Table of Contents
Advertisement
Quick Links
WARNING: If the information in
these instructions is not followed
exactly, a fire or explosion may
result causing property damage,
personal injury or death.
Do not store or use gasoline or
other flammable vapors and
liquids in the vicinity of this or
any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any
appliance.
• Do not touch any electrical
switch; do not use any phone
in your building.
• Immediately call your gas
supplier from a neighbor's
p h o n e . F o l l o w t h e ga s
supplier's instructions.
• If you cannot reach your
gas supplier, call the fire
department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
®
P
ure
Boilers
Gas
PFC-2000, PFC-2500, PFC-3000, PFC-3500, PFC-4000
Installation,
Operation &
Maintenance
Manual
®
F
ire
Advertisement
Table of Contents
Related Manuals for PEERLESS PUREFIRE PFC-2500
Summary of Contents for PEERLESS PUREFIRE PFC-2500
- Page 1 ® ® Boilers PFC-2000, PFC-2500, PFC-3000, PFC-3500, PFC-4000 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
-
Page 2: Table Of Contents
TABLE OF CONTENTS I. Hazard Definitions II. Read Before Proceeding A. Local Codes ................. 5 B. - Page 3 TABLE OF CONTENTS D. T emperature Rise and Heat Exchanger Head Loss ..........38 E.
-
Page 4: Hazard Definitions
I. HAZARD DEFINITIONS The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. It is critical all personnel read and adhere to all information contained in DANGER, WARNING, and CAUTIONS. All DANGERS, WARNINGS, and CAUTIONS are for reference and guidance purpose, and, therefore, do not substitute for strict adherence to applicable jurisdictional and professional codes and regulations. DANGER DANGER CAUTION CAUTION Indicates an imminent hazardous situation which, if not Indicates a potentially hazardous situation which, if avoided, will result in death, serious injury or substantial not avoided, may result in moderate or minor injury, or property damage. property damage. WARNING WARNING NOTICE NOTICE Indicates a potentially hazardous situation which, if Indicates special instructions on installation, operation, not avoided, could result in death, serious injury, or or maintenance which are important but not related to... -
Page 5: Read Before Proceeding
II. READ BEFORE PROCEEDING A. Local Codes 2. Do not block or restrict in any way the flow of combustion or ventilation air from or to the 1. This unit shall be installed in accordance with those appliance installation regulations enforced in the area where 3. Do not use this appliance if any part has been under the installation is to be made. These regulations water. Any appliance that has been under water shall be carefully followed in all cases. Authorities must be replaced. Water damage to the unit can having jurisdiction shall be consulted prior to be extensive and present numerous safety hazards. -
Page 6: Factory Test And Inspections
II. READ BEFORE PROCEEDING (CONTINUED) J. Factory Test and Inspections WARNING WARNING 1. Prior to shipment, final air-fuel adjustments are performed by factory trained service personnel This product can expose you to chemicals, on each appliance. The factory emissions report including chromium, which are known to the state is posted on the back of the front jacket panel as of California to cause cancer and birth defects or a reference for troubleshooting and maintenance. -
Page 7: Product Rating, Specifications, And Dimensional Data
III. PRODUCT RATING, SPECIFICATIONS, AND DIMENSIONAL DATA corrosion. These boilers are not designed for use in gravity PFC boilers are condensing, high-efficiency, gas-fired, hot hot water space heating systems or systems containing water boilers designed for space heating systems or indirect significant amount of dissolved oxygen (swimming pool domestic water heating, where supply water temperature water heating, direct domestic water heating, etc.). does not exceed 190°F. These boilers have special coil type stainless steel heat exchangers, constructed, tested, and stamped per Section IV of the ASME Boiler and Pressure Vessel Code, which provide maximum heat transfer and simultaneous protection against flue gas product Table 1: Performance Ratings PFC Comercial Gas Boiler Gross Thermal Combustion Input (MBH) Net Ratings... - Page 8 III. PRODUCT RATING, SPECIFICATIONS, AND DIMENSIONAL DATA (CONTINUED) Table 3: Product Dimensions PFC Model Dimensions (in.) 2000 2500 3000 3500 4000 66-1/8 75-5/8 75-5/8 97-1/8 97-1/8 74-5/8 83-3/4 83-3/4 105-1/8 105-1/8 76-1/2 86-1/2 86-1/2 34-1/4 13-3/8 19-1/4 19-1/4 19-1/4 19-1/4 42-3/4 36-1/8 48-3/8 48-3/8...
