PEERLESS PureFire PFC-625 Installation, Operation & Maintenance Manual
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PEERLESS PureFire PFC-625 Installation, Operation & Maintenance Manual

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  • Page 1 ® ® Boilers PFC-625 PFC-750 Installation, Operation & Maintenance Manual...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 8. BOILER CONTROL: INTERNAL WIRING & OPERATION A. INSTALLATION SEQUENCE ....1 A. CONTROL OVERVIEW ....35 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 severe personal injury, death or major property has been set in order to provide the installer with a damage.

  • Page 4: Preinstallation

    PREINSTALLATION 1. PREINSTALLATION A. GENERAL • A hard wired carbon monoxide detector with an alarm and battery back-up must be installed 1. Series PFC boilers are supplied completely on the floor level where the gas equipment is to assembled as packaged boilers. The package should be installed AND on each additional level of the be inspected for damage upon receipt and any dwelling, building or structure served by the side...

  • Page 5: Accessibility Clearances

    PREINSTALLATION C. ACCESSIBILITY CLEARANCES 3. Required Combustion Air Volume: The total required volume of indoor air is to be the sum of the 1. The Series PFC boiler is certified for closet required volumes for all appliances located within installations with zero clearance to combustible the space.
  • Page 6 PREINSTALLATION 4. Indoor Air Opening Size and Location: Openings 5. Outdoor Combustion Air: Outdoor combustion air connecting indoor spaces shall be sized and located as is 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 6. Combination Indoor and Outdoor Combustion Air: through horizontal ducts, each opening shall If the required volume of indoor air exceeds the have a minimum free area of 1 in per 2000 available indoor air volume, outdoor air openings or Btu/hr (22 cm per 2000 W) of total rated 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 4. Insert washers and bolts (not provided - See Table A. GENERAL 2.1) through the holes provided in the frame of the lower boiler and holes in the base of the upper boiler. 1. Series PFC boilers are intended for installation in an area with a floor drain or in a suitable drain pan.

  • Page 10: Removing Vent Cover

    BOILER SET-UP C. REMOVING VENT COVER The PFC-625 and PFC-750 comes with a vent cover on the back of the unit to protect the 6” PVC Female exhaust connection from damage during shipping and installation. Once the unit is in its final position, the cover can be removed by removing the 5 screws holding it in place.

  • Page 11: Venting & Air Inlet Piping

    VENTING & AIR INLET PIPING 3. VENTING & AIR INLET PIPING A. GENERAL WARNING 1. Install the Series PFC boiler venting system in Only the materials listed below are approved for use accordance with these instructions and with the National with the P ®...
  • Page 12 VENTING & AIR INLET PIPING d. For multiple boiler installations, the minimum WARNING horizontal distance between the inlet of one boiler to the exhaust of an adjacent boiler is 12” This appliance uses a positive pressure venting edge-to-edge. In addition, the minimum vertical system.
  • Page 13 VENTING & AIR INLET PIPING • Provide a minimum of 4 feet (1.22 m) 8. Figures 3.6 through 3.8 show recommended vertical clearance distance from any door, operable venting configurations. window, or gravity air intake into any building. a. Figure 3.6 illustrates a vertical venting configuration using PVC inlet and exhaust.
  • Page 14 VENTING & AIR INLET PIPING WARNING! Figure 3.6: Vertical Exhaust and Air Inlet Pipe Figure 3.8: Vertical Exhaust Routed Through an Unused Chimney with Outdoor Air WARNING! EXHAUST CONNECTION AIR INLET 5/8" I.D. HOSE TO CONDENSATE TRAP Figure 3.9: Drain Tee and Air Inlet Connections Figure 3.7: Vertical Exhaust Routed Through an Unused Chimney with Indoor Air...

  • Page 15: Exhaust Vent/Air Intake Pipe Sizing

    VENTING & AIR INLET PIPING Table 3.5: Exhaust Adapters PVC to Other’s ii. Locate the opening of the exhaust vent pipe a minimum of 12” above the air inlet opening to Manufacturer Part No. prevent flue gas from recirculating to the air inlet. Duravent PolyPro 6”...

  • Page 16: Test Port For Exhaust Sampling

    VENTING & AIR INLET PIPING 6. Horizontal lengths of exhaust vent must be installed with G. BOILER REMOVAL FROM COMMON a slope of not less than 1/4” per foot (21mm per meter) VENTING SYSTEM toward the boiler to allow condensate to drain from the vent pipe.
  • Page 17 VENTING & AIR INLET PIPING 7. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe. Vérifier toute fuite à l’orifice de décharge du coupe- tirage après que le brûleur ait fonctionné...

