Patterson-Kelley TBIG-03 User Manual

PATTERSON-KELLEY

FD-06C

MODU-FIRE® FORCED DRAFT

GAS-FIRED BOILER

Installation and Owner's Manual

C.S.A. Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers

Installation Date: _______________________

ASME Code, Section IV Certified by Patterson-Kelley

C.S.A. Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers

100 Burson Street, P.O. Box 458 East Stroudsburg, PA 18301 Telephone: (877) 728-5351, Facsimile: (570) 476-7247 www.pkboilers.com

FORCED DRAFT Gas-Fired Boiler Table of Contents

1.0 INTRODUCTION ........................................2

2.0 SAFETY...................................................... 2

2.1 General ....................................................... 2

2.2 Training ....................................................... 2

2.3 Safety Features .......................................... 2

2.4 Safety Labels .............................................. 3

2.5 Safety Precautions...................................... 3

2.5.1 Electrical Hazards................................. 3

2.5.2 Burn, Fire, and Explosion Hazards....... 3

2.5.3 Crush Hazards...................................... 4

2.5.4 Chemical Hazards ................................ 5

2.5.5 Pressure Hazards................................. 5

2.5.6 Slip, Fall Hazards ................................. 5

3.0 INSTALLATION ..........................................6

3.1 Receiving and Storage ............................... 6

3.1.1 Initial Inspection.................................... 6

3.1.2 Storage Prior to Installation .................. 6

3.2 Compliance with Codes .............................. 6

3.3 Setup........................................................... 6

3.3.1 Foundation............................................ 6

3.3.2 Placement............................................. 6

3.3.3 Installation Clearances ......................... 7

3.4 Electrical Connections ................................ 7

3.5 Combustion Air ........................................... 9

3.5.1 Sealed Combustion .............................. 9

3.5.2 Intake Duct Materials and Sizes......... 10

3.5.3 Sealing the Intake Duct ...................... 10

3.5.4 Intake Duct Connection to Boiler........ 10

3.5.5 Intake/Exhaust Layout........................ 10

3.6 Venting (Stack) .........................................10

3.6.1 Vent Components............................... 11

3.6.2 Barometric Damper ............................ 11

3.6.3 Automatic Vent Damper .....................11

3.6.4 Flue Connection ................................. 11

3.6.5 Clearances .........................................11

3.6.6 Vent Terminations...............................12

3.6.7 Venting for Multiple Boilers .................13

3.6.8 Removing an Existing Boiler ...............13

3.7 Gas Piping.................................................14

3.8 Boiler Water Piping....................................15

3.8.1 Piping Design......................................15

3.8.2 Boiler Water Connections ...................16

3.8.3 Boiler Water Piping by Installer...........16

3.8.4 Flushing and Filling .............................16

3.8.5 Water Quality ......................................17

3.9 Burner and Ignition System.......................17

3.9.1 Inspection............................................17

3.10 Pre-Start Check List ................................17

3.11 Safety Checks .........................................18

3.11.1 Test of Ignition Safety System ..........18

3.11.2 Test of Low Water Cut-off .................18

3.11.3 Test of Limit Controls ........................18

3.11.4 Test of Low Gas Pressure Switch.....18

3.11.5 Test of High Gas Pressure Switch....19

3.12 Initial Adjustments ...................................19

3.12.1 Configuring the Temperature Control19

3.12.2 Air Flow Adjustment ..........................21

3.12.3 Fuel/Air Ratio Adjustment .................21

4.0 OPERATION ...........................................22

4.1 General......................................................22

4.1.1 Normal Operation.................................22

4.2 Lighting and Shut-Down Procedures ........22

4.2.1 Initial Lighting Procedures...................22

4.2.2 Normal Shut Off Procedures................23

4.2.3 Emergency Shut Off Procedures .........23

4.3 Typical Boiler Operating Conditions..........23

5.0 MAINTENANCE ......................................24

5.1 Maintenance and Inspection Schedule .....24

5.1.1 Daily ....................................................24

5.1.2 Weekly ................................................24

FORCED DRAFT Gas-Fired Boiler Table of Contents

5.1.3 Monthly ............................................... 24

5.1.4 Annually.............................................. 25

5.2 Cleaning the Burner.................................. 25

5.3 Removing the Exchanger ......................... 26

5.4 After All Repairs or Maintenance .............. 26

5.5 Sequence of Operation.............................. 27

5.6 Troubleshooting ........................................ 28

6.0 PARTS/TECHNICAL SUPPORT ..............30

6.1 Schematic Diagrams.................................. 30

6.1.1 Wiring Schematic................................ 31

6.1.2 Main Control Panel Components ........ 32

WARNING

Improper use may result in fire or injury.

