1. PREINSTALLATION

1

PEERLESS®PUREFIRE ®

Installation, Operation, and Maintenance Instructions Supplement - PF-460

These instructions are intended to supplement the Peerless® PUREFIRE® Installation, Operation, andMaintenance Manual (PF8248).

NOTICE

1. PREINSTALLATIONPlease refer to Figure 1.2 of the PUREFIRE® Installation, Operation, and Maintenance Manual (PF8248) for AccessibilityClearances

3. VENTING & AIR INLET PIPING

Boiler Model Exhaust Vent/Air Intake Size

PF-460 4" (100 mm)

Table 3.2: Exhaust Vent/Air Intake Sizing

Boiler Model

Centrotherm InnoFlue®

DuraVent PolyPro®

PF-460 54633 54631

Table 3.3: Polypropylene Vent Adapter Stock Codes

Boiler Model DescriptionStock Code

PF-460100/150 Concentric Sidewall Termination Kit 54499

100/150 Concentric Vertical Termination Kit 54501

Table 3.6: Concentric Vent Termination Kits

2

Table 4.4: Flow Rate and Pressure Drop for Various System Temperature Rise Values

ΔT(°F)

Flow Rate & Pressure DropPF-460

GPM FT

40 21.9 6.7135 25.0 8.6030 29.2 11.4625 35.0 16.1020 43.8 24.3915 58.4 41.6710 87.6 88.66

Table 4.5: Circulator Selection Chart (General Pump – Primary Secondary)

Circulator Manufacturer Temp. Difference PF-460

Taco

20°F

1915/7.1”1.5 Hp

Grundfos UPS32-160 F B Medium Speed

Bell & Gossett NA

Wilo Top-S 1.5x20 3- 230V max

Taco

25°F

2400-65

Grundfos UPS26-150 SF Hi Speed

Bell & Gossett NA

Wilo Top-S 1.5x20 3- 230V max

Taco

30°F

2400-60

Grundfos UPS26-150 Hi Speed

Bell & Gossett NRF-45 Speed 3

Wilo Top-S 1.5x20 1- 115V min

Taco

35°F

0013

Grundfos UPS26-99 FC Hi Speed


Wilo Star 17 FX

Taco

40°F

0011

Grundfos UPS26-99FC Hi Speed


Wilo Star 17 FX

PUREFIRE®

ModelBoiler InputBtu/hr (kW)

Gross OutputBtu/hr (kW)

PF-460 460,000 (134.8) 438,000 (128.8)

Table 4.3: Boiler Inputs and Outputs

For relief valve installation, refer to Figure 4.3 in the main I,O&M. For the PF-460, be sure to leave enough clearance for theGas Supply piping in front of the Supply and Return Piping.

4. WATER PIPING & CONTROLS

PUREFIRE®

Model

Minimum Flow RateWater

GPM (LPM)50% Glycol Solution

GPM (LPM)

PF-460 13.2 (50.0) 16.5 (62.5)

Table 4.1: Minimum Flow Rate

PUREFIRE®

ModelTotal Water Capacity

Gallons (Liters)PF-460 2.60 (9.84)

Table 4.2: Heat Exchanger Water Capacity

3

5. FUEL PIPING

PUREFIRE®

Model

Required Input Rate*

Natural Gas ft3/hr(m3/hr)

LP Gas ft3/hr(m3/hr)

PF-460 460 (13.0) 184 (5.2)

Table 5.1: Required Fuel Input

* Natural gas input rates are based on 1,000 Btu/ft3, LP input rates are based on 2,500 Btu/ft3.

C. GAS SUPPLY PIPING - INSTALLATION

8. Figure 5.3 below shows the proper gas shutoff valve location for the PF-460. The Boiler Manual Shutoff Valve should belocated within 6 feet of the boiler. See local codes for specific location requirements.

Figure 5.3: PF-460 External Gas Supply Piping and Valve Location

A backer wrench must be used when installing the gas supply piping to the boiler’s gas supplynipple. Damage may occur to internal components if a large torque is applied.

CAUTION

4

E. MAIN GAS VALVES - OPERATION

Use Figure 5.4 for main gas valve orientation and tapping locations. Refer to Section E of main I,O,&M for instructionsregarding main valve adjustment.

F. CSD-1 REQUIREMENTS- PF-460 ONLY

1. The PF-460 has a High and Low Gas Pressure Switch Located in the gas train. The Low Gas Pressure Switch is aHoneywell C6097A1012. The High Gas Pressure Switch is a Honeywell C6097B1028.

2. Both Switches have a Manual reset and are accessible from the front of the boiler

3. Figure 5.5 below shows the gas train, limit switch and blower assembly.

VENTURIAIR INLET

INLETPRESSURE

TAP

OUTLETPRESSURETAP

THROTTLESCREW

OFFSET SCREW-DO NOT ADJUSTTHIS SCREW WITHOUTTHE PROPER TESTEQUIPMENT

Figure 5.4: PF-460 Gas Valve/Venturi

BLOWER, DUNGS NRG137(54428)

LOW GAS PRESSURE SWITCHHONEYWELL C6097A (50700)

HIGH GASPRESSURE SWITCH

HONEYWELL C6097B(50701)

NIPPLE, 1/4 X 9(5831)

NIPPLE, 1/4 X CLOSE(5834)

NIPPLE, GAS INLETPF-4009 (54681)

STRAIGHT FLANGE,DUNGS (252516)

ELBOW FLANGE,DUNGS (251697)

NIPPLE, 3/4 X 4(99218)

GAS VALVE, DUNGS GB-057(54429)

Figure 5.5: PF-460 Internal Gas Train

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7. ELECTRICAL CONNECTIONSB. CUSTOMER CONNECTIONS

For the PF-460, all customer connections remain the same as the PF-300 and PF-399. Refer to the main I,O&M (PF8248).

D. INTERNAL WIRINGFigure 7.7 below shows the complete wiring diagram for the PF-460 with the High and Low Gas Pressure Switch Circuit.

13. High and Low Gas Pressure Switches: A High and Low Pressure switch are provided with the PF-460 to provide compliancewith CSD-1 requirements for installations. These switches prevent the boiler from operating in adverse gas pressure conditions.

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6

8. BOILER CONTROL: OPERATION

B. IGNITION SEQUENCE

Figure 8.1 shows the ignition sequence for the PUREFIRE®

boiler control. Table 8.1 describes each step in thesequence in detail. The PUREFIRE® boiler control providesdual sensing of the flame to maximize the reliability. Thecontrol senses the burner flame with both the flamesensor and the ignition electrode.

Figure 8.1: Ignition Cycle – Graphical Representation

Off

Sta

te

OffOnOffOn

On

OnOffOn

Ignition

LowOff

Pump

Gas Valve

Ignitor

Flame Signal

Pre-

Purg

e

Stan

dby

Fan

Igntion Cycle

Demand

Pre-

Igni

tion

Igni

tion

Circ

ulat

or P

ost

Purg

e

Safety On/Off

Post

Pur

ge 1

Post

Pur

ge 2

Bur

ner O

n

OffHigh

2 se

cond

s

4 se

cond

s

2 se

cond

s

Maximum 24 hours

30 s

econ

ds

min

imum

Dep

ends

on

boile

r set

tings

320 milliseconds

5 se

cond

s

10 s

econ

ds

max

imum

Table 8.1: Ignition Sequence

Period Demand Status Burner LCD Display

Standby

No demand is present

If the power is on to the PUREFIRE® boiler and there is no heat demand, the burner LCD will display “Standby” and show the boiler supply temperature in the lower right corner. The time, in 24 hour format, is shown in the upper right. When a heat demand(either CH or DHW) is present, the boiler begins the ignition cycle.

Pre Purge

A CH or DWH demand must be present to initiate ignition.Once initiated the boiler will light.

When a demand is present, the PUREFIRE® control starts the combustion air fan. The fan speed then increases to ignition speed and the burner LCD displays the source of the call for heat along with “Trial for ignition.” This screen is displayed until the burner is lit and stable or until a fault occurs. Once the ignition sequence begins it will continue through ignition even if thedemand has ended.

The PUREFIRE® PF-460 utilizes a single controlsystem. Treat the PF-460 control as a managingcontrol.

