Patterson-Kelley DVSCM-02 User Manual
DVSCM-02
DIRECT VENT/
SEALED
COMBUSTION
DIRECT VENT/
PATTERSON-KELLEY
THERMIFIC
DIRECT VENT/SEALED COMBUSTION
GAS-FIRED BOILER
Supplement to the standard Installation and
Owner's Manual (TBIG - Latest Edition)
®
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water Boilers
ASME Code, Section IV
Certified by Patterson-Kelley
SEALED
COMBUSTION
DIRECT VENT/
SEALED
COMBUSTION
DIRECT VENT/
SEALED
COMBUSTION
DIRECT VENT/
SEALED
COMBUSTION
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water Boilers
Installation Date:
100 Burson Street, P.O. Box 458,
East Stroudsburg, PA 18301
Telephone: (877) 728-5351, Facsimile: (570) 476-7247
www.pkboilers.com
Patterson-Kelley
P.O. Box 458, 100 Burson Street
East Stroudsburg, PA 18301
Telephone: (570) 421-7500, Facsimile: (570) 476-7247
_______________________
DIRECT VENT/
SEALED
COMBUSTION
DIRECT VENT/
SEALED
COMBUSTION
DIRECT VENT/
SEALED
COMBUSTION
DIRECT VENT/
Thermific® Gas-Fired Boiler Table of Contents
1.0 INTRODUCTION..................................1
1.1 Code Compliance................................1
1.1.1 Direct Vent/Sealed Combustion
System..............................................1
1.1.2 Fresh Air System...........................1
1.2 Basic Inlet/Vent Configurations ...........1
1.3 Purpose and Scope of this Manual......2
2.0 SAFETY ...............................................2
3.0 INSTALLATION....................................3
3.1 Components Provided......................... 3
3.2 Combustion Air Inlet System ...............3
3.2.1 System Design - Pressure Drop....3
3.2.2 Inlet Duct.......................................3
3.2.3 Air Inlet Termination......................3
3.2.4 Inlet Duct Assembly at the Boiler... 4
3.2.5 Inlet Damper and Auxiliary Control
Panel (optional).................................5
3.3 Exhaust Venting System .....................5
3.3.1 System Design - Materials, Length,
Size, and Construction ......................5
3.3.2 Flue Gas Outlet Duct.....................5
3.3.3 Exhaust Vent Connection at the
Boiler.................................................6
3.3.4 Flue Gas Termination....................6
3.4.5 Equivalent Length of Fittings .........7
3.4 Clearances .......................................... 7
3.4.1 Sidewall Installations.....................7
3.4.2 Rooftop Installations......................8
3.4.3 Minimum Clearance for Boiler
Connections ......................................8
4.0 OPERATION ........................................9
4.1 Sequence of Operation .......................9
4.2 Combustion Operating Conditions.......9
4.2.1 Combustion Air Requirement,
SCFM............................................10
5.0 MAINTENANCE .................................10
6.0 WIRING DIAGRAMS..........................11
6.1 On-Off Series 700, 1000, 1200......... 11
6.1a On-Off IRI Series 700, 1000, 1200 .13
6.1b Lo-Hi Lo ..........................................15
6.1c Lo-Hi-Lo IRI .................................... 17
6.1d On-Off Series 1500, 1700, 2000 ..... 19
6.1e On-Off IRI Series 1500, 1700, 2000 21
6.2 Auxiliary Control Panel...................... 23
6.2.1 On-Off Auxiliary Control Panel.... 23
!
WARNING
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
c
1998 HCS, Inc. 800-748-0241
WARNING!
essential
It is
recommendations of this manual before installing,
operating, or servicing this equipment. Failure to do
so could result in fire or explosion and serious injury,
death, and/or property damage.
to read, understand, and follow the
operating or servicing boiler.
Reorder No. 6020-V2WHPK
The same features which permit this boiler to achieve
high-efficiency performance make it unlike most other
boilers of this general size, so it is important to
understand how this boiler operates.
Do not store or use gasoline or other flammable vapors
or liquids in the vicinity of this or any other appliance.
WARNING!
Installation and service must be performed by a
qualified installer, service agency, or gas supplier.
What to do if you smell gas:
Do not try to light any appliance.
Do not touch any electrical switch.
Do not use any phone in your building.
Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
If you cannot reach your gas supplier call the fire
department.
Thermific® Gas-Fired Boiler Introduction
1.0 INTRODUCTION
Direct vent (ANSI Z21.13) is a closed system method
of ducting the combustion air directly from the outside
of the building into the inlet compartment of the
burner, and a sealed exhaust vent from the combustion
chamber to the outdoors.
