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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 . . . . . . . .3

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

2. BOILER SET-UP

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

B. FLOOR STANDING INSTALLATION . . . . . . . . .7

3. VENTING & AIR INLET PIPING

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

B. APPROVED MATERIALS . . . . . . . . . . . . . . . . .8

C. EXHAUST VENT/AIR INTAKE

PIPE LOCATION . . . . . . . . . . . . . . . . . . . . . . . .8

D. EXHAUST VENT/AIR INTAKE PIPE SIZING . .11

E. EXHAUST VENT/AIR INTAKE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .12

F. EXHAUST TAPPING FOR VENT SAMPLE . .14

G. BOILER REMOVAL FROM COMMON

VENTING SYSTEM . . . . . . . . . . . . . . . . . . . .14

4. WATER PIPING AND CONTROLS

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

B. OPERATING PARAMETERS . . . . . . . . . . . . . .15

C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .15

D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .17

5. FUEL PIPING

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . . .24

C. GAS SUPPLY PIPING – INSTALLATION . . . .24

D. GAS SUPPLY PIPING – OPERATION . . . . . . .25

E. MAIN GAS VALVE – OPERATION . . . . . . . . .25

6. CONDENSATE DRAIN PIPING

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

B. CONDENSATE SYSTEM . . . . . . . . . . . . . . . .27

C. CONDENSATE DRAIN PIPE MATERIAL . . . .28

D. CONDENSATE DRAIN PIPE SIZING . . . . . . .28

E. CONDENSATE DRAIN PIPE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .28

7. ELECTRICAL CONNECTIONS

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .29

B. CUSTOMER CONNECTIONS . . . . . . . . . . . . .29

C. INTERNAL WIRING . . . . . . . . . . . . . . . . . . . .29

8. BOILER CONTROL: INTERNAL

WIRING & OPERATION

A. IGNITION SEQUENCE . . . . . . . . . . . . . . . . . .32

B. USER MENU . . . . . . . . . . . . . . . . . . . . . . . . . .34

C. INSTALLER MENU . . . . . . . . . . . . . . . . . . . . .35

9. START-UP PROCEDURE

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

B. CHECK WATER PIPING . . . . . . . . . . . . . . . . .43

C. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . . .43

D. CHECK OPERATION . . . . . . . . . . . . . . . . . . . .43

E. LIGHTING & OPERATING PROCEDURES . . .45

10. TROUBLESHOOTING

A. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . . .46

B. LOCKING ERRORS . . . . . . . . . . . . . . . . . . . . .46

C. WARNING ERRORS . . . . . . . . . . . . . . . . . . . .50

11. MAINTENANCE

A. GENERAL (WITH BOILER IN USE) . . . . . . . .52

B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .52

C. ANNUALLY (BEFORE START OF HEATING

SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

D. CONDENSATE CLEANING

INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .52

E. COMBUSTION CHAMBER COIL CLEANING

INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .53

12. BOILER DIMENSIONS & RATINGS

13. REPAIR PARTS

APPENDIX A. STATUS SCREENS

APPENDIX B. USER MENU

APPENDIX C. INSTALLER MENU

APPENDIX D. 852-1 INTERFACE
ADAPTER

APPENDIX E. COMBUSTION TEST
RECORD

WARRANTY

TABLE OF CONTENTS

TABLE OF CONTENTS

Содержание PUREFIRE PFW-199

Страница 1: ...ter Supply Boilers PFW 199 PFW 210 PFW 399 Gas Installation Operation Maintenance Manual As an ENERGY STAR Partner PB Heat LLC has determined that this product meets the ENERGY STAR guidelines for ene...

Страница 2: ...27 A GENERAL 27 B CONDENSATE SYSTEM 27 C CONDENSATE DRAIN PIPE MATERIAL 28 D CONDENSATE DRAIN PIPE SIZING 28 E CONDENSATE DRAIN PIPE INSTALLATION 28 7 ELECTRICAL CONNECTIONS 29 A GENERAL 29 B CUSTOME...

Страница 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 Indicates special attention is needed but n...

Страница 4: ...pment 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 i...

Страница 5: ...r 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 open...

Страница 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...

