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PATTERSON-KELLEY
THERMIFIC
®
GAS-FIRED BOILER
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
INSTALLATION
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OWNER'S
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INSTALLATION
OWNER'S
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MANUAL
INSTALLATION
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OWNER'S
MANUAL
INSTALLATION
OWNER'S
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OWNER'S
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INSTALLATION
OWNER'S
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Summary of Contents for Patterson-Kelley Thermific
- Page 1 Complies with ANSI Z21.13/CSA 4.9 MANUAL Gas-Fired Low Pressure Steam and Hot Water Boilers INSTALLATION ASME Code, Section IV OWNER’S & Certified by Patterson-Kelley MANUAL C.S.A Design-Certified Complies with ANSI Z21.13/CSA 4.9 INSTALLATION Gas-Fired Low Pressure Steam and Hot Water Boilers &...
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Page 3: Table Of Contents
2.5.6 Slip, Fall Hazards......4 3.12 Initial Adjustments........15 3.0 INSTALLATION ........5 3.12.1 Operating Temperature Controller for 3.1 Receiving and Storage ......5 ® Lo-Hi-Lo Thermific ......15 3.1.1 Initial Inspection ........5 3.12.2 Gas Pressure Adjustment.....16 3.1.2 Storage Prior to Installation....5 3.12.3 Air Flow Adjustments ....16 3.2 Compliance with Codes ......5... - Page 4 ® Thermific Gas-Fired Boiler Table of Contents 5.2 Cleaning the Burner.........22 6.1.2a Lo-Hi-Lo IRI ........34 5.2.1 Semi-Annual Cleaning ....22 6.1.3 Water Cut-Off........36 5.2.2 Annual Cleaning ......22 6.2 Boiler Parts List ........38 5.3 Removing the Exchanger ......23 6.2.1 Main Assembly ....... 38 5.4 After All Repairs or Maintenance .....23...
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Page 5: Introduction
Operating and service personnel must be thoroughly cause of poor circulation, control or other operating familiar with the basic construction of the Thermific characteristics, not deliver heat to the desired location. boiler, the use and locations of the controls, the opera-... -
Page 6: Safety Labels
Although the labels are of high quality, they tight before closing cabinet may become dislodged or unreadable over time. Con- cover after servicing boiler. tact Patterson-Kelley toll-free at (877) 728-5351 for c 1998 HCS, Inc. 800-748-0241 Reorder No. 8032-02NHAK replacement labels. -
Page 7: Crush Hazards
® Thermific Gas-Fired Boiler Safety • 2.5.3 Crush Hazards 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 gas vent during firing operation. -
Page 8: Pressure Hazards
® Thermific Gas-Fired Boiler Safety 2.5.5 Pressure Hazards 2.5.6 Slip, Fall Hazards WARNING WARNING Improper use may Improper use may result in fire or injury. result in fire or injury. Read instructions/safety Read instructions/safety manual before installing, manual before installing, operating or servicing boiler. -
Page 9: Installation
OMPLIANCE WITH ODES adjustable legs are also necessary to provide adequate ® The P-K Thermific Boiler with standard components floor clearance and prevent distortion on the cabinet, and many options complies with American National (twisting, etc.) in addition to leveling. -
Page 10: Clearances
® Thermific Gas-Fired Boiler Installation Adjustable Legs for Leveling and Floor Clearance Minimum Clearances from Adjacent Walls, Ceiling, and Obstructions 3.3.3 Clearances Type of Surface Dimensions (inches) If the boiler is to be installed near combustible sur- C† faces, the minimum clearances shown in the table be- Combustible Surfaces low must be maintained. -
Page 11: Combustion Air
® Thermific Gas-Fired Boiler Installation starting the boiler, check to ensure that the proper instance, 300 square inches (2-1/12 square feet) are voltage and amperage is connected to the boiler. required for 1,200,000 Btu per hour input. An external electrical disconnect (not supplied with... -
Page 12: Vent Elbows
® Thermific Gas-Fired Boiler Installation The venting system and the horizontal portions of the 2. The damper may be located in either side of the venting system shall be supported to prevent sagging. horizontal section of stack. Consult your local vent supplier for correct vent sizing 3. -
Page 13: Vent Termination
® Thermific Gas-Fired Boiler Installation 3.6.5 Vent Termination system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer ex- haust fan. Close fireplace dampers. 4. Place the appliance being inspected in operation. - Page 14 ® Thermific Gas-Fired Boiler Installation intermediate gas pressure regulator of the "lock up" Note: Install a sediment trap (drip leg) and a union type must be provided to reduce the pressure to less connection ahead of the primary manual shutoff valve than 14 inch W.C.
