Related Manuals for PEERLESS PureFire PFC-2000
Summary of Contents for PEERLESS PureFire PFC-2000
- Page 1 ® ® Boilers PFC-2000, PFC-2500, PFC-3000, PFC-3500, PFC-4000 Boiler Control Instruction & Operation Manual...
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Page 2: Table Of Contents
Contents Application The Peerless Boiler Control (Control) has been designed for commercial hot water boiler Introduction applications. Quick Reference Overview Intent This instruction manual includes detailed Product Features functional, installation a n d setup information. Boiler Sequence The intended users are application engineers, I&O... -
Page 3: Introduction Quick Reference
Introduction Quick Reference Energy Management System (EMS) Boiler Control Single Multiple Manual Application Boiler Boilers Single Boiler Multiple Boilers Modulation Operation Setpoint Input Setpoint Input Rate Input Setpoint Temperature Supply Header Supply Header Ignored Ignored Sensor Input J8 (6-7) Input J8 (6-7) Setpoint Operator Operator... -
Page 4: Overview
Control includes supply water temperature, differential water temperature, and Boiler Control The Peerless Boiler Control (Control) contains stack temperature safety limits, as well as stepped features and capabilities which help improve modulation responses. Boiler modulation is adjusted when required to help avoid loss of boiler operation heating system operation, and efficiency. - Page 5 Header Temperature Sensor System Pump Return Water System Supply Water Domestic Hot Water Stack Temperature Sensor Domestic Hot or Switch Water Pump Domestic Hot Water Supply Stack Temperature Outside Air Boiler Pump Sensor Temperature Water Flow Sensor Switch Return Low Water Cutoff Switch Temperature Sensor High Limit Auto Reset Supply...
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Page 6: Product Features Boiler Sequence
Product Features Boiler Sequence Combustion Air Boiler’s Measured Screenshot button Setpoint with Temperatures actual RPM Boiler “Status” Initiate Standby Standby Delay Safe Startup Drive Purge Prepurge Drive to Lightoff Preignition Test Preignition Direct Ignition Running Postpurge Lockout Lockout, Hold, and Navigation Menus Alert Codes Figure 4: Home Screen Details... - Page 7 Product Features Boiler Sequence Boiler Sequence Status is shown on both the Home screen and the Status Screen. Once limits have been established the boiler start/stop sequence progresses as show in the graph below; Boiler “Status” Shown on Display: Low Fire Slow Released Stabilization...
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Page 8: Protection Features
Product Features Boiler Protection Features temperature for longer than a limit time delay, the Supply Water Temperature High Limit Control shuts down the boiler and delays restart. The Control is equipped with internal operating If the inverted temperature is detected more than control and high limit features. - Page 9 Product Features Boiler Sequence Temp >Setpoint CH Enabled & Termp < Setpoint (lead boiler demand active) Boiler “Status” Shown on Display: ILK OFF LCI OFF Warm Weather Shutdown Frost Protection CH Enabled DHW Enabled Blower Output Alarm Relay System Pump DHW Pump Lea d B oiler Isolation Valve...
- Page 10 Product Features Boiler Protection Features Limit Devices The control monitors individual limit devices as shown in Figure 6 below. If any of these limits open the boiler will shut down and an open limit indication is provided. Additionally, the control monitors an air proving switch.
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Page 11: Single Boiler Control
Product Features Single Boiler Control Control Options • Modulating Sensors Header Temperature 1. Supply 2. Header Return 3. Domestic Hot Water System Water • Modulation Setpoint Circulator Outdoor Air Reset Temperature Warm Weather Shutdown Sensor or Frost Protection Switch EMS interface Circulator Options •... -
Page 12: Multiple Boiler Control Sequencer
Product Features Multiple Boiler Control Sequencer Control Options Header • Modulating Sensors Temperature 1. Header • Modulation Setpoint System Outdoor Air Reset Circulator Warm Weather Shutdown Temperature Frost Protection Switch EMS interface ONLY • Circulator Device Control Boiler, System & Domestic Connects to pumps Up to Eight... - Page 13 Product Features Multiple Boiler Control Sequencer (continued) During low loads, the Sequence Master limits firing rates to a “Base Load Rate” to ensure modulating condensing boiler peak operating efficiency. Lower firing rates boost efficiency by helping increase the amount of flue gas water vapor condensation. The Control maintains a “Base Load Rate” until the last lag boiler is started.