The direct vent/sealed combustion option is available
on the Thermific® boilers on Series 700, 1000, 1200,
1500, 1700, and 2000.
Advantages are:
•
Savings in energy costs due to the elimination of
using conditioned air (heated and/or cooled
building air) from going back up the stack.
•
Isolation of the burner from pressure changes in
the building which can cause erratic combustion
performance.
•
Combustion air is taken from the outside which is
generally more clean than indoor air. Halide
contaminants within a building, such as chlorides,
can cause excessive corrosion in the burner, heat
exchanger and venting system.
1.1.2 Fresh Air System
(ducted combustion air system)
In some instances compliance with ANSI Z21.13
may
not be required, in which case a "fresh air system" may
be used. Consultation with qualified professionals is
required to determine whether a "fresh air system" is
suitable for any particular application and in
compliance with all applicable codes and regulations.
All flue gas outlet (exhaust vent) material for a fresh
air system must be certified for use with a Category I
Appliance. (Standard B-vent isapproved.) The
exhaust vent may be run horizontally or vertically.
Proper vent sizing by the vent manufacturer's
recommendation must be followed.
1.2 B
ASIC INLET/VENTCONFIGURATIONS
Four basic configurations are allowable for the
combustion air inlet and flue gas exhaust vent, as
follows; installation details are provided in Section 3.
•
Eliminates the need for two large combustion
air/ventilation air openings into the mechanical
space.
1.1 C
ODECOMPLIANCE
1.1.1 Direct Vent/Sealed Combustion System
(complying with ANSI Z21.13)
All flue gas outlet (exhaust vent) material must
comply with UL-1738. (Standard B-vent
is not
approved.) Proper vent sizing by the vent
manufacturer's recommendation must be followed.
The exhaust vent may be run horizontally or vertically.
The maximum allowable length of the exhaust vent for
horizontal installations, including the boot tee/135º
(not a standard tee) and the termination is
equivalent feet.
Refer to Section 3.4.5 for equivalent
100
lengths.
Exhaust
Vent
Roof
Sidewall
Air Inlet
1. Combustion air inlet duct through the sidewall and
the flue gas exhaust through the roof. This is the
preferred method.
Page 1
Thermific® Gas-Fired Boiler Introduction/Safety
Sidewall
Exhaust
Vent
Air Inlet
2. Both the combustion air inlet and flue gas exhaust
through the sidewall.
Air Inlet
Exhaust
Vent
Air Inlet
Exhaust
Vent
Roof
Sidewall
4. The combustion air inlet from the roof and the flue
gas exhaust through the sidewall.
1.3 P
URPOSE AND SCOPE OF THIS MANUAL
This manual is a supplement and companion to the
Thermific Installation and Owner's Manual. "TBIG."
Both documents must be used together.
Roof
3. The combustion air inlet from the roof and the flue
gas exhaust through the roof.
This companion document describes those safety,
installation, adjustment, and maintenance procedures
which differ from the standard model. Information
that applies to both models is found in the "TBIG"
latest edition.
2.0 SAFETY
Refer to the manual for the standard Thermific® GasFired Boiler for safety information applicable to this
equipment. Safety information applicable only to the
direct vent option appears below.
Danger!
Acceptable Venting Methods:
The only acceptable venting methods are the four
configurations shown in Section 1.2. Do not attempt
to use any other method of obtaining combustion air or
venting flue gases.
Page 2
Thermific® Gas-Fired Boiler Installation
Do not manifold two (2) or more units into a common
sidewall vent system without provisions for additional
forced draft.
3.0 INSTALLATION
3.1 C
OMPONENTS PROVIDED
The direct vent/sealed combustion option is shipped
with the following items shipped loose for field
installation:
Custom 6 inch diameter to 12 inch diameter
transition duct with extension, for attachment to
the combustion air inlet on the boiler.
A 12" inlet damper assembly with actuator and
limit switch mounted to the damper shaft.
Auxiliary Control Panel to operate the inlet
damper assembly.
The inlet damper assembly and control panel will
prevent the flow of cold air through the boiler during
the off cycle and prevent freeze up and "off cycle"
losses. The use of these two items is optional.
3.2 C
OMBUSTION AIRINLETSYSTEM
Note:
silicone sealant, or equivalent, must be used on each
circumferential and horizontal joint before joining
together. At least 24 hours must be allowed for cure
of this sealant and proper bond. Cure time can be
reduced through the application of heat (See
instructions provided with the sealant). After the cure
period, each joint must be wrapped with an aluminum
tape which is faced on the contact side with an
adhesive.
