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PEERLESS PureFire REV2 PF-80 User Manual

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PUREFIRE
®
REV
2
Boilers
PF-50 PF-80 PF-110 PF-140 PF-210 PF-399
Gas
Installation,
Operation &
Maintenance
Manual
As an ENERGY STAR
®
Partner, PB Heat, LLC has determined that
this product meets the ENERGY STAR guidelines for energy efficiency.
®

Table of Contents

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PEERLESS PureFire REV2 PF-80 Specifications

General IconGeneral
ModelPF-80
TypeBoiler
Input BTU/hr80, 000
AFUE95%
Gas Connection Size1/2" NPT
IgnitionElectronic Ignition
Fuel TypeNatural Gas
Vent Size2 inch
Electrical Requirements120V, 60Hz
Efficiency95% AFUE

Summary

USING THIS MANUAL

INSTALLATION SEQUENCE

Follow installation instructions in order to minimize interferences and maximize safety during boiler installation.

SPECIAL ATTENTION BOXES

Boxes supplementing instructions, noting potential hazards and their definitions.

1. PREINSTALLATION

A. GENERAL

General information about boiler inspection, handling, and contractor qualifications.

B. CODES & REGULATIONS

Installation must comply with state, local codes, and national standards like ASME and ANSI.

C. ACCESSIBILITY CLEARANCES

Specifies minimum recommended clearances for boiler installation and access.

D. COMBUSTION AND VENTILATION AIR

Details requirements for combustion air supply, including indoor/outdoor options and sizing.

E. PLANNING THE LAYOUT

Prepare sketches and notes showing boiler installation layout to minimize interferences.

2. BOILER SET-UP

A. GENERAL

General guidelines for boiler installation, ensuring protection from water and proper support.

B. WALL MOUNTING

Instructions for mounting the boiler on a wall using an optional bracket kit.

C. FLOOR STANDING INSTALLATION

Guidance for floor standing installations, emphasizing the need for proper leveling.

3. VENTING & AIR INLET PIPING

A. GENERAL

Install venting system according to instructions and codes. Vent system operates under positive pressure.

B. APPROVED MATERIALS

Lists approved materials for exhaust vent piping, emphasizing correct usage.

C. EXHAUST VENT/AIR INTAKE PIPE LOCATION

Instructions for locating vent and air intake piping for inspection and proper function.

D. EXHAUST VENT/AIR INTAKE PIPE SIZING

Details on sizing vent and air intake piping, including equivalent length calculations.

E. EXHAUST VENT/AIR INTAKE INSTALLATION

Installation guidelines for vent and air intake connections, ensuring proper slope and sealing.

F. EXHAUST TAPPING FOR VENT SAMPLE

Procedure for drilling and tapping the vent pipe for combustion gas sampling.

G. BOILER REMOVAL FROM COMMON VENTING SYSTEM

Steps for safely removing an existing boiler from a common venting system.

4. WATER PIPING AND CONTROLS

A. GENERAL

Size water piping according to system requirements and clean systems before installation.

B. OPERATING PARAMETERS

Information on minimum system pressure and flow rates for proper boiler operation.

C. SYSTEM COMPONENTS

Brief descriptions of system components like gauges, air separators, and expansion tanks.

D. SYSTEM PIPING

Illustrations and explanations of various piping configurations for heating zones.

E. FREEZE PROTECTION

Guidance on using glycol solutions for freeze protection and related system considerations.

F. SPECIAL APPLICATIONS

System piping recommendations for chilled medium systems and forced air systems.

5. FUEL PIPING

A. GENERAL

All fuel piping must be in accordance with local codes and the National Fuel Gas Code.

B. FUEL LINE SIZING

Determine required gas flow rate and size fuel piping based on capacity tables.

C. GAS SUPPLY PIPING - INSTALLATION

Install gas piping ensuring access and including a sediment trap.

D. GAS SUPPLY PIPING - OPERATION

Properly purge gas lines and check gas supply pressure for safe operation.

E. MAIN GAS VALVE - OPERATION

Information on the gas valve/venturi assembly and recommended CO2 settings.

6. CONDENSATE DRAIN PIPING

A. GENERAL

Dispose of condensate according to local codes and ensure proper removal for appliance operation.

B. CONDENSATE SYSTEM

Description of the condensate system components designed to prevent backup and neutralize acidity.

C. CONDENSATE DRAIN PIPE MATERIAL

Specifies approved materials for condensate drain piping, avoiding materials attacked by acid.

D. CONDENSATE DRAIN PIPE SIZING

Guidelines for sizing condensate drain pipe and tubing.

E. CONDENSATE DRAIN PIPE INSTALLATION

Instructions for installing condensate drain piping, ensuring proper slope or using a pump.

