PeerlessBoilers PF-50 Instruction manual

PUREFIRE™
BoilersGas
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.

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 . . . . . . . . . . . . . . . .3
2. BOILER SET-UP 4
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
B. WALL MOUNTING . . . . . . . . . . . . . . . . . . . . .4
C. FLOOR STANDING INSTALLATION . . . . . . . .4
3. VENTING & AIR INLET PIPING 5
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
B. APPROVED MATERIALS . . . . . . . . . . . . . . . .5
C. EXHAUST VENT/AIR INTAKE
PIPE LOCATION . . . . . . . . . . . . . . . . . . . . . . .5
D. EXHAUST VENT/AIR INTAKE PIPE SIZING .8
E. EXHAUST VENT/AIR INTAKE PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .8
F. EXHAUST TAPPING FOR VENT SAMPLE . . .9
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . . .9
4. WATER PIPING AND CONTROLS 10
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .10
B. OPERATING PARAMETERS . . . . . . . . . . . . .10
C. SYSTEM COMPONENTS . . . . . . . . . . . . . . .10
D. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . .13
E. FREEZE PROTECTION . . . . . . . . . . . . . . . . .13
F. SPECIAL APPLICATIONS . . . . . . . . . . . . . . .19
5. FUEL PIPING 21
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .21
B. FUEL LINE SIZING . . . . . . . . . . . . . . . . . . . .21
C. GAS SUPPLY PIPING – INSTALLATION . . .21
D. GAS SUPPLY PIPING – OPERATION . . . . . .22
E. MAIN GAS VALVE – OPERATION . . . . . . . .23
6. CONDENSATE DRAIN PIPING 24
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .24
B. CONDENSATE SYSTEM . . . . . . . . . . . . . . .24
C. CONDENSATE DRAIN PIPE MATERIAL . . .24
D. CONDENSATE DRAIN PIPE SIZING . . . . . .24
E. CONDENSATE DRAIN PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .25
7. ELECTRICAL CONNECTIONS 26
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . .26
B. CUSTOMER CONNECTIONS . . . . . . . . . . . .26
C. INTERNAL WIRING . . . . . . . . . . . . . . . . . . .26
8. BOILER CONTROL: INTERNAL
WIRING & OPERATION 29
A. CONTROL OVERVIEW . . . . . . . . . . . . . . . . .29
B. IGNITION SEQUENCE . . . . . . . . . . . . . . . . .31
C. BOILER CONTROL . . . . . . . . . . . . . . . . . . . .33
D. CENTRAL HEATING . . . . . . . . . . . . . . . . . . .36
E. DOMESTIC HOT WATER (DHW) . . . . . . . . .38
F. SERVICE NOTIFICATION . . . . . . . . . . . . . . .39
G. SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . .40
H. STATUS & FAULT HISTORY . . . . . . . . . . . . .40
9. START-UP PROCEDURE 41
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .41
B. CHECK WATER PIPING . . . . . . . . . . . . . . . .41
C. CHECK GAS PIPING . . . . . . . . . . . . . . . . . . .41
D. CHECK OPERATION . . . . . . . . . . . . . . . . . . .41
E. LIGHTING & OPERATING PROCEDURES . .43
10. TROUBLESHOOTING 44
A. BLOCKING ERRORS . . . . . . . . . . . . . . . . . . .44
B. LOCKING ERRORS . . . . . . . . . . . . . . . . . . . .44
11. MAINTENANCE 48
A. GENERAL (WITH BOILER IN USE) . . . . . . .48
B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .48
C. ANNUALLY (BEFORE START OF HEATING
SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . .48
D. CONDENSATE CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .48
E. COMBUSTION CHAMBER COIL CLEANING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .49
12. BOILER DIMENSIONS & RATINGS 51
13. REPAIR PARTS 52
APPENDIX A. STATUS SCREENS 58
APPENDIX B. USER MENU 61
APPENDIX C. INSTALLER MENU 62
APPENDIX D. COMBUSTION TEST
RECORD 65
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.
5. This boiler can be installed at high altitudes above
5,000 feet with no burner adjustments. This applies to
boilers equipped for firing natural gas or liquefied
petroleum (LP) gas.
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.
·The boiler installation manual, vent manufacturer's
installation manual, and this supplement shall
remain with the boiler at the completion of the
installation.
See the latest edition of Massachusetts Code 248 CMR
for complete verbage 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.
2. Refer to Figure 1.1 for the minimum recommended
clearance to allow for reasonable access to the boiler.
Local codes or special conditions may require greater
clearances.
D. COMBUSTION AND VENTILATION AIR
1. The PUREFIRE boiler is designed only for operation
with combustion air piped from outside the building
(sealed combustion). PVC pipe must be supplied and
connected between the air inlet connection and an
outside wall or roof. Reference Section 3 for vent and
air inlet piping requirements.
2. No additional combustion or ventilation air is required
for this appliance.
3. Refer to Section 3 of this manual, Venting, for specific
instructions for piping 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
3
PREINSTALLATION
Do not install this boiler where gasoline or other
flammable liquids or vapors are stored or are in use.
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
Do not install this boiler on carpeting.
DANGER
Figure 1.1: Minimum Accessibility Clearances