Read instructions/safety manual before installing,

1998 HCS, Inc. 800-748-0241

operating or servicing boiler.

Reorder No. 6020-V2WHPK

WARNING!

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.

The same features which permit this boiler to achieve high-efficiency performance make it unlike most other boilers of this general size. It is important to understand how this boiler operates by reading this manual.

WARNING!!

Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

6.1.3 Main Control Panel Point to Point........33

6.1.4 Junction Box Point to Point and

Customer Connections ...........................34

6.1.5 Customer Connections Details ............35

6.1.6 Gas Train .............................................36

6.1.7 Blower/Burner/Ignition Assembly.........37

6.1.8 Heat Exchanger and Combustion

Chamber.................................................38

6.1.9 Cabinet Assembly ................................39

7.0 LIMITED WARRANTY............................. 40

8.0 FIELD STARTUP REPORT...................... 41

WARNING!

Installation and service must be performed by a qualified and knowledgeable individual such as a PK representative, 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.

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Safety

1.0 INTRODUCTION

The MODU-FIRE® FORCED DRAFT Gas-Fired

Boiler is a revolutionary advance. Patterson-Kelley now combines full-modulation burner control and forced draft advances with our time-tested modular hot water boiler design. The result is a full- modulation boiler utilizing reduced vent sizing for installation and cost efficiencies. This boiler combines the best of our earlier designs with a new generation of burner, control and operating technology. You will achieve high part-load efficiencies – but without the complexity you might expect in this type of high performance boiler. It is high performance made simple and dependable for years of trouble-free operation.

This manual covers installation of the

FORCED DRAFT (MFD)

Boiler series 1500 and

MODU-FIRE®

2000. The model numbers may include a prefix and will include a suffix to indicate special features or different options. While details may differ slightly, basic operation is the same for all models. Boilers are built to operate with natural gas or propane. Check the rating label for the correct gas type and flow rate.

The boiler is only a part of the complete heating system. This boiler may be fully operational and yet, because of poor circulation, controls, or other operating 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.

2.0 SAFETY

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 qualified and knowl-

edgeable personnel in accordance with all applicable codes, laws, and regulations.

• The use of the term “factory-trained personnel”

throughout this manual indicates PattersonKelley trained on this specific piece of equipment.

2.2

TRAINING

WARNING

Improper use may result in fire or injury.

Read instructions/safety manual before installing,

1998 HCS, Inc. 800-748-0241

operating or servicing boiler.

Reorder No. 6020-V2WHPK

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 serious injury, death, and/or property damage.

Proper training is the best protection against accidents. Operating and service personnel must be thoroughly familiar with the basic construction of the

MODU-FIRE® FORCED DRAFT boiler, the

use and locations of the controls, the operation of the boiler, adjustment of its various mechanisms, and all applicable safety precautions. If any of the provisions of this manual are not fully and completely understood, contact the Patterson-Kelley Technical Services Department.

2.1

GENERAL

The MODU-FIRE® FORCED DRAFT gas-fired

boiler

must be:

• Installed in accordance with designs prepared by

qualified facility engineers including: structural,

2.3

SAFETY FEATURES

It is the responsibility of the customer to maintain the safety features of this machine, such as: guards, safety labels, safety controls, interlocks, lockout devices, etc., in place and operable.

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Safety

SAFETY LABELS

2.4

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

DANGER – Used to indicate an imminently hazard-

ous situation which, if not avoided,

will result in

death or serious injury. This signal word is to be limited to the most extreme conditions.

WARNING – Indicates a potentially hazardous situa-

tion which, if not avoided,

could result in death or

serious injury.

CAUTION – Used to indicate a potentially hazardous

situation which, if not avoided,

may result in minor or

moderate injury.

NOTICE/NOTE - NOTICE is the preferred signal

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

The safety labels shown below are affixed to your boiler. Dual language labels may be affixed to your boiler. Although the labels are of high quality, they may become dislodged or unreadable over time. Contact Patterson-Kelley for replacement labels.

2.5

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.

Proper lockout/tagout procedures must be employed whenever this unit is serviced.

2.5.1 Electrical Hazards

WARNING

Electrical hazard.

Follow lockout/tagout procedure when servicing this boiler.

C 1998 HCS, Inc. 800-748-0241

Reorder No. 5025-V1WHPK

• Shock hazard! Properly lockout/tagout the elec-

trical service and all other energy sources before working on or near the machine.

• Shock hazard! Boiler is not rated for wash-

down service.

• Power down unit for at least 10 minutes before

servicing inverter or blower.

2.5.2 Burn, Fire, and Explosion Hazards

General Warning

1998 HCS, Inc. 800-748-0241

WARNING

Improper use may result in fire or injury.