- Page 9 III. PRODUCT RATING, SPECIFICATIONS, AND DIMENSIONAL DATA (CONTINUED) SUPPLY NOZZLE RETURN NOZZLE GAS TRAIN CONNECTION SUPPLY NOZZLE LIFTING LUGS RETURN NOZZLE (Z-COG) (Y-COG) DRAIN VENT AIR SUPPLY (Z-COG) (X-COG) 1" CONDENSATE DRAIN Figure 1: PFC Boiler Dimensions PFC2000-4000 Boiler I,O&M Manual Rev. 2...
-
Page 10: Pfc Component Identification
IV. PFC COMPONENT IDENTIFICATION 1. Communication Interface (Honeywell S7999D 15. Gas supply line Display) Provides a means of connection for incoming gas line to The PFC series is equipped with the Honeywell S7999D the gas train assembly. See Table 29 for model specific Display which provides easy access for viewing and pipe sizes. - Page 11 IV. PFC COMPONENT IDENTIFICATION (CONTINUED) Figure 2: Component Identification PFC2000-4000 Boiler I,O&M Manual Rev. 2...
- Page 12 IV. PFC COMPONENT IDENTIFICATION (CONTINUED) Figure 3: Component Identification PFC2000-4000 Boiler I,O&M Manual Rev. 2...
-
Page 13: Unpacking The Pfc
V. UNPACKING THE PFC A. Unpacking and Inspection 1. Move appliance to approximate installation WARNING WARNING location. Failure to assure the truck forks are long enough 2. Remove all crate fasteners. to extend at least half way through the base will 3. Lift and remove outside container. result in the appliance tipping off the lift truck and potentially falling. This will result in severe 4. -
Page 14: Pre-Installation And Mounting
VI. PRE-INSTALLATION AND MOUNTING A. General Installation 1. Installation must conform to the requirements of WARNING WARNING the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Apply supplied dielectric grease to the gasket Code, ANSI Z223.1/NFPA 54, and/or Natural Gas inside the vent connector. Failure to apply the and Propane Installation Code, CAN/CSA B149.1. -
Page 15: Appliance Mounting
VI. PRE-INSTALLATION AND MOUNTING (CONTINUED) B. Appliance Mounting 1. The PFC is intended for installation in an area with Table 4: Corrosive Combustion Air Contaminants a floor drain, or in a suitable drain pan to prevent Contaminants to Avoid: any leaks or safety relief valve discharge resulting in property damage. Spray cans containing chlorofluorocarbons (CFC’s) 2. This appliance is not intended to support external piping or venting. All external piping and venting Permanent wave solutions must be supported independently of the appliance. Chlorinated waxes/cleaners 3. This appliance must be installed on a level surface Chlorine-based swimming pool chemicals to prevent condensate from backing up inside the Calcium chloride used for thawing heat exchanger. -
Page 16: Clearances
VI. PRE-INSTALLATION AND MOUNTING (CONTINUED) C. Clearances NOTICE NOTICE 1. The PFC is approved for 0" clearance to combustible This appliance is approved for zero inch clearance materials. The clearances for serviceability are to combustible or noncombustible material, but found in Table 5. installing the appliance with smaller than the 2. Minimum clearances from combustible or clearances for serviceability will limit access for noncombustible construction, 0" sides, 0" back, maintenance. -
Page 17: Venting
VII. VENTING A. General Venting Guidelines WARNING WARNING 1. Install vent system in accordance with National This appliance must not be installed in a room Fuel Gas Code, ANSI Z223.1/NFPA 54 or Natural under negative pressure. These direct vent gas Gas and Propane Installation Code, CAN/CSA fired appliances are allowed a maximum leakage B149.1 Installation Code for Canada, or, applicable... -
Page 18: Field Installation
VII. VENTING (CONTINUED) C. Field Installation 1. A factory installed cast aluminum or steel ring WARNING WARNING provides a means for air intake connection. 2. A factory installed vent connector provides a means Failure to follow these instructions could cause for connection to stainless steel venting. products of combustion to enter the building, resulting in severe property damage, personal 3. - Page 19 VII. VENTING (CONTINUED) Table 7: Equivalent lengths of Vent and Combustion Air Components Diameter 8 in. (200 mm) 10 in. (250 mm) 12 in. (315 mm) 90° Elbow 11 ft. (3.4 m) 14 ft. (4.3 m) 18 ft. (5.5 m) 45° Elbow 4 ft.
