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 ·...
PREINSTALLATION which the appliances are installed and through C. ACCESSIBILITY CLEARANCES combustion air openings sized as indicated in Subsection 3 are considered part of the required 1. The P ® boiler is certified for closet installations volume. The required volume of indoor air is to be with zero clearance to combustible construction.
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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).
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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...
PREINSTALLATION b. Motorized dampers shall be interlocked with the E. PLANNING THE LAYOUTS equipment so that they are proven in the full open position prior to ignition and during operation of 1. Prepare sketches and notes showing the layout of the the main burner.
BOILER SET-UP 2. BOILER SET-UP A. GENERAL B. WALL MOUNTING The PFC-460 boiler can be wall mounted by using the 1. P ® boilers are intended for installation in an optional stand (91400). area with a floor drain or in a suitable drain pan. Do not install any boiler where leaks or relief valve 1.
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 P ® boiler venting system in accordance Description Material Standard with these instructions and with the National Fuel Gas PVC (Sch 40 or 80) ANSI/ASTM D1785 Code, ANSI Z223.1/NFPA 54, CAN/CGA B149, and/or...
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VENTING & AIR INLET PIPING 6. Air Intake Pipe Location – Sidewall Venting: 7. Sidewall Venting Configuration: a. Provide 1 foot (30 cm) clearance from the bottom a. See Figure 3.2 for an illustration of clearances for of the air intake pipe to the level of maximum location of exit terminals of direct-vent venting snow accumulation.
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VENTING & AIR INLET PIPING b. Figures 3.3 through 3.6 show approved sidewall venting configurations using the standard fittings supplied. c. Figure 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.
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VENTING & AIR INLET PIPING 8. Vertical Venting Configuration: a. Figure 3.8 shows the approved venting configuration for vertical venting using the standard fittings supplied. Figure 3.6: Sidewall Exhaust with Indoor Air Figure 3.8: Standard Vertical Vent Installation b. Locate the air intake pipe inlet 12" above the expected snow accumulation on the roof surface or 24"...
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VENTING & AIR INLET PIPING Figure 3.9: Concentric Vertical Vent Installation Figure 3.11: Venting Through a Chimney Using Sidewall Outside Air Figure 3.10: Venting Through a Chimney Using Figure 3.12: Venting with a Chimney Using Inside Air Outside Air...
VENTING & AIR INLET PIPING D. EXHAUST VENT/AIR INTAKE PIPE SIZING E. EXHAUST VENT/AIR INTAKE INSTALLATION 1. Table 3.2 shows the Exhaust Vent/Air Intake Size for WARNING ® PFC-460 boilers. Table 3.2: Exhaust Vent/Air Intake Sizing Covering non-metallic exhaust venting material is prohibited and may result in severe personal injury, Boiler Model Exhaust Vent/Air Intake Size...
VENTING & AIR INLET PIPING e. Table 3.6 lists optional concentric air 2. Visually inspect the venting system for proper size and intake/exhaust terminations that are available horizontal pitch and determine there is no blockage or separately from your PB Heat, LLC distributor for restriction, leakage, corrosion and other deficiencies use with P ®...
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VENTING & AIR INLET PIPING 9. Any improper operation of the common venting system 10. When resizing any portion of the common venting should be corrected so that the installation conforms system, the common venting system should be resized with the National Fuel Gas Code, ANSI Z223.1/NFPA to approach minimum size as determined using the 54 or CAN/CGA B149 Installation Codes.
WATER PIPING AND CONTROLS 4. WATER PIPING & CONTROLS Table 4.2: Heat Exchanger Water Capacity A. GENERAL ® Total Water Capacity 1. Size water supply and return piping in accordance Gallons (Liters) Model with system requirements rather than the boiler PFC-460 2.60 (9.84) connections.
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WATER PIPING AND CONTROLS Figure 4.1: Piping Symbol Key 5. Flow Control Valve: Flow control valves such as the Pipe the discharge of the relief valve to within 12" of TACO Flo-Chek or Bell & Gossett Flo-Control™ are the floor and close to a floor drain. used to prevent gravity circulation by incorporating a CAUTION check valve with a weighted disc.