NOTICE

7

Table 8.1: Ignition Sequence (cont’d)

Period Demand Status Burner LCD Display

SafetyOn/Off

A heat demand has no influence in the Safety On/Off period.The Safety On/Off step will continue even if the demand has ended.

This step very quickly opens and closes the gas valve relays and determines if the control is operating correctly. The CH pump isturned off during this test.

Pre-Ignition

A heat demand has no influence in the Pre-Ignition period.

Once the internal check is complete, the control begins a Pre-Ignition sequence. The igniter is energized while the gas valveremains off. If a flame is detected at the end of the pre-ignition period a lockout will occur.

Ignition

A heat demand has no influence in the Ignition period.

The following displays occur on ignition failure only.

The igniter remains energized for the first 4 seconds of the Ignition period. For the final 2 seconds of the Ignition period, the igniter is turned off and the control checks for a flame signal through both the ignition electrode and the flame sensor. If no flame signal ispresent at the end of the Ignition period, the control initiates a post-purge and then begins the ignition cycle again. If the number ofignition failures exceeds the allowable number in one call for heat, the control will post purge and lock out. If the “One Hour Retry”parameter is set to, “ON”, the control will retry ignition one hour after an ignition failure. The control records 4 flame signal valuesduring the last two seconds of this period that can be accessed from the “Installer Menu” under “Status”.

Burner On

A heat demand must be present for the control to stay in this period.

Once a flame signal is established, the burner will run until a demand is satisfied, the setpoint is exceeded, or a blocking/lockouterror occurs. The maximum run period for the burner is 24 hours. If the boiler runs continuously for 24 hours, the control willoverride the demand and turn off the burner. After this a restart will occur and the burner will continue to run.

Post Purge 1

After the Post Purge period begins, a heat demand will beignored until after this period.

The following screen is displayed when the demand has ended.

During post purge 1, the control monitors the flame signal to be sure that the flame has extinguished. If a flame is detected afterthe maximum 10 second time period, a control lockout will occur.

Post Purge 2

During this period a heat demand has no effect on operation.

The following screen will be displayed if the supply temperatureexceeds the target setpoint.

During this period, the combustion air fan runs at high speed to purge combustion gases from the heat exchanger. The default fanpost purge period is 30 seconds. It is adjustable up to 120 seconds.

PumpPurge

No heat demand is present.

The operation of the circulators and the boiler depend on the pump mode and the heat demand status.

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C. USER MENU

To access the user menu, simply press the “Menu” key onthe LCD display. Use the “▲” and “▼” keys on thedisplay to move the cursor to the desired selection.Pressing “Select” will access the submenu for theselection. The submenus are described in detail below.

1. LCD Status MenuStatus Menu: The user status menu gives the user orinstaller access to basic information about the boilersystem. The first screen shows the Current SupplySetpoint. If the boiler is in CH Mode 0, 2 or 6, this isthe temperature that the boiler targets. As the boilerapproaches this target, the burners will modulate theirinput.

The next screens show temperature values read by thetemperature sensors in the control system. The supplyand return temperatures are measured at the headeron the outlet side of the heat exchanger. There is asupply and return sensor for each burner. In additionto the supply and return sensors, there is a header(system) sensor on the boiler supply (outlet) pipe.

Typical Values for Water Sensors:(Supply/Return/System/DHW): 70°F (21°C) to 200°F(93°C).

A value of 14°F (-10°C) indicates an open sensor anda value of 244°F(118°C) indicates a short for thesesensors.

Typical Values for the Vent Sensor are: 70°F (21°C) to200°F (93°C).

A value of 50°F (-10°C) indicates an open sensor anda value of 244°F(118°C) indicates a short. Sinceboilers installed in low temperature environments suchas a garage may experience vent temperatures below50°F, the control works as follows:a. If the Vent Temperature Sensor reads less than

50°F, the boiler will continue to operate normally,unless,

b. If the return temperature exceeds 80°F (27°C) orthe supply temperature exceeds 120°F (49°C) theburners will operate at their minimum modulationuntil the call for heat ends or the vent temperatureexceeds 50°F.

The outdoor sensor temperature should correspond tothe current outdoor temperature. If the sensor ismounted in direct sunlight or near an applianceexhaust vent, erratic operation can result due to largechanges in the apparent outdoor temperature.

A value of -40°F (-40°C) indicates an open sensor anda value of 244°F(118°C) indicates a short for thissensor.

The final screen of the status menu providesinformation on the status of each of the circulators.

2. LCD Settings MenuThe user settings menu provides access to basicsettings on the PUREFIRE® control. After choosing the“Settings Menu” the Central Heating Setpoint menuappears. To access the other menus, press the “�”key. Some of the menus shown below will not appeardepending on the CH or DHW mode chosen.a. Central Heating Setpoint: Depending on the CH

Mode chosen (in the Installer Menu), the user maybe able to adjust the boiler water temperature thatis targeted by the control on a central heatdemand. If the CH Mode is 1 or 2 (OutdoorReset), this screen will show “OD RESET” alongwith the target temperature calculated by thecontrol algorithm. The user is not allowed tooverride the calculated temperature. If CH Mode 0or 6 is chosen, the target temperature can bechanged by pressing the “Select” key and usingthe “�” and “�” keys to increase or decrease thevalue. The following shows the range and defaultvalues for the Central Heating Setpoint.

Figure 8.2: User Menu

Figure 8.3: Status – Supply Setpoint

Figure 8.4: Status – Temperature

Figure 8.5: Status – Circulators

Figure 8.6: Settings – CH Setpoint

Subsections C-E of this supplement are to be used inlieu of subsections C-I in the PF8248 I,O,&Minstructions.

NOTICE

Table 8.2: CH Setpoint Range & Defaults

CentralHeatingSetpoint

Minimum Maximum Default

50°F 195°F 160°F

10°C 91°C 71°C

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b. DHW Boiler Setpoint: This value determines thetarget temperature for the boiler supply to anindirect domestic hot water (DHW) storage tank.This should not be confused with the DHW Tanktemperature. If the DHW Mode is set to Mode 0(No DHW) this screen will not be visible.

c. DHW Tank Setpoint: This screen allows the userto select the target temperature for the indirectDHW storage tank. This screen is only visible ifthe DHW Mode is set to Mode 1 (DHW Tank withSensor) and an optional 12 kΩ DHW Tank sensoris purchased (PB Stock Code 54157).

d. Time & Date: This screen allows the user to setthe current date & time for the burner. Setting thecurrent date and time allows the installer to set upalert messages for routine inspection andmaintenance.

• Press the “Select” key. The third line willalternately flash the day of the week and “---”.

• Use the “�” and “�” keys to change the day.Press the “Select” key to select the correct day.

• The date value will flash. Use the “�” and“�” keys to change the date. Press the“Select” Key.

• The month value will flash. Use the “�” and“�” keys to change the month. Press the“Select” Key.

• The year value will flash. Use the “�” and“�” keys to change the year. Press the“Select” Key.

• The hour value will flash. Use the “�” and“�” keys to change the hour. Press the“Select” Key. (Note that the hour is displayedin the 24 hour format so that 3:00 pm =15:00.)

• The minute value will flash. Use the “�” and“�” keys to change the minutes. Press the“Select” Key.

The date and time will be stored in non-volatilememory so the date will not require resetting if thepower is disconnected.

e. Temperature Units: This screen allows the user tochange the temperature unit display. The defaultunits are Fahrenheit °F. To change the unit display,press the “Select” key. The current unit system willflash. Use the “�” and “�” keys to change thevalue to Celsius °C. Press the “Select” key againto choose the units.

3. LCD Message MenuThe messages menu allows the user to view the lastblocking error or last lockout error. The display willalso show the interval between the last blocking orlockout error and the error before the last. Todetermine the interval between the current time andthe error displayed, create an error by disconnectingthe supply sensor wire.

WARNING

DANGERWater temperatures over 125°F can instantly causesevere burns or death from scalding. Children, elderlyand disabled individuals are at the highest risk ofscalding. See instruction manual for the indirect tankbefore setting the water heater temperature. Instructusers to feel the water temperature before bathing orshowering. Anti-scald valves are recommended.