Read instructions/safety manual before installing, operating or servicing boiler.

Hot Surface

Reorder No. 6020-V2WHPK

NOTE

Make sure this union is tight before closing cabinet cover after servicing boiler.

1998 HCS, Inc. 800-748-0241

Reorder No. 8032-02NHAK

NOTE

When opening leak test valves, always follow instructions in operation and safety manual.

1998 HCS, Inc. 800-748-0241

• Burn, fire, and explosion hazards! Installation

must be in strict conformance to all applicable codes and standards including NFPA 54, ANSI Z223.1 and CSA B.149.

• Hazard from incorrect fuels! Possible fire, ex-

plosion, overheating, and damage. Do not use any fuels except the design fuel for the unit.

Reorder No. 8032-01NHPK

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Safety

• Overfire hazards! High pressure in gas or pro-

pane supply could result in overfiring of other devices supplied from the same source.

• Fire and explosion hazards! Close the 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

the stack during firing operations. Use only factory recommended vent components.

• Burn hazard! Hot fluids. Use caution. Allow

boiler to cool before servicing or draining boiler.

• Fire and explosion hazards! Use caution when

servicing burner or heat exchanger. Fuel may linger in the combustion chamber, vent lines, or elsewhere.

Gas leak hazard! Make sure all connections to

•

main burner are tight when reassembling the burner.

NOTE

Make sure this union is tight before closing cabinet cover after servicing boiler.

1998 HCS, Inc. 800-748-0241

• Gas leak hazard! All threaded gas connections

must be made using a pipe compound that is re-

sistant to liquefied petroleum. 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, close all gas valves and obtain immediate assistance from factory-trained 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. to the boiler main gas valve.

• Overfire hazard! Possible fire and explosion.

Possible malfunction of regulators and/or gas valves. Maintain all gas train components in good condition. Do not alter wiring connections.

Reorder No. 8032-02NHAK

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 fac-

tory-trained personnel.

2.5.3 Crush Hazards

General Warning

• Lifting hazards! Use properly rated lifting

equipment to lift and position the boiler. The load is unbalanced. Test balance before lifting 3 ft. above the floor. Do not allow personnel beneath the lifted load. Refer to approximate weights in the table below:

Boiler Size Weight in Pounds

1,500,000 Btu 915

2,000,000 Btu 930

• Bump hazard from overhead piping. Install pip-

ing with adequate vertical clearance.

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Safety

2.5.4 Chemical Hazards

General Warning

• 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.

2.5.5 Pressure Hazards

WARNING

Improper use may result in fire or injury.

Read instructions/safety manual before installing,

1998 HCS, Inc. 800-748-0241

operating or servicing boiler.

• Pressure hazard! Hot fluids. Install isolation

valves on boiler water inlet and outlet. Make sure isolation valves are closed before servicing boiler.

2.5.6 General Hazards

General Warning

• Tripping hazard! Do not install piping on floor

surfaces. Maintain clear path around boiler.

• Slip and fall hazard! Use drip pan to catch wa-

ter while draining the boiler. Maintain dry floor surfaces.

• Slip and fall hazard! Through-the-wall vents

shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard.

• Fall hazard! Do not stand on any part of the

boiler.

• Catch hazard! Do not wear rings, jewelry, long

hair, loose clothing while working on the boiler.

• Pressure hazard! Hot fluids. Test safety relief

valve bimonthly for proper operation. Do not operate boiler with faulty relief valve.

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation

3.0 INSTALLATION

WARNING!

Installation and service must be performed by a qualified installer, service agency, or gas supplier.

3.1

RECEIVING AND STORAGE

3.1.1 Initial Inspection

Upon receiving the boiler, inspect it for signs of shipping damage.

Important: Note any damage or shortage on the freight bill and immediately notify the carrier. File all claims for shortage or damage with the carrier.

3.1.2 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.

Notice: Controls and other equipment that are dam-

aged or fail due to weather exposure are not covered by warranty.

3.2

COMPLIANCE WITH CODES

The MODU-FIRE® FORCED DRAFT Boiler

with standard components and many options complies with American National Standard/CSA Standard ANSI Z21.13/CSA 4.9, latest edition, GasFired Low Pressure Steam and Hot Water Boilers. The heat exchanger is constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV for 160 psig maximum operating pressure and/or 250º F maximum operating temperature. Other codes or approvals which apply will be labeled on the boiler.

tablished by the authorities having jurisdiction or, in the absence of such requirements, in the U.S. to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, latest edition, and the specific instructions in this manual. In Canada, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CSAB.149, and applicable Provincial Regulations for the class, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

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, see Massachusetts Installation & Owner’s Manual Supplement.