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. Install the boiler level to prevent condensate from
backing up inside the boiler.
4. PUREFIRE boilers can be wall mounted or floor
standing. The following instructions provide guidance
for both configurations.
B. WALL MOUNTING
1. To wall mount the PUREFIRE boiler an optional wall
mounting bracket kit (54171) is available for models
up to PF140 (refer to Figure 2.1).
2. Mount the bracket level on the wall using 5/16" lag
bolts. Be sure that the lag bolts are supported by wall
studs.
3. Boiler will hang on bracket and can be leveled using
(2) 5/16 lag screws as shown.
4. The mounting bracket has (4) holes on 16" centers.
This is intended to give the installer the ability to
mount the bracket on two wall studs spaced at this
interval. If existing wall studs are spaced differently or
if the desired location is not in line with the wall studs,
additional support is required.
5. If the boiler is wall mounted, be sure that the wall
provides adequate support for the boiler.
6. Be sure to adequately support the boiler while
installing external piping or other connections.
7. Be sure that the condensate piping is routed to a
suitable drain or condensate pump.
C. FLOOR STANDING INSTALLATION
1. For floor standing installations, use the leveling feet to
assure that the boiler is completely level. This will
prevent condensate from backing up in the boiler.
2. Be sure to leave adequate space for condensate
piping or a pump if required.
4
BOILER SET-UP
2. BOILER SET-UP
This boiler must be installed level to prevent
condensate from backing up inside the boiler.
CAUTION
Make sure the boiler is adequately supported. Do not
install this boiler on drywall unless adequately
supported by wall studs.
WARNING
Figure 2.1

5
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 a direct vent appliance and is
ETL Listed as a Category IV appliance with Intertek
Testing Laboratories, Inc.
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. Cellular core piping is approved for inlet air piping only.
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 chances of piping interference.
2. The vent piping for this boiler is approved for zero
clearance to combustible construction.
3. The Peerless PUREFIRE boiler, like all high efficiency
products, is likely to produce a vapor plume due to
condensation. Surfaces near the vent termination will
likely be coated with condensation.
4. The maximum combined vent and air inlet vent
length for the Peerless PUREFIRE boiler is 200
equivalent feet (60 m). Be sure that the boiler is
located such that the maximum vent length is not
exceeded.
5. Air Intake Pipe Location – Sidewall Venting:
a. Provide 1 foot (30 cm) clearance from the bottom
of the air intake pipe to the level of maximum
snow accumulation. 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. The maximum distance between the air intake
and exhaust is 6 feet (1.8 m).
d. 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.
e. For multiple boiler installations the minimum
distance between the inlet of one boiler to the
exhaust of another is 8" center-to-center.
f. See Figure 3.1 for an illustration of vent spacing
for multiple boilers.
VENTING & AIR INLET PIPING
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
P URE F IRE 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
Description Material
Conforming to
Standard
Vent Piping & Fittings
PVC (Sch 40 or 80) ANSI/ASTM D1785
CPVC (Sch 40 or 80) ANSI/ASTM D1785
PVC-DWV ANSI/ASTM D2665
MUGROTM PP(s) EN 14471 T120
Pipe Cement
(PVC & CPVC Only) PVC/CPVC Cement ANSI/ASTM D2564
Table 3.1: Approved Materials for Exhaust Vent
Pipe
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
If the maximum equivalent vent length is exceeded,
the maximum burner input rate may be reduced.
NOTICE
Locating air intake and exhaust pipes on different
sides of a building can cause erratic operation due to
wind gusts. When using the sidewall venting
configuration always locate both terminations on the
same outside wall.
NOTICE

