Patterson Kelley ST-2500, ST-3000, ST-3500, ST-4000 User Manual

The information in this manual is the property of Patterson-Kelley. The descriptions and specifications contained in this manual were in

effect at the time this manual was approved for publication. While Patterson-Kelley will continue to support earlier model boilers to

within a reasonable time limit, we reserve the right to discontinue models and replacement parts at any time or change specifications or

design without notice and without incurring any obligation.

P-K STORM™ GAS FIRED BOILER w/ NURO™ CONTROL SYSTEM ST-2500, ST-3000, ST-3500 & ST-4000 Natural Gas Boilers

Part # 2691000273

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

Model Number: Serial Number: Start-Up Date:

Patterson-Kelley 155 Burson Street East Stroudsburg, PA 18301 Telephone: 570.476.7261 Toll Free: 877.728.5351 Fax: 570.476.724 www.pattersonkelley.com

Released: June 26, 2020

INSTALLATION

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OWNER’S

MANUAL

- Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

- 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.

- Installation and service must be performed by a qualified installer,

service agency or the gas supplier.

WARNING: If the information in these instructions is not followed

exactly, a fire or explosion may result causing property damage,

personal injury or death.

P-K STORMTM Gas Fired Boiler

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Safety

General

P-K STORM™ Boilers ST-2500, ST-3000, ST-3500, ST-4000 All P-K STORM™ Gas-Fired Boilers must be:

• Installed, operated, and serviced in accordance with instructions contained in this manual and other supplemental manuals.

• Installed by qualified personnel in accordance with designs prepared by qualified facility engineers including: structural, mechanical, electrical, and other applicable disciplines.

• Operated and serviced in accordance with a comprehensive safety program determined and established by the customer. Do not attempt to operate or service until such a program has been established.

• Operated and serviced by experienced, qualified, and properly trained personnel in accordance with all applicable codes, laws, and regulations.

Safety Precautions

Provide a suitable location for the boiler, away from normal personnel traffic, with adequate working space, adequate clearances, proper ventilation and lighting, with a structure sufficiently strong and rigid to support the weight of the boiler, all piping, and accessories.

NOTICE!

Each safety device must be maintained and checked per the recommended schedule. Refer to

Maintenance.

SAFETY FEATURES

It is the responsibility of the customer to ensure external safety provisions, such as but not limited to: guards, safety labels, safety controls, interlocks, lockout devices are in place and operable.

SAFETY LABELS

The following words are used in this manual to denote the degree of seriousness of the individual hazards.

Indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury. This

signal word is to be limited

to the most extreme

situations.

Indicates a potentially

hazardous situation which, if

not avoided, could result in

death or serious injury.

Indicates a potentially

hazardous situation which, if

not avoided, may result in

minor or moderate injury. It

may also be used to alert against unsafe practices.

NOTICE/NOTE - NOTICE

The preferred signal word to address practices not related to personal injury. The safety alert symbol is not used with this signal word.

P-K STORMTM Gas Fired Boiler

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NOTICE!

The safety labels shown below are affixed to your boiler. Although the labels are of high quality, they may become dislodged or unreadable over time. Contact Patterson-Kelley at 570.476.7261 or toll-free at

877.728.5351 for replacements.

Gas may lose its odor. Proper gas

sensing equipment and procedures

should be used for leak checks.

Failure to detect gas leaks could

result in injury or death.

Training

Proper training is the best protection against accidents. It is essential to read, understand, and follow the 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.

Operating and service personnel must be thoroughly familiar with the basic construction of the P-K STORM™ ST-2500, ST-3000,

ST-3500 and ST-4000 boilers, the use and locations of the

controls, the operation of the boilers, adjustment of their various mechanisms, an d all applicable safety precautions. If any of the provisions of this manual are not fully and completely understood, contact Patterson-Kelley Technical Service at

570.476.7261 or toll free at 877.728.5351.

Hazard Warnings

Electrical Hazards

Shock Hazard! Properly Lockout/Tagout the

electrical service and all other energy sources before working on or near the boiler. Shock Hazard! Do not spray water directly on this boiler or any electrical components. Electrical Hazard! Do not alter wiring connections.

Crush Hazards

Lifting Hazards! Use properly rated lifting

equipment to lift and position the boiler. The load is unbalanced. Test the balance before lifting off the floor. Do not allow personnel beneath the lifted load. Refer to the approximate weights in the table below.

Boiler Model

Weight in

Pounds

ST-2500

2329

ST-3000

2329

ST-3500

2772

ST-4000

2772

Bump Hazard from Overhead Ductwork and Piping

Injury Hazard! Install components with adequate vertical clearance.

Pressure Hazards

Pressure Hazard! Hot fluids. Install isolation valves on boiler water inlet and outlet.

Make sure isolation valves are closed before servicing boiler. Pressure Hazard! Hot fluids. Annually test safety relief valve(s) for proper operation. Do not operate boiler with faulty relief valve(s).

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Slip, Fall Hazards

Tripping Hazard! Do not install piping on floor surfaces. Maintain a clear path around

the boiler. Slip and Fall Hazard! Use a drip pan to catch water while draining the boiler. Maintain dry floor surfaces. Slip and Fall Hazard! Do not locate intake or exhaust terminations above a walkway; dripping of condensate can cause icing of the walking surface. Refer to 2.5.5 for more information.

Fall Hazard! Do not stand on boiler.

Chemical Hazards

Chemical Hazards from Cleaning Products. Use

caution when cleaning the system. The use of professional assistance is recommended. Use safe procedures for the disposal of all cleaning solutions. Combustion Condensate – An acidic pH of

approximately 3.0 to 5.0 can be expected. Use PVC, CPVC, or other corrosion resistant piping for drainage. Collection and disposal must be in accordance with all applicable regulations. A condensate neutralization kit is available. Please contact your local Patterson-Kelley representative for more information.

Burn, Fire and Explosion Hazards Burn, fire, and explosion hazards! Installation must be in strict conformance to all applicable codes

and standards including NFPA 54, ANSI Z223.1 and CAN/CSA B.149. Install all required

vent lines fo r gas devices. Refer to 3.4 and 3.5 for more information.

Hazard from Incorrect Fuels! Possible fire, explosion, overheating, and damage. Do not

use any fuels except the design fuels for the unit.

Overfire Hazards! High pressure in gas supply could result in overfiring of this or other

devices supplied from the same source.

Fire and Explosion Hazards! Close th e main gas shutoff before servicing boiler. Fire and Explosion Hazards! Do not store or use gasoline or other flammable vapors or

liquids in the vicinity of this or any other gas fired appliance. Burn hazard! Possible hot surfaces. Do not touch gas vent during firing operation. Use

only factory recommended vent components. Burn Hazard! Pipes, vents, and boiler components could be hot. Do not touch piping or stack surfaces during operation or immediately after shutdown of the boiler.