3.3

SETUP

3.3.1 Foundation

Provide a firm, level foundation, preferably of concrete.

Caution: The boiler may be installed on a combus-

tible floor; however, the boiler must

never be in-

stalled on carpeting.

Caution: This boiler is certified for indoor installa-

tion only.

3.3.2 Placement

The boiler must be level and upright to function properly.

Use shims or other approved structural devices to properly level boiler.

Installation of the boiler must conform to all the requirements of all national, state and local codes es-

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation

3.3.3 Installation Clearances

If the boiler is to be installed near combustible surfaces, six (6”) inches minimum clearance to the combustible surface must be maintained.

Failure to provide for the service access clearances, even with non-combustible surfaces, may cause future problems servicing the boiler.

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

A B

Clearances from Adjacent Walls,

Ceiling, and Obstructions

Dimensions (inches) Type of Surface

Instructions d'opération de la chaudière

Operating Instructions for this

WATER FLOW

à gaz de série Modu-Fire (Canada)

P-K Modu-Fire Gas-Fir ed Boiler

Procédure de mise en marche de la chaudière :

GAS PRESS

Starting Boiler

1.Électricité, gaz et eau : Mettez la chaudière sous tension électrique.

1. Utilities: Turn on the electric supply to the boiler.

1. Utilities: Turn on the electric supply to the boiler. Ouvrez les robinets d'alimentation en gaz. Assurez-vous que le

Ouvrez les robinets d'alimentation en gaz. Assurez-vous que le

Open the gas supply valves. Make sure the system

système est rempli d'eau et actionnez la pompe de circulation.

LOW AIR

is filled with water and turn on the circulating pump.

2.À l'intérieur du panneau de contrôle, réglez les températures de

2. Set the desired boiler limit and operating temperatures

2. Set the desired boiler limit and operating temperatures limite et de fonctionnement aux valeurs désirées.

limite et de fonctionnement aux valeurs désirées.

inside the control panel.

3.Actionnez l'interrupteur principal. Si le voyant rouge s'allume,

3. Turn the power switch on. If a red warning indicator

ALARM

consultez le manuel d'Installation et d'Utilisation de l'appareil.

is illuminated, see the Installation & Owners Manual.

Attendez 5 minutes avant de tenter une réinitialisation de la chaudière.

Wait five minutes before attempting to reset the boiler.

Procédure d'arrêt de la chaudière :

HEAT

Boiler Shutdown

1. Turn the power switch off.

1. Désactivez l'interrupteur principal.

2. For maintenance, service, or prolonged shutdown:

2. En cas de réparation, d'opération d'entretien ou d'arrêt prolongé;

POWER

turn off the electric supply, close the gas supply

coupez l'alimentation électrique, fermez les robinets d'alimentation

valves, and shut off the circulating pump.

en gaz et arrêtez la pompe de circulation. S'il y a risque de gel,

Drain the system if subject to freezing temperatures.

vidangez l'eau du système.

FOR YOUR SAFETY, DO NOT STOR E OR USE GASOLINE

POUR VOTRE SECURITE, NE PAS ENTREPOSER NI UTILISER

OR OTHER FLAMMABLE VAPORS A ND LIQUIDS IN THE

D'ESSENCE NI D'AUTRES VAPEUR S OU LIQUIDES INFLAMMABLES

VICINITY OF THIS OR ANY OTHER APPLIANCE.

A PROXIMITE DE CET APPAREIL OU DE TOUT AUTRE APPAREIL.

Patterson-Kelley

Harsco

East Stroudsburg, PA 18301

570-476-7261

570-476-7261 www.pkboilers.com

www.pkboilers.com

OFF

Side Clearances for a Row of Boilers

Instructions d'opération de la chaudière

Operating Instructions for this

WATER FLOW

à gaz de série Modu-Fire (Canada)

P-K Modu-Fire Gas-Fired Boiler

Procédure de mise en marche de la chaudière :

GAS PRESS

Starting Boiler

1.Électricité, gaz et eau : Mettez la chaudière sous tension électrique.

1. Utilities: Turn on the electric supply to the boiler.

1. Utilities: Turn on the electric supply to the boiler. Ouvrez les robinets d'alimentation en gaz. Assurez-vous que le

Ouvrez les robinets d'alimentation en gaz. Assurez-vous que le

Open the gas supply valves. Make sure the system

système est rempli d'eau et actionnez la pompe de circulation.

LOW AIR

is filled with water and turn on the circulating pump.

2.À l'intérieur du panneau de contrôle, réglez les températures de

2. Set the desired boiler limit and operating temperatures

2. Set the desired boiler limit and operating temperatures limite et de fonctionnement aux valeurs désirées.

limite et de fonctionnement aux valeurs désirées.

inside the control panel.

