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PEERLESS PUREFIRE PFC-1000, Installation, Operation & Maintenance Manual

The PEERLESS PUREFIRE PFC-1000 is a cutting-edge boiler system designed for optimum performance, reliability, and energy efficiency. To ensure seamless installation and long-term operation, it comes with an comprehensive "Installation, Operation & Maintenance Manual" which you can easily download for free from manualshive.com.

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81

REPAIR PARTS

Table 13.4: Control System

Description

Quantity Required

Stock 

Code

PFC-850 PFC-1000 PFC-1500

1

Primary Burner Safety Control - PFC-850

2

–

–

54731

Primary Burner Safety Control - PFC-1000

–

2

–

54732

Primary Burner Safety Control - PFC-1500

–

–

2

54733

2

User Interface Pixel Display

1

1

1

54738

3

Installer Interface LED Display

2

2

2

54734

4

Interface Module

1

1

1

54737

5

Pump Relay Module 10 Amp

1

1

1

54556

6

Terminal Block - 10 Pole

2

2

2

5450

7

Terminal Block - 6 Pole

2

2

2

5547

8

Ignition Cable with 1K

2

2

2

54298

9

Harness J5M Managing Control Sensors PFC-850/1000*

1

1

–

54740

Harness J5M Managing Control Sensors PFC-1500*

–

–

1

54746

10

Harness J5D Dependent Control Sensors PFC-850/1000*

1

1

–

54449

Harness J5D Dependent Control Sensors PFC-1500*

–

–

1

54615

11

Harness J16M Managing Flapper/Limits PFC-850/1000*

1

1

–

54750

Harness J16M Managing Flapper/Limits PFC-1500*

–

–

1

54745

12

Harness J16D Dependent Flapper/Limits*

1

1

1

54451

13

Harness J2M Managing Control/Blower Power PFC-850/1000*

1

1

–

54742

Harness J2M Managing Control/Blower Power PFC-1500*

–

–

1

54744

14

Harness J2D Dependent Control/Blower Power PFC-850/1000*

1

1

–

54453

Harness J2D Dependent Control/Blower Power PFC-1500*

–

–

1

54618

15

Harness J13M Managing Gas Valve/Flame Sensor/Limit PFC-850/1000*

1

1

–

54454

Harness J13M Managing Gas Valve/Flame Sensor/Limit PFC-1500*

–

–

1

54619

16

Harness J13D Dependent Gas Valve/Flame Sensor/Limit PFC-850/1000*

1

1

–

54455

Harness J13D Dependent Gas Valve/Flame Sensor/Limit PFC-1500*

–

–

1

54620

17

Harness J7 General Circulator PFC-850/1000*

2

2

–

54456

Harness J7 General Circulator PFC-1500*

–

–

2

54621

18

Harness J6M Managing CH/DHW Circulator*

1

1

1

54457

19

Harness Line Voltage Terminal Strip/Power Switch PFC-850/1000*

1

1

–

54587

Harness Line Voltage Terminal Strip/Power Switch PFC-1500*

–

–

1

54622

20

Harness J9 Blower Contol PFC-850/1000*

2

2

–

54459

Harness J9 Blower Contol PFC-1500*

–

–

2

54623

21

Harness Managing Thermal Fuse w/Conduit*

1

1

1

54460

22

Harness Dependent Thermal Fuse w/Conduit*

1

1

1

54461

23

Harness Ground

2

2

2

54465

24

Rocker Switch

2

2

2

6049

25

Harness J2RM Terminal Strip/Relay Module PFC-850/1000*

1

1

1

54741

Harness J2RM Terminal Strip/Relay Module PFC-1500*   

1

1

1

54743

Summary of Contents for PUREFIRE PFC-1000

Page 1: ...PUREFIRE Boilers PFC 850 PFC 1000 PFC 1500 Gas Installation Operation Maintenance Manual ...

Page 2: ...INTERNAL WIRING 30 A GENERAL 30 B CUSTOMER CONNECTIONS 30 C ZONE CIRCULATOR WIRING 31 D INTERNAL WIRING 31 8 BOILER CONTROL OPERATION 34 A IGNITION SEQUENCE 34 B STATUS DISPLAY 36 C USER MENU 39 D INSTALLER MENU 41 E DEFAULTS 53 F MULTIPLE BOILERS 53 9 START UP PROCEDURE 57 A GENERAL 57 B CHECK WATER PIPING 57 C CHECK ELECTRIC POWER 57 D CHECK GAS PIPING 57 E CHECK OPERATION 57 F COMBUSTION TEST 5...