- Page 14 Product Features Multiple Boiler Control Sequencer (continued) Improved Availability - The following features help improve the heat availability: Backup Header Sensor In the event of a header sensor failure the lead boiler’s supply sensor is used by the Sequence Master to control firing rate.
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Page 15: Front Panel General Navigation
Front Panel General Navigation Figure 10: Configure Menu Main Screen DETAILS The Main Screen provides access to all display Status and details are provided on all sensors functions. It is the first screen that appears after connected to the Control as well as cycles and run boot up. -
Page 16: Status Screens
Front Panel Status Screens Boiler Status screens are the primary boiler monitoring screens. The user may simply “tab” through boiler operation by selecting the desired screen along the bottom of the page. These screens are accessed by selecting the “Diagnostics” button from the “Home” screen. Figure 11: Status Screen Navigation Diagnostic Tests Digital I/O... - Page 17 Front Panel Detail Screens The detail screens shows data relevant to current boiler operation. A relevant sensor to the detail category is shown on each page as well as current setpoint, active sensor, and much more. A screen map is shown below.
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Page 18: Installation Quick Setup
Installation Quick Setup The following tables are provided to allow the user to review and adjust the most commonly adjusted parameters, such as Setpoints and pump output settings. Refer to Parameter Adjustment section for additional information. Setpoints Range / Factory Parameter and Description Setting Choices... -
Page 19: Terminal Layout
Installation Terminal Layout Figure 13: Control Terminal Layout and wiring note Boiler Control Instruction & Operation Manual, Rev 1 Page of 64... - Page 20 Installation Terminal Layout Display Rear View Battery located behind door USB Connection for Historical Data Collection COM1 COM2 24 VAC C COM PWR PCB-06 N +24V To Energy Management System (EMS) 24VAC BACnet MSTP, Metasys N2, Transformer Connection to Or LonWorks Communication Protonode Factory Supplied...
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Page 21: Boiler-To-Boiler Network
Installation Boiler-To-Boiler Network The Boiler-To-Boiler Network allows the Control’s Internal Sequence Master to communicate boiler information, including modulation rate and on/off commands, using a standard Ethernet cable. RJ45 Connection Ethernet Cable Inside Boiler (Sold Seperately) (typical) Connects to Up to 8 boilers and Energy Management System Boiler 2... - Page 22 Installation External Sensors Header Sensor (P/N 101935-01 or 103104-01) A header sensor must be installed and wired to the Master Sequencer “enabled” Control. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master. Refer to boiler manual’s piping diagram for installation location and Figure 15a or 15b for installation detail.
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Page 23: Energy Management Interface
Installation Energy Management Interface The control system has a full featured ability to interface with an Energy Management System (EMS). The control system allows remote control and monitoring via RS485 Modbus or through direct wiring. Connecting an EMS Modbus Interface Table 7: Energy Management System Interface Procedure Step Description... - Page 24 Installation Energy Management Interface The following Parameters are adjustable within the Setup menu of the display. Access Setup menu by going to the Main Screen > Setup > Display Setup. READ ALL DIRECTIONS in this manual before entering the Setup Menu. Display Communication Port Setup: COM Port: Com 1...
- Page 25 Installation Energy Management Interface Table 8: Modbus Signal List The following is the list of available Modbus signals; Register addresses start at 0 (zero) based on the Modbus-IDA protocol specification. For more traditional addressing scheme (starting at 40001) a value of 40001 should be added to the decimal address for each register.
- Page 26 Installation Energy Management Interface Table 8: Modbus Signal List (continued) Modbus Protocol Read (R)/ Description Register Name Write (W) 10,211 CH setpoint Status of local setpoint 10,453 DHW setpoint Status of local setpoint 10,546 Lead Lag setpoint Status of local setpoint 10,212 CH TOD setpoint Status of local setpoint...
