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PeerlessBoilers Peerless PureFire PFC-460, Installation, Operation & Maintenance Manual

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PeerlessBoilers Peerless PureFire PFC-460 Installation, Operation & Maintenance Manual Download Page 78

76

REPAIR PARTS

Figure 13.4: Concentric Vertical Vent Termination

Figure 13.3: Concentric Horizontal Vent 

Termination

Figure 13.5: Polypropylene Adapter

Table 13.3: Optional Exhaust Vent Termination Kits

Description

Stock Code

4" Concentric Sidewall Termination Kit (PolyPro 3PPS-HK)

54499

4" Concentric Vertical Termination Kit (PolyPro 4PPS-VK)

54501

Description

Stock Code

4" Polypropylene Vent/Inlet Adapter (Innoflue ISAGL0404)

54633

4" Polypropylene Vent/Inlet Adapter (PolyPro 4PPS-AD)

54631

Table 13.4: Optional Polypropylene Exhaust System Adapters

Summary of Contents for Peerless PureFire PFC-460

Page 1: ...PUREFIRE Boilers PFC 460 Gas Installation Operation Maintenance Manual...

Page 2: ...PIPE MATERIAL 31 D CONDENSATE DRAIN PIPE SIZING 31 E CONDENSATE DRAIN PIPE INSTALLATION 31 7 ELECTRICAL CONNECTIONS 32 A GENERAL 32 B CUSTOMER CONNECTIONS 32 C ZONE CIRCULATOR WIRING 33 D INTERNAL WI...

Page 3: ...ons 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 1 USING THIS MANUAL DANGER Indicates a cond...

Page 4: ...itional 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...

Page 5: ...red 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 Subs...

Page 6: ...stion 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 perman...

Page 7: ...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 jur...

Page 8: ...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 g...

Page 9: ...g instructions provide guidance for both configurations B WALL MOUNTING The PFC 460 boiler can be wall mounted by using the optional stand 91400 1 Use the leveling feet provide with the boiler to assu...

Page 10: ...rless 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 condensatio...

Page 11: ...any 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...

Page 12: ...3 4 is only approved for locations in which the outdoor temperature is above 5 F 21 C in accordance with ASHRAE 90A 1980 recommendations d Figure 3 7 shows a sidewall vent configuration using an optio...

Page 13: ...ent 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 Figu...

Page 14: ...NG 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...

Page 15: ...er 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 Sc...

Page 16: ...me pouvant menacer la s curit 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 a...

Page 17: ...y 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 Venti...

Page 18: ...n 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 th...

Page 19: ...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...

Page 20: ...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 hi...

Page 21: ...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 te...

Page 22: ...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 F SPECIAL APPLICATIONS...

Page 23: ...21 WATER PIPING AND CONTROLS Figure 4 4 Recommended Piping One Boiler Primary Secondary with Two Zones Zone Circulator...

Page 24: ...ATER PIPING AND CONTROLS Figure 4 5 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 boi...

Page 25: ...23 WATER PIPING AND CONTROLS Figure 4 6 Two Boilers Primary Secondary with Four Zones Zone Circulator...

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

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

Page 28: ...26 WATER PIPING AND CONTROLS Figure 4 9 Boiler in conjunction with a Chilled Water System Figure 4 10 Boiler Connected to a Heating Coil in a Forced Air System...

Page 29: ...P Gas ft3 hr m3 hr PFC 460 460 13 0 184 5 2 Table 5 1 Required Fuel Input Pipe Length ft m 1 Pipe 1 1 4 Pipe 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe 10 3 0 520 14 7 1 050 30 1 600 45 3 050 86 4 800 136 8...

Page 30: ...e 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...

Page 31: ...on 3 Venting and Air Intake for information on obtaining vent samples from this boiler 29 FUEL PIPING Figure 5 2 Gas Valve Venturi Natural Gas Propane LP Low Fire High Fire Low Fire High Fire Carbon M...

Page 32: ...Drain Hoses PFC 460 boilers have a drain attached directly to the combustion chamber To prevent debris from entering the heat exchanger a separate drain connection can be added to the vent system at t...

Page 33: ...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 D...

Page 34: ...2 shows customer connections for PFC 460 boilers a Terminals 1 10 on the left side are for low voltage customer connections to the CH thermostat outdoor sensor DHW sensor or thermostat system sensor a...

Page 35: ...er front plate After ignition the control also senses flame through the ignition electrode 9 Gas Valve The gas valve is connected through a special cord and connector The connector is attached to the...

Page 36: ...34 Figure 7 4 Internal Wiring Schematic for PFC 460 ELECTRICAL CONNECTIONS...

Page 37: ...closed 18 F is subtracted from the calculated setpoint 3 Permanent Demand and Setpoint Boiler operates to maintain a fixed setpoint When CH TSTAT terminals 1 2 are closed 18 F is subtracted from the s...

Page 38: ...ue 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 s...

Page 39: ...d 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 temperatur...

Page 40: ...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...

Page 41: ...minimum modulation until the call for heat ends or the vent temperature exceeds 50 F The outdoor sensor temperature should correspond to the current outdoor temperature If the sensor is mounted in dir...

Page 42: ...nnected e Temperature Units This screen allows the user to change the temperature unit display The default units are Fahrenheit F To change the unit display press the Select key The current unit syste...