Page 3: ...ions and make special notice of potential hazards The definition of each of these categories in the judgement of PB Heat LLC are as follows USING THIS MANUAL Indicates special attention is needed but not directly related to potential personal injury or property damage NOTICE Indicates a condition or hazard which will or can cause minor personal injury or property damage CAUTION DANGER Indicates a ...

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: ... 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 ro...

Page 6: ...ustion 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 duct...

Page 7: ...ovide 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 ft3 min per 1000 Btu hr 0 034 m3 min per 1000 W of the total rate...

Page 8: ...xterior of buildings shall have the lowest side of the combustion air intake opening at least 12 inches 305 mm above grade 11 Refer to Section 3 of this manual Venting Air Inlet Piping for specific instructions for piping the exhaust and combustion air E PLANNING THE LAYOUT 1 Prepare sketches and notes showing the layout of the boiler installation to minimize the possibility of interferences with ...

Page 9: ...cked to save floor space on the installation Figure 2 1 shows how the upper boiler is to be attached to the lower boiler 1 Remove all side jacket panels from the both boilers and the top jacket panels from the lower boiler 2 Remove the leveling legs from the boiler to be installed on top 3 Lift the upper boiler into place by passing 5 to 10 foot 2 3 meter lengths of 1 to 1 1 4 Schedule 40 or 80 st...

Page 10: ...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 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 prope...

Page 11: ...l 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...

Page 12: ...onfiguration can be constructed using a FasNSeal stainless steel vent termination PVC or other approved materials may be used for air inlet piping i The opening of the air inlet piping is to be a minimum of 12 300 mm above the expected snow accumulation on the roof surface ii Locate the opening of the exhaust vent pipe a minimum of 12 above the air inlet opening to prevent flue gas from recirculat...

Page 13: ...ertical Exhaust and Air Inlet Pipe Figure 3 7 Vertical Exhaust Routed Through an Unused Chimney with Indoor Air Figure 3 9 Drain Tee and Air Inlet Connections Figure 3 8 Vertical Exhaust Routed Through an Unused Chimney with Outdoor Air 11 ...

Page 14: ...nd debris from the joints and fittings 5 Care should be taken to prevent dirt or debris from entering the air intake connection A screen is provided inside the Air Intake fitting to prevent large objects from entering the combustion system 6 Horizontal lengths of exhaust vent must be installed with a slope of not less than 1 4 per foot 21mm per meter toward the boiler to allow condensate to drain ...

Page 15: ...t birds or rodents from entering F TEST PORT FOR EXHAUST SAMPLING 1 Figure 3 10 shows an illustration of the plugged sample port on the outlet of the drain tee for the PFC 850 PFC 1000 and PFC 1500 boiler 2 To obtain an exhaust sample during operation remove the test port plug and insert the probe from a suitable combustion analyzer 3 Be sure to replace the plug before leaving the boiler unattende...

Page 16: ...ctionner 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...

Page 17: ...nection to the system Thoroughly flush any cleaning agent from the system with clean water prior to connecting the boiler See Table 4 1 for recommended cleaning agents 4 High oxygen levels in the system water will allow scale buildup to occur Steps must be taken to minimize oxygen levels in the system The following items are recommended during installation a Provide Air Elimination Means An automa...

Page 18: ...the expansion tank manufacturer s instructions for specific information regarding installation The expansion tank is to be sized for the required system volume and capacity In addition be sure that the expansion tank is sized based on the proper heating medium Glycol solutions may expand more than water for a similar temperature rise 4 Y Type Strainer or Filter Ball Valve PB Heat recommends the us...

Page 19: ...n which glycol solution is used as the heating medium 8 Pressure Relief Valve The boiler pressure relief valve is shipped in the miscellaneous parts box for field installation It is extremely important to install this device The valve is to be installed on the boiler supply pipe as shown in Figure 4 2 Pipe the discharge of the relief valve to within 12 of the floor and close to a floor drain Provi...

Page 20: ... the design temperature difference from the return to the supply of the boiler For a PFC 850 with a design temperature difference of 20 F the calculation is as follows Output 816 000 Required Flow ________ _________ 81 6 GPM DT x 500 20 x 500 d The boiler pressure drop for various flow rates can be determined using Figure 4 3 PureFire Circulator Sizing Graph below WATER PIPING CONTROLS Figure 4 3 ...

