Page 1
® ® REV 2 Boilers PF-50 PF-80 PF-110 PF-140 PF-210 PF-399 As an ENERGY STAR ® Partner, PB Heat, LLC has determined that this product meets the ENERGY STAR guidelines for energy efficiency. I n s t a l l a t i o n , O p e r a t i o n &...
USING THIS MANUAL USING THIS MANUAL A. INSTALLATION SEQUENCE DANGER Follow the installation instructions provided in this manual Indicates a condition or hazard which will cause in the order shown. The order of these instructions has severe personal injury, death or major property been set in order to provide the installer with a logical damage.
PREINSTALLATION 1. PREINSTALLATION **Please read if installing in Massachusetts** A. GENERAL Massachusetts requires manufacturers of Side Wall Vented boilers to provide the following information 1. P ® boilers are supplied completely assembled from the Massachusetts code: as packaged boilers. The package should be inspected ·...
However, Local codes or special conditions may floors. E. D. require greater clearances. COMBUSTION AND VENTILATION AIR Figure 1.1: Minimum Accessibility Clearances – PF-50, PF-80, PF-110 & PF-140 Figure 1.2: Minimum Accessibility Clearances – PF-210 & PF-399 Downloaded from www.Manualslib.com manuals search engine...
PREINSTALLATION a. Combining Spaces on the Same Floor: Provide two D. COMBUSTION AND VENTILATION AIR permanent openings communicating with additional spaces that have a minimum free area of 1 in 1. The P ® boiler is designed for operation with 1000 Btu/hr (22 cm per 1000 W) of the total input combustion air piped directly to the boiler from...
Page 7
PREINSTALLATION 5. Outdoor Combustion Air: Outdoor combustion air is ii. Where communicating with the outdoors through to be provided through one or two permanent horizontal ducts, each opening shall have a openings. The minimum dimension of these air minimum free area of 1 in per 2000 Btu/hr (22 openings is 3 inches (76 mm).
PREINSTALLATION 6. Combination Indoor and Outdoor Combustion Air: If i. The interlock shall prevent the main burner the required volume of indoor air exceeds the from igniting if the damper fails to open during available indoor air volume, outdoor air openings or burner startup.
Page 9
PREINSTALLATION WARNING This boiler is certified as an indoor appliance. Do not install this boiler outdoors or locate where it will be exposed to freezing temperatures. WARNING Do not install this boiler where gasoline or other flammable liquids or vapors are stored or are in use. WARNING Do not install this boiler in the attic.
2. Be sure to leave adequate space for condensate location is not in line with the wall studs, piping or a pump if required. additional support is required. Figure 2.1: Optional Wall Mounting Bracket for PF-50, PF-80, PF-110 and PF-140 Boilers Downloaded from www.Manualslib.com manuals search engine...
1. Table 3.1 lists approved materials for vent pipe (and 5. The maximum combined vent and air inlet vent adhesives where applicable). Use only these materials length for the Peerless ® ® boiler is about 200 for exhaust vent piping.
Page 12
VENTING & AIR INLET PIPING d. If the vent pipe and air inlet pipe terminations • Provide a minimum of 1 foot (30 cm) distance penetrate the wall at the same level the minimum from any door, operable window, or gravity distance between them is 8"...
Page 13
VENTING & AIR INLET PIPING Figure 3.3: Standard Exhaust and Air Inlet Pipe Figure 3.5: Optional Stainless Steel Vent Kit Penetrations Installation Figure 3.4: Offset Exhaust and Air Inlet Figure 3.6: Optional Concentric PVC Vent Kit Terminations Installation Downloaded from www.Manualslib.com manuals search engine...
Page 14
VENTING & AIR INLET PIPING 8. Vertical Venting Configuration: b. Locate the air intake pipe inlet 12" above the expected snow accumulation on the roof surface a. Figure 3.7 shows the approved venting or 24" above the roof surface, whichever is greater. configuration for vertical venting using the standard fittings supplied.
1. Figures 12.1 & 12.2 show the exhaust connection on top of the boiler, near the rear in the center. a. The exhaust connection for PF-50, PF-80, PF- 110 Figure 3.10 and PF-140 boilers is a 3" CPVC Female Pipe Adapter.
