PEERLESS PUREFIRE PFC-850 Instruction manual

PUREFIRE®
Boilers
PFC-850 PFC-1000 PFC-1500
Gas
Installation,
Operation &
Maintenance
Manual
®

USING THIS MANUAL 1
A. INSTALLATION SEQUENCE ................ 1
B. SPECIAL ATTENTION BOXES .............. 1
1. PREINSTALLATION 2
A. GENERAL............................... 2
B. CODES & REGULATIONS .................. 2
C. ACCESSIBILITY CLEARANCES.............. 3
D. COMBUSTION & VENTILATION AIR ......... 3
E. PLANNING THE LAYOUT .................. 6
2. BOILER SET-UP 7
A. GENERAL............................... 7
B. STACKING MULTIPLE BOILERS............. 7
3. VENTING & AIR INLET PIPING 8
A. GENERAL............................... 8
B. APPROVED MATERIALS................... 8
C. EXHAUST VENT/AIR INTAKE
PIPE LOCATION ......................... 8
D. EXHAUST VENT/AIR INTAKE PIPE SIZING ... 12
E. EXHAUST VENT/AIR INTAKE PIPE
INSTALLATION ......................... 12
F. TEST PORT FOR EXHAUST SAMPLING ..... 13
G. COMMON VENTING MULTIPLE BOILERS .... 13
H. BOILER REMOVAL FROM COMMON
VENTING SYSTEM ...................... 14
4. WATER PIPING & CONTROLS 15
A. GENERAL.............................. 15
B. WATER QUALITY ....................... 15
C. OPERATING PARAMETERS ............... 16
D. SYSTEM COMPONENTS ................. 16
E. SYSTEM PIPING ........................ 20
F. FREEZE PROTECTION ................... 20
G SPECIAL APPLICATIONS ................. 24
5. FUEL PIPING 25
A. GENERAL.............................. 25
B. FUEL LINE SIZING....................... 25
C. GAS SUPPLY PIPING – INSTALLATION ..... 25
D. GAS SUPPLY PIPING – OPERATION ........ 26
E. MAIN GAS VALVES – OPERATION ......... 27
6. CONDENSATE TRAP & DRAIN SYSTEM 28
A. GENERAL.............................. 28
B. CONDENSATE SYSTEM.................. 28
C. CONDENSATE DRAIN PIPING ............. 28
7. ELECTRICAL CONNECTIONS &
INTERNAL WIRING 30
A. GENERAL.............................. 30
B. CUSTOMER CONNECTIONS .............. 30
C. ZONE CIRCULATOR WIRING .............. 31
D. INTERNAL WIRING ...................... 31
8. BOILER CONTROL: OPERATION 34
A. IGNITION SEQUENCE .................... 34
B. STATUS DISPLAY....................... 36
C. USER MENU ........................... 39
D. INSTALLER MENU ...................... 41
E. DEFAULTS............................. 53
F. MULTIPLE BOILERS ..................... 53
9. START-UP PROCEDURE 57
A. GENERAL.............................. 57
B. CHECK WATER PIPING................... 57
C. CHECK ELECTRIC POWER ................ 57
D. CHECK GAS PIPING ..................... 57
E. CHECK OPERATION ..................... 57
F. COMBUSTION TEST..................... 57
G. TEST OPERATING LIMIT ................. 58
H. TEST HIGH LIMIT ....................... 59
I. MULTIPLE BOILER SYSTEMS ............. 59
J. LIGHTING & OPERATING INSTRUCTIONS ... 60
10. TROUBLESHOOTING 61
A. ERRORS............................... 61
B. BLOCKING ERRORS ..................... 61
C. LOCKING ERRORS ...................... 61
D. WARNING ERRORS ..................... 61
E. SPECIAL IGNITION/FLAME FAILURE ........ 62
F. INTERLOCKS OPEN ..................... 62
11. MAINTENANCE 69
A. GENERAL (WITH BOILER IN USE) .......... 69
B. WEEKLY (WITH BOILER IN USE) ........... 69
C. ANNUALLY (BEFORE THE START OF
HEATING SEASON) ..................... 70
D. CONDENSATE SYSTEM CLEANING
INSTRUCTIONS......................... 70
E. COMBUSION CHAMBER COIL CLEANING
INSTRUCTIONS......................... 71
12. BOILER DIMENSIONS & RATINGS 72
13. REPAIR PARTS 74
APPENDIX A. PIXEL DISPLAY SCREEN 84
A. STAND ALONE PIXEL DISPLAY............ 84
B. MULTIPLE BOILER (CASCADE) PIXEL
DISPLAY .............................. 84
APPEN. B. BURNER LCD STATUS
SCREENS 86
APPENDIX C. USER MENU 88
APPENDIX D. INSTALLER MENU
STRUCTURE 90
APPENDIX E. COMBUSTION TEST
RECORD 92
SERVICE LOG 93
TABLE OF CONTENTS
TABLE OF CONTENTS

A. INSTALLATION SEQUENCE
Follow the installation instructions provided in this
manual in the order shown. The order of these
instructions has been set in order to provide the installer
with a logical sequence of steps that will minimize
potential interferences and maximize safety during boiler
installation.
B. SPECIAL ATTENTION BOXES
Throughout this manual special attention boxes are
provided to supplement the instructions and make special
notice of potential hazards. The definition of each of
these categories, in the judgement of PB Heat, LLC
are as follows:
USING THIS MANUAL
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
NOTICE
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
CAUTION
DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING
1
USING THIS MANUAL

