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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 LAYOUTS . . . . . . . . . . . . . . .6

2. BOILER SET-UP

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

B. WALL MOUNTING . . . . . . . . . . . . . . . . . . . . . .7

C. 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 . .13

E. EXHAUST VENT/AIR INTAKE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .13

F. EXHAUST TAPPING FOR VENT SAMPLE . .14

G. BOILER REMOVAL FROM COMMON

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

4. WATER PIPING AND CONTROLS

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

B. OPERATING PARAMETERS . . . . . . . . . . . . . .16

C. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .16

D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .19

E. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .19

F. SPECIAL APPLICATIONS . . . . . . . . . . . . . . . .20

5. FUEL PIPING

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

B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . . .27

C. GAS SUPPLY PIPING – INSTALLATION . . . .27

D. GAS SUPPLY PIPING – OPERATION . . . . . . .28

E. MAIN GAS VALVE – OPERATION . . . . . . . . .29

6. CONDENSATE DRAIN PIPING

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

B. CONDENSATE SYSTEM . . . . . . . . . . . . . . . .30

C. CONDENSATE DRAIN PIPE MATERIAL . . . .31

D. CONDENSATE DRAIN PIPE SIZING . . . . . . .31

E. CONDENSATE DRAIN PIPE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .31

7. ELECTRICAL CONNECTIONS

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .32

B. CUSTOMER CONNECTIONS . . . . . . . . . . . . .32

C. ZONE CIRCULATOR WIRING . . . . . . . . . . . . .33

D. INTERNAL WIRING . . . . . . . . . . . . . . . . . . . .33

8. BOILER CONTROL: OPERATION

A. CONTROL OVERVIEW . . . . . . . . . . . . . . . . . .35

B. IGNITION SEQUENCE . . . . . . . . . . . . . . . . . .37

C. USER MENU . . . . . . . . . . . . . . . . . . . . . . . . . .39

D. INSTALLER MENU . . . . . . . . . . . . . . . . . . . . .41

E. DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . .52

F. MULTIPLE BOILERS . . . . . . . . . . . . . . . . . . . .52

9. START-UP PROCEDURE

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

B. CHECK WATER PIPING . . . . . . . . . . . . . . . . .57

C. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . . .57

D. CHECK OPERATION . . . . . . . . . . . . . . . . . . . .57

E. LIGHTING & OPERATING PROCEDURES . . .59

10. TROUBLESHOOTING

A. HARDWARE ERROR - NO COMM MAIN

BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

B. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . . .60

C. LOCKING ERRORS . . . . . . . . . . . . . . . . . . . . .60

D. ERROR MESSAGES IN A CASCADE

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

E. WARNING ERRORS . . . . . . . . . . . . . . . . . . . .64

F. DELAYED IGNITION (HARD LIGHT-OFF) . . .66

G. BOILER FAILS TO RESPOND TO A CH

CALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

11. MAINTENANCE

A. GENERAL (WITH BOILER IN USE) . . . . . . . .68

B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .68

C. ANNUALLY (BEFORE START OF HEATING

SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

D. CONDENSATE CLEANING

INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .68

E. INSPECTION AND CLEANING OF

COMBUSTION CHAMBER COILS . . . . . . . . .69

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

Содержание Peerless PureFire PFC-460

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

Страница 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...

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 1 USING THIS MANUAL DANGER Indicates a cond...

Страница 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...

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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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