- Page 20 VII. VENTING (CONTINUED) Table 11: Stainless Steel and CPVC Vent Adapters Stainless Steel to CPVC Heat Fab to Z-Vent Vent Diameter (in.) Heatfab # Z-Flex Part # 9858CPVC 2SVSHF08 910510CPVC 2SVSHF10 912512CPVC 2SVSHF12 Table 12: Polypropylene Vent Adapters Vent Centrotherm Part # Z-Flex Part # Model Diameter (in.)
-
Page 21: General Termination
VII. VENTING (CONTINUED) b. When installed on the same wall, locate G. General Termination vent terminal 4 vent pipe diameters above 1. Use only listed vent/combustion air terminals. the combustion air terminal. The snorkle 2. Follow the termination configurations shown configuration can be used when penetrations are in Table 15, and see Table 18 for acceptable at the same hieght. - Page 22 VII. VENTING (CONTINUED) 13. Maintain minimum 24 in. (610 mm) horizontal 7. If window and/or air inlet is within 4 ft. (1.2 m) spacing between vent terminal and a building of an inside corner, maintain at least 6 ft. (1.8 m) corner. spacing between terminal and adjoining wall of inside corner. 14.
- Page 23 VII. VENTING (CONTINUED) Table 16: Direct Vent Terminal Clearances Canadian Installations US Installations Clearance above grade, veranda, 18 in. (46 cm) 12 in (30 cm) porch, deck, or balcony 6 in (15 cm) for appliances ≤ 6 in (15 cm) for appliances 10,000 Btuh (3 kW), 12 in (30 ≤...
- Page 24 VII. VENTING (CONTINUED) Table 17: Other than Direct Vent Terminal Clearances Canadian Installations US Installations Clearance above grade, veranda, 18 in (46 cm) 12 in (30 cm) porch, deck, or balcony 6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW), 12 in (30 4 ft (1.2 m) below or to side of Clearance to window or door that cm) for appliances >...
- Page 25 VII. VENTING (CONTINUED) Table 18: Table of Acceptable Terminations Flue Gas Vent Terminations Sidewall Roof Straight Termination Tee Termination Vertical Run Tee Termination Vertical Run 20°-45° Elbow Terminated Downward Velocity Cone Combustion Air Intake Terminations Sidewall Roof Two 90° Elbows Terminated Downward 90°...
-
Page 26: Ent And Combustion Air Terminations
VII. VENTING (CONTINUED) NOTICE NOTICE Methods of securing and sealing terminals to H. Vent and Combustion Air Terminations the outside wall must not restrain the thermal 1. Vent Piping expansion of the vent pipe. a. Install fire stops where vent passes through floors, ceilings or framed walls. The fire stop Exterior run should be included in equivalent must close the opening between the vent pipe vent/combustion air lengths. - Page 27 VII. VENTING (CONTINUED) 6 Pipe Diameters Min. 24 in. Min. Bird Screen From Intake Vent & Intake Bird Screen Vent Vent & Intake 12 in. Min. Above Snow Line 4 Pipe Diameters min. Vent Combustion Combustion Grade/Snow Line 12 in. min. Above Snow Line Figure 6: Horizontal Sidewall Termination Figure 7: Slopped Roof Termination...