A. GENERAL
1. PureFire®boilers are supplied completely assembled
as packaged boilers. The package should be inspected
for damage upon receipt and any damage to the unit
should be reported to the shipping company and
wholesaler. This boiler should be stored in a clean,
dry area.
2. Carefully read these instructions and be sure to
understand the function of all connections prior to
beginning installation. Contact your PB Heat, LLC
Representative for help in answering questions.
3. This boiler must be installed by a qualified contractor.
The boiler warranty may be voided if the boiler is not
installed correctly.
4. A hot water boiler installed above radiation or as
required by the Authority having jurisdiction, must be
provided with a low water fuel cut-off device either as
part of the boiler or at the time of installation.
B. CODES & REGULATIONS
1. Installation and repairs are to be performed in strict
accordance with the requirements of state and local
regulating agencies and codes dealing with boiler and
gas appliance installation.
2. In the absence of local requirements the following
should be followed:
a. ASME Boiler and Pressure Vessel Code, Section
IV - “Heating Boilers”
b. ASME Boiler and Pressure Vessel Code, Section
VI - “Recommended Rules for the Care and
Operation of Heating Boilers”
c. ANSI Z223.1/NFPA 54 - “National Fuel Gas Code”
d. ANSI/NFPA 70 - “National Electrical Code”
e. ANSI/NFPA 211 - “Chimneys, Fireplaces, Vents
and Solid Fuel Burning Appliances”
3. Where required by the authority having jurisdiction,
the installation must conform to the Standard for
Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1.
**Please read if installing in Massachusetts**
Massachusetts requires manufacturers of Side Wall
Vented boilers to provide the following information
from the Massachusetts code:
·A hard wired carbon monoxide detector with
an alarm and battery back-up must be installed
on the floor level where the gas equipment is to
be installed AND on each additional level of the
dwelling, building or structure served by the side
wall horizontal vented gas fueled equipment.
·In the event that the side wall horizontally vented
gas fueled equipment is installed in a crawl space
or an attic, the hard wired carbon monoxide
detector with alarm and battery back-up may be
installed on the next adjacent floor level.
·Detector(s) must be installed by qualified licensed
professionals.
·APPROVED CARBON MONOXIDE
DETECTORS: Each carbon monoxide detector
shall comply with NFPA 720 and be ANSI/UL
2034 listed and IAS certified.
·SIGNAGE: A metal or plastic identification plate
shall be permanently mounted to the exterior of
the building at a minimum height of eight (8) feet
above grade directly in line with the exhaust vent
terminal for the horizontally vented gas fueled
heating appliance or equipment. The sign shall
read, in print size no less than one-half (1/2) inch
in size, “GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS”.
·EXEMPTIONS to the requirements listed above:
°The above requirements do not apply if the
exhaust vent termination is seven (7) feet or
more above finished grade in the area of the
venting, including but not limited to decks and
porches.
° The above requirements do not apply to a
boiler installed in a room or structure separate
from the dwelling, building or structure used in
whole or in part for residential purposes.
·This boiler installation manual shall remain with
the boiler at the completion of the installation.
See the latest edition of Massachusetts Code 248 CMR
for complete verbiage and also for additional (non-vent
related) requirements (248 CMR is available online).
If your installation is NOT in Massachusetts, please
see your authority of jurisdiction for requirements that
may be in effect in your area. In the absence of such
requirements, follow the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1,
Natural Gas and Propane Installation Code.
2
PREINSTALLATION
1. PREINSTALLATION
Liquefied Petroleum (LP) Gas or Propane is heavier
than air and, in the event of a leak, may collect in low
areas such as basements or floor drains. The gas
may then ignite resulting in a fire or explosion.
WARNING

C. ACCESSIBILITY CLEARANCES
1. The PureFire®boiler is certified for closet installations
with zero clearance to combustible construction. In
addition, it is design certified for use on combustible
floors. Do not install on carpeting.
2. Figure 1.1 shows the minimum recommended
clearances to allow reasonable access to the boiler for
inspection and maintenance. However, local codes or
special conditions may require greater clearances.
D. COMBUSTION AND VENTILATION AIR
1. The PureFire®boiler is designed for operation with
combustion air piped directly to the boiler from
outside the building (sealed combustion). Combustion
air can be supplied from within the building only if
adequate combustion and ventilation air is provided
in accordance with the section of the National
Fuel Gas Code entitled, “Air for Combustion and
Ventilation” or applicable provisions of the local
building codes.
2. If the combustion air is piped directly to the boiler
from outside the building, no additional combustion
or ventilation air is required. Otherwise, follow
the National Fuel Gas Code recommendations
summarized in subsections 3 through 10.
3. Required Combustion Air Volume: The total
required volume of indoor air is to be the sum of the
required volumes for all appliances located within
the space. Rooms communicating directly with the
space in which the appliances are installed and
through combustion air openings sized as indicated
in Subsection 3 are considered part of the required
volume. The required volume of indoor air is to be
determined by one of two methods.
a. Standard Method: The minimum required volume
of indoor air (room volume) shall be 50 cubic feet
per 1000 BTU/Hr (4.8 m3/kW). This method is to
be used if the air infiltration rate is unknown or if
the rate of air infiltration is known to be greater
than 0.6 air changes per hour. As an option, this
method may be used if the air infiltration rate is
known to be between 0.6 and 0.4 air changes
per hour. If the air infiltration rate is known to be
below 0.4 then the Known Air Infiltration Rate
Method must be used. If the building in which this
appliance is to be installed is unusually tight, PB
Heat recommends that the air infiltration rate be
determined.
b. Known Air Infiltration Rate Method:
where:
Ifan = Input of the fan assisted appliances
in Btu/hr
ACH = air change per hour (percent of the
volume of the space exchanged per
hour, expressed as a decimal)
Note: These calculations are not to be used for
infiltration rates greater than 0.60 ACH.
3
PREINSTALLATION
Figure 1.1: Minimum Accessibility Clearances – PFC-850, PFC-1000, PFC-1500
15 ft3Ifan
ACH 1000Btu/hr
Required Volumefan = (
(

4. Indoor Air Opening Size and Location: Openings
connecting indoor spaces shall be sized and located as
follows:
a. Combining Spaces on the Same Floor: Provide
two permanent openings communicating with
additional spaces that have a minimum free area
of 1 in2per 1000 Btu/hr (22 cm2per 1000 W) of
the total input rating of all gas fired equipment but
not less than 100 in2(645 cm2). One opening is
to begin within 12 inches (305 mm) from the top
of the space and the other is to begin within 12
inches (305 mm) from the floor. The minimum
dimension of either of these openings shall be 3
inches (76 mm). See Figure 1.2 for an illustration
of this arrangement.
b. Combining Spaces on Different Floors: Provide
one or more permanent openings communicating
with additional spaces that have a total minimum
free area of 2 in2per 1000 Btu/hr (44 cm2per
1000 W) of total input rating of all equipment. See
Figure 1.3 for an illustration of this arrangement.
5. Outdoor Combustion Air: Outdoor combustion air
is to be provided through one or two permanent
openings. The minimum dimension of these air
openings is 3 inches (76 mm).
a. Two Permanent Opening Method: Provide two
permanent openings. One opening is to begin
within 12 inches (305 mm) of the top of the
space and the other is to begin within 12 inches
(305 mm) of the floor. The openings are to
communicate directly or by ducts with the
outdoors or with spaces that freely communicate
with the outdoors. The size of the openings shall
be determined as follows:
i. Where communicating directly or through
vertical ducts with the outdoors each opening
shall have a minimum free area of 1 in2per
4000 Btu/hr (22 cm2per 4000 W) of total
input rating for all equipment in the space. See
Figure 1.4 for openings directly communicating
with the outdoors or Figure 1.5 for openings
connected by ducts to the outdoors.
4
Figure 1.4: Air Openings – All Air Directly from
Outdoors
Figure 1.5: Air Openings – All Air from Outdoors
through Vertical Ducts
PREINSTALLATION
Figure 1.2: Air Openings – All Air from Indoors
on the Same Floor
Figure 1.3: Air Openings – All Air from Indoors
on Different Floors