Page 21: ...7 74 35 46 7 10 61 8 93 266 81 55 2 12 54 9 29 277 68 82 7 18 79 10 69 319 53 40 40 9 9 29 7 00 209 18 48 3 10 97 7 29 217 90 72 4 16 44 8 35 249 59 Table 4 6 Circulator Selection Chart General Pump Primary Secondary Piping Circulator Manufacturer DT F PFC 850 PFC 1000 PFC 1500 Taco 20 1635 1935 138 133 1635 1935 1641 1941 Grundfos UPS50 160 2F speed 2 UPS50 160 2F speed 3 Bell Gossett PD 38 PD 38...

Page 22: ...e 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 sed...

Page 23: ...21 WATER PIPING CONTROLS Figure 4 4 Recommended Piping One Boiler with Multiple CH Zones One DHW Tank ...

Page 24: ...22 WATER PIPING CONTROLS Figure 4 5 Recommended Piping Multiple Boilers with Multiple CH Zones One DHW Tank ...

Page 25: ...23 WATER PIPING CONTROLS Figure 4 6 Alternate Piping Multiple Boilers with Multiple CH Zones Zone Valves One DHW Tank ...

Page 26: ... gravity flow through the boiler c See Figure 4 7 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 8 for an illustration WATER PIPING CONTROL...

Page 27: ...2 300 65 4 100 116 8 300 235 22 000 623 50 15 2 440 12 670 19 1 270 36 2 000 57 3 600 102 7 400 210 20 000 566 60 18 3 400 11 610 17 1 150 33 1 850 52 3 250 92 6 800 193 18 000 510 70 21 3 370 10 560 16 1 050 30 1 700 48 3 000 85 6 200 176 17 000 481 80 24 4 350 10 530 15 930 26 1 500 42 2 600 74 5 400 153 15 000 425 90 27 4 320 9 490 14 870 25 1 400 40 2 500 71 5 100 144 14 000 396 100 30 5 305 9...

Page 28: ...h the boiler to prevent low pressure conditions b Gas pressures above 26 in w c may result in damage to the automatic gas valve 3 To check the gas supply pressure to the gas valve a Turn off the power at the service switch b Close the gas shutoff valve for the automatic valve being checked c Using a flat screwdriver turn the screw inside the inlet pressure tap fitting see Figure 5 2 one turn count...

Page 29: ...missions in the exhaust vent pipe 3 Turning the throttle screw clockwise will decrease the gas flow decreasing CO2 and turning it counterclockwise will increase the gas flow rate increasing CO2 Markings adjacent to the throttle screw show and indicating this operation a Throttle adjustments should be made only at full input rate with the other burner off b The exhaust emissions should be checked w...

Page 30: ... of the trap to prevent combustion gases from escaping The container is fitted with a blocked condensate float switch b Blocked Condensate Float Switch This switch will cause a blocking error on the boiler control and prevent the boiler from operating if the level of condensate in the vessel becomes too high High condensate levels can occur as a result of a blocked condensate drain or similar prob...

Page 31: ...nsate drain tubes from multiple boilers should be run separately to prevent a nuisance lockout of multiple boilers due to a single clogged drain tube 5 Condensate Pumps If the boiler drain is above the level of a gravity drain a condensate pump should be used Table 6 1 lists several available brands Contact your PB Heat LLC Distributor for availability CONDENSATE TRAP DRAIN SYSTEM Brand Name Model...

Page 32: ... PFC 850 PFC 1000 and PFC 1500 boilers Table 7 1 lists the terminal numbers with nominal voltage and detailed descriptions of the connections ELECTRICAL CONNECTIONS INTERNAL WIRING 7 ELECTRICAL CONNECTIONS INTERNAL WIRING Figure 7 1 Electrical Terminal Access Table 7 1 Terminal Description Terminal Input Output Voltage Description 1 Output 24 VAC CH Thermostat Boiler Output from Zone Control Panel...

Page 33: ...ress for cascade systems 2 Installer Interface Displays The installer interface display allow the installer or service contractor to display status information for many different values These displays also allow the installer contractor to change settings to optimize system efficiency and operation A detailed description of the status and settings available is provided in Section 8 of this manual ...