  • Page 18: Water Piping & Controls

    WATER PIPING & CONTROLS 4. WATER PIPING & CONTROLS A. GENERAL 5. Install this boiler so that the gas ignition system components are protected from water (dripping, Table 4.1: Guide of Maximum Flow Rates for spraying, etc.) during operation and service (circulator Different Pipe Sizes with Input replacement, condensate trap cleaning, sensor replacement, etc.).

  • Page 19: Operating Parameters

    WATER PIPING & CONTROLS b. The Series PFC has a built-in De-Air feature that Table 4.4: Heat Exchanger Water Capacity activates on initial power up. Allow this cycle to Total Water Capacity run fully to help drive any trapped air out of the ®...
  • Page 20 WATER PIPING & CONTROLS Figure 4.1: Piping Symbol Key 5. Flow Control Valve: Flow control valves such as the 8. Pressure Relief Valve: The boiler pressure relief valve TACO Flo-Chek or Bell & Gossett Flo-Control™ are is shipped in the miscellaneous parts box for field used to prevent gravity circulation by incorporating a installation.
  • Page 21 WATER PIPING & CONTROLS 9. Circulator: The boiler circulator is to be sized to overcome the pressure drop of the system while providing the flow required by the boiler. SAFETY RELIEF VALVE a. If the boiler is piped in a secondary loop of a (PIPE TO WITHIN 12 INCHES primary/secondary heating system, the circulator...
  • Page 22 WATER PIPING & CONTROLS e. Table 4.5 provides the flow rate and pressure drop NOTICE information that corresponds to various boiler temperature rise values (DT). The pressure drop The circulator sizing given is for primary/secondary shown is for the boiler only. If there is significant installations only.

  • Page 23: System Piping

    WATER PIPING & CONTROLS E. SYSTEM PIPING concentration and heating requirements. 7. A strainer, sediment trap, or some other means 1. Figure 4.4 shows a single boiler with multiple heating for cleaning the piping system must be provided. zones. In this case, the DHW zone is piped in parallel It should be located in the return line upstream of to the heating zones on the primary loop.
  • Page 24 WATER PIPING & CONTROLS...
  • Page 25 WATER PIPING & CONTROLS...
  • Page 26 WATER PIPING & CONTROLS...

  • Page 27: G Special Applications

    WATER PIPING & CONTROLS G. SPECIAL APPLICATIONS c. See Figure 4.7 for recommended system piping for chiller operation. 1. If the Series PFC boiler is used in conjunction with a 2. For boilers connected to heating coils in a forced chilled medium system, pipe the chiller in a separate air system where they may be exposed to chilled secondary loop.

  • Page 28: Fuel Piping

    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 Series PFC boiler is to be in per hour) with a pressure drop of 0.3” of water (75 Pa). accordance with local codes.

  • Page 29: Gas Supply Piping - Operation

    FUEL PIPING 2. A sediment trap is included from the factory into D. GAS SUPPLY PIPING - OPERATION the supply piping at the boiler. Figure 5.1 shows the 1. The gas line must be properly purged of air to allow sediment trap at the rear of the boiler near the base.

  • Page 30: Main Gas Valves - Operation

    FUEL PIPING l. Turn on the gas shutoff valve and the boiler Table 5.6: PFC-750 Combustion Settings service switch. Natural Gas Propane (LP) PFC-750 m. Start the boiler and check for fuel gas odor around Low Fire High Fire Low Fire High Fire the gas valve.

  • Page 31: Condensate Trap & Drain System

    CONDENSATE TRAP & DRAIN SYSTEM 6. CONDENSATE TRAP & DRAIN SYSTEM A. GENERAL B. CONDENSATE SYSTEM 1. The disposal of all condensate into public sewage 1. The condensate system for Series PFC boilers systems is to be in accordance with local codes and perform the following functions: regulations.

  • Page 32: Condensate Drain Piping

    CONDENSATE TRAP & DRAIN SYSTEM C. CONDENSATE DRAIN PIPING 1. Material: The condensate drain is to be piped using PVC, polypropylene, or other material resistant to acidic condensate. Do not use steel, brass, or galvanized pipe for this purpose. The acidic condensate will attack most metals and cause corrosion.