Burn Hazard! Hot flue! Use caution when servicing or draining boiler. Fire and Explosion Hazards! Use caution when servicing burner. Propane (LPG) is heavier than air

and may linger in the combustion chamber, vent lines, or elsewhere. Gas Leak Hazard! Make sure the burner is installed correctly and blower/transition is securely fastened following any maintenance performed on them. These connections may leak gas if assembled incorrectly. Gas Leak Hazard! All threaded gas connections must be made using a pipe compound that is resistant to liquefied petroleum gas. Do not use Teflon™ tape on threaded gas piping. Gas Leak Hazard! Check entire gas train for leaks after installation. If there is a smell of gas, shut down the boiler and obtain immediate assistance fro m trained service personnel and/or your local fire department. Overfire Hazard! Possible fire and explosion from excess gas pressure. Make sure that gas inlet pressure does not exceed 14 inches W.C. Overfire Hazard! Possible fire and explosion. Possible malfunction of regulators and/or gas safety shut off/control valves. Maintain all gas train components in good condition. Do not alter wiring connections. Annual inspection by factory-trained personnel for proper set-up and operation is recommended. Overfire and Underfire Hazards! Possible fire, explosion, overheating, and component failure. Do not attempt to adjust firing rate of the boiler. The firing rate must be adjusted only by factory trained personnel.

P-K StormTM Gas Fired Boiler

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Revised: June 26, 2020 Released: June 26, 2020

2691000273 P-K Storm ST2500-ST4000

Installation and Owners Manual Rev A.docx

Page v

Table of Contents

1 INTRODUCTION ........................................................................................................................ VIII

1.1 PURPOSE OF THIS DOCUMENT .................................................................................................. 1

1.2 COMMON ABBREVIATIONS ........................................................................................................ 1

2 SITE PREPARATION .................................................................................................................... 2

2.1 INITIAL INSPECTION UPON RECEIVING ........................................................................................ 2

2.2 STORAGE PRIOR TO INSTALLATION ............................................................................................ 2

2.3 COMPLIANCE WITH CODES ........................................................................................................ 3

2.4 LOCATION SETUP ..................................................................................................................... 4

Foundation ................................ ......................................................................................... 4

Clearances ......................................................................................................................... 5

2.5

NLET AIR AND EXHAUST VENTING CONSIDERATIONS

.................................................................. 6

Applicable Codes and Standards ........................................................................................ 6

Combustion Air Inlet Planning (United States and Canada Considerations) ....................... 6

Category II/IV Flue Gas Exhaust Vent Planning ................................................................. 7

Venting Materials for Flue/Exhaust Systems ....................................................................... 8

Required Clearances .......................................................................................................... 9

2.6 GAS PIPING CONSIDERATIONS ................................................................................................ 11

2.7 WATER QUALITY STANDARD ................................................................................................... 11

3 INSTALLATION ........................................................................................................................... 11

3.1 OVERVIEW ............................................................................................................................. 11

3.2 APPLIANCE CONNECTIONS ...................................................................................................... 11

Appliance Connections (ST-2500 & ST-3000) .................................................................. 12

Appliance Connections (ST-3500 & ST-4000) .................................................................. 13

3.3 ELECTRICAL CONNECTIONS .................................................................................................... 14

Power Requirements ........................................................................................................ 14

Three Phase Power Supply Connection ........................................................................... 14

High Voltage (TB2) Terminal Block ................................................................................... 16

Low Voltage (TB1) Terminal Block .................................................................................... 18

3.4 COMBUSTION AIR ................................................................................................................... 20

Air Inlet Requirements – United States ............................................................................. 20

Air Inlet Requirements - Canada ....................................................................................... 21

P-K STORM™ Combustion Air Requirements ................................................................... 22

Direct Vent / Sealed Combustion Installations .................................................................. 22

Motorized Combustion Air Dampers ................................................................................. 23

3.5 FLUE GAS / EXHAUST VENTING ............................................................................................... 25

Category II or IV Venting Installation................................................................................. 25

Vent Termination ............................................................................................................... 26

Venting for Multiple Boilers................................................................................................ 27

Sealed Combustion/Direct Vent Systems .......................................................................... 28

Inlet Duct Connection to Boiler .......................................................................................... 32

Intake Duct Materials and Sizes ....................................................................................... 32

Category II Installations .................................................................................................... 32

Category IV Installations ................................................................................................... 33

Stainless Steel Venting ..................................................................................................... 33

CPVC Vent System Installation..................................................................................... 33

CONDENSATE DRAIN, TRAP & DISPOSAL ............................................................... 34

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3.6 REMOVING AN EXISTING BOILER ............................................................................................. 36

3.7 PIPING ................................................................................................................................... 37

Gas Piping Overview ........................................................................................................ 37

Natural Gas Piping ........................................................................................................... 37

Pressure Testing the Gas Piping ...................................................................................... 38

Boiler Water Piping ........................................................................................................... 39

Boiler Inlet and Outlet Connections ................................................................................... 40

Boiler Water Piping (for Installer) ...................................................................................... 40

3.8 WATER QUALITY .................................................................................................................... 41

3.9 PRE-START CHECKLIST .......................................................................................................... 42

3.10 SAFETY CHECKS .................................................................................................................... 42

Ignition Safety System Test .......................................................................................... 42

Low Water Cut-Out Test ............................................................................................... 42

Flow Switch Test .......................................................................................................... 43

Manual Reset High Temperature Limit Test ..................................................................... 43

Gas Pressure Switch Tests ........................................................................................... 44

3.11 FUEL/AIR ADJUSTMENTS ........................................................................................................ 44

Gas Pressure Adjustment ............................................................................................. 44

Manual Control Mode for High and Low Fire Adjustment .............................................. 45

Adjusting High Fire ....................................................................................................... 46

Adjusting Low Fire ........................................................................................................ 46

Checking Flame Signal ................................................................................................. 46

3.12 INITIAL NURO CONTROL SETUP AND ADJUSTMENT .................................................................. 47

Startup .......................................................................................................................... 47

Home Screen ................................................................................................................ 48

Information Screen ....................................................................................................... 48

Setup Wizard ................................................................................................................ 49

3.13

TYPICAL BOILER OPERATING CONDITIONS ............................................................................... 49

4 OPERATIONS ............................................................................................................................. 50

4.1 NURO

CONTROL PANEL ....................................................................................................... 50

NURO Touch Screen Interface ......................................................................................... 50

Factory Tests .................................................................................................................... 50

4.2 NORMAL LIGHTING AND SHUT-DOWN PROCEDURES ................................................................. 51

Normal Lighting Procedures ............................................................................................. 51

Normal Shut Down Procedures ......................................................................................... 51

4.3 EMERGENCY SHUT-OFF ......................................................................................................... 51

5 MAINTENANCE .......................................................................................................................... 52

5.1 PREVENTATIVE MAINTENANCE ................................................................................................ 52

Daily ................................................................................................................................. 53

Weekly ............................................................................................................................. 53

Monthly ............................................................................................................................. 53

Semi-Annually .................................................................................................................. 53

Annually or 2500 Run Hours (Whichever Comes First) ..................................................... 54

5.2 CLEANING THE COMBUSTION CHAMBER ................................................................................... 57

5.3 AFTER REPAIRS OR MAINTENANCE.......................................................................................... 61

5.4 SEQUENCE OF OPERATIONS ................................................................................................... 62

5.5 TROUBLESHOOTING ............................................................................................................... 62

Loss of Power ................................................................................................................... 63

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Revised: June 26, 2020 Released: June 26, 2020