Page 43: ...will change for DHW demands or CH demands depending on the setpoint chosen for these modes of operation When outdoor reset modes are selected this value is the calculated target for the system b Fan...

Page 44: ...error If the burner is not in lockout this position should show 255 in the error number location Use the arrow keys to scroll through previous errors from 1 to 15 As with blocking errors 255 always i...

Page 45: ...minals for either a low water cutoff or a flow switch The low water cutoff is the factory default and a factory supplied jumper is installed This jumper is to be removed if a low water cutoff or flow...

Page 46: ...t by timing the gas supply meter If these conditions are not met contact your Peerless Representative for assistance l Alarm Mode The alarm mode allows the installing contractor to set the menu to the...

Page 47: ...is useful in buildings with many zones which operate on independent thermostats to prevent the boost function described later in this text from increasing the target temperature due to a long sustaine...

Page 48: ...e values shown below If the installer prefers to use custom values for the outdoor reset parameters the following provides guidance h Design Point The design point is defined by the outdoor design tem...

Page 49: ...ature 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 func...

Page 50: ...t 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...

Page 51: ...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...

Page 52: ...er for very long In this case Choose Pump For CH or Pump for DHW from the System Test menu on the display of the managing boiler in the system before running the dependent boilers 8 Sequence Managing...

Page 53: ...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...

Page 54: ...pendent boiler LWCO contacts are opened 3 System Piping Wiring a Multiple boilers with multiple zones with zone valves Figure 8 49 shows a typical system which uses a CH circulator a DHW circulator an...

Page 55: ...53 Figure 8 49 Multiple Boiler Cascade Piping Electrical Connections for Systems with Zone Valves BOILER CONTROL OPERATION...

Page 56: ...54 Figure 8 50 Multiple Boiler Cascade Piping Electrical Connections for Systems with Zone Circulators BOILER CONTROL OPERATION...

Page 57: ...and the overall status of the cascade system By pressing the M or L key the operator can view the master boiler status b Connecting the Cascade Links PFC 460 Re attach the User Interface Display Conn...

Page 58: ...x 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...

Page 59: ...ure 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 manu...

Page 60: ...O 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...

Page 61: ...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 fl...

Page 62: ...w 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 Appe...

Page 63: ...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 CO...

Page 64: ...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...

Page 65: ...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 SPE...

Page 66: ...he 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 scr...

Page 67: ...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 t...

Page 68: ...re is not 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 combus...

Page 69: ...rovide 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...

Page 70: ...eaking 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 de...

Page 71: ...ot 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...

Page 72: ...1 2 1 1 2 4 3 4 2 3 4 5 1 4 3 1 2 5 3 4 7 1 16 Table 12 3 Combustion Air Fan Speeds SERIES PEERLESS PUREFIRE COMBUSTION AIR FAN SPEEDS Boiler Model Input Rate Fan Speed Low Power Ignition High Power...

Page 73: ...k 77 F 25 C They operate on 5 VDC Supply Sensor 14 F 10 C to 244 F 118 C Return Sensor 14 F 10 C to 244 F 118 C Flue Sensor 50 F 10 C to 280 F 138 C Outdoor Sensor 40 F 40 C to 185 F 85 C Optional Sen...

Page 74: ...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...

Page 75: ...5552 20 Bushing 1 1 2 x 3 4 NPT Brass PF 460 Local Hdwr Supply 1 5556 21 Shut off Valve 3 4 NPT Brass Local Hdwr Supply 1 50764 22 Convenience Outlet 1 54136 23 Hex Nut 8 32 with Lockwasher Local Hdw...

Page 76: ...74 REPAIR PARTS Figure 13 2 Heat Exchanger Burner Assembly Repair Parts PFC 460...

Page 77: ...10 12 1 54248 10 Gasket Glass Rope 1 54188 11 Gasket Rubber 1 54187 12 Insulation Combustion Chamber Cover Plate 1 54255 15 Insulation Target Wall 1 54185 16 Heat Exchanger PFC 460 1 5530 17 Thermal...

Page 78: ...Exhaust Vent Termination Kits Description Stock Code 4 Concentric Sidewall Termination Kit PolyPro 3PPS HK 54499 4 Concentric Vertical Termination Kit PolyPro 4PPS VK 54501 Description Stock Code 4 Po...

Page 79: ...77 APPENDIX A STATUS SCREENS APPENDIX A STATUS SCREENS...

Page 80: ...78 APPENDIX A STATUS SCREENS...

Page 81: ...79 APPENDIX A STATUS SCREENS...

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

Page 83: ...81 APPENDIX B USER MENU APPENDIX B USER MENU...

Page 84: ...82 APPENDIX C INSTALLER MENU APPENDIX C INSTALLER MENU...

Page 85: ...83 APPENDIX C INSTALLER MENU...

Page 86: ...84 APPENDIX C INSTALLER MENU...

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

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

Page 89: ...w c High Fire Outlet Gas Pressure in w c Low Fire Outlet Gas Pressure in w c Combustion Readings Flame Signal High Fire A Flame Signal Low Fire A CO High Fire CO Low Fire CO High Fire ppm CO Low Fire...

Page 90: ...of the owner and must be affixed near the boiler for future reference TO THE OWNER This boiler should be inspected annually by a Qualified Service Agency PF8305 R0 9 17 1C Printed in U S A 2017 PB He...

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