- Page 27 Installation Energy Management Interface Table 8: Modbus Signal List (continued) Modbus Protocol Read (R)/ Description Register Name Write (W) Building Automation may send the controller the outdoor air temperature. Use this register to change the outdoor temperature. When this register is not written every “Modbus Command Time Out”...
- Page 28 Installation Energy Management Interface Table 8: Modbus Signal List (continued) Modbus Protocol Read (R)/ Description Register Name Write (W) Trouble Shooting Reasons for burner lockout No lockout, Supply high limit DHW high limit Stack High limit Flame detected out of sequence Lightoff rate proving failed Purge rate proving failed 10,034...
- Page 29 Installation Energy Management Interface Table 8: Modbus Signal List (continued) Modbus Protocol Read (R)/ Description Register Name Write (W) Pump Status See Table 9 CH pump status See Table 9 DHW pump status See Table 9 Boiler pump status 128- Burner cycle count 0-999,999 (U32) 130-...
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Page 30: Setup & Tuning Manual Operation
Setup & Tuning Manual Operation The Firing rate may be adjusted manually using the Operation screen. The user may adjust firing rate anywhere between minimum rpm and maximum rpm. Figure 17: Operation Screens Auto/Manual Service Trend After selecting Manual Mode the User may adjust Access the trends on the Analysis screen (Home Screen >... - Page 31 Setup & Tuning Parameter Adjustment Login to Adjust Parameters Control operation may be tailored to suit the application by adjusting parameters. To a dj u st parameters select the CONFIGURE button located on the Home screen. Press CONFIGURE icon to review and white adjust all parameters.
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Page 32: Parameter Adjustment
Setup & Tuning Parameter Adjustment From the CONFIGURE menu select the following buttons to view and adjust parameters. Press SYSTEM IDENTIFICATION & ACCESS to adjust the following parameters. Factory Range / Parameter and Description Choices Setting Installer Password Allows for custom password to be set. Must be 9 characters or less. Only allows adjustment of supervisor password (supervisor default: 76). - Page 33 Setup & Tuning Parameter Adjustment Table 11: Response Speed Adjustment Guidelines Central Heat Continued Parameter and Description Factory Range / Setting Choices Central Heat 4-20mAdc Setup, 4 mA Water Temperature 50 – 185 F 130 F Sets the Central Heat Temperature Setpoint corresponding to 4 mA. Central Heat 4-20mAdc Setup 20 mA Water Temperature 50 –...
- Page 34 Setup & Tuning Parameter Adjustment Press OUTDOOR RESET CONFIGURATION to adjust the following parameters. Figure 20: Reset Curve Factory Range / Parameter and Description Setting Choices Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating set point temperature based on the outdoor reset curve in (see Figure 20).
- Page 35 Setup & Tuning Parameter Adjustment Outdoor Reset Continued Factory Range / Parameter and Description Setting Choices Boost Time When the Central Heat Setpoint is decreased by Outdoor Reset settings, the Boost Time parameter is used to increase the operating setpoint when the space heat demand is not satisfied after the Boost Time setting is exceeded.
- Page 36 Setup & Tuning Parameter Adjustment DHW Continued Factory Range / Parameter and Description Choices Setting DHW Demand Switch Domestic Hot Water Demand may respond to the boiler’s DHW Switch or DHW Sensor. When “DHW Switch” is selected the boiler responds to a domestic hot water demand DHW Switch, when a DHW Switch is sensed at J9 terminal 1 &...
- Page 37 Setup & Tuning Parameter Adjustment WARNING Asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are installing a new or replacement Control. The boiler type setting determines minimum and maximum blower speeds.
- Page 38 Setup & Tuning Parameter Adjustment Modulation Continued Factory Range / Parameter and Description Choices Setting Stepped Modulation Recycle Offset This feature helps avoid manual reset and soft lockouts by recycling the boiler when the temperature is “Stepped Modulation Recycle Offset” degrees below the Limit setting. For example, when the setting is 5 F the boiler will recycle when supply temperature is 5 F below the High Limit.
- Page 39 Setup & Tuning Parameter Adjustment Press PUMP CONFIGURATION to adjust the following parameters. Parameter and Description Factory Range / Setting Choices Contact A: CH Pump Activates the system pump output according to selected function. These options are determined by the check box selections found under the “Advanced”...