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Installation and Owners Manual Rev A.docx

Page vii

Loss of Water Level .......................................................................................................... 63

Low Gas Pressure ............................................................................................................ 63

High Gas Pressure ........................................................................................................... 63

High Water Temperature ................................................................................................... 63

Low Air ............................................................................................................................. 63

Flame Failure ................................................................................................................... 64

Flame Error ...................................................................................................................... 64

Flue Problem/Condensate Blockage................................................................................. 64

6 PARTS/TECHNICAL SUPPORT ................................................................................................. 65

6.1 TERMINAL BLOCK ASSIGNMENTS ............................................................................................. 66

Terminal Block Assignments — Low Voltage (TB1) Terminal Block .................................. 66

Terminal Block Assignments — High Voltage (TB2) Terminal Block .................................. 67

6.2 WIRING DIAGRAMS ................................................................ ................................................. 68

Natural Gas 208-240 Volt ................................................................................................. 68

Natural Gas 480 Volt ........................................................................................................ 70

Control Transformer Diagrams ......................................................................................... 72

6.3 BOILER PARTS IDENTIFICATION ............................................................................................... 74

Main Boiler Assembly (ST-2500 & ST-3000) .................................................................... 74

Main Boiler Assembly (ST-3500 & ST-4000) .................................................................... 75

Control Panel .................................................................................................................... 76

Heat Exchanger Assembly ST-2500 & ST-3000 ............................................................... 77

Heat Exchanger Assembly ST-3500 & ST-4000 ............................................................... 78

Natural Gas Train ............................................................................................................. 79

Burner/Blower Assembly 240V ......................................................................................... 80

Burner/Blower Assembly 480V ......................................................................................... 81

7 P-K STORM™ SPECIFIC LIMITED WARRANTY ......................................................................... 82

8 BOILER FIRE-TEST REPORT .................................................................................................... 84

APPENDIX A – MAINTENANCE LOG ................................................................................................ 85

APPENDIX B – BOILER ALTITUDE DERATE SCHEDULE ............................................................... 86

APPENDIX C – WATER QUALITY STANDARDS QUALITY STANDARDS FOR HYDRONIC

BOILERS IN MULTI-METAL SYSTEMS ............................................................................................. 87

APPENDIX D – BEST PRACTICES FOR NEW & RETROFIT SYSTEMS .......................................... 88

APPENDIX E – INSTALLATION AND QUICK REFERENCE ............................................................. 90

FUEL/GAS SUPPLY ............................................................................................................................ 90

ELECTRICAL/POWER SUPPLY ............................................................................................................. 90

EXHAUST VENTING ............................................................................................................................ 90

PROPYLENE GLYCOL FLOW ................................................................................................................ 92

P-K StormTM Gas Fired Boiler

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Revised: June 26, 2020 Released: June 26, 2020

2691000273 P-K Storm ST2500-ST4000

Installation and Owners Manual Rev A.docx

Page viii

1 Introduction

This manual describes the installation and operation of the following P-K STORM™ boilers featuring NURO®

controls.

ST-2500, ST-3000, ST-3500 & ST-4000:

• Natural Gas, 208-240V (three phase)

• Natural Gas, 440-480V (three phase)

Individual differences between boiler models will be called out and defined in separate sections and the titles of these sections will include the boiler model number. If the boiler model numbers are not listed in the section title, that section is common to all boiler models.

If you have any questions on the information contained within, or do not fully and completely understand the content, please contact Patterson-Kelley Technical Service at 570.476.7261 or toll free at 877.728.5351.

The P-K STORM™ gas-fired boiler is fully modulating using a variable speed combustion blower, sophisticated microprocessor controls, modulating gas safety shut off / control valves and a unique stainless steel heat exchanger capable of operating in a fully condensing mode to provide maximum efficiency in a minimum amount of space. The high-quality materials and design of the boiler should provide years of trouble-free service if the instructions in this manual are followed carefully.

The boiler is only a part of the complete heating system. This boiler may be fully operational but because of poor circulation, improper control, or other site related characteristics, not deliver heat to the desired location. Additional equipment such as temperature sensors, pumps, flow switches, balancing valves, and check valves will be required for satisfactory operation of any system. Patterson-Kelley cannot be responsible for the design or operation of such systems and a qualified engineer or contractor must be consulted.

If the information in this manual is not followed, fire or explosion may result causing property damage, personal injury, or loss of life.

Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. Installation and service must be performed by a qualified installer, service agency, or the 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.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR

DE GAZ:

• Ne pas tenter d’allumer d’appareils.

• Ne touches à aucun interrupteur. Ne pas

vous server des téléphones dans le bâtiment où vous vous trouvez.

• Appelez immédiatement votre

fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur.

• Si vous ne pouvez rejoinder le

fournisseur de gaz, appelez le service des incendies.

It is essential to read, understand, and follow

the recommendations of this manual before

installing, operating or servicing this

equipment. Failure to do so could result in

personal injury or death.

Installation and service must be performed

by a qualified and knowledgeable individual

who has been certified on the P-K STORM™

boiler. The features which permit this boiler

to achieve high-efficiency performance can

be misused which could result in personal

injury or death.

NOTICE! This manual covers single fuel P-K STORM® boilers (Natural Gas).

Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any

other appliance.

Ne pas entreposer ni utilizer d’essence ou ni

d’autres vapeurs ou liquids inflammables à

proximité de cet appareil ou de tout autre

appareil.

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Revised: June 26, 2020 Released: June 26, 2020

2691000273 P-K Storm ST2500-ST4000

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Page ix

PRECAUTIONS ASSOCIATED WITH HANDLING REFRACTORY LINING MATERIAL

• This Patterson-Kelley product contains a Combustion Area lined with REFRACTORY CERAMIC FIBERS (RCFs) similar to many other devices produced in this industry.

• RCFs have been identified by the International Agency for Research on Cancer (IARC) as possibly being carcinogenic to Humans.

• AVOID breathing particles or dust from RCFs and avoid contact with Skin or Eyes.

• The National Institute for Occupational Safety and Health (NIOSH) recommends the use

of a respirator meeting current standards, to avoid inhalation of dust. Also recommended is loose fitting, long sleeved clothing, eye protection and gloves whenever handling RCFs. Current NIOSH Recommendations are listed on their website at http://www.cdc.gov/niosh/homepage.html, which should be viewed before the handling or removal of Refractory Lining Materials on this or any similar device.

• Using a SPRAY BOTTLE, saturate with WATER; but not dripping, the combustion chamber lining to prevent dust from becoming airborne.

• Place removed RCFs into a plastic bag for disposal with normal trash.

• Wash exposed clothing (if not disposable), TWICE and DRY separately from other laundry.

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Revised: June 26, 2020 Released: June 26, 2020

2691000273 P-K Storm ST2500-ST4000

Installation and Owners Manual Rev A.docx

Page 1

1.1 Purpose of this Document

It is the purpose of this Installation and Owner’s Manual is to provide complete documentation support for P-K STORM

™

boilers featuring NURO controls. Patterson-Kelley is constantly seeking ways to

produce high quality HVAC products. Our operation is based on the premium quality control program and insures that Patterson Kelley manufactures quality products.

