PEERLESS PureFire PF-110 Page 2 Installation, Operation & Maintenance Manual Download

Page: 2 / 93

USING THIS MANUAL

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

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

1. PREINSTALLATION

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

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

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

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

3. VENTING & AIR INLET PIPING

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

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

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

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

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

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

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

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

8. BOILER CONTROL: INTERNAL

WIRING & OPERATION

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

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

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

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

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

E. LIGHTING & OPERATING PROCEDURES . . .57

10. TROUBLESHOOTING

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

F. BOILER FAILS TO RESPOND TO A CH CALL .64

11. MAINTENANCE

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

13. REPAIR PARTS

APPENDIX A. STATUS SCREENS

APPENDIX B. USER MENU

APPENDIX C. INSTALLER MENU

APPENDIX D. COMBUSTION TEST
RECORD

TABLE OF CONTENTS

TABLE OF CONTENTS

Summary of Contents for PureFire PF-110

Page 1: ...F 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 ...

Page 2: ... 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 SE...

Page 3: ... 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 ...

Page 4: ...ditional 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 licens...

Page 5: ...d 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 Clea...

Page 6: ... 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 Ifan Input of the fan assisted appliances in Btu hr ACH air ch...

Page 7: ... horizontal ducts each opening shall have a minimum free area of 1 in2 per 2000 Btu hr 22 cm2 per 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 o...

Page 8: ...ough 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 s...

Page 9: ...iquids 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 ...

Page 10: ...tach 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 su...

Page 11: ...less 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 ex...

Page 12: ...ny forced air inlet located within 10 ft 3 m Note This does not apply to the combustion air intake of a direct vent 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 ...

Page 13: ...oved 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 11 VENTING AIR INLET PIPING Figure 3 3 Standard Exhaust Air Inlet Pipe Terminations Figure 3 4 Offset Exhaust and Air Inlet Terminations ...

Page 14: ...t 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 Se...

Page 15: ...ING 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 ...

Page 16: ...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...

Page 17: ...n 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 aut...

Page 18: ...el 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 ...

Page 19: ...ttached 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 PUREFIRE 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 g...

Page 20: ...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 o...

Page 21: ...ign temperature difference of 20 F the calculation is as follows Output 101 000 Required Flow ________ _________ 10 1 GPM ΔT x 500 20 x 500 19 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 ...

Page 22: ...C 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...

Page 23: ... 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...

Page 24: ...22 WATER PIPING AND CONTROLS Figure 4 5 Recommended Piping One Boiler Primary Secondary with Two Zones Zone Circulator ...

Page 25: ...WATER PIPING AND CONTROLS Figure 4 6 Alternate Piping One Boiler Primary Secondary with a Peerless Partner Zone Circulators Note The DHW Circulator must be sized to provide minimum flow through the boiler ...

Page 26: ...24 WATER PIPING AND CONTROLS Figure 4 7 Two Boilers Primary Secondary with Four Zones Zone Circulator ...

Page 27: ...25 Figure 4 8 Three Boilers Primary Secondary with Five Zones Zone Circulator WATER PIPING AND CONTROLS ...

Page 28: ...26 WATER PIPING AND CONTROLS Figure 4 9 Three Boilers Primary Secondary with Four Zones Zone Valves ...

Page 29: ...vity flow through the boiler c See Figure 4 10 for recommended system piping for chiller operation 2 For boilers connected to heating coils in a forced air system where they may be exposed to chilled air circulation install flow control valves or other automatic means to prevent gravity circulation of the boiler water during cooling cycles See Figure 4 11 for an illustration WATER PIPING AND CONTR...

Page 30: ...al surface for removal of the pipe cap Natural gas input rates are based on 1 000 Btu ft3 LP input rates are based on 2 500 Btu ft3 FUEL PIPING 5 FUEL PIPING Use a pipe joint sealing compound that is resistant to liquefied petroleum gas A non resistant compound may lose sealing ability in the presence of this gas resulting in a gas leak Gas leaks may potentially cause an explosion or fire WARNING ...

Page 31: ...rom the manometer to the pressure tap fitting e Open the gas valve and start the boiler f Read and record the gas pressure while the boiler is firing at max input as well as with any other appliances to the same gas line at their maximum inputs g Turn off the boiler and close the gas shutoff valve h Remove the manometer tube from the pressure tap fitting i Turn the internal screw clockwise to clos...

