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P-K STORM
™
w/ NURO
CONTROL SYSTEM
™
ST-2500, ST-3000, ST-3500 & ST-4000
Natural Gas Boilers
Part #
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
WARNING: If the information in these instructions is not followed
exactly, a fire or explosion may result causing property damage,
personal injury or death.
- 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.
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
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
GAS FIRED BOILER
2691000273
Released: June 26, 2020
©Patterson-Kelley 2020: All Rights Reserved.
design without notice and without incurring any obligation.
INSTALLATION
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INSTALLATION
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INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
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INSTALLATION
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INSTALLATION
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Related Manuals for Patterson-Kelley STORM ST-2500
Summary of Contents for Patterson-Kelley STORM ST-2500
- Page 1 ©Patterson-Kelley 2020: All Rights Reserved. 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 &...
- Page 2 P-K STORM Gas Fired Boiler Technical Service 1.877.728.5351 Safety General OTICE Each safety device must be ™ P-K STORM Boilers ST-2500, ST-3000, ST-3500, ST-4000 maintained and checked per the ™ All P-K STORM Gas-Fired Boilers must be: recommended schedule. Refer to •...
- Page 3 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...
- Page 4 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.
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Page 5: Table Of Contents
Category IV Installations ....................33 Stainless Steel Venting ..................... 33 CPVC Vent System Installation..................33 CONDENSATE DRAIN, TRAP & DISPOSAL ............... 34 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... - Page 6 AINTENANCE ....................62 EQUENCE OF PERATIONS ....................... 62 ROUBLESHOOTING Loss of Power ........................63 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page vi...
- Page 7 UPPLY ......................90 LECTRICAL OWER UPPLY ..........................90 XHAUST ENTING ........................ 92 ROPYLENE LYCOL © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page vii...
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Page 8: Introduction
Patterson-Kelley cannot be responsible for the equipment. Failure to do so could result in design or operation of such systems and a qualified personal injury or death. - Page 9 Technical Service 1.877.728.5351 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.
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Page 10: Purpose Of This Document
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. -
Page 11: Site Preparation
électrique de la pompe. Fermer plutôt le robinet d’admission de gaz à l’extérieur de l’appareil. service access, increasing the possibility of injury. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... -
Page 12: Compliance With Codes
(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. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 13: Location Setup
Anchor/Lag Bolts (REAR) NOTICE! The appliance may be installed on a combustible floor; however, the appliance must NEVER be installed on carpeting. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... -
Page 14: Clearances
** 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). © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 15: Inlet Air And Exhaust Venting Considerations
Faulty vent installation can allow toxic fumes to be released into living areas. This may cause property damage, injury, or death. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... -
Page 16: Category Ii/Iv Flue Gas Exhaust Vent Planning
ST-2500, ST-3000, (Exhaust Only) 220 °F (gross) 8.75% ST-3500, ST-4000 +0.01” to +0.4” W.C. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 7... -
Page 17: Venting Materials For Flue/Exhaust Systems
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. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 18: Required Clearances
Improper interconnection of venting systems may result in leakage of flue gases into occupied spaces. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... - Page 19 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). © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved.
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Page 20: Gas Piping Considerations
The P-K STORM 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. -
Page 21: Appliance Connections (St-2500 & St-3000)
Gas Fired Boiler Technical Service 1.877.728.5351 Appliance Connections (ST-2500 & ST-3000) All connections must be in compliance with national, state, and local code requirements. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... -
Page 22: Appliance Connections (St-3500 & St-4000)
Gas Fired Boiler Technical Service 1.877.728.5351 Appliance Connections (ST-3500 & ST-4000) All connections must be in compliance with national, state, and local code requirements. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... -
Page 23: Electrical Connections
208 VAC main voltage. Refer to Section 7.2.4 for proper wiring and configuration of the internal control transformer. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... - Page 24 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. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved.