The primary concern of all Patterson-Kelley equipment installation procedures is Safety. Safety instructions and considerations are presented and repeated throughout the document as needed. If you have any questions on the information contained within, or do not fully and completely understand the content, please contact Patterson-Kelley Technical Service at 570.476.7261 or toll free at

877.728.5351.

1.2 Common Abbreviations

Abbreviation

Description

AMP

Ampere or Amperage

ANSI

American National Standards Institute

ASME

American Society of Mechanical Engineers

AWG

American Wire Gauge

BTU

British Thermal Unit

Comfort Heat

CO2

Carbon Dioxide

CSA

Canadian Standards Association

CSD-1

Controls and Safety Devices

CPVC

Chlorinated Polyvinyl Chloride

DHW

Domestic Hot Water

HWR

Heating Water Return / Hot Water Return (From Building)

HWS

Heating Water Supply / Hot Water Supply (To Building)

Inside Diameter

MBH

Thousands of BTU / Hour

MODBUS

A serial communication protocol (not an abbreviation)

NFPA

National Fire and Protection Agency

NTC

Negative Temperature Coefficient

Oxygen

Outside Diameter

OEM

Original Equipment Manufacturer

SCFM

Standard Cubic Feet per Minute

SMACNA

Sheet Metal and Thermoplastic Duct Construction Manual Air Conditioning Contractors National Association

TB<#>

Terminal Block (1, 2, 3 etc.)

VAC

Volts Alternating Current

VDC

Volts Direct Current

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Revised: June 26, 2020 Released: June 26, 2020

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Page 2

2 Site Preparation

2.1 Initial Inspection upon Receiving

Upon receiving the boiler, inspect it for signs of shipping damage. Some damage may be hidden. Unpack the boiler,

open the front and side doors and inspect the boiler. Verify that the total number of pieces shown on the packing slip agrees with those actually received.

2.2 Storage Prior to Installation

If the boiler is not installed immediately, it must be stored in a location adequately protected from the weather, preferably indoors. If this is not possible, then it should remain in the shipping container and be covered by a tarpaulin or other waterproof covering.

Installation and service must be

performed by a qualified

installer, service agency, or gas

supplier. Failure to install the

equipment in accordance with

this manual could result in an

unsafe operating condition.

L’installation et l’entretien

doivent être assures par un

installateur ou un service

d’entretien qualifié ou par le

fournisseur de gaz.

NOTICE!

Controls and other equipment that are damaged or fail due to weather exposure are not covered by warranty.

The boiler is heavy and requires

additional technicians to

support and move the unit(s)

during installation. Use

extreme caution to avoid

dropping the boiler or cause

any bodily injury while lifting or

handling. When positioning this boiler, maintain positive

control of it at all times. Do not

attempt to move the boiler on

surfaces that are not level.

Failure to heed this warning

could result in personal injury

or death.

NOTICE!

The boiler may be installed on a combustible floor; however, the boiler must never be installed on carpeting.

Bumping hazard from overhead

ducts! Install all components

with adequate vertical

clearances. Insufficient

clearance can restrict the

service access, increasing the

possibility of injury.

NOTICE! Note any damage, suspected potential damage,

or shortage of materials on the freight bill and immediately notify the carrier. File all claims for shortage or damage with the carrier. Claims for hidden damages must be filed with your carrier within 7 days. The carton is equipped with a

“Tip (N) Tell”. If the “Tip (N) Tell” arrow point is blue, that

indicates the package has been on its side or tipped over in transit.

NOTICE! Controls and other equipment that are damaged or fail due to weather exposure are not covered by warranty.

If the information in these instructions are not followed

exactly, a fire or explosion may result causing property

damage, personal injury, or death.

AVERTISSEMENT

Assurez-vous de bien suivre les instructions données dans

cette notice pour réduire au minimum le risqué d’incendie

ou d’explosion ou pour éviter tout dommage materiel, toute

blessure ou la mort.

Should overheating occur or the gas supply fail to shut off,

do not turn off or disconnect the electrical supply to the

pump. Instead, shut off the gas supply at a location external

to the appliance.

En cas de surchauffe ou si l’admission de gaz ne peut être

coupée, ne pas couper ni debrancher l’alimentation

électrique de la pompe. Fermer plutôt le robinet

d’admission de gaz à l’extérieur de l’appareil.

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Page 3

2.3 Compliance with Codes

Each P-K STORM™ boiler with standard components complies with American National Standard/CSA Standard ANSI Z21.13/CSA 4.9, latest edition for Gas-Fired Low Pressure Steam and Hot Water Boilers.

The P-K STORM™ ST-2500, ST-3000, ST-3500 and ST-4000 heat exchangers are constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV for 160 psig maximum pressure and 210°F maximum temperature. Other codes or approvals which apply will be labeled on the boiler.

ST-2500, ST-3000, ST-3500 & ST-4000

Code of Construction

(Boiler)

ASME Section IV – “H” (Latest Edition)

Maximum Allowable Working

Pressure

160 PSIG

Maximum Allowable Design

Temperature

210° F

Hi-Limit Setpoint

200° F

Maximum Setpoint

185° F

Installation of the boiler must conform to all the requirements of all national, state and local codes established by the authorities having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 latest edition in the U.S. In Canada, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CAN/CSA-B.149, latest edition, and applicable Provincial Regulations for the class, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before making any installation.

Where required by local codes, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

In the Commonwealth of Massachusetts (a) this unit must be installed by

a licensed pipe fitter/plumber,

(b) field installed gas cocks must be “T” handle type, (c) piping of condensate shall conform to the State

Plumbing Code, and (d) refer to the Massachusetts Supplement for further details.

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2.4 Location Setup

Foundation

The appliance must be installed level, on a housekeeping pad, to function properly. Ensure the base is securely connected to the appliance. Use a bubble level and make sure housekeeping pad is level before installation of appliance. There are six

3/4” holes in the base which may be used for 5/8” anchor

bolts. Three of these are located inside the cabinet and the other three are outside.

The housekeeping

pad is recommended to be 4 inches but no less than 1 inch in height.

NOTICE! The appliance may be installed on a combustible floor; however, the appliance must NEVER be installed on carpeting.

QTY 3: 3/4” Holes

for

Anchor/Lag Bolts

(REAR)

QTY 3: 3/4” Holes

for

Anchor/Lag Bolts

(FRONT inside

cabinet)

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Clearances

If the boiler is to be installed near combustible surfaces, the minimum clearances are shown in the illustration below. Failure to provide adequate service clearances, even with non-combustible surfaces, may present problems during routine maintenance of the boiler. Maintain a clearance from the vent to

combustible surfaces of 18” or as specified in the vent manufacturer’s listed installation instructions.

The boiler must be installed in a space large in comparison to the boiler as described in the National Fuel Gas Code, NFPA 54/ANSI Z223.1, Latest Edition.

Type of Surface

Dimensions (inches)

C† D E

CSA Minimum Clearances to Combustibles

12 0 0**

0**

Required Minimum Service Clearances

12 0 18

Recommended Service Clearances

* “B” Clearance depends upon exhaust vent configuration. † “C” Space required for pipes, ducts, etc. in this area above the boiler.

** 18” required on either the left or right side.

Note: Failure to provide recommended service clearances may make it difficult to perform service on the boiler(s).