Figure 8.7: Settings – DHW Boiler Setpoint

Figure 8.8: Settings – DHW Tank Setpoint

Figure 8.9: Settings – Date & Time

Figure 8.10: Settings – Temperature Units

Table 8.3: DHW Boiler Setpoint Range & Defaults

DHW BoilerSetpoint


122°F 195°F 180°F

50°C 91°C 82°C

Table 8.4: DHW Tank Setpoint Range & Default

DHW TankSetpoint


50°F 158°F 120°F

10°C 70°C 49°C

Be sure to only use the 12 kΩ tank sensor indicated.Other sensors will not provide accurate tanktemperatures and may cause severe personal injurydue to scalding.

DHW Boiler Setpoint Setting is only available in DHWMode 1 & 2.

NOTICE

DHW Tank Setpoint Setting is only available in DHWMode 1.

NOTICE

10

a. Last Lockout Error: The last lock menu allows theuser to view the reason for the last lockout. SeeTable 10.2 for a list of locking errors and theassociated codes. Note that a value of #255indicates that there are no lockout errors in thecontrol history. Also, note that the errors displayedmay have occurred during the factory fire test orfield commissioning of the equipment.

b. Last Blocking Error: The last block screen allows theuser to view the reason for the last blocking error.See Table 10.1 for a list of blocking errors and theassociated “E” codes. Note that a value of #255indicates that there are no blocking errors in thecontrol history. Also, note that the errors displayedmay have occurred during the factory fire test orduring field commissioning of the equipment.

D. INSTALLER MENU

1. Menu OverviewThe installer menu allows installing or servicecontractors to view and/or make adjustments to thepermanent boiler settings based on the installationconfiguration, desired operation and local codes. Themenu structure is shown in Figure 8.12.

To access the installer menu, press and hold the“Menu” and “Select” key on the LCD display.

2. StatusThe status menu is designed to monitor keyparameters and aids the installer or service contractorin determining if there are problems with boileroperation.a. Current Supply Setpoint: The setpoint value will

change for DHW demands or CH demandsdepending on the setpoint chosen for these modesof operation. When outdoor reset modes areselected, this value is the calculated target for thesystem.

b. Fan Speeds: Screens #2 & #3 display fan speedinformation. The current fan speed will varyduring operation between the low power and highpower values. The Low Power, Ignition, and HiPower values are preset at the factory for a specificmodel size. Table 12.3, in Section 12 of thismanual, shows the fan speed presets for eachmodel size. Note that these values may varyslightly due to air setting changes.

c. Flame Measurements: Screens #4, #5 & #6display flame signal information. The first value,Flame Signal, is the current flame rectification signalin micro amps (µA). The minimum value for thissignal that will allow the burner to continue runningis 2.8 µA the maximum value for this is 10 µA.

The next value, Flame Failures, is the number oftimes the burner has dropped out due to flamefailure. Several flame failures may have occurredduring the factory firetests and installation. If thereare a large number of flame failures showing onthis screen, contact your Peerless® Representative.

On Screens #5 and #6, the Flame Measurementvalues 1-4 are logged in the last two seconds ofthe most recent ignition sequence in 1/2 secondintervals. This helps service contractors todiagnose ignition issues.

Figure 8.11: Messages – Last Errors

Figure 8.12: Installer Menu

Figure 8.13: Status – Supply Setpoint

Figure 8.14: Status – Fan Speeds

Figure 8.15: Status – Flame Signal

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d. Ignition Attempts: Screen #7 provides informationabout ignition attempts. Obviously, the total ignitionattempts are the sum of the successful and failedattempts. Several ignition failures may occur duringfactory firetest and equipment commissioning.However, if there are a large number of failedignition attempt showing on this screen, contact yourPeerless® Representative. If there is an unusuallylarge number of total ignition attempts, there may bea problem with the boiler short cycling.

e. Burner Run Time: Screen #8 providesinformation about the total run time of eachburner. The total burner run time is the sum of thecentral heating (CH) and domestic hot water(DHW) hours. The total boiler run time is the sumof both burner run times.

f. Blocking Errors: Screen #9 provides error historyabout the last 16 blocking errors. Blocking errorsare errors that prevent the burner from operatinguntil the condition causing the error is corrected.Sensor errors, low water, and blocked vent areexamples of this type of error. To review previouserrors, press the select key. The number in theupper right changes from the status screen “9” to ablinking “0” indicating that this is the most recenterror. Use the arrow keys to scroll through previouserrors from 0 to 15. If the screen shows “#255” inthe error number location, this indicates that thereis no error stored in this location. All errors onscreens higher than one showing “#255” shouldalso indicate no error. Table 10.1 (in Section 10)provides a list of blocking errors.

g. Lockout Errors: Screen #10 provides error historyabout the last 15 locking errors. Locking errors areerrors that require a manual reset on the controlboard (pushing the “Reset” key on the display) toreset the burner once the condition causing theerror has been corrected. Ignition Failure, FlameFailure and High Limit Temperature are examplesof this type of error. To review previous errors,press the “Select” key. The number in the upperright changes from the status screen number “10”to a blinking “0” indicating that the screen isshowing the most recent lockout error. If theburner is not in lockout, this position should show“#255” in the error number location. Use thearrow keys to scroll through previous errors from 1to 15. As with blocking errors, “#255” alwaysindicates that no error is stored in this location.Table 10.2 provides a list of lock out errors.

3. Burner SettingsThe burner settings menu allows the installation orservice contractor to change settings which effect theburner operation. The following are descriptions ofthe available settings.a. Burner Mode: The burner modes are set by

default from the factory. The burner mode is set to“standalone” from the factory for the PF-460. Donot use any other setting for this parameterwith the PF-460.

b. Boiler Address: PUREFIRE® boilers can be operatedin cascade with as many as 15 identical boilers byadding 2 wire communication links between theboilers. The following chart shows the role of theboiler depending on the boiler address. Multipleboiler operation is covered in-depth at the end ofthis section of the manual.

c. Installation Location & Vent Material: Due todiffering national codes in the United States andCanada, there are different material requirementsfor exhaust vent pipe. Therefore, the maximumvent limit temperature is different depending onthe material used.

Screens #3 and #4 allow the installer to select theinstallation location and vent material. Based onthe information given, Table 8.6 shows theexhaust temperature that the control will allowbefore reducing the burner input rate. If thetemperature of the exhaust gas approaches thesevalues, the control will reduce the input rate onboth burners until the temperature begins to drop.If the flue temperature continues to rise, thecontrol will shut down both burners.

Figure 8.16: Status – Ignition

Figure 8.17: Status – Burner Run Time

Figure 8.18: Status – Blocking Errors

Figure 8.19: Status – Locking Errors

Figure 8.20: Burner Settings – Burner Mode &Boiler Address

The PUREFIRE® PF-460 can only be operated with theBurner set to Standalone. Do not change the BurnerSettings from the factory setting for PF-460 models.

NOTICE

Table 8.5: Boiler Address

Boiler Address Value

Description

0 Stand-Alone Boiler

1 Master Boiler in a Cascade System

2-16 Dependent Boilers in a Cascade System

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Note: Although stainless steel can withstand atemperature higher than 230°F (110°C) thetemperature limit is set to this temperature sincethe vent temperature should not exceed thistemperature unless there is a problem with theheat exchanger.

d. Freeze Protection: Freeze protection is intended toprevent freezing the central heating system.

• First, the control activates pumps to distributeheat uniformly through the system.

– If the boiler supply (header) temperaturedrops below the value selected for “FreezeProtection starts at:”, the General (boiler)circulator is activated.

– If either of the boiler return sensors reports avalue below this temperature, the CHcirculator is started.

• Next, if the return temperature drops more than9° (5°C) below the “Freeze Protection starts at:”value, the controls activates the burner at itsminimum rate.

– If a central heat demand is detected while theburner is operating for Freeze Protection, theburner will run normally to satisfy the demand.

