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INSTALLATION INSTRUCTIONS
HANG THESE INSTRUCTIONS IN VICINITY OF BOILER
PEERLESS ATMOSPHERIC
GAS BOILERS
INSTALLATION
AND
OPERATING INSTRUCTIONS
MOD–U–PAK
SYSTEM
CONTROL SETS
No. 1 - PROPORTIONAL WATER TEMPERATURE CONTROL W/ SUPPLY OR RETURN
WATER TEMPERATURE SENSOR
No. 2 - PROPORTIONAL WATER TEMPERATURE CONTROL W/ OUTDOOR RESET
No. 3 - PROPORTIONAL STEAM PRESSURE CONTROL W/ STEAM PRESSURE
SENSOR
GG8027 R11 (7/07-6C)
Printed in U.S.A.
PB HEAT, LLC
NEW BERLINVILLE, PA 19545-0447
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MOD–U–PAK CONTROL SYSTEM
WATER BOILERS
PROPORTIONAL WATER TEMPERATURE CONTROL W/OUTDOOR RESET (CONTROL SET NO. 2)
1 – DESCRIPTION
This Mod-U-Pak System is a proportional system in which boiler water temperature and boiler gas input are modulated proportionately to changes in outside temperature.
For maximum comfort the boiler-water temperature varies inversely to the change in outside temperature; that is, as the outside temperature increases or decreases, the boiler water temperature decreases or increases correspondingly.
For maximum performance the input to the boiler is varied inversely to the change in outside temperature; that is, as the heating load
requirement changes due to an increase or decrease in outside temperature the gas input to the boiler decreases or increases
respectively.
Three controls are used to accomplish the modulating sequence: an indoor-outdoor reset control, and two dual-acting temperature
controllers. The indoor-outdoor control maintains and modulates the boiler water temperature in accordance with a change in outside
temperature; that is, as the outside temperature varies, the temperature setting of the control automatically changes, thus raising or
lowering the boiler water temperature. The dual-acting temperature controllers vary the gas input to the boiler by sensing a change in
outside temperature and thus opening or closing the three main automatic operating valves. The first gas valve flow circuit incorporates an orifice which provides 50% of the maximum flow rate, the second valve flow circuit incorporates an orifice which provides
75% of the maximum flow rate, and the third valve delivers 100% of the maximum flow rate.
2 – STANDARD CONTROLS
1–Honeywell T475A Outdoor Reset Control
2–Honeywell T675A Temperature Controllers
2–Element Guards for T675A Controllers
2–Split-Plugs for T675A Controllers
1–DP-ST Bypass Disconnect Switch
NOTE: Element guard and split-plug are provided with the T475A as part of the package.
3 – CONTROL INSTALLATION
When installing the T475A Outdoor Reset Control or the T675A Temperature Controllers, follow the manufacturer’s installation instructions supplied with the appropriate control. These instructions cover the proper mounting of the control, sensing element and element
guard.
4 – WIRING
All wiring must be done in accordance with the current National Electrical Code and local codes. Refer to wiring diagrams in rear of
booklet for correct wiring of controls. Contact PB Heat, LLC for application of controls, ignition systems or codes not covered by these
wiring diagrams.
5 – TEMPERATURE CHARTS
The following charts will enable you to set the controls under various design conditions. The charts are based on outside design temperatures of 0°F, -10°F, and -20°F with an indoor temperature of 70°F. The ratio setting of the T475A outdoor reset control is recommended as 1 to 1; that is, as the outdoor temperature varies 1°F the boiler water temperature will vary 1°F. Maximum boiler water temperature is assumed to be 180°F. If other maximum boiler water temperatures are desired, start at the outdoor design temperature,
such as 0°F, and reduce the water temperature 5°F for each increment of 5°F rise in outdoor temperature.