Page 34: ...32 ELECTRICAL CONNECTIONS INTERNAL WIRING Figure 7 4 Internal Wiring Schematic for PFC 850 PFC 1000 PFC 1500 boilers ...

Page 35: ...he exhaust vent temperature to the managing control to prevent unsafe operation of the boiler 10 Supply Limit Switches The supply limit switches are UL353 certified temperature switches that prevent the boiler from exceeding 210 F 99 C which is the maximum operating temperature allowed by ASME Boiler and Pressure Vessel Code Section IV These switches along with the manual reset circuitry of the pr...

Page 36: ...ettings 320 milliseconds 5 seconds 10 seconds maximum Table 8 1 Ignition Sequence Period Demand Status Burner LCD Display Standby No demand is present If the power is on to the PureFire boiler and there is no heat demand the burner LCD will display Standby and show the boiler supply temperature in the lower right corner The time in 24 hour format is shown in the upper right When a heat demand eith...

Page 37: ... Retry parameter is set to ON the control will retry ignition one hour after an ignition failure The control records 4 flame signal values during the last two seconds of this period that can be accessed from the Installer Menu under Status Burner On A heat demand must be present for the control to stay in this period Once a flame signal is established the burner will run until a demand is satisfie...

Page 38: ...e managing burner display is located toward the front of the boiler and controls the upper burner assembly 3 Dependent Burner LCD Display This display is located on the right side of the boiler behind the heat exchanger side panel The dependent display is toward the rear of the boiler and controls the lower burner assembly BOILER CONTROL OPERATION Table 8 2 Initialization Screens Figure 8 2 Pixel ...

Page 39: ...ons Pixel Displays LCD Displays Standby Managing Boiler Pressing the up or down key displays the boiler system information Dependent Central Heating CH Demand Managing Boiler Dependent Domestic Hot Water DHW Demand Managing Dependent Supply at Setpoint Special Demand Functions ...

Page 40: ... Service Notification Pixel Displays Dependent LCD Displays Error Handling Managing LCD Display Table 8 3 Display Screens Under Various Conditions cont d Pixel Displays LCD Displays Ignition Failure Error Handling Flame Failure Error Handling Ignition Retry ...

Page 41: ...re Sensor reads less than 50 F the boiler will continue to operate normally unless b If the return temperature exceeds 80 F 27 C or the supply temperature exceeds 120 F 49 C the burners will operate at their minimum modulation until the call for heat ends or the vent temperature exceeds 50 F The outdoor sensor temperature should correspond to the current outdoor temperature If the sensor is mounte...

Page 42: ...screen allows the user to change the temperature unit display The default units are Fahrenheit F To change the unit display press the Select key The current unit system will flash Use the ñ and ò keys to change the value to Celsius C Press the Select key again to choose the units 3 LCD Message Menu The messages menu allows the user to view the last blocking error or last lockout error The display ...

Page 43: ... external sensors In the following section all parameters which affect only the managing burner will be designated with M Stand Alone configuration or Master Boiler in multiple boiler configuration b Dependent Burner Burner D The bottom burner on each boiler is designated as the Burner D or dependent burner This burner control is started and stopped by the managing burner only Its operation is not...

Page 44: ...ides a list of blocking errors g Lockout Errors Screen 10 provides error history about the last 15 locking errors Locking errors are errors that require a manual reset on the control board pushing the Reset key on the display to reset the burner once the condition causing the error has been corrected Ignition Failure Flame Failure and High Limit Temperature are examples of this type of error To re...

Page 45: ...he burner will run normally to satisfy the demand Finally once the return temperature increases to 9 F 5 C above the chosen value the burner is switched off and the pumps are deactivated f Blower Postpurge Time The blower postpurge time can be increased to address problems under extreme conditions long exhaust vent runs high winds etc where the products of combustion are not fully expelled from th...

Page 46: ...At installation the control can be configured to allow up to 3 ignition attempts before locking out and requiring a manual reset In addition the control may be configured to retry for ignition one hour after lockout without a manual reset Check applicable codes before changing these parameters j Flame Failures The control is configured from the factory to not allow the burner to recycle after a fl...

Page 47: ... load Although the menu items that follow are factory set by default to values that can operate in any installation they can be adjusted to maximize the efficiency of this product The boiler can be configured to operate with a fixed setpoint or using outdoor reset to vary the boiler target temperature according to the load implied by the outdoor temperature a Setpoint Operation When using a setpoi...