– Finally, once the return temperatureincreases to 9°F (5°C) above the chosenvalue, the burner is switched off and thepumps are deactivated.

e. Blower Postpurge Time: The blower postpurge timecan be increased to address problems under extremeconditions (long exhaust vent runs, high winds, etc.)where the products of combustion are not fullyexpelled from the venting system. This featureshould be used sparingly as it may lead to decreasedefficiency and higher fuel bills in certain situations.

f. Additional Safety Features: The Boiler Control isequipped with terminals for either a low watercutoff or a flow switch. The low water cutoff is thefactory default and a factory supplied jumper isinstalled. This jumper is to be removed if a lowwater cutoff or flow switch is installed.

• Low Water Cut Off: The installer can connectthe power supply wires for a probe-type lowwater cutoff to terminal #19 (Hot) and #20(Neutral) in the main terminal box. The contactsshould be wired to terminals #9 and #10.

• Flow Switch: If a flow switch is used, simplywire the contacts to terminals #9 and #10 inthe main terminal box.

g. Ignition Attempts: The control is configured fromthe factory to not allow the burner to recycle aftera failed ignition attempt. At installation, the controlcan be configured to allow up to 3 ignitionattempts before locking out and requiring amanual reset. In addition, the control may beconfigured to retry for ignition, one hour afterlockout without a manual reset. Check applicablecodes before changing these parameters.

Figure 8.23: Burner Settings – Blower Post Purge

Table 8.8: Freeze Protection Range & Default

Table 8.9: Blower Post Purge Range & Default

Table 8.6: Vent Temperature Limits

Vent MaterialLocation

U.S.A. Canada

PVC190°F(80°C)

149°F(65°C)

CPVC230°F

(110°C)190°F(80°C)

Polypropylene(PPs)

230°F(110°C)

230°F(110°C)

Stainless Steel230°F

(110°C)230°F

(110°C)

Freeze ProtectionStarts at

Default Minimum Maximum

50°F (10°C) 45°F (7°C) 56°F (13°C)

Blower Post Purge Time

Default Minimum Maximum

30 sec 30 sec 120 sec

Table 8.7: Location & Vent Material Default

Figure 8.22: Burner Settings – Freeze Protection

Parameter Default

Location U.S.A.

Vent Material PVC

Figure 8.21: Burner Settings – Location & VentMaterial

Figure 8.24: Burner Settings – Additional SafetyFunctions

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h. Flame Failures: The control is configured from thefactory to not allow the burner to recycle after aflame failure. At installation, the control can beconfigured to allow up to 2 retries after a flamefailure before locking out and requiring a manualcontrol reset. In addition, the control may beconfigured to retry for ignition one hour after alockout without a manual reset. Check applicablecodes before changing these parameters.

i. Air Adjustment: Screens #12 and #13 allow thefan speed to be increased if required. Thefollowing is an explanation of the conditions underwhich these adjustments should be made.

j. Minimum Fan Speed: The minimum fan speedadjustment is intended to respond to potentialissues with the loss of flame due to pressurefluctuations in the venting system. These concernsmay be due to wind gusts on sidewall ventedboilers or other sources of exhaust vent pressurespikes. The minimum fan speed may be adjustedin 30 RPM increments up to the minimum fanspeed + 540 RPM. This feature should only beused to address nuisance flame failure or flappervalve failure lockout errors.

k. Maximum Fan Speed: The maximum fan speedadjustment is intended to compensate for longexhaust vent runs if the boiler fails to keep up withthe required load. Since the input rate may dropoff slightly under increased resistance due to longexhaust vent installations, the boiler input may beincrementally increased to compensate. Thisadjustment should only be made if both of thefollowing conditions are met:

• The boiler is not keeping up with the requiredload.

• The input rate has been determined to be belowthe rated input by timing the gas supply meter.

If these conditions are not met, contact yourPeerless® Representative for assistance.

l. Alarm Mode: The alarm mode allows the installingcontractor to set the menu to the modeappropriate for the installation. The default settingis “Stand Alone” in which the alarm contacts(Terminals #31 & #32) simply close if an alarmcondition exists. The PF-460 has no designprovisions that allow it to be included in acommon venting system.

4. Central Heating (CH) SettingsCH settings manage the boiler temperature andcirculators for the central heating load. Although themenu items that follow are factory set, by default, tovalues that can operate in any installation, they canbe adjusted to maximize the efficiency of this product.The boiler can be configured to operate with a fixedsetpoint or using outdoor reset to vary the boilertarget temperature according to the load implied bythe outdoor temperature.

Figure 8.26: Burner Settings – Flame FailuresAllowed

Figure 8.25: Burner Settings – Ignition AttemptsAllowed

Table 8.10: Ignition Attempts Ranges & Defaults

Table 8.11: Flame Failures Allowed Ranges &Defaults

Parameter Default Minimum Maximum

Ignition AttemptsAllowed

1 1 3

Ignition Attempts 1 Hr Retry

OFF OFF ON


Flame Failure Retries Allowed

0 0 2

Flame Failure1 Hr Retry

OFF OFF ON

Figure 8.27: Burner Settings – Air Adjustment

Table 8.12: Air Adjustment Ranges & Defaults


Air Adjustment Min Fan Speed

0 rpm 0 rpm 540 rpm

Air Adjustment Max Fan Speed

0 rpm 0 rpm 540 rpm

Figure 8.28: Burner Settings – Alarm Mode

DANGERThe PF-460 cannot be vented into a common vent withother boilers. There are no provisions to preventbackflow through the heat exchanger. Severe personalinjury, death or major property damage will occur.

14

a. Setpoint Operation: When using a setpointstrategy, the boiler targets a fixed setpoint which isset in the User Menu on the PUREFIRE® control. Asthe boiler supply (outlet) temperature approachesthis target, the burner begins to modulate the fuelinput, reducing the output rate of the boiler. If theboiler reaches a temperature of 9°F (5°C) abovethe setpoint before the heat demand ends, theburner will shut down. If the heat demandcontinues and the boiler temperature drops 9°F(5°C) below the setpoint, the burner will restart.

b. Outdoor Reset Operation: Outdoor reset strategiesare ideal for condensing boilers for two reasons:

• Heat distribution units, such as radiators,radiant floors and copper baseboard are sizedto deliver the heat required on the coldest dayat a set temperature. For the remainder of theheating season, the maximum output is notrequired, so the distribution can be set to acooler temperature.

• Condensing boilers, like the PUREFIRE®, aredesigned to withstand acidic condensate andtherefore can be operated at as low atemperature that is reasonable. At lowertemperatures [below 120°F (49°C) returntemperature], these boilers condense moreand are more efficient.

c. CH Modes: The CH modes allow the operator tochange the way the boiler operates to satisfycentral heating demands.

• Mode 0, Indoor Thermostat: This is the defaultmode in which the boiler responds to ademand from an indoor thermostat or zonecontrol panel at terminals #1 and #2 in thePUREFIRE® control panel. The control targets afixed setpoint and as the boiler watertemperature approaches the target, the controlbegins to reduce the fuel input. This modedoesn’t require an outdoor sensor.

• Mode 1, Indoor Thermostat with Outdoor Reset:When operating in this mode, the control usesthe outdoor temperature and installer selecteddata to calculate a target boiler watertemperature. A detailed description of outdoorreset is presented later in this section.

• Mode 2, Permanent Demand and OutdoorReset: In this mode, the boiler operates tomaintain a supply (header) temperaturecalculated by the outdoor reset algorithm. The boiler operates independently of anyroom thermostats. This is useful in buildingswith many zones which operate onindependent thermostats to prevent the boostfunction (described later in this text) fromincreasing the target temperature due to a longsustained call for central heat resulting fromoverlapping individual calls.

• Mode 3, Permanent Demand: This mode issimilar to Full Outdoor Reset except that thecontrol targets a fixed setpoint instead of acalculated setpoint based on the outdoortemperature. Again, the boiler control operatesindependently of input from room thermostats.If a switch between terminals #1 and #2 isclosed, the target temperature will be set backby 18°F (10°C).

• Mode 4, 0 -10V Input to Modulate Setpoint:This allows the boiler supply target to be setby an external analog 0-10 volt signal. Theinput for this signal is at terminals #15 & #16.A call for heat will be generated by a signal of1.5 VDC or higher. The setpoint for an inputvoltage between 1.5 and 2.0 VDC will result ina boiler setpoint of 68°F (20°C). An inputvoltage of 10 VDC will result in a setpoint of195°F (91°F).