  • Page 33: Electrical Connections & Internal Wiring

    ELECTRICAL CONNECTIONS & INTERNAL WIRING 7. ELECTRICAL CONNECTIONS & INTERNAL WIRING A. GENERAL Table 7.2: Low Voltage Terminal Description Input/ This appliance is to be wired in accordance with local Terminal Voltage Description Output codes and regulations as defined by the Authority having Water jurisdiction.

  • Page 34: Internal Wiring

    ELECTRICAL CONNECTIONS & INTERNAL WIRING 4. An Outdoor Sensor is provided with the Series PFC™ 3. Relay Module: The relay module is located in the boilers. It must be installed for the unit to operate center back edge of the electrical tray. This fused properly and to maximize the efficiency of the unit.
  • Page 35 DIAGNOSE POSSIBLE CAUSES Figure 7.3: Control Fuse Location FOR BLOWN FUSE BEFORE REPLACING. Additional fuses can be ordered as need from your Peerless Boiler Distributor (Part #5562). See Figure 7.3 for location of Boiler Control fuse and spare fuse.
  • Page 36 ELECTRICAL CONNECTIONS & INTERNAL WIRING...

  • Page 37: Boiler Control: Internal Wiring & Operation

    BOILER CONTROL: INTERNAL WIRING & OPERATION 8. BOILER CONTROL: INTERNAL WIRING & OPERATION A. CONTROL OVERVIEW The Series PFC™ boiler control is one of the primary safety devices for the boiler. It controls: • Ignition sequence • Temperature Limits • Circulators •...

  • Page 38: Available Domestic Hot Water Modes

    BOILER CONTROL: INTERNAL WIRING & OPERATION C. AVAILABLE DOMESTIC HOT WATER MODES Table 8.2: Series PFC™ Domestic Hot Water Modes Central Mode Description Heating Mode Operation Mode – Disables DHW sensor and functionality. No Domestic Hot Water – Boiler will function only for Central Heat. –...
  • Page 39 BOILER CONTROL: INTERNAL WIRING & OPERATION Figure 8.2: 900PB Display Icons Table 8.4: Display Icons Icon Description Central Heating enabled. CH demand active when flashing. Central Heating disabled. Domestic Hot Water enabled. DHW demand active when flashing. Domestic Hot Water disabled. Burner Active.

  • Page 40: User Interface Menu Structure

    BOILER CONTROL: INTERNAL WIRING & OPERATION E. USER INTERFACE MENU STRUCTURE Figure 8.3: Menu Structure...

  • Page 41: Main Menu

    BOILER CONTROL: INTERNAL WIRING & OPERATION MAIN MENU Table 8.F.0: Main Menu Menu Item Function/Description Enter the Central Heating (CH) menu Central Heating (CH) Domestic Hot Water (DHW) Enter the Doemstic Hot Water (DHW) menu Information Enter the Information menu Settings Enter the Settings menu System Test...
  • Page 42 BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.I.2: Information -> Boiler Status Menu Item Function/Description Default Value Actual Supply Temperature From Supply Dual Sensor Supply Temperature Actual Supply 2 Temperature From Supply Dual Sensor Supply 2 Temperature Actual Return Temperature Return Temperature Actual DHW Temperature DHW Temperature...

  • Page 43: Settings

    BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.I.4: Information -> Error Log Menu Item Function/Description Options Default Value Display the complete Error Log Error Log Disabled = All Errors Shown Set the Error Log Filter Lockout Filter Error Type Disabled Blocking Clear the complete Error Log Yes/No...
  • Page 44 BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.J.1.2: Settings -> General Settings -> Unit Type Menu Item Function/Description Units Select Metric units Metric ( C, bar) C/bar Imperial ( F, psi) Select Imperial units F/psi Table 8.J.1.3.0: Settings -> General Settings -> Date & Time Menu Item Function/Description Default Value...
  • Page 45 BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.J.1.6: Settings -> General Settings -> Other Settings -> Status Overview Settings Parameter Parameter Description Option Default Display water pressure on main screen On/Off Water Pressure Display boiler state on main screen On/Off State Display Temperature ID On/Off...
  • Page 46 BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.J.2.1 (cont.): Settings -> Boiler Settings -> Boiler Parameters Parameter Parameter Description Unit/Option Default Option Set CH setpoint when outdoor temperature 104.0 (40.0) (21) Baseline Supply Temp. equals Baseline Outdoor Temperature Set the outdoor temperature at which CH (22) Baseline Outdoor setpoint is set to Baseline Outdoor 65.3 (18.5)
  • Page 47 BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.J.2.1 (cont.): Settings -> Boiler Settings -> Boiler Parameters Parameter Parameter Description Unit/Option Default Option # 0-5 0: Disabled Do Not Change Without Factory Approval. 1: Flue 2 Sensor 3: Cascade Sensor (122) Prog. Input 7. Select the function for programmable input 7 3: Cascade Sensor 5: CH Sensor...
  • Page 48 BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.J.2.1 (cont.): Settings -> Boiler Settings -> Boiler Parameters Parameter Parameter Description Unit/Option Default Option 0: Disabled 1: Module Pump 2: CH Pump 3: DHW Pump 4: System Pump 5: Cascade Pump 6: Alarm Relay Do Not Change Without Factory 7: Filling Valve Approval.