VENTING & AIR INLET PIPING 6. All piping must be fully supported. Use pipe hangers G. BOILER REMOVAL FROM COMMON at a minimum of 4 foot (1.22 meter) intervals to VENTING SYSTEM prevent sagging of the pipe. If removing an existing boiler from a common vent 7.
Minimum Flow Rate protect system components from premature failure ® Water 50% Glycol Solution due to corrosion. Model GPM (LPM) GPM (LPM) PF-50 2.2 (8.3) 2.8 (10.6) PF-80 3.3 (12.5) 4.1 (15.5) WARNING PF-110 4.4 (16.7) 5.5 (20.8) PF-140 5.5 (20.8)
Page 18
WATER PIPING AND CONTROLS Figure 4.1: Piping Symbol Key 6. Pressure Reducing Valve: A pressure reducing valve, The valve is to be installed as shown in Figures 4.2 or such as the Bell & Gossett B-38 or a TACO #329, is 4.3.
Page 19
WATER PIPING AND CONTROLS Figure 4.2: Relief Valve Installation – PF-50, PF-80, PF-110 & PF-140 b. The circulator should be sized based on gross Figure 4.3: Relief Valve Installation – PF-210 & PF-399 output of the boiler. Table 4.3 shows the Boiler Output as reported to the Hydronics Institute Section of AHRI.
Page 20
If there is significant heating medium. system pressure drop in the system, this should be included when specifying circulators. Table 4.4: Flow Rate and Pressure Drop for Various System Temperature Rise Values Flow Rate & Pressure Drop PF-50 PF-80 PF-110 PF-140 PF-210 PF-399 (°F)
2. For a single boiler with one heating zone and one automatically when glycol solution is used. Adding DHW zone which utilizes an indirect water heater like make-up water will dilute the system and reduce the the Peerless ® Partner ®...
Page 22
WATER PIPING AND CONTROLS Downloaded from www.Manualslib.com manuals search engine...
Page 23
WATER PIPING AND CONTROLS Downloaded from www.Manualslib.com manuals search engine...
Page 24
WATER PIPING AND CONTROLS Downloaded from www.Manualslib.com manuals search engine...
Page 25
WATER PIPING AND CONTROLS Downloaded from www.Manualslib.com manuals search engine...
Page 26
WATER PIPING AND CONTROLS Downloaded from www.Manualslib.com manuals search engine...
WATER PIPING AND CONTROLS c. See Figure 4.10 for recommended system piping SPECIAL APPLICATIONS for chiller operation. 1. If the P ® boiler is used in conjunction with a 2. For boilers connected to heating coils in a forced air chilled medium system, pipe the chiller in a separate system where they may be exposed to chilled air secondary loop.
® boiler is to be in /hr) /hr) Model accordance with local codes. In the absence of local regulations refer to the National Fuel Gas Code, ANSI PF-50 50 (1.4) 20 (0.6) Z223.1/NFPA 54. PF-80 80 (2.3) 32 (0.9) PF-110 110 (3.1)
FUEL PIPING 3. Install a ground joint union between the sediment trap b. Gas pressure above 13.5 inches of water may and the boiler to allow service to the appliance. result in damage to the automatic gas valve. 4. Install a service valve as shown in Figure 5.1 to allow CAUTION the gas supply to be interrupted for service.
FUEL PIPING E. MAIN GAS VALVE - OPERATION 1. Figure 5.2 is an illustration of the gas valve/venturi assembly for the P ® boiler. a. Adjustments should not be made to the gas valve without instrumentation to measure carbon dioxide (CO ) and carbon monoxide (CO) emissions in the vent pipe.
CONDENSATE DRAIN PIPING 6. CONDENSATE DRAIN PIPING 1. Condensate Drain Hoses: The PF-50, PF-80, PF-110, A. GENERAL and PF-140 boilers have two drain hoses attached to the heat exchanger. The first hose drains condensate 1. The disposal of all condensate into public sewage from the combustion chamber of the boiler.
CONDENSATE DRAIN PIPING 4. Condensate Neutralizer Container: The condensate E. CONDENSATE DRAIN PIPE INSTALLATION neutralizer container is an additional transparent container near the front of the boiler. Fill this 1. Connect a 3/4" schedule 40 PVC Tee to the outlet of container with the condensate neutralizer provided.
The terminals can be removed by gently pulling them away from their wired blocks. This allows the installer to easily attach wires to the connector before plugging it into the block. Figure 7.2: Customer Connections – PF-50, PF-80, PF-100 & PF-140 Downloaded from www.Manualslib.com manuals search engine...