-
Page 28: Multiple Appliance Terminations
VII. VENTING (CONTINUED) M. Multiple Appliance Terminations NOTICE NOTICE The joint between the terminal and the last 1. Vent Piping Terminations piece of pipe must be outside of the building. a. Multiple appliance vent terminations are shown in Figure 9. b. Each individual appliance must have its own vent pipe and vent terminal unless a common venting system is used following the guidlines ... - Page 29 VII. VENTING (CONTINUED) 6D Min. NOTICE NOTICE The required spacing between vent and combustion air terminals is to prevent flue gas recirculation. Recirculation of flue gas products 4D Min. into the combustion air supply can cause damage to property or the appliance. Grade/ Snow Line 12 in.
-
Page 30: Polypropylene Venting
VII. VENTING (CONTINUED) W. Polypropylene Venting WARNING WARNING 1. Running Flexible Polypropylene Vent (Liner) Asphyxiation Hazard. Vent systems made by listed Through Unused Chimney Chase PP vent system manufacturers rely on gaskets for a. It is the responsibility of the installing contractor proper sealing. When this type of vent system is to procure polypropylene vent system pipe and used, take the following precautions: related components. Make sure that gasket is in position and undamaged b. A l l l i s t e d p o l y p ro p y l e n e v e n t sy s t e m in the female end of the pipe. - Page 31 VII. VENTING (CONTINUED) NOTICE NOTICE Pressure drop for flexible polypropylene line is 20 % greater than from rigid pipe. Multiply measured flexible polypropylene liner length by 1.2 to obtain equivalent length. Maximum equivalent vent length of flexible polypropylene liner is 48 ft. (14.6 m). Installation of a polypropylene vent system should adhere to the vent manufacturer's installation instructions supplied with the vent system. WARNING WARNING DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.
- Page 32 VII. VENTING (CONTINUED) c. No manually operated dampers or manually a. Ventilation Air: an opening for ventilation air at operated adjustable louvers are permitted. the highest point that opens to the outdoors d. Motorized dampers or Louvers shall be interlocked shall provide Ventilation of the space. The cross so the burner(s) cannot operate unless the sectional area of this opening shall be at least damper or louver is in the fully open position.
-
Page 33: Removing Existing Appliance
VII. VENTING (CONTINUED) Y. Removing Existing Appliance When an existing appliance is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining appliances. At the time of removal of an existing appliance, the following steps should be performed with each appliance remaining connected to the common venting system. Make sure the appliances are not in operation while carrying out these steps. 1. Seal any unused openings in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and ensure there is no blockage or restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition. 3. Insofar as is practical, close all exterior doors and windows, and all doors between the space where the appliances connect to the common venting system and other spaces of the building. Turn on any exhaust fans, such as range-hoods and bathroom exhausts, so they will operate at maxi-... -
Page 34: Special Installation Requirements For Massachusetts
VII. VENTING (CONTINUED) Z. Special Installation Requirements for Massachusetts 1. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: a. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the sidewall horizontally vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. b. In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the detector on the floor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment, the installer shall have a period of thirty (30) days to comply with this requirement; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. In the event that the sidewall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the carbon monoxide detector may be installed on... -
Page 35: Condensate Disposal
VIII. CONDENSATE DISPOSAL A. General B. Condensate trap installation 1. Note the following when disposing of the 1. Locate the condensate trap assembly shipped loose condensate: with this appliance. a. Condensate is slightly acidic, typical pH around 2. Install the condensate trap on the lower rear of the 3.5 - 4.5. Do not route the drain line through areas appliance as shown in Figure 11. that could be damaged by leaking condensate. 3. Connect condensate float switch wires to the wire a. Do not route or terminate the condensate drain harness extended out of the rear junction box (from line in areas subject to freezing temperatures. terminals 75 and 76 on PCB 1). b. If the point of condensate disposal is above the trap, a condensate pump is required to Flue Gas Trap move the condensate to the drain. -