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Page 15: Gas Supply Piping By Installer
Water Flow in System 3.7.2 Gas Bleeds and Vents ® Ideal operation of the P-K Thermific Boiler would consist of a 20º F temperature differential across the Vent to heat exchanger. The operating thermostat has an ad- Outside Air justable temperature differential. -
Page 16: Boiler Inlet And Outlet Connections
® Thermific Gas-Fired Boiler Installation Piping With Air Handling Units 3.8.3 Boiler Water Piping by Installer The boiler piping system of a hot water heating boiler Strainer connected to heating coils located in air handling units, To avoid possible contamination of the boiler with... -
Page 17: Flushing And Filling
® Thermific Gas-Fired Boiler Installation 3.8.4 Flushing and Filling 1. Flue gas from the boiler is properly vented. 2. Gas connection has been made, pressure tested for Flushing the System leakage, and the line purged of air. Make sure all Before filling the boiler, flush the system to remove required bleeds and vents have been installed. -
Page 18: Test Of Low Water Cut-Off
® Thermific Gas-Fired Boiler Installation sure, water flow and temperature are satisfied, the main burner shuts off. The high-limit switch must be blower will run and pre-purge the boiler. manually reset after testing. This check should also be made for the "Operating Temperature" control (the 3. -
Page 19: Initial Adjustments
(Tb) 3.12.1 Operating Temperature Controller for ® Lo-Hi-Lo Thermific The two stages of this boiler are operated by pro- gramming each set point and differential into the con- troller. The boiler will be turned on at set point 1 mi- nus its differential and turned off at set point 1. -
Page 20: Gas Pressure Adjustment
® Thermific Gas-Fired Boiler Installation Important: After initial programming, altering the set If a replacement Lo-Hi-Lo actuator is required, follow point for stage 1 up or down will result in a change in manufacturers instructions and pre-set the Lo fire set- set point 2 by the same number of degrees and in the ting of the actuator the same as the original actuator. - Page 21 ® Thermific Gas-Fired Boiler Installation On/Off Lo-Hi-Lo (700, 1000, 1200 Series only) This is a two stage firing arrangement with the me- chanical action provided by the two stage gas valve actuator. The boiler is factory fire-tested and adjusted for two firing rates: Hi fire (100% of rated input) and Lo fire (60% of rated input).
- Page 22 ® Thermific Gas-Fired Boiler Installation ther end of the damper rod to obtain the desired Hi Note: Do not utilize the Hi fire definite stop screw to fire air. After adjustments are complete, adjust the adjust Hi fire air on Lo-Hi-Lo models.
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Page 23: Operation
® Thermific Gas-Fired Boiler Operation 4.0 OPERATION 4.2.1 Lighting Procedures 4.1 G ENERAL 4.1.1 Control Panel Front Operating Instructions Reset On-Off Temperature Switch Control Low Pressure Gas Switch Pilot Gas Cock Indicator Lights On-Off Switch Control Panel Main Gas Cock (Lo-Hi-Lo shown - On-Off similar) Become familiar with the basic operation of the boiler. -
Page 24: Normal Shut Down Procedures
® Thermific Gas-Fired Boiler Operation 4.2.2 Normal Shut Down Procedures If overheating occurs or the gas supply fails to shut off, do not turn off or disconnect the electrical supply 1. Close all manual gas valves. to the pump. Instead, shut off the gas supply at a loca- 2. -
Page 25: Maintenance
® Thermific Gas-Fired Boiler Maintenance 5.0 MAINTENANCE until correct flame pattern is achieved. A general glow within the combustion chamber is normal. Correct air adjustment is essential to the efficient op- 5.1 M AINTENANCE AND NSPECTION CHEDULE eration of this boiler. If an adjustment in the combus-... -
Page 26: Annually
® Thermific Gas-Fired Boiler Maintenance 5.1.5 Annually UV Scanner Mixer Core Pilot Tube In addition to the recommended monthly service: 1. Check burner and clean off any soot or foreign material that may have accumulated. See Section 5.2 on "Cleaning the Burner." Check for corrosion of the burner and its parts. -
Page 27: Removing The Exchanger
® Thermific Gas-Fired Boiler Maintenance 9. Before re-installing the burner, check the cleanli- 3. Check air pressure and adjust air flow if necessary. ness of the exchanger and the condition of the (See "Air Flow Adjustment", Section 3.12.3.) firebox floor. -
Page 28: Troubleshooting
® Thermific Gas-Fired Boiler Maintenance 7. A time delay of 10 seconds (standard) or 30 sec- 5.6 T ROUBLESHOOTING onds (depending on insurance or local code re- quirements) occurs after the air proving switch Loss of Power closes and the programmer signals a continuation In the event of a power failure (or when the On/Off of the start sequence. - Page 29 ® Thermific Gas-Fired Boiler Maintenance Low Air Flame Failure If the "Low Air" indicator remains on for longer than In the event of a flame failure during a firing period, 10 seconds, there is insufficient airflow through the the main fuel valves are de-energized and the pro- burner.