6. 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 1 foot (30 cm) distance
from any door, operable window, or gravity
intake into any building.
• 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.
• 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 exit termination directly
under roof overhangs to prevent icicles from
forming.
• Provide 3 feet clearance from the inside corner
of adjacent walls.
b. Figure 3.3 and 3.4 show approved sidewall
venting configurations using the standard fittings
supplied.
c. Figure 3.5 and 3.6 show approved sidewall
venting configurations using optional vent
termination kits.
6
VENTING & AIR INLET PIPING
Condensing flue gases can freeze on exterior
building surfaces which may cause discoloration and
degradation of the surfaces.
CAUTION
Figure 3.1: Vent Pipe Spacing for Multiple
PUREFIRE Boilers
Figure 3.2: Exit Terminal Location for Mechanical Draft and Direct-Vent Venting Systems

7
VENTING & AIR INLET PIPING
Figure 3.3: Exhaust and Air Inlet Pipe Penetration
at Different Elevations
Figure 3.4: Exhaust and Air Inlet Pipe Penetration
at the Same Elevation
Figure 3.5: Optional Stainless Steel Vent Kit
Installation
Figure 3.6: Optional Concentric PVC Vent Kit
Installation

7. Vertical Venting Configuration:
a. Figure 3.7 shows the approved venting
configuration for vertical venting using the
standard fittings supplied.
b. Locate the air intake pipe inlet 12" above the
expected snow accumulation on the roof surface
or 24" above the roof surface, whichever is greater.
c. Locate the end of the exhaust vent pipe a minimum
of 12" above the inlet to the air intake pipe.
d. Figure 3.8 shows an approved vertical vent
configuration using the optional concentric vent
termination kit.
8. Exhaust Vent Pipe Location – Vertical Venting:
a. Figures 3.5 and 3.6 show approved venting
configurations for vertical venting using the
standard fittings supplied.
b. Locate the end of the Exhaust Vent pipe a
minimum of 12" above the air inlet pipe.
D. EXHAUST VENT/AIR INTAKE PIPE SIZING
1. PUREFIRE boiler models PF-50, PF-80, PF-110 and PF-
140 are to be installed using 3" Schedule 40 or 80
PVC or CPVC piping using the provided vent adapter.
2. A concentric polypropylene vent system can be
installed using the optional MUGROTM vent adapter
(54155). Contact your PB Heat, LLC representative
for more information on this option.
3. The total combined length of exhaust vent and air
intake piping is 200 equivalent feet (60 m).
a. The equivalent length of elbows, tees and other
fittings are listed in Table 3.2.
b. The equivalent length can be calculated as follows.
This is well below the 200 feet maximum
equivalent length. If the total is above 200
equivalent feet, alternate boiler locations or
exhaust penetration location should be considered.
E. EXHAUST VENT/AIR INTAKE PIPE
INSTALLATION
1. Figure 12.1 shows the 3" exhaust connection at the
center of the boiler.
2. The Air Intake connection is to the right of the exhaust.
8
VENTING & AIR INLET PIPING
Exhaust Air Inlet Total
Straight Length of Pipe 50' 50' 100'
90° Elbows, SR 2 x 5'= 10' 1 x 5' = 5' 15'
45° Elbows, SR 2 x 3' = 6' 6'
Conc. Vent Termination 1 x 3' = 3' 3'
Total 124'
Table 3.3: Sample Equivalent Length Calculation
Fitting Description Equivalent Length
Elbow, 90° Short Radius 5 feet
Elbow, 90° Long Radius 4 feet
Elbow, 45° Short Radius 3 feet
Coupling 0 feet
Air Intake Tee 0 feet
Stainless Steel Vent Kit 1 foot
Concentric Vent Kit 3 feet
Table 3.2: Equivalent Length of Fittings
Figure 3.7
Figure 3.8