Page 36: Condensate Neutralizer Installation
VIII. CONDENSATE DISPOSAL (CONTINUED) C. Condensate Neutralizer Installation WARNING WARNING 1. Some jurisdictions may require that the condensate be neutralized before being disposed of. Follow Failure to install the condensate drain in accordance local codes pertaining to condensate disposal. with the above instructions could cause flue gas 2. A condensate neutralizer kit is available from to enter the building, resulting in personal injury factory as optional equipment. Refer to Table 20 for or death. size specific part number. Follow local codes and instructions enclosed with the kit for condensate neutralizer installation. -
Page 37: Hydronic Piping
IX. HYDRONIC PIPING A. PFC Boiler Piping CAUTION CAUTION PFC boilers are designed to operate in a closed loop pressurized system. Minimum pressure in the boiler Failure to properly pipe boiler may result in must be 14.5 psi (100 kpa). Proper operation requires improper operation and damage to the boiler or a piping system that can provide sufficient water structure. flow through the boiler and meet the water quality Install boiler so that the gas ignition system requirements. -
Page 38: Temperature Rise And Heat Exchanger Head Loss
IX. HYDRONIC PIPING (CONTINUED) D. Temperature Rise and Heat Exchanger Head Loss 1. The PFC heat exchanger adds pressure drop to the system which must be accounted for in the design of the piping configuration and pump selection. 2. For systems with glycol mixture, the flow rate specified in Table 21 will increase as specified in Table 25 due to the extra frictional loss introduced by the glycol. Size pump accordingly. 3. Strictly follow glycol manufacturer’s guidelines and recommendations when adding glycol in the heating system. 4. The system should be designed to maintain the recommended water flow rate shown in Table 21 while never exceeding the range of absolute flow rates shown in Table 24. Exceeding the maximum water flow rates can cause pipe erosion, damage the flow switch, and allow unsafe operation. a. Maintaining sufficient flow through the boiler will help prevent the buildup of scale. Table 21: Temperature rise, flow rate, and head loss Recommended Range Delta 20 °F Delta 25 °F Delta 30 °F Delta 35 °F Delta 40 °F Delta 45 °F... -
Page 39: Standard Piping Components
IX. HYDRONIC PIPING (CONTINUED) E. Standard Piping Components WARNING WARNING 1. Safety Relief Valve (Required) Burn Hazard. Safety relief valve discharge shall The PFC Boiler is shipped with an installed pressure be piped in such a way to prevent or eliminate relief valve. potential burn risk. a. The safety relief valve must be installed with DO NOT pipe in any area where freezing could spindle in vertical position. Installation of the occur. -
Page 40: Water Quality And Treatments
IX. HYDRONIC PIPING (CONTINUED) 10. Flow Control Valve (Strongly Recommended) The flow control valve prevents flow through NOTICE NOTICE the system unless the circulator is operating. Flow control valves are used to prevent gravity The PFC heat exchanger is made from stainless circulation in circulator zone systems through zones steel tubular double coil having relatively narrow that are not calling for heat. -
Page 41: Oxygen Contamination
IX. HYDRONIC PIPING (CONTINUED) The TDS (in ppm) is determined by measuring the NOTICE NOTICE electrical conductivity (µS/cm) of the water and multiplying by a conversion factor (typically 0.65 Water temperatures over 140 °F (60 °C) greatly for drinking water). increase the affects of corrosive chemicals. 6. Chlorine and Chloride can be very corrosive to Chlorine and Chloride have different levels stainless steel. Ensure the level of chlorine is less of corrosion effects on stainless steel. It is than 5 ppm and the level of chloride is less than recommended for chlorine (Cl2) levels to be below 1000 ppm. - Page 42 IX. HYDRONIC PIPING (CONTINUED) Table 22: Corrosion/Scale Inhibitors and Removal Agents Producers Fernox Sentinel Sotin ADEY Inhibitors Protector F1/Alphi 11 X100, X500 Sotin 212 MC1+ Noise reducer X200 Universal Restorer X300 Cleaner Sludge remover Protector F1, Cleaner F3 X400 Sotin 212 Antifreeze Alphi 11 X500...