ii. Where communicating with the outdoors
through horizontal ducts, each opening shall
have a minimum free area of 1 in2per 2000
Btu/hr (22 cm2per 2000 W) of total rated
input for all appliances in the space. See
Figure 1.6.
b. One Permanent Opening Method: Provide one
permanent opening beginning within 12 inches
(305 mm) of the top of the space. The opening
shall communicate directly with the outdoors,
communicate through a vertical or horizontal
duct, or communicate with a space that freely
communicates with the outdoors. The opening
shall have a minimum free area of 1 in2per 3000
Btu/hr of total rated input for all appliances in
the space and not less than the sum of the cross-
sectional areas of all vent connectors in the space.
The gas-fired equipment shall have clearances of
at least 1 inch (25 mm) from the sides and back
and 6 inches (150 mm) from the front of the
appliance. See Figure 1.7 for this arrangement.
6. Combination Indoor and Outdoor Combustion Air:
If the required volume of indoor air exceeds the
available indoor air volume, outdoor air openings or
ducts may be used to supplement the available indoor
air provided:
a. The size and location of the indoor openings
comply with Subsection 3.
b. The outdoor openings are to be located in
accordance with Subsection 4.
c. The size of the outdoor openings are to be sized
as follows:
where:
Areq = minimum area of outdoor openings.
Afull = full size of outdoor openings calculated
in accordance with Subsection 4.
Vavail = available indoor air volume
Vreq = required indoor air volume
7. Engineered Installations: Engineered combustion
air installations shall provide an adequate supply of
combustion, ventilation, and dilution air and shall be
approved by the authority having jurisdiction.
8. Mechanical Combustion Air Supply:
a. In installations where all combustion air is
provided by a mechanical air supply system,
the combustion air shall be supplied from the
outdoors at the minimum rate of 0.35 ft3/min per
1000 Btu/hr (0.034 m3/min per 1000 W) of the
total rated input of all appliances in the space.
b. In installations where exhaust fans are installed,
additional air shall be provided to replace the
exhaust air.
c. Each of the appliances served shall be interlocked
to the mechanical air supply to prevent main
burner operation when the mechanical air supply
system is not in operation.
d. In buildings where the combustion air is provided
by the mechanical ventilation system, the system
shall provide the specified combustion air rate in
addition to the required ventilation air.
9. Louvers & Grills:
a. The required size of openings for combustion,
ventilation, and dilution air shall be based on the
net free area of each opening.
i. Where the free area through a louver or grille
is known, it shall be used in calculating the
opening size required to provide the free area
specified.
ii. Where the free area through a louver or grille
is not known, it shall be assumed that wooden
louvers will have 25% free area and metal
louvers and grilles will have 75% free area.
iii. Non-motorized dampers shall be fixed in the
open position.
b. Motorized dampers shall be interlocked with the
equipment so that they are proven in the full open
position prior to ignition and during operation of
the main burner.
5
Figure 1.6: Air Openings – All Air from Outdoors
through Horizontal Ducts
Figure 1.7: Air Openings – All Air from Outdoors
through One Opening
PREINSTALLATION
Areq = Afull x 1 – Vavail
Vreq
( (

i. The interlock shall prevent the main burner
from igniting if the damper fails to open during
burner startup.
ii. The interlock shall shut down the burner if the
damper closes during burner operation.
10. Combustion Air Ducts:
a. Ducts shall be constructed of galvanized steel or
an equivalent corrosion- resistant material.
b. Ducts shall terminate in an unobstructed space,
allowing free movement of combustion air to the
appliances.
c. Ducts shall serve a single space.
d. Ducts shall not serve both upper and lower
combustion air openings where both such
openings are used. The separation between ducts
serving upper and lower combustion air openings
shall be maintained to the source of combustion
air.
e. Ducts shall not be screened where terminating in
an attic space.
f. Horizontal upper combustion air ducts shall
not slope downward toward the source of the
combustion air.
g. Combustion air intake openings located on the
exterior of buildings shall have the lowest side
of the combustion air intake opening at least 12
inches (305 mm) above grade.
11. Refer to Section 3 of this manual, Venting & Air Inlet
Piping, for specific instructions for piping the exhaust
and combustion air.
E. PLANNING THE LAYOUT
1. Prepare sketches and notes showing the layout of
the boiler installation to minimize the possibility of
interferences with new or existing equipment, piping,
venting and wiring.
2. The following sections of this manual should be
reviewed for consideration of limitations with
respect to:
a. Venting and Air Inlet Piping: Section 3
b. Water Piping: Section 4
c. Fuel Piping: Section 5
d. Condensate Removal: Section 6
e. Electrical Connections: Section 7
f. Boiler Control: Section 8
g. Boiler Dimensions and Ratings: Section 12
6
PREINSTALLATION
Do not install this boiler where gasoline or other
flammable liquids or vapors are stored or are in use.
WARNING
Do not install this boiler in the attic.
WARNING
This boiler is certified as an indoor appliance. Do not
install this boiler outdoors or locate where it will be
exposed to freezing temperatures.
WARNING