3. Both connections are clearly marked.
4. Remove all burrs and debris from the joints and fittings.
5. 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.
6. 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.
7. Exhaust and air inlet piping is to be supported
separately and should not apply force to the boiler.
8. Penetration openings around the vent pipe and air
intake piping are to be fully sealed to prevent exhaust
gases from entering building structures.
9. 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 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 straight coupling is provided with the boiler to
be used as an outside vent termination. One of
the two screens is to be installed to prevent birds
or rodents from entering.
d. An air intake tee is provided with the boiler to be
used as an outside air intake termination. A screen
is to be installed to prevent birds or rodents from
entering.
e. The following are optional combination air
intake/exhaust terminations that are available
separately from your PB Heat, LLC distributor for
use with PUREFIRE boilers.
f. Refer to Figures 3.3 to 3.6 for sidewall venting
options using PVC or CPVC pipe.
g. Refer to Figures 3.7 & 3.8 for vertical venting
options using PVC or CPVC pipe.
F. EXHAUST TAPPING FOR VENT SAMPLE
To properly install the boiler, carbon dioxide (CO2) and
carbon monoxide (CO) readings are to be determined
from a sample of combustion gases from the vent pipe.
To do this a hole must be drilled in the vent pipe.
a. Drill a 21/64" diameter hole in the exhaust vent
pipe from 6” to 12" from the outlet of the boiler.
b. Tap the hole with a 1/8" NPT pipe tap.
c. Use a 1/8" NPT, PVC Pipe Plug to seal the hole.
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM
If removing an existing boiler from a common vent
system the following steps must be carried out for each
appliance that remains connected. These steps are to be
completed for each appliance while the other appliances
that remain connected are not in operation.
a. Seal any unused openings in the common venting
system.
b. Visually inspect the venting system for proper size
and horizontal pitch. Verify that there is no
blockage or restriction, leakage, corrosion, and
other deficiencies which could cause an unsafe
condition.
c. Where practical, close all building doors and
windows. This includes interior doors between the
space in which the appliances remaining
connected to the common venting system are
located and other interior spaces in the building.
d. Turn on clothes dryers and any other appliance
not connected to the common venting system.
Exhaust fans such as range hoods or bathroom
exhaust fans are to be operated at their maximum
speed (Do not operate a summer exhaust fan).
e. Close fireplace dampers.
f. Place the appliance that is being inspected in
operation. Follow the lighting instructions and
adjust the thermostat so that the appliance will
operate continuously.
g. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame from a match or candle, or smoke from a
cigarette, cigar, or pipe.
h. After each appliance remaining connected to the
common vent system has been determined to vent
properly as outlined above, doors, windows,
exhaust fans, fireplace dampers and any other gas
burning appliance are to be returned to their
previous condition of use.
i. Any improper operation of the common venting
system should be corrected at once so that the
installation conforms with the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA
B149 Natural Gas and Propane Installation Code.
j. When resizing any portion of the common venting
system, it the system should be resized to
approach the minimum size as determined using
the appropriate tables in Part 11 of the National
Fuel Gas Code, ANSI Z223.1/NFPA 54 and or
CAN/CSA B149.1, Natural Gas and Propane
Installation Code.
9
VENTING & AIR INLET PIPING
Description Stock Code
3" PVC Concentric Vent Termination Kit 91403
3" Stainless Steel Vent Termination Kit 54161
Table 3.4: Vent Termination Kits
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

A. GENERAL
1. Size water supply and return piping in accordance
with system requirements. Do not use smaller
diameter piping than the boiler connections.
2. If the PUREFIRE boiler is used to replace an existing
boiler, make sure that the system piping is thoroughly
cleaned and free from debris before installing this boiler.
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. OPERATING PARAMETERS
1. The PUREFIRE boiler is designed to operate in a closed
loop hydronic system under forced circulation. This
requires the system to be completely filled with water
and requires a minimum water flow through the boiler
to operate effectively.
2. The minimum system pressure is 14.5 PSI (69 kPa)
3. Table 4.1 lists the minimum flow rates for each
PUREFIRE model. If a glycol solution is to be used,
contact your PB Heat, LLC representative for
minimum flow rates.
Section 4.E provides detailed information about using
glycol for freeze protection.
Table 4.2 provides the water volume of the heat
exchanger including the supply and return pipes that
are attached at the factory.
C. 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: Any closed loop hydronic system in
which the PUREFIRE boiler is installed must have an air
elimination device. As the system water is heated,
dissolved oxygen and carbon dioxide will separate
from the liquid.
An air elimination device (such as a TACO 430 Series
Air Scoop with automatic air vent) is required to
remove the dissolved gasses from the system
preventing corrosion in the piping system and
eliminating system 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: In older systems where a significant
amount of sediment may be present, it may be
necessary to install a Y-type strainer. The strainer
should be checked often and cleaned during the first
few months of operation to assure that sediment does
not reach the heat exchanger and clog the passages.
Use a large mesh screen in the strainer.
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WATER PIPING AND CONTROLS
4. WATER PIPING & CONTROLS
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
Minimum Flow Rate
Water
GPM (LPM)
50% Glycol
Solution
GPM (LPM)
PF-50 2.2 (8.3) 2.8 (10.6)
PF-80 3.3 (12.5) 4.1 (15.5)
PF-110 4.4 (16.7) 5.5 (20.8)
PF-140 5.5 (20.8) 6.8 (25.7)
Table 4.1: Minimum Flow Rate
PUREFIRE
Model
Total Water Capacity
Gallons (Liters)
PF-50 0.62 (2.35)
PF-80 0.72 (2.73)
PF-110 0.89 (3.37)
PF-140 1.25 (4.73)
Table 4.2: Heat Exchanger Water Capacity