Page 48: ...is closed across terminals 1 2 a setback of 18 F 10 C is applied to the calculated target temperature This feature is useful in a building such as an office building that is unoccupied during certain times A switch or timer can be used to set back the boiler target temperature during unoccupied periods d Pump Purge Time The installer can define the length of time that the circulators operate after...

Page 49: ...or Design Temperature The heat loss for the structure is determined by considering the coldest sustained outdoor temperature that is expected at the site location For a detailed list of outdoor design temperatures by state refer to the H 22 heat loss calculation guide published by AHRI Figure 8 35 Outdoor Reset Operation Table 8 17 System Type Presets System Type Temperatures Boiler Design Mild We...

Page 50: ...fied the target temperature will be increased by the temperature value selected The boiler will never target a temperature higher than that specified by the boiler max parameter There are several reasons why the boost function may or may not be implemented In buildings which have many zones there may seldom be a period when none of the zones is calling for heat In this case the boiler will very of...

Page 51: ...rates a conventional thermostat or with an indirect fired hot water tank equipped with a water tank temperature sensor PB 54157 The configuration using the optional tank temperature sensor allows the control to maximize the efficiency of the system by limiting the input rate to recover from standby losses a Domestic Hot Water Modes This menu is used to change the control response to calls for DHW ...

Page 52: ...k at the end of each cycle improves the overall efficiency of the heating system The heat dump function is designed to take advantage of this principal At the end of a heating cycle when the CH demand is satisfied the control switches off the CH circulating pump and turns on the DHW pump for the Max Time period If the temperature difference between the supply and return of the boiler drops lower t...

Page 53: ... c Both Burners Eliminate all heat demands to the boiler by disconnecting the CH thermostat from terminals 1 2 and disconnecting the DHW sensor or thermostat from terminals 5 6 Start the managing burner setting it to Ignition Power in the Service menu Start the dependent burner setting it to Ignition Power in the Service menu Change the individual burner Power to the required input rate Avoid sett...

Page 54: ...enu Screen Ranges Defaults Minimum Default Maximum 1 Minute 2 Minutes 15 Minutes 1 Minute 2 Minutes 15 Minutes 1 F 0 6 C 9 F 5 C 23 F 13 C 1 F 0 6 C 18 F 10 C 45 F 25 C 0 F 0 C 18 F 10 C 36 F 20 C 0 F 0 C 9 F 5 C 36 F 20 C 40 50 95 5 9 40 0 Days No Rotation 5 Days 30 Days ...

Page 55: ...lect key while in the following menu F MULTIPLE BOILERS F MULTIPLE BOILERS 1 Multiple Boiler Wiring Two methods for connecting the master boiler to the dependent boilers are allowed a Figure 8 53 shows a daisy chain configuration This method is convenient but can lead to more than one boiler shutting down in the case of an open circuit b Figure 8 54 shows the master boiler connected to each depend...

Page 56: ...54 Figure 8 53 Mutiple Boiler Wiring Daisy Chain Configuration Figure 8 54 Multiple Boiler Wiring Independent Connection to each Dependent Boiler BOILER CONTROL OPERATION ...

Page 57: ...ax Offset Up Min 0 F 0 C The master control uses a PID function to scale a target temperature offset for boilers in order to approach the system target temperature Increased values are scaled between the Max Offset Up and the system target Max 36 F 20 C Default 9 F 5 C Max Offset Down Min 0 F 0 C The master control uses a PID function to scale a target temperature offset for boilers in order to ap...

Page 58: ...alue will be 128 f Figure 8 56 illustrates the range defined by the Max Offset Down and Max Offset Up parameters i If the output from the P Value is 1 the dependent setpoint will be set to the minimum value 104 F in this case ii If the output from the P Value is 255 the dependent setpoint will be set to the maximum value 149 F iii From the previous example the output value from a supply temperatur...

Page 59: ... a phase phase power supply configuration D CHECK GAS PIPING 1 Turn off the gas shut off valve to each burner These valves are located in the vestibule area at the front of the boiler 2 Open the gas shut off valve on the rear of the boiler and allow the gas header to be pressurized Press the reset buttons on both gas pressure switches to be sure that they are reset and operational The burner LCD d...

Page 60: ...ne the exhaust emissions of the boiler and compare them with Table 9 1 e Adjust the throttle screw if necessary to correct the combustion 6 Dependent burner combustion test at low fire 1 modulation a ON THE DEPENDENT BURNER enter the Installer Menu and choose System Test b Press select and use the ò key to scroll down to Low Power c The burner will ignite and after a short stabilization period run...

