PEERLESS PUREFIRE PFW-399 Installation, Operation & Maintenance Manual
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PEERLESS PUREFIRE PFW-399 Installation, Operation & Maintenance Manual

Gas hot water supply boilers pfw series
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URE
Gas
Hot Water Supply Boilers
PFW-200 PFW-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 &
M a i n t e n a n c e
M a n u a l
F
®
PFW
IRE
™
S
ERIES

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  • Page 1 ® ® ™ ERIES Hot Water Supply Boilers PFW-200 PFW-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 &...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 7. ELECTRICAL CONNECTIONS A. INSTALLATION SEQUENCE ....1 A. GENERAL ......29 B.

  • Page 3: Using This Manual

    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.

  • Page 4: Preinstallation

    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. PureFire boilers are supplied completely assembled as from the Massachusetts code: packaged boilers. The package should be inspected ·...

  • Page 5: Accessibility Clearances

    PREINSTALLATION 3. Required Combustion Air Volume: The total required C. ACCESSIBILITY CLEARANCES volume of indoor air is to be the sum of the required volumes for all appliances located within the space. 1. The PureFire boiler is certified for closet installations Rooms communicating directly with the space in with zero clearance to combustible construction.
  • Page 6 PREINSTALLATION 4. Indoor Air Opening Size and Location: Openings 5. Outdoor Combustion Air: Outdoor combustion air is connecting indoor spaces shall be sized and located as to be provided through one or two permanent follows: openings. The minimum dimension of these air openings is 3 inches (76 mm).
  • Page 7 PREINSTALLATION ii. Where communicating with the outdoors through 6. Combination Indoor and Outdoor Combustion Air: If horizontal ducts, each opening shall have a the required volume of indoor air exceeds the minimum free area of 1 in per 2000 Btu/hr (22 available indoor air volume, outdoor air openings or per 2000 W) of total rated input for all ducts may be used to supplement the available indoor...

  • Page 8: Planning The Layout

    PREINSTALLATION i. The interlock shall prevent the main burner E. PLANNING THE LAYOUT from igniting if the damper fails to open during burner startup. 1. Prepare sketches and notes showing the layout of the boiler installation to minimize the possibility of ii.

  • Page 9: Boiler Set-Up

    BOILER SET-UP 2. BOILER SET-UP A. GENERAL B. FLOOR STANDING INSTALLATION 1. PureFire boilers are intended for installation in an area 1. For floor standing installations, use the leveling feet to with a floor drain or in a suitable drain pan. Do not assure that the boiler is completely level.

  • Page 10: Venting & Air Inlet Piping

    VENTING & AIR INLET PIPING 3. VENTING & AIR INLET PIPING Table 3.1: Approved Materials for Exhaust Vent Pipe A. GENERAL Conforming to 1. Install the PureFire boiler venting system in Description Material Standard accordance with these instructions and with the PVC (Sch 40 or 80) ANSI/ASTM D1785 National Fuel Gas Code, ANSI Z223.1/NFPA 54,...
  • Page 11 VENTING & AIR INLET PIPING d. If the vent pipe and air inlet pipe terminations 7. Sidewall Venting Configuration: penetrate the wall at the same level the minimum a. See Figure 3.2 for an illustration of clearances for distance between them is 8" center-to-center. location of exit terminals of direct-vent venting systems.
  • Page 12 VENTING & AIR INLET PIPING Figure 3.5: Optional Concentric Vent Kit Figure 3.3: Standard Exhaust & Air Inlet Pipe Terminations Installation Figure 3.4: Offset Exhaust & Air Inlet Terminations Figure 3.6: Exhaust & Air Inlet on Opposite Walls...
  • Page 13 VENTING & AIR INLET PIPING Figure 3.7: Sidewall Exhaust with Indoor Air b. Figure 3.3 and 3.4 show approved sidewall venting configurations using the standard fittings supplied. Figure 3.8: Standard Vertical Vent Installation c. Figure 3.4 is only approved for locations in which the outdoor temperature is above -5°F (-21°C) in •...
  • Page 14 VENTING & AIR INLET PIPING Figure 3.9: Concentric Vertical Vent Installation Figure 3.11: Venting Through A Chimney Using Indoor Air Figure 3.10: Venting Through A Chimney Using Figure 3.12: Venting Through A Chimney Using Outdoor Air Sidewall Outside Air...