7
BOILER SET-UP
A. GENERAL
1. PureFire®boilers are intended for installation in an
area with a floor drain or in a suitable drain pan.
Do not install any boiler where leaks or relief valve
discharge will cause property damage.
2. The
PureFire®boiler is not intended to support
external piping. All venting and other piping should
be supported independently of the boiler.
3. Many jacket panels on the PureFire®boiler are
removable to allow inspection and maintenance. Do
not attached fixed brackets for piping or wiring on
removable jacket parts. Piping and/or wiring should
not obstruct access to removable panels.
4. Install the boiler level to prevent condensate from
backing up inside the boiler.
5. Use leveling feet to assure that the boiler is completely
level. This will prevent condensate from collecting
in the boiler and causing degradation of the heat
exchanger.
B. STACKING MULTIPLE BOILERS
Identical PFC-850, PFC-1000 or PFC-1500 boilers can
be stacked to save floor space on the installation. Figure
2.1 shows how the upper boiler is to be attached to the
lower boiler.
1. Remove all side jacket panels from the both boilers
and the top jacket panels from the lower boiler.
2. Remove the leveling legs from the boiler to be
installed on top.
3. Lift the upper boiler into place by passing 5 to 10 foot
(2-3 meter) lengths of 1” to 1-1/4” Schedule 40 or 80
steel pipe through the holes provided in the boiler frame.
4. Insert spacers, washers and bolts (provided) through
the holes provided in the frame of the lower boiler
and thread them into the threaded inserts on the base
of the upper boiler. Figure 2.1 shows this assembly.
Tighten the bolts securely.
5. Replace all the side jacket panels and discard the top
jacket panels from the lower boiler.
2. BOILER SET-UP
Figure 2.1: Stacking and Securing Boilers
This boiler must be installed level to prevent
condensate from backing up inside the boiler.
CAUTION
Do not lift these boilers by hand. Failure to comply
may result in serious injury, death or major property
damage.
WARNING
Figure 2.2: Lifting the Upper Boiler
CRANE LIFT ONLY
FORKLIFT OR
BY HAND
DO NOT LIFT

8
VENTING & AIR INLET PIPING
A. GENERAL
1. Install the PureFire®boiler venting system in
accordance with these instructions and with the National
Fuel Gas Code, ANSI Z223.1/NFPA 54, CAN/CGA
B149, and/or applicable provisions of local building
codes.
2. The
PureFire®boiler is approved for positive
pressure exhaust venting using either indoor air or
air piped from outside. It is ETL Listed as a Category
IV (Positive Pressure, Condensing Exhaust Vent)
Appliance.
B. APPROVED MATERIALS
1. Table 3.1 lists approved materials for vent pipe (and
adhesives where applicable). Use only these materials
for exhaust vent piping.
2. PVC Pipe and fittings are not to be used for exhaust
venting in confined spaces such as closet or alcove
installations or vent pipe that passes through attics.
3. Table 3.2 lists appropriate materials for air inlet
piping. Air inlet piping is to be sealed suitably to
prevent introduction of dirt, chemicals or other
contaminants to the inlet air stream.
4. Use of cellular core PVC (ASTM F891), cellular core
CPVC, or Radel®(polyphenolsulfone) in venting
systems shall be prohibited. Covering non-metallic
vent pipe and fittings with thermal insulation shall be
prohibited.
* PVC pipe/fittings are not to be used for venting within
confined spaces.
Notice: Installations in Canada require compliance with
ULC S636 - Standard for Type BH Gas Venting Systems.
C. EXHAUST VENT/AIR INTAKE PIPE
LOCATION
1. Install vent piping before installing water, fuel,
or condensate piping. Working from largest to
smallest diameter reduces the complexity of piping
interferences.
2. Vent and air intake piping is to be installed so that
there is sufficient access for routine inspection as
required in Section 11, of this manual.
3. The vent piping for this boiler is approved for zero
clearance to combustible construction. However, a
fire stop must be used where the vent pipe penetrates
walls or ceilings.
3. VENTING & AIR INLET PIPING
The venting system for this product is to be installed
in strict accordance with these venting instructions.
Failure to install the vent system properly may result in
severe personal injury, death or major property damage.
WARNING
This vent system operates under positive pressure.
Vent connectors serving appliances vented by
natural draft shall not be connected into any portion
of this venting system. Failure to comply may result
in serious injury, death or major property damage.
WARNING
Only the materials listed below are approved for use
with the PureFire®boiler. Use only these components
in accordance with these instructions. Failure to
use the correct material may result in serious injury,
death, or major property damage.
WARNING
This appliance uses a positive pressure venting
system. All joins must be sealed completely to
prevent leakage of flue products into occupied
spaces. Failure to do this may result in severe
personal injury, death or major property damage.
WARNING
Use of cellular core pipe for any exhaust vent
component is prohibited. Use of cellular core pipe
may result in severe personal injury, death, or major
property damage.
WARNING
Table 3.1: Approved Materials for Exhaust Vent Pipe
Description Material
Conforming to
Standard
Exhaust
Vent Piping
& Fittings
PVC (Sch 40 or 80)*ANSI/ASTM D1785
CPVC (Sch 40 or 80) ANSI/ASTM D1785
PVC-DWV*ANSI/ASTM D2665
DuraVent FasNSeal©
AL29-4c Stainless UL-1738
DuraVent PolyPro©
Polypropylene ULC-S636
CentroTherm InnoFlue©
Polypropylene ULC-S636
Table 3.2: Approved Materials for Air Inlet Piping
Description Material
Air Inlet Pipe
& Fittings
PVC (Cellular Core or Solid)
CPVC
ABS
Smoke Pipe (Galvanized or Steel)
Dryer Vent Pipe
Flexible Duct
Stainless Steel
Polypropylene