3.2.2.2 PVC Duct
Proper sealing of the tubing is necessary to prevent
flow of combustion air from conditioned space.
The installation must follow the vent manufacturer's
instructions in all respects including proper joining and
sealing of the tubing and fittings. Clearances to
combustible materials and installation of firestops
must conform to applicable codes.
3.2.3 Air Inlet Termination
Centering
Support
Plate
Outside Plate
Cover Plate
Fastener
Sealant
Recommended
Termination
(refer to text).
3.2.1 System Design - Pressure Drop
The air inlet duct system shall be designed for a
maximum pressure drop of 0.05" W.C. taking into
account the equivalent length of all fittings. Refer to
Section 3.4.5 for equivalent length of fittings.
3.2.2 Inlet Duct
Materials shall be single wall galvanized duct
(minimum thickness 26 gauge) or PVC duct tubing
(0.187 inch wall thickness) only.
3.2.2.1 Single Wall Galvanized Duct
No substitutions.
Proper sealing of the tubing is necessary to prevent
flow of combustion air from conditioned space. If
single wall galvanized tubing is used, GE RTV 102
Page 3
Sealant
12" Min.
Field Provided
Inlet Screen
The boiler combustion air inlet duct must be fitted
with a termination device meeting the requirements of
ANSI Z21.13. There are four recommended sidewall
terminations:
•
Double wall B vent 90 degree elbow, or
•
Two double wall B vent 45 degree elbows, or
•
Schedule 40 PVC 90 degree elbow, or
•
Properly engineered intake louver screen.
Thermific® Gas-Fired Boiler Installation
Whichever material is used, the termination must point
down and must be backed by a metal plate secured to
the wall.
Important:
The chosen inlet termination must be
included in the calculation of the maximum allowable
equivalent length. See Section 3.4.5 for equivalent
lengths.
Correct rain cap,
unrestricted.
Typical incorrect
rain cap.
If the combustion air inlet duct is routed through the
roof, the termination must be either the same type as
described for a sidewall installation or a rain cap. The
rain cap must be unrestrictive type similar to the
illustration below.
3.2.4 Inlet Duct Assembly at the Boiler
Damper
Transition
Round
Duct
Damper
Housing
(Sidewall installation shown.)
The boiler is equipped with a special collar attached to
the air inlet opening on the back of the unit (at the
blower housing on Series 700, 1000, and 1200; at the
back of the cabinet on Series 1500, 1700 and 2000.).
A separate box of accessories is sent with the boiler.
1. Attach the 6 inch diameter end of the custom
transition duct and the extension to the collar using
a minimum of 4 sheet metal screws spaced
approximately at 90 degree intervals. This joint
must then be wrapped with an aluminum tape
backed on the contact side with an adhesive. Do
not use "duct tape."
Roof
Transition
Duct
(Roof installation shown.)
Round
Damper
o
90 Elbow
Damper
Housing
Page 4
Important:
do not insulate the transition duct or
extension.
Refer to Section 3.2 for instructions for installing and
wiring the auxiliary control panel; it is required if the
optional inlet damper is used.
3.2.4.1 Sealing PVC Duct Tubing to the Inlet Duct
Apply a 3/4" wide x 1/8" thick gasket to the outside
surface edge of the entire circumference of the
transition duct (or extension). A closed cell foam
rubber gasket with pressure sensitive adhesive works
very well. Insert 3/4" of the transition duct into the
PVC duct tubing so that the gasket lines up with the
edge of the PVC tubing. Lay an approximate 3/8"
wide bead of GE RTV-102 silicone sealant, or
equivalent, along the gap between the gasket and
inside wall of the tubing. Allow the silicone sealant to
cure for 24 hours. The cure time can be shortened
Thermific® Gas-Fired Boiler Installation
with the application of heat. Refer to the
manufacturer's instructions. Wrap the joint with
aluminum tape which is backed with an adhesive on
the contact side.
3.2.5 Inlet Damper and Auxiliary Control
Panel (optional)
Note:
The inlet damper assembly and control panel will
prevent the flow of cold air through the boiler during
the off cycle and prevent freeze up. These two items
optional
are
in all installations.
Refer to Section 4.1 for a description of the control
sequence applicable to the inlet damper.
The damper must be field installed into a section of
horizontal or vertical inlet ductwork. Orient the
damper such that the arrow points towards the boiler.
3.2.5.1 Field Wiring to Auxiliary Control Panel
The auxiliary control panel controls the inlet damper
(if used). The auxiliary control panel does not have to
be mounted on or near the boiler; it can be remotely
mounted.
Use 16GA MTW Wire for all field wiring. See
Section 6 for the logic and wiring diagrams of this
auxiliary control panel and the sealed combustion
boilers.
