PeerlessBoilers PF-50 Installation, Operation & Maintenance Manual
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PeerlessBoilers PF-50 Installation, Operation & Maintenance Manual

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P
URE
Gas
Boilers
As an ENERGY STAR
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
™
IRE
®
Partner, PB Heat, LLC has determined that this

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Summary of Contents for PeerlessBoilers PF-50

  • Page 1 ™ Boilers 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...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 7. ELECTRICAL CONNECTIONS A. INSTALLATION SEQUENCE ... . .1 A. GENERAL ......26 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 3. Where required by the authority having A. GENERAL jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for 1. P ™ boilers are supplied completely assembled Automatically Fired Boilers, ANSI/ASME CSD-1. as packaged boilers. The package should be inspected for damage upon receipt and any damage to the unit should be reported to the shipping company and **Please read if installing in Massachusetts**...

  • Page 5: Accessibility Clearances

    PREINSTALLATION C. ACCESSIBILITY CLEARANCES E. PLANNING THE LAYOUT 1. The P boiler is certified for closet installations 1. Prepare sketches and notes showing the layout of the with zero clearance to combustible construction. In boiler installation to minimize the possibility of addition, it is design certified for use on combustible interferences with new or existing equipment, piping, floors.

  • Page 6: Boiler Set-Up

    BOILER SET-UP 2. BOILER SET-UP 4. The mounting bracket has (4) holes on 16" centers. A. GENERAL This is intended to give the installer the ability to mount the bracket on two wall studs spaced at this 1. P boilers are intended for installation in an interval.

  • Page 7: Venting & Air Inlet Piping

    VENTING & AIR INLET PIPING 3. VENTING & AIR INLET PIPING A. GENERAL WARNING 1. Install the P Boiler venting system in accordance Use of cellular core pipe for any exhaust vent with these instructions and with the National Fuel Gas component is prohibited.
  • Page 8 VENTING & AIR INLET PIPING • Provide a minimum of 4 feet (1.22 m) horizontal clearance from electrical meters, gas meters, gas regulators, and relief equipment. In no case shall the exit terminal be above or below the aforementioned equipment unless the 4 foot horizontal distance is maintained.
  • Page 9 VENTING & AIR INLET PIPING Figure 3.3: Exhaust and Air Inlet Pipe Penetration Figure 3.5: Optional Stainless Steel Vent Kit at Different Elevations Installation Figure 3.4: Exhaust and Air Inlet Pipe Penetration Figure 3.6: Optional Concentric PVC Vent Kit at the Same Elevation Installation...

  • Page 10: Exhaust Vent/Air Intake Pipe Sizing

    12" above the air inlet pipe. D. EXHAUST VENT/AIR INTAKE PIPE SIZING 1. P boiler models PF-50, PF-80, PF-110 and PF- 140 are to be installed using 3" Schedule 40 or 80 PVC or CPVC piping using the provided vent adapter.

  • Page 11: Exhaust Tapping For Vent Sample

    VENTING & AIR INLET PIPING 3. Both connections are clearly marked. To do this a hole must be drilled in the vent pipe. 4. Remove all burrs and debris from the joints and fittings. a. Drill a 21/64" diameter hole in the exhaust vent pipe from 6”...

  • Page 12: Water Piping And Controls

    Unlike automotive antifreeze, solutions for hydronic applications contain corrosion inhibitors that will Water Solution protect system components from premature failure Model GPM (LPM) GPM (LPM) due to corrosion. 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)
  • Page 13 WATER PIPING AND CONTROLS Figure 4.1: Piping Symbol Key 5. Flow Control Valve: Flow control valves such as the TACO Flo-Chek or Bell & Gossett Flo-Control™ are used to prevent gravity circulation by incorporating a check valve with a weighted disc. 6.
  • Page 14 Do not operate this appliance without installing the pressure relief valve supplied with the boiler or one Model Btu/hr (kW) Btu/hr (kW) with sufficient relieving capacity in accordance with PF-50 50,000 (14.7) 40,000 (11.7) the ASME Rating Plate on the boiler heat exchanger. PF-80 80,000 (23.4) 64,000 (18.8)

  • Page 15: System Piping

    Various System Temperature Rise Values 1. Figure 4.4 shows a single boiler with multiple heating Flow Rate & Pressure Drop zones. In this case, the DHW zone is piped in parallel PF-50 PF-80 PF-110 PF-140 to the heating zones on the primary loop.
  • Page 16 WATER PIPING AND CONTROLS...
  • Page 17 WATER PIPING AND CONTROLS...
  • Page 18 WATER PIPING AND CONTROLS...
  • Page 19 WATER PIPING AND CONTROLS...
  • Page 20 WATER PIPING AND CONTROLS...