  • Page 49: System Test

    BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.J.2.2 (cont.): Settings -> Boiler Settings -> Module Cascade Parameter Parameter Description Unit/Option Default Option (144) Hyst. Down Quick Set the fast hysteresis down after which a °F (°C) 18.0 (10.0) Start module is started Set the fast hysteresis up after which a module °F (°C) 10.8 (6.0)

  • Page 50: Installer Menu Code

    BOILER CONTROL: INTERNAL WIRING & OPERATION L. INSTALLER MENU CODE NOTICE The Installer access only Menus are accessible by Installer Code is 0231 inputting the proper PIN number into the PASSWORD screen of the User Menu. The following menus require the Installer Password to access: Boiler Parameters Module Cascade Settings...

  • Page 51: Ignition Sequence

    BOILER CONTROL: INTERNAL WIRING & OPERATION Table 8.8: Outdoor Reset Parameters Outdoor Default Reset Parameter Function Unit/Value Options Parameters Boiler Supply Design Temperature – Sets the reset curve design temperature that will be targeted when the outdoor temperature °F (°C) 179.6 (82.0) is at the chosen outdoor design temperature.

  • Page 52: Additional Safety Functions

    BOILER CONTROL: INTERNAL WIRING & OPERATION Figure 8.6 shows a typical ignition and burn cycle for control allows the unit to run at 1% input until the the Series PFC™ boiler. Pre-purge and Post Pure periods Stayburn temperature is reached at 193°F (88°F). The are shown in a compressed fashion to show the ignition boiler will always shutdown at this temperature and process in detail.
  • Page 53 BOILER CONTROL: INTERNAL WIRING & OPERATION connected to the managing boiler. iii. Number of Units (147) must match the total number of boilers in the cascade system, including the d. The domestic hot water (DHW) circulating pump should managing boiler. If any of the expected number of be connected to the managing boiler.
  • Page 54 BOILER CONTROL: INTERNAL WIRING & OPERATION Figure 8.9: Multi Boiler Wiring - Daisy Chain Figure 8.10: Multi Boiler Wiring - Independent Connection...

  • Page 55: Start-Up Procedure

    START-UP PROCEDURE 9. START-UP PROCEDURE A. GENERAL D. CHECK GAS PIPING 1. Confirm all water, gas and electricity supplies to the 1. Turn on the gas shut-off valve to the burner. The boiler are off. valve is located in the vestibule area at the front of the boiler.

  • Page 56: Valve Zeroing Procedure

    START-UP PROCEDURE 4. Use the ignition sequence, Figure 8.4, to follow the G. VALVE ZEROING PROCEDURE light off and shutdown sequences and to assist in In case of valve replacement or operational issues with the troubleshooting operation problems. If the boiler does not function properly, consult Section 10, boiler, the procedure below can be used to re-establish an Troubleshooting.

  • Page 57: Test Operating Limit

    START-UP PROCEDURE H. TEST OPERATING LIMIT TEST HIGH LIMIT Check that the burner will shut down when the supply Check that the burner will shut down when the high limit water temperature reaches the control setpoint + 9°F (5°C). circuit is open. 1.

  • Page 58: Lighting & Operating Instructions

    START-UP PROCEDURE J. LIGHTING & OPERATING INSTRUCTIONS Figure 9.1: Lighting & Operating Instructions...