  • Page 15: Exhaust Vent/Air Intake Pipe Sizing

    VENTING & AIR INLET PIPING D. EXHAUST VENT/AIR INTAKE PIPE SIZING E. EXHAUST VENT/AIR INTAKE INSTALLATION 1. PureFire boiler model PFW-200 is to be installed using 3” Schedule 40 or 80 PVC or CPVC piping using the 1. Figure 12.1 shows the exhaust connection on top of provided vent adapter.

  • Page 16: Exhaust Tapping For Vent Sample

    VENTING & AIR INLET PIPING e. Table 3.5 shows optional concentric air 1. Seal any unused openings in the common venting intake/exhaust terminations that are available system. separately from your PB Heat distributor for use Sceller toute ouverture du système d’évacuation with PureFire boilers commun non utilisée.

  • Page 17: Water Piping And Controls

    WATER PIPING AND CONTROLS 4. WATER PIPING & CONTROLS 4. Table 4.2 provides the water volume of the heat A. GENERAL exchanger including the supply and return pipes that are attached at the factory. 1. Size water supply and return piping in accordance with system requirements.
  • Page 18 WATER PIPING AND CONTROLS 4. Back Flow Preventer: A back flow preventer (check Table 4.3: Boiler Inputs and Outputs valve) is required by some jurisdictions to prevent water PureFire Max. Boiler Input Gross Output in the system from backing up into the city water supply. Model Btu/hr (kW) Btu/hr (kW)

  • Page 19: System Piping

    WATER PIPING AND CONTROLS c. The boiler pressure drop for various flow rates can D. SYSTEM PIPING be determined using Figure 4.2, the PureFire Boiler Pump Sizing Graph. 1. Figure 4.3 shows piping for a single boiler with a single storage tank. When using the factory specified d.
  • Page 20 WATER PIPING AND CONTROLS Figure 4.3: Schematic Piping - One Boiler with a Single Storage Tank...
  • Page 21 WATER PIPING AND CONTROLS Figure 4.4: Schematic Piping - One Boiler with Multiple Storage Tanks...
  • Page 22 WATER PIPING AND CONTROLS Figure 4.5: Schematic Piping - Two Boilers with a Single Storage Tank...
  • Page 23 WATER PIPING AND CONTROLS Figure 4.6: Schematic Piping - Two Boilers with Multiple Storage Tanks...
  • Page 24 WATER PIPING AND CONTROLS Figure 4.7: Schematic Piping - Alternate Piping with Patented Anti-Scale System...
  • Page 25 WATER PIPING AND CONTROLS Figure 4.8: Schematic Piping - One Boiler with a Single Storage Tank & Plate Heat Exchanger...

  • Page 26: Fuel Piping

    FUEL PIPING 5. FUEL PIPING 3. Install a ground joint union between the sediment trap A. GENERAL and the boiler to allow service to the appliance. 1. All fuel piping to the PureFire boiler is to be in 4. Install a service valve as shown in Figure 5.1 to allow accordance with local codes.

  • Page 27: Gas Supply Piping - Operation

    FUEL PIPING 6. Check all gas piping for leaks prior to placing the 3. To check the gas supply pressure to on the gas valve: boiler in operation. Use an approved gas detector, a. Turn off the power at the service switch. non-corrosive leak detection fluid, or other leak b.
  • Page 28 FUEL PIPING b. Turning the throttle screw clockwise will decrease 2. Refer to Section 3, Venting and Air Intake for the gas flow (decreasing CO ) and turning it information on obtaining vent samples from this boiler. counterclockwise will increase the gas flow rate (increasing CO ).