• Setback: If a switch is closed across terminals#1 & #2, a setback of 18°F (10°C) is appliedto the calculated target temperature. Thisfeature is useful in a building (such as an officebuilding) that is unoccupied during certaintimes. A switch or timer can be used to setback the boiler target temperature duringunoccupied periods.

d. Pump Purge Time: The installer can define thelength of time that the circulators operate after theend of call for heat. The CH and Generalcirculator post purge time can be setindependently. The following chart shows therange and default values for both of these pumps.

Table 8.13: CH Modes

Mode DisplayTarget

Temperature

Action whenTerminals #1 &

#2 Closed

0Indoor

ThermostatFixed Setpoint

Call for CentralHeating

1Indoor

Thermostatwith OD Reset

Outdoor ResetCalculation

Call for CentralHeating

2Permanent

Demand & ODReset

Outdoor ResetCalculation

18°F (10°C)Target Setback

3PermanentDemand

Fixed Setpoint18°F (10°C)

Target Setback

40-10 V Input to Modulate

Setpoint

External Analog(0-10 VDC) Input

of SetpointNo Effect

Figure 8.29: CH Settings – CH Modes

Figure 8.30: CH Settings – Pump Purge Time

Table 8.14: Pump Purge Time Ranges & Defaults

Circulating Pump Minimum Default Maximum

Central Heating (CH) 0 1 minute 60 minutes

General 0 1 minute 60 minutes

15

e. Outdoor Reset: Since heating loads are typicallylower when the outdoor temperature rises,outdoor reset lets the installer reduce the boilertarget temperature as the outdoor temperatureincreases. As mentioned above, this increases theefficiency of the boiler. This is especially true withcondensing boilers because it helps to recover theheat from the water vapor which, in conventionalboilers, carries valuable energy out with theexhaust.

f. System Type Presets: For convenience, thePUREFIRE® boiler control provides preset values forthe outdoor reset parameters based on the systemtype. Table 8.15 shows the values that are appliedwhen different system preset types are selected. Ifthe system type, “User Defined” is chosen theoutdoor reset definition values may be adjusted. Ifchanges are made to the boiler design or mildweather boiler temperatures, the system type isautomatically switched to, “User Defined”.

g. Warm Weather Shutdown: If the boiler is set tooperate in CH Mode 1 or 2, the PUREFIRE® controlis set by default to prevent the boiler from operatingto satisfy a central heat demand if the outdoortemperature is above 70°F (21°C). This value canbe adjusted using the values shown below.

If the installer prefers to use custom values for theoutdoor reset parameters, the following providesguidance.

h. Design Point: The design point is defined by theoutdoor design temperature and the boilerdesign temperature.

i. Boiler Design Temperature: The boiler designtemperature is the temperature at which the boileris designed to operate in order to meet the load.Copper finned tube radiators are typically rated at180°F (82°C). The Table 8.17 shows typical boilerdesign temperatures for different types of headdistribution units.

j. Outdoor Design Temperature: The heat loss for thestructure is determined by considering the coldestsustained outdoor temperature that is expected atthe site location. For a detailed list of outdoordesign temperatures by state, refer to the H-22heat loss calculation guide published by AHRI.

Table 8.15: System Type Presets

System TypeTemperatures

Boiler Design

Mild WeatherBoiler

1. Finned Tube Baseboard 180 140

2. Hydro Air Unit 190 140

3. Cast Iron Radiator 160 120

4. Cast Iron Baseboard 150 110

5. Low Mass Radiant 140 70

6. High Mass Radiant 120 70

7. user Defined (Default) 180 70

Table 8.16: Warm Weather Shutdown Range &Default

Parameter Minimum Default Maximum

Warm Weather Shutdown 35°F (-18°C) 70°F (21°C) 100°F (38°C)

Figure 8.31: CH Settings – Warm Weather Shutdown

Figure 8.34: Outdoor Reset Operation

16

k. Mild Weather Point: The mild weather point isdefined by the mild weather outdoor temperatureand the mild weather boiler temperature.

l. Mild Weather Boiler Temperature: This is theminimum temperature that the boiler will target tosatisfy a CH demand. In radiant floor design, thistemperature can be set very low. However, avoidsetting the temperature too low in systems withlimited radiator surface and in lower floors withopen stairways that can allow heat to migrate upto higher floors.

m. Mild Weather Outdoor Temperature: Thistemperature is the highest outdoor temperature atwhich the boiler is expected to run. The defaultvalue for this is 70 which equals the default warmweather shutdown value.

The example in Figure 8.32 shows an outdoortemperature of 0°F (-18°C) which corresponds tothe value for Springfield, Massachusetts. Theboiler temperature is shown at 160°F (71°C) tomeet the load as determined by the systemdesigners. The mild weather point is at an outdoortemperature of 70°F (21°C) and a boilertemperature of about 85°F (29°C). When theoutdoor temperature is 32°F (0°C), the boiler willtarget 130°F (54°C).

n. Boiler Limits: The boiler limits are available to limitthe minimum and maximum temperature that theboiler can target. Note that these limits willoverride the values set in the outdoor reset designand mild weather outdoor reset parameters.

o. Boiler Min: The boiler will not target a temperaturelower than what is chosen in this menu screen. Thedefault for this is, “Off” since low temperatures willnot affect the boiler. However, it may be useful ininstallations that require a minimum temperature tooperate (like a fan coil unit that will not allow a fanto operate below a certain temperature).

p. Boiler Max: The boiler will not target atemperature higher than that chosen in this menu.This can be useful to prevent damage due to hightemperatures in temperature sensitive situationssuch as radiant floors.

q. Boost: The boost function is designed to compensatefor a system that is not meeting the required load. Ifthere is a constant call for central heat for the lengthof time specified, the target temperature will beincreased by the temperature value selected. Theboiler will never target a temperature higher thanthat specified by the boiler max. parameter.

There are several reasons why the boost functionmay or may not be implemented.

• In buildings which have many zones, there mayseldom be a period when none of the zones iscalling for heat. In this case, the boiler will veryoften be operating at the temperature selectedby the “boiler max.” parameter, and much ofthe advantage of a condensing boiler may belost. Therefore, it may be better to use CHMode 2, “Permanent Demand and OutdoorReset” in these situations. In this mode, theboost function is not applied therefore theboiler will continue to run at the temperaturecalculated by the outdoor reset algorithm.

• Programmable thermostats can give a buildingowner the ability to set back the thermostatsignificantly during unoccupied periods. Afteran aggressive setback, it may take the boiler asignificant amount of time to recover. However,this may lead to the boiler frequently operatingat higher temperatures, where it is less efficient.Before using setback thermostats, the buildingowner should be made aware that aggressivesetback s of 10°F (6°C) or more may not havethe desired effect.

• If the outdoor reset parameters are set fordesign conditions at a certain outdoor designtemperature, and the outdoor temperaturedrops below that temperature for a significantamount of time causing cold indoortemperatures, the boost function can allow theboiler to target temperatures up to the boilermaximum to satisfy the load.

Figure 8.33: CH Settings – Reset Curve Mild Weather

Table 8.18: Reset Curve Mild Weather Ranges &Defaults


Mild Weather Boiler Temp.

36°F (2°C) 70°F (21°C) 160°F (71°C)

Mild Weather Outdoor Temp.

36°F (2°C) 70°F (21°C) 85°F (29°C)

Figure 8.32: CH Settings – Reset Curve Design

Table 8.17: Reset Curve Design Ranges & Defaults


Boiler Design Temp. 61°F (16°C) 180°F (82°C) 195°F (91°C)

Outdoor Design Temp. -40°F (-40°C) 0°F (-18°C) 70°F (21°C)

Figure 8.34: CH Settings – Reset Curve Min/Max

Table 8.19: Reset Curve Min/Max Ranges & Defaults


Boiler Minimum “Off” or 40°F (4°C) OFF 180°F (82°C)Boiler Maximum 81°F (27°C) 195°F (91°C) 195°F (91°C)

Figure 8.35: CH Settings – Temperature Boost

17

r. Anti-Cycling Time: This function allows theinstaller to set the minimum amount of time thatthe boiler can be off on setpoint before recycling. Ifthe supply temperature drops by a value higherthan Tdiff, the boiler will ignore the minimum offtime and resume operation. If excessive cyclingoccurs due to cycling of the thermostat or zonerelay, then the operation of these items should beexamined.

s. System Response Time: To modify the reactiontime of the system for a CH demand, the I-valueparameter can be changed. The following chartshows the range of values with descriptions of thecorresponding response speed.

