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PATTERSON-KELLEY
THERMIFIC
MODU-FIRE® GAS-FIRED BOILER
Supplement to the standard Installation and
Owner's Manual (TBIG - Latest Edition)
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
©2002 Patterson-Kelley, A Harsco Company
®
MOD-02
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Summary of Contents for Patterson-Kelley THERMIFIC MODU-FIRE
- Page 1 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 ©2002 Patterson-Kelley, A Harsco Company...
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Page 2: Table Of Contents
® Modu-Fire Gas-Fired Boiler Table of Contents 3.7.2 Gas Bleeds and Vents ....3 1.0 INTRODUCTION ......... 1 3.8 Boiler Water Piping ......3 2.0 SAFETY..........1 3.8.1 Piping Design.........3 2.1 General ..........1 3.8.2 Boiler Inlet and Outlet Connections..3 2.2 Training..........1 3.8.3 Boiler Water Piping by Installer..3 2.3 Safety Features ........1 3.8.4 Flushing and Filling......3 2.4 Safety Labels ........1... - Page 3 ® Modu-Fire Gas-Fired Boiler Table of Contents 5.2 Cleaning the Burner......12 6.0 PARTS/TECHNICAL SUPPORT..16 5.2.1 Semi-Annual Cleaning ....12 6.1 Schematic Diagrams......16 5.2.2 Annual Cleaning ......12 Standard Unit w/ Siemens Control..17 5.3 Removing the Exchanger ....13 Standard Unit w/ Remote Control ..18 5.4 After All Repairs or Maintenance ..13 IRI with Siemens Control .......19 5.5 SEQUENCE OF OPERATION ...13...
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Page 4: Introduction
The P-K MODU-FIRE Gas Fired Boiler is a differ slightly, basic operation is the same for all revolutionary advance; Patterson-Kelley now models. Boilers are built to operate with natural combines full-modulation burner control with our gas. Check the rating plate for the correct gas flow time-tested modular hot water boiler design. -
Page 5: Installation
® Modu-Fire Gas-Fired Boiler Installation 3.0 INSTALLATION (Refer To TBIG Latest Edition) 3.1 R In Canada, the boiler is certified for installation with ECEIVING AND TORAGE a “Power Venter” by the Canadian Gas Association (Refer To TBIG Latest Edition) when installed with the “listed accessories.” Consult your local distributor for information on 3.1.1 Initial Inspection proper selection. -
Page 6: Gas Supply Piping By Installer
® Modu-Fire Gas-Fired Boiler Installation 3.7.1 Gas Supply Piping by Installer 3.8.1 Piping Design (Refer To TBIG Latest Edition) (Refer To TBIG Latest Edition) 3.7.2 Gas Bleeds and Vents 3.8.2 Boiler Inlet and Outlet Connections (Refer To TBIG Latest Edition) Vent to 3.8.3 Boiler Water Piping by Installer Outside Air... -
Page 7: Test Of Low Water Cut-Off
® Modu-Fire Gas-Fired Boiler Installation 2. With the main gas cock (inlet manual gas valve) 3.11.4 Test of Gas Pressure Switch open and the pilot gas cock open, the burner (Refer To TBIG Latest Edition) should be cycled on. After all the safety limits on gas pressure, water flow and temperature are 3.12 I NITIAL... - Page 8 ® Modu-Fire Gas-Fired Boiler Installation For example, assume the following settings: ITEM DISPLAY VALUE SETPOINT 1 LOW TEMP DIFFERENTIAL HyS1 HIGH TEMP DIFFERENTIAL HyS3 LOW TEMP SETPOINT HIGH TEMP SETPOINT The boiler will modulate to try to maintain 160 The boiler modulates to maintain this setpoint. The If the temperature increases to 172 F which is boiler functions as indicated in internal setpoint;...
- Page 9 ® Modu-Fire Gas-Fired Boiler Installation boiler control. The boiler turns on and off as The following table indicates the menu options directed by the external control. available from each level. The options available depend on the operating mode of the boiler. An operating limit control ensures that the boiler temperature does not exceed the set value.
- Page 10 ® Modu-Fire Gas-Fired Boiler Installation Parameter Level: Change the firing rate of the boiler with The parameters available in this level are used for proper functioning of the boiler with the system. The firing rate increases as long as is pressed. Within the parameter level you can go to the next The firing rate decreases as long as parameter by pressing PGM.
- Page 11 ® Modu-Fire Gas-Fired Boiler Installation Table 1 - Table of Parameters...