  • Page 29: Condensate Drain Piping

    CONDENSATE DRAIN PIPING 6. CONDENSATE DRAIN PIPING 1. Condensate Drain Hoses: The PFW-200 and PFW A. GENERAL 399 have a drain hose attached directly to the combustion chamber and one connected to a 1. The disposal of all condensate into public sewage bulkhead connection on top of the boiler.

  • Page 30: Condensate Drain Pipe Material

    CONDENSATE DRAIN PIPING 4. Condensate Neutralizer Container: The condensate E. CONDENSATE DRAIN PIPE INSTALLATION neutralizer is an additional semi-transparent container near the front of the boiler. Fill this container with the 1. Connect a 3/4" schedule 40 PVC Tee to the outlet of condensate neutralizer provided.

  • Page 31: Electrical Connections

    ELECTRICAL CONNECTIONS 7. ELECTRICAL CONNECTIONS A. GENERAL CAUTION This appliance is to be wired in accordance with local DO NOT Apply line voltage power to terminals 9 & 10. codes and regulations as defined by the Authority having If a jumper is included in the low water cutoff device jurisdiction.
  • Page 32 ELECTRICAL CONNECTIONS Figure 7.2: Customer Connections for PFW-200 & PFW-399 Boilers 7. Convenience Outlet: The convenience outlet is Be sure to only use a 12 kΩ thermistor for this boiler. provided for a condensate pump during operation. It 3. Limit Switch: This component is located on the left is not switched with the service switch to allow its use header and is differentiated from the sensors by a red during maintenance.
  • Page 33 ELECTRICAL CONNECTIONS Figure 7.3: Internal Wiring Schematic for PFW-200 & PFW-399 Boilers...

  • Page 34: Boiler Control: Internal Wiring & Operation

    BOILER CONTROL: INTERNAL WIRING & OPERATION 8. BOILER CONTROL: INTERNAL WIRING & OPERATION sequence in detail. The boiler control provides dual A. IGNITION SEQUENCE sensing of the flame to maximize the reliability. The control senses the burner flame with both the flame Figure 8.1 shows the ignition sequence for the PureFire sensor and the ignition electrode.
  • Page 35 BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.1: Ignition Sequence (continued) Period Demand Status User Interface Display A DHW demand has no influence in the Safety On/Off period. The Safety On/Off step will continue even if the demand has Safety ended.

  • Page 36: User Menu

    BOILER CONTROL: INTERNAL WIRING & OPERATION B. USER MENU To access the User Menu, simply press the Menu key on the display interface. Figure 8.2 shows the menu that will appear: Figure 8.7: Circulator Status 2. USER MENU – SETTINGS a.