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2.5

Inlet Air and Exhaust Venting Considerations

Applicable Codes and Standards

United States Installation Codes:

Canada Installation Codes:

Flue Gas Exhaust Vent Standards:

These codes and standards contain information for the venting of gas fired appliances, including, but not limited to vent sizing, location, clearance to combustibles, and safe installation practices. The installation must comply with both the above Federal Codes and with state, provincial, and local codes.

Combustion Air Inlet Planning (United States and

Canada Considerations)

• Air inlet requirements for the U.S. are established by NFPA 54/ANSI Z223.1 & NFPA/ANSI 211.

• Air inlet requirements for Canada are established by CAN/CSA B149.1.

Refer to see section 3.4, for more details on combustion air inlet requirements in the United States and Canada.

Design and installation of venting systems should be done only by qualified and

knowledgeable venting systems

personnel and in accordance

with vent system

manufacturer’s installation

instructions. Installing a boiler

or vent system using improper

installation methods or

materials can result in serious

injury or death due to fire or

asphyxiation.

Before connecting a boiler to a

venting system, it must be

determined whether the boiler

is to be installed in a

conventional or direct vent

configuration. In the US,

provisions for combustion air

must be in accordance with

NFPA 54/ANSI Z223.1, National

Fuel Gas Code, latest edition, or

applicable provisions of local

building codes. In Canada,

combustion and ventilation air

openings shall comply with

CAN/CSA B-149.1 Natural Gas

and Propane Installation Code.

For correct installation of a vent

system, read all of these

instructions and refer to the

vent manufacturer’s

instructions.

Failure to use a proper vent

system (types and materials), as

described in this manual will

void the boiler warranty and

may result in rapid deterioration

of the venting system, creating

a health or life safety hazard.

Faulty vent installation can

allow toxic fumes to be released

into living areas. This may

cause property damage, injury,

or death.

NBIC – Part I

National Board Inspection Code Installation

NFPA 54/ANSI Z223.1

National Fuel Gas Code

NFPA/ANSI 211

Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances

CAN/CSA B149.1

Installation Codes for Gas Burning Equipment

UL 441 / ULC S605

Standard for Gas Vents

UL 1738

Venting Systems for Gas-Burning Appliances, Categories II, III and IV

ULC S636-95

Standard for Type BH Venting System Sheet Metal and Thermoplastic Duct Construction Manual Air Conditioning Contractors National Association (SMACNA)

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Category II/IV Flue Gas Exhaust Vent Planning

Several codes and standards have categorized appliances in accordance with the flue gas temperature and pressure produced by the appliance. The applicable categories are defined as follows:

• Category II: An appliance that operates with a non-positive vent static pressure and with a vent

temperature that may cause excessive condensate production in the vent.

• Category IV: An appliance that operates with a positive vent static pressure and with a vent

temperature that may cause excessive condensate production in the vent.

• Direct Vent: An appliance that is constructed and installed so that all air for combustion is

derived directly from outdoors and all flue gases are discharged to the outdoors.

All P-K STORM™ boilers are dual-certified as Category II or IV appliances, as defined in ANSI

Z21.13/CSA 4.9, latest edition. The P-K STORM™ series boilers are capable of operating with slightly negative to slightly positive exhaust pressure. It is critical to ensure the flue vent material is certified for

Category II or IV operation.

NOTE: For Category II installations, ensure the flue venting system is designed to maintain a slightly negative exhaust pressure between -0.01” W.C. and -0.05” W.C.

NOTE: For Category IV installations, ensure the flue venting system is designed to maintain a slightly positive exhaust pressure which MUST BE in the following ranges:

• +0.01” W.C. and +0.22” W.C. (Direct Vent / Sealed Combustion)

• +0.01” W.C. and +0.4” W.C. (Exhaust Only)

The vent material to be used for US and Canada is listed in the Table of Acceptable Materials for Venting Systems located in 2.5.4.

Vent installations shall be in accordance with NFPA 54/ANSI Z223.1, the National Fuel Gas Code, or CAN/

CSA-B149.1, the Natural Gas and Propane Installation Code, or applicable provisions of the local

building codes.

Vent Sizing for Category II / IV Operation

The vent must be sized in accordance with the ASHRAE Systems and Equipment handbook (Chapter

30) or according to the vent manufacturer’s recommendations. When using manufactured venting systems, consult your vent supplier for correct sizing and structural support requirements.

P-K STORM™ Boiler Model

Draft

Stack Temperature

CO2

Natural Gas

ST-2500, ST-3000,

ST-3500, ST-4000

Category II

-0.01” to -0.05” W.C.

220 °F (gross)

8.75%

ST-2500, ST-3000,

ST-3500, ST-4000

Category IV

(Sealed Combustion)

+0.01” to +0.22” W.C.

220 °F (gross)

8.75%

ST-2500, ST-3000,

ST-3500, ST-4000

Category IV

(Exhaust Only)

+0.01” to +0.4” W.C.

220 °F (gross)

8.75%

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Venting Materials for Flue/Exhaust Systems

The P-K STORM boilers are dual certified as a Category II and Category IV appliances, which vents with a temperature that is likely to

cause condensation in the vent. Therefore, any venting system used with the P-K STORM™ boiler must comply with the requirements for either Category II or Category IV venting systems as specified in the latest edition of NFPA 54/ANSI Z223.1 in the US or the latest edition of CAN/CSA B-149.1 in Canada.

CPVC Venting

US: CPVC pipe conforming to ASTM F441. Sch. 80 fittings

conforming to ASTM F439. Joints are to be sealed with solvent conforming ASTM 493.

Canada: CPVC Pipe, Fitting and Sealant listed and labeled to ULC S-636 Standard for Type BH Venting Systems.

Polypropylene Venting

US and Canada: Polypropylene such as InnoFlue® from

Centrotherm or PolyPro® from DuraVent or Z-DENS from ZFlex® or other listed manufacturers. When used, the same manufacturer's material must be used throughout the system. It is not permissible to use material from different manufacturers within the same system.

As per ANSI Z21.13b * CSA 4.9b:

• The use of cellular core PVC, cellular core CPVC, or Radel® as venting materials is

prohibited.

• The use of external insulation on plastic vent pipe is prohibited.

Acceptable Venting Materials

Model

Country

AL29-4C

316L SS

PVC

CPVC

POLYPROPYLENE

ST-2500

Yes

Note 2

ST-3000

Yes

Note 2

ST-3500

Yes

Note 2

ST-4000

Yes

Note 2

ST-2500

Canada

Yes

Note 1

ST-3000

Canada

Yes

Note 1

ST-3500

Canada

Yes

Note 1

ST-4000

Canada

Yes

Note 1

NOTE 1: When this material is used for venting, it must be listed to ULC-S636.

NOTE 2: When this material is used for venting, it must be listed to either UL-

1738 or ULC-S636 (depending on the local requirements). Consult the local boiler codes for more information.

The venting materials listed are

intended for the venting of gas

burning appliances only. Do

not use these venting materials

for venting liquid or solid fuel

(such as oil, kerosene, wood,

or coal) appliances.