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Page 12: Air Flow Adjustments
® Modu-Fire Gas-Fired Boiler Installation/Operation Configuration Level: these two rates to maintain a steady outlet temperature. The configuration level is used to set up the control for the sensors used, and the functioning of the Fuel adjustments for proper fuel input are made first alarm relay. -
Page 13: Initial Adjustments
® Modu-Fire Gas-Fired Boiler Installation/Operation cock for measuring the gas supply pressure (1/4” To adjust the gas pressure, remove the cover plate IPS). The supply pressure during main burner from the air / gas ratio control valve. Set the boiler operation must be greater than the minimum at High fire as described in the boiler operation indicated on the rating plate (4 in. -
Page 14: Lighting Procedures
® Modu-Fire Gas-Fired Boiler Operation 4.2.1 Lighting Procedures 1. Close main and pilot gas cocks. 2. Turn On-Off switch to "OFF" position. 3. Wait 5 minutes. 4. Open main and pilot gas cocks. 5. Turn On-Off switch to "ON" position. 6. -
Page 15: Cleaning The Burner
® Modu-Fire Gas-Fired Boiler Maintenance 2. Use low pressure air, Max. 20 psig inside the 5.0 MAINTENANCE burner to remove any accumulated dust or lint build-up. 5.1 M AINTENANCE AND NSPECTION CHEDULE 5.2.2 Annual Cleaning CAUTION! 1. Disconnect the union in the line at the burner. Label all wires prior to disconnection when servicing controls. -
Page 16: Removing The Exchanger
® Modu-Fire Gas-Fired Boiler Maintenance 9. Before re-installing the burner, check the 6 of the programmer, which initiates the burner cleanliness of the heat exchanger and the ignition and operation sequence. condition of the combustion chamber. 6. The programmer first energizes Terminal 4 which supplies power to the motor contactor, the damper motor limit switch, and normally 5.3 R... -
Page 17: Iri Modulating
® Modu-Fire Gas-Fired Boiler Maintenance 12. Relay 1 bypasses the purge switch, removes 4. When the temperature sensed by the high limit power from the closed terminal of the damper temperature control is below the set limit, the motor, and releases the temperature control to switch is closed. -
Page 18: Trouble Shooting
® Modu-Fire Gas-Fired Boiler Maintenance 11. After the 10 second “trial for ignition” period, 5.6 TROUBLE SHOOTING if pilot flame has been established, Terminal 9 of the Combustion Control is energized. This 5.6.1 Loss of Power opens the main gas valve and energizes the air Refer To TBIG Latest Edition) gas ratio control. -
Page 19: Parts/Technical Support
Spare parts and replacement parts can be ordered 6.1 S CHEMATIC IAGRAMS from Patterson-Kelley by calling (570) 421-7500 or Toll Free (877) 728-5351. Ask for the Heat Schematic drawings are shown on the following Transfer Department. The fax number is (570) 476- pages. -
Page 20: Standard Unit W/ Siemens Control
® Modu-Fire Gas-Fired Boiler Parts/Technical Support Standard Unit w/ Siemens Control... -
Page 21: Standard Unit W/ Remote Control
® Modu-Fire Gas-Fired Boiler Parts/Technical Support Standard Unit w/ Remote Control... -
Page 22: Iri With Siemens Control
® Modu-Fire Gas-Fired Boiler Parts/Technical Support IRI with Siemens Control... -
Page 23: Iri With Remote Control
® Modu-Fire Gas-Fired Boiler Parts/Technical Support IRI with Remote Control... -
Page 24: Boiler Parts List
® Modu-Fire Gas-Fired Boiler Parts/Technical Support 6.2 B OILER ARTS 6.2.1 Main Assembly 13, 14. Part Part Mixer Core, Burner (Inside Cabinet) Water Flow Switch Burner Orifice (Inside Cabinet) Blower, Motor (Inside Cabinet) Spark Igniter Electrode Blower, Wheel (Inside Cabinet) UV Scanner Press./Temp. -
Page 25: Control Panel
® Modu-Fire Gas-Fired Boiler Parts/Technical Support 6.2.2 Control Panel Circuit Breaker Relays and Sockets 7, 7a, 7b, 8 Part Part Thermostat (Manual Reset) Ignition Transformer Thermostat (Oper. Temp) 10a. Ignition Cable Air Flow Switch Indicator Light, Red Motor Start Relay Indicator Light, Green Terminal Block, Neutral Terminal Block, Power... -
Page 26: Gas Train
® Modu-Fire Gas-Fired Boiler Parts/Technical Support 6.2.3 Gas Train Part Main Gas, Valve Low Gas Pressure Switch Main Gas, Regulator Main Gas, Shut-off Cock Main Gas Actuator Safety Shut-off Valve... -
Page 27: Limited Warranty
Production of noise, odors, discoloration or rusty water. Warranty - The owner must notify the original installer of the Product and Seller (Attention: Patterson-Kelley Co, Box 458, Damage to surrounding area or property caused by leakage East Stroudsburg, PA 18301), in writing, within the Warranty or malfunction.