3.Actionnez l'interrupteur principal. Si le voyant rouge s'allume,

3. Turn the power switch on. If a red warning indicator

ALARM

consultez le manuel d'Installation et d'Utilisation de l'appareil.

is illuminated, see the Installation & Owners Manual.

Attendez 5 minutes avant de tenter une réinitialisation de la chaudière.

Wait five minutes before attempting to reset the boiler.

Procédure d'arrêt de la chaudière :

HEAT

Boiler Shutdown

1. Turn the power switch off.

1. Désactivez l'interrupteur principal.

2. For maintenance, service, or prolonged shutdown:

2. En cas de réparation, d'opération d'entretien ou d'arrêt prolongé;

POWER

turn off the electric supply, close the gas supply

coupez l'alimentation électrique, fermez les robinets d'alimentation

valves, and shut off the circulating pump.

en gaz et arrêtez la pompe de circulation. S'il y a risque de gel,

Drain the system if subject to freezing temperatures.

vidangez l'eau du système.

FOR YOUR SAFETY, DO NOT STORE O R USE GASOLINE

POUR VOTRE SECURITE, NE PAS ENT REPOSER NI UTILISER

OR OTHER FLAMMABLE VAPORS AN D LIQUIDS IN THE

D'ESSENCE NI D'AUTR ES VAPEURS OU LIQUIDES INFL AMMABLES

VICINITY OF THIS OR AN Y OTHER APPLIANCE.

A PROXIMITE DE CET APPAREIL OU DE TOUT AUTRE APPAREIL.

Patterson-Kelley

Harsco

East Stroudsburg, PA 18301

570-476-7261

570-476-7261 www.pkboilers.com

www.pkboilers.com

OFF

Instructions d'opération de la chaudière

Operating Instructions for this

WATER FLOW

à gaz de série Modu-Fire (Canada)

P-K Modu-Fire Gas-Fired Boiler

Procédure de mise en marche de la chaudière :

GAS PRESS

Starting Boiler

1.Électricité, gaz et eau : Mettez la chaudière sous tension éle ctrique.

1. Utilities: Turn on the electric supply to the boiler.

1. Utilities: Turn on the electric supply to the boiler. Ouvrez les robinets d'alimentation en gaz. Assurez-vous que le

Ouvrez les robinets d'alimentation en gaz. Assurez-vous que le

Open the gas supply valves. Make sure the system

système est rempli d'eau et actionnez la pompe de circulation.

LOW AIR

is filled with water and turn on the circulating pump.

2.À l'intérieur du panneau de contrôle, réglez les températures de

2. Set the desired boiler limit and operating temperatures

2. Set the desired boiler limit and operating temperatures limite et de fonctionnement aux valeurs désirées.

limite et de fonctionnement aux valeurs désirées.

inside the control panel.

3.Actionnez l'interrupteur principal. Si le voyant rouge s'allume,

3. Turn the power switch on. If a red warning indicator

ALARM

consultez le manuel d'Installation et d'Utilisation de l'appareil.

is illuminated, see the Installation & Owners Manual.

Attendez 5 minutes avant de tenter une réinitialisation de la chaudière.

Wait five minutes before attempting to reset the boiler.

Procédure d'arrêt de la chaudière :

HEAT

Boiler Shutdown

1. Turn the power switch off.

1. Désactivez l'interrupteur principal.

2. For maintenance, service, or prolonged shutdown:

2. En cas de réparation, d'opération d'entretien ou d'arrêt prolongé;

POWER

turn off the electric supply, close the gas supply

coupez l'alimentation électrique, fermez les robinets d'alimentation

valves, and shut off the circulating pump.

en gaz et arrêtez la pompe de circulation. S'il y a risque de gel,

Drain the system if subject to freezing temperatures.

vidangez l'eau du système.

FOR YOUR SAFETY, DO NOT STORE OR USE GASOLINE

POUR VOTRE SECURITE, NE PAS ENTREPOSER NI UTILISER

OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE

D'ESSENCE NI D'AUTRES VAPEUR S OU LIQUIDES INFLAMMABLES

VICINITY OF THIS OR AN Y OTHER APPLIANCE.

A PROXIMITE DE CET APPAREIL OU DE TOUT AUTRE APPAREIL.

Patterson-Kelley

Harsco

East Stroudsburg, P A 18 30 1

570-476-7261

570-476-7261 www.pkboilers.com

www.pkboilers.com

OFF

† "C" dimension includes clearance to remove the burner. Do not put pipes, ducts, etc. in this area above the boiler.

* CSA minimum. Actual clearance depends upon venting requirements.