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WATER PIPING AND CONTROLS d. The boiler pressure drop for various flow rates can be determined using Figure 4.3, the P ® Boiler Circulator Sizing Graph. e. Table 4.4 provides the flow rate and pressure drop information that corresponds to various system temperature rise values (ΔT).
WATER PIPING AND CONTROLS Table 4.5: PFC-460 Circulator Selection Chart 5. In Figure 4.8 zone valves are used instead of zone (General Pump – Primary Secondary) circulators. Notice that the system is piped using reverse return piping to help balance the flow through Circulator Temp.
WATER PIPING AND CONTROLS 11. Use water that is low in mineral content and make SPECIAL APPLICATIONS sure that there are no petroleum products in the solution. 1. If the P ® boiler is used in conjunction with a a. Less than 50 ppm of calcium chilled medium system, pipe the chiller in a separate secondary loop.
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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...
FUEL PIPING 5. FUEL PIPING Table 5.2: Pipe Capacity - Natural Gas: A. GENERAL Maximum Capacity of pipe in cubic feet per hour (cubic meters 1. All fuel piping to the P ® boiler is to be in per hour) with a pressure drop of 0.3" of water (75 Pa). accordance with local codes.
FUEL PIPING 2. Install a sediment trap as shown in Figure 5.1. Be sure 2. Table 5.4 shows the maximum and minimum fuel gas to allow clearance from the floor or other horizontal supply pressure to be measured at the gas valve inlet surface for removal of the pipe cap.
FUEL PIPING 2. Refer to Section 3, Venting and Air Intake for E. MAIN GAS VALVE - OPERATION information on obtaining vent samples from this boiler. 1. Figure 5.2 is an illustration of the gas valve/venturi assembly for the PFC-460 boiler. a.
CONDENSATE DRAIN PIPING 6. CONDENSATE DRAIN PIPING 1. Condensate Drain Hoses: PFC-460 boilers have a A. GENERAL drain attached directly to the combustion chamber. To prevent debris from entering the heat exchanger, a 1. The disposal of all condensate into public sewage separate drain connection can be added to the vent systems is to be in accordance with local codes and system at the top bulkhead drain connection as shown...
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.
ELECTRICAL CONNECTIONS 7. ELECTRICAL CONNECTIONS a. Remove one of the nuts and leave the other fully A. GENERAL loosened in order to leave the display interface panel connected to the appliance. This appliance is to be wired in accordance with local codes and regulations as defined by the Authority having b.
ELECTRICAL CONNECTIONS 4. Note that the service switch does not disconnect 6. Service Switch: The service switch interrupts the power to the convenience outlet. power to the P ® boiler to allow service to be performed. C. ZONE CIRCULATOR WIRING 7.
BOILER CONTROL: OPERATION 8. BOILER CONTROL: 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.
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BOILER CONTROL: OPERATION 3. 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 and described in detail later in this section. Table 8.4: Control Features Feature Description...
BOILER CONTROL: OPERATION B. IGNITION SEQUENCE NOTICE Figure 8.1 shows the ignition sequence for the P ® ® The P PFC-460 utilizes a single control boiler control. Table 8.5 describes each step in the system. Treat the PFC-460 control as a managing sequence in detail.
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BOILER CONTROL: OPERATION Table 8.5: Ignition Sequence (cont’d) Period Demand Status Burner LCD 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: OPERATION A value of 50°F (-10°C) indicates an open sensor and NOTICE a value of 244°F(118°C) indicates a short. Since boilers installed in low temperature environments such Subsections C-E of this supplement are to be used in as a garage may experience vent temperatures below lieu of subsections C-I in the PF8248 I,O,&M 50°F, the control works as follows: instructions.