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Page 25: High Voltage (Tb2) Terminal Block
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. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. - Page 26 NURO control. The normally-open contacts on this relay have a maximum voltage rating of 240VAC and maximum current capacity of 1/2 Amp. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved.
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Page 27: Low Voltage (Tb1) Terminal Block
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. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. - Page 28 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. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved.
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Page 29: Combustion Air
1000 1500 ST-3500 3500 7000 1167 1750 ST-4000 4000 8000 1334 1000 1000 2000 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 20... -
Page 30: Air Inlet Requirements - Canada
64,516 6,452 ST-3000 3,000,000 75,484 13.4 8,645 ST-3500 3,500,000 86,451 13.4 8,645 ST-4000 4,000,000 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 21... -
Page 31: P-K Storm ™ Combustion Air Requirements
For example, joints in PVC or CPVC piping must be cemented. For galvanized duct, wrap each joint and seam with adhesive aluminum tape or other sealant. Patterson-Kelley recommends installing a 1” x 1” or larger bird screen on the exterior termination. Ensure that the screen does not become blocked with snow, ice, insects etc. -
Page 32: Motorized Combustion Air Dampers
If the combustion air intake ductwork and the exhaust vent terminate on the same wall of NOTE: the building, they must utilize the same type of termination fitting. Patterson-Kelley recommends including a motorized combustion air damper in each NOTE: appliance’s air intake ductwork. Refer to 3.4.5... - Page 33 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx...
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Page 34: Flue Gas / Exhaust Venting
Vertical vents are allowed to be terminated with a variety of ends, including plain straight pipe, elbow, or vent tee. Horizontal vents must be terminated with an elbow or vent tee. Similarly, a bird screen with 1” x 1” openings is recommended for termination. Patterson-Kelley does not recommend using a vent rain cap of any type. -
Page 35: Vent Termination
This is illustrated in the following diagram. Additionally, the boiler vent shall terminate at least 3 ft. above a forced air inlet located within 10 ft. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 36: Venting For Multiple Boilers
In addition, Patterson-Kelley also recommends the use of motorized combustion air dampers in the combustion air intake ductwork of each individual appliance. When an appliance is offline, its combustion air damper will remain closed which will also help prevent the backflow of flue gases from online appliances. -
Page 37: Sealed Combustion/Direct Vent Systems
™ ™ STORM Category II/IV: STORM Category II/IV: Through-the-roof (exhaust only) Sidewall (exhaust only) © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 28... - Page 38 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) © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx...
- Page 39 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) © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx...
- Page 40 When terminating on the same vertical axis, the air intake must use a 90° termination and the exhaust must have a 45° termination. Must be a minimum of 36” © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved.
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Page 41: Inlet Duct Connection To Boiler
Category IV vent installations. 120VAC motorized dampers with end limit switches are available for purchase from Patterson-Kelley. Other damper motor voltages are acceptable, provided they do not exceed 120VAC. The Air Damper Interlock circuit for the end limit switch is always 120VAC which is sourced from the boiler itself. -
Page 42: Category Iv Installations
CPVC Support Spacing (Feet) Vent Size Sch. 40 Sch. 80 4-1/2 4-1/2 5-1/2 5-1/2 6-1/2 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 33... -
Page 43: Condensate Drain, Trap & Disposal
4. The condensate is slightly acidic (3-5 PH), however, local codes may require it to be neutralized prior to entering the drainage system. An optional, field installed, Condensate Neutralization System is available from Patterson-Kelley. 5. All piping from the condensate trap to the suitable drain must remain below the highest point (top of the condensate outlet pipe) on the properly attached condensate assembly. - Page 44 P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 35...