There are five (5) field run wires between the boiler
and its auxiliary control panel; three (3) for main
power supply and two (2) wires for boiler
interconnect.
1. The main power supply (G/H/N) must come from
the same boiler that the damper is connected to.
2. Remove the blue jumper wire in the terminal block
on the boiler when wiring.
There are also five (5) field run wires between the
auxiliary control panel and the inlet damper assembly;
three (3) to the damper actuator and two (2) to the
limit switch.
1. Terminals for the damper actuator:
DO = Damper Open (CW)
DC = Damper Closed (CCW)
DN = Neutral/Common
2. Terminals for the limit (end) switch
SI = N.O. (Normally Open)
S2 = Common
3.3 E
XHAUST VENTINGSYSTEM
3.3.1 System Design - Materials, Length, Size,
and Construction
The flue gas outlet (exhaust vent) must be designed to
comply with UL 1738 and ULC-636. (Refer to
Section 1.1.2 for situations where alternate compliance
may be permitted.) The exhaust vent can be run
horizontally or vertically.
The vent must be sized according to the vent
manufacture's recommendations. Consult the vent
supplier for correct sizing and structural support
requirements. Vent diameter is dictated by the length
and height of horizontal and vertical portions of the
vent installation and materials of construction. Design
calculations should be based on a negative 0.03 W.C.
with a stack temperature of 325º F (gross) and a CO
2
level of 7.6%; (these values are to be used for vent
sizing calculations.) The
maximum
allowable length
of the vent duct, including the boot tee/135º tee (not a
standard tee) and the termination is 100 equivalent
feet. See Section 3.4.5 for the equivalent length of the
fittings.
3.3.2 Flue Gas Outlet Duct
The installation must follow the vent manufacturer's
instructions in all respects including proper joining and
sealing of the tubing and fittings, clearances to
combustible materials and installation of firestops.
Page 5
Thermific® Gas-Fired Boiler Installation
3.3.3 Exhaust Vent Connection at the Boiler
Pitch toward boiler
1/4" per foot min.
6' Min.
Boot Tee/
o
135 Tee
Trap Loop
3" Min.
Condensate Drain
To s ewe r t rap
or condensate pump.
At the outlet of the boiler, an adjustable or fixed length
(minimum 2 feet for clearance from inlet duct;
maximum 3 feet for proper lift) section may be
utilized. This section must be secured to the outlet
collar by a minimum of 4 sheet metal screws spaced at
approximately 90 degree intervals.
from the outlet of the boot tee/ 135º tee to the inlet of
the elbow. In addition, for sidewall venting, it is
important
to provide a downward pitch of at least 1/4
very
inch per foot of run from the termination at the wall
toward the boiler for proper drainage of the condensate
and for buoyancy assist of the flue gas. Furthermore,
do not
locate sidewall terminations over area of
pedestrian or vehicular traffic due to potential
condensate drippage and ice build-up. See Section 3.4
Clearances for more information.
When joining the double wall tubing and fittings, it is
important to orient the male end of the section toward
the boiler. The female end is positioned away from
the boiler towards the vent terminal. Follow the vent
manufacturer's instructions for proper installation.
3.3.4 Flue Gas Termination
Centering
Support
Plate
Sealant
Outside Plate
Cover Plate
Fastener
Sealant
Recommended
termination
(refer to text).
Even though the unit is classified as a Category I
boiler (Non-pressurized-non condensing), there are
certain abnormal conditions which may cause
condensation in the flue vent. Therefore, it is
recommended that a tee cover with a drain be provided
at the bottom of the boot tee/135º tee. For proper
disposal of the condensate, corrosion resistant tubing
or plastic tubing should be connected to the drain
nipple. Before connecting the tubing to the tee cover
nipple, the trap loop must be primed by pouring a
small quantity of water into the drain line. The
condensate drain line can be routed to a sewer drain
trap or pump. Consult the vent manufacturer's
instructions for proper installation of drain line.
In transitioning from horizontal to vertical, a double
wall boot tee/135º tee must be installed (not a standard
tee). If the flue gas exhaust is to be routed through the
sidewall, a minimum vertical rise of 6 feet is required
Page 6
12" Min.
The exhaust vent termination must be a P-K
recommended device. There are four approved
sidewall terminations:
90º elbow pointing down, or
Two 45º elbows pointing down, or
45º elbow pointing down, or
Standard tee pointing up/down.
Important:
The equivalent length of the chosen
termination must be included in the calculation of the
maximum allowable equivalent length. See Section
3.4.5 for equivalent lengths.
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