4. The Peerless®PureFire®boiler, like all high efficiency,
gas-fired appliances, is likely to produce a vapor plume
due to condensation. Surfaces near the vent termination
will likely become coated with condensation.
5. The maximum combined vent and air inlet pipe length
for PFC-850, PFC-1000 and PFC-1500 boilers is
200 equivalent feet (61 meters) for horizontal venting
and 500 equivalent feet (152 meters) for vertical
venting. Be sure that the boiler is located such that the
maximum vent length is not exceeded.
6. Air Intake Pipe Location – Sidewall Venting:
a. Provide a minimum of 1 foot (30 cm) clearance
from the bottom of the air intake pipe above
expected snow accumulation level. Snow removal
may be necessary to maintain clearances.
b. Do not locate air intake pipe in a parking area
where machinery may damage the pipe.
c. If the vent pipe and air inlet pipe terminations
penetrate the wall at the same level the minimum
distance between them is 8”center-to-center.
d. For multiple boiler installations, the minimum
horizontal distance between the inlet of one
boiler to the exhaust of an adjacent boiler is 8”
center-to-center. In addition, the minimum vertical
distance between the exhaust and air inlet is 6”.
See Figure 3.1 for an illustration.
e. The exhaust outlet of the vent pipe should not be
angled any more than 5º from horizontal.
f. Precautions should be taken to prevent
recirculation of flue gases to the air inlet pipe of
the boiler or other adjacent appliances.
7. Sidewall Venting Configuration:
a. See Figure 3.2 for an illustration of clearances for
location of exit terminals of direct-vent venting
systems.
• This boiler vent system shall terminate at
least 3 feet (0.9 m) above any forced air inlet
located within 10 ft (3 m). Note: This does not
apply to the combustion air intake of a direct-
vent appliance.
• Provide a minimum of 4 feet (1.22 m)
clearance distance from any door, operable
window, or gravity air intake into any building.
• Provide a minimum of 6 feet (1.83 m)
clearance to adjacent facing walls.
• Provide a minimum of 1 foot (30 cm)
clearance from the bottom of the exit terminal
above the expected snow accumulation level.
Snow removal may be required to maintain
clearance.
• Provide a minimum of 4 feet (1.22 m)
horizontal clearance from electrical meters, gas
meters, gas regulators, and relief equipment.
In no case shall the exit terminal be above or
below the aforementioned equipment unless
the 4 foot horizontal distance is maintained.
VENTING & AIR INLET PIPING
Covering non-metallic exhaust venting material is
prohibited and may result in severe personal injury,
death, or major property damage.
WARNING
Figure 3.1: Vent Pipe Spacing for Multiple
PureFire®Boilers
Figure 3.2: Exit Terminal Location for Mechanical Draft and Direct-Vent Venting Systems 9
If the maximum equivalent vent length is exceeded,
the maximum burner input rate may be reduced.
NOTICE

VENTING & AIR INLET PIPING
• Do not locate the exhaust exit terminal over
public walkways where condensate could drip
and create a hazard or nuisance.
• When adjacent to public walkways, locate the
exit terminal at least 7 feet above grade.
• Do not locate the exhaust termination directly
under roof overhangs to prevent icicles from
forming or recirculation of exhaust gases from
occurring.
• Provide 3 feet clearance from the inside corner
of adjacent walls.
b. Figure 3.3, 3.4 and 3.5 show approved sidewall
venting configurations using standard PVC or
CPVC fittings. A similar configuration using
FasNSeal stainless steel exhaust pipe can be used
with either PVC or other approved material for the
combustion air intake piping.
8. Figures 3.6 through 3.8 show recommended vertical
venting configurations.
a. Figure 3.6 illustrates a vertical venting
configuration using PVC inlet and exhaust. A
similar configuration can be constructed using a
FasNSeal stainless steel vent termination. PVC or
other approved materials may be used for air inlet
piping.
i. The opening of the air inlet piping is to be
a minimum of 12” (300 mm) above the
expected snow accumulation on the roof
surface.
ii. Locate the opening of the exhaust vent pipe a
minimum of 12” above the air inlet opening
to prevent flue gas from recirculating to the air
inlet.
b. Figure 3.7 shows vertical exhaust venting through
an unused chimney. In this case, combustion air
is supplied from inside the building. Section 1.D
provides guidelines for determining adequate
inside air.
c. Figure 3.8 illustrates another vertical venting
configuration through an unused chimney. In
this arrangement the combustion air is supplied
through the chimney as well.
Figure 3.3: Sidewall Exhaust Vent and Air Inlet Pipe
Figure 3.4: Sidewall Exhaust Vent with Indoor Air
10
Condensing flue gases can freeze on exterior
building surfaces which may cause discoloration and
degradation of the surfaces.
CAUTION
Figure 3.5: Offset Sidewall Exhaust Vent and Air
Inlet Pipe

VENTING & AIR INLET PIPING
Figure 3.6: Vertical Exhaust and Air Inlet Pipe
Figure 3.7: Vertical Exhaust Routed Through an
Unused Chimney with Indoor Air
Figure 3.9: Drain Tee and Air Inlet Connections
Figure 3.8: Vertical Exhaust Routed Through an
Unused Chimney with Outdoor Air
11

D. EXHAUST VENT/AIR INTAKE PIPE SIZING
1. A list of approved venting materials for the exhaust is
provided in Table 3.1 and a list of approved materials
for air inlet is provided in Table 3.2.
2. The total combined length of exhaust vent and air
intake piping is 200 equivalent feet (60 m).
a. PureFire®boilers may use air from the room
in which they are installed as long as there is
adequate combustion and ventilation air provided.
See Section 1.D: Combustion and Ventilation Air
of this manual for the minimum requirements. In
this case, a maximum of 200 equivalent feet of
exhaust vent pipe can be used.
b. The equivalent length of elbows, tees and other
fittings are listed in Table 3.3.
c. The total equivalent length can be calculated as
shown in Table 3.4.
E. EXHAUST VENT/AIR INTAKEV
INSTALLATION
1. Figure 3.10 shows the exhaust connection on the rear
of the boiler on the vertical centerline. The exhaust
connection is a FasNSeal stainless steel boot tee with
a drain which is included with each PFC-850, PFC-
1000 and PFC-1500 boiler. The tee provided is be
connected directly to the rear of the boiler as shown
in Figure 3.10.
2. The Air Intake connection for the PFC-850 &
PFC-1000 is a 6” galvanized collar to the right and
below the exhaust connection. The PFC-1500 has a
7” connection on the air box within the front blower/
gas valve area. This can be connected to any of the
approved air intake piping materials.
3. The Air Intake connection should be secured with (3)
screws and sealed.
4. Remove all burrs and debris from the joints and fittings.
5. Care should be taken to prevent dirt or debris
from entering the air intake connection. A screen is
provided inside the Air Intake fitting to prevent large
objects from entering the combustion system.
6. Horizontal lengths of exhaust vent must be installed with
a slope of not less than 1/4” per foot (21mm per meter)
toward the boiler to allow condensate to drain from the
vent pipe. If the vent pipe must be piped around an
obstacle that causes a low point in the piping, a drain
with an appropriate trap must be installed.
Les sections horizontales de l’évacuation doivent
être installées avec une pente d’au moins 1/4 po au
pied (21 mm par mètre) en direction de la chaudière
afin que le condensat puisse s’évacuer du tuyau
d’évacuation. Si le tuyau d’évacuation est acheminé
autour d’un obstacle qui crée un point bas dans la
tuyauterie, il est nécessaire alors d’installer un drain
équipé d’une vidange adéquate.
VENTING & AIR INLET PIPING
Figure 3.10: Exhaust Vent Connection
This appliance uses a positive pressure venting
system. All joints must be sealed completely to
prevent leakage of flue products into living spaces.
Failure to do this may result in severe personal
injury, death or major property damage.
WARNING
Exhaust Air Inlet Total
Straight Length of Pipe 100’ 50’ 150’
90° Elbows, SR 2 x 5’= 10’ 1 x 5’ = 5’ 15’
45° Elbows, SR 2 x 3’ = 6’ 6’
Air Intake Tee 0’ 0’
Outlet Coupling 0’ 0’
Total 171’
Table 3.4: Sample Equivalent Length Calculation
Table 3.3: Equivalent Length of Fittings
Fitting Description Equivalent Length
Elbow, 90° Short Radiusz 5 feet (1.5 m)
Elbow, 90° Long Radius 4 feet (1.2 m)
Elbow, 45° Short Radius 3 feet (0.9 m)
Coupling 0 feet (0 m)
Air Intake Tee 0 feet (0 m)
12