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Page 45: Removing An Existing Boiler
11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1 Natural Gas and Propane Installation Code. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 46: Piping
10 equivalent feet of length. Never connect vent piping that is smaller in size than the gas regulator’s vent port connection. This unit comes with a sediment trap (drip leg) already installed. Patterson-Kelley recommends a union connection ahead of the primary manual shutoff valve on the boiler. A gas piping schematic is shown above. -
Page 47: Pressure Testing The Gas Piping
If using soap and water or a similar leak test method, make sure to clean off all moisture from the gas pipe fittings prior to placing the appliance into service. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 48: Boiler Water Piping
EPDM Victaulic seals. prevent freezing in un-insulated spaces. Isolating valves must be installed in both the inlet and outlet water connections. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... -
Page 49: Boiler Inlet And Outlet Connections
All water connections should be in compliance with national, state, and local code requirements. Adapters from Victaulic to NPT are available from Patterson-Kelley. The bottom rear connection to the boiler is the INLET and must be used for the return from the system. The top rear connection to the boiler is the OUTLET and must be connected as the supply to the system. -
Page 50: Water Quality
The condensate is acidic (pH between 3.0 and 5.0) and may be corrosive to some building drain systems. A condensate neutralization system may be required and is available from Patterson-Kelley. If the condensate drainage system is exposed to freezing temperatures, it must be field heat traced. The boiler could generate up to one gallon of condensate per 100,000 BTU input. -
Page 51: Pre-Start Checklist
The low water cut-out circuit board is located inside the boiler’s front door, toward the bottom left of the control panel and is identified with a label. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 52: Flow Switch Test
NURO control. These manual reset high temperature limits are wired in series so if only one switch trips, it would result in the unit locking out. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 53: Gas Pressure Switch Tests
14” W.C. which is the maximum allowable pressure on the gas train components. Each boiler is furnished with a manual shut-off valve which has © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 54: Manual Control Mode For High And Low Fire Adjustment
NOTICE! For high altitude adjustments (greater than 2,000 feet above sea level), see Appendix B – Boiler Altitude Derate Schedule at the end of this manual. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 55: Adjusting High Fire
When the boiler is in standby, prepurge, or postpurge the flame signal should read 0V. During main flame, a strong flame signal should read between 8-30V. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 56: Initial Nuro Control Setup And Adjustment
When the boiler or water heater is powered on, the NURO touchscreen will display an initial Startup Screen then the Local Representative screen. This shows the name, address and phone number of the local Patterson Kelley representative. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 57: Home Screen
NOTE For more information on any value, please refer to the NURO Boiler Controller: Advanced User’s Guide, Part Number is 1004905979. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... -
Page 58: Setup Wizard
208-240 Three Less than 20 3889 3,880,000 ST-4000 4,000,000 440-480 Three Less than 20 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 49... -
Page 59: Operations
Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on this boiler when the boiler underwent factory tests specified in ANSI Z21.13/CSA 4.9, latest edition. (See "Factory Firetest" label on the rear surface of the boiler). © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 60: Normal Lighting And Shut-Down Procedures
See the image to the right for the locations of the Natural Gas valve. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 61: Maintenance
REFRACTORY LINING MATERIAL main gas line and ensure all connections are tight. Use a leak • This Patterson-Kelley product contains a Combustion detector to check for leaks before Area lined with REFRACTORY CERAMIC FIBERS and after servicing any (RCFs) similar to many other devices produced in this component of the gas piping. -
Page 62: Daily
Combustion Setup and Adjustment combustion settings table in 3.11.2. If an adjustment to the combustion is necessary, call a qualified and knowledgeable installer or service agency that has been trained on the Patterson-Kelley appliance. Monthly 1. -
Page 63: Annually Or 2500 Run Hours (Whichever Comes First)
(570) 476-7247. 1. Inspect and clean the inlet screen (if applicable) of any accumulated dust or lint. If using an air filter, inspect and replace (if necessary). Patterson-Kelley suggests replacing air filters at least once per year. For the following points 2 through 4, refer to 5.2. - Page 64 RUNNING PIPE OR HOSE TO A DRAIN. ***Do this flush at low pressures— just enough pressure to push water through the exchanger and out of the drain valve***. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved.