Page 61: ...rner should shut down immediately and enter a lockout condition b Press the reset button on the control to enable normal operation c If it does not shut down turn off the boiler and contact your PB Heat representative 5 Turn System Test to Off on both burner displays I MULTIPLE BOILER SYSTEMS 1 Since all heat distribution circulating pumps CH DHW are connected to the master boiler it may be necess...

Page 62: ...60 START UP PROCEDURE J LIGHTING OPERATING INSTRUCTIONS Figure 9 1 Lighting Operating Instructions ...

Page 63: ...escribed in the next paragraph C LOCKING ERRORS 1 When a locking error occurs the LCD display that corresponds to the burner with the error will show a message in English and an A code A01 Ignition Error 2 Table 10 2 provides a list of locking error codes descriptions and corrective actions for these errors 3 These errors require a manual reset of the display for the burner with the error These di...

Page 64: ...d The managing burner will operate normally However if there is a NO COMM CASCADE error check the Installer Menu under Burner Options on the managing burner to be sure that it is set to managing burner E SPECIAL IGNITION FLAME FAILURE 1 Depending on local codes the allowable number of ignition attempts or flame failures may be different The Installer Menu may allow up to three ignition attempts an...

Page 65: ... it is between 3 5 and 21 of water then the switches should reset If the error is occurring at or after ignition check the gas pressure when the boiler lights off It may be that the gas pressure drops significantly when the gas valve opens In this case contact the gas supplier to increase the available gas pressure Do not leave a jumper between terminals 11 12 if interlocks are attached to these t...

Page 66: ...ept for the 120 VAC control power 2 If problem is corrected systematically replace wires to determine which pump sensor is malfunctioning 3 If problem persists replace the control E20 FALSE FLAME DETECTED Unexpected flame was detected 1 Verify that no flame or spark is present 2 Check clean flame sensor 3 Check boiler ground by assuring 0 5 VAC between neutral and ground E21 HOT NEUTRAL REVERSED P...

Page 67: ... the circuit is free from shorts or unexpected voltage E45 E46 E47 E48 E51 RESET BUTTON ERROR PLEASE WAIT Reset button pushed more than 7 times in one minute 1 Wait five minutes for the control to recycle 2 Exercise patience when resetting errors E52 FLAP NOT CLOSED Flap valve at blower outlet isn t proving closed as expected 1 If error doesn t clear within 1 minute Check the orange and red wire o...

Page 68: ... set at 210 F 1 If the supply temperature does not exceed 208 F before the burner shuts off the overheat limit switch may be faulty Replace the switch 2 Watch the two leftmost lights on the circulator pump relay module in the control cabinet If these do not come on when any burner is firing check for wiring issues 3 With the boiler operating assure that the difference between supply and return tem...

Page 69: ...f Clean any debris from flow switch paddle A24 FLOW SWITCH NOT OPEN When Flow Switch option is selected in the Burner Setting Menu interlock circuit is not open when pump is off 1 If a flow switch is not connected to terminals 11 12 change Additional Safety Functions to LWCO in the Installer Menu under Burner Settings on the managing burner 2 If a flow switch is connected check for continuity from...

Page 70: ...the wires from terminals 5 and 6 on the boiler and check the resistance between them a If the resistance is above 10k W check the resistance at the sensor b If the reading at the sensor is the same replace the sensor c If the reading at the sensor is lower replace the wiring W03 Blinking Screen Press Reset key to view this message DHW Sensor Shorted 1 Check wiring connection to DHW Sensor 2 Remove...

Page 71: ...e medical attention if symptoms persist Skin Contact Wash affected area gently with a mild soap and warm water Seek immediate medical attention if irritation persists Eye Contact Flush eyes with water for 15 minutes while holding eyelids apart Do not rub eyes Seek immediate medical attention if irritation persists Ingestion Drink 1 to 2 glasses of water Do not induce vomiting Seek immediate medica...

Page 72: ...ch burner mounting plate and opening the combustion chambers Replace the burners if necessary 7 With the boiler in operation check that condensate is dripping from the condensate tubing Check for any blockage or restriction in the condensate drain lines D CONDENSATE SYSTEM CLEANING INSTRUCTIONS 1 Removal of Condensate Containers a Close the manual gas shutoff valve at the rear of the boiler and tu...