Page 32: ...tion 3 Venting and Air Intake for information on obtaining vent samples from this boiler 30 FUEL PIPING Figure 5 2 Gas Valve Venturi Natural Gas Propane LP Low Fire High Fire Low Fire High Fire Carbon Monoxide CO 75 ppm 150 ppm 75 ppm 150 ppm Carbon Dioxide CO2 8 8 to 11 5 8 5 to 9 7 9 8 to 12 5 9 5 to 10 5 Excess Oxygen O2 0 7 to 5 4 3 9 to 6 0 1 9 to 6 0 4 9 to 6 5 Excess Air 3 2 to 31 2 20 1 to...

Page 33: ...ensate from the vent system This prevents dirt and debris from the venting system from entering the heat exchanger and fouling the heating surface PF 200 PF 210 PF 300 and PF 399 boilers have only one drain attached directly to the combustion chamber To prevent debris from entering the heat exchanger a separate drain can be added to the vent system at the top bulkhead drain connection as shown in ...

Page 34: ... the bulkhead fitting for attachment to an external drain C CONDENSATE DRAIN PIPE MATERIAL The condensate drain is to be piped using PVC polypropylene or other material resistant to acidic condensate Do not use steel brass or galvanized pipe for this purpose The acidic condensate will attack most metals and corrode D CONDENSATE DRAIN PIPE SIZING The bulkhead fitting for condensate connection is fo...

Page 35: ...m sensor 54156 are optional components and the low water cutoff if used is to be supplied by others b Terminals 11 20 on the right side are for line voltage customer connections to DHW CH and General Circulators voltage supply and low water cutoff LWCO power output 4 Figure 7 3 shows customer connections for the PF 200 PF 210 PF 300 and PF 399 boilers a Terminals 1 10 on the left side are for low ...

Page 36: ...ers to communicate with the control 2 Supply Return Sensors These component located on the left header are a pair thermistors that provide supply and return water temperature information to the control Be sure to use only a PUREFIRE supply thermistors for this boiler 3 Limit Switch This component is a bi metal switch that will prevent the boiler from reaching temperatures above 203 F 95 C to preve...

Page 37: ...35 ELECTRICAL CONNECTIONS Figure 7 5 Internal Wiring Schematic for PF 50 PF 80 PF 110 PF 140 boilers ...

Page 38: ...36 Figure 7 6 Internal Wiring Schematic for PF 200 PF 210 PF 300 PF 399 boilers ELECTRICAL CONNECTIONS ...

Page 39: ...itch is only needed and used on PF 200 210 300 399 to detect a blockage on the exhaust vent 13 PUREFIRE Link Adapter Green Plug The adapter is used by Factory Engineers to review control settings 14 Burner Plate Switch This switch Part 50045 is used to detect overheating of the burner plate primarily caused by broken insulation on the inside of the burner plate 15 Thermal Fuse This fuse Part 54466...

Page 40: ...mand and Setpoint Fixed Setpoint Not for space heating 4 Analog 0 10 VDC Input Setpoint Analog Input External Energy Management System 5 Analog 0 10 VDC Input Modulation Rate Analog Input 6 Hydro Air Unit Fixed Setpoint Not for space heating 7 Internal Reset Default Internal Reset No restrictions Table 8 2 Domestic Hot Water DHW Modes Domestic Hot Water Mode Description 0 No DHW No DHW tank is use...

Page 41: ...tures fall below the specified value If the temperature continues to fall the burner is activated DHW Tank Warm Hold Prevents the boiler from ramping up to high power if the control determines that the DHW demand is only due to tank standby losses Additional Safety Functions Allows the installer to choose between a low water cutoff and a flow switch for water level safety shutdown Vent Temperature...

Page 42: ...milliseconds 5 seconds 10 seconds maximum Table 8 5 Ignition Sequence Period Demand Status User Interface Display Standby No demand is present If the power is on to the PUREFIRE boiler and there is no heat demand the user interface will display Standby and show the boiler supply temperature in the lower right corner The time in 24 hour format is shown in the upper right When a heat demand either C...