Страница 7: ...ons 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 a...

Страница 8: ...mbustion air unless it is directly piped to the air inlet as shown in Figure 3 9 h Combustion air intake openings located on the exterior of buildings shall have the lowest side of the combustion air...

Страница 9: ...should be supported independently of the boiler 3 Install the boiler level to prevent condensate from backing up inside the boiler B FLOOR STANDING INSTALLATION 1 For floor standing installations use...

Страница 10: ...mum combined vent and air inlet vent length for the Infinite Energy boiler is about 200 equivalent feet 60 m Be sure that the boiler is located such that the maximum vent length is not exceeded 6 Air...

Страница 11: ...t 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 direct vent appliance Provide a minimum of...

Страница 12: ...ard Exhaust Air Inlet Pipe Terminations Figure 3 4 Offset Exhaust Air Inlet Terminations 10 VENTING AIR INLET PIPING Figure 3 5 Optional Concentric Vent Kit Installation Figure 3 6 Exhaust Air Inlet o...

Страница 13: ...haust vent pipe a minimum of 12 above the inlet to the air intake pipe b Figure 3 9 shows an approved vertical vent configuration using the optional concentric vent termination kit 3 54500 or 4 54501...

Страница 14: ...a The equivalent length of elbows tees and other fittings are listed in Table 3 3 b The equivalent length can be calculated as follows This is well below the 200 feet maximum equivalent length If the...

Страница 15: ...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 an...

Страница 16: ...ystem 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 contr le visuel...

Страница 17: ...th a hardness of less than 5 grains per gallon will usually have a pH which can be aggressive and corrosive causing non warrantable damage to the pump and associated piping Corrosion due to water chem...

Страница 18: ...based on the design temperature difference from the return to the supply of the boiler For a PFW 199 with a design temperature difference of 20 F the calculation is as follows Output 182 000 Required...

Страница 19: ...piped into a single storage tank 4 Figure 4 6 shows piping for two boilers and two water storage tanks 5 In Figure 4 7 we show a single boiler with a single tank using a patented anti scale principle...

Страница 20: ...18 WATER PIPING AND CONTROLS Figure 4 3 Schematic Piping One Boiler with a Single Storage Tank...

Страница 21: ...19 WATER PIPING AND CONTROLS Figure 4 4 Schematic Piping One Boiler with Multiple Storage Tanks...

Страница 22: ...20 Figure 4 5 Schematic Piping Two Boilers with a Single Storage Tank WATER PIPING AND CONTROLS...

Страница 23: ...21 WATER PIPING AND CONTROLS Figure 4 6 Schematic Piping Two Boilers with Multiple Storage Tanks...

Страница 24: ...22 WATER PIPING AND CONTROLS Figure 4 7 Schematic Piping Alternate Piping with Patented Anti Scale System...

Страница 25: ...23 WATER PIPING AND CONTROLS Figure 4 8 Schematic Piping One Boiler with a Single Storage Tank Plate Heat Exchanger...

Страница 26: ...e 5 Maintain a minimum distance of 10 feet 3048 mm between the gas pressure regulator and the boiler 5 FUEL PIPING Use a pipe joint sealing compound that is resistant to liquefied petroleum gas A non...

Страница 27: ...tap fitting i Turn the internal screw clockwise to close the valve j Turn on the gas shutoff valve and boiler service switch k Fire the boiler and check for fuel gas odor around the gas valve If an o...

Страница 28: ...boiler be allowed to operate with CO emissions above 150 ppm 2 Refer to Section 3 Venting and Air Intake for information on obtaining vent samples from this boiler FUEL PIPING Table 5 4 Recommended Co...

Страница 29: ...at exchanger The first hose drains condensate from the combustion chamber of the boiler The second hose drains condensate from the vent system This prevents dirt and debris from the venting system fro...

Страница 30: ...e system to 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...

Страница 31: ...et active 4 Note that the service switch does not disconnect power to the convenience outlet C INTERNAL WIRING Figure 7 3 shows the complete boiler wiring schematic for Infinite Energy boilers The fol...

Страница 32: ...alve with a screw 10 Ignition Electrode This electrode is located on the left side of the heat exchanger front plate A 10 000 volt charge is initiated by the control to provide a spark for lighting th...

