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Gas-fired
water boiler
PFG Series 7
• Installation • Operation
• Service • Parts
For additional information,
refer to . . .
Control Supplement
Read all instructions before installing
This manual must only be used by a qualified heating installer/service technician.
Read all instructions before installing. Perform steps in the order given. Failure
to comply could result in severe personal injury, death or substantial property
damage.
Installer Leave all instructions with boiler for future re
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Contents Size and install gas piping ........................... 10-11 Section I: Installation 2-14 Draft hood installation ....................................... 12 Codes ................................................................. 2 Spill switch installation ...................................... 12 Combustion air and ventilation openings............ 3 Damper installation ........................................... 12 Select the boi
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Section I: Installation Combustion air and ventilation openings Select the boiler location Combustion air and ventilation openings must comply with Sec- • Consider all connections to boiler before selecting a location. tion 5.3, Air for Combustion and Ventilation, of National Fuel • Boiler must be installed so gas control system components are pro- Gas Code ANSI Z3.1-latest edition, or applicable local build - tected from dripping or spr
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Chimney or vent requirements When removing boiler from (also refer to Breaching erection, Page 12) common venting system Venting must be installed according to Part 7, Venting of Failure to follow all instructions listed Equipment, of National Fuel Gas Code, ANSI Z3.1- below can cause flue gas spillage and latest edition and applicable building codes. Canadian carbon monoxide emissions, resulting in installations must comply with
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Boiler foundation Placing the boiler 1. Remove boiler from shipping pallet. Do not drop boiler or bump Never install boiler on combustible flooring or jacket on floor or pallet. carpeting, even if a concrete or aerated foundation is used. Severe personal injury, death or substantial . Level boiler so that the built-in air separation will work correctly. property damage can result. Shim legs if necessary. Do not alter legs. 1. See Figu
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu 4. Expansion tank installations. Boiler piping connections to the heating a) Closed type expansion tanks - connect from the ¾” N.P.T. system (refer to piping diagrams, Page 7) expansion tank tapping on the left end section (located just Failure to properly pipe the boiler may result in behind the supply outlet tapping) to the expansion tank using improper operation and damage to the boiler or ¾” N.P.T. piping. Any horizontal expansion
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Multiple zoning Figure 2b Piping – Closed type expansion tank 1. Zone valves: a) Refer to zone valve manufacturer’s literature for wiring and application. A separate transformer is required to power zone valves. b) Provide balancing valves to adjust the flow so it is about the same in each zone. . Circulators: a) Zoning with circulators requires a relay for each cir- cuit. b) Install flow control valves to prevent gravity circula- tion.
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Bypass piping Figure 3 Bypass piping is not normally required on any baseboard system. Bypass piping should be used for the following instal- lations. (Bypass, supply, and return piping should be same size.) 1. Use the piping shown in Figure 3 to protect: • radiant panels, plaster, etc. from high temperature water supplied from boiler, or • boiler from condensation caused by low temperature water returned from system. . Use the piping
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu External heat exchangers The PFG boiler can be used with a storage tank/heat exchanger unit for domestic hot water. The boiler/tank combination should be installed and wired in accordance with the tank manufacturer’s instructions, which will also show any additional components required. A zone valve or separate circulator must be installed to regulate the production of hot water. Freeze protection Use antifreeze especially made for hydro
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu If boiler is to be propane fired, a conversion Size and install gas piping kit must be used. Failure to use kit or to In sizing the gas piping, the following factors should properly install kit will result in severe be considered. personal injury, death or substantial property damage. a) Diameter and length of the gas supply piping. 3. Remove jacket door and connect from gas valve to b) Number of fittings. gas meter. Use a street elbo
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Figure 5 Gas supply piping Figure 5a Leak test valve (model PFG-8 ONLY) Part Number 550-110-641/0605 11
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Draft hood installation Wiring Secure the draft hood to the outlet at the top of the boiler For your safety, turn off the electrical with sheet metal screws. The bottom of the draft hood power supply at the service entrance panel or “skirt” must have the clearance dimension above the before making any electrical connections jacket top panel as indicated on the draft hood. to avoid possible electrical shock hazard. Do not alter draft
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Wiring multiple zones Figure 6 Typical wiring – zoning with zone valves Refer to zone valve manufacturer’s literature for wiring and application. A separate transformer is required to power zone valves. Zoning with circulators requires a relay for each zone circulator. Canadian installations – Chain & s-hook See illustration below. The chain and s-hook should be installed according to this instruction by a qualified installer/service
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu b. For standing pilot systems: Turn gas knob to PILOT position Check-out procedure and extinguish pilot flame - Pilot gas flow should stop in less than 3 minutes. Put system back into operation. See page 17. Check off steps as completed. High limit control set to design temperature requirements of the Check to make sure base insulation is secure. See "To inspect base ❏ ❏ system? Maximum high limit setting - 40 °F. insulation," page 17
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Section II: Service Also Refer to Additional Instructions Shipped With The Boiler For Specific Control Operation and Troubleshooting. Verify Proper Operation After Servicing. Your boiler should be inspected, cleaned To avoid personal injury, death or property and, if necessary, adjusted once a year. damage, keep the boiler area clear and free A qualified service agency should be from combustible materials, gasoline and called. other f
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Suggested Minimum Service Schedule for Qualified Service Technician Only Beginning of each heating season: 1. Annual service call by a qualified service agency. . Check burners and flueways and clean if necessary. Reference “To clean boiler heating surfaces” and “To clean main burners,” page 18. 3. Visually inspect base insulation. Reference “To inspect base insulation,” page 17. 4. Follow procedure “To place in operation,” page 17. 5.
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu To inspect base insulation: Check pilot burner flame: 1. Proper pilot flame The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials. See WARNING a) Blue flame. above. Failure to comply could result in severe personal b) Inner cone engulfing pilot flame sensor. injury. c) Pilot flame sensor glows cherry red. Make sure base insulation is secure against base front and back panels. If base insulati
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Inspect venting system: Annual shut-down procedure: 1. Check venting system at least once a month during heating season. 1. Follow lighting/operating instructions label on boiler. With boiler in operation (at least 5 minutes), hold a candle or match . DO NOT drain the system unless exposure to freezing below lower edge of draft hood “skirt.” If flame is undisturbed or temperatures will occur. If antifreeze is used with system, leans und
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Common problems and possible solutions Part Number 550-110-641/0605 19
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PFG SerieS 7 Ga S-Fired Wtera Boiler — Boiler Malanu Section III: Replacement Parts The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials, per instructions on page 15 of this manual. Failure to comply could result in severe personal injury. To avoid personal injury, before replacing any parts on the boiler: 1. Turn off power. . Shut off gas supply. 3. Allow boiler to cool. Item Description Part Number 1 Draft hood: PFG-5 (7” x 7” di