Page 43: ...ds 4 flame signal values during the final 2 seconds of this period that can be accessed from the installer status menu The control will retry ignition one hour after an ignition failure lockout Burner On A heat demand must be present for the control to stay in this period Once the flame signal is established the burner will run until the demand is satisfied the setpoint is exceeded or a blocking e...

Page 44: ...300 399 in the main terminal box The contacts should be wired to terminals 9 10 Flow Switch If a flow switch is used simply wire the contacts to terminals 9 and 10 in the main terminal box D CENTRAL HEATING 1 Heating Modes Table 8 1 provides an overview of the central heating CH modes The following are detailed descriptions of the operation of these modes In accordance with Federal regulations und...

Page 45: ...s is proportional to the signal Note that the boiler high limit is set a 210 F and will cause a lockout if this temperature is reached Mode 6 Hydro Air Units This mode is specifically designed for boiler supplying hot water to a hot water coil in a forced air heating system using fixed supply target and activated by a thermostat contact closure between terminals 1 2 in the electrical panel Based o...

Page 46: ...based on the heat distribution system type Figure 8 3 shows this temperature at its factory default of 70 F 21 C Note that depending on the type of heat distribution used this value should be set higher For example if the boiler targets 70 F when a hydro air heater is used relatively cold air is likely to be supplied to the space if there is no thermostat to keep it from running Mild Weather Outdo...

Page 47: ...hich can cause a boiler to short cycle The Ramp Delay Step Modulation function only applies to Central Heating and is not applied to DHW demands After the ignition sequence the control modulates down to 20 of input Then the input rate is gradually increased until the supply temperature approaches its target At this time the control modulates normally Anti Cycling The PUREFIRE boiler control allows...

Page 48: ...e AK 18 F 28 C Indianapolis IN 2 F 17 C New York City NY 15 F 9 C Juneau AK 1 F 17 C Des Moines IA 5 F 21 C Rochester NY 5 F 15 C Flagstaff AZ 4 F 16 C Wichita KS 7 F 14 C Greensboro NC 18 F 8 C Tucson AZ 32 F 0 C Bowling Green KY 10 F 12 C Fargo ND 18 F 28 C Little Rock AR 20 F 7 C New Orleans LA 33 F 1 C Columbus OH 5 F 15 C Fayetteville AR 12 F 11 C Bangor ME 6 F 21 C Tulsa OK 13 F 11 C Sacrame...

Page 49: ...ode 1 2 The General pump will operate with the DHW pump to direct excess boiler heat to the DHW Tank The CH pump is deactivated The pumps 3 way valves operate to dump heat to the DHW tank until the return temperature is less than the installer selected Min Diff temperature or until the Max Time limit is reached This function can be disabled by choosing Off on the menu under DHW Heat Dump 5 Maximum...

Page 50: ...e boiler Flame Signal Failures Pressing the M key again will display the Flame Signal Failures Screen The flame signal is an indication of combustion stability of the burner If this value is below 2 8 µA microampere the control will close the gas valve and the burner will recycle through the ignition cycle The flame signal should be above 5 0 µA in normal operation If the control loses its flame s...

Page 51: ...ting load to the building A three zone valve control panel not included controls circulation to individual zones A call from any of the heating zones initiates a contact closure from the zone relay across the CH thermostat connections terminals 1 2 on the master boiler This initiates ignition of the lead boiler and its general pump In addition the CH circulator is energized A call for domestic hot...

Page 52: ...50 BOILER CONTROL INTERNAL WIRING OPERATION Figure 8 4 Multiple Boiler Cascade Piping Electrical Connections for Systems with Zone Valves ...

Page 53: ...51 BOILER CONTROL INTERNAL WIRING OPERATION Figure 8 5 Multiple Boiler Cascade Piping Electrical Connections for Systems with Zone Circulators ...

Page 54: ...witch Lever toward the center of the printed circuit board The Master Switch Lever is not marked with ON or OFF but the switch is in the ON position when it is moved to the left as viewed from the back of the display This position is shown in Figure 8 6 Re attach the User Interface Display Connect wires from terminals 11 12 between all boilers in the system 5 Cascade Operation a When a call for Ce...

Page 55: ... increasing the Calculated Setpoint Max Offset Up value the Master boiler will offset individual boiler setpoints temperature by a larger amount in order to achieve the system setpoint By increasing the Calculated Setpoint Max Offset Down value the boilers will decrease the boiler setpoints by a larger amount to achieve the system setpoint i The Rotation Interval is the frequency at which the Mast...