Maintain clearances to

combustibles as listed in the

vent manufacturer’s

installation instructions or as

set forth in the codes and

standards listed in this section. Do not use these vent pipes for

incinerators of any sort!

This boiler is not certified for

use with PVC venting. Use of

PVC venting may result in vent

failure and possible serious

injury or death.

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Required Clearances

Conventional Vent Systems Clearances

The following termination clearance requirements are for conventional non-direct vent installations:

• The vent system shall terminate at least 3 ft. above a forced air inlet located within 10 ft. horizontally.

• The vent system shall terminate at least 4 ft. below, 4 ft. horizontally from, or 1 ft. above any door, operable window or gravity inlet into any building. The bottom of the vent terminal shall be at least 12 in. above grade or highest expected snow line (if applicable).

• Through the wall terminations shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment.

Direct Vent (Sealed Combustion) Systems Clearances

• The vent terminal shall be located at least 12 in. from any air opening into a building. The bottom of the vent terminal shall be at least 12 in. above grade. Both the vent and air intake terminals must be at least 12 in. above the highest expected snow line.

• When multiple direct vent appliances are adjacent, the exhaust must terminate at least 10 ft. horizontally or 3 ft. vertically from the air intake of another appliance.

The boiler vent should not be

connected into any portion of

another mechanical draft system

without consulting the vent

manufacturer. The boiler shall

not be connected to any part of

a vent system serving a

Category I appliance, nor shall a

Category I appliance be

connected to any part of the

vent system serving this

appliance. For Category II

common venting, refer to local

venting codes. Improper

interconnection of venting systems may result in leakage of flue gases into occupied spaces.

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Mark

Description

US Installations

Canadian Installations

Clearance to each side of center line extended above meter/regulator

3 ft. (91 cm) within a height of 15 ft. (4.6 m) above the meter/regulator assembly

Clearance to service regulator vent outlet

3 ft. (91 cm)

Clearance above grade, porch, deck, veranda, or balcony

12 in

Clearance to window or door that may be opened

4 ft. (1.2 m) below or to side of opening

1 ft. (300 mm) above opening

6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW)

12 in (30 cm) for appliances > 10,000

Btuh (3 kW) and ≤ 100,000 Btuh (30

kW) 36 in (91 cm) for appliances > 100,000

Btuh (30 kW)

Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance

4 ft. (1.2 m) below or to side of opening 1 ft. (300 mm) above opening

6 in (15 cm) for appliances ≤ 10,000 Btuh (3 kW)

12 in (30 cm) for appliances > 10,000

Btuh (3 kW) and ≤ 100,000 Btuh (30

kW) 36 in (91 cm) for appliances > 100,000

Btuh (30 kW)

Clearance to a mechanical air supply inlet

3 ft. (91 cm) above if within 10 ft. (3 m) horizontally

6 feet (1.83 m)

For clearances not specified maintain clearance in accordance with local installation codes and the requirements of the gas supplier

Interior Component Clearances

All vent system components shall be installed so as to maintain the following minimum clearances:

Material

Combustible

Non-Combustibles

Unlisted single wall metal pipe

Do NOT Use

Single wall PVC pipe

Do NOT Use

UL 1738 listed Category IV vent

Per manufacturer’s listing

Flue Connection

The connection from the appliance to the vent should be as direct as possible and the upward slope of any horizontal breaching should be at least 1/4 inch per linear foot. Examples of the complete exhaust system with drain is in 3.5. The appliance connector should incorporate provisions to drain condensate formed in the vent system. The connector should include an appropriate drain section (not provided).

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2.6 Gas Piping Considerations

Before making the gas hook-up, make sure the boiler is being supplied with the type of fuel shown on the boiler nameplate.

Supplying a fuel other than that shown on the appliance’s

nameplate can lead to over firing of the appliance. This can cause damage to the equipment which could result in serious injury and/or death.

The boiler shall be installed such that gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control adjustment, etc.).

2.7 Water Quality Standard

The P-K STORM™ boiler’s heat exchanger is made of stainless steel. The heat exchanger requires proper water conditions to remain efficient and function properly. For more information, refer to

Patterson-Kelley’s Water Quality Standards for Hydronic Boilers in Multi-Metal Systems in Appendix C

– Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems, as this

applies to the warranty of your heat exchanger.

3 Installation

3.1 Overview

For site preparation follow the guidelines established in Section 2. Section 3 details the installation requirements for electrical connections, combustion air, and flue vent piping, hydronic piping, etc.

3.2 Appliance Connections

The table below summarizes the appliance connections to the P-K STORM™ series boilers:

Boiler Model

ST-2500

ST-3000

ST-3500

ST-4000

Power Requirement

208-240/3/60 VAC -or- 440-480/3/60 VAC

Air Intake Connection

12”

Nominal Exhaust Vent

Connection

10”

12”

Condensate Drain

3/4" CPVC Pipe

Heat Exchanger Drain

3/4" NPT-F

Natural Gas Shutoff Valve

2” NPT-F

HWR Connection

4” Grooved (Carbon Steel)

HWS Connection

4” Grooved (Carbon Steel)

NOTE: Failure to maintain the water quality according to the requirements of the multi-metal systems water quality standards can void the heat exchanger warranty.

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Appliance Connections (ST-2500 & ST-3000)

All connections must be in compliance with national, state, and local code requirements.

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Appliance Connections (ST-3500 & ST-4000)

All connections must be in compliance with national, state, and local code requirements.

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3.3 Electrical Connections

Power Requirements

The STORM boilers can be manufactured for 208-240 VAC, three phase, 60 hertz electrical service OR 440-480VAC, three phase, 60 hertz electrical service. The total operating amperage is indicated on

the rating nameplate require less than 20 Amps at full load. Before starting the boiler, check to ensure that the proper electrical service is connected to the boiler.

An external electrical disconnect and overload protection (not supplied with the boiler) are required.

Refer to Section 6.2, for proper wiring and configuration of the electrical connections. The electrical service to the boiler must be installed and grounded in accordance with local codes or in the absence of such requirements, in the U.S. with National Electrical Codes, ANSI/NFPA No. 70 latest edition or, in Canada, to the current Canadian Electrical Code, Part I, CSA C22.1 latest edition. Installed conduit must not block any of the boiler’s openings and must allow the front door to be opened.

Three Phase Power Supply Connection

Main Power Connection Box

Always check the rating nameplate of the Storm boiler to determine the required electrical service:

• 208-240VAC, three phase, 60 hertz

• 440-480VAC, three phase, 60 hertz

The incoming three phase power for the ST-2500-ST-4000 boilers is connected to the over-current safety device (rated for 20 Amps) and the Ground terminal located in the main power connection box. The image on the next page shows the Low Voltage (TB1) and High Voltage (TB2) terminal blocks, plus the Main Power Connection Box on the ST-2500-ST-4000.

• Terminal 1 = HOT L1

• Terminal 3 = HOT L2

• Terminal 5 = HOT L3

• Terminal G = GROUND

Control Transformer

The Main Power Connection Box features a Control Transformer which steps down two hot leads from the incoming three-phase power in order to supply 110-120VAC single phase power to the NURO® control system. Be aware that Storm boilers ordered in the 240V configuration, are pre-wired from the factory for operation with 240 VAC three phase incoming power.