Increase this value to reduce cycling in systemswith smaller zones. Decrease this value for a moreaggressive reaction to CH loads. This parametereffects only the CH response time, a similarparameter is available in the DHW Settings menu.

t. Maximum Allowable CH Rate: If the boiler is sizedprimarily for a DHW load that is significantlyhigher than the CH load, this value can bedecreased to limit the input rate of the boiler forcentral heating. The following chart shows theeffective input values for various modulationpercentages. As an example, if the DHW load is460 MBH and the CH load is 310 MBH, set the“Max Allowable CH Rate” to 60%.

5. Domestic Hot Water (DHW) SettingsDHW settings manage the boiler temperature andcirculators for the domestic water heating load. Theboiler can be configured to operate without a domestichot water load, with an indirect-fired hot water tankwhich incorporates a conventional thermostat, or withan indirect-fired hot water tank equipped with a watertank temperature sensor (PB#54157). The configurationusing the optional tank temperature sensor allows thecontrol to maximize the efficiency of the system bylimiting the input rate to recover from standby losses.

a. Domestic Hot Water Modes: This menu is used tochange the control response to calls for DHW.

• Mode 0, No DHW: Mode 0 indicates that thereis no DHW load. The DHW pump outputs willbe deactivated and the control will not respondto any signals at terminals #5 & #6.

• Mode 1, DHW Tank with Sensor: Mode 1 isused with a temperature sensor input from theDHW tank. The optional sensor (PB #54157)transmits the tank temperature to the controlwhich allows the control to determine the mostefficient boiler operation to address the heatdemand.

Table 8.20: Temperature Boost Ranges & Defaults


Boost Temperature 0°F (0°C) 18°F (10°C) 36°F (20°C)Boost Time 1 minute 20 minutes 60 minutes

Figure 8.36: CH Settings – Anti-Cycling

Table 8.21: Anti-Cycling Ranges & Defaults


Anti-Cycling Time 0 minutes 3 minutes 15 minutesAnti-Cycling Tdiff 20°F (11°C) 30°F (17°C) 40°F (22°C)

Figure 8.37: CH Settings – System Response

Table 8.22: System Response Range & Default

I-Value Response Time Description

15-20 Very Fast25-40 Fast

45-80 (Default=60) Medium85-110 Slow

115-120 Very Slow

Figure 8.38: CH Settings – Maximum CH Rate

Table 8.23: Maximum CH Rate Range & Default

% Modulation

Input Rate per Burner

PF-460Btu/hr

50% 230

60% 276

70% 322

80% 368

90% 414

100% 460

Figure 8.39: DHW Settings – DHW Modes

Table 8.24: DHW Modes

Mode DisplayInput to Terminals

#5 & #60 No DHW None Required

1DHW Tank with Sensor

NTC ThermistorTemperature Input

2DHW Tank

with ThermostatDry Contacts fromDHW Thermostat

18

When this mode is chosen, the DHW BoilerTemperature and the DHW Tank Temperaturesetpoint values are available on the User Menu.The control will modulate the burner inputbased on feedback from the boiler supplytemperature sensor. Therefore, if the tanktemperature meets its setpoint before the boilersupply is close to its setpoint, the boiler mayshut down while still in high fire. If this occursoften, lowering the DHW boiler supply setpointwill help to initiate modulation sooner.

Mode 1 can also decrease operating costs byassuring that the boiler operates at itsminimum firing rate to address loads due onlyto standby losses.

• Mode 2, DHW Tank with Thermostat: This isthe default DHW mode and it operates with acontact closure from a typical indirect tankthermostat. In this mode, the control targetsthe DHW boiler setpoint in the User Menu.

b. DHW Switch Time: When the PUREFIRE® boilercontrol is supervising the CH and DHW circulatingpumps, it operates with a limited DHW prioritystrategy.

• If there is a CH demand from the thermostatwhen the DHW tank calls for heat, the controlwill immediately switch from CH to satisfy theDHW demand.

– The control will continue to attempt tosatisfy the DHW load until the selectedswitch time is reached.

– Once the switch time is reached, the boilerwill switch back to the CH demand.

– If either the CH or DHW demand is satisfied,the boiler will then focus on satisfying theremaining load.

• If there is a CH demand during a call forDHW, the boiler will continue satisfying thetank load until the switch time is reached.

– After that it will alternate loads at the end ofeach switch time until one of the loads issatisfied.

– Then again, it will focus on the remainingcall for heat.

c. DHW Heat Dump: Scientists at BrookhavenNational Laboratories have performedexperiments which suggest that diverting heatfrom the boiler into an indirect storage tank at theend of each cycle improves the overall efficiencyof the heating system. The heat dump function isdesigned to take advantage of this principal.

• At the end of a heating cycle, when the CHdemand is satisfied, the control switches offthe CH circulating pump and turns on theDHW pump for the Max Time period.

• If the temperature difference between thesupply and return of the boiler drops lower thanthe Min Diff value, the pumps shut down.

d. System Response Time: The system response timeworks identically for DHW demands as it does forCH demands. These values are designed to allowindependent modification of the response time forCH and DHW loads. For small DHW loads, the I-Value can be increased. For large DHW loads, thisvalue can be decreased. If the burner doesn’tmodulate when it satisfies a DHW load, this valueshould be increased.

e. Maximum Allowable DHW Rate: If the boiler issized primarily for a CH load that is significantlyhigher than the DHW load, this value can bedecreased to limit the input rate of the boiler fordomestic hot water.

6. Service NotificationThe PUREFIRE® boiler control gives installers severaloptions to notify building owners when boiler serviceshould be performed. The first screen that appears,after choosing Service Notification, is Reset Notifications.Pressing select resets the hours and cycles to “0”.

The default for this optional feature is, “OFF”.However, if it is enabled, the installer can choose thenumber of hours, the number of cycles or the datewhen, “SERVICE” appears on the LCD menu screens.

The following chart shows the range and defaultvalues for the Service Notification feature.

Figure 8.40: CH Settings – DHW Priority Switch Time

Table 8.25: DHW Priority Switch Time Range &Default


CH/DHW Switch Time 5 minutes 30 minutes 60 minutes

Figure 8.41: DHW Settings – Heat Dump

Table 8.26: DHW Heat Dump Ranges & Defaults


DHW Heat Dump OFF OFF ONMaximum Time 0 minutes 1 minute 60 minutes

Minimum Difference 0°F (0°C) 5°F (3°C) 10°F (6°C)

Figure 8.42: DHW Settings – Response Time

Figure 8.43: DHW Settings – Maximum DHW Rate

19

If desired, the installer can select a specific date for theService Notification. Simply press the “Select” keywhen viewing the “Notification on:” date screen. Usethe “�” and “�” keys to set the value. Pressing“Select” activates the next date parameter.

7. System TestSystem Test settings allow the installer or serviceperson to operate each burner manually at itmaximum, minimum and ignition rates. The followingoutlines the system test operation.

a. Burner Only:

• Eliminate all heat demands to the boiler bydisconnecting the CH thermostat from terminals#1 & #2 and disconnecting the DHW sensoror thermostat from terminals #5 & #6.

• Use the “�” and “�” keys to position thearrow at the desired power setting.

• Press select to activate System Test. Theburner will ignite and then operate at theselected input rate until “Off” is selected fromthe System Test menu or for 1 hour. Theburner may cycle off on limit if the input rateexceeds the heating load.

b. Pump For CH/DHW:

• This function can be used to check thefunction of the CH and DHW circulating pumpoutputs.

• While in “Standby”, choose the desired pumpoutput from the Installer Menu, System Testscreen on the display.

• The pump terminals should be activated. If thepumps don’t appear to be operating, check thevoltage on the pump output terminals.

c. Multiple Boiler Systems:

• These selections may also be used in amultiple boiler, cascade system when testing adependent burner.