Page 73: ...nylon or brass brush do not use steel and scrub coils to remove any buildup then vacuum the debris from the coils 4 Spray coils with clear water making sure to confine the spray to the area being cleaned try to avoid wetting the back ceramic wall of the unit Flush the combustion chamber with fresh water At this point the PureFire should be ready to power back up 5 Reinstall the burner plate assemb...

Page 74: ...R RATINGS Series Peerless PureFire Boiler Model Input Gross Output Net Water Ratings Thermal Efficiency Minimum Maximum MBH kW MBH kW MBH kW MBH kW PFC 850 85 24 9 850 249 1 818 239 7 711 208 4 96 2 PFC 1000 100 29 3 1 000 293 1 966 283 1 840 246 2 96 6 PFC 1500 150 43 9 1 500 439 6 1 448 424 3 1 259 368 9 96 5 Table 12 3 Combustion Air Fan Speeds SERIES PEERLESS PUREFIRE COMBUSTION AIR FAN SPEEDS...

Page 75: ...Contacts Voltage 24 VAC DHW Contacts Voltage 24 VAC Flame Current Limits Current Minimum running 2 8 µA Minimum ignition 3 1 µA Maximum 10 0 µA Temperature Sensors NTC Thermistors 12kW at 77 F 25 C Supply 14 F 10 C to 244 F 118 C Return 14 F 10 C to 244 F 118 C Flue 50 F 10 C to 280 F 138 C Header 14 F 10 C to 244 F 118 C Outdoor 40 F 40 C to 185 F 85 C Optional Sensors DHW 14 F 10 C to 244 F 118 ...

Page 76: ...m your local PB Heat LLC distributor or from Parts To Your Door at 1 610 916 5380 www partstoyourdoor com Note Remember to include the boiler model number and serial number when ordering parts 13 REPAIR PARTS Figure 13 1 Heat Exchanger Repair Parts ...

Page 77: ...54625 7 Supply Return Sensor 1 8 NPT 12 kW 4 4 4 54438 8 High Limit Switch 1 4 NPT 2 2 2 54419 9 Header Supply Sensor 1 4 NPT 12 k W 1 1 1 54418 10 Hex Flange Nut M6 Fine Thread 12 12 12 51614 11 Flapper Valve Screw M5 0 80 x 16 mm Zinc 10 10 10 12 Burner Gasket 2 2 2 54467 13 Ignitor Flame Sensor Screw M4 x 8mm Zinc 8 8 8 6507 14 Flue Temperature Sensor 1 4 BSP 12 kW 1 1 1 54111 15 Thermal Fuse 3...

Page 78: ...76 REPAIR PARTS Figure 13 2a Blower Gas Train Assembly PFC 850 1000 Figure 13 2b Blower Gas Train Assembly PFC 1500 ...

Page 79: ... Hex Head Cap Screw M5 0 80 x 12 mm 2 2 5688 12 1 8 ID Reference Tube 5 ft 5 ft 1052 13 1 8 Hose Tee 1 1 6159 14 Gas Inlet Header PFC 850 1 54473 Gas Inlet Header PFC 1000 1 54474 Description Quantity Required Stock Code PFC 1500 1 Combustion Air Blower PFC 1500 2 54595 2 Gas Valve Inlet Flange 1 NPT 2 54601 3 Gas Valve w Shutter Swirl Plate Adapter 2 54598 4 Gas Valve Nozzle 12 MM 2 54602 5 1 NPT...

Page 80: ...78 REPAIR PARTS Figure 13 3a Jacket Assembly PFC 850 1000 Figure 13 3b Jacket Assembly PFC 1500 ...

Page 81: ... Fuse Cover 2 2 2 PFC2031 9 Blower Cabinet Floor Pan 1 1 PFC2033 Blower Cabinet Floor Pan 1 PFC2039 10 Condensate System Tray PF 850 1 PFC5027 Condensate System Tray PF 1000 1 PFC5027 1 Condensate System Tray PF 1500 1 PFC5027 2 11 Air Inlet Plenum Assembly PF 850 1000 1 1 PFC5044 Air Inlet Plenum Base PF 1500 1 PFC5051 11A Air Inlet Plenum Cover PF 1500 1 PFC5052 12 Blower Cabinet Top Panel PF 85...