  • Page 37: Installer Menu

    BOILER CONTROL: INTERNAL WIRING & OPERATION c. Time & Date: C. INSTALLER MENU Þ After setting the target setpoints, press the to view the current time and date. To access the Installer Menu, press the Menu and Select key on the display interface simultaneously and hold them until the INSTALLER MENU is displayed.
  • Page 38 BOILER CONTROL: INTERNAL WIRING & OPERATION e. Boiler Run Time: S T A ▲ Þ Once again, pressing the key advances to the F a n S p e e d next status screen. Screen #8 (Figure 8.24) displays the total run time of the control which I g n i t i o n 4 6 5 0 R P M includes the total of all time that the control is...
  • Page 39 BOILER CONTROL: INTERNAL WIRING & OPERATION When error #255 is displayed (Figure 8.32), this indicates that no errors occurred and the remainder of the errors displayed will show this message. Pressing the Menu/Return exits the control history screen. Figure 8.28: Blocking Error – History Screen Error #255 g.
  • Page 40 BOILER CONTROL: INTERNAL WIRING & OPERATION b. DHW Pump Post Purge: Table 8.6 shows the vent temperature limit based After the storage tank is satisfied and the on vent material and installation location (due to combustion blower post-purge stops, the control National Codes).
  • Page 41 BOILER CONTROL: INTERNAL WIRING & OPERATION e. Additional Safety Functions: • The installer can choose between a low water cut-off (LWCO) or a flow switch to prevent firing of the boiler without sufficient water in the system. Figure 8.39 shows the selection screen for Additional Safety Functions.
  • Page 42 BOILER CONTROL: INTERNAL WIRING & OPERATION f. Finally, to set a fixed date: 5. Installer Menu – Default Settings a. The boiler allows a service person to reset all of • Press the Select key while viewing Screen #5, the boiler settings to the default settings that were shown in Figure 8.46, and press the t and s set up at the factory.
  • Page 43 BOILER CONTROL: INTERNAL WIRING & OPERATION Figure 8.52: Interconnection of Cascade Link Wires Table 8.11: Boiler Address Selection Range Stand-alone Managing Dependent Parameter (Default) Boiler Boilers Boiler Address e. Cascade Operation: When a call for hot water is present, either from a thermostat or a by sensing low tank temperature, the master boiler chooses a lead boiler based on the Cascade Rotation Interval (See Below).
  • Page 44 BOILER CONTROL: INTERNAL WIRING & OPERATION • With all the boilers operating, the system will Table 8.13 shows the range of values for these modulate the gas input to each of the boilers parameters. to follow the system load. The control uses the Table 8.13: Calculated Setpoint Max Offset Stop Delay Time and the Stop Boiler Up/Down...

  • Page 45: Start-Up Procedure

    START-UP PROCEDURE 9. START-UP PROCEDURE A. GENERAL 1. Confirm that all water, gas and electricity are turned off. 2. Verify that the water piping, venting & air intake piping, gas piping, electrical wiring and electrical Figure 9.1: Status Display DHW Disabled components are installed in accordance with the manufacturer’s instructions.
  • Page 46 START-UP PROCEDURE e. Manually set the boiler to Low Power by entering the System Test Mode. See Appendix C, Installer Menu. • Verify that the fan speed indicated is within 100 rpm of the Low Power fan speed listed in Table 12.2.

  • Page 47: Lighting & Operating Procedures

    START-UP PROCEDURE E. LIGHTING & OPERATING PROCEDURES Figure 9.4: Lighting & Operating Instructions...

  • Page 48: Troubleshooting

    TROUBLESHOOTING 10. TROUBLESHOOTING A. BLOCKING ERRORS WARNING 1. When a Blocking Error occurs the controller will Do not use this appliance if any part has been under display a message and an “E” error code on the water. Improper or dangerous operation may result. display module.
  • Page 49 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 50 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 51 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...

  • Page 52: Warning Errors

    TROUBLESHOOTING c. This will also occur if the wires are not properly C. WARNING ERRORS connected. The PureFire boiler control will display a blinking d. If there is a short at the DHW sensor terminals screen under several conditions. Several of these and the DHW mode is set to Mode 1, the DHW conditions provide the error information directly on system will not operate.

  • Page 53: Maintenance

    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 (982°C), they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans.

  • Page 54: Weekly (With Boiler In Use)

    MAINTENANCE 6. Remove the top/front jacket panel and inspect for B. WEEKLY (WITH BOILER IN USE) any foreign debris that may have entered through air Flush float-type low-water cut-off (if used) to remove intake vent. sediment from the float bowl as stated in the manufacturer’s instructions.

  • Page 55: Instructions

    MAINTENANCE 5. Reinstall the burner plate assembly using the E. COMBUSTION CHAMBER COIL following steps: INSPECTION AND CLEANING a. Inspect the inside of the heat exchanger for dirt INSTRUCTIONS and debris. NOTICE b. Install the burner plate assembly and replace the six 10 mm nuts.