7. All piping must be fully supported. Use pipe hangers
at a minimum of 4 foot (1.22 meter) intervals to
prevent sagging of the pipe.
Tous les tuyaux doivent être parfaitement soutenus.
Utiliser des attaches de tuyau tous les 4 pieds (1,22
mètres) pour éviter le fléchissement des tuyaux.
8. Exhaust and air inlet piping is to be supported
separately and should not apply force to the boiler.
Les tuyaux d’évacuation et d’arrivée d’air doivent
avoir des dispositifs de support distincts et ne pas
exercer de pression sur la chaudière.
9. Penetration openings around the vent pipe and air
intake piping are to be fully sealed to prevent exhaust
gases from entering building structures.
10. PVC & CPVC Piping:
a. Use only solid PVC or CPVC Schedule 40 or 80
pipe for exhaust venting. Cellular core PVC or
CPVC is not approved for exhaust vent.
b. All joints in vent pipe, fittings, attachment to the
boiler stub, and all vent termination joints must be
properly cleaned, primed and cemented. Use only
cement and primer approved for use with PVC or
CPVC pipe that conforms to ANSI/ASTM D2564.
c. A PVC or CPVC coupling can be used as an
outside vent termination. In this configuration,
place one of the screens provided between the
coupling and exhaust connection before gluing it.
This is intended to prevent birds or rodents from
entering.
d. A PVC or CPVC tee can be used as an outside air
intake termination. When using this configuration,
place one of the screens provided between the
tee and the air inlet connection before gluing it.
This is intended to prevent birds or rodents from
entering.
F. TEST PORT FOR EXHAUST SAMPLING
1. Figure 3.10 shows an illustration of the plugged
sample port on the outlet of the drain tee for the
PFC-850, PFC-1000 and PFC-1500 boiler.
2. To obtain an exhaust sample during operation,
remove the test port plug and insert the probe from a
suitable combustion analyzer.
3. Be sure to replace the plug before leaving the boiler
unattended.
G. COMMON VENTING MULTIPLE BOILERS
1. Multiple PureFire®PFC-850, PFC-1000 and PFC-
1500 boilers may be connected to a common venting
system if they are set up to operate in the cascade
mode described in Section 8.
a. The boilers must communicate in a Master/
Dependent relationship provided in the system
software.
b. The backflow prevention valves supplied on
the gas/air premix inlet prevent products of
combustion from backing up through the burners
into occupied space.
c. A safety control algorithm will operate the
blower to prevent backflow in case of a backflow
prevention valve failure.
2. Figure 3.11 shows two PureFire®boilers connected
with a common vent system.
a. The drain tee from the common vent section
should be trapped and neutralized separately from
the boilers.
b. The condensate drain from each boiler should
be run separately to the drain system to prevent
a clogged condensate line from shutting down
multiple boilers.
c. Table 3.5 shows recommended sizing for common
vent piping.
VENTING & AIR INLET PIPING
Figure 3.11: Multiple Boilers with Common Venting
Table 3.5: Common Exhaust Vent Sizing
Number
of Boilers
Boiler Model
PFC-850 PFC-1000 PFC-1500
2 8” 9” 10”
3 10” 12” 12”
4 12” 12” 14”
5 14” 14” 16”
6 14” 16” 18”
7 16” 16” 18”
8 16” 18” 20”
9 18” 18” 22”
10 18” 20” 22”
11 20” 20” 24”
12 20” 22” 24”
13 20” 22” 26”
14 22” 24” 26”
15 22” 24” 28”
16 24” 24” 28”
13