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Page 30: Parts/Technical Support
Parts/Technical Support 6.0 PARTS/TECHNICAL SUPPORT Spare parts and replacement parts can be ordered from Patterson-Kelley by calling (570) 421-7500 or (877) 728-5351. Ask for the Heat Transfer Department. The fax number is (570) 476-7247. Refer to the parts list shown on the assembly drawing provided with this manual. -
Page 31: Wiring Diagrams
® Thermific Gas-Fired Boiler Parts/Technical Support 6.1 W IRING IAGRAMS Wiring and control schematic drawings are shown on the following pages. Table of Contents for this Section: 6.1.1 On-Off On-Off Wiring Diagram page 28 On-Off Logic Diagram 6.1.1a On-Off IRI... -
Page 32: On-Off
® Thermific Gas-Fired Boiler Parts/Technical Support 6.1.1 On-Off On-Off Wiring Diagram Page 28... -
Page 33: On-Off Logic Diagram
® Thermific Gas-Fired Boiler Parts/Technical Support On-Off Logic Diagram Page 29... -
Page 34: On-Off Iri
® Thermific Gas-Fired Boiler Parts/Technical Support 6.1.1a On-Off IRI On-Off/IRI Wiring Diagram Page 30... -
Page 35: On-Off Iri Logic Diagram
® Thermific Gas-Fired Boiler Parts/Technical Support On-Off/IRI Logic Diagram Page 31... -
Page 36: Lo-Hi-Lo
® Thermific Gas-Fired Boiler Parts/Technical Support 6.1.2 Lo-Hi-Lo Lo-Hi-Lo Wiring Diagram Page 32... -
Page 37: Lo-Hi-Lo Logic Diagram
® Thermific Gas-Fired Boiler Parts/Technical Support Lo-Hi-Lo Logic Diagram Page 33... -
Page 38: Lo-Hi-Lo Iri
® Thermific Gas-Fired Boiler Parts/Technical Support 6.1.2a Lo-Hi-Lo IRI Lo-Hi-Lo/IRI Wiring Diagram Page 34... -
Page 39: Lo-Hi-Lo Iri Logic Diagram
® Thermific Gas-Fired Boiler Parts/Technical Support Lo-Hi-Lo/IRI Logic Diagram Page 35... -
Page 40: Water Cut-Off
® Thermific Gas-Fired Boiler Parts/Technical Support 6.1.3 Water Cut-Off On-Off Low Water Cut-Off Diagram Page 36... -
Page 41: Lo-Hi-Lo Water Cut-Off
® Thermific Gas-Fired Boiler Parts/Technical Support Lo-Hi-Lo Low Water Cut-Off Diagram Page 37... -
Page 42: Boiler Parts List
® Thermific Gas-Fired Boiler Parts/Technical Support 6.2 B OILER ARTS 6.2.1 Main Assembly 700/1000/1200 On-Off 1500/1700/2000 Lo-Hi-Lo 1, 2 14, 15 Part Part Mixer Core, Burner Blower, Wheel Burner Orifice Press./Temp. Gauge Spark Igniter Electrode (w. 100 PSI relief valve) -
Page 43: Control Panel
® Thermific Gas-Fired Boiler Parts/Technical Support 6.2.2 Control Panel On-Off Panel Lo-Hi-Lo Panel Part Part Thermostat (Manual Reset) Ignition Transformer Thermostat (Oper. Temp) 11a Ignition Cable Air Flow Switch Connector, Spark Plug Motor Starter Relay Indicator Light, Red Terminal Block, Neutral... -
Page 44: Gas Train
® Thermific Gas-Fired Boiler Parts/Technical Support 6.2.3 Gas Train Part Main Gas, Valve (Diaphragm) Low Gas Pressure Switch Main Gas, Regulator Main Gas, Shut-off Cock Pilot, Solenoid Valve Pilot, Regulator Pilot, Shut-off Cock High Gas Pressure Switch Main Gas, Valve Body... -
Page 45: Cabinet
® Thermific Gas-Fired Boiler Parts/Technical Support 6.2.4 Cabinet 4, 5 4, 5 Part Exterior Cabinet, Assy. Exterior Cabinet, Door Exterior Cabinet, Top Sight Glass Sight Glass Bezel Combustion Chamber, Assy. Combustion Chamber, Door Combustion Chamber, Top Control Panel, Label 10 Control Panel, Cover 11 Control Panel, Sub Panel 12 Control Panel, Base Assy. -
Page 46: Limited Warranty
® Thermific Gas-Fired Boiler Limited Warranty 7.0 LIMITED WARRANTY 7.1 E 7.2 W XPRESS ARRANTY ARRANTY ISCLAIMER Seller warrants that the products sold hereunder are EXCEPT AS SET FORTH ABOVE, THERE ARE free of defects in material and workmanship, when...