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BOILER CONTROL: OPERATION Table 8.8: DHW Tank Setpoint Range & Default NOTICE Minimum Maximum Default DHW Boiler Setpoint Setting is only available in DHW DHW Tank 50°F 158°F 120°F Mode 1 & 2. Setpoint 10°C 70°C 49°C b. DHW Boiler Setpoint: This value determines the d.
BOILER CONTROL: OPERATION a. Last Lockout Error: The last lock menu allows the user to view the reason for the last lockout. See Table 10.2 for a list of locking errors and the associated codes. Note that a value of #255 indicates that there are no lockout errors in the Figure 8.13: Status –...
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BOILER CONTROL: OPERATION d. Ignition Attempts: Screen #7 provides information about ignition attempts. Obviously, the total ignition attempts are the sum of the successful and failed attempts. Several ignition failures may occur during factory firetest and equipment commissioning. Figure 8.19: Status – Locking Errors However, if there are a large number of failed ignition attempt showing on this screen, contact your Peerless...
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BOILER CONTROL: OPERATION – Finally, once the return temperature increases to 9°F (5°C) above the chosen value, the burner is switched off and the pumps are deactivated. Table 8.12: Freeze Protection Range & Default Default Minimum Maximum Freeze Protection Starts at 50°F (10°C) 45°F (7°C) 56°F (13°C)
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BOILER CONTROL: OPERATION Table 8.16: Air Adjustment Ranges & Defaults Parameter Default Minimum Maximum Air Adjustment 0 rpm 0 rpm 540 rpm Min Fan Speed Air Adjustment 0 rpm 0 rpm 540 rpm Max Fan Speed j. Minimum Fan Speed: The minimum fan speed adjustment is intended to respond to potential Figure 8.25: Burner Settings –...
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BOILER CONTROL: OPERATION a. Setpoint Operation: When using a setpoint • Mode 1, Indoor Thermostat with Outdoor Reset: strategy, the boiler targets a fixed setpoint which is When operating in this mode, the control uses the set in the User Menu on the P ®...
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BOILER CONTROL: OPERATION e. Outdoor Reset: Since heating loads are typically g. Warm Weather Shutdown: If the boiler is set to lower when the outdoor temperature rises, operate in CH Mode 1 or 2, the P ® control is set by default to prevent the boiler from operating outdoor reset lets the installer reduce the boiler to satisfy a central heat demand if the outdoor target temperature as the outdoor temperature...
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BOILER CONTROL: OPERATION o. Boiler Min: The boiler will not target a temperature lower than what is chosen in this menu screen. The default for this is, “Off” since low temperatures will not affect the boiler. However, it may be useful in installations that require a minimum temperature to Figure 8.32: CH Settings –...
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BOILER CONTROL: OPERATION Table 8.24: Temperature Boost Ranges & Defaults Parameter Minimum Default Maximum Boost Temperature 0°F (0°C) 18°F (10°C) 36°F (20°C) Boost Time 1 minute 20 minutes 60 minutes Figure 8.38: CH Settings – Maximum CH Rate r. Anti-Cycling Time: This function allows the Table 8.27: Maximum CH Rate Range &...
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BOILER CONTROL: OPERATION When this mode is chosen, the DHW Boiler Temperature and the DHW Tank Temperature setpoint values are available on the User Menu. The control will modulate the burner input based on feedback from the boiler supply Figure 8.41: DHW Settings – Heat Dump temperature sensor.
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BOILER CONTROL: OPERATION If desired, the installer can select a specific date for the b. Pump For CH/DHW: Service Notification. Simply press the “Select” key • This function can be used to check the function when viewing the “Notification on:” date screen. Use of the CH and DHW circulating pump outputs.
BOILER CONTROL: OPERATION calculated based on the Calculated Setpoint • Determines which boiler operates first (lead) Max offset up. Similarly, if the system target is and when to bring on additional boilers. above its target a calculated negative offset based •...
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BOILER CONTROL: OPERATION • A DHW call results in the operation of the lead boiler and its general pump. The DHW pump is also energized. • Wiring for a typical circulator zone relay is shown in Figure 7.4. 4. Setting up Multiple Boiler Operation: a.
