-99FC

Med Speed

UPS26-99FC

Med Speed

UPS32-80F Med Speed

UPS26-150 SF

Hi Speed

UPS32-160F

Med Speed

Bell & Gossett

NRF-22 NRF-22 NRF-36 NRF-25 NRF-36 NRF-36 NRF-45 Speed 3 PL-55

Wilo

Star S 21 FX

Med Speed

Star S 21 FX

Hi Speed

Star S 21 FX

Hi Speed

Star 30 F

Top S 1.25 x 25

Max

Top S 1.25 x 25

Max

Top-S 1.5 x 20 1

- 115V Min

Top S 1.25 x 35

Max

Armstrong

Astro 230CI

Speed 2

Astro 250CI

Speed 3

Astro 280CI

Speed 2

Astro 280CI

Speed 2

E9 E9 — E21

Taco

25°F

006F* 007 008 007 0014 0014 0011 1400-20

Grundfos

UPS15-58FC

Lo Speed

UPS15-58FC

Med Speed

UPS15-58FC

Hi Speed

UPS15-58FC

Hi Speed

UPS26-99FC

Med Speed

UPS26-99FC

Med Speed

UPS26-99 FC

Med Speed

UPS32-80F Med Speed

Bell & Gossett

NRF-9F/LW NRF-22 NRF-22 NRF-22 NRF-45 NRF-45 NRF-36 Speed 2 PL-50

Wilo

Star S 21 FX

Low Speed

Star S 21 FX

Med Speed

Star S 21 FX

Hi Speed

Star S 21 FX

Hi Speed

Star 30 F Star 30 F Star 17 FX

Top S 1.25 x 35

Max

Armstrong

Astro 230CI

Speed 2

Astro 230CI

Speed 3

Astro 230CI

Speed 3

Astro 230CI

Speed 3

Astro 280CI

Speed 2

Astro 280CI

Speed 2

— E11

Taco

30°F

006F* 005* 005* 005* 0014 0014 0011 0013

Grundfos

UP15-10F

UPS15-58FC

Med Speed

UPS15-58FC

Med Speed

UPS15-58FC

Med Speed

UPS26-99FC

Med Speed

UPS26-99FC

Med Speed

UPS44-43

Med Speed

UPS26-99FC

Hi Speed

Bell & Gossett

NRF-9F/LW NRF-22 NRF-22 NRF-22 NRF-25 NRF-25 NRF-45 Speed 1 NRF-36

Wilo

Star S 21 FX

Min Speed

Star S 21 FX

Med Speed

Star S 21 FX

Med Speed

Star S 21 FX

Hi Speed

Star 30 F Star 30 F Star 30 F Star 17 FX

Armstrong

Astro 230CI

Speed 1

Astro 230CI

Speed 2

Astro 230CI

Speed 2

Astro 230CI

Speed 3

Astro 280CI

Speed 2

Astro 280CI

Speed 2

—

Astro 290CI

Speed 3

Taco

35°F

006F* 006F* 006F* 006F* 0010 0010 0011 0014

Grundfos

UP15-10F

UPS15-58FC

Lo Speed

UPS15-58FC

Med Speed

UPS15-58FC

Med Speed

UPS15-58FC

Hi Speed

UPS15-58FC

Hi Speed

UPS15-55 SFC

Hi Speed

UPS26-99FC

Hi Speed

Bell & Gossett

N/A NRF-9F/LW NRF-9F/LW NRF-9F/LW NRF-22 NRF-22 NRF-25 Speed 2 NRF-45

Wilo

Star S 21 FX

Min Speed

Star S 21 FX

Min Speed

Star S 21 FX

Med Speed

Star S 21 FX

Med Speed

Star S 21 FX Hi

Speed

Star S 21 FX

Hi Speed

Star S 33 RFC Star 30 F

Armstrong

Astro 230CI

Speed 1

Astro 230CI

Speed 2

Astro 230CI

Speed 2

Astro 230CI

Speed 2

Astro 250CI

Speed 3

Astro 250CI

Speed 3

—

Astro 290CI

Speed 2

Taco

40°F

006F* 006F* 006F* 006F*

007

007 0011 0010

Grundfos

UP15-10F

UPS15-58FC

Lo Speed

UPS15-58FC

Lo Speed

UPS15-58FC

Lo Speed

UPS15-58FC

Hi Speed

UPS15-58FC

Hi Speed

UPS15-58FC

Hi Speed

UPS26-99FC

Med Speed

Bell & Gossett

N/A NRF-9F/LW NRF-9F/LW NRF-9F/LW NRF-22 NRF-22 NRF-25 Speed 2 NRF-33

Wilo

Star S 21 FX

Min Speed

Star S 21 FX

Min Speed

Star S 21 FX

Min Speed

Star S 21 FX

Min Speed

Star S 21 FX

High Speed

Star S 21 FX

Hi Speed

Star S-21 F Star 30 F

Armstrong

Astro 230CI

Speed 1

Astro 230CI

Speed 1

Astro 230CI

Speed 2

Astro 230CI

Speed 2

Astro 250CI

Speed 3

Astro 250CI

Speed 3

—

Astro 290CI

Speed 2

* A model 007 circulator can be substituted for those marked with an asterisk based on availability.