Figure 7.5 shows the complete boiler wiring schematic for g. Terminals 31 & 32 are not yet active. PF-50, PF-80, PF-110 and PF-140 boilers. Figure 7.6 shows the schematic for the PF-210 and PF-399 boilers. 5. Note that the service switch does not disconnect The following is a list of internal wiring components.
Page 35
ELECTRICAL CONNECTIONS Downloaded from www.Manualslib.com manuals search engine...
Page 36
ELECTRICAL CONNECTIONS Figure 7.6: Internal Wiring Schematic for PF-210 & PF-399 boilers. Downloaded from www.Manualslib.com manuals search engine...
Page 37
ELECTRICAL CONNECTIONS 7. Convenience Outlet: The convenience outlet is provided for a condensate pump during operation. It is not switched with the service switch to allow its use for lighting during maintenance. 8. Flame Sensor: The flame sensor uses the principal of flame rectification to sense the burner flame.
BOILER CONTROL: INTERNAL WIRING & OPERATION 8. BOILER CONTROL: INTERNAL WIRING & OPERATION 1. Central Heating (CH) Modes: A. CONTROL OVERVIEW The P ® boiler control allows the installer to choose from several different central heating modes. The P ® boiler control is one of the primary safety The following table shows the central heating modes.
Page 39
BOILER CONTROL: INTERNAL WIRING & OPERATION 4. Special Features: The P ® control offers several special features to give the installer options in setting up the boiler. These options are shown in the following table. Table 8.4: Control Features Detail Feature Brief Description Page...
BOILER CONTROL: INTERNAL WIRING & OPERATION B. IGNITION SEQUENCE Figure 8.1 shows the ignition sequence for the P ® boiler control. Table 8.4 describes each step in the sequence in detail. The P ® boiler control provides dual sensing of the flame to maximize the reliability. The control senses the burner flame with both the flame sensor and the ignition electrode.
Page 41
BOILER CONTROL: INTERNAL WIRING & OPERATION Period Demand Status User Interface Display A heat demand has no influence in the Safety On/Off period. The Safety On/Off step will continue even if the demand Safety has ended. On/Off This step very quickly opens and closes the gas valve relays and determines if the control is operating correctly. The CH pump is turned off during this test.
BOILER CONTROL: INTERNAL WIRING & OPERATION Figures 8.2 & 8.3 both show the electrical connections C. BOILER CONTROL from the boiler to the circulators. Either the CH pump or the DHW pump can be energized but they can 1. Pump Modes: never run simultaneously.
Page 43
BOILER CONTROL: INTERNAL WIRING & OPERATION Pump Mode 1 – General Pump with 3-Way Valve: This mode is preferred if multiple heating zones are Mode 1 allows the boiler to be installed with a three used. The general pump operates to assure proper way valve which diverts water from the boiler supply flow through the boiler at all times.
BOILER CONTROL: INTERNAL WIRING & OPERATION 2. Installation Location & Vent Material: installed. The P ® boiler allows the installer to input the Low Water Cutoff: The installer can connect the installation location and the vent material used. This power supply wires for a probe-type low water cutoff information is used to determine the suitable vent to terminal #19 (Hot) and #20 (Neutral) in the main temperature limit based on National Codes.
Page 45
BOILER CONTROL: INTERNAL WIRING & OPERATION Mode 5 – 0-10 V Input to Modulate Firing Rate: Outdoor Design Temperature: The outdoor design This feature also requires the use of an optional PFA-1 temperature is the outdoor temperature used to Interface Adapter kit (54271). With this adapter, this calculate the heat loss of the building to determine the mode allows the boiler input firing rate to be controlled maximum heat load.
Page 46
BOILER CONTROL: INTERNAL WIRING & OPERATION Boiler Minimum: The boiler minimum is a value Warm Weather Shutdown: In any CH mode that is used to limit the minimum temperature that utilizing outdoor reset, the warm weather the boiler can target as a supply setpoint. shutdown feature prevents the boiler from operating if the outdoor temperature exceeds the This is useful if the boiler is used in conjunction...
BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.8: Outdoor Design Temperature (ODT) – U.S. Cities City State City State City State Mobile 29°F -2°C Springfield 2°F -17°C Albuquerque 16°F -9°C Anchorage -18°F -28°C Indianapolis 2°F -17°C New York City 15°F -9°C Juneau 1°F...