Страница 33: ...31 Figure 7 3 Internal Wiring Schematic for PFW 199 PFW 210 PFW 399 Boilers ELECTRICAL CONNECTIONS...

Страница 34: ...Depends on boiler settings 320 milliseconds 5 seconds 10 seconds maximum Table 8 1 Ignition Sequence Period Demand Status User Interface Display Standby No demand is present If the power is on to the...

Страница 35: ...ignition failures the control will post purge and 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...

Страница 36: ...ure 8 8 8 9 The Offset value is added to the Tank Setpoint to provide a target setpoint for the boiler supply outlet temperature Boiler SP when the unit is firing To change the value press the Select...

Страница 37: ...ltaneously and hold them until the INSTALLER MENU is displayed Figure 8 15 shows the menu Use the and keys to move the arrow pointer to the desired menu option Then press Select to choose it 1 Install...

Страница 38: ...ative time of the error Figure 8 25 The error number in the format E corresponds to the English language description at the bottom of the screen A complete list of Blocking Errors is provided in Table...

Страница 39: ...is used to choose between several different configurations Press the Select key causes the mode number to flash Use the and keys to change the mode to the desired number Press the Select key again to...

Страница 40: ...the boiler input to minimum firing rate 1 of modulation This is done to prevent overheating of the exhaust vent material d Freeze Protection This feature is intended to protect from freezing temperatu...

Страница 41: ...ication criteria are met the screen shown in Figure 8 41 is displayed with SERVICE flashing b To reset the hour or cycle counters press the Select key on Screen 1 under Service Notification shown in F...

Страница 42: ...a service person to reset all of the boiler settings to the default settings that were set up at the factory To reset the default values choose Default Values from the Installer Menu Figure 8 49 shows...

Страница 43: ...hat the tank temperature will fall before all boilers are in operation If many boilers are installed and the load is highly variable consider using two cascade systems In this case the tank sensors fo...

Страница 44: ...e 8 15 shows how the Rotation Interval affects the boiler rotation sequence Figure 8 56 Cascade Stop Delay Time C A S C A D E S t o p D e l a y T i m e 1 m i n Figure 8 57 Cascade Stop Boiler Differen...

Страница 45: ...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 Close terminal 1 2 either with a switch or jumper to e...

Страница 46: ...nd 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...

Страница 47: ...E LIGHTING OPERATING PROCEDURES 45 Figure 9 4 Lighting Operating Instructions START UP PROCEDURE...

Страница 48: ...remove the flame sensor and igniter for inspection Also be sure that the lead to the flame sensor is not grounded 10 TROUBLESHOOTING If overheating occurs or the gas supply fails to shut off do not tu...

Страница 49: ...OR 45 Mains frequency differs more than 2 from 60Hz Contact electrical provider and or an electrician E24 POOR GROUND 46 Earth connection is not ok Check boiler ground and harness E25 BLOCKED VENT 38...

Страница 50: ...s out on flame failure during normal operation a Check gas pressure at the inlet to the gas valve See figure 5 2 while the boiler is operating b Check the flame signal in the Installer Menu under Stat...

Страница 51: ...9 10 from field supplied flow switch 2 If there is continuity when the pump is off there is a system piping or pump control problem A24 FLOW_SW_NOT_CLOSED 26 CH flow switch not working 1 Check for ele...

Страница 52: ...tions Several of these conditions provide the error information directly on the screen Table 10 3 shows sensor errors and corresponding corrective actions DHW Sensor Error a If the boiler control is s...

Страница 53: ...s 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 handli...

Страница 54: ...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 i...

Страница 55: ...s 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 Inf...

Страница 56: ...80 23 4 399 116 9 373 324 93 4 BOILER DIMENSIONS RATINGS Figure 12 1 Dimensional Drawing PUREFIRE SERIES DIMENSIONS Boiler Model A B C D E F G H J K L PFW 199 16 9 16 421 mm 17 3 16 436 mm 40 1 2 1029...