- Page 40 Setup & Tuning Parameter Adjustment Pumps Continued Parameter and Description Factory Range / Choices Setting Overrun Time: CH Pump (System) 0 Min 0 to 60 Min Time that pump runs after demand is satisfied. Used to dissipate heat within the system.
- Page 41 Setup & Tuning Parameter Adjustment Press FROST PROTECTION CONFIGURATION to adjust the following parameters. Parameter and Description Factory Range / Choices Setting CH Frost Protection Disable Frost Protection is not used. Enable Boiler and system circulators start and boiler fires when low outside air, supply and return temperatures are sensed as follows: Device Start Temperatures...
- Page 42 Setup & Tuning Parameter Adjustment Press FAN CONFIGURATION to adjust the following parameters. Factory Range / Parameter and Description Setting Choices Fan Speed-Up Ramp 0 to 12000 Whenever the burner is firing it will be commanded to increase its RPM no faster rpm/sec.
- Page 43 Setup & Tuning Parameter Adjustment Press LEAD LAG MASTER CONFIGURATION to adjust the following parameters. Range / Factory Parameter and Description Setting Choices Master Enable/Disable The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Lead- Enable Lag Control. Disabled Disable WARNING:...
- Page 44 Setup & Tuning Parameter Adjustment Lead L ag Master Continued Range / Factory Parameter and Description Setting Choices Lead Lag Outdoor Boost Maximum Off Point Maximum value the setpoint can reach due to boost function. Should be set to match 187 (ºF) 50 to 190 (ºF) Central Heat Setpoint.
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Page 45: Display Setup
Setup & Tuning Press these buttons to adjust the following parameters. Factory Range / Parameter and Description Setting Choices System Date Date used by display Alarm History screen. A battery is provided to maintain the xx/xx/xxxx system date and time while the display is powered down. System Time Time used by display Alarm History screen. -
Page 46: Troubleshooting General Issues
Troubleshooting General Issues WARNING Electrical Shock Hazard. Turn off power to boiler before working on wiring. This boiler must only be serviced by skilled and experienced service technician. Troubleshooting when the is NO alert; Indication Condition Possible Cause Boiler is not seeing Enable/Disable of Demand Input. Check Boiler not responding to call for Demand Not wiring loose connection, miswiring. - Page 47 Troubleshooting General Issues (continued) The History button on the Home page serves not only as a button, but also displays Sola Control lockouts, holds, and alerts as they occur. The History button can be selected at any time, regardless of which type of information is displayed, to view history information. Pressing the History button displays a dialog box that allows the user to select the type of history to view.
- Page 48 Troubleshooting General Issues (continued) History Bar Condition Description Color • A lockout causes the boiler control to shut down and requires manual or remote reset to clear the lockout. Lockout • Always causes alarm contacts to close. • Logged in lockout history. •...
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Page 49: Sensor Status
Troubleshooting Sensors Status Supply -768 F Shorted Figure 22: Sensor Screen The sensor status screen is selected from the DIAGNOSTICS menus. A failed sensor is shown with a white bar and the type of failure in text below that. Not all analog I/O can be displayed at the same time on the page, so a horizontal scroll bar is used to move the view left and right to show all analog I/O status. -
Page 50: Limit String Status
Troubleshooting Limit String The Limit String Status screen shows the safety limit status. A contact icon, either “ON” or “OFF”, graphically represents each safety limit. “ON” means that the contact is closed and there is no issue. An “OFF” limit means the contact is open and the limit is not “made”. -
Page 51: Holds
Troubleshooting Holds Display Faults When a hold occurs, the boiler will shut down and the “History” button will turn yellow. Consult the table below to determine the cause of the soft lockout. The boiler will automatically restart once the condition that caused the hold is corrected. - Page 52 Troubleshooting Holds (continued) Lockout Condition Number Possible Cause Shorted or miswired flame rod wiring. Flame rod shorted to ground Defective flame rod. Flame rod shorted to ground Inadequate boiler water flow. Verify that circulator is Temperature rise between supply operating and that circulator and piping are sized per Delta T and return is too high.