-
Page 43: Heating Boiler Piping Diagrams
X. HEATING BOILER PIPING DIAGRAMS Figure 14: Single Boiler, Primary/Secondary Piping Single AMP/BFIT Primary/Secondary Piping System Circulator To System Pressure Reducing Valve Isolation Valve Air Vent Purge Valve Make Up Water From System Factory Supplied Manifold Isolation Valve Expansion Tank Check Valve Boiler Circulator Y-Strainer No more than 12 inches or 4 pipe diameters... - Page 44 X. HEATING BOILER PIPING DIAGRAMS (CONTINUED) Figure 15: Multiple Boiler, Primary/Secondary with Common Header Piping AMP Pipng with Common Header System Circulator To System Air Vent Make Up Water Purge Valve From System Check Valve Pressure Reducing Valve Expansion Tank Isolation Valve Check Valve Factory Supplied Manifold Y-Strainer...
- Page 45 X. HEATING BOILER PIPING DIAGRAMS (CONTINUED) Figure 16: Multiple Boiler, Primary Reverse-Return Piping Air Vent From System System Pump Full Port Isolation Valve Expansion Tank Y-Strainer Motorized isolation Valve Pressure Reducing Valve Make Up Water Factory Supplied Manifold Check Valve To System AMP Variable Primary Piping 8/30/2019 1.
- Page 46 Multiple AMP Boiler Piping with Hydraulic Separator 11/12/2018 X. HEATING BOILER PIPING DIAGRAMS (CONTINUED) Figure 18: Multiple Boiler, Primary Secondary Piping with Hydronic Separator System Circulator Hydraulic Separator Isolation Valve To System Check Valve From System Make Up Water Check Valve Pressure Reducing Valve Expansion Tank Boiler Circulator...
-
Page 47: Gas Piping
XI. GAS PIPING A. Guidelines and Requirements 10. If the high or low gas pressure switch tripped, it All installation must conform to the National Fuel must be manually reset before the appliance can Gas Code ANSI Z223.1/NFPA54, and/or local codes. be restarted. (See Figure 21) In Canada, installation must conform to the latest 11. Gas piping shall be supported by fixed hangers or edition of CSA B149.1 National Gas and Propane Gas stands and not by the appliance. - Page 48 XI. GAS PIPING (CONTINUED) Maximum capacity of schedule 40 black pipe in CFH* Table 26: Natural Gas, Inlet Pressure 14.0 in wc (3.4 kPa)or less; 0.5 in wc (0.12 kPa) Pressure Drop Nominal Inside Length of Pipe (Ft) Pipe Size Diameter (In) (In)
- Page 49 XI. GAS PIPING (CONTINUED) WARNING WARNING Table 28: Specific Gravity Correction Factors Specific Correction Specific Correction Failure to properly pipe gas supply to appliance may Gravity Factor Gravity Factor result in improper operation and damage. Always assure gas piping is absolutely leak free and of the 0.60 1.00 0.90 0.82 proper size and type for the connected load. 0.65 0.96 0.78 An additional gas pressure regulator may be 0.70 0.93 1.10 0.74...
-
Page 50: Electrical
XII. ELECTRICAL A. General DANGER DANGER Install wiring and electrically ground the appliance in accordance with authority having jurisdiction or, in the Electrical Shock Hazard: Ensure all electrical absence of such requirements, follow the National connections are disconnected before attempting Electrical Code, NFPA 70, and/or Canadian Electrical installation or service of electrical components or Code Part 1, CSA C22.1. connections of the appliance or building. Lockout 1. A separate electrical circuit must be run from all electrical boxes with padlock once power is the main electrical service with an over-current turned off. -
Page 51: Appliance Wiring
XII. ELECTRICAL (CONTINUED) C. Appliance Wiring f. Avoid placing senors near potential sources of electrical noise such as transformers, power lines, 1. Connect to field wiring inside the control box. . and fluorescent lighting. Wire the sensor to the I I nside the control box are five printed circuit boards appliance using 22 gauge or larger wire. As with (PCB’s). the sensor, the sensor wiring should be routed away from sources of electrical noise. Where it is Table 31: PFC PCB's impossible to avoid such noise sources, wire the sensor using a 2 conductor, UL Type CM, AWM Printed Circuit Functions/Connection Style 2092, 300 Volt 60 C shielded. - Page 52 XII. ELECTRICAL (CONTINUED) Boiler must be grounded in accordance with ANSI National Electric Code. Connect to V/C/P Power Supply Primary To Grounding Fuses Ground Screw Conductor Blower Terminal Combustion Blower Power Fuses Fuses used for only 208 V and 230 V Transformer used for only 208 V and 230 V...