NOTE: The STORM boilers MUST be ordered to the correct voltage! IT IS NOT POSSIBLE to convert the boiler between the 240V and 480V configurations in the field!

NOTICE: If 208 VAC three phase power is supplied to the boiler, the internal control transformer must be re-wired for operation at this lower voltage. The wire in terminal X3 on the load side of the

internal control transformer must be moved to terminal X4. This supplies 110 VAC power to the NURO® control from the 208 VAC main voltage. Refer to Section 7.2.4 for proper wiring and

configuration of the internal control transformer.

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Do not over-tighten the hot lead terminal screws. Maximum tightening torque = 13 in-lbs!

NOTE: The hot lead terminals can accommodate maximum 12AWG wire. The ground terminal can accommodate maximum 8AWG wire.

Control

Transformer

High Voltage

Terminal Block

(TB2)

Low Voltage

Terminal Block

(TB1)

Main Power

Connection

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High Voltage (TB2) Terminal Block

Start Interlock #2 –

The Start Interlock #2 TB2-1 and TB2-2 terminals are in series with Start Interlock #1 and provide additional connection points for auxiliary safety devices. This circuit is energized with 120VAC, so the contacts on any auxiliary safety devices must be rated for minimum 120VAC.

Start Interlock #1 –

The Start Interlock #1 TB2-3 & TB2-4 terminals can be used for auxiliary safety devices such as damper limit switches, control valve limit switches, emergency stop buttons, and low water cutoff devices. This circuit is energized with 120VAC, so the contacts on any auxiliary safety devices must be rated for a minimum of 120VAC. The appliance ships with a factory-installed jumper across Start Interlock #1 and Start Interlock #2 terminals. Remove the jumper(s) if using any auxiliary safety devices.

Be sure to check the

nameplate on the boiler

before connecting the

electrical supply.

NOTICE!

A dedicated earth ground (green wire) is required to avoid nuisance shutdowns. Do not ground through the conduit!

The high voltage (TB2)

terminal block on the Storm

boilers with NURO controls contains dry-contact relays

with a maximum voltage

rating of 240VAC and 1/2 Amp

maximum current capacity.

Incorrect wiring can result in

equipment damage, injury, or

death.

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Auxiliary Input #1 –

The TB2-7 & TB2-8 terminals are reserved for future use. This circuit is energized

with 120VAC

Air Damper Interlock – The Air Damper Interlock TB2-9 & TB2-10 terminals

allow for proof of open end limit switch on a motorized air damper. This circuit is energized with 120VAC, so the contacts on the end limit switch must be rated for minimum 120VAC. The appliance ships with a factory-installed jumper across the Air Damper Interlock terminals. Remove the jumper if connecting a motorized air damper with end limit switch.

Ground – Grounding connection for auxiliary safety/limit devices on terminals TB2-11 & TB2-12.

Relay A, B, C & D – User-configurable relay outputs A (TB2-19 & TB2-20), B (TB2-17 & TB2-18), C

(TB2-15 & TB2-16) & D (TB2-13 & TB2-14). The normally-open contacts on these relays have a maximum voltage rating of 240VAC and maximum current capacity of 1/2 Amp.

Master Alarm Relay – The Master Alarm Relay TB2-21 & TB2-22 terminals are normally-open dry contacts that close in the event of an alarm output from the NURO control. The normally-open contacts on this relay have a maximum voltage rating of 240VAC and maximum current capacity of 1/2 Amp.

NOTE: The Start Interlock circuit must close within 5 minutes of a call for heat. Failure to close the Start Interlock circuit will cause the appliance to lockout on alarm.

NOTE:

The boiler ships with a factory-installed jumper across the Air Damper Interlock terminals.

Remove the jumper if connecting a motorized air damper with end limit switch.

NOTE: This ground terminal is connected to the TB2 sheet metal and is not common with the appliance’s electrical service ground.

NOTE: Refer to 6.1 or proper wiring and configuration of the electrical connections. Relays A

through D can be user-configured through the NURO® touch screen interface to control devices such as the Comfort Heat (CH) pump, Domestic Hot Water (DHW) Pump, Air Damper, System Pump, etc.

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Low Voltage (TB1) Terminal Block

Enable/Disable –TB1-1 and TB1-2 can be used to remotely enable or disable the boiler. The

functionality of these terminals is user-configurable through the NURO® controls, but generally closure of the Enable/Disable circuit provides a call for heat to the boiler. Opening this circuit prevents the boiler from running.

4-20mA Analog Input – TB1-3 and TB1-4 can be used to provide a remote analog 4-20mA control signal to the boiler. This analog signal can be used to change the boiler’s operating setpoint/firing rate.

Spare Analog Input – TB1-5 and TB1-6 are reserved for future use.

NOTE: The boiler ships with a factory-installed jumper across the Enable/Disable terminals. This

circuit is energized with a 24VAC potential, so the contacts on any remote enable devices must be rated for minimum 24VAC.

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HDR Temp Sensor – TB1-7 and TB1-8 can be used to connect a remote header temperature sensor, installed in the primary hydronic system piping, downstream of all the boilers. This temperature sensor must be a 2-wire 12kΩ NTC thermistor. This circuit is energized by the boiler with a 5VDC potential.

DHW Stat/Sensor – TB1-9 and TB1-10 can be used to connect either an aquastat or remote DHW temperature sensor installed in a domestic hot water storage tank. If using an aquastat, use a SPST normally-closed, break on rise type with either a fixed or adjustable deadband above and below the setpoint. Alternatively, if using a temperature sensor, it must be a 2-wire 12kΩ NTC thermistor and be of sufficient length to measure an accurate storage tank temperature. This circuit is energized by the boiler with a 5VDC potential.

Outdoor Temp Sensor – TB1-11 and TB1-12 can be used to connect an outdoor air temperature sensor which allows the NURO control to be programmed to run an outdoor air schedule. The outdoor air temperature sensor must be a 2-wire 12kΩ NTC thermistor and should be installed on the North face of the building and shielded from direct sunlight exposure. This circuit is energized by the boiler with a 5VDC potential.

Night Setback – TB1-13 and TB1-14 can be used to connect a day/night or occupancy timer. Closure of the Night Setback circuit enables the Night Setback mode which reduces the boiler’s operating

setpoint. Opening this circuit resumes normal operation. This circuit is energized by the boiler with a 5VDC potential, so the contacts on the day/night timer must be rated for minimum 5VDC.

4-20mA Analog Output – TB1-15 and TB1-16 provide a 4-20mA analog output signal which tracks the boiler’s firing rate. When operating at full power (maximum firing rate), the boiler will provide a 20mA

output. When operating at minimum power (minimum firing rate), the boiler will provide a 4mA output. Ground – TB1-17 provides an equipment (frame) ground connection for input, output, or

communication connections. For independently powered control devices, it may be necessary to create a common ground.

Cascade Shield & Cascade – TB1-18, TB1-19, and TB1-20 can be used to setup a cascade system with multiple STORM boilers with NURO controls. Terminals TB1-19 and TB1-20 are reserved for the cascade communication between the master and member boilers. Terminal TB1-18 should be used to connect the cascade communication wiring shield between all boilers. The cascade and shielding must be wired from the master boiler to each individual member boiler in a daisy-chain fashion.