BOILER CONTROL: INTERNAL WIRING & OPERATION Mode 2 – DHW Store with Thermostat: In this mode, Essentially the boiler will operate normally on a call the P ® control is connected to the DHW tank for heat. Once the call for heat ends, the pumps will temperature limit.
BOILER CONTROL: INTERNAL WIRING & OPERATION Pressing the “ ” key displays the “SERVICE Notification Fan Speeds: By pressing the “ ” key the operator can on” screen. The default setting for “Notification on:” is view the current fan speed and the low power fan “Off”...
• A call for domestic hot water can either be initiated internally by the control when it sees 1. To cascade PF-50 and PF-80 models, check that the a drop in indirect tank temperature or by a display sub base has the cascade link as illustrated in tank thermostat.
Page 53
Hot Water (DHW) is present, the Master boiler chooses which boiler will lead based on the b. Connecting the Cascade Links – PF-50 through Cascade Rotation Interval. PF-140. b. Before starting the Lead boiler, the Master control •...
Page 54
BOILER CONTROL: INTERNAL WIRING & OPERATION To cascade PF-50 and PF-80 models, check that the display sub-base has the cascade link as illustrated in Figure 8.10. Figure 8.11: Interconnection of Cascade Link Wires f. After operation of the second boiler is initiated, •...
BOILER CONTROL: INTERNAL WIRING & OPERATION b. Similarly, the WWSD Temperature set on the K. DEFAULTS master boiler will prevent any boilers from operating for a CH demand when the outdoor 1. Factory Defaults – Restore: By pressing the temperature is above this value. “Select”...
START-UP PROCEDURE 9. START-UP PROCEDURE 4. Use the ignition sequence, Figure 8.1 to follow the A. GENERAL light off and shutdown sequences and to assist in troubleshooting operation problems. If the boiler does 1. Confirm that all water, gas and electricity are turned off. not function properly, consult Section 10, Troubleshooting.
Page 57
START-UP PROCEDURE e. If the values in either of these instances falls outside the parameters listed in Table 5.4, turn off the boiler and contact your PB Heat representative. For best results, the value should be set for the middle of the range (9% for Natural Gas and 10% for LP Gas).
START-UP PROCEDURE E. LIGHTING & OPERATING PROCEDURES FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. If you cannot reach your gas supplier, A.
TROUBLESHOOTING 10. TROUBLESHOOTING A. BLOCKING ERRORS WARNING 1. When a Blocking Error occurs the controller will display Do not use this appliance if any part has been under a message and an “E” error code on the display module. water. Improper or dangerous operation may result. Contact a qualified service technician immediately to 2.
Page 60
TROUBLESHOOTING Table 10.1: Control Board Blocking Error Codes (automatic reset): “E” Internal Error Display Error Description Corrective Action CODE SUPPLY SENSOR Supply sensor not connected. Check harness and sensor. NOT CONNECTED RETURN SENSOR Return sensor not connected. Check harness and sensor. NOT CONNECTED If DHW Mode is not intended to be set to Mode 1, DHW Store with Sensor, then change it to the...
Page 61
TROUBLESHOOTING Table 10.2: Control Board Locking Error Codes (manual reset): “A” Internal Error Display Error Description Corrective Action CODE 1. Watch the igniter through the observation window. 2. If no spark is present, check the spark electrode for the proper 3/16" gap. 3.
Page 62
TROUBLESHOOTING Table 10.2 (cont’d): Control Board Locking Error Codes (manual reset): “A” Internal Error Display Error Description Corrective Action CODE SOFTWARE OUT OF DATE Contents of e2prom is not Replace Control E2PROM OUT OF DATE up-to-date. INTERNAL ERROR Internal Software Error Replace Control INTERNAL ERROR Internal Software Error...
TROUBLESHOOTING 3. Flue Sensor Error: D. WARNING ERRORS a. If the control senses that the flue temperature does The P ® boiler control will display a blinking not rise to above 50°F after ignition, and either the screen under several conditions. Several of these supply water temperature rises above 120°F or the conditions provide the error information directly on return water temperature rises above 80°F , the control...
Page 64
TROUBLESHOOTING Table 10.3: Control Board Warning Error Codes “W” Error Error Display Corrective Action CODE Description 1) Check wiring connection to Outdoor Sensor. 2) Remove the wires from terminals #3 and #4 on the boiler and check the resistance between them. •...