** Service access need be only on one side of a boiler or row of boilers. Boilers may be installed immediately adjacent to each other. However, P-K recommends this clearance between

each boiler

when there is insufficient access at the rear to allow for service and adjustment.

3.4

ELECTRICAL CONNECTIONS

All field wiring connections for power and controls are in the junction box on the back of the boiler. The boiler wiring label is attached to the inside front door of the boiler. An external electrical disconnect (not supplied with the boiler) with adequate overload protection is required. The boiler must be 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 and in Canada, wire according to the current Canadian Electrical Code.

Recommended Service Clearances

A B C† D

30 24* 24 24**

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation

Notice: A dedicated earth ground (green wire) is

required to avoid nuisance shutdowns. Do not ground through the conduit. It is also important that proper polarity be maintained.

START

120VAC

INTERLOCK

OUTDOOR SETPOINT

SEE INSTALLATION & OWNER'S MANUAL FOR RATINGS AND DESCRIPTIONS

ALARM

120VAC

OVERRIDE

PUMP ENABLE

INDICATOR

BOILER RUN

DRY CONTACT

WITH DELAY OFF

ALL LIMIT POINTS

FLAME FAILURE

ALARM 120VAC

PILOT DUTY ONLY

1912345678910 1112131415161718

START

120VAC

CUTOFF

AUXILIARY

INTERLOCK

LOW WATER

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HEADER SENSOR

OUTDOOR AIR

SENSOR

ANALOG INPUT

DIRECT DRIVE

4 - 20 mA

ANALOG OUTPUT

0 - 10 V

Boiler Electrical Connections

The junction box at the rear of the boiler contains terminal strips for power and control connections. These connections are described as follows:

Power Terminal Block

The boiler power circuit requires 208-240 volts, single phase, 60 hertz, with a dedicated neutral for the control circuit as labeled. The voltage from each line (L1, L2) to the neutral must be approximately 115V AC. The 1500 & 2000 series boilers require less than 12 amps. Before starting the boiler, check to ensure that the proper voltage and amperage are connected to the boiler and that the boiler is connected to a suitable fused disconnect switch.

High Voltage (HV) Strip

#1 Start Interlock – Use for boiler enable. Closing

this circuit allows the boiler to run. Opening this circuit prevents the boiler from running, provided the remote/local enable switch is in the remote position. This circuit is energized by the boiler. It has a 120VAC potential. Devices connected to these terminals must be rated for 120VAC and 5 Amps.

WARNING: The remote/local switch bypasses the #1 start interlock when in the local position. Do not connect safety devices into #1 start interlock

Outdoor Air Override – Use for override of out-

door air schedule. Closing this circuit overrides the outdoor air reset schedule to a fixed setpoint. Opening this circuit allows the control to reset the setpoint based on outdoor air temperature when in outdoor air reset mode. This circuit is energized by the boiler. It has a 120VAC potential. Devices connected to these terminals must be rated for 120VAC.

Pump Enable w/Delay Off - This contact closes

when there is a call for heat. When the call for heat is removed, the contact remains closed for a period of time. Dry contact with a 120VAC 1 Amp max rating. (See 3.12.1)

All Limit Points Alarm (ALPA) – Pilot duty alarm

contact that is closed if the boiler does not start within five minutes of receiving a call for heat. Dry contact with a 120VAC 1 Amp max rating.

Boiler Run Indicator – This contact closes when

the flame is on. Dry contact 120VAC 1 Amp max rating.

Flame Failure Alarm – Alarm output from the

flame safeguard control. This circuit is energized by the boiler. It has a 120VAC potential with a max rating of 1 Amp.

Auxiliary Low Water Cutoff – These terminals are

used for connection of a low water cutoff. This circuit is energized by the boiler. It has a 120VAC potential. Devices connected to these terminals must be rated for 120VAC and 5 Amps.

#2 Start Interlock - Use for additional field safety

device to close this circuit. Closing this circuit allows the boiler to run. Opening this circuit prevents the boiler from running. This circuit is energized by the boiler. It has a 120VAC potential. Devices connected to these terminals must be rated for 120VAC and 5 Amps.

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation

Low Voltage (LV) Strip

Header Sensor – Connected when a header sensor

is used. The temperature control should be in Mode 2 or 5. The sensor is available from the local P-K Representative.

Outdoor Air Sensor – Location for outdoor air sen-

sor wires to be connected. The temperature control should be in Mode 4 or 5. The sensor is available from the local P-K Representative.

Analog Input Direct Drive – Remote signal for

controlling the boiler firing rate directly. Input 4-20 mA signal only. The temperature control should be in Mode 6. (See 3.12.1)

Analog Output – Boiler output 0-10VDC, indicat-

ing approx firing rate/modulation percentage of the burner.