Page 82: ...80 Figure 13 4 Control System REPAIR PARTS ...

Page 83: ... 1 1 54742 Harness J2M Managing Control Blower Power PFC 1500 1 54744 14 Harness J2D Dependent Control Blower Power PFC 850 1000 1 1 54453 Harness J2D Dependent Control Blower Power PFC 1500 1 54618 15 Harness J13M Managing Gas Valve Flame Sensor Limit PFC 850 1000 1 1 54454 Harness J13M Managing Gas Valve Flame Sensor Limit PFC 1500 1 54619 16 Harness J13D Dependent Gas Valve Flame Sensor Limit P...

Page 84: ...82 Figure 13 5 Condensate System REPAIR PARTS ...

Page 85: ...2 ft 5563 Description Quantity Required Stock Code PFC 850 PFC 1000 PFC 1500 1 Relief Valve PFC 850 1 51300 Relief Valve PFC 1000 1 51301 Relief Valve PFC 1500 1 51302 2 Temperature Pressure Gauge 1 1 1 51324 3 6 Stainless Steel Boot Tee with Test Port 1 1 5680 7 Stainless Steel Boot Tee with Test Port 1 5747 4 6 Stainless Steel Drain Fitting 1 1 5681 7 Stainless Steel Drain Fitting 1 5748 5 6 Sta...

Page 86: ...ot active Section 8 provides information about status messages for this display B MULTIPLE BOILER CASCADE PIXEL DISPLAY To operate 2 or more boilers in cascade the boilers must be connected by 2 wire link connections as described is Section 8 APPENDIX A PIXEL DISPLAY SCREEN APPENDIX A PIXEL DISPLAY SCREEN Figure A 1 Pixel Display Screen Stand Alone Boilers Figure A 2 Pixel Display Module ...

Page 87: ...re A 2 this is accessed by toggling the keys APPENDIX A PIXEL DISPLAY SCREEN Figure A 3 Cascade Status Display Table A 1 Cascade Menu Cascade Menu Boiler Address 0 Start Delay Time 4 min Stop Delay Time 4 min Start Boiler Diff 9 F Stop Boiler Diff 9 F Stop All Boiler Diff 18 F Max Offset Up 36 F Max Offset Down 9 F Rotation Interval 5 days P Value 20 I Value 40 D Value 0 Stew Rate 1 ...

Page 88: ...IX B BURNER LCD STATUS SCREENS APPENDIX B BURNER LCD STATUS SCREENS Initialization Screen Status Screens Boiler Screens Failure Screens Error Handling Blocking Errors Error Handling Locking Errors Warning Screen ...

Page 89: ...87 APPENDIX B BURNER LCD STATUS SCREENS CH Burn Cycle DHW Burn Cycle Special Functions DHW Tank Warm Hold ...

Page 90: ...88 APPENDIX C USER MENU APPENDIX C USER MENU Figure C 1 User Menu Managing Burner ...

Page 91: ...89 APPENDIX C USER MENU Figure C 1 User Menu Dependent Burner ...

Page 92: ...90 APPENDIX D INSTALLER MENU STRUCTURE APPENDIX D INSTALLER MENU STRUCTURE ...

Page 93: ...91 APPENDIX D INSTALLER MENU STRUCTURE ...

Page 94: ...ombustion Readings Burner 1 Flame Signal High Fire µA Flame Signal Low Fire µA CO2 High Fire CO2 Low Fire CO High Fire ppm CO Low Fire ppm Fan Speed High Fire RPM Fan Speed Low Fire RPM Combustion Readings Burner 2 Flame Signal High Fire µA Flame Signal Low Fire µA CO2 High Fire CO2 Low Fire CO High Fire ppm CO Low Fire ppm Fan Speed High Fire RPM Fan Speed Low Fire RPM Combustion Readings Both Bu...

Page 95: ...93 SERVICE LOG SERVICE LOG Date Serviced By Description of Service Serial Number ...

Page 96: ...94 NOTES ...

Page 97: ...95 NOTES ...

Page 98: ...owner and must be affixed near the boiler for future reference TO THE OWNER This boiler should be inspected annually by a Qualified Service Agency PF8302 R2 7 19 3C Printed in U S A 2019 PB Heat LLC All rights reserved PB HEAT LLC 131 S CHURCH STREET BALLY PA 19503 PFC 850 PFC 1000 PFC 1500 PUREFIRE CONTROLS ...

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