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a. 0°F OUTDOOR DESIGN TEMPERATURE:
BOILER
OUTDOOR INPUT WATER
TEMP. °F % TEMP. °F
70 50 110
65 50 115
60 50 120
55 50 125
50 50 130
45 50 135
40 50 140
35 75 145
30 75 150
25 75 155
20 100 160
15 100 165
10 100 170
5 100 175
0 100 180
Setting of #1 T675A Temperature Controller — 35°F
Setting of #2 T675A Temperature Controller — 20°F
Setting of T475A Outdoor Reset Control — 110°F
b. -10°F OUTDOOR DESIGN TEMPERATURE:
BOILER
OUTDOOR INPUT WATER
TEMP. °F % TEMP. °F
70 50 100
65 50 105
60 50 110
55 50 115
50 50 120
45 50 125
40 50 130
35 50 135
30 75 140
25 75 145
20 75 150
15 75 155
10 100 160
5 100 165
0 100 170
– 5 100 175
– 10 100 180
Setting of #1 T675A Temperature Controller — 30°F
Setting of #2 T675A Temperature Controller — 10°F
Setting of T475A Outdoor Reset Control — 100°F
c. -20°F OUTDOOR DESIGN TEMPERATURE:
BOILER
OUTDOOR INPUT WATER
TEMP. °F % TEMP. °F
70 50 90
65 50 95
60 50 100
55 50 105
50 50 110
45 50 115
40 50 120
35 50 125
30 50 130
25 75 135
20 75 140
15 75 145
10 75 150
5 100 155
0 100 160
– 5 100 165
– 10 100 170
– 15 100 175
– 20 100 180
Setting of #1 T675A Temperature Controller — 25°F
Setting of #2 T675A Temperature Controller — 5°F
Setting of T475A Outdoor Reset Control — 90°F
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6 – OPERATING SEQUENCE
TO START
a. Refer to Lighting Instructions on boiler and ignite pilot(s), if necessary.
b. With pilot(s) proven, close main line power switch, set all safety interlocks with contacts closed and open main manual shut-off
gas valve.
c. Set outdoor reset control and outdoor temperature controllers to desired settings.
d. Close bypass disconnect switch, adjust gas manifold pressure to required setting at 100% input rate (Natural
Gas - 3.5” W.C./ LP Gas - 10” W.C.) and check main burner operation.
e. When all necessary adjustments are completed, open bypass disconnect switch for automatic operation.
OPERATION
a. First Stage:
Outdoor reset control activates the “A” valve(s) (50% Rate) through contacts “R” and “W” of the #1 temperature controller.
The main burners will continue to operate until the outdoor reset control is satisfied.
The 50% input rate will be maintained until the outdoor air temperature drops to 1°F below the setting of the #1 temperature
controller.
b. Second Stage:
When the outdoor air temperature drops to 1°F below the setting of the #1 temperature controller contacts “R” and “B” make,
closing the “A” valve(s).
The outdoor reset control activates the “B” valve(s) (75% Rate) through contacts “R” and “B” of the #1 temperature controller
and “R” and “W” of the #2 temperature controller.
The main burners will continue to operate until the outdoor reset control is satisfied.
The second stage or 75% input rate will be maintained until the outdoor air temperature drops to 1°F below the setting of the
#2 temperature controller.
c. Third Stage:
When the outdoor air temperature drops to 1°F below setting of the #2 temperature controller contacts “R” and “B” make,
closing the “B” valve(s).
The outdoor reset control activates the “C” valve (100% Rate) through contacts “R” and “B” of both #1 and #2 temperature
controllers. The main burners will continue to operate until the outdoor reset control is satisfied.
The sequence of operation is in reverse as the outside air temperature rises. The actuating points of the temperature controllers
will be at the set-point.
TO SHUT DOWN
To shut down the boiler, open main disconnect switch and close main manual shut-off gas valve.
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MOD–U–PAK CONTROL SYSTEM
WATER OR STEAM BOILERS
PROPORTIONAL WATER TEMPERATURE CONTROL
W/SUPPLY OR RETURN WATER TEMPERATURE SENSOR (CONTROL SET NO. 1)
or
PROPORTIONAL STEAM PRESSURE CONTROL
W/STEAM PRESSURE SENSOR (CONTROL SET NO. 3)
1 – DESCRIPTION
This Mod-U-Pak System is a proportional system in which boiler gas input is modulated proportionately to changes in load conditions.
For maximum performance, the input to the boiler is varied to the change in the heating load requirements within the range of 50% to
100% of input.
Three controls are used to accomplish the modulating sequence: an operating control and two dual-acting temperature controllers for
water boilers or pressure controllers for steam boilers. The operating control maintains the designed boiler water temperature or steam
pressure. The dual acting temperature or pressure controllers vary the gas input to the boiler by sensing a change in heating load
requirements, thus opening or closing the three automatic modulating gas valves. The low rate gas valve flow circuit incorporates an
orifice which provides 50% of the maximum flow rate, the medium rate gas valve flow circuit incorporates an orifice which provides
75% of the maximum flow rate, and the full rate gas valve provides 100% of the maximum flow rate.