  • Page 21: Special Applications

    WATER PIPING AND CONTROLS 6. Due to increased flow rate and fluid viscosity, the 12. Check with the local water supplier for chemical circulator head requirement will increase. Contact the properties of the water. pump manufacturer to correctly size the circulator for 13.
  • Page 22 WATER PIPING AND CONTROLS PEERLESS PUREFIRE BOILER Figure 4.9: Boiler in conjunction with a Chilled Water System PEERLESS PUREFIRE Figure 4.10: Boiler Connected to a Heating Coil in a Forced Air System...

  • Page 23: Fuel Piping

    1. All fuel piping to the P boiler is to be in Model /hr) /hr) 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)

  • Page 24: Gas Supply Piping - Operation

    FUEL PIPING 6. Check all gas piping for leaks prior to placing the CAUTION boiler in operation. Use an approved gas detector, non-corrosive lead detection fluid, or other leak Do not subject the gas valve to more that 1/2 psi detection method.

  • Page 25: Main Gas Valve - Operation

    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.

  • Page 26: Condensate Drain Piping

    CONDENSATE DRAIN PIPING 6. CONDENSATE DRAIN PIPING 2. Condensate Collector Container: The condensate A. GENERAL collector container is a transparent container in the base of the boiler near the back. This container 1. The disposal of all condensate into public sewage collects the condensate and acts as a part of a trap to systems is to be in accordance with local codes and prevent combustion gases from escaping.

  • Page 27: Condensate Drain Pipe Installation

    CONDENSATE DRAIN PIPING 2. Be sure that the piping slopes away from the boiler E. CONDENSATE DRAIN PIPE INSTALLATION with a pitch of 1/4" per foot of pipe. 1. Connect a 3/4" schedule 40 PVC Tee to the outlet of 3.

  • Page 28: Electrical Connections

    ELECTRICAL CONNECTIONS 7. ELECTRICAL CONNECTIONS 5. Figure 7.3 also shows the wiring of the service switch A. GENERAL and the convenience outlet. Note that the convenience outlet is powered even when the service This appliance is to be wired in accordance with local switch is off.
  • Page 29 ELECTRICAL CONNECTIONS Figure 7.3: Line Voltage Customer Connections 7. Convenience Outlet: The convenience outlet is 10. Ignition Electrode: This electrode is located on the left provided for a condensate pump during operation. It side of the heat exchanger front plate. A 10,000 volt is not switched with the service switch to allow its use charge is initiated by the control to provide a spark for for lighting during maintenance.
  • Page 30 ELECTRICAL CONNECTIONS...

  • Page 31: Boiler Control: Internal Wiring & Operation

    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 32 BOILER CONTROL: INTERNAL WIRING & OPERATION 3. Pump Modes: The P boiler allows four different pump modes to give the installer flexibility in piping arrangements. Table 8.3: Pump Modes Pump Detail Display Text Brief Description Page Mode Section The General pump is on when the CH pump runs on CH demand. DHW or CH &...

  • Page 33: Ignition Sequence

    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 34 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.

  • Page 35: Boiler Control

    BOILER CONTROL: INTERNAL WIRING & OPERATION Figure 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 36 BOILER CONTROL: INTERNAL WIRING & OPERATION Pump Mode 1 – General Pump with 3-Way Valve: Pump Mode 2 – Manifold with Pump for DHW: Mode 1 allows the boiler to be installed with a three Mode 2 is intended for use with primary/secondary way valve which diverts water from the boiler supply piping or other hydraulic separation.
  • Page 37 BOILER CONTROL: INTERNAL WIRING & OPERATION Figure 8.7: Pump Mode = 2, DHW Mode = 1 or 2 2. Installation Location & Vent Material: The control will operate the burner at minimum The P boiler allows the installer to input the power until the both the supply and return boiler installation location and the vent material used.

  • Page 38: Central Heating

    BOILER CONTROL: INTERNAL WIRING & OPERATION 3. Outdoor Reset Operation D. CENTRAL HEATING To maximize fuel savings, P boilers are factory equipped for outdoor reset operation. The following 1. Heating Modes: describes the operating principal of this feature. Table 8.1 provides an overview of the central heating (CH) modes.
  • Page 39 BOILER CONTROL: INTERNAL WIRING & OPERATION The design point is shown for an outdoor design This value will continue to increase by the Temp temperature of 0°F and a boiler design supply value if the demand continues through temperature of 160°F. The mild weather point is consecutive Time periods.

  • Page 40: Domestic Hot Water (Dhw)

    BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.7: 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...

  • Page 41: Service Notification

    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.

  • Page 42: System Test

    BOILER CONTROL: INTERNAL WIRING & OPERATION blower runs during the ignition period. The high G. SYSTEM TEST power fan speed corresponds to the maximum input The System Test feature allows the installer or service to the boiler. person to make the control operate at Low Power, Ignition Power, or Maximum Power.