Страница 57: ...tacts 24 VAC DHW Contacts 5 VDC Flame Current Limits Minimum running 2 8 A Minimum ignition 3 1 A Maximum 10 A Temperature Sensors NTC Thermistors are 12 k 77 F 25 C 5 VDC Supply Sensor 14 F 10 C to 2...

Страница 58: ...B 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 Figur...

Страница 59: ...Module PF PFW 210 1 54286 Control Module PF PFW 399 1 54287 27 Rocker Switch 20 A 120 VAC 1 1 1 5701 28 Pump Isolation Relay Module 1 1 1 54610 29 3 Exhaust Vent Air Inlet Adapter PF PFW 199 210 1 1...

Страница 60: ...58 Figure 13 2 Heat Exchanger Burner Assembly Repair Parts REPAIR PARTS...

Страница 61: ...1 54188 11 Gasket Rubber 1 1 1 54187 12 Combustion Chamber Cover Plate Insulation 1 1 1 54255 13 M4 x 8 mm Stainless Steel Screw 1 1 1 14 M4 Stainless Steel Fender Washer 1 1 1 15 Target Wall Insulat...

Страница 62: ...l Termination Kit PolyPro 4PPS VK 54501 Table 13 4 Optional Polypropylene Exhaust System Adapters Description Quantity Stock Code PFW 199 PFW 210 PFW 399 3 Polypropylene Vent Inlet Adapter Innoflue IS...

Страница 63: ...61 APPENDIX A STATUS SCREENS APPENDIX A STATUS SCREENS...

Страница 64: ...62 APPENDIX A STATUS SCREENS...

Страница 65: ...63 APPENDIX A STATUS SCREENS...

Страница 66: ...64 APPENDIX B USER MENU APPENDIX B USER MENU...

Страница 67: ...65 APPENDIX B USER MENU...

Страница 68: ...66 APPENDIX C INSTALLER MENU APPENDIX C INSTALLER MENU...

Страница 69: ...67 APPENDIX C INSTALLER MENU...

Страница 70: ...68 APPENDIX C INSTALLER MENU...

Страница 71: ...69 APPENDIX C INSTALLER MENU...

Страница 72: ...ge Ignition Firing Postpurge or Alarm conditions c Error Information If the boiler is in a lockout or blocking error the interface will allow access to the error code B PRE INSTALLATION 1 IE 199 IE399...

Страница 73: ...olts dc will disable boiler operation 2 volts corresponds to a boiler setpoint temperature of 60 F and 10 volts corresponds to a boiler setpoint temperature of 200 F Input voltage between 2 and 10 vol...

Страница 74: ...g Registers Read Only Item Index Parameter Name Address Holding Registers Notes Word byte Range Start 0x0000 Range Start 0x0001 0 High byte 0 STATE 0x0000 0x0001 See Table 3 0 Low byte 1 STATUS 0x0000...

Страница 75: ...RE_BLOCK_ERROR Error Handling 21 0x15 WAIT_A_SECOND Error Handling The following example describes how to read the temperature holding registers byte 4 7 and 14 15 The boiler supply and return tempera...

Страница 76: ...LAY_ERROR Internal Control Error 8 0x08 FAN_ERROR Incorrect Fan Speed 9 0x09 RAM_ERROR Internal Control Error 10 0x0A WRONG_EEPROM_SIGNATURE Internal Control Error 11 0x0B RETURN_HIGHER_THEN_SUPPLY Bo...

Страница 77: ...UE_GAS_ERROR High Vent Temperature 40 0x28 RETURN_TEMP_ERROR High Return Temp 194 F 90 C 41 0x29 BLOCKED_DRAIN_ERROR Blocked Condensate Drain 43 0x2B WD_50HZ_ERROR Poor Ground Connection 44 0x2C PHASE...

Страница 78: ...resets and the command must be re issued to change the setpoint NOTICE If an invalid value is written after the Write Command is issued the control resets and the command must be re issued to change...

Страница 79: ...ssure Drop After Boiler Startup in 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...

Страница 80: ...its required for installation reinstallation or repair V charges to return the water heater and or components to the manufacturer d Any failed component of the water heater system not manufactured as...

Страница 81: ...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 XXXXXX R0 xx 14 xM Printed in U S A 2014 PB H...

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