MAINTENANCE 11. MAINTENANCE WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF fibers, when inhaled, have been classified by the International Agency for Research on Cancer (IARC), as a possible carcinogen to humans. After the RCF materials have been exposed to temperatures above 1800°F, they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans.
MAINTENANCE 3. Test low-water cut-off (if used) as described by the A. GENERAL (WITH BOILER IN USE) manufacturer. General boiler observation can be performed by the owner. If any potential problems are found, a qualified 4. Test limit as described in Section 9, Part D, installer or service technician/agency must be notified.
MAINTENANCE 2. Before re-starting the P ® boiler follow the 4. Spray coils with clear water, making sure to confine steps below: the spray to the area being cleaned (try to avoid wetting the back ceramic wall of the unit). Flush the a.
Page 69
BOILER DIMENSIONS & RATINGS Figure 12.2: Dimensional Drawing – PF-210 & PF-399 Table 12.3: Combustion Air Fan Speeds ® ® SERIES PEERLESS PUREFIRE COMBUSTION AIR FAN SPEEDS Fan Speed Boiler Input Model Rate Low Power Ignition High Power PF-50 50 MBH...
Page 70
BOILER DIMENSIONS & RATINGS Table 12.5: Electrical Ratings ® ® SERIES PEERLESS PUREFIRE ELECTRICAL RATINGS Blower Gas Valve Pumps Max Total Supply Boiler Frequency Service Max. Voltage Voltage Current Voltage Current Voltage Model (±1.2 hz) Current to Current (-15%, +10%)
Page 71
This page intentionally left blank. Downloaded from www.Manualslib.com manuals search engine...
Repair parts are available from 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. Figure 13.1: General Repair Parts – PF-50, PF-80, PF-110 & PF-140 Downloaded from www.Manualslib.com...
Page 73
Control Module, 852MN Kit – PF-110 Revision 0 54267 Control Module, 852MN Kit – PF-140 Revision 0 54268 Control Module, 852MN Kit – PF-50 Revision 1 & 2 54282 Control Module, 852MN Kit – PF-80 Revision 1 & 2 54283 Control Module, 852MN Kit –...
Page 74
REPAIR PARTS Figure 13.2: Heat Exchanger/Burner Assembly Repair Parts – PF-50, PF-80, PF-110 & PF-140 Downloaded from www.Manualslib.com manuals search engine...
Page 76
REPAIR PARTS Figure 13.3: General Repair Parts – PF-210 & PF-399 Downloaded from www.Manualslib.com manuals search engine...
Page 77
REPAIR PARTS Table 13.3: General Repair Parts – PF-210 & PF-399 Quantity Stock Description Required Code Panel, Jacket Front Door, with Ball Studs 54256 Lens for Jacket Front Door 54167 Display Module, Argus 852RC 54281 Gasket for Display Bracket 54153 Bracket for Display Module PF2007-1 Hex Nut, #6-32 with Lockwasher...
Page 78
REPAIR PARTS Figure 13.4: Heat Exchanger/Burner Assembly Repair Parts – PF-210 & PF-399 Downloaded from www.Manualslib.com manuals search engine...
Page 79
REPAIR PARTS Table 13.4: Heat Exchanger/Burner Assembly Repair Parts – PF-210 & PF-399 Quantity Stock Description Required Code Ignitor, with Gasket 54246 Sensor, with Gasket 54247 Premix Channel – PF-210 54249 Premix Channel – PF-399 54250 Gasket, Channel to Burner 54186 Burner –...
APPENDIX D. COMBUSTION TEST RECORD APPENDIX D. COMBUSTION TEST RECORD Peerless ® ® Combustion Test Record Contact: Company Name: Address: Phone Number: Fax Number: Email Address: Jobsite Data Job Name: Jobsite Address: Boiler Data Boiler Model: Boiler Serial No.: Manufacture Date:...
Page 91
Downloaded from www.Manualslib.com manuals search engine...
Page 92
® ® REV 2 Boilers PF-50 PF-80 PF-110 PF-140 PF-210 PF-399 I n s t a l l a t i o n , O p e r a t i o n & M a i n t e n a n c e...
Need help?
Do you have a question about the PF-50 and is the answer not in the manual?
Questions and answers