3.5

COMBUSTION AIR

Combustion air must be free from dust, lint, etc. The presence of such materials in the air supplied to the burner could cause nuisance "Low Air" shutdowns or premature burner failure. The boiler should not be operated during construction while the possibility of drywall dust, demolition dust, etc. exists.

Provisions for combustion and ventilation air must be in accordance with the National Fuel Gas Code, ANSI Z223.1, Section 8.3, latest edition, or applicable provisions of the local building codes. The formula is "1 sq. in. per 1,000 Btu/hr of gas input not less than 100 sq. in." The location shall be "neither more than 18 inches, nor less than 6 inches above the floor level."

In Canada, combustion air openings shall comply with CSA B149.

The boiler room shall be provided with two openings to ensure adequate combustion air and proper ventilation. One opening should be 6 to 12 inches above the floor and the other 6 to 12 inches below the ceiling, preferably on opposite walls. The size of each opening is determined by whether air is taken from inside or outside the building. In Canada, ventilation air openings shall be at least 10% of

the cross sectional area required for combustion air, but not less than 10 square inches. It is to be located at the highest practical point communicating with outdoors.

If air is taken directly from outside the building, each opening should have a net free area of 1 square inch for each 4,000 Btu per hour of total boiler input. For instance, 300 square inches (2-1/12 square feet) are required for 1,200,000 Btu per hour input.

When air is taken from the outdoors through a vertical duct, 1 square inch per 4,000 Btu per hour is required. If a horizontal duct is used, 1 square inch per 2,000 Btu per hour is required, i.e., 600 square inches for 1,200,000 Btu per hour input.

If air is taken from another interior space, each opening should have a net free area of 1 square inch for each 1,000 Btu per hour of boiler input (i.e. 1,200 square inches for a 1,200,000 Btu/Hr boiler.)

WARNING!

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.

The combustion air supply must be completely free of chemical fumes which may be corrosive when burned in the boiler. Common chemicals which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as freon, trichlorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the boiler tubes, tube sheets, flue collectors and the boiler vent. The result is improper combustion and premature boiler failure.

3.5.1 Sealed Combustion

The boilers are also certified for operation with a sealed combustion air system. Such a system employs a sealed combustion air intake duct leading from outdoors to the boilers. Air flow through the system is maintained by the fan inside the boiler assembly. Typical installations utilize through the

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation

wall or through the roof routing for the supply of combustion air through a duct. It is important to locate the intake duct in such a way that it does not become blocked due to snow, ice, and other natural or man-made obstructions.

3.5.2 Intake Duct Materials and Sizes:

Material: PVC, CPVC (Schedule 40), single wall galvanized steel, or other suitable materials. The intake duct must be sized for a maximum pressure drop of 0.50 inches W.C. at 500 SCFM. The installation of a bird screen on the intake termination is recommended.

3.5.3 Sealing the Intake Duct

Proper sealing of the intake ductwork is necessary to prevent infiltration of air from conditioned spaces. Joints in PVC or CPVC must be cemented. For galvanized duct, wrap each joint and seam with adhesive aluminum tape.

3.5.4 Intake Duct Connection to Boiler

Connect the air supply duct to the collar on the back of the boiler. This collar is 7-7/8” OD. Fasten the duct to the collar with sheet metal screws at 90º angles. Wrap the joint with adhesive aluminum tape.

3.5.5 Intake/Exhaust Layout

A variety of configurations for the intake/exhaust

may be used.

Refer to Section 3.6.5 for required

clearances for all terminations. The inlet and/or

exhaust may be routed through the building sidewall and/or the roof.

To prevent the possible recirculation of flue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building configurations, etc. P-K cannot be responsible for the effects such adverse conditions may have on the operation of the boilers. Dimensions specified in this document are minimum clearances, and may or may not be sufficient for conditions at a specific job site.

3.6

VENTING (STACK)

This boiler requires a special vent system.

This

boiler is not certified for use with Type "B" vent.

This boiler is a Category IV appliance as defined

in ANSI Z21.13/CSA 4.9, latest edition. The vent material must be listed Category IV vent pipe (316L or AL29-4C Stainless Steel) and comply with UL 1738 or UL 103. In Canada it must comply with ULC-636. The exhaust vent can be run horizontally or vertically.

Vent installations shall be in accordance with the National Fuel Gas Code, ANSI Z223.1, Part 10 or CSA B.149 code, or applicable provisions of the local building codes.

The venting system and the horizontal portions of the venting system shall be supported to prevent sagging.