  • Page 43: Start-Up Procedure

    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 44 START-UP PROCEDURE e. If the values in either of these instances falls outside the parameters listed in Table 4.5, turn off the boiler and contact your PB Heat representative. f. Be sure to set the System Test mode to Off so that the boiler will modulate correctly in accordance with the load.

  • Page 45: Lighting & Operating Procedures

    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.

  • Page 46: 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 47 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 48 TROUBLESHOOTING Table 10.2: Control Board Blocking Error Codes (manual reset): “E” 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 49 TROUBLESHOOTING Table 10.2 (cont’d): Control Board Blocking Error Codes (manual reset): “E” Internal Error Display Error Description Corrective Action CODE 1. Check flame sensor to be sure there is no short to ground. FALSE FLAME DETECTED Flame signal detected 10 sec. 2.

  • Page 50: Maintenance

    MAINTENANCE 11. MAINTENANCE e. If the valve continues to leak, it must be replaced A. GENERAL (WITH BOILER IN USE) before the boiler is returned to operation. General boiler observation can be performed by the owner. If any potential problems are found, a qualified f.

  • Page 51: Combustion Chamber Coil Cleaning Instructions

    MAINTENANCE f. Clean tank and hose with water and inspect the 1. Shut the boiler down and access the heat exchanger rear tank for sediment in the lower connection using the following steps: port. The rear tank can be removed for cleaning a.
  • Page 52 MAINTENANCE f. Turn the power to the P on. Observe the 6. Inspect exhaust vent and air intake vents for proper UREFIRE display module to assure proper operation. support and joint integrity. Repair as necessary. Refer to Section 5, VENTING. g.

  • Page 53: Boiler Dimensions & Ratings

    Dimensions Heating Net I=B=R Boiler AFUE (MBH) (inches) Capacity Ratings Model (MBH) (MBH) “A” “B” PF-50 95.0% 13 1/2 3 3/4 PF-80 95.2% 13 1/2 4 7/8 PF-110 95.8% 7 5/8 PF-140 95.3% 10 1/2 Table 12.2: Combustion Air Fan Speeds SERIES PEERLESS ®...

  • Page 54: Repair Parts

    REPAIR PARTS 13. REPAIR PARTS Repair parts are available from your installer or by contacting PB Heat, LLC, 131 S. Church St., Bally, PA 19503. Note: Remember to include boiler model number and serial number when ordering parts.
  • Page 55 Screw, #10x1/2" LG Hex Hd 99992 Coupling, 1"NPT SS 5424 Nipple, 1" NPT x 6" LG SS 5423 Jacket Side Panels - PF-50, PF-80 54173 Jacket Side Panels - PF-110, PF-140 54192 Bulk Head Fitting for Condensate Hose 54140 Gasket for Bulk Head Fitting...
  • Page 56 REPAIR PARTS...
  • Page 57 Swirl Plate, PF-80, Black 54143 Swirl Plate, PF-110, White 54145 Swirl Plate, PF-140, Red 54146 Gas Valve, PF-50, includes Item #57 54178 Gas Valve, PF-80, includes Item #57 54179 Gas Valve, PF-110, includes Item #57 54180 Gas Valve, PF-140, includes Item #57...
  • Page 58 REPAIR PARTS...
  • Page 59 REPAIR PARTS Quantity Description Stock Code Required Tank, Condensate Neutralizer 54121 – Neutralizer, Bag 54159 Cap, Neutralizer Tank 5430 Clamp, 3/4" ID Tubing 54138 Pre-formed 3/4" ID Tubing, Tank to Jacket, with (2) clamps 54172 Tubing, 3/4" ID x 1/8" Wall PVC, 19.5" LG 19.5"...

  • Page 60: Appendix A. Status Screens

    APPENDIX A. STATUS SCREENS APPENDIX A. STATUS SCREENS...
  • Page 61 APPENDIX A. STATUS SCREENS...
  • Page 62 APPENDIX A. STATUS SCREENS...

  • Page 63: Appendix B. User Menu

    APPENDIX B. USER MENU APPENDIX B. USER MENU...

  • Page 64: Appendix C. Installer Menu

    APPENDIX C. INSTALLER MENU APPENDIX C. INSTALLER MENU...
  • Page 65 APPENDIX C. INSTALLER MENU...
  • Page 66 APPENDIX C. INSTALLER MENU...

  • Page 67: Appendix D. Combustion Test Record

    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: Startup Date: Gas Pressure Intake Gas Pressure...
  • Page 68 NOTES...
  • Page 69 NOTES...
  • Page 70 ™ Boilers 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 be affixed near the boiler for future reference.

This manual is also suitable for:

Pf-80Pf-110Pf-140

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