MODBUS COM & MODBUS Shield – TB1-22, TB1-23, and TB1-24 can be used to integrate the boiler with a Building Management System (BMS), Protocol Converter, or other device capable of RS-485 2wire MODBUS communication. Terminals TB1-22 and TB1-23 are reserved for MODBUS and terminal TB1-18 provides a connection for the MODBUS communication wire shield.

ECOM 1, 2 & 3 – TB1-25, TB1-26, and TB1-27 can be used to connect a wireless outdoor air temperature sensor. The wireless receiver should be installed at or near the boiler, and the wireless temperature sensor should be installed on the North face of the building and shielded from direct sunlight exposure.

NOTE: Only ground the Cascade shield wire at the master boiler.

NOTE: Only ground the MODBUS shield wire at the master boiler.

P-K StormTM Gas Fired Boiler

Technical Service 1.877.728.5351

Revised: June 26, 2020 Released: June 26, 2020

2691000273 P-K Storm ST2500-ST4000

Installation and Owners Manual Rev A.docx

Page 20

3.4 Combustion Air

Air Inlet Requirements – United States

Air inlet requirements for the United States are established by NFPA 54/ANSI Z223.1 & NFPA/ANSI

211. When air is supplied from inside the building, the total required volume shall be the sum of the required volume for all the appliances located in the mechanical room. Adjacent rooms furnished with fixed openings communicating directly with the mechanical room are considered part of the required volume. The minimum volume is 50 ft3 per 1,000 Btu/Hr (4.8 m3/kW) of installed appliance input capacity.

Openings used to connect indoor spaces to obtain the required minimum volume shall be sized as follows:

• When rooms are on the same floor, each opening shall have an area equal to 1 square inch for

each 1,000 Btu/Hr (2,200 mm2/kW) of installed appliance input capacity, but not less than 100 square inches. One opening should commence less than 12 inches above the floor and the other less than 12 inches below the ceiling. The minimum dimension of air openings shall be 3 inches.

• When rooms are on different floors, each opening shall have an area equal to 2 square inches for

each 1,000 Btu/Hr (4,400 mm2/kW) of installed appliance input capacity.

When combustion air is supplied from outside the building, th e boiler room shall be provided with one or two openings to ensure adequate combustion air and proper ventilation.

When using one permanent opening, th e opening shall commence within 12 inches of the ceiling and shall

communicate directly with the outdoors or through a vertical or horizontal duct that communicates to the outdoors. Minimum free area of th e opening is 1 square inch for each 3,000 Btu/Hr (700 mm2/kW) of installed appliance input capacity, and not less than the sum of the areas of all vent connectors in the room. When using two permanent openings, one opening shall commence within

12 inches above the floor and the other within 12 inches below the ceiling, preferably on opposite walls. The openings shall communicate directly, or by way of ducts, with free outdoor air. The minimum net free area of the openings shall be calculated in accordance with the following:

• When air is taken directly from outside the building, each opening

(minimum of two, as outlined above), 1 square inch for each 4,000 Btu per hour (550 mm2/kW) of total boiler input is required.

• When air is taken from the outdoors through a vertical duct into

the mechanical room, 1 square inch per 4,000 Btu per hour (550 mm2/kW) of total boiler input is required.

When air is taken from the outdoors through a horizontal duct into the mechanical room, 1 square inch per 2,000 Btu per hour (1,100

mm2/kW) of total boiler input is required.

United States Minimum Area of Ventilation Openings per Boiler (Sq. In)

Under no circumstances

shall the boiler room ever be

under a negative pressure.

Particular care should be

taken when exhaust fans,

compressors, air-handling

units, or other equipment

may rob air from the boiler.

Note that this equipment

might be in rooms other

than the boiler room. This

applies to both sealed

combustion and

atmospheric room

combustion air applications.

STORM Boiler

MODEL

AIR SOURCE

INDOOR AIR SUPPLY

OUTDOOR AIR SUPPLY

SAME

FLOOR

DIFF

FLOORS

ONE

OPENING

TWO OPENINGS

DIRECT

VERT DUCT

HORIZ

DUCT

ST-2500

2500

5000

833

625

1250

ST-3000

3000

6000

1000

750

1500

ST-3500

3500

7000

1167

875

1750

ST-4000

4000

8000

1334

1000

2000

P-K StormTM Gas Fired Boiler

Technical Service 1.877.728.5351

Revised: June 26, 2020 Released: June 26, 2020

2691000273 P-K Storm ST2500-ST4000

Installation and Owners Manual Rev A.docx

Page 21

Air Inlet Requirements - Canada

Air inlet requirements for the Canadian Provinces are established by CAN/CSA B149.1. Ventilation of

the space occupied by fuel burning appliance(s) or equipment shall be supplied by a ventilation opening at the highest practicable point communicating with the outdoors. The total cross sectional area of the ventilation opening must be either 10% of the net free area required for combustion air or 10 sq. in. (6,500 mm2), whichever is greater.

A. Ventilation of the space occupied by fuel burning appliance(s) or equipment shall be supplied by

a ventilation opening at the highest practicable point communicating with the outdoors. The total cross sectional area of the ventilation opening must be either 10% of the net free area required for combustion air or 10 sq. in. (6,500 mm2), whichever is greater.

B. Use the following opening calculation for P-K STORM boilers:

When combustion air is supplied for a forced draft burner by natural airflow from the outdoors and there is no draft regulator or draft hood in the same space, there shall be a permanent opening with a cross sectional area not less than 1 sq. in/30,000 Btu/Hr (70 mm2/kW) of the total rated input to the burner(s). This opening must not interfere with the ventilation air opening defined in Paragraph A.

C. When combustion air is supplied by natural airflow into a space containing the type of appliance

described in Paragraph B, the cross sectional area of the opening shall not be less than the sum of the cross sectional areas for all appliances in the space as calculated by the applicable method. This opening is in addition to the ventilation air opening defined in Paragraph A.

D. When a duct is used to meet the requirement for combustion air supply, as described in

Paragraphs A through C, above, the opening of the duct shall be located so there is no

possibility of cold air affecting steam or water piping, electrical equipment or mechanical equipment.

E. When combustion air is supplied by mechanical means, an airflow-sensing device must be

installed. It must be wired into the pre-ignition limit/interlock to prevent the burner from starting or to stop an operating burner in case of air supply failure.

F. When all combustion air is supplied through a make-up air heater, and the appliance is

interlocked to the heater, the requirements of Paragraphs A through E do not apply.

Canadian Minimum Area of Combustion and Ventilation Air Openings

P-K STORM™ Model #

BTU/Hr

Required Combustion

Air Opening

Ventilation Air

Opening

Input

in2

mm2

in2

mm2

ST-2500

2,500,000

53,548

6,452

ST-3000

3,000,000

100

64,516

6,452

ST-3500

3,500,000

117

75,484

13.4

8,645

ST-4000

4,000,000

134

86,451

13.4

8,645

NOTES:

1. The required size of openings for combustion and ventilation air shall be based on the net free area of the opening.

2. Screens shall not be smaller than 1/4 inch.

3. Motorized louvers shall be interlocked with the appliance so that they are proven open prior to main burner ignition and operation.

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