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 separately for field installation. It is
extremely important that this is installed on the boiler
return pipe (at the rear of the boiler).
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WATER PIPING AND CONTROLS
Figure 4.1: Piping Symbol Key
Figure 4.2: Relief Valve Installation

The valve is to be installed 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.
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 the net
output of the boiler. Table 4.3 shows the Boiler
Output as reported to the Hydronics Institute
Section of AHRI. These values are based on a
pickup factor of 1.15.
c. The required flow is calculated based on the
design temperature difference from the return to
the supply of the boiler. For a PF-110 with a
design temperature difference of 20°F the
calculation is as follows.
Output 88,000
Required Flow = _________ = ________ = 8.8 GPM
D Tx 500 20 x 500
d. Table 4.4 shows the pressure drop (in feet of
water) for a flow rate for each boiler model that
produces a temperature difference of 20°F.
e. The boiler pressure drop for various flow rates can
be determined using Figure 4.3, the PUREFIRE
Boiler Circulator Sizing Graph.
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WATER PIPING AND CONTROLS
PUREFIRE
Model
Boiler Input
Btu/hr (kW)
Net I=B=R
Output
Btu/hr (kW)
PF-50 50,000 (14.7) 40,000 (11.7)
PF-80 80,000 (23.4) 64,000 (18.8)
PF-110 110,000 (34.2) 88,000 (25.8)
PF-140 140,000 (41.0) 113,000 (33.1)
Table 4.3: Boiler Inputs and Outputs
Table 4.4: Flow Rate and Pressure Drop at 20°F
Temperature Rise
Figure 4.3: PUREFIRE Circulator Sizing Graph
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
PUREFIRE
Model
Flow Rate
GPM (LPM)
Pressure Drop
Feet (Meters)
PF-50 4.0 (15.1) 5.1 (1.6)
PF-80 6.4 (24.2) 10.2 (3.1)
PF-110 8.8 (33.3) 10.0 (3.0)
PF-140 11.3 (42.8) 7.0 (2.1)

