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PATTERSON-KELLEY
THERMIFIC
MODU-FIRE® 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
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
Installation Date:
_______________________
100 Burson Street, P.O. Box 458,
East Stroudsburg, PA 18301
Telephone: (877) 728-5351, Facsimile: (570) 476-7247
www.pkboilers.com
®
MOD-04
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Related Manuals for Patterson-Kelley MOD-04
Summary of Contents for Patterson-Kelley MOD-04
- Page 1 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 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 Installation Date: _______________________ 100 Burson Street, P.O.
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Page 2: Table Of Contents
3.6.3 Automatic Vent Damper ... 8 3.6.4 Flue Connection ... 8 3.6.5 Vent Termination ... 8 3.6.6 Removing an Existing Boiler ... 9 3.7 Gas Piping ... 9 3.7.1 Gas Supply Piping by Installer ... 11 3.7.2 Gas Bleeds and Vents by Installer ... 11 3.8 Boiler Water Piping ... - Page 3 The same features which permit this boiler to achieve high-efficiency performance make it unlike most other boilers of this general size, so it is im- portant to understand how this boiler operates.
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Page 4: Introduction
Patterson-Kelley cannot be re- sponsible for the design or operation of such sys- tems and a qualified engineer or contractor must be consulted. -
Page 5: Safety Labels
Reorder No. 5025-V1WHPK The safety labels shown above are 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 S AFETY RECAUTIONS Provide a suitable location for the boiler, away from... -
Page 6: Crush Hazards
• 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 •... -
Page 7: Pressure Hazards
1998 HCS, Inc. 800-748-0241 • 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 for proper operation. -
Page 8: Installation
3.3.2 Placement The boiler must be level to function properly. To as- sist in leveling the boiler, the four (4) leg bolts (1/2"- NC) holding the boiler to the shipping skid must be reinstalled in the threaded legs on the bottom. The... -
Page 9: Clearances
* CSA minimum. Actual clearance depends upon stacking requirements. ** Service access need be only on one side of a boiler or row of boilers. Boilers may be installed immedi- ately adjacent to each other. However, P-K recom-... -
Page 10: Combustion Air
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. -
Page 11: Vent Elbows
It is not necessarily the same size as the boiler connection. Correct sizing should be based on High fire input at a nominal -.04" w.c. draft pres- sure at the boiler outlet with a gross stack temp of 325º F and CO ratings at 7.5%. -
Page 12: Removing An Existing Boiler
At the time of removal of an existing boiler, while the other appliances remaining connected to the common venting system are not in operation, the following... - Page 13 3.068 7.67 4.026 10.1 on the boiler. Gas piping should be installed in accor- dance with National Fuel Gas Code, ANSI Z223.1, latest edition, and any other local codes which may apply; in Canada see CAN/CGA-B 149. Note: See chart below for required pipe size, based on overall length of pipe from meter plus equivalent length of all fittings.
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Page 14: Gas Supply Piping By Installer
1/2 psig (14 inch w.c.). During any pressure testing of the gas supply piping system at pressures equal to or less than 1/2 psig (14 inch w.c.), the boiler should be isolated from the gas supply piping system by closing the manual shut- off. -
Page 15: Boiler Inlet And Outlet Connections
The bottom connection to the boiler is the INLET and must be used for the return from the system. The top connection to the boiler is the OUTLET and must be connected as the supply to the system. Piping must be installed such that no piping stresses are transmitted to the boiler. -
Page 16: Flushing And Filling
Filling To be sure that the boiler is not air-bound, open the pressure-relief valve located at the rear of the boiler. Leave the relief valve open until a steady flow of water is observed. -
Page 17: Safety Checks
3. Water connections are complete, and the boiler and system have been filled and purged of air. 4. The boiler must be connected to a 120 volt / 60 Hz power source with proper polarity and dedi- cated machinery ground. Provide a disconnect having adequate overload protection. -
Page 18: Test Of Low Gas Pressure Switch
3.11.4 Test of Low Gas Pressure Switch Manual Reset Gas Pressure Switch The boiler is furnished with a low gas pressure switch. The operation of this switch must be checked by slowly closing the main gas cock while the burner is operating. The switch should shut down the main burner. - Page 19 (See the configuration menu.) Display HyS1 HyS3 The setpoint of the boiler is controlled by an out- F which is Set- door temperature sensor. As the outdoor tempera- ture falls the setpoint of the boiler is increased. The boiler modulates to maintain this setpoint. The F which is boiler functions as indicated in internal setpoint;...
- Page 20 ® Modu-Fire Gas-Fired Boiler Analog Input Direct Drive The firing rate of the boiler is controlled by an ex- ternal analog signal, usually from a multiple boiler control. The boiler turns on and off as directed by the external control.
- Page 21 To change to manual operation press EXIT for 5 seconds. The LED above the hand symbol lights up. Change the firing rate of the boiler with The firing rate increases as long as The firing rate decreases as long as pressed.