Page 56: ...ing feature is active on all boilers unless it is disabled b This will prevent dependent boilers from operating within the prescribed time limit However it will only prevent the boiler from cycling on its own limit Repetitive calls from the master boiler will result in cycling 9 Multiple Boilers DHW Operation a Since the DHW tank sensor or thermostat is connected only to the Master boiler this is ...

Page 57: ...sure doesn t drop off significantly under operation D CHECK OPERATION 1 Either disconnect or set CH thermostat and DHW tank thermostat to assure that no call for heat 2 Turn on electricity and all manual gas valves to the boiler Check to see if the LCD display is lit The control will display Standby 3 Refer to Section 8 Boiler Control to set up the control for the desired operation 4 Use the ignit...

Page 58: ...CO and CO2 emissions are within the parameters specified in Table 5 4 f If the values in either of these instances falls outside the parameters listed in Table 5 4 turn off the boiler and contact your PB Heat representative For best results the value should be set for the middle of the range 9 for Natural Gas and 10 for LP Gas g Be sure to set the System Test mode to Off so that the boiler will mo...

Page 59: ...r Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU DO SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone ...

Page 60: ...ow remove the flame sensor and igniter for inspection Also be sure that the lead to the flame sensor is not grounded D ERROR MESSAGES IN A CASCADE SYSTEM See paragraph D and the Cascade section of Appendix A for further information on how errors are displayed when using a Cascade System 10 TROUBLESHOOTING If overheating occurs or the gas supply fails to shut off do not turn off electrical power to...

Page 61: ...D VENT 38 Blocked Vent Switch is Open This error applies to PF 200 PF 210 PF 300 and PF 399 models Check for blocked vent pipe or blocked heat exchanger Check switch and tubing to switch E26 BLOCKED CONDENSATE DRAIN 41 Condensate drain blocked Check condensate tanks hoses condensate switch and harness E30 HIGH STACK TEMPERATURE 39 Flue gas sensor above max flue setpoint diff If flue pipe is hot ch...

Page 62: ...ess appears correct replace the gas valve Before beginning this replacement connect the gas valve to be sure it operates correctly before removing the old one If it doesn t operate correctly the existing valve may not be bad A02 FLAME FAILURE 24 Three consecutive flame failures during one demand 1 If boiler sparks lights briefly and then goes out a Disconnect the flame sensor cable and then retry ...

Page 63: ... switch 2 If there is no continuity check to be sure the circulator is working 3 If the circulator is working correctly check the flow switch A32 FAN NOT RUNNING 23 Internal Software Error A33 FAN SPEED ERROR 8 Fan speed detected is more than 300 rpm dif ferent from targeted value for more than 60 seconds 1 Does the fan run at full speed after resetting the control Check connections in the 4 wire ...

Page 64: ...the DHW sensor terminals and the DHW mode is set to Mode 1 the DHW system will not operate The display will blink to indicate a warning error Pressing the Reset key will display the following error screen 3 Flue Sensor Error a If the control senses that the flue temperature does not rise to above 50 F after ignition and either the supply water temperature rises above 120 F or the return water temp...

Page 65: ...ensor If the reading is higher at the sensor replace the wiring W02 Blinking Screen Press Reset key to view this message DHW Sensor Open 1 Be sure the optional DHW Sensor 54157 is connected 2 Remove the wires from terminals 5 and 6 on the boiler and check the resistance between them a If the resistance is above 10 k Ω check the resistance at the sensor b If the reading at the sensor is the same re...

Page 66: ...ot above 13 5 while the boiler is off or at any time during its operation INCORRECT AIR FUEL RATIO Using a suitable combustion analyzer check the products of combustion to assure correct combustion air fuel ratio as described in Section 9 D 7 of these instructions If the vent CO2 or CO is out of range in accordance with table 5 4 in these instructions please contact your PB Heat representative SPA...

Page 67: ...Provide adequate ventilation Wear a NIOSH MSHA approved respirator Wear long sleeved loose fitting clothing and gloves to prevent skin contact Wear eye goggles Minimize airborne dust prior to handling and removal by water misting the material and avoiding unnecessary disturbance of materials Wash work clothes separately from others Rinse washer thoroughly after use Discard RCF materials by sealing...