- Page 53 XII. ELECTRICAL (CONTINUED) Boiler must be grounded in accordance Connect to V/C/P with ANSI National Electric Code. Power Supply Primary To Grounding Fuses Ground Screw Conductor Blower Terminal Fuses Combustion Blower Power Transformer 120vac 24vac Continue to low Concert Boiler voltage circuit PCB-01 Control (A1167)
- Page 54 XII. ELECTRICAL (CONTINUED) PCB-01 (3A Slow Blow) PCB-05 Continue from high voltage circuit P4b-1 P18a-4 P5-11 Central Heat Concert Boiler 24vac Enable/ Control (A1167) J17/W1 Disable Input (STAT) J8-3 P5-8 P4b-2 P18a-3 J8-6 P5-2 P18a-2 P4b-4 Setpoint or Modulation P5-1 J8-7 P4b-3 P18a-1...
- Page 55 XII. ELECTRICAL (CONTINUED) Concert Boiler Control (A1167) PCB-02 F2 (6.3A Slow Blow) J4-6 P31-4 Power Supply (120 or 24 VAC) P31-5 J4-7 System Pump (Supplied by others) Spare F3 (6.3A Slow Blow) J4-4 P31-2 Power Supply (120 or 24 VAC) P31-6 J4-5 Boiler Pump/Circulator...
-
Page 56: System Start-Up
XIII. SYSTEM START-UP A. Check System Setup DANGER DANGER 1. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer Do not use matches, candles, or other open flame to installation instructions contained in this manual. ignition sources to check for leaks. 2. Confirm all electrical, water, and gas supplies are Make sure that the area around the appliance is turned off at the source and that venting is clear clear and free from combustible materials, gasoline of obstructions. and other flammable vapors and liquids. 3. Flush the system to remove sediment, flux, and other contaminants. This must be done with the appliance isolated from the system. ... - Page 57 XIII. SYSTEM START-UP (CONTINUED) FOR YOUR SAFETY READ BEFORE OPERATING/P OUR VOTRE SECURITE LISEZ AVANT DE METTRE EN MARCHE WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. AVERTISSEMENT: Quiconque ne respecte pas à...
-
Page 58: Combustion Air/Fuel Adjustment
XIII. SYSTEM START-UP(CONTINUED) C. Combustion Air/Fuel Adjustment 6. Verify O (or CO ) and CO concentration are within limits specified in Table 32. Note: the values in 1. For high fire adjustment this table are for sea level only. For high altitude a. Lock the appliance in high fire and allow fan speed installation, above 2000 ft. consult factory. and combustion analyzer reading to stabilize before taking combustion readings. To lock in high fire, select MAIN MENU >> OPERATION. Select lock symbol, type password and select ENTER. From the Operation screen, select Automatic / Manual Firing Rate Control >>Manual... -
Page 59: Field Conversion Of Gas Type
XIII. SYSTEM START-UP(CONTINUED) D. Field Conversion of Gas Type WARNING WARNING This appliance is factory tested and set up for the gas type selected but can be field converted with the Make sure that all adjustments at high fire are following steps. made with the throttle, not offset screw. 1. Connect the new gas supply to the appliance, check The offset screw has been factory set using for leaks, and purge the gas line in accordance with precision instruments and must never be adjusted the National Fuel Gas Code, ANSI Z223.1/NFPA... -
Page 60: Pump Control
XIII. SYSTEM START-UP(CONTINUED) E. Pump Control H. Testing of Controls and Safety Devices Ensure the appropriate pump parameters are selected Prior to placing the appliance in operation, the in the Pumps menu of the Honeywell S7999D Display. installing contractor or other responsible personnel Refer to the Honeywell S7999D Display manual for must perform safety and control device limit tests more information. to ensure proper operation of the appliance. Refer to Table 34 for recommended method(s) of carrying F. Check Thermostat Operation out these safety limit devices tests. Verify that the appliance starts and stops in response to calls for hot water. Make sure that the appropriate circulator(s) start and stop. G. Adjust Supply Water Temperature As shipped, the central heat and DHW setpoint is 180°F (82.2°C). If necessary, adjust this to the appropriate settings for the system to which this appliance is connected. For information on how to... -