- Page 65 It is recommended that a copy of this report is filed for future reference. 10. Perform a leak test of the gas valve in accordance with the gas valve manufacturer’s instructions. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved.
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Page 66: Cleaning The Combustion Chamber
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 5.2 Cleaning the Combustion Chamber Patterson-Kelley recommends cleaning the combustion chamber once annually using the following procedure: 1. Lockout/Tagout gas supply to the boiler. 2. Lockout/Tagout electrical power to the boiler. 3. Disconnect the condensate piping and install a temporary drain hose into the condensate trap/drain. - Page 67 9. Swing open the burner door/heat exchanger door to provide access to the inside of the heat exchanger. The burner does not need to be removed. Patterson-Kelley does not recommend removing the burner, though it may be removed to provide better access for cleaning the exchanger.
- Page 68 After several minutes of washing, turn off the hose and allow all the wash water to drain from the boiler. Patterson-Kelley recommends rinsing until the water draining from the condensate runs clear. © Patterson-Kelley 2020...
- Page 69 Kelley recommends replacing the ignition cable, ignition electrode, and ionization rod at this time). Double check the tightness of all bolted joints and connections. Verify that gaskets have been installed in the correct locations. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved.
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Page 70: After Repairs Or Maintenance
Technical Service 1.877.728.5351 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. -
Page 71: Sequence Of Operations
The NURO control will display graphical and/or text based error descriptions to announce any problems with the boiler. There are two types of lockouts: manual reset lockouts which require the operator to © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 72: Loss Of Power
Ensure there is no air flow through the boiler when the blower is offline. An excessive negative draft in the flue piping can cause air flow through the offline boiler which may be strong enough to maintain closure of the air switch. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 73: Flame Failure
If no blockages are found, it may be necessary to replace either the high exhaust back pressure switch or the Condensate Blockage System. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 74: Parts/Technical Support
Technical Service 1.877.728.5351 6 Parts/Technical Support Spare parts and replacement parts can be ordered from Use of Non-Factory Authorized Patterson-Kelley by calling toll free (877) 728-5351. Reach replacement parts are not us by fax at (570) 476-7247. recommended for this Refer to the parts list shown on the assembly drawings equipment. -
Page 75: Terminal Block Assignments
4-20mA ANALOG INPUT [+] ENABLE / DISABLE Contact Closure Enables Comfort Heat Operation ENABLE / DISABLE Open Circuit Disables Comfort Heat Operation © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... -
Page 76: Terminal Block Assignments - High Voltage (Tb2) Terminal Block
External Interlock Circuit #1 START INTERLOCK #1 START INTERLOCK #2 External Interlock Circuit #2 (In Series w/ #1) START INTERLOCK #2 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... -
Page 77: Wiring Diagrams
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 6.2 Wiring Diagrams Natural Gas 208-240 Volt © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 68... - Page 78 P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 69...
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Page 79: Natural Gas 480 Volt
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Natural Gas 480 Volt © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 70... - Page 80 P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 71...
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Page 81: Control Transformer Diagrams
Gas Fired Boiler Technical Service 1.877.728.5351 Control Transformer Diagrams 208 VAC, Three Phase, 60 Hz 220-240 VAC, Three Phase, 60 Hz © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... - Page 82 220-240V, three phase, 60Hz • 440-480V, three phase, 60Hz Improper configuration of the control transformer could result in serious injury or death. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx...