  • Page 56: Boiler Dimensions & Ratings

    BOILER DIMENSIONS & RATINGS 12. BOILER DIMENSIONS & RATINGS Figure 12.1: Dimensional Drawing Table 12.1: Boiler Dimensions PUREFIRE SERIES DIMENSIONS Boiler “A” “B” “C” “D” “E” “F” “G” “H” “J” “K” “L ” Model 16-9/16" 1" 3" 1-3/4" 4-1/2" 3" 6-1/2"...
  • Page 57 BOILER DIMENSIONS & RATINGS Table 12.3: Combustion Air Fan Speeds PUREFIRE SERIES COMBUSTION AIR FAN SPEEDS Fan Speed Boiler Input Rate Model (MBH/kW) Low Power Ignition High Power PFW-200 199/58.3 1350 4650 5940 PFW-399 399/116.9 1710 5790 7740 Table 12.4: PureFire Main Control Specifications PUREFIRE SERIES MAIN CONTROL SPECIFICATIONS 120 VAC Nominal (102-132 VAC) Power Supply...

  • Page 58: Repair Parts

    REPAIR PARTS 13. REPAIR PARTS 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...
  • Page 59 REPAIR PARTS Table 13.1: General Repair Parts – PFW200 & PFW399 Quantity Description Stock Code PFW-200 PFW-399 Jacket Front Panel with Ball Studs (Provide Wiring Diagram Form No. when Ordering) 54256 Smoked Control Lens 54167 Display Module - PFW Boilers 54650 Display Bracket Gasket 54153...
  • Page 60 REPAIR PARTS Figure 13.2: Heat Exchanger/Burner Assembly Repair Parts...
  • Page 61 REPAIR PARTS Table 13.2: Heat Exchanger/Burner Assembly Repair Parts Quantity Description Stock Code PFW-200 PFW-399 Ignitor with Gasket 54246 Sensor with Gasket 54247 M4 x 8 mm Screw M5.5 x 14 mm Screw Fine Thread (0.5) Premix Channel - PFW-200 54249 Premix Channel - PFW-399 54250...
  • Page 62 REPAIR PARTS Figure 13.3: Concentric Horizontal Vent Termination Figure 13.4: Concentric Vertical Vent Termination Figure 13.5: Polypropylene Adapter Table 13.3: Optional Exhaust Vent Termination Kits Quantity Description Stock Code PFW-200 PFW-399 – 3" Concentric Sidewall Termination Kit (PolyPro 3PPS-HK) • 54498 4"...

  • Page 63: Appendix A. Status Screens

    APPENDIX A. STATUS SCREENS APPENDIX A. STATUS SCREENS...
  • Page 64 APPENDIX A. STATUS SCREENS...
  • Page 65 APPENDIX A. STATUS SCREENS...

  • Page 66: Appendix B. User Menu

    APPENDIX B. USER MENU APPENDIX B. USER MENU...
  • Page 67 APPENDIX B. USER MENU...

  • Page 68: Appendix C. Installer Menu

    APPENDIX C. INSTALLER MENU APPENDIX C. INSTALLER MENU...
  • Page 69 APPENDIX C. INSTALLER MENU...
  • Page 70 APPENDIX C. INSTALLER MENU...
  • Page 71 APPENDIX C. INSTALLER MENU...
  • Page 72 APPENDIX C. INSTALLER MENU...
  • Page 73 APPENDIX C. INSTALLER MENU...

  • Page 74: Appendix D. Combustion Test Record

    APPENDIX D. COMBUSTION TEST RECORD APPENDIX D. COMBUSTION TEST RECORD PureFire 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: Startup Date: Gas Pressure Static Inlet Gas Pressure Inlet Gas Pressure...
  • Page 75 NOTES...
  • Page 76 ® ® ™ ERIES Hot Water Supply Boilers PFW-200 PFW-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 M a n u a l TO T H E I N S TA L L E R : This manual is the property of the owner and must...

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