Page 61: Service And Maintenance
XIV. SERVICE AND MAINTENANCE IMPORTANT PRODUCT SAFETY INFORMATION IMPORTANT PRODUCT SAFETY INFORMATION REFRACTORY CERAMIC FIBER PRODUCT REFRACTORY CERAMIC FIBER PRODUCT WARNING: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperature above 1805 °F, such as during direct flame contact, RCF changes into crystaline silica, a know carcinogen. When disturbed as a result of servicing or repair, these substances became airborne and, if inhaled, may be hazardous to your health. AVOID Breathing Fiber Particulates and Dust Do not remove or replace RCF parts or attempt any service or repair work involving RCF without Precautionary Measures: wearing the following protective gears: 9. -
Page 62: General Maintenance
XIV. SERVICE AND MAINTENANCE A. General Maintenance WARNING WARNING 1. Keep the area around the appliance free from combustible materials. (Gasoline and other Read and understand the entire manual before flammable vapors and liquids) attempting installation, start-up, operation, or 2. Keep the area around the combustion air inlet service. Installation and service must be performed terminal free from contaminants. - Page 63 XIV. SERVICE AND MAINTENANCE (CONTINUED) 2. Igniter Electrode DANGER DANGER a. Disconnect power to the unit and remove ignition electrode from the burner door. This appliance uses flammable gas, high voltage electricity, moving parts, and very hot water under b. Visually inspect igniter assembly (ceramic high pressure. Ensure that all gas and electric power insulators, bracket, and graphite gasket) for damage. Replace igniter assembly if the electrodes supplies are off and that the water temperature is are deformed or ceramic insulators are cracked. cool before attempting any disassembly or service. Do not attempt any service work if gas is present in the air around the appliance. Never modify, remove or tPFCer with any control device.
- Page 64 XIV. SERVICE AND MAINTENANCE (CONTINUED) WARNING WARNING d. Inspect ultra-violet (uv) scanner lens and remove any debris with a soft cloth. If Failure to properly secure the burner/blower/gas condensate or fog is observed on the glass, valve assembly to the heat exchanger could lead the gaskets may need to be replaced. to property damage, personal injury or loss of life. Read, understand and follow all the instructions and warnings contained in ALL of the component instruction manuals.
-
Page 65: Restarting After Prolong Shutdown
XIV. SERVICE AND MAINTENANCE (CONTINUED) E. Troubleshooting g. Any accumulation of soot or debris should be Refer to the troubleshooting section in the Honeywell thoroughly cleaned out. S7999D Display manual on how to navigate the Limit 6. Combustion air filter with air box String Status screen which shows an active safety limit h. Undo the latches on the filter box to lift the lid status and for an in-depth guide to all the possible and access the filter. lockouts as well as recommended corrective actions to restore operation. Clean the filter of dust and debris using compress air or water. j. Replace filter if it appears damaged or deteriorated. -
Page 66: Appendix A: Tables
APPENDIX A: TABLES XIII. System Start-up I. Hazard Definitions Table 32: Combustion O Levels ..... 58 II. Read Before Proceeding Table 33: Approximate Throttle Screw III. Product Rating, Specifications, and Dimensional Data 7 Position for Gas Types . -
Page 67: Appendix B: Figures
APPENDIX B: FIGURES I. Hazard Definitions II. Read Before Proceeding III. Product Rating, Specifications, and Dimensional Data Figure 1: PFC Boiler Dimensions ..................9 IV. PFC Component Identification Figure 2: Component Identification . - Page 68 ® ® Boilers PFC-2000, PFC-2500, PFC-3000, PFC-3500, PFC-4000 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.