- Page 22 ® Modu-Fire Gas-Fired Boiler Installation Table 1 - Table of Parameters...
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Page 23: Optional Remote Control
The configuration level must be ad- justed by factory-trained personnel only. 3.12.1B Optional Remote Control This option is used when the firing rate of the boiler is controlled by an external analog signal, usually from a multiple boiler control. The boiler turns on and off as directed by the external control. -
Page 24: Gas Pressure Adjustment
Check high fire and low fire again To adjust the gas pressure, remove the cover plate from the air / gas ratio control valve. Set the boiler at High fire as described in the boiler operation sec- tion of the manual. The High fire gas pressure is adjusted with the lower screw of the air / gas ratio control vale. -
Page 25: Operation
4.2 L IGHTING AND Do not use this boiler if any part has been under wa- ter. Immediately call factory-trained personnel to inspect the boiler and to replace any part of the con- trol system and any gas control which has been un- der water. -
Page 26: Normal Shut Down Procedures
If overheating occurs or the gas supply fails to shut off, do not turn off or disconnect the electrical sup- ply to the pump. Instead, shut off the gas supply at a location external to the boiler. 4.3 T YPICAL... -
Page 27: Maintenance
WARNING! Check daily to be sure that the boiler area is free and clear of any combustible materials, including flammable vapors and liquids. The motorized gas valves contain hydraulic oil which may be hazardous to the environment. -
Page 28: Annually
2. Inspect combustion chamber through access door on front side of boiler. To remove doors, remove fasteners, pull door forward slightly, then pull upward. Note any signs of deteriora- tion. Take corrective action as necessary. -
Page 29: Removing The Exchanger
3. Remove the top panel of the inner cabinet. 4. Close the isolation valves to the system. 5. Drain the boiler. 6. Disconnect the supply and return lines. 7. Remove the manifold assembly containing the temperature-pressure indicator, relief valve and... -
Page 30: Sequence Of Operation
2. The water flow limit switch is closed when there is water flow through the boiler. Note: The closing of this switch does not prove that flow is adequate. Refer to Technical Data Sheet # TD110 for proper flow requirements. -
Page 31: Iri Modulating
Gas-Fired Boiler 14. When the load is below the low fire rating of the boiler the boiler will continue firing and the out- let water temperature will rise until it reaches the set point + hysterises value. At this point... -
Page 32: Troubleshooting
8 of the combustion control is de-energized, closing the pilot valve. Terminal 15 is ener- gized, providing power to the modulating con- trol of the boiler. If main flame has not been es- tablished, the unit will lock out on main flame failure. - Page 33 ® Modu-Fire Gas-Fired Boiler • Check the cabinet pressure for a minimum of 0.3" w.c. • Check burner is clean (refer to Section 5.2). Ignition Failure In the event the pilot flame is not detected by the UV scanner during the 10 second trial-for-ignition period (Step 9), the pilot gas valve and spark igni- tion are de-energized.
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Page 34: Parts/Technical Support
Gas-Fired Boiler 6.0 PARTS/TECHNICAL SUPPORT Spare parts and replacement parts can be ordered from your local representative or Patterson-Kelley by calling (570) 476-7261 or Toll Free (877) 728- 5351. The fax number is (570) 476-7247. Refer to the parts list shown on the assembly drawing pro- vided with this manual. - Page 35 ® Modu-Fire Gas-Fired Boiler Standard Unit - Local Control - Logic Diagram Parts/Technical Support ALARM SAFEY FLAME INTERLOCK START INTERLOCK START...
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Page 36: Standard Unit - Remote Control - Logic Diagram
® Modu-Fire Gas-Fired Boiler Standard Unit - Remote Control - Logic Diagram Parts/Technical Support INPUT ANALOG ALARM SAFEY FLAME INTERLOCK START INTERLOCK START... -
Page 37: Standard Unit - Local & Remote Control - Logic Diagram
® Modu-Fire Gas-Fired Boiler Standard Unit - Local & Remote Control - Logic Diagram Parts/Technical Support INPUT ANALOG ALARM SAFEY FLAME INTERLOCK START INTERLOCK START... -
Page 38: Standard Unit - Local & Remote Control W Options - Logic Diagram