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Page 83: Boiler Parts Identification
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 6.3 Boiler Parts Identification Main Boiler Assembly (ST-2500 & ST-3000) © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx... -
Page 84: Main Boiler Assembly (St-3500 & St-4000)
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Main Boiler Assembly (ST-3500 & ST-4000) © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 75... -
Page 85: Control Panel
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Control Panel © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 76... -
Page 86: Heat Exchanger Assembly St-2500 & St-3000
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Heat Exchanger Assembly ST-2500 & ST-3000 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 77... -
Page 87: Heat Exchanger Assembly St-3500 & St-4000
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Heat Exchanger Assembly ST-3500 & ST-4000 © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 78... -
Page 88: Natural Gas Train
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Natural Gas Train © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 79... -
Page 89: Burner/Blower Assembly 240V
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Burner/Blower Assembly 240V © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 80... -
Page 90: Burner/Blower Assembly 480V
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Burner/Blower Assembly 480V © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 81... -
Page 91: K Storm Specific Limited Warranty
Last Updated 12/12/2016 Subject to the terms and conditions herein and the Terms and Conditions of Sale (as defined herein), Patterson-Kelley (“Seller”) warrants to the purchaser of the product (“Buyer”) that the heat exchanger and burner are free of defects in material and workmanship, when... - Page 92 No sales representative, agent, or employee of Seller or any reseller in the chain of sale of the product is authorized to make any modification, extension, or addition to this Specific Limited Warranty, unless agreed to in writing by Seller. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved.
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Page 93: Boiler Fire-Test Report
(Print Name) A copy must be returned within 30 days of startup to Patterson-Kelley A copy must be returned within 30 days of startup to Harsco Industrial Patterson-Kelley Patterson-Kelley • 155 Burson Street • E. Stroudsburg, PA 18301 Harsco Industrial Patterson-Kelley • 155 Burson Street • E. Stroudsburg, PA 18301 P) 570-476-7261 F) 570-476-7247 pkchtsupport@spx.com... -
Page 94: Appendix A - Maintenance Log
Appendix A – Maintenance Log Hi Fire / Stack Date Action Low Fire Temp © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 85... -
Page 95: Appendix B - Boiler Altitude Derate Schedule
Although the appliance’s capacity is reduced due to the lower air density, the combustion tuning should follow the standard combustion guidelines of 3.11. Tune the combustion for the same O and CO levels as discussed in 3.11.2. © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. -
Page 96: Appendix C - Water Quality Standards Quality Standards For Hydronic Boilers In Multi-Metal Systems
Gas Fired Boiler Technical Service 1.877.728.5351 Appendix C – Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems Patterson-Kelley boilers are designed to be incorporated into any multi-metal hydronic heating system. All multi-metal hydronic systems require that attention be paid to water treatment. -
Page 97: Appendix D - Best Practices For New & Retrofit Systems
This strainer is not intended to remove fine particulate matter from the boiler system which will be discussed later in this appendix. 4. Patterson-Kelley recommends installing a water meter on the cold water fill piping. The intention of this device is to periodically monitor the amount of fresh water introduced into the system piping. - Page 98 (blended) sample. 11. Within the first three months after startup, Patterson-Kelley recommends collecting a follow-up water sample from the hydronic system. This should be compared to the initial startup sample in order to determine any changes in pH, Alkalinity, conductivity, etc.
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Page 99: Appendix E - Installation And Quick Reference
Maximum Inlet Pressure = 14.0” W.C. NOTE: Patterson-Kelley recommends installing an individual lock-up type gas regulator in the gas supply piping to each boiler. For installations where one master lock-up type gas pressure regulator will service multiple boilers, Patterson-Kelley recommends contacting the local regulator representative for application assistance specifying the appropriate lock-up type regulator and gas pipe sizing. - Page 100 The chart below represents the pressure drop (Ft of Head) versus the water flow rate (GPM) for the P-K STORM ST-2500 through ST-4000. This information is useful to help size an appropriate circulation pump. Keep in mind this pressure drop represents the boiler only, additional consideration is needed for any connecting piping, valves, strainers, couplings, flanges, etc.
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Page 101: Propylene Glycol Flow
23.9 ft 346 GPM 34.5 ft 403 GPM 27.8 ft 461 GPM 36.3 ft © Patterson-Kelley 2020 Revised: June 26, 2020 2691000273 P-K Storm ST2500-ST4000 All Rights Reserved. Released: June 26, 2020 Installation and Owners Manual Rev A.docx Page 92...