• In multiple boiler systems, these pumps are tobe connected to the master boiler in thecascade. Therefore, when a dependent boileris being tested, there will not likely be sufficientheating load to run the boiler for very long.

• In this case. Choose “Pump For CH” or“Pump for DHW” from the System Test menuon the display of the managing boiler in thesystem before running the dependent boilers.

8. Sequence (Managing Burner Display Only)

Adjustments in the sequence menu affect thesequence of burner operation. The first six parameterswill stop and start burners as follows:

a. On a call for heat (either CH or DHW) the 1stburner will start. The 1st burner can be either themanaging or dependent burner based on theRotation Interval chosen.

b. After the 1st burner is activated, the 2nd burner willcome on if all three of the following conditions aremet:

i. Supply Temperature < Target Temperature –Start Burner Differential

ii. 1st Burner Input Rate > Next Burner StartRate

iii. Start Delay Time has elapsed (Time fromwhen both prior parameters are met)

c. The 2nd burner will be deactivated if the followingconditions are met:

i. Supply Temperature > Target Temperature +Stop Burner Differential

ii. Both Burner Input Rates < Next BurnerStop Rate

iii. Stop Delay Time has elapsed (Time fromwhen both prior parameters are met)

d. Calculated Setpoint Max Offset Up/Down: Thetarget supply temperature of both burners areadjusted if the system supply temperature is aboveor below the targeted value. For example, if thesystem supply target temperature is 150°F, eachburner will target this temperature. However, ifthey approach their individual target temperaturebefore the system supply approaches its target, atemperature offset is applied. This offset is

Figure 8.44: Service Notification

Table 8.27: Service Notification Ranges & Defaults

Notification OnMinimum Default Maximum

OFF OFF ON

Hours 0 4,000 8,000Cycles 0 50,000 20,000

Figure 8.45: System Test Menu

The following features are non-functional for the PF-460.

NOTICE

20

Table 8.28: Sequence Menu, Ranges & Defaults

Menu ScreenRanges & Defaults

Minimum Default Maximum

1 Minute 2 Minutes 15 Minutes

1 Minute 2 Minutes 15 Minutes

1°F(0.6°C)

9°F(5°C)

23°F(13°C)

1°F(0.6°C)

18°F(10°C)

45°F(25°C)

0°F(0°C)

18°F(10°C)

36°F(20°C)

0°F(0°C)

9°F(5°C)

36°F(20°C)

40% 50% 95%

5% 9% 40%

0 Days(No Rotation)

5 Days 30 Days

21

calculated based on the Calculated SetpointMax offset up. Similarly, if the system target isabove its target a calculated negative offset basedon the Calculated Setpoint Max offset downis applied. The maximum increased setpointtemperature is 195°F (91°C).

E. DEFAULTS

1. Factory Defaults – Restore: By pressing the“Select” key while in the “Factory Defaults” screen. All factory settings will be restored on the control.

2. Site Defaults – Save: To save the current settings as“Site Defaults,” press the “Select” key while in thefollowing menu.

3. Site Defaults – Reset: To restore the “Site Defaults,”press the “Select” key while in the following menu.

F. MULTIPLE BOILERS

1. PUREFIRE® boiler controls can operate together tocontrol up to 16 boilers for one central heat or domestichot water demand. Only the addition of a systemsensor (54156) is required to provide this operation.

2. Overview:a. Master Boiler: In a multiple boiler system, a boiler

designated as the “Master” boiler controls thefunction of the boiler system.

• Attached to a system sensor which monitorsthe system water temperature.

• Can also be connected to an outdoor sensor(54112), included with each boiler, as well asan optional DHW sensor (54157) or astandard DHW thermostat.

• Determines which boiler operates first (lead)and when to bring on additional boilers.

• Determines the setpoint temperature ofindividual boilers.

• Shuts down all boilers in the system if theLWCO contacts are opened.

b. Dependent Boilers: The “dependent” boilersoperate at the setpoint temperature that theMaster boiler specifies.

• Maintain all of their own safety parameterssuch as safety limit, vent temperature limit,and freeze protection.

• Control their own general circulator that isenergized whenever there is a call for eitherCentral Heat or Domestic Hot Water.

• Shuts down the individual boiler if thedependent boiler LWCO contacts are opened.

3. System Piping & Wiring:a. Multiple boilers with multiple zones with zone

valves.

• Figure 8.49 shows a typical system which uses aCH circulator, a DHW circulator and zonevalves to distribute the heating load to thebuilding.

• A three zone valve control panel (not included)controls circulation to individual zones.

• A call from any of the heating zones initiates acontact closure from the zone relay across theCH thermostat connections (terminals #1 &2)on the master boiler. This initiates ignition ofthe “lead” boiler and its general pump. Inaddition, the CH circulator is energized.

• A call for domestic hot water can either beinitiated internally by the control when it seesa drop in indirect tank temperature or by atank thermostat. In either case, the lead boileris ignited and its general pump operates. TheDHW circulator is also energized.

b. Multiple boilers with multiple zones with zonecirculators.

• Figure 8.50 shows a typical system which usesa circulator zone control panel to control thecentral heating zones.

• The DHW circulator can be operated by thepriority zone or can be connected directly tothe boiler (as shown). In either case, thepriority zone cannot be used for heating.

• Again, a call for heat from any of the heatingzones causes the master boiler to initiateoperation of the lead boiler and its generalcirculator. The CH circulators are controlled bythe zone control relay panel.

Figure 8.46: Restore Factory Defaults Screen

Figure 8.47: Save Site Defaults Screen

Figure 8.48: Restore Site Defaults Screen

Before selecting cascade operation, connect theSystem sensor to terminals #7 & #8. Failure to dothis will result in a blinking screen warning ascovered in Section 10.D.

NOTICE

The central heating (CH) circulator and the domestichot water (DHW) circulator must be sized inaccordance with good Engineering practices basedon the required flow and pressure drop of thesystem. Failure to do so may result in systemperformance problems.

NOTICE

22

Fig

ure

8.4

9:

Mult

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Boiler

(Casc

ade)

Pip

ing / E

lect

rica

l C

onnect

ions

for

Syst

em

s w

ith Z

one V

alv

es

23

Fig

ure

8.5

0:

Mult

iple

Boiler

(Casc

ade)

Pip

ing / E

lect

rica

l C

onnect

ions

for

Syst

em

s w

ith Z

one C

ircu

lato

rs

24

• A DHW call results in the operation of the leadboiler and its general pump. The DHW pump isalso energized.

• Wiring for a typical circulator zone relay isshown in Figure 7.4.

4. Setting up Multiple Boiler Operation:a. Setting the Boiler Address:

• Press the “Menu” and “Select” keyssimultaneously for 5 seconds to enter theInstaller Menu.

• Find screen #2, Boiler Address. Use the “�”key to scroll down to “Burner Settings” on themenu.

• Pressing “Select” will cause the Boiler Addressvalue to blink. Use the “�” or “�” key tochange the value.

• The master boiler will be designated as BoilerAddress: 1.

• All dependent boilers must have sequential boileraddress settings as shown on the following table.

• Once a boiler is designated as a dependentboiler, the display will show the individualboiler supply temperature and its status.

• The master boiler will display the systemtemperature and the overall status of thecascade system.

• By pressing the “�” or “�” key the operatorcan view the master boiler status.

b. Connecting the Cascade Links – PF-460.

• Re-attach the User Interface Display.

• Connect wires from terminals #11 & #12between all boilers in the system.

5. Cascade Operation:a. When a call for Central Heat (CH) or Domestic

Hot Water (DHW) is present, the Master boilerchooses which boiler will lead based on theCascade Rotation Interval.