® Modu-Fire Gas-Fired Boiler Standard Unit - Local & Remote Control w Options - Logic Diagram Parts/Technical Support INPUT DELAY ANALOG PUMP ALARM POINTS LIMIT ALARM RANGE SETPOINT SETPOINT ALTERNATE ALARM SAFEY FLAME TEMPERATURE OUTDOOR INTERLOCK START SETPOINT INPUT INTERLOCK... -
Page 39: Iri Unit - Local Control - Logic Diagram
® Modu-Fire Gas-Fired Boiler IRI Unit - Local Control - Logic Diagram Parts/Technical Support ALARM SAFETY FLAME INTERLOCK START INTERLOCK START... -
Page 40: Iri Unit - Remote Control - Logic Diagram
® Modu-Fire Gas-Fired Boiler IRI Unit - Remote Control - Logic Diagram Parts/Technical Support INPUT ANALOG ALARM SAFETY FLAME INTERLOCK START INTERLOCK START... -
Page 41: Iri Unit - Local & Remote Control - Logic Diagram
® Modu-Fire Gas-Fired Boiler IRI Unit - Local & Remote Control - Logic Diagram Parts/Technical Support INPUT ANALOG ALARM SAFETY FLAME INTERLOCK START INTERLOCK START... -
Page 42: Iri Unit - Local & Remote Control W Options - Logic Diagram
® Modu-Fire Gas-Fired Boiler IRI Unit - Local & Remote Control w Options - Logic Diagram Parts/Technical Support INPUT DELAY ANALOG PUMP ALARM POINTS LIMIT ALARM RANGE SETPOINT SETPOINT ALTERNATE ALARM SAFETY FLAME TEMPERATURE OUTDOOR INTERLOCK START SETPOINT INPUT INTERLOCK... -
Page 43: Standard Unit - Panel Layout
® Modu-Fire Gas-Fired Boiler Parts/Technical Support Standard Unit – Panel Layout... -
Page 44: Iri Unit - Panel Layout
® Modu-Fire Gas-Fired Boiler Parts/Technical Support IRI Unit – Panel Layout... -
Page 45: Boiler Parts List
® Modu-Fire Gas-Fired Boiler 6.2 B OILER ARTS 6.2.1 Main Assembly Part Mixer Core, Burner (Inside Cabinet) Burner Orifice (Inside Cabinet) Spark Igniter Electrode UV Scanner Thermowell w/Clamp Electrode Assembly w/Mica (Inside Cabi- net) Pilot Tube (Inside Cabinet) Burner (Inside Cabinet) Heat Exchanger 10. -
Page 46: Control Panel
® Modu-Fire Gas-Fired Boiler 6.2.2 Control Panel Circuit Breaker Forced Recycle Time Delay Relay Part Thermostat (Manual Re- set) Thermostat (Oper. Temp) Air Flow Switch Motor Start Relay Terminal Block, Neutral Terminal Block, Power Relays and Sockets Local Control Panel... - Page 47 ® Modu-Fire Gas-Fired Boiler Circuit Breaker Forced Recycle Time Delay Relay Part Thermostat (Manual Re- set) Thermostat (Oper. Temp) Air Flow Switch Motor Start Relay Terminal Block, Neutral Terminal Block, Power Relays and Sockets Remote Control Panel Part Flame Safeguard Pro-...
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Page 48: Gas Trains
® Modu-Fire Gas-Fired Boiler 6.2.3 Gas Trains 6.2.3.1 Standard Gas Train - 1000 Part Main Gas Shutoff Cock Main Gas Valve Actuator Main Gas Valve Air/Gas Ratio Control Low Gas Pressure Switch High Gas Pressure Switch Leak Test Valve Pilot Gas Cock... - Page 49 ® Modu-Fire Gas-Fired Boiler 6.2.3.2 Standard Gas Train - 1500 & 2000 Part Main Gas Shutoff Cock Main Gas Valve Actuator Main Gas Valve Air/Gas Ratio Control Low Gas Pressure Switch High Gas Pressure Switch Leak Test Valve Pilot Gas Cock...
- Page 50 ® Modu-Fire Gas-Fired Boiler 6.2.3.3 IRI Gas Train - 1000 Part Main Gas Shutoff Cock Main Gas Valve Actuator Main Gas Valve Air/Gas Ratio Control Low Gas Pressure Switch High Gas Pressure Switch Leak Test Valve Normally Open Vent Valve...
- Page 51 ® Modu-Fire Gas-Fired Boiler 6.2.3.4 IRI Gas Train - 1500 & 2000 Part Main Gas Shutoff Cock Main Gas Valve Actuator Main Gas Valve Air/Gas Ratio Control Low Gas Pressure Switch High Gas Pressure Switch Leak Test Valve Normally Open Vent Valve...
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Page 52: Cabinet
® Modu-Fire Gas-Fired Boiler 6.2.4 Cabinet Internal Cabinet 10. Control Panel, Cover 11. Control Panel, Sub Panel 12. Control Panel, Base Assy. 1000 - External Cabinet Part Exterior Cabinet, Assy. Exterior Cabinet, Door Exterior Cabinet, Top Sight Glass Sight Glass Bezel Combustion Chamber, Assy. -
Page 53: Limited Warranty
Installation is not included. Warranty - The owner must notify the original installer of the Product and Seller (Attention: Patterson-Kelley Co, Box 458, East Stroudsburg, PA 18301), in writing, within the Warranty Period, providing a detailed description of all claimed defects. - Page 54 Additional Comments: Volts Volts BLUE Please return a copy to P-K, ATTN: Boiler Tech. Support Department Patterson-Kelley • 100 Burson Street • E. Stroudsburg, PA 18301 gpm flow through boiler b. Bias Setting c. Ratio Setting Ft. Horizontal Ft. Vertical...