Page 68: ...leaking 3 Test low water cut off if used as described by the manufacturer 4 Test limit as described in Section 9 Part D Check Operation 5 Test function of ignition system safety shut off features as described in Section 9 Part D Check Operation 6 Remove the top front jacket panel and inspect for any foreign debris that may have entered through air intake vent 7 Inspect burner for deterioration Rep...

Page 69: ...not use steel and scrub coils to remove any buildup then vacuum the debris from the coils 4 Spray coils with clear water making sure to confine the spray to the area being cleaned try to avoid wetting the back ceramic wall of the unit Flush the combustion chamber with fresh water At this point the PUREFIRE should be ready to power back up 5 Reinstall the burner plate assembly using the following s...

Page 70: ... 4 7 8 2 1 2 4 1 2 5 1 8 3 1 N A PF 110 19 17 1 4 29 1 2 3 1 8 7 5 8 2 1 2 4 1 2 5 1 8 3 1 N A PF 140 19 17 1 4 29 1 2 3 1 8 10 1 2 2 1 2 4 1 2 5 1 8 3 1 N A PF 200 16 1 2 17 1 4 40 1 2 1 3 3 4 1 3 4 4 1 2 3 6 1 2 3 1 2 PF 210 16 1 2 17 1 4 40 1 2 1 3 3 4 1 3 4 4 1 2 3 6 1 2 3 1 2 PF 300 28 17 1 4 40 1 2 1 1 2 4 3 4 2 3 4 5 1 4 3 1 2 5 3 4 7 PF 399 28 17 1 4 40 1 2 1 1 2 4 3 4 2 3 4 5 1 4 3 1 2 5 ...

Page 71: ...F 210 PF 300 PF 399 Table 12 2 Boiler Ratings Series Peerless PUREFIRE Boiler Model Input MBH Heating Capacity MBH Net Rating MBH AFUE Min Max PF 50 16 50 47 41 95 0 PF 80 20 80 75 65 95 0 PF 110 27 5 110 103 90 95 0 PF 140 35 140 131 114 95 0 PF 200 42 199 185 161 95 0 PF 210 42 210 195 170 95 1 Gross Output MBH Net Rating MBH Thermal Efficiency PF 300 80 300 290 252 96 5 PF 399 80 399 373 324 93...

Page 72: ...20 VAC 60 hz 120 2 58 120 0 21 120 20 00 22 79 BOILER DIMENSIONS RATINGS Table 12 4 PUREFIRE Main Control Specifications SERIES PEERLESS PUREFIRE MAIN CONTROL SPECIFICATIONS Power Supply 120 VAC Nominal 102 132 VAC 60 Hertz 40 70 Hz Phase Neutral Fuse 5650 3 15 Amp 250 VAC Blower Voltage 120 VAC Gas Valve Voltage 120 VAC Thermostat Contacts 24 VAC DHW Contacts 24 VAC Flame Current Limits Minimum r...

Page 73: ...al PB Heat LLC distributor or from Parts To Your Door at 1 610 916 5380 www partstoyourdoor com Note Remember to include the boiler model number and serial number when ordering parts 13 REPAIR PARTS Figure 13 1 General Repair Parts PF 50 PF 80 PF 110 PF 140 ...

Page 74: ...rol Module 852MN PF 50 1 54282 Control Module 852MN PF 80 1 54283 Control Module 852MN PF 110 1 54284 Control Module 852MN PF 140 1 54285 22 Switch Round Toggle 120 VAC 1 6050 23 Vent Air Inlet Adapter 3 1 54135 24 Gasket Vent Adapter 3 1 54133 25 Screw 10 x 5 8 Long Phil Pan Head Type A Zinc Local Hardware Supply 6 5507 26 Condensate Receiver Kit with Hardware Tubing 1 54205 26a Condensate Receiv...

Page 75: ...73 REPAIR PARTS Figure 13 2 Heat Exchanger Burner Assembly Repair Parts PF 50 PF 80 PF 110 PF 140 ...