2 – STANDARD CONTROLS
Water Boilers
1–Honeywell L4006A Operating Control
2–Honeywell L6006A Dual Acting Temperature Controllers
1–DP-ST Bypass Disconnect Switch
Steam Boilers
1–Honeywell L404F Operating Control
2–Honeywell L404F Dual Acting Pressure Controllers
1–DP-ST Bypass Disconnect Switch
3 – CONTROL INSTALLATION
When installing the operating control and dual acting controllers, they are generally located in the main supply header. The dual acting
temperature controllers can be located in the return piping.
4 – WIRING
All wiring must be done in accordance with the current National Electrical Code and local codes. Refer to wiring diagrams in rear of
booklet for correct wiring of controls. Contact PB Heat for application of controls, ignition systems or codes not covered by these
wiring diagrams.
5 – TEMPERATURE PRESSURE CHART
The following chart will enable you to set the controls under various design conditions. The chart is based on water temperatures or
steam pressure and can be varied depending on the requirements of each operating condition.
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TEMPERATURE - PRESSURE CHART
WATER BOILERS
CONTROL SET NO. 1
CONTROL NO. 1 CONTROL NO. 2
Design Operating R - B Breaks R - W Breaks R - B Breaks R - W Breaks
Temp. Control R - W Makes R - B Makes R - W Makes R - B Makes
°F °F °F °F °F °F
220 230 220 215 210 205
210 220 210 205 200 195
200 210 200 195 190 185
180 200 180 175 170 165
NOTES:
1—Set high limit control 10°F above the operating control setting.
2—Staging Controls - two (2) L6006A w/Bypass switch for 100% input rate.
STEAM BOILERS
CONTROL SET NO. 3
CONTROL NO. 1 CONTROL NO. 2
Design Operating R - B Breaks R - W Breaks R - B Breaks R - W Breaks
Pressure. Control R - W Makes R - B Makes R - W Makes R - B Makes
psig psig psig psig psig psig
10 12 10 9 8 7
810 8 7 6 5
68 6 5 4 3
46 4 3 2 1
NOTES:
1—Set high limit control 2 psig above the operating control setting.
2—Staging Controls - two (2) H-
L404F w/bypass switch for 100% input rate.
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6 – OPERATING SEQUENCE
TO START
a. Refer to Lighting Instructions on boiler and ignite pilot(s), if necessary.
b With pilot(s) proven, close main line power switch, set all safety interlocks with contacts closed and open main manual shut-off
gas valve.
c. Set operating control and dual acting temperature or pressure controls to desired settings.
d. Close bypass disconnect switch, adjust gas manifold pressure to required setting at 100% input rate (Natural Gas - 3.5”
W.C./LP Gas -10” W.C.) and check main burner operation.
e. When all necessary adjustments are completed, open bypass disconnect switch for automatic operation.
OPERATION
a. First Stage:
On the initial start-up of a cold boiler, the operating control opens the “C” gas valve(s) (100% rate) through contacts “R” and “B”
of both staging controls No. 1 and No. 2.
The 100% rate will be maintained until the boiler water temperature or steam pressure increases to the set point of staging
control No. 2.
b. Second Stage:
When the boiler water temperature or steam pressure reaches the set point of staging control No. 2, contacts “R” and “B” break,
closing the “C” gas valve(s).
Contacts “R” and “W” of staging control No. 2 make, opening the “B” gas valve(s) (75% rate).
The 75% rate will be maintained until the boiler water temperature or steam pressure increases to the set point of staging
control No. 1.
c. Third Stage:
When the boiler water temperature or steam pressure reaches the set point of staging control No. 1, contacts “R” and “B” break,
closing the “B” gas valve(s).
Contacts “R” and “W” of staging control No. 1 make, opening the “A” gas valve(s) (50% rate).
The 50% input rate will be maintained until the boiler water temperature or steam pressure increases to the set point of the
operating control.
On boiler water temperature or steam pressure decrease, the staging controls and gas valves will operate in reverse of the
above sequence, except that the staging controls will actuate at the set point minus the differential.
TO SHUT DOWN
To shut down the boiler, open main disconnect switch and close main manual shut-off gas valve.
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211A SERIES CONTROL SET #2
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211A SERIES CONTROL SET #1 or #3
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