BoilerOperation

CascadeAddress

SystemSensor

OutdoorSensor

DHWSensor

Stand-aloneBoiler 0 Not

Active Active Active

Boiler #1Master 1 Active Active Active

Boiler #2Dependent 2 Not

ActiveNot

ActiveNot

ActiveBoiler #3Dependent 3 Not

ActiveNot

ActiveNot

Active➞ ➞ ➞ ➞ ➞

Boiler #16Dependent 16 Not

ActiveNot

ActiveNot

Active

Table 8.29: Cascade Addresses and Sensor Functions

Figure 8.52: Interconnection of Cascade Link Wires

TAB

OPEN

OFF

DISPLAY BOARD(BACK VIEW)SUB-BASE

CONNECTION TO CUSTOMERTERMINALS 11 AND 12

CONNECTION TO MAIN CONTROL

Figure 8.51: Cascade Link Connection & Switch Setting

25

b. Before starting the Lead boiler, the Master controlwill first check to be sure that the Systemtemperature is lower than the System Setpoint +Stop Boiler Differential.

c. After a Trial For Ignition (TFI), the lead boiler willmodulate its input rate to meet the heat demand.

d. Any time that a boiler is started the Cascade StartDelay Time will be initiated and no boiler will beallowed to start before this time elapses. This is toallow time for the system to stabilize beforebringing on an additional boiler.

e. After the delay time has elapsed, one of thefollowing conditions must be met before startingthe next boiler:

• The System Temperature must be lower thanthe Set Point minus the Cascade Start BoilerDifferential temperature, or

• The input rate of all boilers operating must behigher than the Next Boiler Start Rate.

f. After operation of the second boiler is initiated,the Cascade Start Delay Time must elapse beforebringing on additional boilers. Again, in order toinitiate operation of additional boilers one of thesame conditions must be met.

g. When the boiler system approaches its Setpoint,the boilers will reduce input rates at approximatelyequal values. When the input rates of all of theoperating boilers fall below the Next Boiler StopRate, the master control will shut down the lastboiler that started after the Cascade Stop DelayTime has elapsed.

h. The Calculated Setpoint Max Offset Up andCalculated Setpoint Max Offset Down are appliedto individual boilers in multiple boiler cascadeoperation.

• These temperature offset values are used tochange the response of individual boilers tothe system setpoint.

• Increasing these values will cause the systemto react more quickly, but may result infrequent cycling.

• Decreasing these values will cause the systemto react more slowly to achieve the setpoint.

• By increasing the Calculated Setpoint MaxOffset Up value, the Master boiler will offsetindividual boiler setpoints temperature by alarger amount in order to achieve the systemsetpoint.

• By increasing the Calculated Setpoint MaxOffset Down value, the boilers will decreasethe boiler setpoints by a larger amount toachieve the system setpoint.

i. The Rotation Interval is the frequency at which theMaster Boiler will change the Lead boiler in thesequence.

• For example, if the Rotation Interval is set to 4 days and there are 4 boilers operatingtogether, the following chart shows theoperating sequence over the next 25 days.

6. Multiple Boilers – Boost & Warm WeatherShutdown (WWSD):a. To use the Boost function with multiple boilers,

the parameters on the master boiler are used.Boost parameters set on dependent boilers haveno effect on the system operation.

b. Similarly, the WWSD Temperature set on themaster boiler will prevent any boilers fromoperating for a CH demand when the outdoortemperature is above this value.

7. Multiple Boilers – Ramp Delay:a. The ramp delay feature can be set on each

individual boiler.

b. However, it is important to note that since thedependent boilers treat DHW demands as a CHcall, the ramp delay will take effect even when theDHW tank calls.

8. Multiple Boilers – Anti-Cycling:a. The Anti-Cycling feature is active on all boilers

unless it is disabled.

b. This will prevent dependent boilers from operatingwithin the prescribed time limit. However, it willonly prevent the boiler from cycling on its ownlimit. Repetitive calls from the master boiler willresult in cycling.

9. Multiple Boilers – DHW Operation:a. Since the DHW tank sensor or thermostat is

connected only to the Master boiler, this is theonly boiler that will receive the DHW demand.

b. The master control will start boilers as necessaryto meet the demand.

c. Boilers with a boiler address of 2 or higher willautomatically be switched to DHW Mode 0 (NoDHW).

Table 8.30: Rotation Interval Sequence

Days of Operation Start/Stop Sequence

1-5 1-2-3-4

6-10 2-3-4-1

11-15 3-4-1-2

16-20 4-1-2-3

21-25 1-2-3-4

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11. MAINTENANCE

F. PF-460 MAINTENANCE AND SERVICE

The internal gas system of the PF-460 uses a hard piped configuration as opposed to the other PUREFIRE® models. A flangeconnection is provided to allow for easy maintenance access to the combustion chamber.

1. Shut off all power to the boiler.

2. Close the manual gas shut off valve to the boiler.

3. Remove the 4 M5 by 12mm screws located on the straight flange connection on the left side of the gas valve. Shown in Figure11.1.

4. The entire valve/blower/burner assembly can now be removed as described in Section 11: Maintenance, Part E, of themain PUREFIRE® I,O&M (PF8248)

Figure 11.1: Straight Flange removal for PF-460 Gas Train

To replace the gas valve follow the steps below:

1. Shut off all power to the boiler.

2. Close the manual gas shut off valve to the boiler.

3. Remove the 4 M5 by 12mm screws located on the straight flange connection on the left side of the gas valve.

4. Remove the 4 screws on the elbow flange on the right side of the valve.

5. The entire valve can now be removed independent of the gas train and the blower/burner assembly.

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12. BOILER DIMENSIONS & RATINGSTable 12.1: Boiler Dimensions

SERIES PEERLESS® PUREFIRE® DIMENSIONS (INCHES)

BoilerModel “A” “B” “C” “D” “E” “F” “G” “H” “J” “K” “L”

PF-460 27-15/16" 17-3/16" 40-1/2" 1-1/2" 4" 3/4" 2-3/4" 5-1/4" 3-1/2" 5-3/4" 7-1/16"

Figure 12.3: PF-460 Dimensions

Table 12.3: Combustion Air Fan Speeds

SERIES PEERLESS® PUREFIRE® COMBUSTION AIR FAN SPEEDS

BoilerModel

InputRate

Fan Speed

Low Power Ignition High Power

PF-460 460 MBH 1650 4110 6180

Table 12.2: Boiler Ratings

Series Peerless® PUREFIRE®

BoilerModel

Input (MBH) Gross Output(MBH)

Net Rating(MBH)

Thermal Efficiency(%)Min. Max.

PF-460 92 460 438 381 95.2

SERIES PEERLESS® PUREFIRE® BOILER RATINGS

Table 12.5: Electrical Ratings

SERIES PEERLESS® PUREFIRE® ELECTRICAL RATINGS

BoilerModel

Supply Voltage

(-15%, +10%)

Frequency(±1.2 hz)

Blower Gas Valve Pumps Max TotalService

Current toBoiler

Voltage(VAC)

Current(Amps)

Voltage(VAC)

Current(Amps)

Voltage(VAC)

Max.Current(Amps)

PF-460 120 VAC 60 hz 120 2.58 120 0.21 120 20.00 22.79

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13. REPAIR PARTSTable 13.5: PF-460 Repair Components

Description QuantityRequired

StockCode

1 Ignitor, with Gasket 1 4246

2 Sensor, with Gasket 1 54247

5 Premix Channel – PF-399/460 1 54250

6 Gasket, Channel to Burner 1 54186

7 Burner – PF-399/460 1 54264

9 Combustion Chamber Cover Plate, includes items #10-#12 1 54248

10 Gasket, Glass Rope 1 54188

11 Gasket, Rubber 1 54187

12 Insulation, Combustion Chamber Cover Plate 1 54255

15 Insulation, Target Wall 1 54185

16 Heat Exchanger – PF-399/460 1 5530

17 Thermal Fuse 1 54466

18 Gasket, Blower to Channel 1 54122

19 Blower- PF-460 1 55428

21 90° Flange Connection 1 5543

22 Dungs 057 Gas Valve 1 54429

23 Straight Flange Connection 1 5855

24 Gas Manifold- PF-460 1 54681

25 High Gas Pressure Switch- Honeywell C6097B1028 1 50701

26 Low Gas Pressure Switch- Honeywell C6097A1012 1 50700

– 852MN/T Main Control Board for PF-460 1 54684

– 852RT Display Board 1 5445

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Figure 13.5: PF-460 Internal Gas Train

1. PREINSTALLATION

Documents

Transcript of 1. PREINSTALLATION