  • Page 59: Troubleshooting

    TROUBLESHOOTING 10. TROUBLESHOOTING A. LOCKOUT ERRORS D. TYPICAL OPERATION CYCLE – HIGH TEMPERATURE CENTRAL HEAT LWCO LIMIT SUPPLY SENSOR PROBE FLUE SENSOR 1. Boiler is in standby. No demand. Central Heat Radiator symbol is constant. 2. Demand is applied. Central Heat Radiator symbol begins flashing.
  • Page 60 TROUBLESHOOTING 11. Gas valve closes, Fan returns to ignition speed. 13. Pump remain energized for pump post purge period. 12. 10 second post purge period. 14. Full unit standby WARNING WARNING When servicing or replacing any components of this Do not use this appliance if any part has been under boiler be certain that: water.
  • Page 61 TROUBLESHOOTING Table 10.1 (cont.): Lockout Errors Error Error Display Corrective Action Number Fan runs too fast for more than 60 seconds – Check for continuity through blower control harness, 5 pin connector to J4 connector on FAN_ERROR_TOO_FAST control board. If continuity is not found, replace harness. –...
  • Page 62 TROUBLESHOOTING Table 10.1 (cont.): Lockout Errors Error Error Display Corrective Action Number Low water cut off error. – Check system for leaks and filling valve for operation, ensure there is no air in the system. LWCO_1_ERROR – Check wiring to LWCO probe and that the connector to the probe is securely attached. –...
  • Page 63 TROUBLESHOOTING Table 10.2: Blocking Errors Error Error Display Corrective Actions Number WD_ERROR_RAM Internal software error. If error persists, replace control. WD_ERROR_ROM Internal software error, If error persists, replace control. WD_ERROR_STACK Internal software error. If error persists, replace control. WD_ERROR_REGISTER Internal software error. If error persists, replace control. WD_ERROR_XRL Internal software error.
  • Page 64 TROUBLESHOOTING Table 10.2 (cont.): Blocking Errors Error Error Display Corrective Actions Number FLUE2_OPEN Flue 2 sensor open Outdoor Sensor open – Check sensor wiring for solid connection and continuity. Replace wiring if bad or repair break. OUTDOOR_OPEN – Check for resistance though the sensor by touching meter leads across both pins on the sensor.
  • Page 65 TROUBLESHOOTING Table 10.2 (cont.): Blocking Errors Error Error Display Corrective Actions Number Flow is too low, demand needs to be stopped with fan at ignition speed, but no error needed to LOWEXFLOW_PROTECTION be stored at this time. Main supply voltage too low for more than 60 seconds VSUPPLY_TOO_LOW –...
  • Page 66 TROUBLESHOOTING Table 10.3: Warning Errors Error Error Display Corrective Actions Number Cascade System: Managing cascade control lost communication with one of the depending controls. – Check if expected number of dependent boilers are all powered on and wired to managing CC_LOSS_COMMUNICATION boiler.

  • Page 67: 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, they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans.

  • Page 68: Annually (Before The Start Of Heating Season)

    MAINTENANCE DANGER C. ANNUALLY (BEFORE THE START OF HEATING SEASON) When servicing or replacing components, be absolutely sure that the following conditions are met: CAUTION • Water, gas and electricity are off. The following annual inspection must be performed • The boiler is at room temperature. by a qualified service technician.

  • Page 69: Combusion Chamber Coil Cleaning Instructions

    MAINTENANCE d. Attach the drain hose to the outlet of the system. 4. Spray coils with clear water, making sure to confine the spray to the area being cleaned (try to avoid e. Connect the wires to the blocked condensate wetting the back ceramic wall of the unit).

  • Page 70: Boiler Dimensions & Ratings

    BOILER DIMENSIONS & RATINGS 12. BOILER DIMENSIONS & RATINGS 4 1/8" 41 9/16" 14 3/16" 3 7/16" 27 1/8" 2" NPT 7 3/4" 12 1/16" SUPPLY (OUTLET) 2" NPT RETURN (INLET) C L - 6" 6" DIA. AIR INLET EXHAUST VENT 3/4"...
  • Page 71 BOILER DIMENSIONS & RATINGS Table 12.3: Series PFC Main Control Specifications SERIES PFC MAIN CONTROL SPECIFICATIONS Voltage 120 VAC Nominal (102-132 VAC) Power Supply Frequency 60 Hz Nominal (40 Hz to 70 Hz) Phase Neutral Primary Control 5AT, 250 VAC (Type GDG) Fuses Pump Relay (2) 10 Amp, 250 VAC...