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BOILER CONTROL: OPERATION b. Before starting the Lead boiler, the Master control i. The Rotation Interval is the frequency at which the will first check to be sure that the System Master Boiler will change the Lead boiler in the temperature is lower than the System Setpoint + sequence.
START-UP PROCEDURE 9. START-UP PROCEDURE 3. Refer to Section 8, Boiler Control, to set up the A. GENERAL control for the desired operation. 1. Confirm that all water, gas and electricity are turned off. 4. Use the ignition sequence, Figure 8.1 to follow the light off and shutdown sequences and to assist in 2.
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START-UP PROCEDURE b. Polypropylene vent systems from Centrotherm or • Verify that the fan speed indicated is within Duravent should include a sample port fitting 100 rpm of the Low Power fan speed listed in connected to the exhaust outlet port of the boiler. Table 12.3.
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. HARDWARE ERROR- NO COMM MAIN WARNING BOARD Do not use this appliance if any part has been under If the display shows “NO COMM MAIN BOARD”, water. Improper or dangerous operation may result. Contact your PB Heat representative or PB Heat Contact a qualified service technician immediately to Technical Support.
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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...
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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"...
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TROUBLESHOOTING Table 10.2 (cont’d): Control Board Locking Error Codes (manual reset): “A” Internal Error Display Error Description Corrective Action CODE INTERNAL ERROR GAS Gas Valve Relay See Note** VALVE RELAY Problems. INTERNAL ERROR SAFE- Safety Relay Problems. See Note** TY RELAY INTERNAL SOFTWARE Internal Software Error.
TROUBLESHOOTING 3. Flue Sensor Error: E. WARNING ERRORS a. If the control senses that the flue temperature does The P ® boiler control will display a blinking screen not rise to above 50°F after ignition, and either the under several conditions. Several of these conditions provide supply water temperature rises above 120°F or the the error information directly on the screen.
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TROUBLESHOOTING Table 10.3: Control Board Warning Error Codes “W” Error Error Display Corrective Action CODE Description 1) Check to see if the Outdoor Sensor is connect- 2) Check wiring connectons to outdoor sensor. Outdoor Sensor 3) Remove wires from terminals #3 and #4 on #W00 Open the boiler and check the resistance between...
TROUBLESHOOTING DELAYED IGNITION (HARD LIGHT-OFF) There are several factors that may cause a delayed ignition in the PureFire boiler due to a pressure pulse at light-off. Table 10.4: Hard Light-Off Conditions: Condition Description Corrective Action Condition If the gas inlet pressure at the inlet port on the gas valve is Be sure that the incoming gas pressure does not drop below 3.5"...
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 3. Use the nylon or brass brush (do not use steel) and steps below: scrub coils to remove any buildup, then vacuum the debris from the coils. a. Reconnect the thermostat wires. 4.
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BOILER DIMENSIONS & RATINGS Table 12.4: 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%) (VAC) (Amps) (VAC)
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 –...
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REPAIR PARTS Table 13.1: General Repair Parts – PFC-460 Quantity Stock Description Required Code Panel, Jacket Front Door, with Ball Studs 54256 Lens for Jacket Front Door 54167 Display Module 852RT- PFC-460/1500 54735 Gasket for Display Bracket 54513 Bracket for Display Module PF2007-1 Hex Nut, #6-32 with Lock washer (Local Hdwr Supply) 51553...
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REPAIR PARTS Figure 13.2: Heat Exchanger/Burner Assembly Repair Parts – PFC-460...
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REPAIR PARTS Table 13.2: Heat Exchanger/Burner Assembly Repair Parts – PFC-460 Quantity Stock Description Required Code Ignitor, with Gasket 4246 Sensor, with Gasket 54247 Premix Channel – PFC-460 54250 Gasket, Channel to Burner 54186 Burner – PFC-460 54264 Combustion Chamber Cover Plate, includes items #10-#12 54248 Gasket, Glass Rope 54188...
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 Static Inlet Gas Pressure...
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® ® Boilers PFC-460 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.
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