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Page 53: Lockouts
Troubleshooting Lockouts Display Faults When a lockout occurs a notification pops up and the “History” button turns red. The “History” button will lead you to the lockout history log, which shows the last 15 lockouts. Touch any lockout on the history page to investigate further. - Page 54 Troubleshooting Lockouts (continued) Lockout Number Condition Possible Cause - Inadequate boiler water flow The difference between the inlet/return and the Delta T Inlet/Outlet High outlet/supply temperature is too large. - Water flow reversed The temperature of the - No flow, sensor reversed, sensor bad return/inlet is higher than the Return Temp Higher Than temperature of the...
- Page 55 Troubleshooting Lockouts (continued) Lockout Number Condition Possible Cause - No gas pressure. - Gas pressure under minimum value shown on rating plate. - Gas line not completely purged of air. - Defective Electrode. - Loose burner ground connection. Flame failure Ignition failure - Defective Ignition Cable.
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Page 56: History
Troubleshooting History The History screens are a fundamental resource for the users interested in commissioning, optimizing, and troubleshooting an issue with the boiler. Using the history screens a user may the last 15 alerts and lockouts, or cycle and run history. Data may be simply viewed on screen, or a screenshot may be exported to a thumb drive for sharing with technical support. - Page 57 Troubleshooting History Alert History The alert history will record the last 15 alerts. These alerts include any problem that is NOT a Lockout or Hold. The alerts are recorded in a list with the most recent appearing at the top. The alarm list can be scrolled through. Touching the alert The alerts are given a date and time stamp which allows for better troubleshooting capability.
- Page 58 Troubleshooting History USB Thumb Drive Requirements The Thumb Drive must be formatted as a FAT32 for use with the display. In order to check the format of a USB Thumb Drive, follow these instructions: • Plug the USB Drive into a computer •...
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Page 59: Specifications General
Specifications General Control Display Dimensions: 9 21/64” x 6 21/64” Dimensions: • Bezel: 9-7/16” x 6-21/32” x 1-27/32” • Electrical Ratings: Panel Cutout: 8” x 5-1/2” • Operating voltage: 24Vac (20 to 30 Vac, 60 Hz ±5%) Electrical Ratings: • Input voltage: 24 Vac（-25% ~+25%) •... - Page 60 Specifications General Replacement Parts Listed in Table 13 are available replacement parts for the boiler. These include temperature sensors, the control, display, and more. Part numbers are included to simplify the ordering process. Part Number Name Description Commercial Boiler Control, CSD-1 Compliant, Auto Temperature Control, 120 Vac Ignition Control, 8 Limit Monitoring 105681-01 Control...
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Page 61: Parameter Summary
Specifications Parameter Summary Parameter Range/Choices Security Page SYSTEM IDENTIFICATION & ACCESS Installer Password 9 Character Maximum Factory MB2 Modbus Address 1 to 8 Supervisor CENTRAL HEAT CONFIGURATION CH Setpoint 50 to 190 °F Basic CH TOD Setback Setpoint 50 to 190 °F Basic CH Off Hysteresis 3 to 29 °F... - Page 62 Specifications Parameter Summary Parameter Range/Choices Security Page MODULATION CONFIGURATION CH Max Modulation Rate Minimum to Maximum Modulation Factory DHW Max Modulation Rate Minimum to Maximum Modulation Factory Minimum Modulation Rate Minimum + 100 to Maximum - 100 Factory CH & DHW Forced Rate Time 0 to 30 minutes Supervisor CH &...
- Page 63 Specifications Parameter Summary Parameter Range/Choices Security Page FAN CONFIGURATION Fan Speed - Up Ramp 0 to 12000 Supervisor Fan Slow - Down Ramp 0 to 12000 Supervisor Fan Gain Up 1 to 100 Factory Fan Gain Down 1 to 100 Factory SENSOR CONFIGURATION Outdoor Temperature Source...
- Page 64 Notes Page 63 of 64 Boiler Control Instruction & Operation Manual, Rev 1...
- Page 65 Notes Page 64 of 64 Boiler Control Instruction & Operation Manual, Rev 1...
- Page 66 ® ® Boilers PFC-2000, PFC-2500, PFC-3000, PFC-3500, PFC-4000 Boiler Control Instruction & Operation 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.