The vent must be sized according to the vent manufacturer’s recommendations. Consult your

vent supplier for correct sizing and structural support requirements. Design calculations should be based on a back pressure of 1.0 inches w.c. frictional resistance in the vent with a stack temperature of 325° F (gross) and a CO

level of 8.5% (natural

gas) or 9.9% (propane). These values are to be used for vent sizing calculations. The maximum certified back pressure allowable is 2.0 inches w.c. frictional resistance.

The boiler has an 8” OD connection for the vent. This connection may be reduced to 6” diameter provided the above backpressure conditions are met. A reducer is available from the factory for this purpose. Additional care must be used with sidewall venting as the exhaust velocity is high and the exhaust gas plume may extend significantly beyond the termination.

In addition to the information provided in this manual, visit the Gas Appliance Manufacturers Association’s (GAMA) web site (www.gamanet.org) for a series of flash videos explaining the proper selection and installation of venting systems for gas appliances.

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation

3.6.1 Venting Components

The connection from the boiler to the vent should be made using an adapter that is designed to fit the OD of the boiler outlet. The vent manufacturer’s adapter must be sealed to the boiler outlet with sealant listed for use with the vent material. The first turn from horizontal to vertical should be made with a tee. A tee cover with a condensate drain shall be provided at the bottom of the tee. The condensate drain line from the boiler must be connected to the stack drain upstream of the stack trap using stainless steel tubing or piping. The stack trap shall have a minimum height of 4 inches. The condensate must be routed to a suitable drain that complies with all local codes.

WARNING! The boiler condensate drain line can get as hot as the stack. This may be up to 400ºF. This line should be insulated to prevent thermal injury or burns.

WARNING! Do NOT use copper or plastic for the boiler condensate line, as these may fail and allow exhaust gas to leak into the room.

Building Sidewall

Pitch Towards Boiler

”

Bird Screen Not Recommended

3.6.2 Barometric Damper

WARNING! Do not use a barometric damper with this

boiler. (This is a positive pressure system; combustion gas may leak into the room.)

3.6.3 Automatic Vent Damper

WARNING!

This equipment MUST NOT be used with an auto-

matic vent damper.

3.6.4 Flue Connection

The connection from the boiler 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. Provisions must be made for supports to prevent contact of the vent with combustible surfaces.

This boiler operates under a positive vent pressure. Do not connect any portion of the vent system of this boiler into a vent system operating under natural draft.

Notice: Make sure that the weight of the vent is not supported

by the boiler vent collar. The collar is not designed to support the weight of the vent. Structural support and spacing from combustible surfaces must be in accordance with the vent manufacturer's requirements.

3.6.5 Clearances

Provide clearances between combustion air intake, exhaust vent, roof and window and snow line as shown in the following diagrams. The exhaust vent termination must not be less than 7 feet above grade in accordance with ANSI Z221 (NFPA 54), section

10.3.4.6, 2002 edition. The exhaust may not be

Boiler Outlet

8” OD

Tee/Boot Tee w/Drain

vented directly above a public walkway per section

Boiler Condensate Drain (stainless steel)

Stack Drain w/Trap 4” min height

10.8.4 of the above standard. It must also have a minimum 6 foot horizontal and 6 foot vertical clear-

ance (above or below) any electric meters, gas

MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation

meters, regulators, or relief equipment. See the diagrams on this page to further illustrate clearance requirements.

WARNING!

Do not locate intake or exhaust terminations directly above a walkway; dripping of condensation can cause icing of the walking surface.

Mechanical draft vent

12 in. min.

terminal

Grade

Forced

air inlet

Direct vent terminal clearance minimum 12 in.

4 ft. min.

12 in. min.

12 in.

min

Mechanical draft

vent terminal

4 ft. min

Reference: ANSI Z223.1 – 2002

Air Inlet and Venting Installations

3.6.6 Vent Terminations

P-K does not recommend the use of a vent cap. A screen termination is not recommended due to the possibility of ice formation on the screen. Rain is actually beneficial to the vent internals.

If less than 10 ft. then

↓

3 ft. min.

The minimum vent height should extend at least 3 feet above the roof, or at least 2 feet above the highest part of any structure within 10 feet of the vent.

Combustion

Air Inlet

d < 10'.

3' min.

Flue Gas

Outlet

If the exhaust vent terminates within 10 ft. horizontally of the air inlet, the exhaust vent must be at least 3 ft. above the inlet. Dimensions listed above and those illustrated are minimum, and may or may not be sufficient for conditions at a specific job site.

To prevent the possible re-circulation of flue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building configurations, etc. P-K cannot be responsible for the effects such adverse conditions may have on the operation of the boilers. It is important to locate the exhaust duct in such a way that it does not become blocked due to snow, ice, and other natural or manmade obstructions.

Thru the roof

Thru the Wall

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