  • Page 72: 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: Heat Exchanger Repair Parts...
  • Page 73 REPAIR PARTS Table 13.1: Heat Exchanger Stock Code Description Qty. Igniter Electrode 54883 Gasket, Igniter Electrode 54882 Ionization Electrode 54891 Gasket, Ionization Electrode 54890 Screw, M4 x 8 54878 Gasket, Intake Manifold 54889 Intake Manifold, GM10-20-141 5940 Screw, M5 x 16 54888 Washer, M5 54887...
  • Page 74 REPAIR PARTS Figure 13.2: Blower/Gas Train Assembly...
  • Page 75 REPAIR PARTS Table 13.2: Blower/Gas Train Assembly Description Qty. Stock Code Screw (Blower to Heat Exchanger), M8 x 55mm Hex Zinc Local Hardware Nut Flange (Blower to Heat Exchanger), M8-1.25 Zinc Local Hardware Blower, Ametek Naut 8.9 54635 Screw (Blower to Venturi), M8-1.25 x 20mm Hex Local Hardware Gasket (Blower to Venturi) 14"...
  • Page 76 REPAIR PARTS Figure 13.3: Supply/Return Piping...
  • Page 77 REPAIR PARTS Table 13.3: Supply/Return Piping Description Qty. Stock Code Nipple, 2 x 3" SCH40 BLK 99263 Elbow, 2" BLK Return Sensor, TSD00BS 54418 Nipple, 2 x 5.5" NPT with 1/4" NPT Hot Tap PFC1001 Adapter, NPT x GRV PFC1000 Coupling, Slidelok 2"...
  • Page 78 REPAIR PARTS Figure 13.4: Jacket Assembly...
  • Page 79 REPAIR PARTS Table 13.4: Jacket Assembly Stock Code Description Qty. Inner Panel PFC2001 Rear Panel PFC2002 Electrical Tray Mounting Bracket PFC2006 Electrical Chase PFC2010 Electrical Chase Cover PFC2011 Electrical Tray PFC2005 Air Box - Heat Exchanger Cabinet PFC5001 Air Box - Venturi Cabinet PFC5000 Air Box - Venturi Cabinet Cover PFC5002...
  • Page 80 REPAIR PARTS * THIS WIRE LATCH GATE GOES IN FROM THE BOTTOM SIDE; THE REMAINING LATCHES GO IN FROM THE TOPSIDE. Figure 13.5: Electrical Tray Control Locations...
  • Page 81 REPAIR PARTS Table 13.5: Electrical Tray Control Locations Description Qty. Stock Code Switch, DPST (20A, 125V) 5918 Control Module, PFC-625/750 54867 Nut, Hex (#8-32) 51573 Wire Holder, Top Entry 5917 Pump Relay Module, 10A 54556 Track, Pump Relay Module 54551 Screw, #6-32 X 1/2 PHIL 5449 Terminal Block, 6 Pole...
  • Page 82 REPAIR PARTS Figure 13.6: Condensate System...
  • Page 83 REPAIR PARTS Table 13.6: Condensate System Description Qty. Stock Code Condensate Collector Container 54120 Condensate Blocked Drain Switch w/ Cap 54137 Blocked Vent Pressure Switch, 3.5" W.C. 54208 Tubing, 1" OD x 3/4" ID 22" 5417 Tubing, 1" OD x 3/4" ID 3"...
  • Page 84 REPAIR PARTS Figure 13.7: Wiring Harnesses...
  • Page 85 REPAIR PARTS Table 13.7: Wiring Harnesses WIRING HARNESS LINE TYPE KEY STOCK CODE LINE TYPE DESCRIPTION BLOWER CONTROL (J4) PFC7001 LOW VOLTAGE (RIGHT SIDE) PFC7002 POWER (RIGHT SIDE) PFC7003 GAS VALVE (NAT & LP) PFC7004 GAS VALVE & FLAME SENSOR (J5) PFC7007 PFC7008 PC COM / ARGUS LINK ADAPTER...

  • Page 86: Appendix A. Combustion Test Record

    APPENDIX A. COMBUSTION TEST RECORD APPENDIX A. COMBUSTION TEST RECORD Installation Information Contact: Phone Number: Service Contractor: Fax Number: Contractor Address: Email Address: Job Name: Jobsite Address: Boiler Model: Boiler Serial No.: Manufacture Date: Conversion Date: Pressure Readings Inlet Gas Pressure – Static Inlet Gas Pressure Drop (in.

  • Page 87: Service Log

    SERVICE LOG SERVICE LOG Serial Number Date Serviced By Description of Service...
  • Page 88 ® ® Boilers PFC-625 PFC-750 Installation, Operation & Maintenance Manual TO THE INSTALLER: This manual is the property 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.

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