f. Table 4.5 provides the flow rate and pressure drop
information that corresponds to various system
temperature rise values (DT). The pressure drop
shown is for the boiler only. If there is significant
system pressure drop in the system, this should be
included when specifying circulators.
g. Table 4.6 provides a list of recommended
circulators for boilers on a secondary loop of a
primary/secondary system which uses water as a
heating medium.
h. Special consideration must be given if a glycol
based anti-freeze solution is used as a heating
medium. Propylene glycol has a higher viscosity
than water, therefore the system pressure drop will
be higher.
10. Indirect Water Heater: An indirect water heater should
be piped to a dedicated zone. The PUREFIRE boiler
provides electrical terminals for connecting a domestic
hot water (DHW) circulator. Examples of piping for
the indirect water heater are shown under subsection
“E”, System Piping of this section.
D. SYSTEM PIPING
1. Figure 4.4 shows a single boiler with multiple heating
zones. In this case, the DHW zone is piped in parallel
to the heating zones on the primary loop.
2. For a single boiler with one heating zone and one
DHW zone which utilizes an indirect water heater like
the Peerless Partner, pipe the boiler as shown in
Figure 4.5. In systems like this, the DHW circulator
must be sized to provide the minimum flow rate
through the boiler.
3. In Figure 4.6 an additional boiler is added and more
heating zones are shown. Notice that the two boilers
are piped in parallel on the secondary loop. This
maximizes the efficiency of the boilers since the lowest
temperature system water is returning to both boilers.
4. Figure 4.7 shows a multiple boiler system with several
different types of heat distribution units. This system
illustrates how different temperature zones can be
supplied from the same source by blending supply
and return water to the zone.
5. In Figure 4.8 zone valves are used instead of zone
circulators. Notice that the system is piped using
reverse return piping to help balance the flow through
the zones. If the zone lengths vary balancing valves
are required on each loop.
E. FREEZE PROTECTION
1. Glycol for hydronic applications is specially
formulated for heating systems. It includes inhibitors
which prevent the glycol from attacking metallic
system components. Make sure that the system fluid is
checked for correct glycol concentration and inhibitor
level.
2. Use only inhibited polypropylene glycol solutions of
up to 50% by volume. Ethylene glycol is toxic and
can chemically attack gaskets and seals used in
hydronic system.
3. The anti-freeze solution should be tested at least once
per year and as recommended by the manufacturer of
the product.
4. Anti-freeze solutions expand more than water. For
example, a 50% by volume solution expands 4.8%
with a 148°F temperature rise while water expands
about 3% for the same temperature increase.
Allowance for this expansion must be considered in
sizing expansion tanks and related components.
5. The flow rate in systems utilizing glycol solutions
should be higher than in a water system to
compensate for decreased heating capacity of the fluid.
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WATER PIPING AND CONTROLS
Table 4.5: Boiler Pressure Drop and Flow Rates for
Various System Temperature Rise Values
DT
(°F)
Flow Rate & Pressure Drop
PF-50 PF-80 PF-110 PF-140
GPM FT GPM FT GPM FT GPM FT
40 n/a 3.20 3.2 4.40 3.1 5.65 2.3
35 2.28 2.3 3.65 4.0 5.02 3.8 6.45 2.9
30 2.66 2.9 4.26 5.1 5.86 5.0 7.53 3.7
25 3.20 3.7 5.12 7.0 7.03 6.8 9.03 5.2
20 4.00 5.4 6.39 10.4 8.79 10.0 11.29 8.0
15 5.33 8.8 8.53 17.5 11.72 17.0 15.05 14.0
10 7.99 18.5 n/a n/a n/a
The circulator sizing given is for primary/secondary
installations only. The system circulators must be
sized based on the flow and pressure drop
requirements of the system.
NOTICE
Table 4.6: Circulator Selection Chart
Circulator selections are based on boiler net output which
includes a 1.15 pick-up factor for piping losses.
Pump
Manufacturer
Temp
Difference PF-50 PF-80 PF-110 PF-140
Taco 10 0014 N/A N/A N/A
Grundfos UPS 26-99 N/A N/A N/A
Taco 15 007 0014 0014 0014
Grundfos UPS 15-58 UPS 26-99 UPS 26-99 UPS 26-99
Taco 20 006 008 008 007
Grundfos UPS 15-58 UPS 15-58 UPS 26-99 UPS 26-99
Taco 25 003 007 007 007
Grundfos UPS 15-58 UPS 15-58 UPS 15-58 UPS 15-58
Taco 30 003 006 007 007
Grundfos UPS 15-58 UPS 15-58 UPS 15-58 UPS 15-58
Taco 35 003 006 006 006
Grundfos UPS 15-58 UPS 15-58 UPS 15-58 UPS 15-58
Taco 40 N/A 003 006 006
Grundfos N/A UPS 15-58 UPS 15-58 UPS 15-58

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WATER PIPING AND CONTROLS
Figure 4.4: Recommended Piping – One Boiler, Primary/Secondary with Two Zones (Zone Circulator)

15
WATER PIPING AND CONTROLS
Figure 4.5: Alternate Piping – One Boiler, Primary/Secondary with one heating zone and a Peerless Partner (Zone Circulators)
Note: The DHW Circulator must be sized to provide minimum flow through the boiler

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WATER PIPING AND CONTROLS
Figure 4.6: Two Boilers, Primary/Secondary with Four Zones (Zone Circulator)

17
WATER PIPING AND CONTROLS
Figure 4.7: Three Boilers, Primary/Secondary with Five Zones (Zone Circulator)

18
WATER PIPING AND CONTROLS
Figure 4.8: Three Boilers, Primary/Secondary with Four Zones (Zone Valves)