7. ELECTRICAL CONNECTIONS

A. GENERAL

Appliance must be wired according to local codes and the National Electrical Code.

B. CUSTOMER CONNECTIONS

Details on electrical knockouts and terminals for connecting wiring and components.

C. ZONE CIRCULATOR WIRING

Wiring diagram for a typical circulator zone relay.

D. INTERNAL WIRING

Explanation of internal wiring components for boiler schematics.

8. BOILER CONTROL: INTERNAL WIRING & OPERATION

A. CONTROL OVERVIEW

The boiler control manages ignition, limits, circulators, and gas flow, offering unique features.

B. IGNITION SEQUENCE

Graphical and step-by-step description of the boiler's ignition cycle and flame sensing.

C. BOILER CONTROL

Details on pump modes for flexible piping arrangements and circulator sizing.

D. CENTRAL HEATING

Explanation of various central heating modes, including thermostat and outdoor reset.

E. DOMESTIC HOT WATER (DHW)

Description of DHW modes, priority settings, and heat dump functions.

F. SERVICE NOTIFICATION

Enables setting up service reminders based on hours, cycles, or a specific date.

G. SYSTEM TEST

Allows installers to test boiler operation at low power, ignition, or maximum power.

H. STATUS & FAULT HISTORY

Provides access to view system status and detailed fault history logs.

I. SENSOR RESISTANCE

Information on typical resistance values for boiler sensors at different temperatures.

J. MULTIPLE BOILERS

Instructions for cascading boilers, including master/dependent setup and system piping.

K. DEFAULTS

Options to restore factory defaults or save/reset site-specific default settings.

9. START-UP PROCEDURE

A. GENERAL

Confirm all utilities are off, verify installation, and turn on electricity and gas.

B. CHECK WATER PIPING

Fill the boiler and system with water, purging air and checking for leaks.

C. CHECK GAS PIPING

Turn on gas, connect manometer, check pressure, and double check fuel gas supply.

D. CHECK OPERATION

Set thermostats, turn on power, check display, and set up control for desired operation.

E. LIGHTING & OPERATING PROCEDURES

Safety instructions for operating the boiler, including what to do if gas is smelled.

10. TROUBLESHOOTING

A. BLOCKING ERRORS

Details blocking errors displayed on the controller with corresponding corrective actions.

B. LOCKING ERRORS

Explains locking errors, their display codes, and steps to reset and resume operation.

C. ERROR MESSAGES IN A CASCADE SYSTEM

Information on error display and handling within a multiple boiler cascade system.

D. WARNING ERRORS

Lists warning errors related to sensor faults, flue issues, and cascade communication.

11. MAINTENANCE

A. GENERAL (WITH BOILER IN USE)

General boiler observations and checks for owners, including safety and potential issues.

B. WEEKLY (WITH BOILER IN USE)

Procedure for flushing the float-type low-water cut-off weekly.

C. ANNUALLY (BEFORE START OF HEATING SEASON)

Annual inspection checklist for qualified service technicians.

D. CONDENSATE CLEANING INSTRUCTIONS

Detailed instructions for removing and cleaning condensate tanks and components.

E. COMBUSTION CHAMBER COIL CLEANING INSTRUCTIONS

Procedure for cleaning heat exchanger coils and combustion chamber.

APPENDIX A. STATUS SCREENS

Boiler Status Displays

Describes various boiler status screens including initialization, standby, and demand modes.

Special Demand & Ignition Status

Details status screens for freeze protection, store warm hold, and ignition/flame handling.

Error Handling Status

Explains status screens for blocking errors, lockout errors, and system warnings.

Cascade System Status

Shows status displays for master and dependent boilers in a cascade system.

APPENDIX B. USER MENU

Status Screens

Displays current supply setpoint, system/vent temperatures, and circulator status.

Settings Screens

Allows adjustment of Central Heating, DHW, and Time/Date settings.

Messages Screen

Displays the last block message and the last lock message.

APPENDIX C. INSTALLER MENU

Installer Menu Overview

Instructions on how to access and navigate the installer menu.

Status Screens

Displays system status, fan speeds, flame signal, and ignition attempts.

Boiler Settings

Configuration options for pump mode, installation location, vent material, and safety functions.

CH (Central Heating) Settings

Settings for CH modes, outdoor reset, boost function, and anti-cycling.

DHW (Domestic Hot Water) Settings

Settings for DHW modes, priority, heat dump function, and maximum allowable rate.

Service Notification

Enables setting service reminders based on time, cycles, or a specific date.

System Test

Allows forcing control operation at low power, ignition, or maximum power for testing.

Cascade Settings

Configuration for multiple boiler cascade operation, including addresses and rotation intervals.

Default Settings

Options to restore factory or site default settings.

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