14
VENTING & AIR INLET PIPING
H. BOILER REMOVAL FROM COMMON
VENTING SYSTEM
At the time of removal of an existing boiler, follow these
steps with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation:
Retrait de la chaudière d’un système d’évacuation
commun. Au moment de retirer une chaudière existante,
il est important de suivre les étapes suivantes pour chaque
appareil raccordé au système d’évacuation commun qui
sont en service, alors que les autres appareils demeurant
raccordés au système d’évacuation commun ne sont pas
en service :
1. Seal any unused openings in the common venting
system.
Sceller toute ouverture du système d’évacuation
commun non utilisée.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
Effectuer un contrôle visuel du système d’évacuation
pour vérifier la taille et la pente horizontale et
s’assurer qu’il n’existe aucun blocage ou obstruction,
fuite, corrosion ni tout autre problème pouvant
menacer la sécurité.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building.
Dans la mesure du possible, fermer toutes les portes
et fenêtres de l’immeuble ainsi que toutes les portes
entre l’espace dans lequel les appareils qui demeurent
raccordés au système d’évacuation commun se
trouvent et le reste de l’immeuble.
4. Turn on any clothes dryers and any appliance not
connected to common venting system. Turn on any
exhaust fans, such as range hoods and bathroom
exhausts, so they will operate at maximum speed. Do
not operate a summer exhaust fan.
Mettre en marche les sécheuses et tout autre appareil
non raccordé au système d’évacuation commun.
Mettre en marche tous les ventilateurs aspirant, tels
que les hottes de cuisinière et les ventilateurs de salle
de bain, en les faisant fonctionner à vitesse maximum.
5. Close fireplace dampers.
Ne pas faire fonctionner les ventilateurs aspirant d’été.
Fermer les registres de foyers.
6. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.
Mettre en service l’appareil à inspecter. Suivre
les instructions concernant l’allumage. Régler le
thermostat afin que l’appareil fonctionne sans arrêt.
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 pendant 5
minutes. Utiliser la flamme d’une allumette ou d’une
chandelle ou encore la fumée d’une cigarette, d’un
cigare ou d’une pipe.
8. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas-burning appliance to their previous
conditions of use.
Après avoir établi que les résidus de combustion de
chaque appareil qui demeure raccordé au système
commun sont adéquatement évacués lorsque soumis
au test décrit ci-dessus, remettre en place les portes,
fenêtres, portes intérieures, ventilateurs aspirants,
registres de foyer et appareils fonctionnant au gaz.
9. Any improper operation of the common venting system
should be corrected so that the installation conforms
with the National Fuel Gas Code, ANSI Z223.1/NFPA
54 or CAN/CGA B149 Installation Codes.
Tout fonctionnement inadéquat du système
d’évacuation commun doit être corrigé de manière
à respecter les normes du National Fuel Gas Code,
ANSI Z223.1/NFPA 54 et/ou des Codes d’installation
CAN/ACG B149.
10. When resizing any portion of the common venting
system, the common venting system should be resized
to approach minimum size as determined using the
appropriate tables located in the chapter “Sizing of
Category I Venting Systems,” of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54 or CAN/CGA B149
Installation codes.
Lorsqu’il est nécessaire de modifier les dimensions
de toute portion du système d’évacuation commun,
ces dernières doivent être modifiées de manière à
respecter les dimensions minimums indiquées dans les
tableaux du chapitre « Sizing of Category I Venting
Systems » du National Fuel Gas Code, ANSI Z223.1/
NFPA 54 ou des Codes d’installation CAN/ACG
B149.

15
A. GENERAL
1. Size water supply and return piping in accordance with
system requirements rather than the boiler connections.
2. If the PureFire®boiler is used to replace an existing
boiler, make sure the system piping is thoroughly
cleaned and free from debris before installing this
boiler. Sentinel Performance Solutions (http://www.
sentinel-solutions.net/us/) offers a full line of cleaners
(X300), sludge remover (X400), antifreeze (X500)
and corrosion inhibitors (X100/X500) for hydronic
applications.
3. In hydronic systems where sediment may exist, install
a strainer in the boiler return piping to prevent large
particles and pipe scale from entering the boiler heat
exchanger. Use a large mesh screen in the strainer.
4. Install this boiler so that the gas ignition system
components are protected from water (dripping,
spraying, etc.) during operation and service (circulator
replacement, condensate trap cleaning, sensor
replacement, etc.).
B. WATER QUALITY
PureFire®boilers are intended for use in a closed-loop
hydronic system. Make-up fresh water for the system
will include oxygen, calcium and other substances
which may cause corrosion, calcium scale buildup
or other attacks on the hydronic system and boiler
components.
The following steps should be taken to maximize the
longevity of the boiler and system:
1. Water hardness must be between 3 Grains/Gal (gpg)
and 9 Grains/Gal (gpg). Use of a water treatment
system may be required on make-up water in areas
with hard water.
2. The systems water pH level should fall between 6
pH and 8 pH. The slightly alkaline water will work to
prevent corrosion and neutralize any acidic buildup
over time minimizing potential sources of corrosive
attacks on the heat exchanger.
3. The system should be flushed and cleaned thoroughly
with fresh water and a rinsing agent prior to boiler
installation. Any new system must be cleaned to
remove any flux or welding residue. Any existing
system must be cleaned to remove scale and
particulate matter prior to boiler connection to the
system. Thoroughly flush any cleaning agent from the
system with clean water prior to connecting the boiler.
See Table 4.1 for recommended cleaning agents.
4. High oxygen levels in the system water will allow scale
buildup to occur. Steps must be taken to minimize
oxygen levels in the system. The following items are
recommended during installation:
a. Provide Air Elimination Means: An automatic air
vent should be installed at the highest point in
the system and at any points air could potentially
be trapped. When replacing an existing boiler,
ensure any automatic air vents installed in the
system are functioning correctly and installed in a
proper location. A hydronic separator is another
option to provide a low velocity zone for trapped
air bubbles to separate and be eliminated from
the system while providing primary/secondary
operation.
4. WATER PIPING & CONTROLS
WATER PIPING & CONTROLS
Failure to properly analyze and treat system water when installing a high efficiency boiler can cause heat
exchanger failure due to water passageway fouling. Black oxide sludge (magnetite – Fe3O4), red oxide sludge
(iron oxide – Fe2O3), and calcium scale (limescale) will settle over the hottest portion of the heat exchang-
er coils. This buildup will reduce thermal transfer in the areas where the buildup is greatest resulting in an
increased fouling rate. The high temperatures in these locations will compromise the natural corrosion resis-
tance of the stainless steel material leading to accelerated failure of the heat exchanger.
Failure to address the causes of the fouling in the system can void heat exchanger warranty, and risk property
damage, personal injury or death.
System must be cleaned before the boiler is connected!
- Flush the system with fresh water
- Use a cleaning agent appropriate for the system material and debris to be removed
- Thoroughly flush cleaning agent residue from the system with fresh water
The following actions must be taken after the boiler is connected to the system:
- Treat system water with a corrosion and scale inhibitor to prevent oxidization and scale buildup.
Follow the inhibitor manufacturer’s instructions when treating the system water
WARNING