Page 76: ...16 MM SS Screw Target Wall 1 6511 13 Washer M4 1 6510 14 Insulation Target Wall 1 54185 15 Heat Exchanger PF 50 80 1 5411 Heat Exchanger PF 110 1 5412 Heat Exchanger PF 140 1 5413 16 Gasket Blower to Channel 1 54122 17 Blower PF 50 80 1 54189 Blower PF 110 1 54190 Blower PF 140 1 54191 18 M5 X 12MM Screw 4 5415 19 Blower Adapter Rate 1 5421 20 M4 x 10mm Screw 3 5422 21 Swirl Plate PF 50 80 Black 1...

Page 77: ...75 REPAIR PARTS Figure 13 3 General Repair Parts PF 200 PF 210 PF 300 PF 399 ...

Page 78: ...ply 1 50764 22 Convenience Outlet 1 54136 23 Hex Nut 8 32 with Lockwasher Local Hdwr Supply 4 51573 24 Control Module 852MN PF 200 1 54685 Control Module 852MN PF 210 1 54287 Control Module 852MN PF 300 1 54683 Control Module 852MN PF 399 1 54287 25 3 15A 250V 5x20mm Slow Blow Glass Fuse Radio Shack 270 1067 1 5650 26 Rocker Switch 20A 120 VAC Local Hdwr Supply 1 6050 27 Pump Isolation Relay Modul...

Page 79: ...77 Figure 13 4 Heat Exchanger Burner Assembly Repair Parts PF 200 PF 210 PF 300 PF 399 REPAIR PARTS ...

Page 80: ...over Plate Kit Current Current includes items 8 12 1 54207 9a Combustion Chamber Cover PF 1 54183 10 Thermal Temp Limit Manual Reset 435F Burner Plate 1 50045 11 Gasket Rubber 1 54187 12 Insulation Combustion Chamber Cover Plate 1 54255 13 M4 X 8 MM SS Screw Target Wall Local Hdwr Supply 1 6511 14 Washer M4 Local Hdwr Supply 1 6510 15 Insulation Target Wall 1 54185 16 Heat Exchanger PF 200 210 1 5...

Page 81: ...centric Sidewall Termination Kit PolyPro 4PPS HK 54499 3 Concentric Vertical Termination Kit PolyPro 3PPS VK 54500 4 Concentric Vertical Termination Kit PolyPro 4PPS VK 54501 Table 13 6 Optional Polypropylene Exhaust System Adapters Description Application Stock Code PF 50 thru PF 210 PF 300 PF 399 3 Polypropylene Vent Inlet Adapter Innoflue ISAGL0303 54632 4 Polypropylene Vent Inlet Adapter Innof...

Page 82: ...80 APPENDIX A STATUS SCREENS APPENDIX A STATUS SCREENS ...

Page 83: ...81 APPENDIX A STATUS SCREENS ...

Page 84: ...82 APPENDIX A STATUS SCREENS ...

Page 85: ...83 APPENDIX A STATUS SCREENS ...

Page 86: ...84 APPENDIX B USER MENU APPENDIX B USER MENU ...

Page 87: ...85 APPENDIX C INSTALLER MENU APPENDIX C INSTALLER MENU ...

Page 88: ...86 APPENDIX C INSTALLER MENU ...

Page 89: ...87 APPENDIX C INSTALLER MENU ...

Page 90: ...88 APPENDIX C INSTALLER MENU ...

Page 91: ...89 APPENDIX C INSTALLER MENU ...

Page 92: ...w c High Fire Outlet Gas Pressure in w c Low Fire Outlet Gas Pressure in w c Combustion Readings Flame Signal High Fire µA Flame Signal Low Fire µA CO High Fire CO Low Fire CO High Fire ppm CO Low Fire ppm Fan Speed High Fire Fan Speed Low Fire Excess Air High Fire Excess Air Low Fire Exhaust Temperature High Fire F Exhaust Temperature Low Fire F System Information Water Pressure Condensate Line S...

Page 93: ... affixed near the boiler for future reference TO THE OWNER This boiler should be inspected annually by a Qualified Service Agency PF8248 R2 8 16 1M Printed in U S A 2016 PB Heat LLC All rights reserved PB HEAT LLC 131 S CHURCH STREET BALLY PA 19503 PF 50 PF 80 PF 110 PF 140 PF 200 PF 210 PF 300 PF 399 PUREFIRE REV2 CONTROLS ...

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PEERLESS PureFire PF-110, Installation, Operation & Maintenance Manual

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