WATER PIPING AND CONTROLS

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.

11. Indirect Water Heater: An indirect water heater should be piped to a dedicated zone. The P

UREFIRE

boiler provides electrical terminals for connecting a domestic hot water (DHW) circulator. Examples of piping for the indirect water heater are shown under subsection “D”, System Piping of this section.

D. SYSTEM PIPING

1. Figure 4.5 shows a single boiler with multiple heating zones. In this case, the DHW zone is piped in parallel to the heating zones on the primary loop.

2. For a single boiler with one heating zone and one DHW zone which utilizes an indirect water heater like the Peerless

Partner®, pipe the boiler as shown in Figure 4.6. In systems like this, the DHW circulator must be sized to provide the minimum flow rate through the boiler.

3. In Figure 4.7 an additional boiler is added and more heating zones are shown. Notice that the two boilers are piped in parallel on the secondary loop. This maximizes the efficiency of the boilers since the lowest temperature system water is returning to both boilers.

4. Figure 4.8 shows a multiple boiler system with several different types of heat distribution units. This system illustrates how different temperature zones can be supplied from the same source by blending supply and return water to the zone.

5. In Figure 4.9 zone valves are used instead of zone circulators. Notice that the system is piped using reverse return piping to help balance the flow through the zones. If the zone lengths vary balancing valves are required on each loop.

E. FREEZE PROTECTION

1. Glycol for hydronic applications is specially formulated for heating systems. It includes inhibitors which prevent the glycol from attacking metallic system components. Make sure that the system fluid is checked for correct glycol concentration and inhibitor level.

2. Use only inhibited polypropylene glycol solutions of up to 50% by volume. Ethylene glycol is toxic and can chemically attack gaskets and seals used in hydronic system.

3. The anti-freeze solution should be tested at least once per year and as recommended by the manufacturer of the product.

4. Anti-freeze solutions expand more than water. For example, a 50% by volume solution expands 4.8% with a 148°F temperature rise while water expands about 3% for the same temperature increase. Allowance for this expansion must be considered in sizing expansion tanks and related components.

5. The flow rate in systems utilizing glycol solutions should be higher than in a water system to compensate for decreased heating capacity of the fluid.

6. Due to increased flow rate and fluid viscosity, the circulator head requirement will increase. Contact the pump manufacturer to correctly size the circulator for a particular application based on the glycol concentration and heating requirements.

7. A strainer, sediment trap, or some other means for cleaning the piping system must be provided. It should be located in the return line upstream of the boiler and must be cleaned frequently during the initial operation of the system. Glycol is likely to remove mill scale from new pipe in new installations.

8. Glycol solution is expensive and leaks should be avoided. Weld or solder joints should be used where possible and threaded joints should be avoided. Make-up water should not be added to the system automatically when glycol solution is used. Adding make-up water will dilute the system and reduce the ability of the solution to protect from freezing.

9. Check local regulations to see if systems containing glycol solutions must include a back-flow preventer or require that the glycol system be isolated from the water supply.

10. Do not use galvanized pipe in glycol systems.

11. Use water that is low in mineral content and make sure that there are no petroleum products in the solution.

a. Less than 50 ppm of calcium

b. Less than 50 ppm of magnesium

c. Less than 100 ppm (5 grains/gallon) of total

hardness

d. Less than 25 ppm of chloride

e. Less than 25 ppm of sulfate

12. Check with the local water supplier for chemical properties of the water.

13. The following test will determine if the water is of the appropriate hardness. Collect a sample of 50% water to 50% propylene glycol. Let the solution stand for 812 hours shaking it occasionally. If white sediment forms, the water is too hard and should not be used to dilute the glycol.

14. Mix the solution at room temperature.

15. Do not use a chromate treatment.

16. Refer to Technical Topics #2a published by the Hydronics Institute for further glycol system considerations.

The circulator sizing given is for primary/secondary installations only. The system circulators must be sized based on the flow and pressure drop requirements of the system.

NOTICE