b. It is recommended that a water meter be installed
on the system fresh water intake to monitor the
system for any leaks by monitoring make-up water
usage. Untreated fresh water sources will introduce
oxygen, minerals and contaminants into system.
c. Correct any system leaks prior to placing the boiler
in operation.
C. OPERATING PARAMETERS
1. The PureFire®boiler is designed to operate in a
closed loop hydronic heating system under forced
circulation. This requires the system to be completely
filled with water and requires a minimum water
flow rate through the boiler to assure proper flow
distribution.
2. The minimum system operating pressure is 14.5 PSI
(69 kPa).
3. Table 4.2 lists the minimum flow rates for each
PureFire®model covered in this manual. Also shown
is the minimum flow rate for 50% glycol solution. For
other glycol concentrations, contact your PB Heat,
LLC representative for the minimum flow rates.
4. Section 4.E provides detailed information about using
glycol for freeze protection. Table 4.3 provides the
water volume of the heat exchangers for calculating
the system volume.
D. SYSTEM COMPONENTS
Figure 4.1 shows the symbol key for piping diagrams in
this section. The following are brief descriptions of system
components.
1. Pressure/Temperature Gauge: A combination
pressure/temperature gauge is provided with each
PureFire®boiler to be mounted in the piping from the
boiler supply to the system as shown in Figure 4.2.
Most local codes require this gauge.
2. Air Elimination: Closed loop hydronic systems require
air elimination devices. As the system water is heated,
dissolved oxygen and other gases will separate from
the liquid. An air elimination device (such as a TACO
Vortech®Air Separator) is required to remove the
dissolved gases preventing corrosion in the piping
system and eliminating noise.
3. Expansion Tank: An expansion tank (such as a Bell
& Gossett Series HFT) is required to provide room
for expansion of the heating medium (water or glycol
solution). Consult the expansion tank manufacturer’s
instructions for specific information regarding
installation. The expansion tank is to be sized for the
required system volume and capacity. In addition,
be sure that the expansion tank is sized based on the
proper heating medium. Glycol solutions may expand
more than water for a similar temperature rise.
4. Y-Type Strainer or Filter Ball®Valve: PB Heat
recommends the use of a strainer device in the system
to prevent dirt or sediment from clogging the heat
exchanger. A 20 mesh stainless steel screen is adequate
to protect the heat exchanger. The strainer should be
cleaned often in the first several months of operation. The
Filter Ball®Valve from Jomar International incorporates
a strainer into a ball valve which allows the technician to
isolate the water circuit while cleaning the strainer.
16
Table 4.1: Recommended Water Treatment Products
for use in Stainless Steel Condensing Boiler Applications
Supplier
Fernox Sentinel Sotin ADEY
Universal Cleaner Restorer F3 or F5 X300 - -
Sludge Remover Cleaner F3 or F5 X400 Sotin 212 -
Inhibitors Protector F1/
Alphi 11 X100, X500 Sotin 212 MC1+
Antifreeze Alphi 11 X500 - -
Do not use petroleum based cleaners when cleaning
the boiler system. Damage to the gaskets found in
typical system components can occur resulting in
significant property damage.
WARNING
Use only inhibited propylene glycol solutions which
are specifically formulated for hydronic systems.
Unlike automotive antifreeze, solutions for hydronic
applications contain corrosion inhibitors that will
protect system components from premature failure
due to corrosion.
CAUTION
Use only inhibited propylene glycol solutions
which are specifically formulated for hydronic
systems. Ethylene glycol is toxic and may cause any
environmental hazard if a leak or spill occurs.
WARNING
PureFire®
Model
Total Water Capacity
Gallons Liters
PFC-850 6.2 23.4
PFC-1000 7.2 27.1
PFC-1500 12.5 47.3
Table 4.3: Heat Exchanger Water Capacity
PureFire®
Model
Minimum Flow Rate
Water
GPM (LPM)
50% Glycol Solution
GPM (LPM)
PFC-850 39.5 (149.5) 49.4 (187.0)
PFC-1000 46.5 (176.0) 58.2 (220.3)
PFC-1500 69.8 (264.2) 87.3 (330.5)
Table 4.2: Minimum Boiler Flow Rates
WATER PIPING & CONTROLS

17
5. Flow Control Valve: Flow control valves such as the
TACO Flo-Chek or Bell & Gossett Flo-Control™ are
used to prevent gravity circulation by incorporating a
check valve with a weighted disc.
6. Pressure Reducing Valve: A pressure reducing valve,
such as the Bell & Gossett B-38 or a TACO #329, is
used in a hydronic system to automatically feed water
to the system whenever pressure in the system drops
below the pressure setting of the valve. These valves
should not be used on glycol systems unless close
supervision of the glycol solution is practiced.
7. Back Flow Preventer: A back flow preventer (check
valve) is required by some jurisdictions to prevent water
in the hydronic system from backing up into the city
water supply. This is especially important on systems in
which glycol solution is used as the heating medium.
8. Pressure Relief Valve: The boiler pressure relief valve
is shipped in the miscellaneous parts box for field
installation. It is extremely important to install this
device.
The valve is to be installed on the boiler supply pipe
as shown in Figure 4.2. Pipe the discharge of the relief
valve to within 12” of the floor and close to a floor
drain.
Provide piping that is the same size or larger than the
relief valve outlet.
WATER PIPING & CONTROLS
Do not operate this appliance without installing the
pressure relief valve supplied with the boiler or one
with sufficient relieving capacity in accordance with
the ASME Rating Plate on the boiler heat exchanger.
WARNING
Pipe the discharge of the relief valve as close as
possible to the floor and away from high traffic areas.
Pipe the discharge to a floor drain. Failure to do so
may result in personal injury and/or property damage.
CAUTION
Figure 4.1: Piping Symbol Key

18
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.
a. If the boiler is piped in a secondary loop of a
primary/secondary heating system, the circulator
will need only to overcome the resistance of the
boiler and any fittings in that loop.
b. The circulator should be sized based on gross
output of the boiler. Table 4.3 shows the Boiler
Output as reported to the Hydronics Institute
Section of AHRI.
c. The required flow is calculated based on the design
temperature difference from the return to the
supply of the boiler. For a PFC-850 with a design
temperature difference of 20°F the calculation is as
follows:
Output 816,000
Required Flow = ________ =_________ = 81.6 GPM
DTx 500 20 x 500
d. The boiler pressure drop for various flow rates
can be determined using Figure 4.3, PureFire®
Circulator Sizing Graph below.
WATER PIPING & CONTROLS
Figure 4.3: PureFire®Circulator Sizing Graph (General Pump – Primary/Secondary)
Figure 4.2: Relief Valve and Pressure/Temperature
Gauge Installation
Table 4.4: Boiler Input and Output
PureFire®
Model
Boiler Input Boiler Output
Btu/hr kW Btu/hr kW
PFC-850 850,000 249 817,700 240
PFC-1000 1,000,000 293 966,000 283
PFC-1500 1,500,000 440 1,447,500 424